Injection Moulding Startup Control With Pre-Programmed Phases
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Solution Overview
Problem
Existing injection moulding machines require complex and application-specific knowledge for operators to start up and shut down, making it difficult for operators with lower technical qualifications to perform these tasks reliably and efficiently, leading to increased personnel costs and potential errors.
Innovation Solution
The injection moulding machine is divided into several phases for starting up and shutting down, with pre-programmed sequences of machine movement commands and state change commands, allowing operators to initiate these processes using a single control element, such as a start-up or shut-down key, without needing application-specific knowledge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple control elements and application-specific knowledge are required for starting up and shutting down, then the machine can be controlled precisely for different production cases, but the operation becomes complex and difficult for operators with lower technical qualifications
Solution Approach 1:
The starting-up and shutting-down processes are divided into multiple phases (e.g., phase 1, phase 2, phase 3), with each phase having specific pre-programmed sequences of machine movement commands and state change commands. This segmentation allows the complex overall process to be broken down into manageable, automatically executed steps that operators can initiate with simple control elements.
Solution Approach 2:
The machine controller is pre-programmed with sequences of commands for each phase of starting-up and shutting-down. These sequences include specific machine movement commands and state change commands that are prepared in advance, so that when an operator actuates a control element, the appropriate pre-programmed sequence is automatically activated without requiring the operator to manually configure complex parameters.
2Ease of operation
If extensive training and application-specific knowledge are provided, then operators can perform complex machine operations, but personnel costs increase and the system becomes less accessible to operators with lower technical qualifications
Solution Approach 1:
The machine controller automatically executes pre-programmed sequences of commands without requiring operator intervention for each individual command. The system serves itself by automatically managing the complex sequences of machine movements and state changes, while operators only need to initiate phases through simple control elements, effectively making the complex control functions self-executing.
Solution Approach 2:
The patent replaces manual operator actions with automated electronic control sequences. Instead of operators manually performing complex machine movements and state changes, the machine controller electronically executes pre-programmed sequences, substituting automated digital control for manual mechanical operation.
3Ease of operation
If a single control element is used to initiate phases, then the operation is simplified and training requirements are reduced, but the control functionality must be more automated and pre-programmed
Solution Approach 1:
The control elements (such as start-up key and shut-down key) are designed to be multi-functional. A single start-up key can initiate multiple different phases (phase 1, phase 2, phase 3) depending on the machine's current state, and similarly for shut-down phases. This universality allows simple control elements to trigger complex automated sequences without requiring separate controls for each individual command or phase transition.
Data Source
AI summary
An injection moulding machine having a machine controller and a control unit, capable of starting up the injection moulding machine from a switched-off mode or a standby mode into a production operation for producing injection-moulded parts and to shut down back into a switched-off or standby mode. Start-up and shutdown of the injection moulding machine are each divided into a number of phases, and a sequence of specific machine movement commands and/or specific machine mode change commands is pre-programmed for each phase of start-up and for each phase of shutdown. One or more control elements are provided on the control unit which, when actuated, activate a pre-programmed sequence so that a phase of start-up or shutdown can be started, the functions of start-up or shutdown of the injection moulding machine associated with the machine movement command and/or the machine mode change command of this sequence then being triggered.