Continuous Transport Device for Insert Overmolding
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Solution Overview
Problem
The existing methods for producing fiber composite or hybrid components are technically and time-consuming, often resulting in unwanted deformation or destruction of the fiber structure due to complex handling processes and the need for multiple handling robots, which increases production costs and space requirements.
Innovation Solution
A continuous handling concept using a transport device that runs through the preparation station, injection molding machine, and post-processing station, with a heating device to maintain the stability of the insert, allowing for precise and uninterrupted movement of the insert, which remains attached to the transport device throughout the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If handling robots are used to transport inserts, then the insert can be moved between stations, but the fiber structure may be deformed or destroyed
Solution Approach 1:
A transport device acts as an intermediary carrier that the insert remains on throughout the entire production process. This mediator transports the insert from the preparation station through the injection molding machine to the post-processing station without requiring handovers to handling robots, thus preventing fiber structure deformation while enabling movement between stations
Solution Approach 2:
The insert remains continuously on the transport device throughout the entire production process without being removed or handed over. This continuous action eliminates the need for multiple handling operations that would otherwise be required to move the insert between stations, maintaining fiber structure integrity while achieving transport
2Ease of operation
If multiple handling robots are used, then the insert can be transported between stations, but production costs and space requirements increase
Solution Approach 1:
The transport device is merged with the production line, running continuously through the preparation station, injection molding machine, and post-processing station. This consolidation replaces multiple separate handling robots with a single integrated transport system, reducing both production costs and space requirements while maintaining transport capability
Solution Approach 2:
The transport device serves multiple functions: it transports the insert through all production stations, provides heating capability through integrated heating devices, and acts as a support structure throughout processing. This multi-functional design eliminates the need for separate handling robots at each station, reducing system complexity
3Ease of manufacture
If the insert is removed from the transport device, then it can be processed in the injection molding machine, but complex handovers are required
Solution Approach 1:
The insert remains on the transport device throughout the entire injection molding process without being removed. The transport device is integrated into the molding machine, allowing continuous processing while the insert stays secured on its carrier, eliminating time-consuming handovers and simplifying the manufacturing process
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 approach significantly reduces cycle time and eliminates the need for complex handovers, ensuring the insert is handled precisely and reduces the risk of deformation, thereby simplifying the production of fiber composite or hybrid components.
Implementation Method 1
the preparation station (1) has a heating device, through which the insert (4) is heated or can be heated
Data Source
Figure 1
Figure 2~4
AI summary
Method and arrangement for manufacturing a fiber composite or hybrid component (9), comprising a preparation station (1) in which an insert (4) can be machined, a clamping unit (2) of an injection molding machine, with a cavity (5) in which the machined insert (4) can be arranged or is arranged, an injection unit (6) of the injection molding machine for injecting plastic melt into the cavity (5) while overmolding the insert (4) arranged in the cavity (5), a transport device (7) by which the insert (4) can be transported into the preparation station (1) and into the cavity (5) of the clamping unit (2), wherein the insert (4) remains in conjunction with the transport device (7) during machining in the preparation station (1), during transport to the clamping unit (2) and during overmolding in the cavity (5).