Vacuum Sucker Controller for Molded Product Removal

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Solution Overview

Problem

Existing systems for taking out molded products do not account for the variability in suction time due to fluctuations in the operation of ejector pins and the measurement time required by pressure detectors, leading to difficulties in setting the optimal start time for the vacuum sucker and increasing the likelihood of suction errors.

Innovation Solution

A system comprising a vacuum sucker, a moving mechanism, and a controller that measures the stable time interval between pressure detection and the start of the sucking operation, ensuring it is longer than the bias time interval, thereby automatically determining the optimal sucking operation start time to prevent suction errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the operator manually sets the sucking operation start time by trial and error, then the system can operate, but the suction time is not optimized and errors occur

Engineering Contradiction:

Improvesuction operation reliabilityVSAvoidparameter setting complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system automatically determines the sucking operation start time by itself using the pressure detector and time interval measuring section, eliminating the need for operator intervention and trial-and-error setting. The controller self-adjusts the timing based on actual pressure conditions.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The pressure detector provides real-time feedback on the pressure in the pipe, which the controller uses to automatically determine when to start the sucking operation. This closed-loop feedback system ensures reliable suction timing without manual adjustment.

Inventive Principle:

Principle #23Feedback

2Productivity

If the vacuum generator operation time is shortened to increase productivity, then output increases, but suction errors occur due to insufficient suction time

Engineering Contradiction:

Improvetake-out cycle speedVSAvoidsuction accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The pressure detector detects the predetermined pressure in advance before the sucking operation actually starts. This preliminary detection allows the system to prepare for suction at the optimal moment, ensuring reliable suction even when the overall operation time is shortened.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the sucking operation start time based on the actual pressure conditions detected. Rather than using a fixed timing, the controller adapts the start time to match the actual suction readiness, allowing optimized cycle times without sacrificing reliability.

Inventive Principle:

Principle #15Dynamics

3Duration of action of stationary object

If the sucking operation start time is set too early, then the vacuum generator can operate for less time, but the pressure is not stable and suction errors occur

Engineering Contradiction:

Improvevacuum generator operation timeVSAvoidpressure stability

Core Design Contradiction:

Duration of action of stationary objectVSStability of the object's composition

Solution Approach 1:

The system replaces mechanical timing methods with electronic pressure detection and automated control. The pressure detector and controller work together to determine the optimal start time based on actual pressure conditions, eliminating the need for manual timing adjustments and ensuring pressure stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 eliminates the need for manual determination of the sucking operation start time, ensures reliable product removal even with shortened vacuum generator operation times, and reduces air consumption, thereby stabilizing the molded product take-out process.

Implementation Method 1

a vacuum generator connected to the suction member via a pipe to apply a vacuum pressure to the suction member

Methodology Applied

Scientific EffectVacuum pressure: Vacuum

Implementation Method 2

a pressure detector operable to detect a pressure in the pipe between the pressure valve and the suction member

Methodology Applied

Scientific EffectPressure detection:

Data Source

PatentUS12318968B2Apparatus for taking out molded product using vacuum sucker with controller that determines sucking operation start time based on a stable time interval

Publication Date: 2025.06.03 YUSHIN PRECISION EQUIP CO LTD

AI summary

A system for taking out a molded product that does not require an operator to determine the sucking operation start time for a vacuum sucker by himself/herself by trial and error is provided. A controller includes a time interval measuring section configured to measure a time interval judging from an output from a pressure detector. The time interval measuring section measures a stable time interval since the pressure in a pipe reaches a predetermined pressure until a sucking operation start pressure is detected judging from an output from the pressure detector. The sucking operation start pressure indicates that a suction nozzle starts operation to suck up a molded product hereby the predetermined pressure is maintained. A sucking operation start time determining section of the controller determines a sucking operation start time such that a stable time interval is longer than a bias time interval, concurrently with movement control for a moving mechanism.