Patent Application
20230373142
The disclosures of all of the following are incorporated by reference in their entirety as if fully set forth herein: U.S. Pat. Nos. 5,894,025, 6,062,840, 6,294,122 (7018), U.S. Pat. Nos. 6,309,208, 6,287,107, 6,343,921, 6,343,922, 6,254,377, 6,261,075, 6,361,300 (7006), U.S. Pat. Nos. 6,419,870, 6,464,909 (7031), U.S. Pat. No. 6,062,840 (7052), U.S. Pat. No. 6,261,075 (7052US1), U.S. Pat. Nos. 6,599,116, 7,234,929 (7075US1), U.S. Pat. No. 7,419,625 (7075US2), U.S. Pat. No. 7,569,169 (7075US3), U.S. Pat. No. 8,297,836 (7087) U.S. patent application Ser. No. 10/214,118, filed Aug. 8, 2002 (7006), U.S. Pat. No. 7,029,268 (7077US1), U.S. Pat. No. 7,270,537 (7077US2), U.S. Pat. No. 7,597,828 (7077US3), U.S. patent application Ser. No. 09/699,856 filed Oct. 30, 2000 (7056), U.S. patent application Ser. No. 10/269,927 filed Oct. 11, 2002 (7031), U.S. application Ser. No. 09/503,832 filed Feb. 15, 2000 (7053), U.S. application Ser. No. 09/656,846 filed Sep. 7, 2000 (7060), U.S. application Ser. No. 10/006,504 filed Dec. 3, 2001, (7068), International Application WO2011119791 filed Mar. 24, 2011 (7094), U.S. application Ser. No. 10/101,278 filed Mar. 19, 2002 (7070) and PCT Application No. PCT/US11/062099 (7100WO0) and PCT Application No. PCT/US11/062096 (7100W01), U.S. Pat. Nos. 8,562,336, 8,091,202 (7097US1) and U.S. Pat. No. 8,282,388 (7097US2), U.S. Pat. No. 9,205,587 (7117US0), U.S. application Ser. No. 15/432,175 (7117US2) filed Feb. 14, 2017, U.S. Pat. No. 9,144,929 (7118U50), U.S. Publication No. 20170341283 (7118US3), U.S. Pat. No. 9,724,861 (7129US4), U.S. Pat. No. 9,662,820 (7129US3), international application WO2014172100 (7131WO0), Publication No. WO2014209857 (7134WO0), international application WO2015066004 (7140WO0), Publication No. WO2015006261 (7135WO0), International application Publication No. WO2016153632 (7149W02), International application publication no. WO2016153704 (7149WO4), U.S. Pat. No. 9,937,648 (7135US2), U.S. patent Ser. No. 10/569,458 (7162US1), International Application WO2017214387 (7163WO0), International Application PCT/US17/043029 (7165WO0) filed Jul. 20, 2017, International Application PCT/US17/043100 (7165WO1), filed Jul. 20, 2017 and International Application PCT/US17/036542 (7163WO0) filed Jun. 8, 2017 and International Application WO2018129015 (7169WO0), International application WO2018148407 (7170WO0), International application WO2018148407 (7171WO0), international application WO2018175362 (7172WO0), international application WO2018194961 (7174WO0), international application WO2018200660 (7176WO0), international application WO2019013868 (7177WO0), international application WO2019100085 (7178WO0), international application WO2020176479 (7185WO0), international application WO2021/034793 (7187WO0), international application WO2021080767 (7188WO0).
Injection molding systems have been developed for performing injection molding cycles controlled by an electric motor actuator the rotary drive component of which is interconnected directly to a valve pin via a rotary to linear travel converter device that drives the valve pin along a linear path of travel between gate closed and one or more gate open positions.
In accordance with the invention there is provided an injection molding apparatus (5), comprising:
In such an apparatus the electrically powered actuator (940, 941, 942) exerts drive force on and drives movement of the first piston (940p, 941p, 942p) which in turn drives the second piston which in turn drives the valve pin (1040, 1041, 1042).
In such an apparatus, the electrically powered actuator (940, 941, 942) is typically the sole source of drive force on the first piston (940p, 941p, 942p). The electrically powered actuator is mechanically interconnected to the first piston and exerts drive force on the first piston via such mechanical interconnection
In such an apparatus the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) are typically drivably interconnected in a closed fluid circuit arrangement.
In such an apparatus the electrically powered actuator (940, 941, 942) is typically mounted in a position remote from the heated manifold (40).
In such an apparatus the electrically powered actuator is typically mounted such that the electrically powered actuator is isolated from substantial communication of heat with the heated manifold (40).
In such an apparatus the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) are typically interconnected via fluid sealed conduit (500, 600) that enables drive fluid to flow directly between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac), the fluid sealed conduit including one or more connectors (700) adapted to enable the conduit interconnection (500, 600) between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) to be readily disconnected and readily connected.
In such an apparatus the electrically powered actuator can comprise either a linear actuator (940) or a rotatable actuator (940) having a driver (940ls, 940ld) arranged to drive the first piston (940p, 941p, 942p) reciprocally upstream and downstream within the first fluid drive cylinder (940c, 941c, 942c).
In such an apparatus the electrically powered actuator can comprise a linear travel converter (940l) adapted to drive the first piston (940p, 941p, 942p) along a selected linear converter path of travel (XX) that is non-coaxial with an axis (X) of the driver (940ls, 940ld).
Such an apparatus can further comprise a controller (16) and one or more of:
Such an apparatus can further comprise a signal converter (1500) for converting signals generated by an injection molding machine (IMM) having a drivably rotatable barrel screw (BS) that generates an injection fluid (18), wherein the injection molding machine (IMM) includes a machine controller (MC) or a control unit (HPU) that generates one or more directional control valve compatible signals (VPS), wherein the direction control valve compatible signals (VPS) are compatible for use by a signal receptor, interface or driver of a standard fluid directional control valve (12) to instruct the fluid directional control valve (12) to move to a position that routes a source of drive fluid to flow in a direction that drives an interconnected fluid drivable actuator (940f, 941f, 9420 to move in a direction that operates to begin an injection cycle and to move in a direction that operates to end an injection cycle,
In another aspect of the invention there is provided an injection molding method, comprising:
Such a method typically further comprises using the electrically powered actuator (940, 941, 942) as the sole source of drive force on the first piston (940p, 941p, 942p).
