Molding System Timing Correction and Core Support
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Solution Overview
Problem
Existing molding systems face challenges such as timing deviations in resin injection and mold opening/closing, leading to molding defects, and issues with core material alignment and temperature differences causing warping in molded bodies.
Innovation Solution
A molding system comprising first and second parison forming devices, molds that can be opened and closed, and a control unit that determines the timing of operations based on historical data to correct deviations and improve synchronization, along with a support arm design that stabilizes the core material and a mold configuration that reduces temperature differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic drive is used for resin injection and mold opening/closing, then the system can achieve high power and speed, but the timing of operations deviates from predetermined state due to oil temperature changes
Solution Approach 1:
The control unit receives actual operation timing information from sensors and compares it with predetermined timing, then automatically adjusts hydraulic pressure and flow rate to correct timing deviations in real-time, ensuring consistent molding cycle timing despite hydraulic system variations
Solution Approach 2:
The system dynamically changes hydraulic parameters (pressure, flow rate) based on detected timing deviations, adjusting these parameters to compensate for oil temperature changes and maintain precise operation timing throughout the molding cycle
2Measurement precision
If the support beam is made rigid to maintain position, then positioning accuracy improves, but the support arm cannot adapt to core material pressing forces causing bending
Solution Approach 1:
The support beam incorporates controlled flexibility allowing it to elastically deform under core material pressing forces, then return to its original position, enabling the system to absorb mechanical shocks while maintaining positioning accuracy through dynamic adaptation rather than rigid resistance
3Productivity
If one mold sucks the thermoplastic resin sheet while the other presses it, then molding efficiency improves, but temperature difference occurs on both sides of the resin sheet causing warping
Solution Approach 1:
The molding process uses periodic alternation between suction and pressing actions on both molds, with each mold performing suction during one phase and pressing during another phase, ensuring both sides of the resin sheet experience similar thermal and mechanical conditions that prevent warping while maintaining high productivity
Solution Approach 2:
The system temporarily creates asymmetric conditions during molding (one mold sucking while the other presses) but systematically alternates these asymmetric states between cycles and between molds, ensuring that cumulative thermal and mechanical effects remain balanced and prevent warping
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
The system effectively reduces molding defects by correcting timing deviations, ensures stable core material alignment, and minimizes warping by maintaining consistent temperatures, resulting in improved reproducibility and quality of molded bodies.
Implementation Method 1
the first parison forming device comprises a first extruder, a first accumulator, and a first injection head, the first parison forming device is configured to form a first parison by injecting a first molten resin from the first injection head after the first molten resin extruded from the first extruder is accumulated in the first accumulator
Implementation Method 2
the control unit is configured to determine a timing of starting operation of at least one of the first and second parison forming devices and the first and second molds in a next cycle on the basis of history data in a past cycle
Data Source
AI summary
A molding system capable of reducing molding defects including first and second parison forming devices; first and second molds configured to be opened and closed; and a control unit. The first parison forming device comprises a first extruder, a first accumulator, and a first injection head, the first parison forming device is configured to form a first parison by injecting a first molten resin from the first injection head after the first molten resin extruded from the first extruder is accumulated in the first accumulator, the second parison forming device comprises a second extruder, a second accumulator, and a second injection head, the second parison forming device is configured to form a second parison by injecting a second molten resin from the second injection head after the second molten resin extruded from the second extruder is accumulated in the second accumulator.