The present invention relates, in general, to a drive system for plasticizing unit of an injection molding machine.
Nothing in the following discussion of the state of the art is to be construed as an admission of prior art.
A plasticizing unit of an injection molding machine typically includes a plasticizing screw which is received in a plasticizing cylinder for rotation and axial movement. As it rotates, the plasticizing unit converts plastic material into plastic melt while subject to shearing energy and moves forward. As plastic melt accumulates at the tip end of the plasticizing screw, the plasticizing screw is forced to move backwards. When enough plastic melt has accumulated, the plasticizing screw is moved forwards for injecting plastic melt into a cavity of a mold. The movement of the plasticizing screw is normally realized by a rotary drive, e.g. a hydraulic motor, and an axial drive, e.g. a piston and cylinder assembly. The use of two electric motors has also been proposed, e.g. in U.S. Pat. No. 5,540,495 to Pickel, in order to rotate and axially move the plasticizing screw. Combinations of electric and hydraulic drives, so-called hybrids, have also been proposed.
It would be desirable and advantageous to provide an improved drive system to obviate prior art shortcomings.
According to one aspect of the present invention, a drive system for a plasticizing unit of an injection molding machine includes at least one drive motor operatively coupled to a plasticizing screw of the plasticizing unit for providing power for axial movement and rotation of the plasticizing screw in a plasticizing cylinder, a spindle-nut assembly converting the power of the drive motor to cause a movement of the plasticizing screw in an axial direction, and a torque transfer case arranged between the drive motor and the plasticizing screw.
According to another feature of the present invention, the torque transfer case may be constructed in the form of an epicyclic or planetary gear system having at least one sun wheel and at least one planet wheel, with the epicyclic gear system having an input side coupled to the drive motor and an output side coupled to the plasticizing screw. An epicyclic gear system having planet wheels mounted on a planet carrier has, depending on the respective construction, a number of degrees of freedom which can be limited by controlling the individually revolving components. As a result, different rotation movements can be realized and a torque distribution can be effected. The plasticizing screw can thus be moved axially forward as well as rotated, using a single drive motor only. Various constructions are possible. For example, the spindle of the spindle-nut assembly may be securely connected to the drive motor, e.g. an electric motor or hydraulic motor, whereas the spindle nut of the spindle-nut assembly is formed by the sun wheel of the epicyclic gear system. Suitably, the epicyclic gear system may also have a ring gear which may be disposed in coaxial relationship to the sun wheel and securely fixed to the plasticizing screw. Of course, the plasticizing screw may also be coupled to the planet carrier for the planet wheels.
According to another feature of the present invention, the drive motor may have a rotor which is securely fixed to the spindle of the spindle-nut assembly, with the sun wheel of the epicyclic gear system constituting the spindle nut. As alternative, the spindle nut may be formed integral with the rotor, with the spindle securely fixed to the sun wheel of the epicyclic gear system. Kinematically reversed options are also possible. For example, the drive motor may be firmly connected to the ring gear or planet carrier, whereas the plasticizing screw may be securely coupled to the spindle which runs in a spindle nut that forms the sun wheel. This construction, too, provides rotary and axial movements of the plasticizing screw.
According to another feature of the present invention, a device may be provided for controlling a rotational speed of individual components, e.g. ring gear. The device may hereby be implemented as a brake unit for the ring gear, planet carrier, planet wheels, or central sun wheel. As an alternative, the device may also be constructed as a drive unit which assumes braking function at the same time. Thus, an electric motor may be used which is able to not only decelerate a gear system component but also to accelerate this gear system component. Such accelerations basically allow also a dynamic enhancement of a particular process (melting, injecting). There are many ways of realizing deceleration and acceleration of components, only several of which will be detailed here. However, other embodiments which generally follow the concepts outlined here are considered to be covered by this disclosure. For example, components of the epicyclic gear system may be decelerated or accelerated absolutely, i.e. in relation to a fixed casing. It is also conceivable to brake or accelerate various gear system components in relation to one another. Instead of the use of electric motors, it is, of course, also possible to employ other drive units, such as hydraulic motor which operates also as hydraulic pump, for influencing the rotation of the respective gear system component.
According to another aspect of the present invention, a plasticizing unit includes a plasticizing cylinder, a plasticizing screw accommodated in the plasticizing cylinder, at least one drive motor operatively coupled to the plasticizing screw for providing power for axial movement and rotation of the plasticizing screw in the plasticizing cylinder, a spindle-nut assembly converting the power of the drive motor to cause a movement of the plasticizing screw in an axial direction, and a torque transfer case arranged between the drive motor and the plasticizing screw.
Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
Throughout all the figures, same or corresponding elements may generally be indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
Common to all constructions, as illustrated in the figures is the arrangement of a spindle-nut assembly, as shown in
Turning now to the drawing, and in particular to
The spindle nut 18 forms the central sun wheel of a epicyclic gear system, generally designated by reference numeral 12 and further including two planet wheels 20, constructed as cylindrical gears. Arranged in coaxial relationship radially outside to the spindle nut 18 is a ring gear 22 having internal teeth meshing with the planet wheels 20.
The ring gear 22 is firmly coupled with the plasticizing screw 10. The planet wheels 20 are supported on a revolving planet carrier 24 which rotates about the same axis as the spindle nut 18 and the ring gear 22. The planet carrier 24 is operatively connected to a hydraulic pump 26 such that the hydraulic pump 26 rotates, as the planet carrier 24 revolves. The hydraulic pump 26 is connected via a hydraulic conduit 28 and an adjustable proportional valve 30 to a hydraulic accumulator 32 from which a supply conduit 34 leads away.
