CN117042945A

CN117042945A - Synchronous controller for electric actuator valve, and monitoring and control method

Info

Publication number: CN117042945A
Application number: CN202180080548.XA
Authority: CN
Inventors: L·杨; V·加拉蒂
Original assignee: Synventive Molding Solutions Inc
Current assignee: Synventive Molding Solutions Inc
Priority date: 2020-09-30
Filing date: 2021-09-30
Publication date: 2023-11-10
Also published as: WO2022072598A1

Abstract

A wireless communication device programmed to: displaying synchronized control of valve pin positioning during injection molding and accepting user input related to preconfigured synchronization of valve pin positioning in real time during injection molding, such that a user can monitor and communicate changes to such control via a synchronization controller; the synchronization controller communicates with a plurality of electrical actuator assemblies that are inaccessible during the molding process, and wherein the preconfigured synchronization may require reconfiguration based on real-time changes in the delivery of molten plastic material from the barrel screw of the IMM to the actuator assemblies and associated gates of the mold cavity.

Description

Synchronous controller for electric actuator valve, and monitoring and control method

Technical Field

The present invention relates to electric actuators for controlling the positioning of valve pins in injection molding systems, and more particularly to controllers capable of synchronizing and remotely controlling such systems.

Background

Injection molding systems have been developed that have a flow control mechanism that controls the movement of the valve pin during an injection cycle to move the valve pin upstream or downstream during the injection cycle to vary the timing, speed, and/or rate of flow of fluid material into the gate of the mold cavity to correspond to a predetermined profile or recipe of the injection cycle. The sensor senses a condition of the fluid material or the instrument (e.g., valve pin position) and sends a signal indicative of the sensed condition to a program contained in a controller that uses the signal as a variable input to control movement of the valve pin according to a predetermined profile.

Such systems typically have multiple zones to control the positioning of multiple valve pins that feed material sequentially or simultaneously into multiple gates of a mold cavity. These systems must also synchronize with the conditions of the material being processed in the barrel screw of the injection molding machine itself, as opposed to a heated manifold assembly in which actuators controlling multiple valve pins are installed.

Electric actuators for controlling valve pins are generally preferred because they provide better control and repeatability of the injection molding process. However, they do require different control systems and methods than conventional fluid driven actuators, and placing these components near the heating manifold is more problematic due to the temperature sensitivity of the electric motor and drive.

There is a continuing need for systems and methods for monitoring and controlling injection procedures using an electric motor driven actuator assembly.

Disclosure of Invention

According to one embodiment, an electrical actuator control system includes:

a wireless communication device programmed to: displaying synchronized control of valve pin positioning during injection molding and accepting user input related to preconfigured synchronization of valve pin positioning in real time during injection molding, enabling a user to monitor and communicate changes to such control via an electrically actuated synchronization controller; the electrically actuated synchronization controller communicates with a plurality of electrical actuator assemblies that are inaccessible during the molding process, and wherein the preconfigured synchronization is reconfigured based on real-time changes in the delivery of molten plastic material from the barrel screw of the IMM to the actuator assemblies and associated gates of the mold cavity.

According to an embodiment, the housing includes an electric actuator synchronous controller and one or more input interfaces configured to receive: a) A control signal (VS) generated by an Injection Molding Machine (IMM), the control signal (VS) adapted to instruct an actuator to begin driving the valve pin along a travel path from a gate closed position upstream toward a gate end-of-travel position, and to begin driving the valve pin from the end-of-travel position downstream toward the gate closed position; and b) a valve pin Position Signal (PS) indicative of a valve pin position between a gate closed position and an end-of-travel position;

the synchronous controller includes a processor and a computer readable medium having a program of instructions for preconfigured actuation control of valve pin position by the electric actuator assembly during an injection cycle; wherein the processor generates an output control signal based on the input signal (VS, PS) and the instructions, the output control signal being used by the electric actuator assembly to controllably drive the electric actuator assembly during an injection cycle; and

a wireless communication device comprising a processor, a user interface, an interface adapted to wirelessly communicate with a synchronization controller, and a computer readable medium having a program of instructions for generating an output signal for synchronization of preconfigured actuation control of valve pin position by an electric actuator assembly based on user selectable data entered via the user interface; and the program of instructions is for displaying via the user interface the position of the valve pin along the travel path during an injection cycle.

According to one embodiment, the program of instructions is configured to calibrate a set of valve pin settings stored in a terminal block in communication with the electric actuator assembly and the synchronous controller.

According to an embodiment, the synchronization controller is configured to be mounted to an outer surface of a housing of the injection molding machine.

According to an embodiment, the synchronous controller is configured to generate the valve pin opening and closing signals at a maximum speed (e.g., 50 mm/sec) throughout the stroke, the maximum speed being determined by the electric actuator assembly.

According to an embodiment, the synchronization controller is configured to generate the valve pin opening signal at a decreasing speed that is less than the maximum speed, thereby allowing a user time to adjust the flow rate of the fluid material into the mold cavity during an injection cycle.

According to an embodiment, the synchronization controller is configured to: when the actuator assembly and the valve pin are positioned in the hot runner assembly, a valve pin arrangement for the closed position is created.

According to an embodiment, the synchronization controller is configured to: valve pin settings are generated for a predetermined slow opening rate and travel distance to stabilize the flow front rate of the fluid material in the mold cavity.

According to an embodiment, the synchronization controller is configured to: valve pin settings are generated for intermediate pin positions between a gate closed position and an end-of-travel position, for example, to control filling of fluid material in a mold cavity.

According to one embodiment, the preconfigured actuation control is a recipe stored in a junction box that communicates with the electrical actuator assembly and the synchronization controller.

According to one embodiment, the recipe is automatically transferred to the synchronization controller when the synchronization controller is connected to the junction box.

According to one embodiment, the recipe includes a set of valve pin settings displayed on a wireless user interface.

According to an embodiment, the output signals are generated for preconfigured actuation control of the valve pin positions by the plurality of electric actuator assemblies.

According to an embodiment, the wireless communication device is a handheld wireless computing device, such as a phone or tablet.

