Molded Product Suction Pressure Monitoring for Error Cause Detection

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Solution Overview

Problem

Existing apparatuses for taking out molded products are unable to accurately determine the cause of suction errors that occur after suction is started, and cannot predict when a suction error is likely to occur.

Innovation Solution

An apparatus that includes a vacuum suction device, a moving mechanism, a controller, a pressure data storing section, and a suction error cause determining section. The suction error cause determining section uses time-series pressure data and predetermined reference data to determine the cause of suction errors and potential errors by comparing pressure changes over time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vacuum pressure is detected only before suction to determine vacuum abnormality, then pre-suction vacuum abnormality can be detected, but suction errors occurring after suction starts cannot be detected or their causes determined

Engineering Contradiction:

Improvedetection accuracy of suction errorsVSAvoidinformation on suction error causes

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The system performs preliminary detection of vacuum abnormality before suction starts by comparing idle suction pressure with a reference range. This preliminary action identifies potential issues (pipe damage, clogging, vacuum generator problems) before they cause actual suction errors, allowing preventive measures to be taken.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors vacuum pressure during suction and provides feedback by comparing detected pressure with reference values. This feedback mechanism enables real-time detection of suction errors and their causes, allowing the system to identify whether errors result from pipe issues, suction member problems, or vacuum generator failures.

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If vacuum pressure is distinguished in multiple stages to determine component quality and suction state, then component classification is possible, but it becomes difficult to set reference values when the head is frequently changed

Engineering Contradiction:

Improveadaptability to head changesVSAvoidvacuum pressure measurement reference

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The system dynamically adapts to different heads by detecting the idle suction pressure specific to each head configuration before suction starts. Instead of using fixed reference values that become invalid when heads are changed, the system establishes head-specific baseline pressure values, making the measurement system adaptable to frequent head changes while maintaining precision.

Inventive Principle:

Principle #15Dynamics

3Reliability

If only idle suction pressure is monitored, then pre-suction vacuum abnormality can be detected, but suction errors occurring during the suction process cannot be identified

Engineering Contradiction:

Improvedetection of suction errors during operationVSAvoidresponse time to suction errors

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system continuously monitors vacuum pressure throughout the entire suction process, not just before suction starts. This continuous monitoring ensures that suction errors occurring at any stage are detected immediately, maintaining reliable operation and enabling rapid response to prevent production delays.

Inventive Principle:

Principle #20Continuity of useful action

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

This solution allows for accurate determination of suction error causes and prediction of potential errors, improving the detection of suction errors and enabling predictive maintenance to prevent significant decreases in production efficiency.

Implementation Method 1

a vacuum generator connected to the suction member via a pipe to apply a vacuum pressure to the suction member

Methodology Applied

Scientific EffectVacuum pressure: Vacuum

Implementation Method 2

a pressure detector operable to detect a pressure to be applied to the suction member

Methodology Applied

Scientific EffectPressure detection:

Data Source

PatentUS12326715B2Apparatus for taking out molded product

Publication Date: 2025.06.10 YUSHIN PRECISION EQUIP CO LTD

AI summary

Provided is an apparatus for taking out a molded product, which is capable of determining occurrence of a suction error and/or likelihood of a suction error of the molded product with high accuracy and of knowing a cause thereof. A pressure data storing section stores time-series pressure data from a pressure detector. A suction error cause determining section determines occurrence of a suction error and/or likelihood of a suction error of a molded product by a suction member on a basis of a time-series comparison result obtained by comparing the stored time-series pressure data with predetermined time-series reference data. When the suction error cause determining section determines the occurrence of the suction error and/or the likelihood of the suction error, the suction error cause determining section determines a cause of the occurring suction error and a solution therefor based on a time-series change pattern.