The present invention relates to a system for controlling a shutter slidably arranged in a plastic material injection nozzle.
A “hot runner” type injection system normally comprises:
These control means may comprise a hydraulic cylinder, a pneumatic cylinder or an electric actuator.
The control of the opening and the closing of the shutter has a particular importance for the quality of the parts formed in the moulding cavity, notably in the case of sequential injection, that is to say when the moulding cavity is supplied by several injection nozzles, the opening and closing are temporally offset.
Compared to hydraulic and pneumatic technologies, an electric actuator has the advantage of enabling more precise and reproducible control of the position of the shutter and consequently the flow of material from the distributor to the moulding cavity.
Furthermore, such an actuator is also cleaner and has a longer lifetime due to the absence of oil.
In general, the actuator comprises a rotary electric motor, which thus has a rotationally driven output shaft. Different mechanisms have already been described for coupling the output shaft to the shutter and to convert rotation of the output shaft into translation of the shutter.
The document U.S. Pat. No. 6,294,122 thus describes a system based on a screw-nut type mechanism which is a known means for converting rotation into translation. According to an embodiment, the output shaft is coaxial with the shutter and fixed directly to the element of the screw-nut mechanism which is translationally moveable. However, since the actuator is arranged on the rear face of the distributor (that is to say the face opposite to the moulding cavity), such a solution is particularly bulky and substantially increases the thickness of the mould. According to another embodiment, the output shaft is perpendicular to the shutter and to the screw-nut mechanism, and coupled to the screw by a gearing. However, even if the bulk in the sense of the thickness may be reduced thanks to this arrangement of the actuator, the gearing is subjected to considerable wear and problems of friction, liable to reduce the precision of the control of the position of the shutter.
The document EP 2 679 374 aims to reduce the bulk in thickness of the hot runner, by arranging the actuator on one side of the distributor, with its output shaft parallel to the shutter. A mechanism including a ball screw makes it possible to convert the rotational movement of the output shaft of the actuator into a translational movement, which makes it possible to actuate a rocker coupled to the shutter. However, this mechanism is particularly complex and, even though part of the actuator is offset on one side of the distributor, it remains bulky.
The document EP 2 918 389 for its part describes a system wherein the electric actuator is arranged in a base plate situated on the rear face of the mould, the output shaft and the screw-nut mechanism being arranged parallel with one another and perpendicularly to the shutter, the shutter being coupled to the element of the screw-nut system translationally moveable by an oscillating lever.
Finally, the document U.S. Pat. No. 6,086,357 describes a system wherein an eccentric cam is rotationally driven by the output shaft of the motor with respect to an axis perpendicular to the shutter, the rotation of the cam causing an alternating translational movement of the shutter. However, such a system is subjected to considerable thermal expansions, which are liable to reduce the closing precision.
An aim of the invention is to design an injection system wherein the shutter is controlled by an electric actuator, of which the bulk in thickness is reduced compared to known solutions.
In accordance with the invention, a system is proposed for controlling a shutter slidably arranged in a plastic material injection nozzle, comprising a rotary electric motor and a mechanism adapted to couple said motor to the shutter to slidably drive it between a closing position of the nozzle and a maximum opening position of the nozzle, characterised in that said mechanism comprises:
This system has several advantages.
On the one hand, its bulk is limited. In particular, the electric actuator may be arranged in a housing of the base plate normally provided for a hydraulic or pneumatic cylinder. A change of actuating energy may thus be carried out easily.
On the other hand, the actuating efficiency is improved thanks to the direct conversion of rotation of the output shaft into translation of the shutter.
Furthermore, compared to a lever system, the system according to the invention consumes little energy in the two extreme positions of the shutter (complete opening or complete closing) because these two positions are stable equilibrium positions of the mechanism.
According to other advantageous characteristics of the invention, potentially combined:
Another subject matter of the invention relates to a plastic material injection system, comprising:
According to an embodiment, the actuator and/or the shutter is provided with a position sensor and the sequential control unit is configured to control the transmission of control signals as a function of measurements supplied by said position sensor.