According to another embodiment, an electric actuator control system includes:

a sensor that senses and generates a signal indicative of the position of a valve pin driven by the electric actuator assembly through a downstream flow channel of a gate leading to the mold cavity during an injection cycle;

a controller having a processor and instructions for instructing the electric actuator assembly to drive the valve pin through the downstream flow channel between a gate closed position and an injection cycle end position or end-of-travel position; the controller receives signals from the sensors, and the instructions instruct the plurality of electric actuator assemblies to drive each of the plurality of valve pins along a predetermined travel path at one or more predetermined travel rates or speeds during an injection cycle based on receipt of the one or more received signals;

A wireless communication device comprising a processor, a user interface, an interface adapted for wireless communication with a synchronization controller, and a computer readable medium having a program of instructions for generating an output signal for synchronization with a preconfigured actuation control of a valve pin position by the electric actuator assembly based on user selectable data entered via the user interface; and the program of instructions is for displaying via the user interface the position of the valve pin along the travel path during an injection cycle.

According to another embodiment, the instructions are configured to instruct the electric actuator assembly to drive the valve pin upstream at a first rate or speed of travel to a predetermined position intermediate the gate closed position and the end-of-travel position and to drive the valve pin between the predetermined intermediate position and the end-of-travel position at a second rate or speed that is higher than the first rate or speed of travel.

According to another embodiment, an electric actuator of an electric actuator control system, the method comprises:

a housing including an electric actuator synchronous controller and one or more input interfaces configured to receive: a) A control signal (VS) generated by an Injection Molding Machine (IMM), the control signal (VS) adapted to instruct an actuator to begin driving the valve pin along a travel path from a gate closed position upstream toward a gate end-of-travel position, and to begin driving the valve pin from the end-of-travel position downstream toward the gate closed position; and b) a valve pin Position Signal (PS) indicative of a valve pin position between a gate closed position and an end-of-travel position;

A synchronous controller comprising a processor and a computer readable medium having instructions for preconfigured actuation control of valve pin positions by a plurality of electric actuator assemblies during an injection cycle; wherein the processor generates an output control signal based on the input signal (VS, PS) and the instructions, the output control signal being used by the electric actuator assembly to controllably drive the electric actuator assembly during an injection cycle; and

providing a wireless communication device comprising a processor, a user interface, an interface adapted to wirelessly communicate with a synchronization controller, and a computer readable medium having a program of instructions for generating an output signal for synchronization with a preconfigured actuation control of the valve pin position by the electric actuator assembly based on user selectable data entered via the user interface; and the program of instructions is for displaying via the user interface the position of the valve pin along the travel path during an injection cycle;

and providing user selectable data input to the user interface to adjust control of the electric actuator assembly in real time during the injection molding process.

According to another embodiment, the program of instructions is configured to calibrate a set of valve pin settings stored in a terminal block in communication with the electric actuator assembly and the synchronous controller.

According to another embodiment, the synchronization controller is mounted to an outer surface of a housing of the injection molding machine.

According to another embodiment, the synchronous controller generates the valve pin opening and closing signals at a maximum speed (e.g., 50 mm/s) throughout the stroke, the maximum speed being determined by the electric actuator assembly.

According to another embodiment, the synchronous controller generates the valve pin opening signal at a reduced rate that is less than the maximum rate, thereby allowing the user time to adjust the flow rate of fluid material into the mold cavity during an injection cycle.

According to another embodiment, the synchronization controller generates a valve pin setting for the closed position when the actuator assembly and the valve pin are positioned in the hot runner assembly.

According to another embodiment, the synchronous controller generates the valve pin settings for a preset slow opening rate and travel distance to stabilize the flow front rate of the fluid material in the mold cavity.

According to another embodiment, the synchronization controller generates a valve pin setting for an intermediate pin position between a gate closed position and an end-of-travel position, for example, to control filling of the cavity with fluid material.

According to an embodiment, there is provided an electric actuator control system including:

a housing including an electric actuator synchronous controller and one or more input interfaces configured to receive: a) A control signal (VS) generated by an Injection Molding Machine (IMM), the control signal (VS) adapted to instruct a fluid drivable actuator to begin driving the valve pin along a travel path from a gate closed position upstream toward a gate end-of-travel position, and to begin driving the valve pin from the end-of-travel position downstream toward the gate closed position; and b) a valve pin Position Signal (PS) indicative of a valve pin position between a gate closed position and an end-of-travel position;

The synchronous controller includes a processor and a computer readable medium having instructions for preconfigured actuation control of valve pin position by the electric actuator assembly during an injection cycle; wherein the processor generates an output control signal based on the input signal (VS, PS) and the instructions, the output control signal being used by the electric actuator assembly to controllably drive the electric actuator assembly during an injection cycle; and

a handheld wireless communication device comprising a processor, a user interface, an interface adapted for wireless communication with a synchronization controller, and a computer readable medium having a program of instructions for generating an output signal for synchronization with a preconfigured actuation control of the valve pin position by the electric actuator assembly based on user selectable data entered via the user interface; and the program of instructions is for displaying via the user interface the position of the valve pin along the travel path during an injection cycle.

In one embodiment, the program of instructions is configured to calibrate a set of valve pin settings stored in a terminal block in communication with the electric actuator assembly and the synchronous controller.

In one embodiment, the synchronization controller is configured to be mounted to an exterior surface of a housing of an injection molding machine.

In an embodiment, the synchronous controller is configured to generate the valve pin opening and closing signals at a maximum speed (e.g., 50 millimeters/second) throughout the stroke, the maximum speed being determined by the electrical actuator assembly.

In an embodiment, the synchronization controller is configured to generate the valve pin opening signal at a reduced speed that is less than the maximum speed, thereby allowing a user time to adjust the flow rate of the fluid material into the mold cavity during an injection cycle.

In an embodiment, the synchronization controller is configured to: when the actuator assembly and the valve pin are positioned in the hot runner assembly, a valve pin arrangement for the closed position is created.

In an embodiment, the synchronization controller is configured to: valve pin settings are generated for a predetermined slow opening rate and travel distance to stabilize the flow front rate of the fluid material in the mold cavity.

In an embodiment, the synchronization controller is configured to: valve pin settings are generated for intermediate pin positions between a gate closed position and an end-of-travel position, for example, to control filling of fluid material in a mold cavity.

A controller having a processor and instructions for instructing the electric actuator assembly to drive the valve pin through the downstream flow channel between a gate closed position and an injection cycle end position or end-of-travel position; the controller receives signals from the sensor, and the instructions instruct the electric actuator assembly to drive the valve pin along a predetermined travel path at one or more predetermined travel rates or speeds during an injection cycle based on receipt of the one or more received signals;

a handheld wireless communication device comprising a processor, a user interface, an interface adapted for wireless communication with a synchronization controller, and a computer readable medium having a program of instructions for generating an output signal for synchronization with a preconfigured actuation control of a valve pin position by an electric actuator assembly based on user selectable data entered via the user interface; and the program of instructions is for displaying via the user interface the position of the valve pin along the travel path during an injection cycle.