Such a method typically further comprises drivably interconnecting the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) in a closed fluid circuit arrangement.
Such a method typically further comprises disposing the electrically powered actuator in a position remote from the heated manifold.
Such a method typically further comprises sensing one or more of:
In another aspect of the invention there is provided an injection molding system (5) comprising:
In such an apparatus the second actuator (940a, 941a, 942a) is typically mounted to noe or the other or both of the heated manifold (40) and the top clamp plate (80).
In such an apparatus the electrically powered actuator (940, 941, 942) is typically the sole source of drive force on the first piston (940p, 941p, 942p).
In such an apparatus the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) are typically drivably interconnected in a closed fluid circuit arrangement.
In such an apparatus the electrically powered actuator (940, 941, 942) is typically mounted in a position remote from the heated manifold (40).
In another aspect of the invention there is provided an injection molding apparatus (5) comprising an injection molding machine (13) that injects a flow of injection fluid (18) to a heated manifold (40) mounted between a top clamp plate (80) and a mold (300) having a mold cavity (30), the manifold distributing the injection fluid (18) to a flow channel (20f, 22f, 240 that delivers the injection fluid to a gate (32, 34, 36) of the mold cavity (30), a valve pin (1040, 1041, 1042) adapted to be controllably driven upstream and downstream within the flow channel (20f, 22f, 240 between gate closed and gate open positions, the injection molding apparatus (5) further comprising:
The second piston is typically adapted to drive the valve pin (1040, 1041, 1042) upstream and downstream along the injection fluid flow control path of travel (Y) through the flow channel (20f, 22f, 240 between gate closed and one or more gate open positions.
The first piston (940p, 941p, 942p and the first fluid drive cylinder (940c, 941c, 942c) preferably form first upstream and first downstream fluid sealed drive chambers (940uc, 940dc) and wherein the second piston and the second fluid drive chamber form second upstream and second downstream fluid sealed drive chambers (940auc, 940adc), the first upstream and first downstream fluid sealed drive chambers (940uc, 940dc) and the second upstream and second downstream fluid sealed drive chambers (940auc, 940adc) being interconnected in an arrangement such that back and forth movement of the first piston (940p, 941p, 942p) drives concomitant back and forth movement of the second piston (940ap, 941ap, 942ap) along the injection fluid flow control path of travel (Y).
The second piston (940ap, 941ap, 942ap) is typically interconnected to a valve pin (1040, 1041, 1042) adapted to be driven by the second piston (940ap, 941ap, 942ap) along a reciprocal upstream and downstream path of linear travel (Y) between a gate closed and a gate open position.
The second actuator (940a, 941a, 942a) is mounted to one or the other or both of the heated manifold (40) and the top clamp plate (80).
The electrically powered actuator (940, 941, 942) is typically mounted in a position remote from the heated manifold (40).
The electrically powered actuator is preferably mounted such that the electrically powered actuator is isolated from substantial communication of heat with the heated manifold (40).
The electrically powered actuator (940, 941, 942) and the first fluid drive cylinder (940c, 941c, 942c) are typically mounted in a position remote from the heated manifold (40).
The electrically powered actuator (940, 941, 942) and the first fluid drive cylinder (940c, 941c, 942c) are preferably mounted such that the electrically powered actuator (940, 941, 942) and the first fluid drive cylinder (940c, 941c, 942c) are isolated from substantial communication of heat with the heated manifold (40).
The first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) are typically interconnected via fluid sealed conduit (500, 600) that enables drive fluid to flow between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac), the fluid sealed conduit including one or more connectors (700) adapted to enable the conduit interconnection (500, 600) between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) to be readily disconnected and readily connected.
The electrically driven device (940r, 941r, 942r) preferably comprises a rotatably driven rotor (940r) interconnected to the drive shaft (940s, 941s, 942s) by a driver (940ls) in arrangement wherein driven rotation of the driven rotor (940r) drives the driver (940ls) along a selected linear converter path of travel (X, XX).
The driver (940ls) is typically interconnected to or integral with the drive shaft (940s, 941s, 942s) in an arrangement wherein driven travel of the driver (940ls) along the selected linear path of converter travel (X, XX) drives the drive shaft (940s, 941s, 942s) along a selected linear shaft path of travel (X).
The selected linear converter path of travel (X, XX) can be coaxial or non coaxial relative to the selected linear shaft path of travel (X).
The driver (940ls) is typically interconnected to an input end (9401i) of a linear to linear converter (9401) that is interconnected via an output end (940o) to the drive shaft (940s, 941s, 942s), the linear to linear converter (9401) converting driven movement of the driver (940ls) along the selected linear converter path of travel (XX) to driven movement of the drive shaft (940s, 941s, 942s) along a selected linear shaft path of shaft travel (X) that is non coaxial relative to the selected linear converter path of travel (XX).
The first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) typically contain a selected drive fluid (DF), typically hydraulic (oil) or pneumatic (gas, air) that is adapted to be selectively driven via driven movement of the first piston (940p, 941p, 942p) as a back and forth flow between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) through fluid flow conduits (500, 600), wherein the second piston (940ap, 941ap, 942ap) is controllably driven back and forth along the flow control path of travel (Y) via selective driven flow of the drive fluid (DF) back and forth between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac).
The first fluid drive cylinder typically includes first upstream and first downstream fluid sealed drive chambers (940uc, 940dc) and wherein the second fluid drive chamber includes second upstream and second downstream fluid sealed drive chambers (940auc, 940adc), the selected drive fluid (DF) being driven via driven movement of the first piston (940p, 941p, 942p) as a back and forth flow between the first and second upstream drive chambers (940uc, 940auc) and between the first and second downstream drive chambers (940dc, 940adc), or between the first upstream drive chamber (940uc) and the second downstream drive chamber (940adc) and between the first downstream drive chamber (940dc) and the second upstream drive chamber (940auc).
