Multi-Mold Injection System for Productivity and Quality Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current injection molding systems face inefficiencies in productivity and cost when switching between multiple molds, particularly in inspecting and re-manufacturing parts, as they require additional equipment for heating and cooling and longer processing times.
Innovation Solution
A method for injection molding that alternates between multiple molds using conveying machines to manage mold switching, inspection, and re-manufacturing, where acceptable parts are ejected and replaced, while non-acceptable parts are re-manufactured without mold change, optimizing the use of the injection molding machine and reducing processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple molds are alternated using conveying machines outside the injection molding machine, then productivity is improved by up to two times, but the system complexity and cost increase due to additional conveying devices and cooling apparatus
Solution Approach 1:
The patent combines the mold switching function with the injection molding machine itself by providing multiple molds that can be alternated within the machine's clamping unit. This eliminates the need for separate conveying machines and external cooling apparatus, as the injection molding machine performs both molding and mold switching operations internally, thereby improving productivity without increasing system complexity
Solution Approach 2:
The injection molding machine is designed to perform multiple functions: it can clamp multiple molds simultaneously, inject resin into different molds, and switch between molds all within a single machine system. This multi-functionality allows the machine to act as both the molding device and the mold switching mechanism, avoiding the need for dedicated conveying and cooling equipment
2Manufacturing precision
If heat and cool molding technique is used to prevent appearance defects, then molded part quality is improved, but the molding process time is longer and additional heating/cooling equipment is required
Solution Approach 1:
The patent implements continuous molding operations by alternating between multiple molds while one mold is being processed. While the injection molding machine is injecting and dwelling in one mold, another mold is simultaneously cooling the molded part. This continuous operation eliminates idle time and removes the need for separate heating and cooling phases, maintaining quality without extending process time
Solution Approach 2:
The system prepares multiple molds in advance with different thermal states - one mold is heated and ready for injection while another mold is pre-cooled for immediate part cooling. This preliminary preparation of molds in different thermal conditions allows the molding process to proceed without additional heating or cooling equipment, as the thermal preparation is done in advance during mold alternation
3Productivity
If mold switching is performed frequently to maximize productivity, then output increases, but the time required for mold replacement processes increases
Solution Approach 1:
The system establishes a periodic cycle where molds are alternated in a regular sequence - mold A is injected while mold B is cooled, then mold B is injected while mold A is cooled, and so on. This periodic alternation creates a rhythmic production flow that maximizes output while minimizing mold replacement time, as the switching follows a predictable, optimized pattern rather than frequent random changes
Data Source
AI summary
A method for manufacturing a molded part while changing between multiple molds including a first ejecting step of opening a first mold and ejecting the molded part from the first mold, a checking step of checking the ejected molded part to determine if the molded part is acceptable, a first injecting step of closing the first mold and performing injection into the first mold, a second ejecting step of, where the ejected molded part is determined to be acceptable, changing the first mold to a second mold and ejecting the molded part from the second mold after the first injecting step, and a third ejecting step of, in a case where the molded part ejected in the first ejecting step is determined to be non-acceptable, not changing the first mold to the second mold and ejecting the molded part from the first mold.