In such embodiments, the instructions may instruct the electric actuator assembly to drive the valve pin upstream to the predetermined position at a first rate or speed of travel and to drive the valve pin between the predetermined intermediate position and the end-of-travel position at a second rate or speed that is higher than the first rate or speed. The predetermined position is located intermediate the gate closing position and the stroke end position.

Drawings

FIG. 1 is a schematic diagram of various system components according to an embodiment of the invention.

Fig. 2 is a partial cross-sectional and perspective view of the components of fig. 1 mounted on an IMM (200) and a hot runner (400) according to an embodiment.

Fig. 3 is a perspective view of one embodiment of an injection molding apparatus 200 (useful in the context of the present invention) comprising an injection molding machine.

Fig. 4A-4I illustrate various views and functions of a synchronous controller telephony application.

Figures 5A-5F are schematic illustrations of 6 valve pin positioning and monitoring functions implemented by the synchronous controller telephony application and related system components of the present embodiment.

Fig. 6 illustrates an example computing system architecture (e.g., of a controller or mobile telephone device) in which components of system 2000 communicate with each other using connection 2005.

Fig. 7 is a schematic diagram of an embodiment of a handheld wireless device (mobile computing device/phone with microcontroller MCU and mobile user interface), a synchronization controller (with MCU) and a junction box (with MCU and recipe memory).

FIG. 8 is a schematic side view of an embodiment of an electric motor driven injection molding system wherein the valve includes an electric actuator; the system includes a machine signal converter that receives a standard signal generated by an injection machine controller and converts the signal into a control signal compatible with the electric actuator.

Fig. 8A is a schematic diagram of signal communication between an Injection Molding Machine (IMM) controller, sensors, signal transducers, and electrical actuators, according to an embodiment.

Fig. 8B is another schematic diagram illustrating signal communication between various components in fig. 8A.

9A-9B illustrate the position of the tapered end of the valve pin at different times between the start gate closed position and various upstream open positions shown in FIG. 9A; where RP represents the optional path length over which the velocity of the valve pin retracting upstream from the gate closed position to the open position is reduced relative to the velocity of upstream movement; when the valve pin velocity is at a maximum, the valve pin typically has this upstream velocity of movement over an uncontrolled velocity path FOV.

10A-10B illustrate various positions of the tip of the cylindrical structure of the valve pin.

11A-11B illustrate an alternative to downstream and upstream drive pin positions.

Detailed Description

Synchronous controller (figures 1-3)

Fig. 1-3 illustrate various components in accordance with an embodiment of the present invention, wherein a wireless communication device is programmed to: displaying synchronized control of valve pin positioning during injection molding and accepting user input related to preconfigured synchronization of valve pin positioning in real time during injection molding, such that a user can monitor and communicate changes to such control via a synchronization controller; wherein the synchronization controller communicates with a plurality of electrical actuator assemblies that are inaccessible during the molding process, and wherein the preconfigured synchronization may require reconfiguration based on real-time changes in the delivery of molten plastic material from the barrel screw of the IMM to the actuator assemblies and associated gates of the mold cavity.

The following table, labeled section headings a-F, provides an overview of the various functional and structural features of each component, as well as the communication channels and signals between the various components for the electrical actuator control of valve pin positioning during the injection molding process. The system components include:

A. a handheld wireless communication device, such as a mobile phone MP (100), has:

a wireless communication interface (103) with a synchronization controller SC (20), and optionally with an IMM machine controller MC (see MC user interface (304) in fig. 3 and MC in fig. 6-7B) for transmitting/receiving the various signals mentioned herein;

-a user input interface (101) for accepting user input, such as a touch screen, or a keyboard;

a user display (101) for monitoring one or more valve pin profiles, positions, timings or speeds, or other conditions of various system components;

computer program (instruction set) and processor, receives input data regarding the various system components via the synchronization controller SC and the optional IMM machine controller MC, and processes the input data via instructions to generate output signals indicative of desired control functions of one or more of the system components.

B. The synchronization controller SC (20) has:

A wireless communication interface (103) with the mobile phone (100), and a wired or wireless communication interface with the IMM machine controller, junction box JB (40), and SVG controller (16 in fig. 6-7B) for transmitting/receiving the various signals mentioned herein;

computer program (instruction set) and processor, receives input data regarding the various system components via IMM machine controller MC, junction box JB (40), SVG controller (16) and mobile phone (100), and processes the input data via instructions to generate output signals indicative of desired control functions of one or more of the system components.

Imm machine controller MC having:

a wired or wireless communication interface with the synchronization controller (20) and/or the SVG controller (16), and an optional wireless communication interface with the mobile phone (100) for transmitting/receiving the various signals mentioned herein;

-a user input interface (304) for accepting user input, such as a touch screen or a keyboard;

a user display (304) for monitoring one or more IMM machine parameters, such as barrel screw position and temperature, or other conditions of various system components.

A computer program (instruction set) and a processor, receives input data regarding various machine parameters, such as signals from a position sensor detecting the position of the barrel screw BS or a temperature sensor detecting the melt temperature, or input data regarding various other components via a synchronous controller or valve controller (e.g., sequential valve SVG controller (16)), and processes the input data via instructions to generate output signals indicative of desired control functions of one or more system components or IMM machine components.

The program includes instructions for generating a valve opening/closing timing control signal VS that is output to the SVG controller (16), the synchronization controller (20) and/or the mobile phone (100).

D. A sequential valve SVG controller (16) having:

communication interfaces with the electric actuator assembly (80 in fig. 1-3; 940e, 941e, 942e in fig. 6-7B), the synchronization controller SC (20) and/or the IMM machine controller MC for transmitting/receiving the various signals mentioned herein; in one embodiment, the SVG controller may be housed in a synchronous controller.

-a user input interface (1510) for accepting user input, such as a touch screen or a keyboard;

a user display (1510) for monitoring one or more parameters of various system components.

A computer program (instruction set) and a processor that receives input data regarding various system parameters and processes the input data via instructions to generate an output signal (MOCPS) that is indicative of a desired control function of one or more actuator assemblies to cause the one or more actuator assemblies to begin driving the valve pin along a travel path upstream from a gate closed position toward an end-of-travel position and to begin driving the valve pin downstream from the end-of-travel position toward a gate closed position (where gates refer to gates of a mold cavity), as shown, for example, in fig. 9A-11B.