The first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) preferably contain a selected drive fluid (DF) that is adapted to be selectively driven via driven movement of the first piston (940p, 941p, 942p) as a back and forth flow between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac) through fluid flow conduits (500, 600), wherein the valve pin (1040, 1041, 1042) is controllably driven back and forth along the flow control path of travel (Y) via selective driven flow of the drive fluid (DF) back and forth between the first fluid drive cylinder (940c, 941c, 942c) and the second fluid drive cylinder (940ac, 941ac, 942ac).
The first fluid drive cylinder typically includes first upstream and first downstream fluid sealed drive chambers (940uc, 940dc) and wherein the second fluid drive chamber includes second upstream and second downstream fluid sealed drive chambers (940auc, 940adc), the selected drive fluid (DF) being driven via driven movement of the first piston (940p, 941p, 942p) as a back and forth flow between the first and second upstream drive chambers (940uc, 940auc) and between the first and second downstream drive chambers (940dc, 940adc), or between the first upstream drive chamber (940uc) and the second downstream drive chamber (940adc) and between the first downstream drive chamber (940dc) and the second upstream drive chamber (940auc).
Such an apparatus can further comprise a controller (16) wherein the drive shaft (940s, 941s, 942s) and the first piston (940p, 941p, 942p) are controllably drivable by the controller (16) according to an algorithm such that the second piston (940ap, 941ap, 942ap) and the valve pin (1040, 1041, 1042) are controllably driven:
Such an apparatus can further comprise a controller (16) and a pressure sensor (800) adapted to sense pressure of drive fluid (DF) disposed within a fluid drive cylinder (940c, 941c, 942c, 940ac, 941ac, 942ac) and generate a signal indicative of the pressure of the drive fluid (DF), the controller (16) including an algorithm that utilizes one or more signals generated by the pressure sensor (800) as a variable to controllably drive the second piston (940ap, 941ap, 942ap) and the valve pin (1040, 1041, 1042):
Such an apparatus can further comprise a controller (16) and a position sensor (900) adapted to sense axial position of the second piston (940ap, 941ap, 942ap) or the valve pin (1040, 1041, 1042) and generate a signal indicative of axial position of the second piston or the valve pin, the controller (16) including an algorithm that utilizes one or more signals generated by the position sensor (900) as a variable to controllably drive the second piston (940ap, 941ap, 942ap) and the valve pin (1040, 1041, 1042):
Such an apparatus can further comprise a controller (16) and a position sensor (950) adapted to sense one or more of axial position of a piston, rotational position and velocity of a rotor (940r) of the electrically powered actuator (940, 941, 942) and generate a signal indicative of one or the other or both of rotational position and velocity of the rotor (940r), the controller (16) including an algorithm that utilizes one or more signals generated by the position sensor (950) as a variable to controllably drive the second piston (940ap, 941ap, 942ap) and the valve pin (1040, 1041, 1042):
Such an apparatus can further comprise a controller (16) and a sensor (950) adapted to sense one or the other or both torque exerted by or current used by the electrically powered actuator (940, 941, 942) and generate a signal indicative of one or the other or both of torque and current, the controller (16) including an algorithm that utilizes one or more signals generated by the sensor (950) as a variable to controllably drive the second piston (940ap, 941ap, 942ap) and the valve pin (1040, 1041, 1042):
The valve pin (1040, 1041, 1042) can include a flow control surface (102mds) disposed axially upstream of a distal tip end (1041de) of the valve pin and the flow channel (20f, 22f, 240 includes a complementary flow control surface (103s, 103ts) disposed upstream and away from the gate (32), the flow control surfaces (102mds, 103s, 103ts) being adapted to interface with each other to vary rate or velocity of flow of the injection material to and through the gate (32, 34, 36) via controlled axial positioning of the valve pin, wherein apparatus includes:
The controller (16) can include a profile of preselected pressures extending over the course of an injection cycle, the program generating instructions based on the received signals that control interfacing of the flow control surfaces (102mds, 103s, 103ts) to adjust pressure of the injection fluid (18) sensed by the pressure sensor (PS0) to be adjusted to match the profile of preselected pressures extending over the course of the injection cycle.
The electrically powered actuator can includes an electrical drive device (940d, 941d, 942d) comprised of an interface that receives drive signals (DC) from a controller (16) and controllably distributes electrical energy or power in controllably varied amounts according to the drive signals (DC) to a driver (940dr, 941dr, 942dr) that drives the rotor (940r, 941r, 942r),
The electrical drive device (940d, 941d, 942d) typically receives electrical energy or power from a power source (PS) and controllably distributes the received electrical energy or power in controllably varied amounts during the course of an injection cycle to a driver (940dr, 941dr, 942dr) of the electrically powered actuator (940).
The electrical drive device (940d, 941d, 942d) typically includes a pulse-width modulator (PWM) that converts received electrical energy or power into sinusoidal voltage waveforms, each sinusoidal voltage waveform being adapted to drive a corresponding phase-coil of the actuator driver (940dr, 941dr, 942dr).
The pulse-width modulator (PWM) can comprise an inverter or a comparator.
The pulse width modulator (PWM) can comprise a three-phase inverter that converts electrical energy or power received from the interface into three sinusoidal voltage waveforms, each one of the three sinusoidal voltage waveforms being adapted to drive a corresponding one of three phase-coils of the actuator driver.
The electrical energy or power received at or by the pulse width modulator (PWM) can comprise a DC bus voltage.
The interface of the electrical drive (940d, 941d, 942d) is preferably adapted to receive one or more control signals from a controller (16) of the injection molding apparatus (10) and to convert electrical energy or power received from the power source (PS) into sinusoidal waveforms based on the one or more control signals.
The interface is typically comprised of the pulse width modulator (PWM) which converts electrical energy or power received from the power source into sinusoidal waveforms based on the one or more control signals.