Furthermore, the sequential control unit may be configured to further take into account at least one of the following data: a time of the injection method, a position of a sensor, a pressure or a temperature in the injection tooling, a signal of the injection moulding machine.
According to an embodiment, the sequential control unit is configured to send an electrical control signal in the form of a direct current.
In an alternative manner, the sequential control unit is configured to send an electrical control signal in the form of an alternating current.
The invention finally relates to a method for modifying a plastic material injection system, wherein said system comprises:
Other characteristics and advantages of the invention will become clear from the detailed description that follows, with reference to the appended drawings wherein:
Identical reference signs from one figure to the other designate identical elements or elements fulfilling the same function.
In a manner known per se, the injection system comprises a shutter slidably arranged in a plastic material injection nozzle.
The nozzle and the shutter are known per se and will not be described in detail. As regards the general architecture of the injection system, those skilled in the art may refer to the description provided in the document EP 1 196 274 which is applicable to the present invention, apart from that which concerns the actuation of the shutter (the document EP 1 196 274 describing a hydraulic actuation).
Generally speaking, the system (actuator) for controlling the shutter comprises a rotary electric motor and a mechanism linking the output shaft of the motor to said shutter to slidably drive it between a closing position of the nozzle and a maximum opening position of the nozzle.
The injection system comprises a mould (not illustrated) having a moulding cavity. In a conventional manner, the terms “rear” and “front” are understood in the present text with respect to the direction of injection of the plastic material into the moulding cavity, a rear region being upstream of a front region with respect to this injection direction. This direction is represented by the arrow on the left of
The mould is provided with at least one injection well opening into the moulding cavity and intended to receive a respective nozzle, the nozzle and the well being coaxial.
Each nozzle 11 is integral with a distributor 10 which comprises a plastic material distribution channel 100 opening into a transit passage of the nozzle 11. A single nozzle is represented in
The distributor 10 is mounted on a base plate 12 fixed on the rear face of the mould in such a way that the distributor can undergo thermal expansion with respect to the base plate and to the mould without affecting the centring of the nozzle with respect to the injection well.
A shutter 110 is slidably arranged in the nozzle 11 between a closing position preventing the passage of plastic material in the transit passage up to the moulding cavity, and an opening position wherein the flow of plastic material can flow without restriction from the distribution channel 100 into the transit passage. The shutter has a general shape of revolution around a longitudinal axis X.
The shutter 110 has, at its rear end, a collar 111 extending radially with respect to the longitudinal axis X.
In the embodiment illustrated, the shutter 110 is made integral (by screwing or any other means) with the front end of a rod 112 coaxial with the shutter. At the rear end of said rod is fixed an annular washer forming the collar 111, said washer being made integral with the rod by a bolt 113 or any other means. Alternatively, the collar could form an integral part of the rod.
The rod 112 makes it possible to guide the sliding of the shutter in the transit passage of the nozzle.
The base plate 12 comprises, in the rear part thereof, a housing 120 intended to receive the actuator. As will be described hereafter, the actuator is coupled to the rear part of the shutter 110/rod 112 assembly.
The actuator 2 comprises an electric motor M. Said motor is advantageously associated with a reducer (not represented) to form a gear motor. In the remainder of the text, the term “motor” comprises a gear motor.
The motor comprises an output shaft (designated by the reference 20 in
The mechanism of transmission of movement comprises an eccentric 21 which is rigidly integral with the output shaft of the motor and is thus adapted to be rotationally driven by said shaft. The eccentric 21 comprises a crank pin 22 parallel to the output shaft of the motor but non-coaxial therewith.
A slide 23 is configured to be made integral with the rear end of the shutter.
According to an embodiment, also illustrated in
Alternatively, illustrated in
A connecting rod 25 is arranged between the eccentric 21 and the slide 23. The connecting rod comprises an orifice 25a adapted to engage on the crank pin 22 of the eccentric and enable the rotational driving of the connecting rod, and an articulation axis 25b perpendicular to the sliding axis of the shutter. The slide is mounted on said articulation axis by a pivot link.
