Hot Runner Repair Tool for Modular Injection Molding Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing injection molding systems with hot runners require extensive downtime for maintenance, as the entire system must be shut down for on-site repairs, leading to significant financial losses due to prolonged periods of inoperability.
Innovation Solution
A tool is designed to support the hot runner module, allowing it to be removed and serviced remotely, featuring a first and second plate structure with nozzle acceptance openings and elongate spacers for secure placement and withdrawal, enabling modular hot runner systems to be isolated and replaced without disrupting the entire injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hot runner system is integrally constructed with the molten material feed system, then the structural integrity and reliability are improved, but the ease of repair and maintenance time are worsened
Solution Approach 1:
The hot runner system is divided into modular components including a manifold assembly and separate nozzle assemblies that can be independently removed and serviced. The manifold plate is separable from the injection molding machine, allowing specific components to be accessed and replaced without dismantling the entire system.
Solution Approach 2:
The nozzle assemblies are designed to be extractable from the manifold plate through removable connections. This allows individual nozzles to be taken out for replacement or repair while the manifold and other nozzles remain in place, enabling selective maintenance without system-wide shutdown.
2Device complexity
If on-site repair of the hot runner system is performed, then the device complexity is reduced, but the loss of time and productivity are worsened
Solution Approach 1:
Replacement nozzle assemblies are prepared in advance and kept ready for immediate installation. The modular design allows pre-assembled nozzle units to be swapped in quickly without requiring on-site fabrication or complex repair procedures, significantly reducing downtime.
Solution Approach 2:
The system utilizes replaceable nozzle assemblies that can be quickly swapped out when worn or damaged. Rather than repairing individual nozzle components in detail, entire nozzle assemblies can be replaced with new or refurbished units, reducing maintenance time and ensuring reliable operation.
3Ease of repair
If the mold plates are removed for hot runner repair, then the ease of repair is improved, but the productivity and operational continuity are worsened
Solution Approach 1:
The manifold assembly is designed to be extractable from the injection molding machine without removing the mold plates. This allows maintenance personnel to access and service the hot runner components while the mold remains installed and ready for immediate resumption of production.
Solution Approach 2:
The manifold plate serves as an intermediary component that can be disconnected from both the injection molding machine and the mold plates independently. This allows the hot runner system to be serviced without affecting the mold assembly, enabling maintenance operations to proceed while keeping the molding capability intact.
Data Source
AI summary
A tool and method adapted to facilitate access to a hot runner system in an injection molding system wherein the hot runner system includes one or more injection nozzles projecting away from a hot runner surface. The tool includes a first plate structure having one or more nozzle acceptance openings adapted to engage the injection nozzles. A second plate structure is disposed in opposing, spaced apart relation from the first plate structure. One or more elongate spacers are disposed in connective spacing relation between the first plate structure and the second plate structure.