Diecasting Injection Plunger Drive for High-Speed Clean Casting
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Solution Overview
Problem
Conventional diecasting machines relying solely on electric servomotors for high-speed injection face limitations in acceleration and require large motors, making it difficult to achieve high injection speeds while maintaining a clean and efficient process.
Innovation Solution
A diecasting machine design that combines an electric servomotor as the primary drive source with a hydraulic drive source as an auxiliary power source, allowing for the release of hydraulic power to achieve high-speed injection by advancing the injection plunger quickly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an electric servomotor is used as the sole drive source for injection, then the machine is clean and maintenance-free, but the injection speed acceleration is limited and large motors are required
Solution Approach 1:
The injection process is segmented into two distinct phases: low-speed injection driven by the electric servomotor and high-speed injection driven by the hydraulic drive source. This segmentation allows each drive source to operate in its optimal performance range, with the electric motor handling precision positioning and the hydraulic system providing high-speed acceleration.
Solution Approach 2:
The patent combines two different drive sources (electric servomotor and hydraulic drive source) into a single injection system. The electric servomotor and hydraulic drive source are merged to work together, with the electric motor providing initial movement and the hydraulic system providing boosted acceleration for high-speed injection.
2Speed
If a large hydraulic drive source is used for high-speed injection, then high injection speed is achieved, but the machine involves potential risk of smear with oil
Solution Approach 1:
The injection process is divided into low-speed and high-speed phases, with different drive sources used for each phase. The hydraulic drive source is only activated during the high-speed injection phase, minimizing oil exposure and smear risk while still achieving the required injection speed.
Solution Approach 2:
The electric servomotor performs preliminary action by advancing the injection plunger to the required position before the high-speed injection phase begins. This preliminary positioning allows the hydraulic system to be activated only when needed for high-speed acceleration, reducing overall oil exposure.
3Speed
If a large motor is used to assure high injection speed, then the injection speed is achieved, but the device size and power consumption increase
Solution Approach 1:
The drive system is segmented into two stages with different power requirements. The electric servomotor uses smaller power for low-speed positioning, and the hydraulic drive source provides high-power output only during the brief high-speed injection phase, reducing overall power consumption and motor size requirements.
Solution Approach 2:
The hydraulic drive source operates periodically only during the high-speed injection phase rather than continuously. This periodic activation reduces the average power consumption and allows for smaller motor and hydraulic system sizing compared to continuous high-power operation.
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 combination enables high-speed injection with improved responsibility and efficiency, ensuring high-quality castings are produced in a shorter time while minimizing the risk of fluid smear and energy consumption.
Implementation Method 1
an electric servomotor usable as a first drive source capable of driving the injection plunger at an advancing speed lower than 1 m/sec
Implementation Method 2
a hydraulic drive source usable as a second drive source capable of driving the injection plunger at an advancing speed not lower than 1 m/sec
Data Source
AI summary
A diecasting machine is provided with a mold and an injection plunger to inject and fill molten metal in the mold by an advancement of the injection plunger. The diecasting machine includes an electric servomotor and a hydraulic drive source. The electric servomotor is usable as a first drive source capable of driving the injection plunger at an advancing speed lower than 1 m/sec, while the hydraulic drive source is usable as a second drive source capable of driving the injection plunger at an advancing speed not lower than 1 m/sec.