In-Mold Assembly Manipulator for Injection Molding
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Solution Overview
Problem
Current injection molding technologies face challenges in efficiently assembling and handling parts within the mold, particularly in aligning and transferring articles between different mold cavities for forming and assembly processes.
Innovation Solution
The proposed solution involves an injection molding machine with a manipulator system that includes multiple sets of receivers and ejectors, allowing for the alignment and assembly of articles between different mold cavities through a combination of linear and rotary movements, enabling simultaneous formation and assembly of parts with separate injection barrels for different material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a manipulator system with multiple receivers and ejectors is used to assemble parts within the mold, then assembly efficiency and productivity are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple receivers and ejectors into a single manipulator system that operates within the mold cavity. The first and second receivers are integrated on the same manipulator, allowing simultaneous handling of multiple parts. The ejectors are integrated with the mold structure to work in coordination with the manipulator, reducing the need for separate handling systems and improving assembly efficiency while managing complexity through functional integration.
Solution Approach 2:
The manipulator system is designed to perform multiple functions: receiving first articles from the first cavity, receiving second articles from the second cavity, and assembling them together. The same manipulator structure handles different types of parts and performs both transfer and assembly operations, making the system versatile and reducing the need for multiple specialized devices.
2Adaptability or versatility
If separate injection barrels are used for different material properties, then manufacturing versatility is improved, but device complexity increases
Solution Approach 1:
The injection system is divided into separate injection barrels, each capable of injecting different materials with different properties into different cavities. The first injection barrel serves the first cavity and the second injection barrel serves the second cavity, allowing independent control of material properties for each part type while maintaining a modular system architecture that manages complexity through functional segmentation.
3Manufacturing precision
If the manipulator moves between multiple positions for alignment, then manufacturing precision is improved, but cycle time increases
Solution Approach 1:
The receivers are pre-positioned in specific locations within the mold cavity before the injection cycle begins. The first receiver is positioned to receive the first article from the first cavity, and the second receiver is positioned to receive the second article from the second cavity. This preliminary positioning eliminates the need for time-consuming realignment operations after injection, as all components are already in their correct positions for assembly.
Solution Approach 2:
The patent combines the reception and assembly operations into a single manipulator system that can handle multiple parts simultaneously. By integrating the first and second receivers on the same manipulator structure, the system can perform multiple alignment and assembly operations in parallel or sequence without requiring the manipulator to retract and reposition multiple times, thereby reducing cycle time while maintaining precision.
Data Source
AI summary
A method for injection molding comprises forming a set of first articles in a mold of an injection molding machine and forming a set of second articles in the mold of the injection molding machine. The method includes transferring the set of first articles from the mold to a first set of first receivers of a tooling plate, and then moving the first set of first receivers to align with the set of second articles. Thereafter the set of second articles is transferred from the mold toward the first set of first receivers and into assembled condition with the set of first articles held in the first set of first receivers.