E. The electric actuator assemblies (80; 940e, 941e, 942e in FIGS. 1-3), each have:

mechanical and electrical components, including rotors, coils and driving means;

communication interface with the SVG controller (16) for sending/receiving the various signals mentioned herein to drive the rotor and affect the linear torque of the valve pins to open and close the gates of the mold cavities.

F. An injection molding machine IMM (200) is provided with:

mechanical and electrical components, including barrel screw BS and position sensor; the position sensor is used to detect the position of the barrel screw and generate an output signal as referred to herein, such as an output control signal VS (e.g., as shown in fig. 8) indicative of the position of the barrel screw for starting an injection cycle.

FIG. 1 is a schematic illustration of various system components according to an embodiment of the invention, including:

a synchronization controller SC (20), a modular device of relatively compact size, designed to be mounted directly on the outer surface of the IMM housing (as shown in fig. 2-3), preferably comprising a light bar indicating ready and alarm status;

3 electric actuator EA assemblies (80), each driving one of 3 independent valve pins (e.g., 1040, 1041, 1042 as shown in fig. 8-8B); each EA component includes: a housing (81) containing the electric motor, and other actuator components (82-84), all mounted to a cooling plate (85) to isolate the electric motor from heat transfer from the heating manifold; electric actuators typically include an electric motor having a rotor rotatably driven by an electric coil as disclosed in us patent 6294122; one end of the shaft is connected to the rotary rotor, and the other end is connected to the rotary-linear converter; the additional EA assembly may include a rotation reducer for adjusting the shaft speed, and an eccentric cam and slide for mounting the valve pin eccentrically with respect to the EA shaft; a valve pin mounted in a channel of the heated manifold for delivering fluid material to a gate of the mold cavity controlled by the EA assembly; in the cross-sectional view of fig. 2, the EA assembly is shown mounted within the heating manifold assembly (along with top clamp plate 212);

Junction box JB (40), each connector connecting up to 12 EA components to the synchronization controller SC; the motor power and signal cables 53, 54 are connected to the junction box and the synchronization controller to power the EA component and provide bi-directional communication of data signals (via the junction box) between the EA component and the synchronization controller, as described herein;

a handheld user equipment, here a mobile phone MP (100), comprising: a processor, a user interface (e.g., touch screen 101) for accepting user input data, a user display (e.g., touch screen 101) for monitoring the injection cycle and viewing various system parameters (e.g., valve pin position and valve pin settings and mold data), and having: a valve synchronization software application installed thereon, capable of wirelessly connecting to the synchronization controller SC via bluetooth (for transmitting and receiving various data signals therebetween); and program of instructions for processing, monitoring and controlling the various injection cycle parameters mentioned herein.

Fig. 2-3 are partial cutaway and perspective views of the components of fig. 1 mounted on an IMM (200) and hot runner (400) showing a synchronization controller SC (20) mounted outside the IMM housing with motor power and data signal cables 53, 54 connecting the synchronization controller and junction box (40), cables 51 and 52 connecting the junction box (40) and 3 electrical actuator assemblies (80), and power and SVG cables 21 and 22 connected to the synchronization controller (20), according to an embodiment. Also shown in fig. 2-3 are: a stationary platen (218) on which a top clamp plate TCP (212), a hot runner HR (400) and a first mold half (224) are mounted; 4 tie bars (214, 216) on which a movable platen (220) of a second mold half (222) is carried, slidable toward and away from the fixed platen, so as to open and close the two mold halves (at the beginning and end of an injection cycle); an electrical actuator EA assembly (80) mounted on top clamp plate (212) (shown in cross-section in fig. 2); and junction box JB (40) is also mounted to top clamping plate (212) by offset bracket.

The synchronization controller (20) is designed to be mounted on an Injection Molding Machine (IMM), preferably on the operator side. The synchronization controller is programmed to communicate with the mobile telephone (100) for simple wireless communication with the synchronization controller.

As previously described, junction box JB (40) provides a 12-zone configuration and allows up to 12 actuators (80) per connector to be connected to the synchronization controller SC. The connection to the junction box includes a motor power supply (53) and an encoder signal cable (54).

The various components (junction box power and signal cables; SVG cables) are connected to the synchronization controller via cables.

Injection molding machine overview (FIG. 3)

Fig. 3 is a perspective view of one embodiment of an injection molding apparatus 200 (useful in the context of the present invention) comprised of an injection molding machine (referred to herein as an "IMM") that can be used to automatically produce molded articles or objects by injecting an injection fluid (e.g., a heated polymer) into a mold (in the mold, the injection fluid cools and solidifies into a hardened article) under high pressure. IMM can generally be divided into two parts: an injection unit 201 and a clamping unit 203.

The injection unit 201 includes: a hopper 202, a screw motor 204 for driving a reciprocating screw (not shown), a barrel assembly 206, an injection nozzle 208, and a mold 210; in general, the mold 210 is a heat exchanger that enables the fluid injected into the mold to solidify into the desired shape and dimensional details of the cavity defined within the mold 210. Thus, the injection unit 201 is used to inject or otherwise provide injection fluid into the mold 210.

Specifically, injection fluid (e.g., plastic) is introduced from the hopper 202 and accumulates in the barrel assembly 206 in front of and/or around the reciprocating screw. The screw motor 204 drives a reciprocating screw, forcing injection fluid through the barrel assembly 206 and into the injection nozzle 208. The injection nozzle 208 connects the barrel assembly 206 to the mold 210, allowing injection fluid to flow under pressure from the barrel assembly 206 through the injection nozzle 208 and into the cavity of the mold 210 where the injection fluid solidifies.

The clamping unit 203 applies a clamping force to hold the two halves of the mold 210 in proper alignment to hold the mold 210 closed in a manner sufficient to resist injection forces and/or pressures generated during injection of the injection fluid into the cavity of the mold 210. As shown, the clamping unit 203 includes: one or more tie bars 214, 216, a fixed platen 218, a movable platen 220, and forming plates 222, 224 that house the mold 210 (i.e., cavity).

