Double Color Injection Shaft Disc Positioning
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Solution Overview
Problem
Existing double color injection molding machines, particularly those with a shaft and disc designs, face issues with precise positioning due to wear, gear backlash, and complex structures, leading to increased costs and reduced assembly efficiency.
Innovation Solution
A double color injection machine with a shaft and disc design featuring a slotted disc, axial hole, and shaft sleeve with bearings, driven by a servo motor and encoder for precise positioning, minimizing friction and wear, and using a drive mechanism for horizontal movement of the shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a positioning pin and positioning slot are used for positioning, then the structure is simple, but after long term use the positioning pin has wear or the positioning slot is enlarged leading to imprecise positioning
Solution Approach 1:
The patent replaces the traditional mechanical positioning pin and slot system with a shaft and gear system. The gear engages with a rack to provide positive positioning, eliminating the wear issues associated with repeated engagement of positioning pins and slots. This substitution maintains structural simplicity while significantly improving positioning precision and durability.
2Manufacturing precision
If a gear rack system is used for positioning, then positioning precision is improved, but gear backlash causes problems between mating components
Solution Approach 1:
The patent extracts and eliminates the gear rack system entirely, replacing it with a direct shaft and disc engagement mechanism. The shaft is precisely fitted within the disc, allowing the disc to rotate to precise positions without requiring engaging gears. This removal of the gear system eliminates backlash issues while maintaining positioning precision.
3Adaptability or versatility
If the shaft and disc are rotated relatively by means of shaft mounting tube, disc mounting tube and bearings, then the structure is flexible, but the structure is quite complicated leading to increased cost and time-consuming assembly
Solution Approach 1:
The patent merges the shaft and disc into a single integrated assembly where the shaft is directly fitted within the disc. This integration eliminates the need for separate mounting tubes and multiple bearings, reducing structural complexity while maintaining the rotational flexibility needed for the double color injection molding process. The unified structure simplifies assembly and reduces manufacturing costs.
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
The solution enables fast and precise positioning, reduces manufacturing costs, and improves assembly efficiency by decoupling the rotation of the shaft and disc, while the servo motor and encoder ensure accurate alignment.
Implementation Method 1
By the design of the shaft sleeve on the shaft corresponding to the first bearing of the disc, friction and wear are minimized
Implementation Method 2
A servo motor is used to drive the shaft to rotate. Thereby by the design of the shaft sleeve on the shaft corresponding to the first bearing of the disc, the shaft is not rotated when the disc is driven to rotate. When the servo motor drives the shaft to rotate, the disc is not rotated. At the same time, fast and precise positioning is provided.
Data Source
AI summary
A double color injection machine with a shaft and a disc is revealed. The double color injection machine includes a main body with a shaft and a disc. The disc is arranged with a slotted hole while the main body is disposed with an axial hole for being assembled with a shaft sleeve. The shaft sleeve is inserted through the axial hole to be mounted to the slotted hole of the disc. A first bearing is mounted in the slotted hole and is corresponding to the shaft sleeve. A servo motor is used to drive the shaft to rotate. Thereby by the shaft sleeve on the shaft corresponding to the first bearing of the disc, the shaft is not rotated with the rotation of the disc. When the servomotor drives the shaft to rotate, the disc is not rotated. At the same time, fast and precise positioning is attained.