Modular Injection Mold for Rapid Rotor Encapsulation Changeover
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Solution Overview
Problem
The existing injection molding technologies for encapsulating rotors of electrical machines lack flexibility and efficiency, requiring a new molding tool for each geometrical variant, leading to increased costs and complexity in producing a variety of rotor sizes and diameters.
Innovation Solution
An injection mold with a modular design featuring an exchange unit and rotary elements that allow for rapid adjustment of mold segments, enabling the cavity size to be altered without extensive re-heating, thus accommodating different rotor diameters and lengths without the need for multiple tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a new molding tool is designed for each geometrical variant, then manufacturing precision is maintained, but device complexity and production costs increase
Solution Approach 1:
The molding tool is divided into multiple interchangeable mold segments that can be independently selected and combined. Each segment corresponds to a specific rotor geometrical variant, allowing the molding tool to be reconfigured for different production needs without requiring complete tool redesign.
Solution Approach 2:
A single molding tool system is designed to perform multiple functions by accommodating different mold segments. The universal molding tool can produce various rotor geometrical variants (different diameters, lengths, and configurations) using the same basic structure and exchange unit mechanism.
2Productivity
If mold segments are exchanged rapidly, then productivity increases, but heating time is reduced which may affect manufacturing precision
Solution Approach 1:
Mold segments are pre-heated independently before being installed in the molding tool. The exchange unit includes heating elements that prepare each segment to the required temperature in advance, ensuring that when the segment is installed, it is already at the correct temperature for precise encapsulation, eliminating the need for extensive re-heating after exchange.
Solution Approach 2:
The exchange unit acts as an intermediary system between mold segment storage and the active molding position. It provides a controlled environment with independent heating capabilities, allowing segments to be prepared and maintained at optimal temperatures separately from the main molding process, ensuring precision is maintained during rapid exchanges.
3Adaptability or versatility
If multiple mold segments are stored for different variants, then adaptability increases, but device complexity increases
Solution Approach 1:
Multiple mold segments are stored in a nested or compact arrangement within the exchange unit. The exchange unit itself is designed with a space-efficient structure that allows several segments to be housed in a limited space, reducing the overall footprint and visual complexity while maintaining full adaptability for different geometrical variants.
Data Source
AI summary
An injection mold, in particular for encapsulating rotors of electric machines, has a mold, wherein the mold has an arrangement of mold segments. The arrangement forms, along a longitudinal axis, a cavity for a component to be arranged. An exchange unit is provided, which is designed to remove at least one mold segment from and/or insert at least one mold segment into the arrangement, with the result that a size of the cavity can be changed.