The air cylinder 219 may be actuated to close and open (i.e., clamp and unclamp) the mold 210 at the appropriate times. Once the mold 210 is clamped, an injection unit 201 is used to inject an injection fluid into the cavity of the mold 210 under high pressure. During this injection, a sufficiently strong clamping force is applied by the clamping unit 203 so that the mold 210 is not opened (e.g., by injection pressure). To amplify the clamping force, one or more toggle links 226 are used. The toggle link 226 is coupled to the movable platen 220, wherein the toggle link 226 is advanced or retracted by a ball screw that is rotationally driven by the cylinder 219 to generate a clamping force.

The IMM and system 200 may be automated and/or controlled by an IMM controller 228, which IMM controller 228 is used to automate and monitor various processes and process conditions to control the quality and consistency of injection molded objects generated by the IMM. For example, the IMM controller 228 may generate drive signals that control the speed of movement of the screw motor 206 and/or the speed of injection of the injection fluid into the cavity of the mold 210. Further, the IMM controller 228 may control the amount of pressure applied during injection into the cavity of the mold 210. IMM controller 228 (and its associated user interfaces (keyboard 231 and mouse 230) and user display screen 229) may include one or more processors that process software or other machine-readable instructions, and may include memory that stores software or other machine-readable instructions and data.

Synchronous controller application and wireless communication device (FIGS. 4-5)

Fig. 4-5 illustrate various views and functions of a synchronous controller phone application accessed via a touch screen user interface (101) on a mobile phone display (102) (fig. 4A), including: a user screen for managing (setting, monitoring, modifying and viewing) the status of various injection molding parameters and recipes (valve position data and other system parameter settings) stored on junction box JB (40), including a die diagram showing the status of zone numbers 1-12, set values in each zone, 12 switches connected to sequencer or SVG valves; a setting screen for changing the travel distance (upstream travel path of the valve pin in millimeters), the replacement motor and the resulting adjustment of the closed position; and recipe data for retrieving, modifying and replacing recipe data stored in the JB; and an information screen for checking the temperatures of the synchronization controller SC and the junction box JB; and troubleshooting (4B-4I).

Once connected, the user interface application will load (fig. 4A); the dots in the lower left hand corner are green indicating that the user interface is connected and grey indicating that it is not connected. If the user interface is used for monitoring only, the user may select the "production user" icon. Alternatively, if it is to be used for parameter settings, the user selects the "set user" icon.

FIG. 4B-set user mode

1. In the home screen, touching the "set user" icon enters the synchronous set user mode. In this mode, the top row of buttons is:

1) Homepage button: touching the button switches to the production user mode.

2) Operation buttons: touching the button switches between idle mode and run mode. When the button is yellow, the controller is in idle mode. Green, in run mode.

3) Setting a button: touching the button sets the stroke/activation, motor adjustment, and die map screen for each zone.

4) The formula button: touching the button manages the recipe stored in the JB.

5) Information button: touching the button displays the software version, controller and JB temperature.

6) Screen selection: touching the button selects the upper 3 buttons.

2. A mold plot. The dots display the area numbers and the area states in the mold map. Any point can be moved by touch; the point is held for half a second and then any blank on the screen is touched and dragged on the screen.

3. A set value region. In each of the 12 areas, the left hand number displays the area. The right hand number shows the stroke value in millimeters. The green check box indicates that the region is enabled or disabled.

Fig. 4C-switch state. The status of the 12 switches connected to the sequencer or SVG valve will be shown in this area. If the zone is red in color, the switch state is "pin off". Green, is "pin open". Touching and holding the point on switch-6 for half a second, all the areas in the mold map area will appear. Touching and holding the point on switch-12 for half a second, all unused area points at the bottom of the mold map will be hidden. Touching and holding the point on switch-7 for half a second, all zone point positions will reset to the default position.

Fig. 4D-setup screen. Touching the setup button enables the setup screen, as indicated by the red block in the figure. Any one of the set value areas, or an area point in the mold diagram is touched, and an area number will be displayed in the set screen. Touching the up and down arrow changes the stroke value of the area in millimeters. An "enable" check box is touched to enable/disable region operation. Touching the "enter" arrow button confirms and writes the set point to the JB. If the "all" button is selected, the modified value will be applied to all regions. In the middle portion of the setting screen, the home button starts a motor reset operation of the selected area. When the motor is replaced, please refer to the following notes. The left/right arrow buttons cause the motor to move the stroke distance of the selected area. The start and end buttons operate the selected motor in increments of 0.06 millimeters per touch. The back and forward buttons operate the motor in increments of 0.01 mm per touch. The button clears the die map screen. Touching and holding the button for half a second activates. The camera button photographs the mold map. Touching and holding the button for half a second activates. The old mold map need not be purged before the new mold map is taken. Touching the return button returns the setting screen to the home screen.

After clearing the operating value for that area, the new motor needs to work to adjust the pin to the closed position. When the user clicks, the job value is stored in the JB. The click value will be saved in the JB and automatically invoked the next time the JB is connected to the synchronization controller.

If the operation value of all areas needs to be cleared, a lamp button on the controller is pressed, and a power switch on the controller is turned on.

FIG. 4E-formulation screen. Touching the recipe button enables the recipe screen, as shown in the red block of the figure below. On screen, the recipe can be switched between the work recipe (the activated recipe) and 8 stored recipes. During the conversion process, the user can change the recipe name as desired. Even if the JB power is turned off, the working formulation and stored formulation are always kept in the JB.

FIG. 4G-step of converting a working recipe to a preservation recipe:

1. the WR (work formula) button is touched and held for half a second. Any one of the save recipe buttons (R1-R8) is touched. The recipe name will appear.

2. Touching the name may alter the recipe name.

3. Touching the input button makes a transition. Or touching the return button ceases operation.

FIG. 4F-step of converting a preservation recipe into a work recipe:

1. any one of the save recipe buttons (R1-R8) is touched. Touching WR (work formula) buttons. The recipe name will be displayed in the edit field.

2. Touching the name may alter the recipe name.

3. Touching the enter button causes a transition to an active (work) recipe. Or touching the return button ceases operation.

Fig. 4H-information screen. Touching the "i" button enables the information screen in the red block. The screen displays the user interface application version, controller firmware version, JB firmware version, and IMM box firmware version, as well as the temperatures of the controller and junction box.

FIG. 4I-production user mode. Production user top row button:

1. touching the homepage button: switch to set user mode.

2. Touching the operation button: switching between idle and run modes.

3. Touching the information button: the software version, junction box and controller temperature are displayed.

4. Touching the "screen select/alarm" button: an information screen is selected.

The production user only allows the monitoring procedure (as production user cannot make any changes).

FIG. 4I-troubleshooting.