The one or more control signals received by the interface can contain control information causing the pulse width modulator (PWM) to convert the received electrical energy or power into sinusoidal waveforms adapted to drive the corresponding phase-coils of the actuator driver to adjust one or more of a position, a velocity or torque of the actuator rotor (940r, 941r, 942r).
The one or more control signals typically comprise analog electrical signals received at the electrical drive from the controller (16).
The electrical drive (940d, 941d, 942d) can comprises one or the other or both of a digital signal receiving (16r) and transmitting (16s) device, wherein: the digital signal receiving and transmitting device is adapted to receive (16r) and transmit (16s) digital signals between the electrical drive (940d, 941d, 942d) and the controller (16) of the injection molding apparatus (10); and wherein, the digital signals include the one or more control signals, where the one or more control signals are digital control signals received from the controller.
The digital control signals can include one or more of differential position commands, differential current commands, and differential velocity commands.
The digital signal receiving and transmitting device (16r, 16s) can be adapted to receive digital signals from the actuator, wherein: the digital signals received from the actuator include one or more feedback signals corresponding to operation of one or more of the actuator and the actuator rotor.
The pulse width modulator (PWM) preferably converts the electrical energy or power received from the interface into sinusoidal waveforms adapted to drive the corresponding phase-coils of the actuator driver based at least in part on the one or more feedback signals.
The one or more feedback signals received from the actuator typically includes one or more of an incremental feedback signal and an absolute feedback signal.
The electrically powered actuator (940, 941, 942) typically comprises a driver (940dr, 941dr, 942dr) comprised of one or more of a stator and armature that are interconnected to a rotatably mounted rotor or shaft (940r, 941r, 942r) such that when the drivers (940dr, 941dr, 942dr) rotate on application and receipt of electrical energy or power, the shafts (940r, 941r, 942r) are rotated.
The rotor (940r, 941r, 942r) typically has a drive axis (Y), the driver (940dr, 941dr, 942dr) being interconnected to the rotor (940r, 941r, 942r) and adapted to controllably drive the rotor (940r, 941r, 942r) rotatably around the drive axis Y.
The driver (940dr, 941dr, 942dr) typically receives electrical energy or power from the electrical drive (940d, 941d, 942d).
The electrical drive (940d, 941d, 942d) can be housed within or by the housing (940h, 941h, 942h) or is physically mounted on or to the housing (940h, 941h, 942h) in thermally conductive communication or contact therewith.
The apparatus described above can further comprise a signal converter (1500) for converting signals generated by an injection molding apparatus (10) that is comprised of an injection molding machine (IMM) having a drivably rotatable barrel screw (BS) that generates an injection fluid (18), a heated manifold (40) that receives an injection fluid (18) from the injection molding machine (IMM) and distributes the injection fluid (18) to one or more gates (32, 34, 36), a mold (42) having a cavity (30) communicating with the gates to receive the injection fluid (18), wherein the injection molding machine (IMM) includes a machine controller (MC) or a control unit (HPU) that generates one or more directional control valve compatible signals (VPS), wherein the direction control valve compatible signals (VPS) are compatible for use by a signal receptor, interface or driver of a standard fluid directional control valve (12) to instruct the fluid directional control valve (12) to move to a position that routes a source of drive fluid to flow in a direction that drives an interconnected fluid drivable actuator (940f, 941f, 9420 to move in a direction that operates to begin an injection cycle and to move in a direction that operates to end an injection cycle,
The directional control valve compatible signals (VPS) comprise a voltage signal of predetermined voltage or magnitude indicative of a predetermined rotational position of the barrel screw (BS) of the injection molding machine (IMM) that generates pressurized injection fluid (18) within the apparatus.
The apparatus (10) can further comprise one or more sensors (950, 951, 952, SN, SC, SPSR, BPSR) that detect and generate one or more sensor signals indicative of one or more of rotational or linear position of an actuator (940e, 941e, 942e, 940p, 941p, 942p) or its associated valve pin (1040, 1041, 1042), pressure or temperature of the injection fluid (18) within a fluid channel (19) of the manifold (40) or within a nozzle channel (42, 44, 46) or within the cavity (30) of the mold (33) or within a barrel of the injection molding machine (IMM), the apparatus (10) including an actuator controller (16) that receives and uses the one or more sensor signals in a program that:
In another aspect of the invention there is provided, an injection molding apparatus (5) comprising an injection molding machine (13) that injects a flow of injection fluid (18) to a heated manifold (40) mounted between a top clamp plate (80) and a mold (300) having a mold cavity (30), the manifold distributing the injection fluid (18) to a flow channel (20f, 22f, 240 that delivers the injection fluid to a gate (32, 34, 36) of the mold cavity (30), a valve pin (1040, 1041, 1042) adapted to be controllably driven upstream and downstream within the flow channel (20f, 22f, 240 between gate closed and gate open positions, the injection molding apparatus (5) further comprising:
In such an apparatus as described above the electrically powered actuator (940, 941) can drive the valve pin (1040, 1041, 1042) upstream along a path of travel between a downstream gate closed position and one or more intermediate upstream gate open positions, the downstream gate closed position being a position wherein the tip end (1142, 1155) of the valve pin obstructs the gate (32, 34, 36) to prevent fluid material (18, 1153) from flowing into the mold cavity (30), the one or more intermediate upstream gate open positions (COP, COP2) being predetermined positions between the downstream gate closed position and a fully open, end of stroke position (EOS) upstream of the intermediate upstream gate open position at which the fluid mold material flows at a maximum rate through the gate, wherein the gate is partially open when the valve pin is in the one or more intermediate upstream gate open positions; the apparatus further including
In such an apparatus the tip end (1142, 1153) of the valve pin and a surface (1254) the gate (32, 34) are typically adapted to cooperate with each other to restrict and continuously increase rate of flow of the fluid material through the gate over the course of at least a portion of the upstream travel of the valve pin from the downstream gate closed position to the intermediate upstream gate open position.
