Hydraulic Pump Segmentation for Injection Molding Control
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Solution Overview
Problem
Conventional injection molding machines require large and expensive servomotors to control discharge flow rate and pressure, leading to energy waste, high initial costs, unstable control, and reduced reliability due to the need for a single servomotor to manage all operational processes.
Innovation Solution
The use of a hydraulic pump with multiple fixed discharge flow rates, allowing for variable control of the drive motor's revolutions based on predetermined conditions, enabling the selection of appropriate flow rates for each operational process, thereby reducing the need for oversized motors and stabilizing control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large-sized servomotor is used to control discharge flow rate and pressure, then control capability is improved, but energy waste increases and running costs increase
Solution Approach 1:
The patent divides the hydraulic pump system into multiple fixed displacement pumps with different discharge flow rates, replacing the single large servomotor system. Each pump handles specific flow rate requirements, eliminating the need for a large servomotor to operate across all ranges and reducing energy consumption during low-flow operations.
Solution Approach 2:
The system dynamically switches between different fixed displacement pumps based on required discharge flow rate, rather than using a single variable displacement pump controlled by a large servomotor. This dynamic selection optimizes energy efficiency by matching pump capacity to actual operational needs.
2Adaptability or versatility
If a large-sized servomotor is used to control discharge flow rate and pressure, then control capability is improved, but initial cost increases
Solution Approach 1:
The patent segments the hydraulic power supply into multiple fixed displacement pumps with different capacities, replacing the expensive large servomotor and servo amplifier system. This segmentation allows the use of simpler, more cost-effective pump units without the need for high-cost variable displacement mechanisms and advanced control electronics.
Solution Approach 2:
The system uses multiple simpler fixed displacement pumps that can be switched between, rather than investing in a single expensive variable displacement pump with sophisticated control systems. The fixed displacement pumps are more economical components that achieve the same functional outcome through a different, cost-effective approach.
3Device complexity
If a single servomotor controls all operations, then device complexity is reduced, but control stability deteriorates and reliability decreases
Solution Approach 1:
The patent segments the control system into multiple independent fixed displacement pumps, each optimized for specific operational ranges. This segmentation improves control stability by ensuring that the appropriate pump is always selected for the current operational requirements, avoiding the instability that occurs when a single servomotor operates across all ranges.
Solution Approach 2:
The system achieves multi-functionality through multiple fixed displacement pumps that can handle different discharge flow rate requirements. Each pump serves multiple operational processes within its optimal range, providing universal coverage across all molding operations while maintaining stability and reliability.
Data Source
AI summary
When controlling each operational process in a molding cycle by variably controlling the number of revolutions of a drive motor 3 in a hydraulic pump 2, a hydraulic pump 2 where at least multiple fixed discharge flow rate Qo and Qs can be set is used as the hydraulic pump 2. At the same time, the fixed discharge flow rates Qo . . . are set corresponding to operational processes based upon predetermined conditions in advance, respectively, and the hydraulic pump 2 is switched to the fixed discharge flow rates Qo . . . by corresponding to each operational process at the time of molding. At the same time, each operational process is controlled by variably controlling the number of revolutions of the drive motor 3.