Variable-Flow Mould Thermoregulation for Faster Production Cycles
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Solution Overview
Problem
Existing temperature conditioning methods in industrial processes, such as moulding and chemical reactor systems, are inefficient in terms of energy usage and process speed, failing to optimize the temperature profile for improved product quality.
Innovation Solution
A machine for temperature control in industrial plants, featuring a thermoregulating hydraulic circuit with a variable flow rate pump, heat exchange unit, and electronic control system, synchronizes thermoregulating liquid flow with the production cycle to optimize heat exchange and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If constant flow rate cooling is used throughout the moulding process, then the mould temperature can be maintained, but energy consumption increases and process speed decreases
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant flow rate system to a dynamic variable flow rate system. The pump flow rate is continuously adjusted based on real-time mould temperature feedback and process stage requirements, allowing the cooling system to adapt its intensity to actual thermal conditions rather than operating at fixed maximum capacity throughout the cycle.
Solution Approach 2:
The patent implements parameter changes by varying the pump flow rate parameter according to different moulding process stages and temperature conditions. The system modifies the flow rate parameter dynamically - using higher flow rates during high-heat-generation phases and lower flow rates during cooling or low-heat phases, thereby optimizing energy consumption while maintaining temperature control.
2Temperature
If constant flow rate cooling is used throughout the moulding process, then the mould temperature can be maintained, but the process speed decreases
Solution Approach 1:
The patent applies periodic action by synchronizing the variable flow rate cooling cycles with the periodic moulding process stages. The cooling system operates in distinct phases corresponding to injection, holding, cooling, and ejection stages, with flow rate adjustments timed to match the thermal demands of each phase, thereby accelerating the overall process while maintaining temperature control.
Solution Approach 2:
The patent applies dynamics by transitioning from a static constant flow rate system to a dynamic variable flow rate system. The pump flow rate is continuously adjusted based on real-time mould temperature feedback and process stage requirements, allowing the cooling system to adapt its intensity to actual thermal conditions rather than operating at fixed maximum capacity throughout the cycle.
3Reliability
If standard temperature conditioning is used, then the process can operate, but product quality and temperature profile optimization are limited
Solution Approach 1:
The patent implements feedback by incorporating temperature sensors that continuously monitor mould temperature and feed this information back to the control system. The controller uses this feedback to automatically adjust the pump flow rate in real-time, creating a closed-loop control system that optimizes temperature profiles and product quality without requiring complex manual intervention or overly complicated hardware architecture.
Solution Approach 2:
The patent applies mechanics substitution by replacing complex mechanical temperature control mechanisms with an electronically controlled variable speed pump system. Instead of using multiple fixed-flow-rate pumps or complex valve arrangements, the system uses a single pump with electronic speed control and feedback-based automation, reducing mechanical complexity while improving temperature control precision and product quality.
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
The solution enables reduced energy use and faster production cycles by optimizing the temperature profile of industrial parts, enhancing product quality and efficiency.
Implementation Method 1
a heat exchange unit for the thermoregulating liquid, placed between the return section and the pump, wherein the thermoregulating liquid is thermoregulated
Implementation Method 2
a recirculating pump for the thermoregulating liquid, of the variable flow type
Implementation Method 3
the machine is adapted to cool said forming mould... the flow rate variation profile for the thermoregulating liquid entering the mould is synchronized with the moulding cycle
Data Source
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AI summary
Machine (10) for the temperature control of part of an industrial plant adapted for the formation of a product, comprising at least one thermoregulating hydraulic circuit (11) adapted to be operationally connected with a part of an industrial plant adapted for the formation of a product, wherein a thermoregulating liquid circulates in said hydraulic circuit (11); said hydraulic circuit comprising - a recirculating pump (12) for the thermoregulating liquid, of the variable flow type, - downstream of the pump (12), a section (13) for delivery of the thermoregulating liquid from the hydraulic circuit (11) to the product formation part (B) of an industrial plant, - a section (14) for returning the thermoregulating liquid from the product formation part (B) of an industrial plant to the hydraulic circuit (11), - a heat exchange unit (15) for the thermoregulating liquid, placed between said return section (14) and said pump (12), wherein the thermoregulating liquid is thermoregulated, said machine (10) further comprising an electronic control and management apparatus (30), in which there is set at least one value for the operating temperature of the thermoregulating liquid and at least one predetermined time-based pump flow rate variation profile, according to which, upon receipt of a synchronization signal at a predetermined moment of the industrial process of product formation in the part (B) of the plant to be thermoregulated, the pump (12) moves the thermoregulating liquid with a variable flow rate based on said predetermined time-based flow variation profile.