Servo Control Frequency Analysis for Injection Molding Repair Alerts
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Solution Overview
Problem
Existing methods for issuing repair alerts for mechanical components in electric injection molding machines require manual measurements and skilled personnel, leading to inefficiencies and variability in inspection outcomes, as they rely on visual checks and acoustic senses, and are not capable of automatic alert issuance.
Innovation Solution
A method and apparatus that measure and compare the first and second frequency response characteristics of mechanical components over time, determining resonance frequency deviations to automatically issue repair alerts, utilizing a white noise generator and fast Fourier converting section within the servocontrol system, eliminating the need for manual measurements and allowing for automated data acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual inspection methods using tension meters and visual checks are used, then measurement flexibility is maintained, but inspection time and labor cost increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection methods (tension meters, visual checks) with an acoustic vibration-based measurement system. A vibration exciter applies controlled vibrations to the timing belt, and sensors detect the vibrational responses, automatically analyzing tension changes without requiring worker intervention or time-consuming manual procedures.
Solution Approach 2:
The inspection system performs self-measurement by automatically exciting the timing belt with vibrations and detecting its response characteristics. The system autonomously determines tension status through frequency analysis of the vibrational signals, eliminating the need for external manual measurement tools and operators.
2Measurement precision
If skilled personnel perform visual and acoustic inspections, then diagnostic accuracy improves, but inspection consistency deteriorates due to individual differences
Solution Approach 1:
The patent replaces human sensory-based inspection (visual and acoustic judgment by skilled personnel) with an automated acoustic vibration measurement system. The system uses sensors and frequency analysis to objectively detect timing belt tension changes, providing consistent and repeatable measurements independent of individual inspector variability while maintaining high diagnostic accuracy through precise vibrational response analysis.
3Reliability
If frequent inspections are performed to reduce machine downtime, then reliability improves, but productivity decreases due to increased inspection time
Solution Approach 1:
The patent enables continuous or frequent inspection capability by using an automated vibration-based measurement system that can be performed quickly and repeatedly without requiring machine shutdown or extensive manual procedures. The system maintains continuous monitoring capability, allowing frequent inspections to be conducted with minimal disruption to production, thereby improving reliability without sacrificing productivity.
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 enables automatic diagnostic processing for issuing repair alerts, reducing the workload for operators and ensuring consistent inspection outcomes by comparing changes in mechanical components' resonance frequencies, thus facilitating timely maintenance and preventing machine failures.
Implementation Method 1
vibration is applied to a structure body of a machine with a vibration exciter and its vibration waveform is detected at other portions of the structure with a sensor
Implementation Method 2
a fast Fourier-converting method has been proposed. In the method, a signal from an encoder is converted by fast Fourier transform
Data Source
AI summary
White noise is applied to a servocontrol system of a servomotor in order to measure a frequency characteristic of a mechanical component in an electric injection molding machine, and a signal from an encoder is applied to a fast Fourier converter. Data from the fast Fourier converter is applied to a memory unit, and the content of the memory unit is displayed on a display unit in the form of a board diagram. Repair announcement is issued when a deviation of the resonant frequency of each mechanical component with respect to data at an initial setting time exceeds a predetermined value.