Electric Clamping with Check Point for Core Drawing
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Solution Overview
Problem
Die casting machines face inefficiencies and potential damage due to the need for serial operation of clamping and core-drawing-in processes, which lengthen cycle time and risk damage to mechanisms unless the core-drawing-in process is completed before final mold closing.
Innovation Solution
A method for electric clamping using a die casting machine with a servo-motor driven clamping unit that performs core-drawing-in and clamping processes in parallel, utilizing a check point to ensure safety by detecting the completion of core-drawing-in before proceeding with clamping, thereby preventing premature clamping and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clamping process and core-drawing-in process are performed in series, then the clamping operation is safe and secure, but the cycle time is lengthened and productivity is reduced
Solution Approach 1:
The patent applies preliminary action by performing the core-drawing-in process before the final clamping operation. A check point is set at a position nearer to the operational start position by a predetermined distance, allowing the core to be drawn into the cavity in advance. This ensures the core is properly positioned before clamping force is applied, maintaining safety while enabling parallel processing to reduce cycle time.
2Productivity
If the clamping process and core-drawing-in process are performed in parallel, then the cycle time is shortened and productivity is enhanced, but the risk of damage to the core, mechanism, or mold increases
Solution Approach 1:
The patent implements feedback control by detecting whether the movable mold reaches the check point during parallel operation. The system monitors the position of the movable mold and the completion status of core-drawing-in, and only allows the clamping process to continue if the core has been fully drawn into the cavity. This feedback mechanism ensures safety while maintaining the productivity benefits of parallel processing.
3Productivity
If the movable mold speed is increased to enhance productivity, then the cycle time is reduced, but the risk of premature clamping and damage to mechanisms increases
Solution Approach 1:
The patent applies preliminary action by setting a check point at a position nearer to the operational start position by a predetermined distance. This allows the system to verify core-drawing-in completion before the movable mold reaches the final clamping position, even at high speeds. The predetermined distance provides a safety buffer that prevents premature clamping 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 approach shortens molding cycle time, enhances productivity, and securely prevents damage to the clamping mechanism and mold/core by ensuring the core-drawing-in process is complete before clamping, thus improving efficiency and safety.
Implementation Method 1
the clamping unit driven by a servo-motor to reciprocate the movable mold through a predetermined stroke and clamp the two molds together
Implementation Method 2
a core system for reciprocating a core between a retreating position and a position in which the core is fully drawn into the cavity using an actuator provided on the movable mold
Data Source
AI summary
Disclosed is a method for electric clamping, which performs a clamping process in parallel with a core-drawing-in process, avoiding damages of molds and core mechanisms and enabling secure clamping. The method comprises the steps of: setting a check point, for judging safety of the clamping process in advance, in a position that is nearer to the operational start position by a predetermined distance in the mold opening direction than a position of the movable mold when the core-drawing-in process is expected to be completed, wherein the core-drawing-in process and the clamping process proceed in parallel with each other in a straight course for reciprocating a movable mold; activating a core system and a servo-motor to start an operation to draw a core into a cavity in parallel with an operation to move the movable mold in the mold closing direction; detecting whether or not the movable mold reaches the check point; judging whether or not the core reaches the position in which the core is fully drawn into the cavity at a point of time at which the movable mold reaches the check point, and confirming the completion of the core-drawing-in process. Thereafter, the clamping process of the molds is further continued if confirming that the core-drawing-in process is already completed.