Reciprocating Apparatus High-Speed Push-Pin Positioning
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Solution Overview
Problem
Current injection molding apparatuses face challenges in precisely positioning and reciprocating the push-pin at high speed, which is essential to shorten molding time, as existing techniques can only accurately control the push-pin's position during the backward movement, failing to achieve precise positioning at other stages and high-speed reciprocation.
Innovation Solution
A reciprocating apparatus with a drive mechanism, input device, work-switch position calculating unit, direction-switch position calculating unit, remaining-distance calculating unit, target direction-switch position calculating unit, and corrected position calculating unit work together to ensure the push-pin starts moving in the opposite direction at a precise target position, allowing for accurate and high-speed reciprocation by correcting the work-switch position of the servomotor based on input conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the push-pin is moved at high speed to shorten molding time, then productivity is improved, but manufacturing precision deteriorates because the push-pin cannot be accurately positioned except during backward movement
Solution Approach 1:
The control device calculates and sets the work-switch position in advance based on the relationship between push-pin position and servomotor shaft position. This preliminary calculation ensures that when high-speed reciprocation occurs, the push-pin is already positioned accurately at the predetermined position before the high-speed movement begins, resolving the contradiction between speed and positioning accuracy.
Solution Approach 2:
The control device uses feedback from position sensors to detect the actual push-pin position and servomotor shaft position, then adjusts the work-switch position calculations accordingly. This feedback mechanism ensures that even during high-speed reciprocation, the push-pin reaches and maintains the predetermined position accurately, enabling both high speed and high precision.
2Manufacturing precision
If the push-pin is accurately positioned at the predetermined position, then manufacturing precision is improved, but productivity deteriorates because the reciprocation speed must be reduced
Solution Approach 1:
The system dynamically adjusts the work-switch position based on the reciprocation phase. During positioning phases, the control device ensures accurate positioning by calculating precise work-switch positions. During reciprocation phases, the system allows high-speed movement. This dynamic adaptation enables the system to achieve both accurate positioning and high-speed reciprocation at different times in the cycle, resolving the contradiction between precision and speed.
3Device complexity
If the servomotor is switched at a fixed position, then device complexity is reduced, but manufacturing precision deteriorates because the push-pin cannot start moving in the opposite direction at the accurate position
Solution Approach 1:
The control device changes the work-switch position parameter dynamically based on the detected push-pin position and reciprocation phase. Instead of using a fixed servomotor switch position, the system calculates and adjusts the work-switch position to ensure the push-pin always starts moving in the opposite direction from the accurate predetermined position. This parameter change enables accurate direction switching without adding mechanical complexity.
Data Source
AI summary
A reciprocating apparatus comprises a reciprocating member, a drive mechanism, an input device, a work-switch position calculating unit configured to calculate a work-switch position for the drive mechanism, a direction-switch position calculating unit configured to calculate a direction-switch position, a remaining-distance calculating unit configured to calculate a remaining distance that is a difference between the direction-switch position calculated by the direction-switch position calculating unit and a direction-switch position input at the input device, a target direction-switch position calculating unit configured to add the remaining distance, to the direction-switch position calculated by the direction-switch position calculating unit, thereby to calculate a target direction-switch position, and a corrected position calculating unit configured to calculates a corrected work-switch position for the drive mechanism so that the drive mechanism may cause the reciprocating member to start moving in the opposite direction at the target direction-switch position calculated by the target direction-switch position calculating unit.