Wax Injection Molding Apparatus with Pressure-Based Control
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Solution Overview
Problem
The existing wax mold injection molding apparatus requires manual setting of various parameters for each rubber mold, leading to reduced productivity and increased labor and management costs due to the need for trial-and-error methods to optimize vacuuming and injection times, which can result in air bubbles in the wax molds.
Innovation Solution
A wax mold injection molding apparatus equipped with a vacuum chamber, pressure sensor, and operation control unit that automatically adjusts vacuuming and wax injection times based on pressure measurements in the vacuum chamber, allowing for precise control of the vacuuming and injection processes to minimize air bubbles and optimize production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual setting of vacuuming and injection times is used, then flexibility in operation is maintained, but productivity decreases and labor costs increase
Solution Approach 1:
The system automatically determines vacuuming time and injection time based on real-time pressure sensor feedback without requiring manual intervention. The operation control unit self-adjusts parameters by monitoring pressure changes and calculating optimal timing, enabling the system to serve itself and eliminate manual parameter setting while improving productivity
Solution Approach 2:
The pressure sensor continuously monitors pressure changes during vacuuming and injection processes, providing real-time feedback to the operation control unit. This feedback mechanism enables automatic adjustment of vacuuming and injection times based on actual process conditions, resolving the contradiction between automation and operational flexibility
2Manufacturing precision
If trial-and-error methods are used to optimize vacuuming and injection times, then operating conditions can be adjusted, but time consumption increases and air bubbles may form
Solution Approach 1:
The system pre-calculates optimal vacuuming and injection times based on pressure sensor data before actual molding operations. By determining optimal parameters in advance through automated calculation rather than trial-and-error, the system eliminates time-consuming adjustments and prevents air bubble formation from the outset
Solution Approach 2:
The patent replaces manual trial-and-error adjustment with an automated control system that uses pressure sensor measurements and computational algorithms to determine optimal parameters. This substitution of mechanical/manual optimization with automated electronic control eliminates time loss and improves manufacturing precision
3Manufacturing precision
If vacuuming time is extended to remove air bubbles, then wax mold quality improves, but production cycle time increases
Solution Approach 1:
The system dynamically adjusts vacuuming time based on real-time pressure sensor feedback rather than using fixed extended timing. The operation control unit monitors pressure changes and automatically terminates vacuuming when optimal conditions are achieved, ensuring high wax mold quality while minimizing production cycle time through adaptive control
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 enables automatic setting of operating conditions for each rubber mold, reducing labor and management costs, improving productivity, and significantly reducing air bubbles in the wax molds, thereby enhancing the quality of the casting process.
Implementation Method 1
a vacuum chamber (50)
Implementation Method 2
a pressure sensor (51) for measuring a pressure in the vacuum chamber (50)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Disclosed is a wax mold injection molding apparatus 10A capable of efficiently performing vacuuming and/or wax injection, reducing operation time of the apparatus, and improving a wax mold quality, and a method of casting articles using the same. The wax mold injection molding apparatus 10A includes a vacuum chamber 50, a nozzle 31 connected to the vacuum chamber 50, and a pressure sensor 51 for measuring a pressure P in the vacuum chamber 50, and is capable of vacuuming a mold 3 by using the vacuum chamber 50 through the nozzle 31, and wax injection to the mold 3 after the vacuuming. An operation control unit 60 controls the vacuuming and/or the wax injection based on the pressure P in the vacuum chamber 50. In a preferable embodiment, the operation control unit 60 controls execution time of the vacuuming and/or the wax injection based on a vacuum voltage Vg of the mold 3 calculated from the pressure P in the vacuum chamber 50.