An injection part integral moving support integrated device and an integral moving control method

Abstract

This invention discloses an integrated device and method for adjusting and supporting the movement of injection components. It includes a height-adjusting support mechanism for adjusting the overall height of the device and providing support, an electric movement mechanism integrated into the height-adjusting support mechanism, and an adjustable elastic clamping mechanism. The electric movement mechanism uses a gear and rack transmission structure to provide movement force to the injection component. The adjustable elastic clamping mechanism provides contact pressure to the gear and rack transmission mechanism through elastic force, and includes an adjustment component, an elastic preload component, and a clamping component connected to the elastic preload component. The device combines support and drive functions, resulting in a more compact structure. The adjustable elastic clamping mechanism provides contact pressure to the gear and rack transmission mechanism through elastic force, which not only prevents tooth skipping and backlash caused by vibration, uneven force, or small displacement of the barrel, but also compensates for tooth surface wear and assembly errors, ensuring meshing accuracy during long-term operation, thereby significantly improving the reliability and service life of the system.

Description

Technical Field

[0001] This invention relates to the field of injection molding machine technology, specifically to an integrated device for adjusting and supporting the movement of injection components and a method for adjusting and controlling the movement. Background Technology

[0002] In existing injection molding machine components, one or two hydraulic cylinders are installed depending on the machine size to achieve the overall movement of the injection unit. Large injection molding machines, due to the excessive length of the injection barrel and injection unit's hydraulic cylinders, require longitudinal supports to ensure the structural safety and stability of the barrel and cylinders. The barrel of a large injection molding machine relies on a column for support, and the two hydraulic cylinders of the injection unit also require longitudinal supports to ensure structural stability. This increases the number of connection points in the entire device, raising the risk of oil leakage during assembly. Furthermore, it results in larger space requirements at the connection points, reducing assembly accuracy.

[0003] Meanwhile, the hydraulic system needs to run continuously, which will increase the standby power consumption of the whole machine. Hydraulic components are at risk of hydraulic oil leakage, and more hydraulic components will increase the risk of oil leakage of the whole machine and pollute the working environment.

[0004] For example, Chinese patent document CN 205929242U discloses an injection seat repositioning device for a thermosetting injection molding machine, including an injection seat and a fixed template disposed in front of the injection seat. The injection seat is provided with a mounting base, and the mounting base is provided with a material cylinder. A nozzle is installed at the front end of the material cylinder. The mounting base is connected to a hydraulic cylinder, and the hydraulic cylinder is connected to a piston rod, which is connected to the fixed template. This technical solution also suffers from the aforementioned problems.

[0005] To address the shortcomings of the barrel support and injection movement cylinder support in large injection molding machines, it is necessary to design an integrated structure that can simultaneously fulfill both movement and support functions, thereby improving assembly convenience and reducing overall machine energy consumption and the risk of oil leakage. Summary of the Invention

[0006] The purpose of this invention is to solve the problem that existing large injection molding machines require external supports for the hydraulic cylinders and barrels, resulting in large assembly space requirements and reduced assembly efficiency. This invention provides an integrated device and control method for moving and supporting injection components. It aims to replace traditional hydraulic cylinders with a motor-driven rack and pinion structure, combined with an adjustable height support mechanism and an adjustable elastic clamping mechanism to achieve the movement and support of the injection components. This device effectively reduces space requirements, improves accuracy and stability, and lowers maintenance costs.

[0007] The technical solution adopted by this invention to achieve its objective is: an integrated device for adjusting and supporting the movement of injection components, comprising a height-adjusting support mechanism for adjusting the overall height of the device and providing support, an electric movement mechanism integrated on the height-adjusting support mechanism, and an adjustable elastic clamping mechanism; wherein, The electric adjusting mechanism uses a gear and rack transmission structure to provide adjusting force for the injection component; The adjustable elastic clamping mechanism provides contact pressure to the gear and rack transmission mechanism through elastic force, and includes an adjustment component, an elastic preload component, and a clamping component connected to the elastic preload component.

[0008] This integrated injection component transfer and support device replaces the hydraulic cylinders used for barrel and injection unit movement in injection molding machines with a gear and rack transmission structure. Combined with an adjustable height-adjustable support mechanism and an adjustable elastic clamping mechanism, it solves the problems of traditional hydraulic cylinders being too long, requiring longitudinal support, and having a cumbersome structure. This allows the transfer device to perform both support and drive functions in a more compact structure. The adjustable elastic clamping mechanism provides contact pressure to the gear and rack transmission mechanism through elasticity, preventing tooth skipping and backlash caused by vibration, uneven force, or minor barrel displacement. It also compensates for tooth wear and assembly errors, ensuring meshing accuracy during long-term operation. Utilizing the flexible preload characteristics of the elastic preload component, the clamping force automatically adjusts according to the meshing state, resulting in smooth transmission, reduced impact and noise, thus significantly improving system reliability and service life. This integrated injection component transfer and support device reduces space occupation and dependence on the hydraulic system, offering higher reliability and greater application value.

