Hydraulic Pump Flow Rate Switching for Injection Molding Motor Overload
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Solution Overview
Problem
Conventional methods for controlling injection molding machines face issues with drive motor overload during high-flow rate operations, leading to interrupted production and decreased molding quality, and inefficient energy consumption due to fixed discharge flow rates that are not optimized for each process.
Innovation Solution
Implementing a method that variably controls the drive motor's rotations by using a hydraulic pump with high and low fixed discharge flow rates, switching between them based on load conditions to prevent overload and optimize energy use, with a variable discharge hydraulic pump that adjusts flow rates by changing the inclined plate angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high fixed discharge flow rate is set for the hydraulic pump to complete injection processes quickly, then productivity is improved, but the drive motor may be overloaded and tripped during extended operation, worsening reliability
Solution Approach 1:
The hydraulic pump's discharge flow rate is made dynamically adjustable through variable displacement mechanism, allowing it to switch between high flow rate (for fast injection) and low flow rate (for extended pressure maintaining) based on real-time process needs, preventing motor overload while maintaining productivity
Solution Approach 2:
The discharge flow rate parameter of the hydraulic pump is changed during operation - set to high flow rate for the injection phase and switched to low flow rate for the pressure maintaining phase, optimizing both speed and motor reliability across different process stages
2Manufacturing precision
If a high fixed discharge flow rate is set for the entire pressure maintaining process, then injection quality is improved, but energy consumption increases due to excessive flow rate in later stages, worsening energy efficiency
Solution Approach 1:
The hydraulic pump operates in periodic phases - high flow rate during the injection phase when quality is critical, then switches to low flow rate during the pressure maintaining phase when less flow is needed, reducing energy consumption while preserving molding quality
Solution Approach 2:
The discharge flow rate is dynamically adjusted to match the actual needs of each process phase, using high flow only when necessary for injection quality and reducing to low flow for pressure maintenance, optimizing energy efficiency throughout the cycle
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 prevents drive motor tripping, ensures continuous production, improves molding quality and efficiency, reduces energy consumption, and allows for optimal operation conditions, while also reducing the size of the hydraulic circuit and enabling quick detection of abnormalities.
Implementation Method 1
as the hydraulic pump 2, a hydraulic pump 2 that can set at least a high fixed discharge flow rate Qm and a low fixed discharge flow rate Qs lower than the high flow rate is used
Data Source
AI summary
When the number of rotations of a drive motor (3) driving a hydraulic pump (2) is variably controlled and thus each operation process in a molding cycle is controlled, as the hydraulic pump (2), a hydraulic pump (2) that can set at least a high fixed discharge flow rate (Qm) and a low fixed discharge flow rate (Qs) lower than the high flow rate is used, limit conditions for a threshold for the load condition of the drive motor (3) are preset and, during a molding operation, by setting a predetermined operation process at the high fixed discharge flow rate (Qm), the operation process is controlled and, when the load condition of the drive motor (3) is monitored and the load condition reaches the limit conditions, the flow rate is switched to the low fixed discharge flow rate (Qs) to control the predetermined operation process.