Hybrid Ejector Actuation for High-Force Molding
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Solution Overview
Problem
Molding machines face challenges in efficiently ejecting articles with high internal depth to surface area ratios or surface features like threads, requiring unusually high ejection forces, which increases costs when using electrically driven ejection devices.
Innovation Solution
The apparatus combines a primary electrically operated actuator with at least one hydraulically operated actuator to supplement force, using a selector to control the operation of the secondary actuators for enhanced ejection force without the prohibitive costs of larger electrical components or force multipliers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the size of electrical components and motion converters is increased to provide higher ejection force, then the ejection capability is improved, but the cost increases substantially
Solution Approach 1:
The patent combines a primary electrically operated actuator with at least one second actuator (hydraulic or pneumatic) to create a hybrid ejection system. The second actuator is selectively engaged to supplement force during the ejection stroke, allowing the system to achieve high ejection forces without requiring a proportionally sized electrical motor, thereby reducing cost while maintaining capability.
Solution Approach 2:
The system dynamically adjusts its configuration by selectively engaging or disengaging the second actuator based on the ejection requirements. A selector mechanism allows the system to switch between using only the primary actuator for standard ejections and engaging the second actuator for high-force ejections, optimizing performance and cost-effectiveness for different operating conditions.
2Force
If force multipliers are interposed between the motor and ejector members to increase ejection force, then the ejection capability is improved, but the device complexity increases
Solution Approach 1:
Instead of using mechanical force multipliers like gear trains or linkages within the electrical actuator system, the patent merges a second actuator (hydraulic or pneumatic cylinder) that directly provides supplemental force. This approach achieves force multiplication through parallel actuation rather than mechanical advantage mechanisms, reducing structural complexity.
Solution Approach 2:
The patent employs hydraulic or pneumatic principles by using a fluid-operated second actuator to supplement ejection force. Fluid pressure systems naturally provide high force output with compact components, achieving force multiplication without complex mechanical linkages, gears, or levers that would increase device complexity.
3Force
If a hybrid actuator system is implemented to supplement ejection force, then the ejection capability is improved, but the device complexity increases
Solution Approach 1:
The ejection system is segmented into a primary electrical actuator and a secondary fluid actuator, each with distinct functions. The primary actuator handles normal ejection operations, while the secondary actuator provides supplemental force only when needed. This segmentation allows the system to maintain simplicity for standard operations while gaining enhanced capability when required.
Solution Approach 2:
The system incorporates a selector mechanism that dynamically engages or disengages the second actuator based on ejection requirements. This dynamic configuration allows the system to maintain low complexity during normal operation (using only the primary actuator) while being able to activate the supplemental force capability when high ejection force is needed, optimizing the balance between complexity and performance.
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 solution effectively increases the ejection force applied to molded articles, improving the likelihood of complete separation from mold surfaces without substantial increases in costs or complexity, enabling efficient operation in molding machines.
Implementation Method 1
a first actuator comprising an electrically operated device and coupled to advance ejector elements into a mold cavity and retract the ejector elements from the cavity
Implementation Method 2
at least one second actuator comprising a fluid operated device for supplementing force applied to the ejector elements
Data Source
Figure 1
Figure 2~3a
Figure 3b
AI summary
Force from an electrically operated ejector mechanism (50) of a molding machine (10) is selectably supplemented by operation of second actuators (51,53). Second actuators are advantageously fluid (hydraulic or pneumatic) operated to supplement force provided by an electrically operated primary actuator when the ejector mechanism is driven to advance ejector members into cavities of a mold assembly. The second actuators may be enabled to be operated during automatically controlled execution of a machine cycle of operation and may be operated in response to operator selections when machine operation is controlled manually.