Transformer-Based Power Supply Adaptation for Injection Molding Machines
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Solution Overview
Problem
Injection molding machines face challenges in efficiently managing voltage differences from facility power supplies when relocated, leading to operational issues and increased costs due to the need for additional transformers and larger machine sizes.
Innovation Solution
A power supplying method that includes a transformer with interchangeable primary and secondary terminals to adapt to different voltage requirements, allowing direct connection of servo amplifiers to the main power supply based on the transformer configuration, and incorporating voltage detection and alarm systems to monitor and address voltage deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a 400 V servo amplifier is employed for each servo motor in an injection molding machine, then high output power is obtained, but the servo amplifiers occupy large portions of storage space and cannot all be stored in the machine
Solution Approach 1:
The injection molding machine is equipped with a single 400V servo amplifier that can be switched to serve different servo motors (injection motor, mold opening/closing motor, ejector motor) depending on the operating mode. This multi-functional approach allows one amplifier to replace what would otherwise require multiple amplifiers, significantly reducing the space occupied by control components while maintaining the capability to deliver high output power when needed
2Adaptability or versatility
If a transformer is additionally installed outside the injection molding machine to adapt to different facility power supply voltages, then the machine can operate in different locations, but the installation burden and cost increase
Solution Approach 1:
The patent integrates the transformer function directly into the control box of the injection molding machine, merging it with the existing 400V servo amplifier and control components. This combination eliminates the need for separate external transformers when relocating the machine to facilities with different voltage standards (200V or 400V), as the integrated system can internally adapt to the available power supply through switching configurations
Solution Approach 2:
The control box is designed with multi-functionality to handle both 200V and 400V power supplies by incorporating a transformer that can operate in different configurations. The system can switch between direct connection mode (for 400V facilities) and transformed connection mode (for 200V facilities), making the machine universally adaptable to different facility power supplies without requiring additional external equipment
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 method enables injection molding machines to handle voltage differences from facility power supplies with a simple reconstruction, reducing the need for external transformers, lowering costs, and minimizing installation burdens, while ensuring proper operation across varying power supply conditions.
Implementation Method 1
a transformer 30 to transform a voltage of 200 V (voltage of facility power supply) into a voltage of 400 V
Data Source
AI summary
An injection molding machine has a first servo amplifier configured to operate with a first voltage, a second servo amplifier configured to operate with a second voltage, and a transformer which has a primary side terminal and a secondary side terminal and transforms voltages mutually in a predetermined voltage ratio. A main power supply is connected to a primary side terminal or a secondary side terminal of the transformer, depending on whether a voltage of the main power supply supplied to the injection molding machine is equal to the first voltage or the second voltage, respectively. The first or the second servo amplifier is connected to a terminal of the transformer on the side where the main power supply is not connected.