Remote Diagnostic System for Mold Clamp Devices
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Solution Overview
Problem
In mold handling devices, it is challenging for central offices to manage diverse local mold clamp systems installed at remote production sites, as the types of clamping mechanisms vary widely, leading to difficulties in monitoring and diagnosing their states effectively.
Innovation Solution
A remote diagnostic system is implemented, featuring a control unit with memory and communication capabilities and a smartphone with terminal memory, communication, and display units, which detects and monitors the states of mold clamp devices using multiple switches for position detection, pressure thresholds, and clamp states, allowing for comprehensive diagnostic messaging and real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of mold clamp systems are installed at remote production sites to meet diverse user requests, then the adaptability and versatility of the mold handling device is improved, but the difficulty of monitoring and diagnosing their states effectively increases
Solution Approach 1:
The system segments the monitoring function by providing separate state detection switches for different clamp device states (clamped, unclamped, locked, released). Each switch independently monitors a specific state, allowing the central office to receive discrete, organized information about diverse clamp systems rather than overwhelmed complex data.
Solution Approach 2:
The patent introduces state detection switches as intermediary devices between the diverse clamp systems and the remote monitoring system. These switches convert various clamp states into standardized electrical signals that can be transmitted and interpreted by the central office, bridging the gap between different clamp system types and the monitoring infrastructure.
2Reliability
If comprehensive state detection switches are installed to detect all clamp device states, then the reliability of monitoring is improved, but the device complexity increases
Solution Approach 1:
The state detection switches are designed with multi-functionality to detect multiple clamp device states (clamped, unclamped, locked, released) using a single device. This universal approach allows one switch to perform multiple detection functions, reducing the need for separate specialized sensors for each state and thereby limiting the increase in device complexity.
Solution Approach 2:
The system performs preliminary action by pre-defining all possible clamp device states and installing corresponding detection switches before operational issues arise. This proactive configuration ensures complete state coverage and reliable monitoring from the outset, preventing gaps in detection that would require later system modifications.
3Productivity
If real-time monitoring of clamp device states is implemented, then the productivity of remote diagnostics is improved, but the use of energy for communication and data transmission increases
Solution Approach 1:
The monitoring system uses periodic action by transmitting clamp state data only when state changes occur rather than continuous real-time streaming. The state detection switches monitor continuously but communicate intermittently, triggering data transmission only when a clamp transitions between states, thereby maintaining diagnostic productivity while significantly reducing energy consumption compared to continuous monitoring.
Data Source
AI summary
In the present invention, constructed is a highly reliable system that does not allow unforeseen conditions to occur in the remote diagnosis of a clamp device. All combinations of status of a state detection switch mounted on a clamp device are anticipated in advance by a recursive method, and the states are defined with no omissions. A control unit 9 includes: a main body memory 9c that stores the ON/OFF state of a state switch together with the status of an injection molding machine main body, the clamp status and time information; and a main body communication unit 9d which is capable of short-range wireless communication. A message diagnosing a failure is stored in a smartphone 12 for all combinations of the ON/OFF state of the state detection switch for each of the following cases: whether in mold replacement mode or not; and whether a clamp device is in a clamped state or an unclamped state, or in a state other than the forgoing. The history of the ON/OFF state of the state detection switch with respect to the status of the main body and the clamp status is read from the main body memory 9c by wireless communication, and a corresponding message is displayed.