Mold Clamping Force Control via Platen Position Sensors
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Solution Overview
Problem
Conventional methods for setting mold clamping force in injection molding machines are inadequate in determining a proper clamping force, as they rely on detecting mold opening which is not comprehensive for avoiding flash and do not account for mold deformation, leading to excessive force application and energy consumption.
Innovation Solution
The method involves using mold position sensors to detect the relative position of the movable platen with respect to the fixed platen, allowing for the setting of a proper mold clamping force by adjusting the force based on detected variations, thereby avoiding flash and obtaining comprehensive information on mold deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the maximum mold clamping force is applied to achieve secure clamping without flash, then the reliability of mold clamping is improved, but the mold degradation accelerates and energy consumption increases
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the mold clamping force based on detected mold deformation. Instead of using a fixed maximum clamping force, the system varies the clamping force parameter according to actual mold conditions, thereby preventing excessive force application while maintaining sufficient clamping to prevent flash. This resolves the contradiction by optimizing the clamping force parameter in real-time based on mold deformation feedback.
2Manufacturing precision
If the maximum mold clamping force is applied to prevent flash, then the manufacturing precision is improved, but the energy consumption increases
Solution Approach 1:
The patent implements feedback control by using mold position sensors to detect mold deformation during the molding process. The detected deformation information is fed back to the control system, which then adjusts the mold clamping force accordingly. This feedback mechanism ensures that sufficient clamping force is applied to prevent flash while avoiding excessive force that would waste energy, thereby resolving the contradiction between manufacturing precision and energy consumption.
3Device complexity
If the mold opening is detected to determine clamping force, then the control simplicity is maintained, but the measurement precision is insufficient
Solution Approach 1:
The patent replaces the conventional mechanical detection method (detecting mold opening) with a more precise measurement approach using mold position sensors that directly measure mold deformation. This substitution of the detection mechanism provides comprehensive deformation information while maintaining relatively simple control implementation, thereby resolving the contradiction between measurement precision and device complexity.
Data Source
AI summary
Test molding is performed by sequentially clamping a mold 2 with a mold clamping force (100%, 80%, 70%, . . . ) obtained by sequentially lowering a mold clamping force by a predetermined amount from the maximum mold clamping force (100%); with mold position sensors 4 provided on outer surfaces 3cf and 3mf of a fixed platen 3c supporting a fixed mold 2c of the mold 2 and a movable platen 3m supporting a movable mold 2m of the mold 2, a relative position (mold position Xc) of the movable platen 3m with respect to the fixed platen 3c in an injection process is detected; and, when at least a variation that meets predetermined conditions is produced on the mold position Xc, a mold clamping force obtained by increasing a mold clamping force at a time of occurrence of the variation by a predetermined amount is set as a proper mold clamping force Fs.