Injection Molding Power Supply Converter Control
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Solution Overview
Problem
Existing control apparatuses for injection molding machines with power supply converters suffer from high energy losses and shorter component life due to continuous operation at predetermined target voltages, leading to increased complexity and inefficiency.
Innovation Solution
A control apparatus that divides the molding cycle into continuous, step-up, and intermittent operation intervals for the power supply converter, allowing for optimized power supply and reduced energy losses by adjusting the operating mode based on the power requirements of the servo motor, eliminating the need for additional charging or supply controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the power supply converter operates continuously to maintain a predetermined target voltage, then the voltage stability is improved, but energy losses increase and component life decreases
Solution Approach 1:
The power supply converter operates intermittently rather than continuously, switching between ON and OFF states based on whether the DC link voltage is below or above the target voltage. This periodic operation reduces energy losses and component wear while maintaining voltage stability through feedback control.
2Measurement precision
If the power supply converter operates continuously to maintain target voltage, then voltage control precision is improved, but component life decreases
Solution Approach 1:
The converter operates periodically based on voltage feedback, maintaining precise voltage control through on-off switching rather than continuous operation, thereby extending component life while preserving control precision.
Solution Approach 2:
The control apparatus monitors the DC link voltage and adjusts the power supply converter operation accordingly, switching the converter ON when voltage is below target and OFF when voltage exceeds target, achieving precise voltage control with reduced continuous operation.
3Adaptability or versatility
If additional charging or supply controllers are added to manage power supply, then power supply control capability is improved, but device complexity increases
Solution Approach 1:
The power supply converter performs multiple functions including voltage regulation, power storage charging, and power supply to the servo motor, eliminating the need for separate charging controllers or supply controllers and reducing overall device complexity.
Solution Approach 2:
The control apparatus integrates the power supply control functionality directly into the existing power supply converter, combining voltage regulation and power management functions in a single device rather than adding separate control components.
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 reduces energy losses and prolongs the life of power supply converter components while maintaining the necessary voltage for the motor, without complicating the machine's configuration.
Implementation Method 1
a power supply converter configured to supply power to the driving apparatus after a voltage from a power supply is increased
Implementation Method 2
providing an electric storage unit in a DC voltage unit of a driving apparatus that drives the servo motor to store energy necessary for a high-speed operation by raising the voltage of the electric storage unit
Data Source
AI summary
A power supply converter controller in an injection molding machine continuously operates a power supply converter in a continuous operation interval, operates the power supply converter in a step-up interval to increase a voltage of an electric storage unit up to a step-up voltage, and intermittently operates the power supply converter in an intermittent operation interval.