In such an apparatus the instructions can instruct velocity of the valve pin to be adjusted to a selected higher velocity in response to a signal generated by the sensor (900, 950) having detected and indicating the valve pin has reached the intermediate upstream gate open position.
The selected higher velocity is typically a maximum velocity at which the actuator is capable of driving the valve pin.
In such an apparatus the tip end of the valve pin and the gate can be adapted to cooperate with each other to restrict to less than the maximum flow rate and continuously increase rate of flow of the fluid material through the gate over the course of at least a portion of the continuous upstream travel of the valve pin from the downstream gate closed position to the intermediate upstream gate open position.
The one or more selected intermediate velocities are typically less than about 75% of the higher velocities.
The one or more selected intermediate velocities are typically a single selected velocity.
The instructions of the controller can utilize the signals received from the sensor to calculate real time velocity of the valve pin and compare the calculated real time velocity to one or more predetermined velocities for the pin during the course of travel of the tip end of the pin from at least the downstream gate closed position to the intermediate upstream gate open position.
The controller (16) can include instructions that compares the calculated real time velocity to the predetermined velocities and instruct the sending of a signal instructing the actuator to match the velocity of the pin to the predetermined velocities based on the comparison at any given position of the valve pin.
The controller can include instructions that calculate real time velocity based on a value corresponding to the position of the pin signal received in real time from the sensor.
The controller (16), in response to the one or more signals received from the sensors (900, 950), can instruct the electrically powered actuator to move the valve pin upstream of the one or more intermediate upstream gate open positions to a fully open, end of stroke position at one or more velocities that are higher than the one or more velocities of the valve pin during travel from the downstream gate closed position to the intermediate upstream gate open position.
In another aspect of the invention there is provided a method of performing an injection molding cycle comprising operating any apparatus or device as described herein to perform an injection cycle.
In such an apparatus the electrically powered actuator can be adapted to drive the tip end of the valve pin upstream and downstream between a first closed position where the tip end (1142, 155) of the valve pin obstructs the gate (1254) to prevent the injection fluid from flowing into the cavity, a full open position (FOP) where the injection fluid material flows freely without restriction from the tip end of the pin through the gate, and one or more intermediate positions between the first position and the full open position wherein the tip end of the valve pin restricts flow of the injection fluid along at least a portion of the length of the drive path extending between the first closed position and the intermediate position,
The controller can include instructions that instruct the actuator to drive the valve pin downstream beginning from the full open (FOP) or end of stroke (EOS) position to the selected intermediate position, to hold the valve pin in the selected intermediate position for the selected period of time, and to subsequently drive the valve pin downstream from the selected intermediate position to the first closed position.
The controller can include instructions that instruct the actuator to drive the valve pin downstream beginning from the full open or end of stroke position at a high rate of downstream travel, to subsequently drive the valve pin downstream at one or more of the intermediate rates of downstream travel the selected intermediate position, to subsequently hold the valve pin in the selected intermediate position for the selected period of time and to subsequently drive the valve pin downstream from the selected intermediate position to the first closed position.
The controller can includes instructions that instruct the actuator to controllably drive the valve pin upstream beginning from the first closed position to the selected intermediate position, to hold the valve pin in the selected intermediate position for the selected period of time, and to subsequently drive the valve pin upstream from the intermediate position to the full open or end of stroke position.
The controller can include instructions that instruct the actuator to drive the valve pin upstream beginning from the first closed position at a reduced rate of upstream travel, to subsequently hold the valve pin in the selected intermediate position for the selected period of time and to subsequently drive the valve pin upstream from the intermediate position to the full open or end of stroke position at a high rate of upstream travel greater than the reduced rate of upstream travel.
In another aspect of the invention there is provided a method of performing an injection molding cycle in an injection molding apparatus as described above comprising:
Such a method can further comprise subsequently driving the valve pin upstream from the selected intermediate position to the full open or end of stroke position at the selected high rate of upstream travel.
Such a method can further comprise controllably operating the actuator to drive the valve pin downstream beginning from the full open position at a selected high rate of downstream travel, subsequently driving the valve pin downstream at one or more intermediate rates of downstream travel that are less than the selected high rate of downstream travel.
In such a method the high rate of upstream travel can be a maximum rate of upstream travel.
In such a method the selected intermediate position in which the valve pin is disposed or held can be a position at which pressure of the injection fluid is a pack pressure.
In another aspect of the invention the electrically powered actuator can be adapted to drive the valve pin upstream and downstream along the axis (Y) and to drive the tip end (1142, 1155) of the valve pin upstream and downstream between a first closed position where the tip end of the valve pin obstructs the gate to prevent the injection fluid from flowing into the cavity, a full open or end of stroke position where the injection fluid material flows freely without restriction from the tip end of the pin through the gate, and one or more intermediate positions between the first position and the full open position wherein the tip end of the valve pin restricts flow of the injection fluid along at least a portion of the length of the drive path extending between the first closed position and the one or more intermediate positions, the apparatus including a controller (16) that contains instructions that instruct the actuator to controllably drive the valve pin upstream beginning from the first closed position at a reduced rate of upstream travel relative to a high rate of upstream travel to a selected intermediate position and to hold the valve pin in the selected intermediate position for a selected period of time.
In another aspect of the invention there is provided a method of performing an injection molding cycle in an injection molding apparatus as described above comprising:
In another aspect of the invention there is provided a method of performing an injection molding cycle in an injection molding apparatus as described above comprising:
In another aspect of the invention in an apparatus as described above the electrically powered actuator (940, 941, 942) drives the valve pin upstream and downstream along the axis and drives the tip end of the valve pin upstream and downstream between a first closed position where the tip end of the valve pin obstructs the gate to prevent the injection fluid from flowing into the cavity and a full open position where the injection fluid material flows freely without restriction from the tip end of the pin through the gate at a maximum pressure,
The accompanying drawings contain numbering of components and devices that correspond to the numbering appearing in the following Summary.
The nozzles can be configured as shown in
Such a valve pin and nozzle configuration as shown in
The downstream fluid driven actuator 940a, 941a, 942a is drivably interconnected to a valve pin 1040, 1041, 1042 that is arranged to be reciprocally movable along a linear drive axis Y to close and open a gate 32, 34, 36 to a mold cavity 30.
