Automated Insert Gripping for Injection Overmolding
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Solution Overview
Problem
Current manufacturing devices for thermoplastic parts with composite inserts require manual operator intervention for insert positioning, leading to inefficiencies and challenges in achieving high production rates, especially for parts with complex geometries, and often necessitate additional finishing steps.
Innovation Solution
An automated gripping device transports and positions the insert within the mold, enabling automated manufacturing processes that eliminate the need for manual operator intervention, integrate injection nozzles for resin distribution, and utilize simulation software to predict and adjust parameters for precise geometry and mechanical properties, allowing for direct transfer to storage or assembly without finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operator intervention is used for insert positioning, then the device complexity is reduced, but the productivity decreases and manufacturing precision is compromised
Solution Approach 1:
The gripping device automatically positions the insert in the mold without requiring manual operator intervention. The system serves itself by incorporating automated gripping mechanisms that transport and position inserts, enabling continuous operation at high manufacturing rates of 60-90 seconds per part while maintaining precision through controlled positioning mechanisms
Solution Approach 2:
Manual mechanical positioning by operators is replaced with an automated gripping device system. The gripping device uses mechanical grippers controlled by automation systems to transport and position inserts, substituting human labor with automated mechanical systems that achieve both high speed and precision
2Productivity
If automated gripping device is implemented, then the productivity increases, but the device complexity increases
Solution Approach 1:
The gripping device is designed with multi-functionality to justify its complexity. It performs multiple operations including gripping the insert, transporting it to the mold, positioning it precisely, and also recovering finished parts from the mold. This consolidation of multiple functions into one device maximizes productivity while managing complexity through functional integration
3Manufacturing precision
If injection nozzles are integrated into the mold, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The injection nozzles are integrated directly into the mold structure, merging the injection system with the molding tooling. This integration ensures precise resin delivery to the insert, achieving accurate geometry and proper impregnation. The merging of functions reduces the number of separate components and improves manufacturing precision through controlled injection positioning
4Manufacturing precision
If simulation software is used to predict parameters, then the manufacturing precision is improved, but the loss of time in setup increases
Solution Approach 1:
Simulation software is used in advance to predict and optimize manufacturing parameters such as resin injection timing, temperature, and pressure before actual production. This preliminary action allows precise parameter determination that ensures accurate geometry and mechanical properties, preventing defects before they occur and reducing the need for trial-and-error adjustments during production
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
The solution significantly increases manufacturing efficiency by automating the insert positioning and part recovery, achieving high production rates of up to 60-90 seconds per part, eliminates the need for finishing steps, and ensures precise geometry and mechanical properties, suitable for complex parts, thereby enhancing productivity and reducing reworking costs.
Implementation Method 1
injection means, comprising injection nozzles... the injection of a resin into the injection cavity, to overmold the insert
Implementation Method 2
the heating of the insert, in a furnace... The temperature in the injection overmolding stamping mold is advantageously between 100 and 160°C
Implementation Method 3
injection of a resin into the injection cavity, to overmold the insert, in order to form the part, hardening the part
Data Source
Figure 1
Figure 2
AI summary
The manufacturing device (10) includes at least one insert (14), the manufacturing device (10) comprising a mold (16) having first (18) and second (20) parts movable relative to each other, delimiting between them an injection cavity, and the first part of the mold (18) having means (22) for receiving the insert (14), characterized in that it includes a device (32) for gripping the insert (14), suitable for transporting the insert (14) from a first location to the means (22) for receiving the insert.