1. The screen select button is red. Possible problems:

1. the controller is not connected to the JB.

Jb has drawbacks.

2. The motor is out of order and is stationary. Possible problems:

1. the motor exceeds its torque limit.

2. The motor temperature reaches a limit of 83 degrees celsius.

3. The wrong click value is saved (see "annotation").

Valve pin positioning and monitoring function (FIGS. 5A-5F)

Fig. 5A-open/closed. The pin opens and closes at maximum speed throughout the stroke.

In one example shown in fig. 5A, an open/close control signal (VS) from an IMM controller is converted to a valve pin open and close signal profile for an electric actuator assembly, where the valve pin open and close is directed at a maximum speed (of the electric actuator assembly) for an entire stroke (upstream and downstream along a travel path from a gate closed position, upstream to a gate fully open (end of stroke) position, and downstream back to a gate closed position).

FIG. 5B-balance control. The opening stroke may be reduced for basic flow regulation.

In one example shown in fig. 5B, the open/close control signal (VS) from the IMM controller is converted to valve pin opening and closing signal profiles for the electric actuator assembly, where the length of the valve pin opening stroke can be reduced to allow the user (via a user interface on the telephony application) to make basic flow adjustments.

Fig. 5C-pin arrangement. A valve pin closed position can be set in the IMM.

In one example shown in fig. 5C, the valve pin closed position may be set via a user interface on a telephony application when the valve pin is in the IMM.

Fig. 5D-one-touch synthesis flow. The slow opening speed and distance are preset to stabilize the flow front speed and to address the appearance defects of the relevant parts.

In one example shown in fig. 5D, the open/close control signal from the IMM controller is converted to a valve pin open and close signal profile for the electric actuator assembly that provides a preset slow open speed and distance to stabilize the flow front speed (e.g., to correct for related molded part defects).

Fig. 5E-fill control. Upon switching, the pins are moved to the desired neutral position to control differential filling.

In one example shown in fig. 5E, the open/close control signal (VS) from the IMM controller is converted to a valve pin open and close signal profile for the electric actuator assembly, wherein the valve pin is moved to a desired intermediate position during the downstream stroke to control differential filling.

FIG. 5F-alarm. An alarm signal is sent in several situations, including those in which the pin is not fully open or closed.

In one example shown in fig. 5F, the open/close control signal (VS) from the IMM controller is converted to a valve pin open and close signal profile for an electric actuator assembly that sends an alarm signal for one or more conditions, including a condition in which the pin does not fully open or close the gate.

Computer system, control system and data (FIGS. 6-7)

As used in this disclosure with respect 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, or software in execution. For example, a component or controller can be, but is not limited to being, a process running on a processor, an object, an executable, a thread of execution, a program, and/or a computer. For example, both an application running on a processor (or server) and the processor (or server) can be one 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.

In various embodiments of the invention disclosed herein, the term "data" or the like refers to any sequence of symbols (commonly referred to as "0" and "1") that may be entered into a computer, stored and processed there, or transmitted to another computer. As used herein, data includes metadata, descriptions of other data. The data written to the storage may be data elements of the same size or may be data elements of different sizes. Some examples of data include information, program code, program state, program data, other data, and the like.

As used herein, computer storage media and the like include 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 storage technology, CD-ROM, digital Versatile Disks (DVD) 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 the desired information and which can be accessed by a computer.

The methods described herein may be implemented in a suitable computing and storage environment, for example, in the context of computer-executable instructions that may run on one or more processors, microcontrollers, or other computers. For example, in a distributed computing environment, 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 communication network may include a global network such as 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 a communications link between the computers may be used.

A computer may include one or more processors and memory, such as a processing unit, a system memory, and a system bus that couples system components including, but not limited to, the system memory and the processing unit. The computer may also include a disk drive and an interface to external components. Various computer readable media can be accessed by the computer and includes both volatile and nonvolatile media, removable and non-removable media. The computer may include a variety of user interface devices including a display screen, a touch screen, a keyboard, or a mouse.

As used herein, "controller" also refers to electrically and electronically controlled appliances, which comprise a single box or multiple boxes (typically interconnected and in communication with each other) containing all of the individual electronic processing, storage, and electrical signal generating components necessary or desirable for performing and constructing the methods, functions, and appliances described herein. These electronic and electrical components include programs, microprocessors, computers, PID controllers, voltage regulators, current regulators, circuit boards, motors, batteries, and instructions for controlling any of the variable elements discussed herein (e.g., length of time, degree of electrical signal output, etc.). For example, as the term is used herein, the components of the controller include programs, controllers, etc. that perform functions such as monitoring, alerting, and initiating an injection molding cycle, including control equipment that serves as a stand-alone device for performing conventional functions such as signaling and instructing individual injection valves or a series of interdependent valves to begin injection, i.e., moving an actuator and associated valve pin from a gate closed position to a gate open position.

Fig. 6 illustrates an example computing system architecture (e.g., of a controller or mobile telephone device or tablet computer device) in which components of system 2000 communicate with each other using connection 2005. Connection 2005 may be a physical connection via a bus or a direct connection to processor 2010, such as in a chipset architecture. Connection 2005 may also be a virtual connection, a network connection, or a logical connection. The connection may be wired or wireless (e.g., a bluetooth connection).

In some cases, system 2000 is a distributed system in which the functionality described with respect to the components herein may be geographically distributed within one building, multiple buildings, one data center, multiple data centers, and so forth. In some embodiments, one or more of the described system components represent many such components, each of which performs some or all of the functions described for that component. In some embodiments, the components described herein may be physical or virtual devices.

The example system 2000 includes at least one processing unit (CPU or processor) 2010 and a connection 2005, the connection 2005 coupling various system components including a system memory 2015, such as Read Only Memory (ROM) 1020 and Random Access Memory (RAM) 2025, to the processor 2010. The system 2000 may include a cache 2012 of high-speed memory, the cache 2012 being directly connected to the processor 2010, immediately adjacent to the processor 2010, or integrated as part of the processor 2010.

Processor 2010 may include any general purpose processor and hardware services or software services such as service-1 (2032), service-2 (2034), and service-3 (2036) stored in storage 2030, the hardware services or software services configured to control processor 1010 as well as a special purpose processor in which software instructions are incorporated into the actual processor design. Processor 2010 may be a substantially independent computing system including a plurality of cores or processors, a bus, a memory controller, a cache, and the like. The multi-core processor may be symmetrical or asymmetrical.