The valve pins 1040, 1041, 1042 are controllably drivable according to a predetermined program to any axial positions intermediate the gate 32, 34, 36 closed and gate open positions. Programmed controllable drive of the electrically powered actuators 940, 941, 942 is typically carried out employing a predetermined algorithm that operates using one or more sensor signals as a variable in the algorithm to control movement of the valve pins beginning from the gate closed position to one or more intermediate positions upstream of gate closed up to a fully gate open position.
The algorithm and program used to control operation of the electrically powered actuators can employ any one or more of multiple sensor signals as variables to control pin position, pin velocity and pin movement generally. As shown in
Such a position sensor as sensor 950,
A position signal can also be generated and used in the control algorithm by employing a suitable position sensor such as a Hall Effect sensor or a trip sensor as described to detect the position of the driver 940ld of a linear electrically powered actuator as shown in
A position signal can also be generated and used in the control algorithm by employing a position sensor that senses the rotational position of a rotary electrically powered actuator such as by use of an encoder that detects the rotational position of the rotor of a rotary actuator.
The drive fluid circuit of the
Similar to the
While rotary electric actuators are commonly used, linearly driven actuators or linear actuators can alternatively be used in place of rotary electric actuators. One example of a linear actuator that uses electric energy to directly produce linear motion in instead of rotary motion, is a proportional solenoid as shown in
The linear motor,
A linear actuator is particularly suited for use in a configuration where the drive axis of the actuator and the pin movement axis X are coaxially arranged A linear actuator as described can be used to drive any pin drive member 940ld as an alternative to the rotor based actuators described herein.
In alternative embodiments, the center gate 32 and associated actuator 940 and valve pin 1040 can remain open at, during and subsequent to the times that the lateral gates 34, 36 are opened such that fluid material flows into cavity 30 through both the center gate 32 and one or both of the lateral gates 34, 36 simultaneously.
When the lateral gates 34, 36 are opened and fluid material NM is allowed to first enter the mold cavity into the stream 102p that has been injected from center nozzle 22 past gates 34, 36, the two streams NM and 102p mix with each other. If the velocity of the fluid material NM is too high, such as often occurs when the flow velocity of injection fluid material through gates 34, 36 is at maximum, a visible line or defect in the mixing of the two streams 102p and NM will appear in the final cooled molded product at the areas where gates 34, 36 inject into the mold cavity. By injecting NM at a reduced flow rate for a relatively short period of time at the beginning when the gate 34, 36 is first opened and following the time when NM first enters the flow stream 102p, the appearance of a visible line or defect in the final molded product can be reduced or eliminated.
The rate or velocity of upstream withdrawal of pins 1041, 1042 starting from the closed position is controlled via controller 16,
The position sensors 950 for sensing the position of the actuator pistons and their associated valve pins (such as 1040, 1041, 1042) and feed such position information to controller 16 for monitoring purposes. As shown, fluid material 18 is injected from an injection machine into a manifold runner 19 and further downstream into the bores 44, 46 of the lateral nozzles 24, 22 and ultimately downstream through the gates 32, 34, 36. When the pins 1041, 1042 are withdrawn upstream to a position where the tip end of the pins 1041 are in a fully upstream open position such as shown in
Beginning from a gate closed position, the pins 1040, 1041 can be controllably withdrawn at one or more reduced velocities (less than maximum) for one or more periods of time over the entirety of the length of the path RP over which flow of mold material 1153 is restricted. Preferably the pins are withdrawn at a reduced velocity over more than about 50% of RP and most preferably over more than about 75% of the length RP. As described with reference to
The trace or visible lines that appear in the body of a part that is ultimately formed within the cavity of the mold on cooling above can be reduced or eliminated by reducing or controlling the velocity of the pin 1041, 1042 opening or upstream withdrawal from the gate closed position to a selected intermediate upstream gate open position that is preferably 75% or more of the length of RP.
RP can be about 1-8 mm in length and more typically about 2-6 mm and even more typically 2-4 mm in length. As shown in
As used in this application with regard to various monitoring and control systems, the terms “controller,” “component,” “computer” and the like are intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component or controller may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a server and the server can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers.
Claimed methods of the present invention may also be illustrated as a flow chart of a process of the invention. While, for the purposes of simplicity of explanation, the one or more methodologies shown in the form of a flow chart are described as a series of acts, it is to be understood and appreciated that the present invention is not limited by the order of acts, as some acts may, in accordance with the present invention, occur in a different order and/or concurrent with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the present invention.
In various embodiments of the invention disclosed herein, the term “data” or the like means any sequence of symbols (typically denoted “0” and “1”) that can be input into a computer, stored and processed there, or transmitted to another computer. As used herein, data includes metadata, a description of other data. Data written to storage may be data elements of the same size, or data elements of variable sizes. Some examples of data include information, program code, program state, program data, other data, and the like.
As used herein, computer storage media or the like includes both volatile and nonvolatile, removable and non-removable media for storage of information such as computer-readable instructions, data structures, program modules, or other data. Computer storage media includes RAM, ROM, EEPROM, FLASH memory or other memory technology, CD-ROM, digital versatile disc (DVDs) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store desired information and which can be accessed by the computer.
The methods described herein may be implemented in a suitable computing and storage environment, e.g., in the context of computer-executable instructions that may run on one or more processors, microcontrollers or other computers. In a distributed computing environment (for example) certain tasks are performed by remote processing devices that are linked through a communications network and program modules may be located in both local and remote memory storage devices. The communications network may include a global area network, e.g., the Internet, a local area network, a wide area network or other computer network. It will be appreciated that the network connections described herein are exemplary and other means of establishing communications between the computers may be used.
A computer may include one or more processors and memory, e.g., a processing unit, a system memory, and system bus, wherein the system bus couples the system components including, but not limited to, the system memory and the processing unit. A computer may further include disk drives and interfaces to external components. A variety of computer-readable media can be accessed by the computer and includes both volatile and nonvolatile media, removable and nonremovable media. A computer may include various user interface devices including a display screen, touch screen, keyboard or mouse.
