Injection Molding Machine Base Horizontal Degree Detection
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Solution Overview
Problem
Conventional injection molding machines require costly and operation-intensive methods to detect the horizontal degree of the base, often necessitating the replacement of sensors with each change in support shape or position, leading to increased downtime and operational costs.
Innovation Solution
The implementation of a system using multiple laser displacement meters attached to the base and mounting surface to measure distances and calculate the horizontal degree, allowing for continuous detection without stopping the machine and reducing the need for multiple sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a level or position sensor is mounted on the base or support to detect horizontal degree, then the horizontal degree can be detected, but the operation cost increases and the system becomes complex when replacing supports
Solution Approach 1:
The base itself serves as the measurement platform by utilizing its own vibration characteristics. The vibration sensor mounted on the base detects the base's vibration frequency, which changes when the horizontal degree deviates. This eliminates the need for external levels or position sensors, allowing the system to self-diagnose horizontal deviations through the base's inherent mechanical properties
Solution Approach 2:
The patent replaces traditional mechanical measurement tools (levels, position sensors) with a vibration-based detection system. By measuring the vibration frequency of the base and comparing it to a reference frequency, the system detects horizontal degree deviations through mechanical vibration analysis rather than direct geometric measurement
2Measurement precision
If a position sensor is mounted on the support to detect horizontal degree, then the horizontal degree can be detected, but the sensor must be replaced when the support shape or position changes
Solution Approach 1:
The base serves as its own sensor mounting platform and reference frame. The vibration sensor is mounted directly on the base and measures the base's own vibration characteristics. This self-referential approach means the detection system adapts automatically to any support configuration changes, as long as the base itself remains the measurement reference
Solution Approach 2:
The vibration detection system is universally applicable to different support configurations. By measuring the base's vibration frequency rather than relying on fixed sensor positions relative to the support, the system maintains functionality regardless of support shape or position changes, making it adaptable to various mounting scenarios
3Measurement precision
If conventional sensor mounting methods are used, then horizontal degree can be detected, but downtime increases due to sensor replacement during support changes
Solution Approach 1:
The base's vibration characteristics serve as the detection mechanism, eliminating the need for external sensors that would require replacement. The single vibration sensor mounted on the base continues to function regardless of support changes, preventing downtime associated with sensor replacement during maintenance or reconfiguration
Solution Approach 2:
Instead of mounting sensors at multiple fixed positions on the support structure, the system uses a single vibration sensor on the base that captures overall horizontal degree information through vibration frequency analysis. This reduced sensor configuration eliminates replacement needs while maintaining detection capability
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
Enables simple, low-cost, and continuous detection of the horizontal degree of the base, reducing downtime and operational costs by allowing for variable measurement directions and easy sensor attachment, independent of base shape changes.
Implementation Method 1
a plurality of measurement units (for example, laser displacement meters 5a, 5b, 5c, 5d described below) attached to the base so as to measure distances respectively to the mounting surface
Data Source
AI summary
An injection molding machine according to the present invention includes a base mounted on a mounting surface with a support interposed therebetween with a distance D1 and a distance D2 to the mounting surface, a plurality of measurement units attached to the base so as to measure distances respectively to the mounting surface, and a horizontal degree calculation unit for calculating a horizontal degree of the base on a basis of the distances measured by the plurality of measurement units.