Edge Interface Monitoring for Injection Molding Robot Signals
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Solution Overview
Problem
Current injection molding systems lack efficient monitoring, recording, and analysis capabilities for control and response signals between injection-molding machines and robotic handling devices, leading to inefficiencies and potential mechanical defects that affect production consistency and quality.
Innovation Solution
An edge device interface system that captures and analyzes control and response signals between injection-molding machines and robotic handling devices, using standards-compliant connectors and computational resources for real-time data recording, analysis, and adjustment, allowing for simulation of virtual devices and remote processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an automated injection molding system uses robots and IMM without monitoring capabilities, then productivity is increased through automation, but manufacturing precision deteriorates due to lack of control and detection of defects
Solution Approach 1:
The patent implements a monitoring system that captures control signals from the IMM controller and response signals from the robotic handling device, storing them in databases for analysis. This feedback mechanism enables real-time or post-process analysis of system performance, allowing detection of deviations and maintenance of manufacturing precision while preserving automated productivity.
Solution Approach 2:
The monitoring system acts as an intermediary between the IMM controller and robotic handling device, intercepting and analyzing control and response signals without disrupting the automated operation. This intermediary capability enables precision monitoring and defect detection while maintaining the productivity benefits of automation.
2Device complexity
If no monitoring system is implemented, then device complexity remains low, but measurement precision deteriorates due to inability to detect and analyze control signals
Solution Approach 1:
The monitoring system serves as an intermediary that interfaces with existing IMM and robotic systems through standard connectors, capturing control and response signals without requiring fundamental system redesign. This approach enables precise signal measurement while adding minimal complexity to the existing automated injection molding system.
3Manufacturing precision
If real-time monitoring and analysis capabilities are added, then manufacturing precision is improved through defect detection, but device complexity increases due to additional hardware and software components
Solution Approach 1:
The monitoring system is designed as an intermediary layer that interfaces with existing IMM and robotic systems through standard Euromap connectors, capturing control and response signals without requiring fundamental system redesign. This modular approach enables precise monitoring while managing complexity through standardized interfaces and separate functional modules including signal capture, data storage, and analysis components.
4Reliability
If comprehensive signal capture and analysis is implemented, then reliability is improved through identification of mechanical defects, but loss of time increases due to data processing requirements
Solution Approach 1:
The monitoring system captures and stores control signals from the IMM controller and response signals from the robotic handling device in databases during normal operation, preparing data for analysis in advance. This preliminary data collection enables subsequent rapid analysis and defect identification, improving reliability without significant time loss during critical manufacturing operations.
Data Source
AI summary
An edge device interface system and method for monitoring, recording, and calculating control and response signals generated by and between an injection molding system including an injection-molding machine and a robotic handling device. The edge device interface system of the invention includes an edge device interposed between the connector of the injection-molding machine and the connector of a robotic handling device using standardized connectors. The edge device interface system may be interposed between the connector of the injection-molding machine and the connector of a robotic handling device to emulate the function of either device as desired. The edge device interface system and method utilizes data observed both from standardized connectors and auxiliary inputs to provide insight into molding process steps and equipment, including what components of the injection molding system that may be contributing to any molding process instability or inefficiency, and for generating signals for real-time adjustment of the molding process.