[0009] Preferably, the clamping assembly is positioned above the injection component to provide downward clamping force. A roller-type clamping assembly is used, comprising a roller shaft and rollers mounted on the roller shaft. The roller shaft is rotatably mounted on the elastic preload assembly via a set of roller shaft bearing assemblies. The clamping assembly provides a continuous downward clamping force to the injection component, thereby ensuring stable meshing between the lower drive gear and the drive rack.

[0010] Preferably, the elastic preload assembly includes multiple spring guide shafts, preload springs sleeved on the spring guide shafts, and roller mounting plates disposed at the lower ends of the spring guide shafts. Preferably, the preload springs are the main component of the elastic preload assembly. Utilizing the flexible preload characteristics of the springs, the clamping force is automatically adjusted according to the engagement state, resulting in smooth transmission, reduced impact and noise, and thus significantly improved system reliability and service life. Of course, the elastic preload assembly can also use structures such as elastic blocks to provide preload force.

[0011] Preferably, the roller adjustment assembly includes an adjustable clamping seat support frame with a frame structure and a clamping roller limiting block that is vertically adjustable to the adjustable clamping seat support frame. The clamping roller limiting block can dynamically adjust its height according to changes in the material cylinder size and the required clamping force, and is fixedly connected to the adjustable clamping seat support frame through adjustment. The relative height can be adjusted by the clamping roller limiting block to control the clamping force.

[0012] Preferably, the high-power electric displacement mechanism includes a servo motor and a rack and pinion drive mechanism; a torque sensor is connected between the servo motor and the rack and pinion drive mechanism. The rack and pinion drive mechanism enables the forward and backward movement and support of the barrel. The servo motor drives the gear to rotate, and the drive gear meshes with the drive rack fixed to the injection component, achieving displacement of the barrel and providing support force. A dynamic torque sensor is connected between the servo motor and the rack and pinion drive mechanism. This combination of the dynamic torque sensor and the motor control system ensures that the system only begins calculating displacement under effective load, thus avoiding no-load errors.

[0013] Preferably, the gear and rack drive mechanism includes a drive gear driven by a servo motor and a drive rack meshing with the drive gear. The drive rack is connected to the injection component and drives the injection component to move.

[0014] Preferably, the servo motor is connected to the torque sensor via a coupling, and then the transmission is transmitted to the drive gear via the coupling.

[0015] Preferably, the torque sensor is used to detect torque changes in real time during the transmission process, and to determine the gear and rack meshing state and the cumulative displacement of the injection component in combination with the control system logic.

[0016] Preferably, the height-adjustable support mechanism includes a lifting device, a base support plate, and a base support frame assembly. The lifting device adjusts the meshing height between the drive gear and the drive rack to ensure precise drive under different operating conditions.

[0017] The technical solution adopted by this invention to achieve its second objective is: a method for controlling the movement of an integrated device for moving and supporting injection components, comprising: a control system setting an effective engagement threshold T0, a host computer sending a movement command, a servo motor starting, a torque sensor detecting torque in real time, determining the engagement state, and dynamically adjusting the cumulative displacement logic through different stages of the detection curve; wherein, the determination of the engagement state includes: (1) During the no-meshing no-load stage, the torque is lower than the set effective meshing threshold T0. The torque is in the low value range, and the system judges it as no-load and does not accumulate displacement. (2) Initial contact stage: When the drive gear and the drive rack make initial contact, the torque signal rises but does not enter a stable state. The control system uses one or more of the following methods, such as delay judgment, secondary confirmation and filtering, to determine the stability of the torque change in order to avoid misjudgment caused by instantaneous impact, vibration or meshing jitter. (3) During the stable engagement stage, the torque exceeds the set effective engagement threshold T0 and stabilizes, confirming that the effective engagement state has been entered. The motor rotation angle is converted into the linear displacement of the injection molded part, and the displacement is accumulated. (4) Abnormal fluctuation stage: Abnormal fluctuation is detected during operation, accumulation is paused and recalibrated, and accumulation of displacement continues after the torque stabilizes. If reverse movement occurs during operation to release backlash or if the load suddenly increases due to blockage, the control system immediately pauses accumulation or recalibrates, and continues accumulation after the torque stabilizes.

[0018] Preferably, when the torque signal experiences short-term fluctuations or instantaneous increases, a delay judgment phase is initiated. During the delay, if the torque drops back to the effective meshing torque threshold T0, it is determined to be an instantaneous collision or jitter signal, and displacement is not accumulated. After the delay ends, the control system enters a secondary confirmation phase. If the torque value detected in multiple consecutive sampling cycles is higher than the effective meshing torque threshold T0, and the fluctuation range is within the allowable range, displacement accumulation begins. The control system can also use a moving average filtering algorithm to process the torque signal. Only when the average torque value is continuously higher than the set effective meshing torque threshold T0 will the control system allow entry into the effective displacement accumulation state.

