Injection Molded Part Grouping Unit for Grid Compaction
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Solution Overview
Problem
Existing methods for handling injection molded parts from multi-cavity molds are limited in their ability to efficiently handle groups other than eight and do not compact the parts effectively in a two-dimensional grid arrangement.
Innovation Solution
A method involving a removal unit that transfers injection molded parts into a first grouping unit, where they are arranged in a two-dimensional grid and compacted in both coordinate directions using a second grouping unit, allowing for flexible handling of various group sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molded parts are removed from multi-cavity molds in groups of eight using conventional methods, then the parts can be handled and transferred, but the parts cannot be compacted effectively in both longitudinal and transverse directions to form a dense two-dimensional grid arrangement
Solution Approach 1:
The invention divides the handling process into two distinct stages: first, removal of parts from the mold in groups of eight using a removal unit; second, compaction of these groups into a dense two-dimensional grid arrangement using a separate grouping unit. This segmentation allows each unit to be optimized for its specific function, with the grouping unit specifically designed to compact parts in both longitudinal and transverse directions.
Solution Approach 2:
The invention introduces a transfer unit as an intermediary between the removal unit and the grouping unit. This transfer unit receives the groups of eight parts from the removal unit and delivers them to the grouping unit for compaction. The transfer unit acts as a mediator that enables the coordinated operation of the removal and grouping units, facilitating the transition from mold removal to compact grid arrangement.
2Device complexity
If a removal unit is designed to work with fixed group sizes (groups of eight), then the removal process is simplified, but the system lacks flexibility to handle different group sizes and configurations
Solution Approach 1:
The grouping unit is designed with movable support strips that can be positioned dynamically to accommodate different group sizes and configurations. The support strips can be adjusted to receive and compact varying numbers of parts, allowing the system to handle groups of different sizes while maintaining the simple fixed-group removal mechanism. This dynamic adaptability is achieved through the movable nature of the support strips rather than through complex removal unit modifications.
3Productivity
If parts are arranged in a loose grid arrangement after removal, then the transfer process is simpler, but the final arrangement is not compact and requires larger space in the finished part holder
Solution Approach 1:
The grouping unit performs preliminary compaction of the parts into a dense two-dimensional grid arrangement before they are transferred to the finished part holder. By pre-compacting the parts in both longitudinal and transverse directions within the grouping unit, the system eliminates the need for additional compaction space in the holder, thereby reducing the overall space requirement while maintaining efficient transfer operations.
Data Source
AI summary
A handling system and/or a grouping unit of a handling system and a method for handling individual parts that have to be removed from a preceding production process, in particular injection-molded parts in the form of pipette tips that are produced in groups in an injection molding machine with a multiple tool and must be removed from the multiple tool for the further handling, the multiple tool including at least one distributing star having a plurality of mold cavities, whereby a removal arrangement is defined by the multiple tool for the further handling of the injection-molded parts. The method includes removing the finished injection molded parts, loading the parts into a grouping unit to produce a grid arrangement, and removing the parts from one grouping unit with a second grouping unit.