The slide 23 is itself slidably mounted in a guide 24 extending along the axis X, such that a rotational movement of the connecting rod causes a translational movement of the slide in the guide, the slide translationally driving the shutter along the axis X.
This movement is cyclic, that is to say that the slide is alternately displaced from front to back (direction of opening of the nozzle) and from back to front (direction of closing of the nozzle). It is thus not necessary to reverse the direction of rotation of the output shaft of the electric motor to reverse the direction of displacement of the shutter. This oscillation of the shutter makes it possible, during the phase of maintaining the injection cycle, to force diffusion of pressure lines within the plastic material and to avoid the interface between pressure lines becoming set along a determined line which would cause a visible defect.
Another advantage of the invention is its compactness.
An additional advantage of the invention is that the electric actuator that has been described is interchangeable with a hydraulic or pneumatic cylinder. Indeed, the electric actuator may be installed in the housing 120 initially provided in the base plate for a hydraulic or pneumatic cylinder, and the link up of the shutter with the actuator is identical to that provided for a cylinder.
It is thus easy to modify an injection system initially comprising a hydraulic or pneumatic cylinder to switch to electric actuation of the shutter.
Such a replacement of a hydraulic or pneumatic cylinder by an electric actuator has several advantages. On the one hand, the electric actuator enables greater complexity of the law of positioning the shutter in the course of an injection cycle. On the other hand, the electric actuator procures greater precision and has more reproducibility of positioning and speed of displacement of the shutter. Finally, the electric motor is more reliable, cleaner and less subject to wear than a hydraulic or pneumatic cylinder. A change of actuating technology on an existing injection system is thus entirely relevant.
The displacement speed of the shutter is adjusted by an electrical signal transmitted by a component of an electronic control board to the motor. Similarly, a blocking of the travel of the shutter may be obtained by a specific electrical signal transmitted by a component of the electronic control board to the motor.
A fine adjustment of the travel of the shutter is thus obtained, capable of substantially improving the quality of the injected parts. This adjustment is advantageously specific to each actuator-shutter assembly comprised in the injection system, in order to optimise the control of the flow of plastic material inside the cavity.
The electronic control board is electrically connected to a sequential control unit. Such a control unit, also known by the term sequencer, is commercially available according to different models and does not require particular adaptation to be able to be used in the present invention.
The sequential control unit comprises at least two control paths, each electrically connected to a component of the control board.
The sequential control unit is configured to send selectively an electrical control signal via one and/or the other of said control paths to the components of the electronic board in such a way that:
In so far as the movement described by the axis of the connecting rod on which is articulated the slide is sinusoidal, there is no proportionality between the speed of rotation of the output shaft and the speed of translation of the shutter. The speed of rotation of the output shaft of the motor must thus be controlled continuously as a function of the angular position of the connecting rod so that the translation speed of the shutter is the desired speed.
Each control signal may be transmitted in the form of a direct or an alternating electric current.
In a particularly advantageous manner, the actuator or the shutter is provided with a position sensor coupled to the sequential control unit and the sequential control unit controls the transmission of control signals as a function of measurements supplied by said position sensor. The use of such a sensor is known per se and does not need to be described in greater detail in the present text. The fact of generating control signals from measurement data of such a position sensor enables more precise control of the opening-closing sequence than from purely temporal sequencing.
Furthermore, the sequential control unit may take into account one at least of the following data—combined with the data of the aforementioned position sensor—for the transmission of the control signals: a time, the position of a sensor (for example: the position of the extrusion screw), a pressure or a temperature in the tooling (injection mould or hot runner), signal of the injection moulding machine (for example: top injection, top maintain), etc. These data are commonly recorded during the implementation of the thermoplastic injection method, and the injection moulding machine and the injection tooling are equipped with appropriate sensors, coupled to an acquisition box. The exploitation of these data thus does not require acquisition means developed specifically for the invention. Those skilled in the art are capable to processing one or more of said signals and deducing therefrom a programming of each opening-closing sequence of the shutter.
The actuator is designated by the reference 100. The shutter is not represented in this figure.