[0019] The beneficial effects of this invention are as follows: This integrated injection component movement and support device replaces the hydraulic cylinders used for barrel and injection stage movement in injection molding machines with a servo motor-driven rack and pinion transmission mechanism. Combined with an adjustable height-adjustable support mechanism and an adjustable elastic clamping mechanism, it solves the problems of traditional hydraulic cylinders, which require longitudinal support due to their excessive length and have a complex structure. This allows the movement device to perform both support and drive functions, resulting in a more compact structure. Simultaneously, the torque sensor is linked to the motor control system, performing displacement calculations only when the drive gear and drive rack are effectively meshed and generating a load. This avoids displacement errors caused by backlash, improving the accuracy and stability of the movement of injection components such as the barrel and injection stage. Compared to traditional solutions relying on hydraulic cylinders, this device reduces space occupation, lowers dependence on the hydraulic system, and has higher reliability and wider application value. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of a structural design of the integrated injection component transfer and support device of the present invention.

[0021] Figure 2 This is a front view of the integrated injection component transfer and support device of the present invention.

[0022] Figure 3 This is a top view of the integrated injection component transfer and support device of the present invention.

[0023] Figure 4 yes Figure 3 Sectional view of AA.

[0024] Figure 5 This is a schematic diagram of one structure of the electric moving mechanism in this invention.

[0025] Figure 6 This is the control flowchart of the present invention.

[0026] Figure 7 This is a detection curve diagram of each stage of the meshing state in this invention.

[0027] In the diagram: 1. Material cylinder; 101. Rack and pinion fixing plate; 102. Pressing stroke structure; 2. Adjustable elastic clamping mechanism; 21. Clamping assembly; 22. Adjustment assembly; 23. Elastic pre-tightening assembly; 201. Adjustable clamping seat support frame; 202. Clamping roller limit block; 203. Spring guide shaft cover; 204. Spring; 205. Spring guide shaft; 206. Roller shaft; 207. Roller; 208. Roller shaft bearing assembly; 209. Limit bolt; 210. Roller mounting plate; 211. Adjustable long slot; 3. Electric moving mechanism; 301. Servo motor; 302. Coupling; 303. Torque sensor; 304. Drive gear; 305. Drive gear bearing housing; 306. Drive gear bearing base plate; 307. Drive rack; 308. Gear shaft; 309. Motor drive shaft. 4. Height adjustment support mechanism; 401. Lifting device; 402. Base support plate; 403. Upper base support foot; 404. Lower base support foot; 405. Push-fixing plate; 406. Base support frame assembly; 407. Base adjustment elongated hole; 408. Base adjustment connection hole. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Components, control methods, etc. not specifically described in the present invention are all existing components or general components or existing control methods.

[0029] Example 1:

[0030] In Figure 1, Figure 2 , Figure 3 In the illustrated embodiment, an integrated injection component transfer and support device includes a height-adjusting support mechanism 4 for adjusting and supporting the overall height of the device, an electric transfer mechanism 3 integrated on the height-adjusting support mechanism 4, and an adjustable elastic clamping mechanism 2; wherein, The electric adjusting mechanism 3 uses a gear and rack transmission structure to provide adjusting force for the injection component; The adjustable elastic clamping mechanism 2 provides contact pressure to the gear and rack transmission mechanism through elastic force, and includes an adjustment component 22, an elastic pre-tightening component 23, and a clamping component 21 connected to the elastic pre-tightening component.

[0031] The injection unit is the main component of the injection unit, which mainly includes components such as the barrel, barrel seat, and injection stage.

[0032] The height adjustment support mechanism 4 includes a lifting device 401, a base support plate 402, and a base support frame assembly 406.

[0033] The lifting device 401 can be a jack-type lifting device, a hydraulic cylinder-type lifting device, a pneumatic cylinder-type lifting device, or a scissor-type lifting device, etc., the purpose of which is to achieve overall height adjustment and support. In this embodiment, the lifting device 401 adopts a jack-type lifting device.

[0034] The base support frame assembly 406 includes an upper base support foot 403, a lower base support foot 404, and a lifting device fixing plate 405, which together support the electric moving system and enable height adjustment.

[0035] The base support plate 402 is horizontally arranged and mounted on the base support frame assembly 406 to support the material cylinder 1, the adjustable elastic clamping mechanism 2, and the electric adjusting mechanism 3.

[0036] The adjustable elastic clamping mechanism 2 is arranged above the material cylinder 1 to provide downward clamping force to the material cylinder. The electric adjusting mechanism 3 is arranged below the material cylinder to provide adjusting force.

[0037] The barrel 1, as the core component of the injection unit, is longitudinally moved along the barrel axis via an electric moving mechanism 3. The barrel employs a reinforced structure, and a pressing stroke structure 102 is provided on the upper part of the barrel 1 along the barrel axis. In this embodiment, the pressing stroke structure 102 is a moving plane disposed on the barrel. A rack fixing plate 101 arranged along the barrel axis is provided at the lower part of the barrel.

[0038] The height adjustment support mechanism 4 is located below the electric moving mechanism 3 and is used to adjust the overall height and support of the device.

[0039] See Figure 5 The electric transfer mechanism 3 includes a servo motor 301 and a gear and rack drive mechanism; a torque sensor 303 is connected between the servo motor and the gear and rack drive mechanism.

[0040] The gear and rack drive mechanism includes a drive gear 304 driven by a servo motor and a drive rack 307 meshing with the drive gear 304. The drive rack 307 is connected to the injection component and drives the injection component to move.

