RF Generator Multiplexing for Plastic Tubing Mold Control
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Solution Overview
Problem
Current methods for forming, molding, tipping, and welding plastic tubing require multiple RF generators and manual operator input for setting parameters, leading to inefficiencies, errors, and increased costs due to the need for frequent loading and unloading of molds and the high cost of dedicated RF generators for each mold.
Innovation Solution
A single RF generator with a multiplexing circuit and semiconductor memory in each mold assembly allows for automatic parameter control and energy distribution to multiple molds without operator input, using a shared RF generator and computer to manage settings and operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single RF generator is used to energize a single mold, then capital expense is reduced, but throughput is decreased due to manual loading and unloading time
Solution Approach 1:
The patent combines multiple molds into a single mold assembly that can be energized by a single RF generator. The mold assembly includes multiple molds arranged in an array, with each mold having its own heating elements but sharing common RF energy distribution through a multiplexing circuit. This merging approach reduces the number of RF generators needed while maintaining the ability to process multiple tubes simultaneously, thereby reducing capital expense without sacrificing throughput.
Solution Approach 2:
The mold assembly is segmented into multiple independent molds within a single assembly, allowing selective energizing of individual molds or groups of molds. The multiplexing circuit divides the RF energy distribution into separate channels, each controllable independently. This segmentation enables parallel processing of multiple tubes across different molds while using a single RF generator, thus improving throughput without requiring multiple expensive generators.
2Adaptability or versatility
If each mold has its own RF generator, then operational independence is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces a multiplexing circuit as an intermediary between the single RF generator and the multiple molds. This multiplexing circuit acts as a mediator that distributes RF energy to different molds selectively, allowing each mold to be controlled independently as if it had its own generator. The circuit includes switching elements and control logic that route energy to specific molds based on operational requirements, maintaining operational independence while eliminating the need for multiple generators.
3Ease of operation
If manual parameter entry is required for each mold operation, then flexibility is improved, but operator error and setup time increase
Solution Approach 1:
The patent implements self-service through automated parameter management. Each mold or mold group has pre-programmed parameters stored in memory, and the system automatically retrieves and applies the correct parameters when a mold is selected for operation. This eliminates the need for manual parameter entry by operators, ensuring consistent and accurate settings while maintaining the ability to adjust parameters as needed. The system serves itself by automatically configuring the RF energy distribution based on the selected mold and operational requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces operator errors, decreases setup time, and lowers costs by enabling efficient, automated control of multiple molds with a single RF generator, improving throughput and reducing the risk of incorrect settings, while maintaining accurate and consistent operations across various mold configurations.
Implementation Method 1
In the latter case, radio frequency (RF) energy is employed and an RF generator is electrically connected to the mold to provide the requisite energy source
Implementation Method 2
Heating of the mold may be by resistance heating or inductive heating as the most common forms
Data Source
AI summary
Each platform mounted mold assembly for plastic tubing includes a circuit board containing parameters defining elements of the forming, molding, tipping or welding operation to be undertaken on the tubing. A control unit includes an RF generator for providing the RF energy to effect the forming, molding, tipping or welding process, a source of air under pressure to operate the mechanical elements attendant each mold assembly, various sensors and a multiplex unit. In operation, the control unit serially addresses each of the mold assemblies, senses the parameters attendant the mold and applies the appropriate power level of RF energy for a specific duration and temperature while activating the mechanical aspects of the mold assembly. The mold assemblies may be serially activated through a multiplex unit or in a particular sequence that may be operator controlled.