Injection Molding Factory Layout with Vertical Resin Supply

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Solution Overview

Problem

Injection molding plants face high operational costs and safety risks due to the need for expensive equipment, extensive space, and manual handling of resin and mold sets, which also requires active lighting and significant operator input.

Innovation Solution

An injection molding factory system with injection molding machines arranged on a first floor and resin supply on a mezzanine level, utilizing automatic product conveyors and an overhead crane for efficient space use, reducing manual handling, and incorporating a remote monitoring system for operation without human operators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual handling of resin and mold sets is used, then operator control and flexibility are maintained, but safety risks increase and operational costs rise

Engineering Contradiction:

ImprovesafetyVSAvoidmanual handling

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The system enables self-service through automated resin delivery where resin is automatically transported from storage to injection molding machines via conveyors and piping, eliminating the need for manual handling by operators. Similarly, mold sets are automatically changed using robotic systems, reducing human involvement in hazardous manual tasks while maintaining operational reliability

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical handling of resin and mold sets is replaced with automated mechanical systems including conveyors, piping networks, and robotic manipulators. These automated systems perform material transport and mold changing operations, substituting human operators with machine-based solutions that improve safety and consistency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If extensive space is provided for movement and storage, then operational flexibility is maintained, but factory space requirements increase

Engineering Contradiction:

Improveoperational flexibilityVSAvoidfactory space

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The system transitions from two-dimensional floor-based material storage and transport to three-dimensional vertical utilization. Resin is stored in elevated silos and automatically delivered through vertical piping networks, while mold sets are stored on overhead racks and transported via robotic arms, freeing up extensive floor space while maintaining operational flexibility

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Material storage and transport functions are extracted from the production floor area and relocated to overhead spaces and adjacent vertical structures. Resin storage silos are positioned separately and connected via piping, while mold storage racks are mounted overhead, separating storage functions from manufacturing space and reducing overall footprint

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If active lighting is used to facilitate movement, then operator visibility is improved, but energy consumption increases

Engineering Contradiction:

Improveoperator visibilityVSAvoidenergy consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The system achieves self-service operation through automated controls that monitor and adjust lighting based on actual operational needs. Sensors detect machine operation status and activate lighting only in relevant areas during active cycles, eliminating continuous illumination and reducing energy consumption while maintaining visibility when required

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Lighting operates periodically rather than continuously, synchronized with injection molding cycles. Lighting is activated during material loading, molding operations, and product ejection phases, then deactivated during idle periods, matching visibility requirements with actual operational demands to reduce overall energy consumption

Inventive Principle:

Principle #19Periodic action

4Productivity

If operators are directly involved in machine operation, then real-time control is maintained, but labor costs increase

Engineering Contradiction:

Improvelabor efficiencyVSAvoidoperator input

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The injection molding system performs self-service through automated process control where computers monitor injection parameters, regulate temperatures, control cycle timing, and detect defects automatically. Operators are replaced by automated systems that maintain real-time control of molding operations, improving productivity while eliminating the need for direct operator involvement in routine machine operation

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS9573302B2Injection molding factory system and manufacturing method

Publication Date: 2017.02.21 PLASTIC COMPONENTS INC

AI summary

The present invention includes an injection molding factory system and an associated facility that comprises a building having a series of injection molding machines array on a first floor with the resin supply placed on a mezzanine level. The injection molding machines are arranged with automatic product conveyors to move injection molded product from the injection molding machines without the need for human operators or separate vehicles.