To enable a user to interact with the computing device 2000, the input device 2045 may represent any number of input mechanisms, such as a microphone for voice, a touch-sensitive screen for gesture or graphical input, a keyboard, a mouse, motion input, voice, and so forth. Output device 2035 may also be one or more of a variety of output mechanisms known to those skilled in the art. In some cases, the multi-mode system may enable a user to provide multiple types of inputs to communicate with computing device 2000. Communication interface 2040 typically controls and manages user inputs and system outputs. There is no limitation on the operation on any particular hardware configuration, so the basic features herein may be readily replaced by improved hardware or firmware configurations that are developed.

The storage device 2030 may be a non-volatile memory and may be a hard disk or other type of computer readable medium capable of storing data that is accessible by a computer, such as magnetic cassettes, flash memory cards, solid state storage devices, digital versatile disks, magnetic cassettes, random access memories (ROM) 2025, read Only Memories (ROM) 2020, and mixtures thereof.

Storage 2030 may include code that, when executed by processor 2010, causes system 2000 to perform functions. Hardware services that perform particular functions may include software components stored in a computer-readable medium in combination with hardware components (such as processor 2010, bus 2005, output device 2035, etc.) to perform the functions.

For clarity of explanation, in some cases, the present technology may be presented as including individual functional blocks including devices, device components, steps or routines in a method implemented in software or a combination of hardware and software.

Any of the steps, operations, functions, or processes described herein may be performed or implemented by a combination of hardware and software services, alone or in combination with other devices. In some embodiments, the service may be software residing in memory of one or more servers of the client device and/or content management system, and that when executed by the processor performs one or more functions associated with the service. In some embodiments, a service is a program or collection of programs that perform a particular function. In some embodiments, the service may be considered a server. The memory may be a non-transitory computer readable medium.

In some embodiments, the computer readable storage devices, media, and memory may comprise wired or wireless signals including bitstreams and the like. However, when mentioned, non-transitory computer-readable storage media expressly exclude media such as energy, carrier signals, electromagnetic waves, and signals themselves. The methods according to the examples described above may be implemented using computer-executable instructions stored in or obtained from a computer-readable medium. Such instructions may include, for example, instructions and data which cause or otherwise configure a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. The portion of the computer resources used may be accessible through a network. The computer-executable instructions may be, for example, binary, intermediate format instructions, such as assembly language, firmware, or source code. Examples of computer readable media that may be used to store instructions, information, and/or created information for use during a method according to the examples include magnetic or optical disks, solid state storage devices, flash memory, USB devices equipped with non-volatile memory, network storage devices, and the like.

Devices implementing methods according to these disclosures may include hardware, firmware, and/or software, and may take any of a variety of form factors. Typical examples of such form factors include servers, notebook computers, smart phones, mini-personal computers, personal digital assistants, and the like. The functions described herein may also be implemented in a peripheral device or add-in card. As a further example, such functionality may also be implemented on circuit boards between different chips, or in different processes executing in a single device.

The instructions, the medium for transmitting such instructions, the computing resources for executing them, and other structures for supporting such computing resources are means for providing the functionality described in these publications.

IMM, synchronization controller and signal in injection molding (FIGS. 8-11)

FIG. 8 is a schematic side view of an embodiment of an electric motor driven injection molding system wherein each valve includes an electric actuator and a transducer; the electric actuator directs the position of the associated valve pin to move between a valve closed position and a valve open position; the converter receives a standard signal generated by the injection machine controller and converts the signal into a control signal compatible with the electric actuator.

9A-9B illustrate one embodiment of utilizing a valve pin having a tapered end and varying the velocity of the valve pin, showing the position of the tapered end between a start gate closed position (FIG. 9A) and various upstream open positions (FIG. 9B); where RP represents the optional path length over which the velocity of the valve pin retracting upstream from the gate closed position to the open position is reduced relative to the velocity of upstream movement; when the valve pin velocity is at a maximum, the valve pin typically has this upstream velocity of movement over an uncontrolled velocity path FOV.

Similar to fig. 9A-9B, fig. 10A-10B illustrate different positions of the process utilizing a cylindrically configured valve pin tip.

The electric actuator (electrically driven actuator, driven by an electric motor) cannot directly receive and utilize the 0 volt (gate off), 24 volt (gate on) or 0 volt (gate off), 120 volt (gate on) standard signal generated by the start and stop cycle controller or signal generator typically incorporated into conventional injection molding machine IMM controllers.

The system shown in fig. 8, 8A, 8B incorporates a signal converter 1500, 1502 that can receive a standard injection machine generated cycle start and end signal VS (e.g., 0 volts, 24 volts, or 120 volts) and convert the received standard signal VS into a motor output power signal MOCPS that is suitable for receipt and use by an electric motor of an electric actuator assembly. In the present invention, the signal converter 1502 of FIG. 8B is the synchronous controller 20 as previously described and has a user interface 1510, the user interface 1510 being configured for wireless communication with the wireless communication device 100, the wireless communication device 100 allowing a user to input settings adjustments to the signal converter to control the injection molding process and monitor the status of the system and process.

Fig. 8 illustrates one embodiment of a cascade or sequential injection molding process wherein a central nozzle 22 supplies molten material 18 from an injection molding machine IMM through a main inlet 18a to a distribution channel 19 of a manifold 40. IMM typically includes a barrel (not shown) and a barrel screw BS controllably driven or rotated; the barrel screw BS begins and ends the injection cycle at selected points in time as the barrel screw BS is rotationally driven to produce a flow of injection fluid 18. The start of the injection cycle is typically defined at a selected point in time when the screw BS initially rotates from the rest position, or at a point in time that occurs shortly after the time when the screw BS initially begins to rotate (e.g., as detected by the screw position sensor SPSR). The end of the cycle is generally defined by the time after which the screw BS stops rotating; the selected time defines the start of a cycle when the screw BS is drivably rotated. The distribution channel 19 is typically fed to, for example, 3 individual nozzles 20, 22, 24, which are all typically fed to a common cavity 30 of a mold 33. In fig. 8, the central nozzle 22 is controlled by an electric actuator 940e and is arranged to feed into the cavity 30 at an inlet point or gate located near the center 32 of the cavity. A pair of lateral nozzles 20, 24 (controlled by fluid driven actuators 941f and 942 f) are fed into cavity 30 at gate locations 34, 36 remote from center gate feed location 32. In fig. 8, the nozzles (22, 20, 24) are controlled by electric actuators (940 e, 941e, 942 e), respectively.

