Molded Product Take-Out Control for Collision Retraction
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Solution Overview
Problem
Existing control systems for taking out molded products face challenges in preventing damage during manual operations due to unpredictable collisions, leading to increased costs and difficulty in detecting and retracting from collisions, especially when sensors are not uniformly installed across the apparatus frame.
Innovation Solution
A control system incorporating a servo system control section, manual command generation, torque detection, collision detection, and deviation clearing to manage collisions by detecting torque deviations, providing feedback control, and displaying torque directions for safe retraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor exclusively for collision detection is attached to the entire frame including the take-out head, then collision detection capability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The encoder already installed on the servomotor is made to serve dual purposes: both position control and collision detection. By monitoring torque through the existing servo system control section, the patent eliminates the need for separate collision detection sensors while maintaining comprehensive collision detection capability throughout the apparatus.
Solution Approach 2:
The servomotor's built-in encoder and control system are utilized to perform collision detection without requiring external sensors. The system uses its own existing components (encoder, servo amplifier) to detect collisions by monitoring torque deviations, making the system self-sufficient for collision detection.
2Reliability
If the servomotor is turned off when collision occurs, then safety is improved, but the ability to retract from collision state deteriorates
Solution Approach 1:
The control system dynamically adjusts its response based on the collision state. Instead of a static on/off decision, the system maintains the servomotor in an on state with modified control parameters, allowing continuous monitoring and controlled retraction while still providing safety through torque-limited operation and operator awareness.
Solution Approach 2:
The system provides continuous feedback through the alarm signal and torque monitoring even after collision detection. This feedback mechanism allows the operator to understand the collision state and perform controlled retraction operations while the servomotor remains on, balancing safety with operational flexibility.
3Manufacturing precision
If deviation clearing is performed when servomotor is turned off, then positioning accuracy is improved, but operational continuity deteriorates
Solution Approach 1:
The deviation clearing operation is performed preliminarily while the servomotor is still on and the system is operational. By clearing deviations before stopping the motor, the system maintains positioning accuracy without interrupting operational continuity, allowing immediate resumption of controlled movements after collision.
4Measurement precision
If torque detection threshold is set low for manual operation, then collision detection sensitivity is improved, but false detection during normal operation increases
Solution Approach 1:
The torque threshold is dynamically adjusted based on the operation mode (manual or automatic). During manual operation, a lower threshold provides high sensitivity for detecting collisions, while during automatic operation, a higher threshold prevents false detections. This dynamic adaptation resolves the contradiction between sensitivity and false detection rate.
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
Enables smooth retraction from collision states by accurately detecting and addressing torque deviations, preventing damage to the take-out head and frame, and facilitating safe manual operations.
Implementation Method 1
a servo system control section configured to detect, using an encoder, a position and a speed of a drive portion of a servomotor
Implementation Method 2
The torque detection section detects torque applied to the frame when the servomotor is manually operated
Data Source
Figure 1
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AI summary
There is provided a control system for an apparatus for taking out a molded product, the apparatus performing appropriate operation when a collision occurs while a servo system control section is manually operated. When a collision detection section outputs an operation stop command, a deviation clearing section performs clearing operation to bring deviations in a servo system control section to zero with the servo system control section kept on. Positioning is completed as the deviations are brought to zero, which enables operation to be performed again. When a retracting operation is performed after the operation is stopped, servomotors are operated according to an operation command, which allows smooth retraction from the collision state.