Robotic Injection Molding System with Segmented Mold and C-Clamp
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Solution Overview
Problem
Conventional injection molding systems are cumbersome and unsuitable for applying high pressures on small details over large structures, requiring heavy and inflexible machinery that limits efficiency and precision in thermoplastic molding.
Innovation Solution
A compact and lightweight thermoplastic robotic injection molding system with movable mold segments and a C-shaped clamp, integrated with articulated robotic systems, allowing for precise application of high pressures and efficient molding of small details over large substrates using thermoplastics like PA, PP, and ABS.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding machines are used to apply high pressures on small details, then molding precision is improved, but device weight and complexity increase significantly
Solution Approach 1:
The mold is divided into multiple segments that can move independently. The first mold segment remains stationary while the second mold segment moves with the robotic system. This segmentation allows the heavy clamping function to be separated from the movable injection function, enabling precise high-pressure molding on small details while keeping the moving injection unit lightweight.
Solution Approach 2:
A robotic system acts as an intermediary between the stationary mold and the injection unit. The robotic system carries the lightweight injection unit and positions it precisely over the mold cavity, enabling accurate application of high pressure to small details without requiring the entire molding machine to be heavy and complex.
2Force
If conventional injection molding machines are used for high pressure molding, then clamp force is sufficient, but device complexity and inflexibility increase
Solution Approach 1:
The clamping function is separated from the injection function. The mold segments provide the clamping structure while the robotic system provides the injection function. This segmentation allows sufficient clamp force to be generated through the mold segment design without requiring a complex conventional injection molding machine structure.
Solution Approach 2:
The conventional mechanical injection molding machine system is replaced with a robotic system that carries a lightweight injection unit. The robotic system provides the necessary positioning and injection forces through controlled movement rather than through a complex mechanical transmission system, reducing overall device complexity.
3Ease of operation
If lightweight injection units are used for robotic manipulation, then ease of operation is improved, but maximum clamp force capability is reduced
Solution Approach 1:
The system segments the clamping function (provided by the mold segments) from the injection function (provided by the lightweight robotic unit). This allows the injection unit to remain lightweight and easy to manipulate while the mold segments generate the necessary clamp force through their structural design and movement.
Solution Approach 2:
The system combines a lightweight robotic injection unit with a structured mold segment system. The composite arrangement allows the lightweight unit to be easily manipulated by the robotic system while the mold segments provide the necessary clamping force through their design, achieving both ease of operation and sufficient force capability.
Data Source
AI summary
An injection molding module for performing a series of injection molding actions, includes a robotic system. The molding module in addition includes a series of anchoring members for fixing at least a portion of the robotic system at each location where an injection molding action takes place.