[0041] The servo motor 301 is connected to the torque sensor 303 via a coupling 302, and then transmitted to the drive gear 304 via the coupling.

[0042] The torque sensor 303 is used to detect torque changes in the transmission process in real time, and to determine the gear and rack meshing state and the cumulative displacement of the injection component in combination with the control system logic.

[0043] The servo motor 301 is horizontally mounted on the base support plate 402. The gear and rack drive mechanism includes a drive gear 304 driven by the servo motor and a drive rack 307 meshing with the drive gear 304. The servo motor outputs power to drive the gear and rack to mesh, thereby driving the material cylinder 1 to move longitudinally.

[0044] The drive rack 307 is mounted on the rack fixing plate 101 and connected to the lower part of the barrel through the rack fixing plate 101, thereby driving the drive rack and barrel to move as a whole through the drive gear. In other embodiments, the drive rack can also be set on the barrel seat, as long as the overall movement of the injection component can be achieved.

[0045] See Figure 1 , Figure 2 , Figure 4 The clamping assembly is pressed above the injection component to provide downward clamping force to the injection component; a roller-type clamping assembly is adopted, including a roller shaft 206 and a roller 207 disposed on the roller shaft. The roller shaft 206 is rotatably disposed on the elastic preload assembly 23 through a set of roller shaft bearing assemblies 208.

[0046] The elastic preload assembly 23 includes multiple spring guide shafts 205, preload springs 204 sleeved on the spring guide shafts, and roller mounting plate 210 disposed at the lower end of the spring guide shafts.

[0047] The roller adjustment assembly 22 adjusts the clamping force of the roller clamping assembly 21, and includes an adjustable clamping seat support frame 201 with a frame structure and a clamping roller limit block 202 that is vertically and vertically connected to the adjustable clamping seat support frame 201.

[0048] See Figure 6 , Figure 7 A method for controlling the movement of an integrated support and displacement device for injection components includes: a control system that presets a torque threshold and dynamically adjusts the cumulative displacement logic based on different stages of a detection curve. (1) No-meshing no-load stage: During the no-meshing stage, the torque is in the low value range, and the system judges it as no-load idling and does not accumulate it; (2) In the initial contact stage, when the drive gear and the drive rack make initial contact, the torque signal rises but does not stabilize. The system uses a delay, secondary confirmation, or filtering algorithm. When the torque signal fluctuates briefly or rises instantaneously, it enters the delay judgment stage. During the delay, the torque drops back to the effective meshing torque threshold T0 and is judged as an instantaneous collision or jitter signal, and the displacement is not accumulated. After the delay ends, the control system enters the secondary confirmation stage. If the torque value detected in multiple consecutive sampling cycles is higher than the effective meshing torque threshold T0 and the fluctuation range is within the allowable range, the displacement is accumulated. The control system can also use a moving average filtering algorithm to process the torque signal. Only when the average torque value is continuously higher than the set effective meshing torque threshold T0 will the control system allow the effective displacement accumulation state.

[0049] (3) Stable engagement stage: When the torque exceeds the set threshold and enters the stable range, it is confirmed that the effective engagement state has been entered, and the motor rotation angle is converted into the linear displacement of the injection molded part. (4) During the abnormal fluctuation phase, if the backlash is released due to reverse motion or the load suddenly increases due to blockage, the control system will immediately stop the accumulation or recalibrate, and continue the accumulation after the torque stabilizes.

[0050] Example 2:

[0051] See Figures 1-5 An integrated support and transfer device for injection components includes a height-adjusting support mechanism 4 for adjusting the overall height of the device and providing support, an electric transfer mechanism 3 integrated on the height-adjusting support mechanism 4, and an adjustable elastic clamping mechanism 2; wherein... The electric adjusting mechanism 3 uses a gear and rack transmission structure to provide adjusting force for the injection component; The adjustable elastic clamping mechanism 2 provides contact pressure to the gear and rack transmission mechanism through elastic force, and includes an adjustment component 22, an elastic pre-tightening component 23, and a clamping component 21 connected to the elastic pre-tightening component.

[0052] The height adjustment support mechanism 4 includes a lifting device 401, a base support plate 402, and a base support frame assembly 406.

[0053] The lifting device 401 can be a jack-type lifting device, a hydraulic cylinder-type lifting device, a pneumatic cylinder-type lifting device, or a scissor-type lifting device, etc., the purpose of which is to achieve overall height adjustment and support. In this embodiment, the lifting device 401 adopts a jack-type lifting device.

[0054] The base support frame assembly 406 includes an upper base support foot 403, a lower base support foot 404, and a lifting device fixing plate 405. It provides overall support for the electric adjustment system and enables height adjustment. The upper base support foot 403 and the lower base support foot 404 are connected by an adjustable height connection. An adjustment elongated hole 407 is provided on the lower base support foot 404, and an adjustment connection hole 408 is provided on the upper base support foot 403.

[0055] The base support plate 402 is horizontally arranged and mounted on the base support frame assembly 406 to support the material cylinder 1, the adjustable elastic clamping mechanism 2, and the electric adjusting mechanism 3.

