Injection Motor Drive Unit with Free-Wheel Decoupling
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Solution Overview
Problem
Existing injection molding units face inefficiencies due to the need for oversized dosing motors and increased energy consumption, as they must support torque for both dosing and injection processes, leading to unnecessary energy expenditure and potential over-dimensioning.
Innovation Solution
A compact injection molding unit design where the spindle of the injection motor is rigidly connected to the dosing motor, but with a free-wheel device to allow partial power decoupling, enabling energy-saving operation by passively countering torque during the injection process, and supporting the injection spindle with a force measuring diaphragm for dynamic pressure measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the dosing motor is dimensioned to support torque for both dosing and injection processes, then the injection process can be supported, but the motor becomes oversized and energy consumption increases
Solution Approach 1:
The patent divides the torque support function into two separate motors: a dosing motor for dosing operations and an injection motor for injection operations. This segmentation allows each motor to be optimally sized for its specific function, eliminating the need for an oversized dosing motor that would consume excessive energy.
Solution Approach 2:
The dosing motor shaft serves dual purposes: it drives the dosing process and provides counter-hold support for the injection motor during injection operations. This multi-functionality allows the dosing motor to support injection torque without requiring a separate dedicated support motor, reducing overall system energy consumption.
2Use of energy by moving object
If two separate motors are used for dosing and injection, then each motor can be optimally sized, but the device complexity increases
Solution Approach 1:
The patent merges the dosing motor shaft with the injection motor shaft, creating a shared mechanical axis. This merging reduces device complexity by eliminating the need for separate mounting structures and control systems while maintaining the energy efficiency benefits of having two separately sized motors.
Solution Approach 2:
The shared motor shaft performs multiple functions: driving the dosing screw during dosing operations and providing counter-hold support during injection operations. This multi-functionality simplifies the overall device structure while maintaining optimal motor sizing for energy efficiency.
3Reliability
If the dosing motor actively counters torque during injection, then precise control is maintained, but energy consumption increases
Solution Approach 1:
The dosing motor shaft automatically provides counter-hold support during injection operations through its mechanical connection to the injection motor shaft. This passive, self-service approach eliminates the need for active control and energy expenditure while maintaining system stability and reliability.
Solution Approach 2:
The dosing motor shaft acts as a mechanical counterweight that passively balances the torque loads during injection operations. This passive counterbalancing mechanism maintains control precision without requiring additional energy input, as the counter-hold is provided by the mechanical structure itself rather than active motor control.
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 design results in a mechanically simple, energy-efficient injection molding unit that meets production requirements while reducing energy consumption and allowing precise measurement of dynamic and injection pressures.
Implementation Method 1
the dosing motor is blocked in one direction of rotation by a free-wheel device
Implementation Method 2
the dynamic pressure and the injection pressure can be measured there in a reliable and expedient manner by force measuring instruments in the form of a force measuring diaphragm
Data Source
AI summary
The invention relates to an injection molding unit for an injection molding machine for processing plastics, comprising an electro-mechanical dosing motor (D) for rotating a worm conveyor (11) during dosing of the plasticizable material, and an electro-mechanical injection motor (E) for the axial movement of the worm conveyor (11) relative to a plasticization unit (10). The injection motor (E) comprises a spindle drive having a spindle (16). The axes of the dosing motor (D) and of the injection motor (E) are aligned with one another. Due to the spindle (16) of the injection motor (E) being rigidly connected to the rotor (12) of the dosing motor (D) and due to the fact that the dosing motor (D) can be blocked by a braking means in a direction of rotation, an alternative compact, energy-saving injection molding unit is created.