The drive system, shown in
In order to ensure an axial support between the plasticizing screw 10 and the spindle nut 18, a ball bearing 21, shown only schematically in
The drive system of
When the injection phase is over, the brake unit 23 is released and the back pressure in the hydraulic conduit 28 is decreased. Application of a certain torque is required to be able to rotate the plasticizing screw 10 because of friction between the plasticizing screw 10 in the plasticizing cylinder. When the plasticizing screw 10 does not rotate and the planet carrier 24 rotates only slightly, the spindle nut 18 would again move forwards until a certain pressure builds up that bars any further advance of the spindle nut 18. At that point, i.e., when the spindle nut 18 can no longer move forward, the spindle nut 18 is caused to spontaneously rotate. This rotation by the spindle nut 18 is transferred via the planet wheels 20 onto the plasticizing screw 10 which thus rotates to effect a plasticizing of incoming plastic material, with produced plastic melt being advanced and accumulating at the tip end of the plasticizing screw 10. As plastic melt accumulates at the tip end, pressure builds up, causing the plasticizing screw 10 to move backwards, resulting in a rotational movement which is transmitted via the planet wheels 20 to the ring gear 22. The retraction of the plasticizing screw 10 as a result of back pressure that builds up as plastic melt accumulates at the tip end of the plasticizing screw 10 thus causes the plasticizing screw 10 to accelerate rotation. The pressure at the tip end of the plasticizing screw 10 can hereby be adjusted until equilibrium is realized between the forwardly pushing spindle nut 18, the rotation of the plasticizing screw 10 with respective friction, and the back pressure. These various rotation values can be controlled by the back pressure in the hydraulic conduit 28 with the assistance of the proportional valve 30 and the brake unit 23. Of course, the spindle-nut assembly, in particular screw lead and screw configuration, should be selected such that the spindle nut can be moved backwards when a certain back pressure has been reached.
When the back pressure in the hydraulic conduit 28 decreases to zero, the hydraulic pump 26 operates in the absence of any resistance and thus could freely rotate jointly with the planet carrier 24. As a result, the planet wheels 20 can loosely revolve about the spindle nut 18 (sun wheel). Thus, when the spindle 14 is driven by the electric motor 16, the spindle nut 18 only would rotate while the planet wheels 20 revolve about the spindle nut 18. The revolving speed of the planet carrier 24 is reduced in response to an increase of the back pressure in the hydraulic conduit 28, so that the rotation of the spindle nut 18 causes the ring gear 22 and thus the plasticizing screw 10 to rotate.
Thence, the plasticizing screw 10 can thus be moved axially as well as rotated by a single electric motor 16.
The hydraulic accumulator 32 is used to utilize the pressure that builds up therein for other systems. For example, the pressure can be used for forcing the plasticizing unit against a mold, using one or more piston and cylinder units. Another example involves the utilization of this pressure for operating core pulling elements in a clamping unit.
The drive can be controlled in response to a measurement of the back pressure and respective operation of the proportional valve 30.
Of course, the configuration of the drive system of
Referring now to
The drive system of
The use of auxiliary drives, such as electric motors 20, allows a rotation of the spindle nut in opposite direction to the rotation of the plasticizing screw, when the ring gear is at a standstill. As a result, the system dynamics are enhanced. In particular, injection speeds can be increased and the time can be reduced until a maximum speed is reached. Such an enhancement of system dynamics can be realized when auxiliary drives are used to rotate the spindle nut in opposition to the rotation of the plasticizing screw.
Turning now to
Placed on the outer circumference of the ring gear 122 is a further brake unit 125 which, when actuated, stops the ring gear 122, thereby necessarily moving the plasticizing screw 110 axially forwards as the spindle 114 rotates in relation to the spindle nut 118. When the brake unit 125 is released, the ring gear 122 is able to rotate, causing a rotation of the planet carrier 124, when the brake unit 123 is actuated. Again, the back pressure of plastic melt adjusts at the tip end of the plasticizing screw 110 until an equilibrium of forces has been established. The rotational speed of the plasticizing screw 110 can be controlled by varying the extent of brake release.
At operation, the ring gear 222 is driven by means of the electric motor 216 via the shaft 200. When the brake unit 225 is actuated, the planet carrier 224 is brought to a halt relative to the ring gear 222 so that the planet wheels 220 are also unable to rotate. As a result, the spindle nut 218 rotates at a same angular velocity as the ring gear 222. Stoppage of the spindle 214 through actuation of the brake unit 223 causes the plasticizing screw 210 to move axially. During the metering phase, the brake unit 223 s slightly released so that the plasticizing screw 210 is able to rotate, whereby the rotational speed of the plasticizing screw 210 can be adjusted by how firmly the brake units 223, 225 are applied.
Of course, the brake units 223, 225 may be substituted by active drives which provide a driving force as well as apply a braking action. When using these drives as generators at the same time, energy can be recovered for feedback into the system.
Referring now to
While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
Number | Date | Country | Kind |
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10 2005 012 337.6 | Mar 2005 | DE | national |
This application is a continuation of prior filed copending PCT International application no. PCT/EP20061050924, filed Feb. 14, 2006, which designated the United States and has been published but not in English as International Publication No. WO 2006/097394 and on which priority is claimed under 35 U.S.C. §120, and which claims the priority of German Patent Application, Serial No. 102005012337.6, filed Mar. 17, 2005, pursuant to 35 U.S.C. 119(a)-(d), the content of which is incorporated herein by reference in its entirety as if fully set forth herein.
Number | Date | Country | |
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Parent | PCT/EP2006/050924 | Feb 2006 | US |
Child | 11854190 | Sep 2007 | US |