Mold Shutter Control Using an External Signal Converter
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Solution Overview
Problem
Current injection molding machines lack the capability to finely control the movement of shutters using primitive digital or analog signals, limiting their ability to perform sophisticated molding methods, and face challenges in remote operation and data security for injection parameters.
Innovation Solution
An external signal converter is introduced to convert primitive signals from the injection molding machine into control signals for electric actuators, allowing for precise shutter control and facilitating remote operation by dissociating data from the machine, thus enabling the use of the same converter with multiple molds and reducing the need for extensive hardware modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If primitive digital or analog signals are used to control shutters, then the injection molding machine can operate with simple control signals, but the precision and flexibility of shutter control is limited
Solution Approach 1:
A signal converter is introduced as an intermediary device between the injection molding machine and the electric actuators. The converter receives primitive digital or analog signals from the machine and transforms them into precise control signals for multiple electric actuators, enabling fine shutter control without requiring complex modification of the original machine control system.
Solution Approach 2:
The patent replaces traditional pneumatic or hydraulic actuator systems with electric actuators controlled by converted signals. This substitution enables more precise control of shutter movement while maintaining compatibility with simple primitive signals from the injection molding machine, achieving both precision and simplicity.
2Adaptability or versatility
If control hardware is integrated into the mold, then the mold can independently control shutters, but the cost and complexity of mold installation and reprogramming increases
Solution Approach 1:
The signal converter is extracted from the mold structure and placed as a separate external device. This allows the mold to be used with different injection molding machines without requiring integrated control hardware, reducing installation complexity while maintaining versatility through the external converter's ability to interface with various machine types.
Solution Approach 2:
The external signal converter serves multiple functions: it interfaces with different injection molding machine types, controls multiple electric actuators, and works with various mold configurations. This universal device eliminates the need for mold-specific control hardware, simplifying installation and reprogramming across different production sites.
3Reliability
If data regarding injection parameters is stored in the press, then the press can maintain process information, but the data may be lost when changing molds or production sites
Solution Approach 1:
The signal converter acts as an intermediary data storage and management node between the press and the control system. It maintains process information independently, ensuring data retention when molds or production sites change, while still allowing the press to operate with simple primitive signals.
Solution Approach 2:
The control system is segmented into separate functional components: the press generates primitive signals, the external converter stores and manages process data, and the electric actuators execute control actions. This segmentation allows data to be preserved in the converter independent of the press, enabling flexibility across different production sites while maintaining reliability.
Data Source
Figure 1
AI summary
An injection molding apparatus is described. It comprises a press equipped with a screw for generating molten material for injection into a mold, and a signal generator for generating a control signal adapted for a plurality of directional valves so that they can regulate the movement of one or more actuators adapted for controlling the movement of one or more shutters which regulate a flow of molten material to the mold. The mold comprises one or more cavities, one or more heated manifolds for receiving the molten material from the press and distribute it to one or more injectors each equipped with a nozzle and a shutter suitable for regulating the flow molten material leaving the nozzle towards the cavity, and one or more electric actuators, e.g. mounted on the mold plates or on the manifold, associated with each injector for moving its shutter. There is a signal converter connected between the press and the mold for converting the signal emitted by the generator into a signal adapted for activating one or more electric actuators, wherein the signal converter is external to the press and the mold.