Screw-moving assembly with bias-adjustment mechanism
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Solution Overview
Problem
All-electric injection molding systems require higher instantaneous power, leading to higher installed power supply and hardware with high inertias, limiting dynamic operation and increasing manufacturing costs, especially for packaging and closure markets.
Innovation Solution
A screw-moving assembly comprising a screw-moving actuator and a bias-adjustment mechanism that transmit forces to the screw assembly, optimizing the biasing force during molding cycles to reduce energy consumption and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If all-electric injection units are used, then manufacturing precision can be maintained, but instantaneous power requirements increase leading to higher installed power supply and hardware inertias
Solution Approach 1:
The patent combines electric drive components with hydraulic components into a hybrid system. The electric motor provides precise control for positioning and low-speed operation, while the hydraulic system handles high-force requirements. This merging allows the system to achieve manufacturing precision comparable to all-electric systems without requiring the same level of instantaneous power, as the hydraulic system provides force multiplication through pressure.
Solution Approach 2:
The patent introduces a hydraulic system with a piston and cylinder to assist the electric drive. The hydraulic fluid transmits force from the motor through the piston to the screw assembly, enabling high force output with lower motor power requirements. The incompressible nature of the hydraulic fluid ensures precise force transmission while reducing the instantaneous power demand on the electric motor.
2Power
If higher installed power supply is used, then instantaneous power requirements are met, but hardware inertias increase limiting dynamic operation
Solution Approach 1:
By merging electric and hydraulic systems, the patent achieves high power output without proportionally increasing hardware inertia. The hydraulic system provides force multiplication, allowing smaller, lighter components to deliver the same effective force. This reduces the inertia penalty associated with high-power all-electric systems while maintaining the ability to perform dynamic operations quickly and efficiently.
3Power
If larger electric drives are used, then power requirements are satisfied, but manufacturing cost increases
Solution Approach 1:
The hybrid system merges electric and hydraulic components, allowing the use of smaller, less expensive electric motors compared to all-electric systems. The hydraulic system compensates for the reduced motor size by providing force multiplication through hydraulic pressure. This combination reduces the overall cost of the drive system while maintaining the required power output and performance characteristics.
Data Source
AI summary
A screw-moving assembly (100) for a screw assembly (903), the screw-moving assembly (100) comprising: a screw-moving actuator (102); and a bias-adjustment mechanism (104); wherein the screw-moving actuator (102) and the bias-adjustment mechanism (104) are configured to connect to the screw assembly (903); the screw-moving actuator (102) is configured to transmit, in use, a screw-translation force (112) to a longitudinal central axis (905) of the screw assembly (903); and the bias-adjustment mechanism (104) is configured to transmit, in use, a biasing force (114) to the longitudinal central axis (905) of the screw assembly (903).