[0056] The adjustable elastic clamping mechanism 2 is arranged above the material cylinder 1 to provide downward clamping force to the material cylinder. The electric adjusting mechanism 3 is arranged below the material cylinder to provide adjusting force.

[0057] The barrel 1, as the core component of the injection unit, is moved longitudinally via an electric moving mechanism 3. The barrel employs a machined structure, and a pressing stroke structure 102 is provided on the upper part of the barrel 1 along its axial direction. In this embodiment, the pressing stroke structure 102 is a moving plane disposed on the barrel. A rack fixing plate 101, arranged along the barrel's axial direction, is provided at the lower part of the barrel.

[0058] The height adjustment support mechanism 4 is located below the electric moving mechanism 3 and is used to adjust the overall height and support of the device.

[0059] The electric straightening mechanism 3 includes a servo motor 301 and a gear and rack drive mechanism. The servo motor 301 is horizontally mounted on the base support plate 402. The gear and rack drive mechanism includes a drive gear 304 driven by the servo motor and a drive rack 307 meshing with the drive gear 304. The servo motor outputs power to drive the gear and rack to mesh, thereby driving the material cylinder 1 to perform a straightening motion along the longitudinal direction.

[0060] The drive rack 307 is mounted on the rack fixing plate 101 and connected to the lower part of the material cylinder through the rack fixing plate 101, thereby driving the drive rack and the material cylinder to move as a whole through the drive gear.

[0061] The adjustable elastic clamping mechanism 2 includes a roller clamping assembly 21, a roller adjusting assembly 22, and an elastic pre-tightening assembly 23.

[0062] The roller-type clamping assembly 21 is positioned above the material cylinder 1 to provide downward clamping force to the material cylinder. The roller adjustment assembly 22 allows for adjustment of the clamping force of the roller-type clamping assembly 21.

[0063] The roller adjustment assembly 22 includes an adjustable clamping seat support frame 201 with a frame structure mounted on the base support plate 402, and a clamping roller limiting block 202 that is vertically adjustable to the adjustable clamping seat support frame 201. The elastic pre-tightening assembly 23 is disposed between the clamping roller limiting block 202 and the roller-type clamping assembly 21.

[0064] The pressure roller limiting block 202 is fixed to the adjustable pressure seat support frame 201 by screws and can be adjusted up and down along the adjustable pressure seat support frame 201. To enable the pressure roller limiting block 202 to be adjusted up and down along the adjustable pressure seat support frame 201, an adjusting slot 211 is provided on the adjustable pressure seat support frame 201. The adjustable pressure seat support frame 201 is adjustablely connected to the adjusting slot 211 by a set of limiting bolts 209, which are used to adjust and limit the pressure stroke.

[0065] The elastic preload assembly 23 includes multiple spring guide shafts 205, preload springs 204 sleeved on the spring guide shafts, and a roller mounting plate 210 disposed at the lower end of the spring guide shafts. The elastic preload assembly 23, in conjunction with the roller-type pressing assembly, forms a spring-preloaded adjustable elastic pressing mechanism 2.

[0066] The spring guide shaft 205 passes through the pressure roller limiting block 202, with its upper end extending out of the upper end of the pressure roller limiting block 202. It is positioned by the spring guide shaft cover 203, thus guiding the roller mounting plate 210. The roller mounting plate 210 has a floating structure and is suspended inside the adjustable pressure seat support frame 201.

[0067] The roller-type clamping assembly 21 includes a roller shaft 206 and rollers 207 disposed on the roller shaft. The roller shaft 206 is rotatably disposed below the roller mounting plate via a set of roller shaft bearing assemblies 208.

[0068] The roller 207 is supported by the roller shaft 206 and the roller shaft bearing assembly 208. It can rotate with the movement of the material cylinder and apply a continuous downward clamping force to the material cylinder 1, thereby ensuring stable meshing between the lower drive gear 304 and the drive rack 307.

[0069] The spring guide shaft 205 is fitted with a compression spring, and the spring guide shaft cover 203 is fixed to the upper end of the clamping limit block, serving as a guide and limiter; the roller shaft 206 is rotatably mounted through the roller shaft bearing assembly 208, supporting the roller 207. The roller 207 contacts the upper part of the material cylinder, generating rolling friction as the material cylinder moves, and providing continuous clamping force to ensure stable meshing of the gear and rack.

[0070] like Figure 4As shown, the electric transfer mechanism 3 further includes a servo motor 301, a coupling 302, a torque sensor 303, a drive gear 304, a drive gear bearing seat 305, and a drive gear bearing base plate 306.

[0071] The drive shaft 309 of the servo motor 301 is connected to the torque sensor 303 via a coupling 302, and then transmitted to the drive gear 304 via the coupling. The drive gear 304 is mounted on the drive gear bearing base plate 306 via a drive gear bearing seat 305, and meshes with the drive rack 101. The torque sensor 303 is used to detect torque changes in real time during transmission, and, in conjunction with the control system logic, determines the meshing state and displacement accumulation to achieve high-precision displacement control.