A “controller,” as used herein also refers to electrical and electronic control apparatus that comprise a single box or multiple boxes (typically interconnected and communicating with each other) that contain(s) all of the separate electronic processing, memory and electrical signal generating components that are necessary or desirable for carrying out and constructing the methods, functions and apparatuses described herein. Such electronic and electrical components include programs, microprocessors, computers, PID controllers, voltage regulators, current regulators, circuit boards, motors, batteries and instructions for controlling any variable element discussed herein such as length of time, degree of electrical signal output and the like. For example a component of a controller, as that term is used herein, includes programs, controllers and the like that perform functions such as monitoring, alerting and initiating an injection molding cycle including a control device that is used as a standalone device for performing conventional functions such as signaling and instructing an individual injection valve or a series of interdependent valves to start an injection, namely move an actuator and associated valve pin from a gate closed to a gate open position. In addition, although fluid driven actuators are employed in typical or preferred embodiments of the invention, actuators powered by an electric or electronic motor or drive source can alternatively be used as the actuator component.
The actuator controller 16 typically includes additional instructions that can instruct a valve pin 1041, 1042, 1040 to be driven either upstream or downstream starting from either a fully closed downstream or a fully upstream, gate open position at one or more reduced upstream or reduced downstream velocities over at least the beginning portion of the upstream path of travel of the valve pins 1040, 1041, 1042 or the latter portion of the downstream path of travel of the valve pins toward the gates 32, 34, 36 where the tip end 1142 of the pin 1041 restricts flow of the injection fluid through the gate RP, RP2, RP3 such as shown in
In one embodiment, the valve pin is driven along the axis
In an embodiment such as shown in
In alternative embodiments, the center gate 32 and associated actuator 940e, 940p and valve pin 1040 can remain open at, during and subsequent to the times that the lateral gates 34, 36 are opened such that fluid material flows into cavity 30 through both the center gate 32 and one or both of the lateral gates 34, 36 simultaneously. When the lateral gates 34, 36 are opened and fluid material NM is allowed to first enter the mold cavity into the stream 102p that has been injected from center nozzle 22 past gates 34, 36, the two streams NM and 102p mix with each other. If the velocity of the fluid material NM is too high, such as often occurs when the flow velocity of injection fluid material through gates 34, 36 is at maximum, a visible line or defect in the mixing of the two streams 102p and NM will appear in the final cooled molded product at the areas where gates 34, 36 inject into the mold cavity. By injecting NM at a reduced flow rate for a relatively short period of time at the beginning when the gate 34, 36 is first opened and following the time when NM first enters the flow stream 102p, the appearance of a visible line or defect in the final molded product can be reduced or eliminated.
In a conventional system, the injection molding machine IMM includes its own internal manufacturer supplied machine controller that generates standardized beginning of cycle gate closed and end of cycle gate open and gate closed machine voltage signals VS typically 0 volts for gate open and 24 volts for gate open (or 0 volts and 120 volts respectively). The standardized machine voltage signals VS are typically sent either directly to the solenoids of a master directional control valve 12 (that controls the direction of flow of actuator drive fluid into or out of the drive chambers of all of the plurality of fluid driven actuators 940f, 941f, 9420 to cause the directional control valve 12 (DCV) to move to a gate closed or gate open actuator drive fluid flow position. Or, the same standardized voltage signals VSC can be sent to the directional control valve 12 via the actuator controller 16 which generates the same standardized voltage signals VSC as the VS signals in response to receipt from a screw position sensor SPSR of a machine screw position signal SPS sent by the injection molding machine IMM to the actuator controller 16, the actuator controller 16 thus generating the same beginning of cycle and end of cycle control voltage signals VSC as the machine IMM can otherwise generate and send VS directly to the directional control valve 12. Thus, where conventional standardized directional control valves 12 are used, the sending of start of cycle and end of cycle signals can be simplified via electrical or electronic signal connections directly to the internal signal generator or controller contained within the injection molding machine.
Electrically powered actuators or electric motors and proportional directional control valves cannot directly receive and utilize a standardized 0 volt (gate closed), 24 volt (gate open) or 0 volt (gate closed) 120 volt (gate open) signals generated by the start and stop cycle controller or signal generator that is typically included in a conventional injection molding machine.
As shown in a generic schematic form in
In an alternative embodiment, the electric actuators 940e, 941e, 942e can be mounted remote from the manifold 40 and mechanically interconnected to a first upstream fluid cylinder 940c, 941c, 942c which is coupled to a second downstream fluid actuator 940a, 941a, 942a in the same manner as described above with respect to the
In the
The distribution channel 19 commonly feeds three separate nozzles 20, 22, 24 which all commonly feed into a common cavity 30 of a mold 33. The nozzle 22, 24, 26 as shown can be controlled upstream by a configuration of an electric motor actuator 940e mechanically interconnected to a first upstream fluid actuator 940c and downstream actuator 940a as described above regarding the
As shown in the
Also as with a conventional system, the
A signal converter 1500,
Thus the standard start and stop control signals generated by an IMM (VS, VSC) can operate in conjunction with the converter 1500 to instruct either the electric actuators, 940e, 941e, 942e to at least initiate or begin an injection cycle (such as by instructing the actuators 940e, 941e, 942e to drive a valve pin upstream from a gate closed position) and to end or stop an injection cycle (such as by instructing the actuators 940e, 941e, 942e, 940p, 941p, 942p to drive a valve pin downstream from a gate open position into a gate closed position).
The
Most preferably the physical or mechanical electric signal connectors that are typically used to connect a wire or cable from the IMM (or machine controller MC) to the signal conversion device 1500, are the same physical or mechanical connectors that are used in conventional systems to connect the IMM (or machine controller MC) to the DCVs of a conventional system as described with reference to
As shown in
The MOCPS and PDCVS signals include signals that correspond to the VS signals that operate to affect the beginning and end of an injection cycle.
