Remote Feedback Controller for Injection Melt Pressure Stability

Solution Overview

Problem

Existing injection molding systems face challenges in maintaining consistent melt pressure, which affects the quality of molded parts due to variations in material viscosity and pressure fluctuations, requiring frequent adjustments and reprogramming of native controllers.

Innovation Solution

A remote controller is retrofitted to the native controller system, sensing both control variables and pressure, generating a modified feedback signal that combines with the original feedback signal to adjust the actuation unit's operation, allowing for precise control of melt pressure without altering the native controller's architecture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a native controller is used to control injection molding parameters, then basic control functions are provided, but the system cannot maintain consistent melt pressure due to material viscosity variations and pressure fluctuations

Engineering Contradiction:

Improvemelt pressure consistencyVSAvoidresponse to material viscosity variations

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent implements a feedback control system where a sensor continuously monitors melt pressure and feeds this information back to the controller. The controller compares the actual pressure with the desired setpoint and dynamically adjusts the actuation unit to maintain consistent melt pressure, resolving the contradiction between reliability and adaptability to material variations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent introduces an intermediary control system that sits between the native controller and the actuation unit. This intermediary receives feedback signals from pressure sensors and modifies control signals before sending them to the actuation unit, enabling precise melt pressure control without altering the native controller's architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the native controller architecture is modified to improve melt pressure control, then better pressure consistency is achieved, but the complexity of the control system increases and requires reprogramming

Engineering Contradiction:

Improvemelt pressure controlVSAvoidcontroller architecture

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the control system into distinct functional modules: a native controller for basic control functions, a separate feedback control system for melt pressure regulation, and sensor/actuator units. This segmentation allows the feedback control to be added without modifying the native controller's architecture, maintaining simplicity while improving reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an intermediary control system that sits between the native controller and the actuation unit. This intermediary receives feedback signals from pressure sensors and modifies control signals before sending them to the actuation unit, enabling precise melt pressure control without altering the native controller's architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If frequent adjustments and reprogramming of the native controller are made to maintain melt pressure, then pressure consistency improves, but production time is lost and efficiency decreases

Engineering Contradiction:

Improvemelt pressure consistencyVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements continuous feedback control where the sensor continuously monitors melt pressure and the controller continuously adjusts the actuation unit throughout the molding cycle. This eliminates the need for frequent stoppages to make manual adjustments or reprogramming, maintaining both pressure consistency and production efficiency.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent implements a feedback control system where a sensor continuously monitors melt pressure and feeds this information back to the controller. The controller compares the actual pressure with the desired setpoint and dynamically adjusts the actuation unit to maintain consistent melt pressure, resolving the contradiction between reliability and adaptability to material variations.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP3389981B1Remote controller for controlling apparatus by diverting feedback signal from native controller to the remote controller and methods for same

Publication Date: 2022.07.20 IMFLUX INC

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AI summary

A remote controller can be provided on any apparatus that employs feedback control from a native controller to add functionality to the apparatus where the native controller is not capable of providing such functionality independently.