[0072] The working principle of the integrated injection component transfer and support device is as follows: After the injection unit and barrel are assembled, the overall installation height is first precisely adjusted using the height adjustment support mechanism 4 to ensure that the drive gear 304 meshes correctly with the drive rack 101 fixed on the barrel rack fixing plate. The height adjustment support mechanism 4 uses a jack-type lifting device, which adjusts the overall height by pushing the fixing plate 405 and the base support plate 402, and the base support feet assist in bearing the weight of the structure.

[0073] In terms of control execution, the electric rectifier mechanism 3 starts after receiving instructions from the host computer. The servo motor 301 transmits power sequentially through the coupling 302, torque sensor 303, and drive gear 304 to achieve linear motion of the rack 101. To reduce the impact of gear and rack backlash, reverse backlash, and instantaneous impact on displacement accuracy, a torque sensor 303 is installed between the servo motor 301 and the drive gear 304, forming a closed-loop linkage control with the control system. This sensor is used to monitor the output torque in real time and form a closed-loop linkage with the control system.

[0074] See Figure 6 Control flow diagram and reference Figure 7 The detection curves for each stage of engagement are generated. The control system presets torque thresholds and dynamically determines the current engagement state and displacement accumulation logic based on real-time detected torque changes. (1) No-meshing no-load stage: The torque is in the low range, the system judges it as no-load idling and does not accumulate.

[0075] When the servo motor 301 starts, the drive gear 304 has not yet made contact with the drive rack 101, and the output value of the torque sensor 303 remains in the low range, which the system determines as an unloaded idling state. At this time, although the servo motor 301 has rotated, no displacement accumulation is performed, thereby avoiding false displacement caused by backlash.

[0076] (2) Initial contact stage: When the drive gear and the drive rack make initial contact, the torque signal rises but does not stabilize. The system adopts a delay or secondary confirmation method to avoid errors caused by meshing jitter.

[0077] As the drive gear 304 gradually approaches and begins to contact the drive rack 101, the torque signal shows a slow upward trend. However, since the meshing is not yet stable, there may be momentary jitter, slight impact, or contact on one side of the tooth surface. During this stage, the control system uses a delayed judgment, secondary confirmation, or filtering algorithm. Only when the torque continues to rise steadily and reaches the set condition is the system allowed to proceed to the next stage to avoid misjudgment.

[0078] To avoid misjudgment caused by backlash, vibration, or instantaneous impact during the initial contact phase between the drive gear 304 and the drive rack 101, a delay judgment, secondary confirmation, and filtering logic are incorporated into the control system. The specific control process is as follows: When the servo motor 301 starts, the control system collects the output signal of the torque sensor 303 in real time at a fixed period (e.g., 10ms) and sets the effective engagement torque threshold T0.

[0079] When the drive gear 304 has not yet contacted the drive rack 101, the torque value is always lower than the effective meshing torque threshold T0. The control system determines that it is in an unloaded idle state. At this time, although the servo motor has rotated, it does not accumulate displacement to avoid false displacement caused by backlash.

[0080] When the drive gear 304 gradually contacts the drive rack 101, the torque signal will fluctuate briefly or rise instantaneously. At this time, the control system will not immediately enter the displacement calculation, but will enter the delay judgment stage. The delay time can be set as needed from 20ms to 80ms. For example, the continuous delay can be set to 50ms, and the torque change will continue to be detected. If the torque drops below the effective meshing torque threshold T0 again during the delay period, it is judged as a momentary collision or jitter signal and will not be accumulated. After the delay ends, the control system will further enter the secondary confirmation stage, setting 2 to 5 consecutive sampling cycles. For example, if the torque value is detected to be higher than the effective meshing torque threshold T0 for 3 consecutive sampling cycles, and the fluctuation range is within the allowable range, it is confirmed that the drive gear and the drive rack have formed a stable mesh. At this time, the servo motor encoder angle is converted into the actual linear displacement of the barrel and the injection table and accumulated.

[0081] To further reduce errors caused by mechanical vibration and impact, the control system can also use a moving average filtering algorithm to process the torque signal. For example, the average of the five most recent sampled values ​​T1, T2, T3, T4, and T5 can be calculated and used as the final judgment criterion. Tavg=(T1+T2+T3+T4+T5) / 5 The control system is only allowed to enter the effective displacement accumulation state when the average torque value is continuously higher than the set effective engagement torque threshold T0.

[0082] If, during the reverse movement or stop of the equipment, the average torque is detected to drop below the effective meshing torque threshold T0, the control system automatically pauses displacement accumulation and re-enters the meshing state judgment process. Displacement accumulation resumes only after the torque stabilizes. This control logic effectively eliminates accumulated errors caused by gear and rack backlash, reverse travel, and instantaneous impacts, improving the positioning accuracy, repeatability, and operational stability during the repositioning of the injection unit in large injection molding machines.

[0083] (3) Stable meshing stage: When the detected torque exceeds the set effective meshing torque threshold T0 and remains stable, the control system confirms that the drive gear and drive rack have entered an effective meshing state. At this time, the servo motor rotation angle and encoder signal are converted into the actual linear displacement of the barrel and the injection table, and the cumulative calculation is performed. The displacement data in this stage serves as the effective feedback data for the displacement control.

