Material Feeding Device Plunger Position Detection
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Solution Overview
Problem
Existing material feeding devices for three-dimensional shaping and injection molding face challenges in accurately setting the origin position of the plunger due to variations in pressure-based and operator-dependent methods, leading to inconsistencies in material feeding.
Innovation Solution
Incorporation of a detection unit, including a plunger motor and encoder, to accurately detect the position of the plunger within the cylinder, allowing for precise setting of the origin position through a Scotch yoke mechanism and pressure control units, ensuring consistent material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the origin position of the plunger is set using pressure-based or operator-dependent methods, then the device complexity is reduced, but the measurement precision of the plunger position deteriorates
Solution Approach 1:
The patent replaces manual pressure-based positioning or operator-dependent methods with an automated detection system using a sensor to detect plunger position and a motor to drive plunger movement. This substitution of mechanical/manual systems with automated sensing and actuation systems resolves the contradiction by achieving high measurement precision through electronic detection while maintaining manageable device complexity through systematic automation.
Solution Approach 2:
The patent implements a feedback mechanism where a sensor continuously detects the plunger position and provides this information to a control unit, which then adjusts the motor-driven plunger to achieve the desired origin position. This closed-loop feedback system ensures high measurement precision by constantly monitoring and correcting the plunger position, while the automated nature of the feedback system keeps the overall device complexity manageable.
2Measurement precision
If a detection unit with motor and encoder is added to accurately detect plunger position, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The patent integrates multiple functions into unified components: the motor serves both to drive the plunger and its position is detected by an encoder, while a separate sensor provides additional position detection capability. The control unit coordinates these components to achieve precise origin positioning. This multi-functionality approach improves measurement precision through redundant detection methods while managing device complexity by having components serve multiple purposes.
Solution Approach 2:
The patent introduces a control unit as an intermediary that coordinates between the motor, encoder, and sensor to achieve precise plunger positioning. This intermediary component manages the complexity introduced by the detection unit by providing centralized control logic that harmonizes the interactions between multiple components, thereby improving measurement precision while keeping the overall system complexity manageable through systematic coordination.
3Ease of operation
If the plunger origin position varies due to pressure or operator dependence, then the ease of operation is maintained, but the manufacturing precision of material feeding deteriorates
Solution Approach 1:
The patent replaces operator-dependent manual positioning with an automated motor-driven system controlled by a control unit that uses sensor feedback to achieve precise origin positioning. This substitution eliminates the variability introduced by operator dependence while maintaining ease of operation through automated control, thereby improving manufacturing precision of material feeding without sacrificing operational simplicity.
Solution Approach 2:
The patent implements a feedback mechanism where a sensor detects the actual plunger position and provides this information to a control unit, which then adjusts the motor-driven plunger to achieve the desired origin position consistently. This closed-loop feedback system ensures that the plunger origin position is accurately and consistently established regardless of operational variations, thereby improving manufacturing precision of material feeding while maintaining ease of operation through automated correction.
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 accurate and consistent feeding of plasticized material, improving the precision and reliability of three-dimensional shaping and injection molding processes by ensuring precise control over the plunger's position and material flow.
Implementation Method 1
a detection unit configured to detect a position of the plunger in the cylinder
Implementation Method 2
a motor configured to drive the plunger
Implementation Method 3
a suction unit including a plunger configured to suction the plasticized material into a cylinder
Data Source
AI summary
A material feeding device includes a plasticizing unit configured to plasticize resin pellets to generate a plasticized material, a nozzle that has a nozzle opening and is configured to send out the plasticized material from the nozzle opening to the outside, a flow path that communicates with the nozzle opening and through which the plasticized material flows, a suction unit including a plunger configured to suction the plasticized material into a first cylinder coupled to the flow path, and a plunger motor configured to drive the plunger, and a detection unit configured to detect a position of the plunger in the first cylinder.