Actuator Controller for Selective Piston Velocity Control
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Solution Overview
Problem
Injection molding systems lack the ability to selectively adjust the velocity and travel length of an actuator piston during the injection cycle, limiting precision and efficiency in molding processes.
Innovation Solution
An injection molding apparatus with an actuator controller that adjusts the rate of travel of the actuator piston by routing drive fluid at different flow rates, allowing for two distinct velocities and adjustable travel lengths, enabling precise control over the piston's movement from a gate closed position to an intermediate and further upstream position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single velocity control mode is used for the actuator piston, then the device complexity is reduced, but the manufacturing precision and process control capability deteriorate
Solution Approach 1:
The controller divides the piston travel into multiple segments (first travel length and second travel length) and assigns different velocity control modes to each segment. The first segment uses a first velocity adjustor for lower velocity control, while the second segment uses a second velocity adjustor for higher velocity control, enabling precise control at different stages without requiring a completely complex unified control system.
Solution Approach 2:
The system dynamically switches between different velocity control modes based on the piston's travel position. The controller automatically transitions from the first velocity control mode during the first travel length to the second velocity control mode during the second travel length, allowing the system to adapt its control characteristics to the specific requirements of each stage of piston movement.
2Adaptability or versatility
If multiple velocity adjustors and travel length adjustors are implemented, then the adaptability and process control capability are improved, but the device complexity increases
Solution Approach 1:
The controller is designed as a multi-functional device that integrates both velocity adjustors and travel length adjustors in a single unit. The first velocity adjustor controls velocity during the first travel length, while the second velocity adjustor controls velocity during the second travel length. The controller universally manages all adjustment functions, reducing the need for separate independent control devices and minimizing overall system complexity.
3Productivity
If the piston travels at high velocity throughout the entire行程, then the productivity is improved, but the manufacturing precision deteriorates
Solution Approach 1:
The piston movement is divided into periodic phases with different velocity characteristics. During the first phase (first travel length), the piston moves at a lower velocity controlled by the first velocity adjustor to ensure precision. During the second phase (second travel length), the piston moves at a higher velocity controlled by the second velocity adjustor to improve productivity. This periodic variation in velocity optimizes both precision and efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the precision and efficiency of the injection molding process by allowing selective adjustment of piston velocity and travel length, improving the molding outcome and process control.
Implementation Method 1
the piston 56 dividing the piston bore into an upstream fluid drive chamber 75 communicating with a source S of drive fluid through an upstream drive fluid channel 72u and a downstream fluid drive chamber 77 communicating with the source S of drive fluid through a downstream drive fluid channel 72d
Implementation Method 2
the controller housing 202 and the piston 300 being adapted to route drive fluid that exits 6ue the upstream drive chamber 75 of the actuator 50 to exert a drive fluid force that drives the piston 300 upstream through a predetermined path of upstream controller travel FP1 through the controller piston bore 302
Data Source
AI summary
An injection molding apparatus comprising an injection machine, a manifold, a mold, a clamp plate, an actuator interconnected to a valve pin and an external actuator controller, the actuator controller comprising a controller housing adapted to control upstream flow of drive fluid from an upstream actuator drive chamber such that the rate of travel of the drive piston is selectively adjustable to a first rate of travel or velocity over a first course of travel from a gate closed position to a predetermined position of upstream travel and such that the rate of travel of the drive piston beyond the predetermined intermediate upstream position occurs at a second rate of travel or velocity that is higher than the first rate of travel or velocity.