[0084] (4) Abnormal fluctuation stage: During operation, if backlash release, motion obstruction, or sudden load increase occurs due to reverse motion, the torque signal will fluctuate significantly. After detecting the abnormality, the control system immediately pauses displacement accumulation and re-enters the state judgment process; after the torque stabilizes, displacement calculation continues. This dynamic adjustment logic can effectively avoid cumulative errors caused by instantaneous impact or meshing clearance.

[0085] The above control method achieves dynamic coupling control of displacement accumulation and torque state, effectively improving the repeatability, operational stability, and long-term reliability during injection unit relocation. It is particularly suitable for high-load, high-precision relocation conditions in large injection molding machines. It effectively eliminates cumulative deviations caused by backlash, instantaneous impact, or assembly errors, significantly improving relocation accuracy and repeatability. It also solves the problem of backlash errors that may occur in traditional systems during gear and rack meshing, leading to inaccurate positioning, especially under no-load and backlash conditions, which may cause malfunctions and affect the system's accuracy and reliability.

[0086] The injection component transfer and support integrated device has an adjustable elastic clamping mechanism above the barrel 1. It uses a floating roller with pre-clamping force to continuously apply downward clamping force to the barrel to ensure that the lower drive gear and drive rack always maintain tight meshing.

[0087] An adjustable clamping seat support frame 201 is mounted on a base support plate 402. The clamping roller limit block 202 is connected to the adjustable clamping seat support frame 201 by bolt adjustment, allowing for adjustment of the relative height to control the clamping force. A spring guide shaft 205 restricts the freedom of the roller mounting plate and is coaxially arranged with the spring. The roller is mounted on a roller shaft 206 with a roller bearing assembly, directly contacting the upper surface of the material cylinder 1 to provide clamping force. This design not only prevents gear rack and pinion from skipping teeth and creating backlash due to vibration, uneven force, or slight displacement of the material cylinder, but also compensates for tooth surface wear and assembly errors, ensuring meshing accuracy during long-term operation. Utilizing the flexible preload characteristics of the spring, the clamping force automatically adjusts according to the meshing state, resulting in smooth transmission, reduced impact and noise, thereby significantly improving the system's reliability and service life.

[0088] The material cylinder's forward and backward movement and support functions are achieved through a gear and rack drive mechanism. A servo motor drives the gear to rotate, and the drive gear meshes with a drive rack fixed to the material cylinder, realizing the overall movement of the material cylinder and providing support force. A dynamic torque sensor is connected between the servo motor and the drive gear. This scheme, combining the dynamic torque sensor with the motor control system, ensures that the system only starts calculating displacement under effective load, thus avoiding no-load errors.

[0089] The engagement height between the drive gear and the drive rack is adjusted by a jack-type lifting device to ensure precise drive under different working conditions.

[0090] The adjustable elastic clamping mechanism 2 ensures that the drive rack and drive gear always maintain appropriate contact pressure through spring force, thus guaranteeing the stability of the barrel.

[0091] The gear shaft 308 of the drive gear 304 is rotatably supported by two drive gear bearing seats 305, ensuring that it can provide support force to the barrel. The drive gear bearing seats 305 are connected to the base support plate 402 through the drive gear bearing base plate 306.

[0092] In another embodiment, the height adjustment support mechanism 4 may also employ other lifting devices such as hydraulic cylinder type, pneumatic cylinder type, or lifting fork type.

[0093] The electric repositioning mechanism for moving the injection unit and barrel includes a servo motor. The servo motor is connected to a dynamic torque sensor via a coupling. The dynamic torque sensor is connected to a gear shaft 308 via a coupling. A drive gear is mounted on the gear shaft 308, and both ends of the gear shaft are fixed to two drive gear bearing seats. The drive gear bearing seats are bolted to the base support plate. The drive gear works in conjunction with a drive rack fixed to a rack fixing plate 101. When the drive gear rotates, the drive rack achieves linear motion, driving the rack fixing plate 101 and the barrel to move. The reinforced barrel then drives the entire injection stage to achieve the repositioning function. When the drive motor starts working, the torque sensor can monitor the torque, speed, and other information transmitted on the current motor drive shaft 309 in real time and feed it back to the controller to provide feedback on the current position information of the barrel.

[0094] The adjustable elastic clamping mechanism is bolted to the base support plate 402, allowing for height adjustment along with the base support plate. The spring guide shaft is mounted on the floating roller mounting plate and connected to the clamping roller limit block via a spring guide shaft steel sleeve mounted on the clamping roller limit block. The spring guide shaft cover is mounted on the top of the spring guide shaft, serving as a limit. The floating roller mounting plate can move up and down along the spring guide shaft. The clamping roller limit block can dynamically adjust its height according to changes in the cylinder size and required clamping force, and is fixedly connected to the adjustable clamping seat support frame via bolt adjustment.

[0095] In other embodiments, various equivalent replacements or improvements can be made to the installation method of the servo motor, the arrangement of the gear and rack transmission mechanism, the structural style of the roller clamping mechanism, and the detection and control strategy of the torque sensor. For example, different types of drive devices can be used, the connection method between the barrel and the injection table can be adjusted, or the method of achieving the clamping force can be changed.

