Returnable Box Tracking for Injection Molding History Control
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Solution Overview
Problem
In injection molding, it is difficult to trace the molding history of individual molding members when defects are found, as they are stored in returnable boxes of the same shape, leading to challenges in identifying the molding history information and often requiring inspection or discard of entire lots.
Innovation Solution
A control system that uses a first mark on the returnable box to indicate information, including a first image pickup means for analyzing the mark and acquiring information, and a construction means for associating this information with the molding member's time and order of production, allowing for database construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If laser marking is applied to each molding member to identify production history, then traceability is improved, but productivity deteriorates due to additional processing time
Solution Approach 1:
The patent divides the identification target from individual molding members to returnable boxes that contain multiple molding members. By placing a single mark on each box rather than marking every individual member, the system segments the identification unit to match the storage and handling unit, thereby maintaining traceability while eliminating per-piece marking time
Solution Approach 2:
The patent uses optical copying methods (such as barcodes or 2D codes) to represent molding history information on returnable boxes. Instead of physically altering each molding member with laser marking, the system creates an information copy that can be read optically, enabling rapid identification without contact or physical modification of the actual molding members
2Loss of information
If laser marking is applied to each molding member, then identification capability is improved, but manufacturing cost increases due to additional equipment and process
Solution Approach 1:
The returnable box serves multiple functions: it acts as a container for storing molding members, a handling unit for transportation, and an identification carrier for tracking production history. By combining these functions into a single object, the system eliminates the need for separate identification processes on each molding member, reducing both equipment requirements and manufacturing complexity
Solution Approach 2:
The patent employs inexpensive markable surfaces on returnable boxes (such as printed barcodes or stickers) instead of expensive laser marking equipment. These marks can be applied using low-cost methods and are sufficient for tracking purposes, making the identification system economically viable without requiring significant capital investment
3Loss of information
If laser marking is applied to each molding member, then traceability is improved, but the appearance of molding members deteriorates
Solution Approach 1:
The patent separates the identification function from the molding member itself and relocates it to the returnable box. This segmentation ensures that molding members remain unmarked and preserve their original appearance, while the box carrying the mark handles all identification tasks
Solution Approach 2:
The returnable box acts as an intermediary carrier that holds and transmits information about the molding members without requiring direct marking of the members themselves. This intermediary approach allows traceability to be achieved while keeping the actual product surfaces intact and aesthetically pleasing
Data Source
AI summary
In a control system, at least one first mark indicating information on at least the returnable box is attached to a returnable box, and a mark reading portion 140 for picking up the returnable box, an image analyzing portion 150 for analyzing an image, of the first mark of the returnable box, picked up by the mark reading portion and acquiring the information on the returnable box and record controlling portion 130 for constructing a database by associating the information on the returnable box acquired by the image analyzing portion 150 with at least one of information on time and information on an order of the molding member.