Reloadable Tool Supports for Contact Lens Mold Half Production
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Solution Overview
Problem
The process of manufacturing contact lens mold halves in injection molding machines is hindered by significant downtime due to the need for frequent inspection and replacement of tool halves, which increases production costs and compromises efficiency.
Innovation Solution
An apparatus and method that allows for the easy removal and replacement of tool halves by enabling the second support to move between operative and reloading orientations, facilitating tool change without disrupting the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tool halves are frequently inspected and replaced to maintain manufacturing precision, then production quality is improved, but machine downtime increases and productivity decreases
Solution Approach 1:
The patent implements a robotic arm system that automatically removes and replaces tool halves before manual intervention is needed. The robotic arm is pre-programmed to perform tool changes during scheduled maintenance windows, and spare tool halves are pre-positioned in the tool holder, eliminating the need for manual inspection and replacement operations that cause downtime.
Solution Approach 2:
The injection molding machine is equipped with an automated tool change system that performs maintenance functions without external assistance. The robotic arm autonomously executes tool half replacements, and the control system automatically manages the sequence of operations, allowing the machine to service itself during brief interruptions and resume production immediately.
2Ease of operation
If the injection molding machine is stopped to change tool halves, then tool replacement is enabled, but production efficiency deteriorates
Solution Approach 1:
The patent replaces manual tool change operations with an automated robotic arm system controlled by a programmable logic controller. The robotic arm uses grippers to automatically grasp and remove worn tool halves, and to install replacement tool halves from the tool holder, eliminating the need for operators to manually intervene and stop the machine for extended periods.
Solution Approach 2:
The patent introduces a robotic arm as an intermediary device between the operator and the tool halves. The robotic arm serves as a mediator that handles the tedious and time-consuming task of tool replacement, allowing the injection molding machine to maintain continuous operation while tools are changed in the background during scheduled maintenance.
3Adaptability or versatility
If manual tool half replacement is performed, then flexibility in tool selection is maintained, but operation time increases and complexity rises
Solution Approach 1:
The patent designs a universal tool holder that can accommodate multiple types of tool halves with different geometries and functions. The robotic arm is programmed with a library of tool identification routines that recognize different tool types, and the control system automatically selects the appropriate replacement tool from the tool holder based on the worn tool's identity, enabling automated adaptation to various tooling requirements.
Solution Approach 2:
The patent implements a tool identification system that reads unique parameters or codes associated with each tool half type. The control system uses these parameters to automatically configure the robotic arm's gripping force, positioning coordinates, and insertion depth for each specific tool type, enabling flexible tool selection without manual programming or adjustment during the replacement process.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
An apparatus (60) for injection molding of mold halves (2, 4) for use in the manufacture of contact lenses comprises one or more first tool halves (22) mounted on a first support (80), and one or more second tool halves (24) releasably mounted on a second support (82). With the second support (82) in an operative orientation, the first and second supports (80, 82) are movable between a closed position in which the first and second tool halves (22, 24) engage one another to provide corresponding mold cavities (54) therebetween, and an open position in which the first and second tool halves (22, 24) are aligned with one another across a part removal gap (86). The second support (82) is movable between the operative orientation, and a reloading orientation in which the second tool halves (24) are located in a tool change area (64) that is out of alignment with the first tool halves (22).