Molding System with Feedback Control for Screw Engagement
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Solution Overview
Problem
The existing molding systems often fail to achieve sufficient fastening between injection-molded articles and workpieces, even when a servomotor rotates them through a predetermined rotational amount, leading to insufficient engagement.
Innovation Solution
A molding system that includes a rotation detector, an assembled state judging unit, and a control unit to relative rotate and displace the molded article and workpiece until a predetermined rotational amount is exceeded and a predetermined assembled state is achieved, ensuring sufficient screw engagement between the two.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a servomotor rotates the molded article and workpiece through a predetermined rotational amount only, then the assembly process is simple and fast, but the fastening between the molded article and workpiece becomes insufficient
Solution Approach 1:
The patent employs feedback mechanisms including rotation detectors to monitor the actual rotational amount and assembled state judging units to detect whether proper engagement has been achieved. The control unit continuously adjusts the rotation based on feedback from these detectors, ensuring that the molded article and workpiece are properly fastened regardless of variations in thread pitch or engagement conditions.
Solution Approach 2:
The system transitions from a fixed predetermined rotation approach to a dynamic adaptive rotation process. The control unit modifies the rotation amount in real-time based on feedback from rotation detectors and assembled state judges, allowing the system to adapt to different fastening conditions and achieve reliable engagement without excessive rotation.
2Manufacturing precision
If the molded article or workpiece is rotated but not engaged, then the assembly process continues, but the fastening remains insufficient after predetermined rotation
Solution Approach 1:
Rotation detectors monitor the actual rotational movement and provide feedback to the control unit. Combined with assembled state judging units that detect proper engagement, this feedback mechanism ensures precise engagement by continuously comparing actual state with target state, stopping rotation exactly when engagement is achieved rather than using a fixed predetermined amount.
Solution Approach 2:
The patent replaces purely mechanical predetermined rotation with a control system that uses detection and judgment units. This substitution allows for precise control of the engagement process, ensuring that rotation continues only until proper engagement is detected, thereby improving precision without significant time loss.
Data Source
AI summary
A molding system for assembling a part by moving a workpiece gripped by a hand of a robot toward a mold of an injection molding machine, while rotating a molded article supported on the mold and the workpiece relative to each other, whereby the molded article and the workpiece are screw-engaged. The molding system includes a rotation detector for detecting a rotational amount between the molded article and the workpiece, an assembled state judging unit for judging if the assembled part is in a predetermined state, and a control unit for relatively rotating and displacing the molded article and the workpiece until the rotational amount exceeds a predetermined rotational amount and the assembled state becomes the predetermined state.