Molding Machine Barrel Heating Control for Faster Zone Warm-Up
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Solution Overview
Problem
Existing automatic temperature rise control methods for molding machines require an excessively long time for master and slave sections to reach their final target temperatures due to simultaneous heating, which inefficiently utilizes the heat generation capacity of slave sections.
Innovation Solution
An automatic temperature rise control method that sets tentative target temperatures for heating zones, selects a master and slave zone based on temperature attainment rates, and adjusts heating to reach final target temperatures individually, optimizing heat transfer and utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If simultaneous temperature rise control is applied to master and slave sections, then temperature uniformity is improved, but temperature rise time becomes excessively long
Solution Approach 1:
The patent applies preliminary action by having slave sections heat up to tentative target temperatures before the master section reaches its final target temperature. This preliminary heating of slave sections ensures they are ready to quickly respond and transfer heat when needed, rather than waiting for synchronized temperature rise. The control device sets tentative target temperatures for slave sections that are reached in advance, creating a head start that will be utilized in the subsequent coordinated heating phase.
Solution Approach 2:
The patent implements dynamics by dynamically adjusting the target temperatures of slave sections based on the master section's temperature rise progress. The control device continuously monitors the master section's temperature and dynamically modifies the slave sections' target temperatures from tentative values to final values as the master section approaches its target. This dynamic adjustment allows the system to adapt heating rates and timing, enabling slave sections to heat faster initially and then synchronize with the master section, thus reducing overall temperature rise time while maintaining temperature uniformity.
2Productivity
If slave sections heat at full capacity simultaneously with master section, then productivity is improved, but heat transfer efficiency deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-heating slave sections to tentative target temperatures before the master section completes its heating. This preliminary heating allows slave sections to accumulate thermal energy in advance, so when the master section needs additional heat transfer, the slave sections are already prepared to provide it efficiently. This avoids the energy waste that would occur if slave sections heated at full capacity simultaneously without needing to transfer heat to the master section.
Solution Approach 2:
The patent implements feedback by continuously monitoring the master section's temperature rise progress and using this information to adjust slave section heating targets. The control device receives temperature information from the master section and dynamically adjusts the slave sections' target temperatures accordingly. This feedback mechanism ensures that slave sections only heat to full capacity when the master section actually needs the heat transfer, optimizing heat transfer efficiency while maintaining high productivity.
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 method reduces the time required for master and slave sections to reach their final target temperatures, accelerating the start-up operation of molding machines by optimizing heat transfer and utilizing heating capacities more efficiently.
Implementation Method 1
multiple heaters are disposed on an outer peripheral portion of the heating cylinder... For raising the temperatures of the respective heating sections, the heating section that requires the longest time to reach a preset target temperature is set as a master section
Implementation Method 2
thereby decreasing an amount of heat to be transferred from the slave sections to the master section via the barrel
Data Source
AI summary
A method for controlling temperature rise in divided heating zones of a barrel of a molding machine includes: setting tentative target temperatures for the respective heating zones; simultaneously raising temperatures in the heating zones to the set tentative target temperatures; when temperatures in the heating zones reach the respective tentative target temperatures, selecting a master zone from the heating zones, and selecting, as a slave zone, a heating zone which is other than the master zone among the heating zones; and after temperatures in the heating zones reach the respective tentative temperatures, raising the temperatures in the master zone and the slave zone to respective final target temperatures according to an attainment degree of temperature rise in the master zone.