The electronic board for controlling 200 the actuator comprises three components 201, 202, 203 of which one is a component for regulating the speed of the shutter adjusted to a first constant speed (called slow speed), another is a component for regulating the speed of the shutter adjusted to a second constant speed (called rapid speed), greater than the first speed, and yet another is a component for blocking the opening travel of the shutter.
The sequential control unit is designated by the reference 300. It comprises three output paths 301, 302, 303, each connected to a respective component 201, 202, 203 of the electronic control board, making it possible to send thereto a respective control signal S1, S2, S3.
Whatever the form of implementation, the components of the electronic board are programmed beforehand according to techniques known per se.
As indicated above, the control unit comprises at least two control paths, each electrically connected to one of the components of the electronic board.
Thus, the sending of a control signal via a first control path to one of the components (for example, a component for adjusting the speed of rotation of the output shaft of the motor) triggers the operation of the motor in such a way as to obtain the desired translation speed.
A control signal sent via a second control path to another component (for example, the component for blocking the rotation of the shaft) has the effect of stopping the motor to immobilise the shutter.
It is thus possible to obtain different graphs of the travel of the shutter in the course of an opening-closing sequence, examples of which that are in no way limiting are illustrated in
Zero travel corresponds to total closing of the shutter.
A first step O1 of the opening phase O is carried out at rapid speed.
A second step O2 of the opening phase O is carried out at slow speed.
A third step O3 of the opening phase O is carried out with the shutter blocked.
A fourth step O4 of the opening phase O is carried out at slow speed.
A fifth step O5 of the opening phase O is carried out at rapid speed.
In a sixth step O6 of the opening phase O, the maximum opening travel of the shutter being reached, said shutter is blocked.
The closing step F1 is for its part at rapid speed.
A second opening-closing sequence comprises a first step O1′ at rapid speed, a second step O2′ with the shutter blocked, and a closing step at rapid speed F1′.
The signals S1, S2, S3 of each of the three paths of the sequential control unit respectively connected to the components 201 (regulation at rapid speed), 202 (regulation at slow speed), 203 (blocking) of the electronic control board have either zero amplitude (OFF), or an amplitude of a determined value (ON). The OFF state corresponds to an absence of power supply to the considered component.
In a first step O1 of the opening phase O, the signal S1 is in the ON state whereas the signals S2 and S3 are in the OFF state. The shutter begins its opening travel at the rapid speed.
In a second step O2 of the opening phase O, the signal S1 is still in the ON state and the signal S2 switches to the ON state, the signal S3 remaining in the OFF state. The travel of the shutter slows down to the slow speed.
In a third step O3 of the opening phase O, the signal S1 is still in the ON state and the signal S3 switches to the ON state, the signal S2 switching to the OFF state or not. The travel of the shutter is then blocked.
In a fourth step O4 of the opening phase O, the signal S1 is still in the ON state and the signal S2 switches to the ON state, the signal S3 switching to the OFF state. The travel of the shutter then restarts with the slow speed.
In a fifth step O5 of the opening phase O, the signal S1 is still in the ON state and the signal S2 switches to the OFF state, the signal S3 remaining in the OFF state. The travel of the shutter then continues with the rapid speed.
In a sixth step O6 of the opening phase O, the signal S1 is still in the ON state. The maximum opening travel Cmax of the shutter being reached, said shutter is blocked.
To engage the closing phase F, the signal S1 switches to the OFF state. The signal S2 switches to the ON state and the signal S3 remains in the OFF state, a slow closing speed is thus imposed during step F1.
In a second closing step F2, the signal S3 switches to the ON state and drives a blocking of the shutter, the signal S2 remaining in the ON state or switching to the OFF state.
In a third closing step F3, the signal S3 switches to the OFF state and the signal S2 switches to (or remains in) the ON state, thus driving a closing at slow speed.
It goes without saying that the examples that have been given are only particular illustrations in no way limiting as regards the opening-closing profiles of the shutter.
Number | Date | Country | Kind |
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1872029 | Nov 2018 | FR | national |
Filing Document | Filing Date | Country | Kind |
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PCT/FR2019/052813 | 11/27/2019 | WO | 00 |