Modular Hot Runner System for Rapid Maintenance
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Solution Overview
Problem
Existing injection molding systems with integral hot runner systems require extensive downtime for maintenance, as the entire machine must be shut down for on-site repairs, leading to significant financial losses due to prolonged periods of inoperability.
Innovation Solution
A modular hot runner system with displaceable hot runner modules and a support frame, allowing for rapid removal and replacement of hot runner modules, enabling maintenance to be performed remotely and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hot runner system is integrally constructed with the molten material feed system, then the structural integrity and reliability are improved, but the ease of repair deteriorates as the entire machine must be shut down for on-site repairs
Solution Approach 1:
The hot runner system is divided into modular components including a removable manifold assembly that can be separated from the injection molding machine. The manifold is detached by releasing mold plates and disconnecting fluid lines, allowing the modular section to be removed and replaced without shutting down the entire machine, thus maintaining reliability while improving ease of repair.
2Stability of the object's composition
If the hot runner system remains in place during repair, then the structural stability is maintained, but the loss of time increases due to extended machine downtime
Solution Approach 1:
The system transitions from a static fixed configuration to a dynamic modular configuration. The manifold assembly can be dynamically removed and repositioned during maintenance operations, allowing repairs to be performed on detached components while the remaining system stays stable and operational, thereby reducing machine downtime while maintaining system stability.
3Ease of repair
If the mold plates are released from the hot runner system manifold plate, then the ease of repair is improved by providing access to the hot runner system, but the productivity decreases as the injection molding machine becomes inoperable
Solution Approach 1:
The system is segmented into independently serviceable modules. When mold plates are released, only the specific manifold assembly requiring maintenance is detached and removed, while other manifolds and injection nozzles remain in place and operational. This selective modular removal provides repair access while maintaining manufacturing productivity through continued operation of unaffected system sections.
Data Source
AI summary
An injection molding hot runner system of modular construction adapted for rapid removal and replacement during required maintenance. The system includes at least one hot runner module adapted for mounting at a support surface. The hot runner module includes one or more injection nozzles adapted for fluid communication with a supply of molten material and an arrangement of acceptance openings adapted to engage mounting projection elements extending away from the support surface.