Pressure Vessel Mold Air Injection Control for Deformation-Free Ejection
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Solution Overview
Problem
Existing injection mold apparatuses lack accurate control over air injection during the removal of injection molded products, leading to deformation due to expansion or contraction, which damages the product's appearance.
Innovation Solution
An injection mold apparatus with an air injection rate setting device and pneumatic controller that uses distance and pressure sensors to control air injection based on measured distances and pressures, preventing expansion or contraction of the molded product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control method is used for air injection, then operation simplicity is maintained, but manufacturing precision deteriorates due to product expansion or contraction
Solution Approach 1:
The patent replaces the manual mechanical control method with an automated pneumatic control system. Sensors detect the actual air injection amount and feed back to a controller, which automatically adjusts the air injection rate to maintain precise control without manual intervention, thereby resolving the contradiction between operational simplicity and manufacturing precision.
Solution Approach 2:
The patent implements a feedback control mechanism where sensors continuously monitor the air injection amount and product state, and the controller adjusts the air injection rate based on this feedback information. This closed-loop system ensures precise control of product expansion/contraction while maintaining ease of operation through automation.
2Ease of operation
If air injection amount is increased to facilitate product removal, then ease of operation improves, but manufacturing precision deteriorates due to product expansion and appearance deformation
Solution Approach 1:
The patent employs a dynamic air injection control system that continuously adjusts the air injection rate based on real-time sensor feedback. The controller modulates the air injection amount according to the actual product removal progress and product state, enabling easy product removal while preventing excessive expansion and appearance deformation through adaptive control.
Solution Approach 2:
The patent changes the air injection parameters (rate, pressure, timing) dynamically during the product removal process. The controller adjusts these parameters based on sensor feedback to optimize the balance between facilitating product removal and maintaining product appearance precision, resolving the contradiction between ease of operation and manufacturing precision.
3Manufacturing precision
If air injection amount is decreased to maintain product appearance, then manufacturing precision is maintained, but productivity deteriorates due to difficult product removal
Solution Approach 1:
The patent uses feedback control to monitor both product appearance state and removal progress. The controller receives feedback from sensors and automatically adjusts the air injection rate to maintain manufacturing precision while ensuring sufficient air injection for efficient product removal, thereby resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The patent dynamically changes air injection parameters based on real-time conditions. The controller adjusts the air injection rate, pressure, and timing to optimize the balance between maintaining product appearance precision and achieving efficient product removal, thus resolving the contradiction between manufacturing precision and productivity.
4Manufacturing precision
If automated air injection control is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent replaces complex manual control operations with an automated pneumatic control system equipped with sensors and a controller. While this increases device complexity, it achieves precise air injection control that prevents product expansion and appearance deformation, resolving the contradiction between manufacturing precision and device complexity by demonstrating that the precision gain justifies the added complexity.
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
Prevents product deformation by accurately controlling air injection, ensuring rapid and easy removal of molded products without damage.
Implementation Method 1
an ejector fluidically-communicating with the air injection passage of the lower mold and injecting air through the air injection passage between the lower mold and the taken-out pressure vessel
Implementation Method 2
a pneumatic controller interlocking with the air injection rate setting device and controlling a pressure of the air injected between the lower mold and the pressure vessel
Data Source
AI summary
An injection mold apparatus of a pressure vessel includes an upper mold including an internal surface in a shape corresponding to a shape of an external surface of the pressure vessel provided with a nozzle with a closed inlet; a lower mold including an external surface in a shape corresponding to the shape of the internal surface of the pressure vessel, engaged with the upper mold, and formed with an air injection passage therein; an ejector injecting air through the air injection passage between the lower mold and the taken-out pressure vessel; an air injection rate setting device configured for controlling an injection rate of the air injected between the lower mold and the pressure vessel using the ejector; and a pneumatic controller interlocking with the air injection rate setting device and controlling a pressure of air injected.