Typically the
The actuator controller 16 can include a program that receives and processes a real time signal indicative of a condition of the injection fluid 18 or a component of the apparatus (10) such as rotational position of a rotor 940r, 941r, 942r or axial linear position of a valve pin 1040, 1041, 1042. The real time signals sent to and received by the actuator controller 16 are generated by one or more of position sensors 950, 951, 952 or fluid condition sensors SN, SC. The sensors detect and send a signal to the actuator controller that is typically indicative of one or more of rotational position (sensors 950, 951, 952) of a rotor 940r, 941r, 942r or of linear axial position of a valve pin 1040, 1041, 1042. The fluid condition sensors typically comprise one or more of a pressure or temperature sensor SN that senses injection fluid 18 within a manifold channel 19 or a nozzle channel 42, 44, 46 or senses pressure or temperature of the injection fluid SC within the cavity 30 of the mold 33.
The actuator controller 16 can include a program that processes the received signal(s) from one or more of the sensors 950, 951, 952, SN, SC according to a set of instructions that use the received signals as a variable input or other basis for controlling one or more of the position or velocity of the actuators 940e, 941e, 942e or their associated valve pins 1040, 1041, 1042 throughout all or selected portion of the duration of an injection cycle or all or a portion of the length of the upstream or downstream stroke of the actuators 940e, 941e, 942e.
As shown the controller 16 can be included within and comprise a component of the converter 1500. Where the converter 1500 includes a controller 16 that includes position and velocity control instructions, the converter 1500 can thus send its machine open close power signals MOCPS (or valve open close signals PDCVS) together with position velocity signals (PVS) to either the electric actuators 940e, 941e, 942e or proportional directional control valves V, V1, V2. The control signals MOCPS and PDCVS thus include a signal that has been converted from and corresponds to one or the other of the converted VS signals received by the converter 1500 from the IMM controller MC or the HPU. The position or velocity control signals PVS can control the position or velocity of the valve pin according to any predetermined profile of pin position or velocity versus time of injection cycle. The form, format, intensity and frequency of the MOCPS, PDCVS and PVS signals are compatible with the signal receiving interface of the electric actuators 940e, 941e, 942e or valves V, V1, V2.
User Interface and Target Profiles
The graphs of
The valve pin associated with graph 1235 is opened sequentially at 0.5 seconds after the valves associated with the other three graphs (1237, 1239 and 1241) were opened at 0.00 seconds. At approximately 6.25 seconds, at the end of the injection cycle, all four valve pins are back in the closed position. During injection (for example, 0.00 to 1.0 seconds in
Through the user interface, target profiles can be designed, and changes can be made to any of the target profiles using standard (e.g., windows-based) editing techniques. The profiles are then used by controller 1016 to control the position of the valve pin. For example,
Screen 1300 is generated by a windows-based application performed on the user interface, e.g., any of the user interfaces 21 shown in
A profile 1310 includes (x, y) data pairs, corresponding to time values 1320 and pressure values 1330 which represent the desired pressure sensed by the pressure transducer for the particular nozzle being profiled. The screen shown in
The screen also allows the user to select the particular valve pin they are controlling displayed at 1390, and name the part being molded displayed at 1400. Each of these parameters can be adjusted independently using standard windows-based editing techniques such as using a cursor to actuate up/down arrows 1410, or by simply typing in values on a keyboard. As these parameters are entered and modified, the profile will be displayed on a graph 1420 according to the parameters selected at that time.
By clicking on a pull-down menu arrow 1391, the user can select different nozzle valves in order to create, view or edit a profile for the selected nozzle valve and cavity associated therewith. Also, a part name 1400 can be entered and displayed for each selected nozzle valve.
The newly edited profile can be saved in computer memory individually, or saved as a group of profiles for a group of nozzles that inject into a particular single or multi-cavity mold. The term “recipe” is used to describe one or more of profiles for a particular mold and the name of the particular recipe is displayed at 1430 on the screen icon.
To create a new profile or edit an existing profile, first the user selects a particular nozzle valve of the group of valves for the particular recipe group being profiled. The valve selection is displayed at 1390. The user inputs an alpha/numeric name to be associated with the profile being created, for family tool molds this may be called a part name displayed at 1400. The user then inputs a time displayed at 1340 to specify when injection starts. A delay can be with particular valve pins to sequence the opening of the valve pins and the injection of melt material into different gates of a mold.
The user then inputs the fill (injection) pressure displayed at 1350. In the basic mode, the ramp from zero pressure to max fill pressure is a fixed time, for example, 0.3 seconds. The user next inputs the start pack time to indicate when the pack phase of the injection cycle starts. The ramp from the filling phase to the packing phase is also fixed time in the basic mode, for example, 0.3 seconds.
The final parameter is the cycle time which is displayed at 1380 in which the user specifies when the pack phase (and the injection cycle) ends. The ramp from the pack phase to zero pressure may be instantaneous when a valve pin is used to close the gate, or slower in a thermal gate due to the residual pressure in the cavity which will decay to zero pressure once the part solidifies in the mold cavity.
User input buttons 1415 through 1455 are used to save and load target profiles. Button 1415 permits the user to close the screen. When this button is clicked, the current group of profiles will take effect for the recipe being profiled. Cancel button 1425 is used to ignore current profile changes and revert back to the original profiles and close the screen. Read Trace button 1435 is used to load an existing and saved target profile from memory. The profiles can be stored in memory contained in one or more of the operator interface 21, the main MCU 9, and the recipe storage MCU 16. Save trace button 1440 is used to save the current profile. Read group button 1445 is used to load an existing recipe group. Save group button 1450 is used to save the current group of target profiles for a group of nozzle valve pins. The process tuning button 1455 allows the user to change the settings (for example, the gains) for a particular nozzle valve in a control zone. Also displayed is a pressure range 1465 for the injection molding application.
| Number | Date | Country | |
|---|---|---|---|
| 63244579 | Sep 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US22/43567 | Sep 2022 | US |
| Child | 18229307 | US |