[0096] The injection component transfer and support integrated device in the above embodiments replaces the hydraulic cylinder used for barrel and injection stage transfer in the injection molding machine with a servo motor driven gear and rack transmission mechanism. Combined with the height adjustment support mechanism 4 and the adjustable elastic clamping mechanism 2, it solves the problem that the traditional hydraulic cylinder is too long and requires longitudinal support and has a complicated structure. This makes the transfer device have both support and driving functions and the structure is more compact.

[0097] Meanwhile, the torque sensor is linked with the motor control system, performing displacement calculations only when the drive gear and drive rack are effectively meshed and generate a load. This avoids displacement errors caused by backlash and improves the accuracy and stability of the barrel and injection stage movement. Compared with traditional solutions that rely on hydraulic cylinders, this integrated device reduces space occupation, lowers reliance on the hydraulic system, and has higher reliability and wider application value.

Claims

1. An integrated device for adjusting and supporting injection components, characterized in that: It includes a height-adjusting support mechanism (4) for adjusting and supporting the overall height of the device, an electric adjusting mechanism (3) integrated on the height-adjusting support mechanism (4), and an adjustable elastic clamping mechanism (2); wherein, The electric adjusting mechanism (3) adopts a gear and rack transmission structure to provide adjusting force for the injection component; The adjustable elastic clamping mechanism (2) provides contact pressure to the gear and rack transmission mechanism through elastic force, including an adjustment component (22), an elastic pre-tightening component (23), and a clamping component (21) connected to the elastic pre-tightening component.

2. The integrated injection component transfer and support device according to claim 1, characterized in that: The clamping assembly (21) is pressed above the injection component to provide downward clamping force to the injection component; a roller-type clamping assembly is adopted, including a roller shaft (206) and a roller (207) disposed on the roller shaft. The roller shaft (206) is rotatably disposed on the elastic preload assembly (23) through a set of roller shaft bearing assemblies (208).

3. The integrated injection component transfer and support device according to claim 1, characterized in that: The elastic preload assembly (23) includes multiple spring guide shafts (205), a preload spring (204) sleeved on the spring guide shaft, and a roller mounting plate (210) disposed at the lower end of the spring guide shaft.

4. The integrated injection component transfer and support device according to claim 1, characterized in that: The roller adjustment assembly (22) includes an adjustable pressure seat support frame (201) with a frame structure and a pressure roller limit block (202) that is vertically and vertically connected to the adjustable pressure seat support frame (201).

5. The integrated injection component transfer and support device according to any one of claims 1 to 4, characterized in that: The high-electric-speed transfer mechanism (3) includes a servo motor (301) and a gear and rack drive mechanism; a torque sensor (303) is connected between the servo motor (301) and the gear and rack drive mechanism.

6. The integrated injection component transfer and support device according to claim 5, characterized in that: The gear and rack drive mechanism includes a drive gear (304) driven by a servo motor and a drive rack (307) meshing with the drive gear (304). The drive rack (307) is connected to the injection component and drives the injection component to move. The servo motor (301) is connected to the torque sensor (303) through a coupling (302) and then transmitted to the drive gear (304) through the coupling.

7. The integrated injection component transfer and support device according to claim 5, characterized in that: The torque sensor (303) is used to detect torque changes in the transmission process in real time, and to determine the gear and rack meshing state and the cumulative displacement of the injection component in combination with the control system logic.

8. The integrated injection component transfer and support device according to any one of claims 1 to 4, characterized in that: The height adjustment support mechanism (4) includes a lifting device (401), a base support plate (402), and a base support frame assembly (406).

9. A method for controlling the movement of the device according to any one of claims 1 to 8, comprising: The control system sets an effective engagement threshold T0, the host computer sends a displacement command, the servo motor starts, the torque sensor detects the torque in real time, the engagement state is determined, and the displacement accumulation logic is dynamically adjusted according to different stages of the detection curve; the engagement state determination includes: (1) During the no-meshing unloaded stage, if the torque is lower than the threshold T0, it is judged as unloaded and the displacement is not accumulated; (2) In the initial contact stage, the torque signal rises but does not stabilize. The system adopts a delayed judgment, secondary confirmation or filtering algorithm. (3) During the stable engagement stage, the torque exceeds the threshold T0 and stabilizes, and the cumulative displacement begins; (4) Abnormal fluctuation stage: Abnormal fluctuation is detected during operation, the accumulation is paused and recalibrated, and the displacement continues to accumulate after the torque recovers and stabilizes.

10. The displacement control method according to claim 9, characterized in that: When the torque signal experiences short-term fluctuations or instantaneous increases, it enters the delay judgment stage. During the delay, if the torque drops back to the effective meshing torque threshold T0, it is judged as an instantaneous collision or jitter signal, and displacement is not accumulated. After the delay ends, the control system enters the secondary confirmation stage. If the torque value detected in multiple consecutive sampling cycles is higher than the effective meshing torque threshold T0, and the fluctuation range is within the allowable range, displacement accumulation begins. The control system can also use a moving average filtering algorithm to process the torque signal. Only when the average torque value is continuously higher than the set effective meshing torque threshold T0 will the control system allow it to enter the effective displacement accumulation state.

Images