In a cascade or sequential process, injections are performed in the following order: first from the central nozzle 22 and then from the lateral nozzles 20, 24 at a later predetermined time. The injection cycle begins by: valve pin 1040 of central nozzle 22 is first opened and fluid material 100a (typically a polymer or plastic material) is allowed to flow into the mold cavity just prior to the distally (laterally) disposed inlet of cavities 34, 36 into the gates of lateral nozzles 20, 24. After the injection cycle begins, the gate and pin 1040 of the center injection nozzle 22 are typically opened only for a period of time to allow the fluid material 100a to travel to a position just past the lateral gate positions 34, 36, at which point the center gate 32 of the center nozzle 22 is typically closed by the pin 1040. The lateral gates 34, 36 are then opened by withdrawal upstream of the lateral nozzle pins 1041, 1042. The upstream withdrawal rate or travel speed of the lateral pins 1041, 1042 may be controlled as described below (in various embodiments). Center gate 32 and associated actuator and valve pin 1040 may remain open as, during, and after side gates 34, 36 are opened, such that fluid material flows into cavity 30 through center gate 32 and one or both side gates 34, 36 simultaneously. When the side gates 34, 36 are open, the fluid material is allowed to first enter the mold cavity into a stream that has been injected from the central nozzle 22 through the gates 34, 36, the two streams intermixing. If the velocity of the fluid material from the side gates 34, 36 is too high (as is often the case when the flow rate of the injected fluid material through the gates 34, 36 is maximized), visible lines or defects in the mixing of the two streams will occur in the area of the finally cooled molded product where the gates 34, 36 are injected into the mold cavity. By injecting fluid from the gates 34, 36 at a reduced flow rate for a relatively short period of time at the beginning when the gates 34, 36 are first opened, the occurrence of visible lines or defects in the final molded product may be reduced or eliminated.

The rate or speed of upstream and downstream travel of pins 1040, 1041, 1042 from the gate closed position or fully open upstream position is controlled via an electric motor that drives each electric actuator assembly (940 e, 941e, 942 e). A predetermined profile of sensed injection fluid pressure or temperature, sensed by the sensor SN sensing fluid within the nozzle channels 42, 44, 46, or a profile of sensed valve pin or actuator position, or a profile of sensed injection fluid pressure or temperature within the mold cavity, sensed by the cavity sensor SC, may be input to the actuator controller 16 as a basis for controlling the travel of the valve pins 1040, 1041, 1042, etc. upstream and downstream at one or more selected speeds during travel of the valve pins through the upstream or downstream stroke lengths. For example, the actuator controller 16 may include instructions to move the actuator at a reduced speed relative to one or more selected higher withdrawal speeds. The higher speed is typically selected as the highest speed at which the system can drive the actuator. Generally, the instructions instruct the actuator to move the valve pin upstream from the gate closed position at a reduced velocity (see, e.g., FIGS. 9-10) during travel, wherein the tip of the valve pin limits the flow rate of the injection fluid 18 to less than if the valve pin were fully upstream; the reason for this limitation is that: the tip of the valve pin (see, e.g., fig. 9A-9B) limits the size of the flow path or opening at or near the gate 32, 34, 36 to be smaller than the size of the opening or flow path if the valve pin were disposed entirely upstream of the gate 32, 34, 36.

The actuator controller (here, microcontroller 16 of fig. 8B) includes a program that receives and processes real-time signals indicative of the status of the injection fluid 18 or components of the instrument (10), such as the rotational position of rotors 940r, 941r, 942r or the axial linear position of valve pins 1040, 1041, 1042. The real-time signals sent and received by the actuator controller 16 are generated by one or more of the position sensors 950, 951, 952, or the fluid state sensors SN, SC. The sensors detect and send signals to the actuator controller that generally indicate the rotational position of one or more rotors 940r, 941r, 942r (sensors 950, 951, 952), or the linear axial position of valve pins 1040, 1041, 1042. In fig. 8B, the electrical actuator assembly itself (940 e, 941e, 942 e) includes a motor encoder (with an optional limit switch) to measure the valve pin position and send a valve pin position signal PS to interface 1504, and interface 1504 generates signal 1504S that signal 1504S is sent to microcontroller 16 of synchronous controller 20. The fluid state sensors typically include one or more pressure or temperature sensors SN that sense the injection fluid 18 within the manifold channel 19 or nozzle channels 42, 44, 46, or the pressure or temperature of the injection fluid SC within the cavity 30 of the mold 33.

Actuator controller 16 can include a program that processes signals received from one or more of the sensors 950, 951, 952, SN, SC in accordance with 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 actuators 940e, 941e, 942e or their associated valve pins 1040, 1041, 1042 throughout all or a selected portion of the duration of an injection cycle or all or a portion of the upstream or downstream travel of actuators 940e, 941e, 942e.

As shown in fig. 8B, a controller (microcontroller 16) may be included in a signal converter 1502 (identical to the synchronization controller 20) and include the components of the signal converter 1502. Where the converter 1502 includes the controller 16, the controller 16 includes position and speed control instructions, the converter 1502 may therefore send its machine open close power signal MOCPS (or valve open close signal PDCVS) along with the position and speed signals (PVS) to the electric actuators 940e, 941e, 942e. Thus, the control signals MOCPS and PDCVS include signals converted from and corresponding to one or the other of the converted VS signals; the converted VS signal is received by the converter 1502 from the IMM controller MC or HPU. The position or velocity control signal PVS can control the position or velocity of the valve pin according to any predetermined profile of valve pin position or velocity relative to the injection cycle time. The form, format, strength and frequency of the MOCPS, PDCVS and PVS signals are compatible with the signal receiving interfaces of the electrical actuators 940e, 941e, 942e.

Valve pin restricted flow path and travel rate (FIGS. 9A-11B)

In one embodiment, valve pins 1040, 1041, 1042 and their associated gates are configured or adapted to cooperate with each other to limit and vary the flow rate of fluid material 1153 during travel of the tip of the valve pin through limited velocity path RP (fig. 9A-9B and 10A-10B). Most typically, as shown in fig. 9A-9B, the radial tip surface 1155 of the end 1142 of the pin 1041, 1042 is conical or tapered, and the surface of the gate 1254 is a complementary conical or tapered structure, with the pin surface 1155 intended to cooperate with the surface of the gate 1254 to close the gate 34. Alternatively, as shown in fig. 10A-10B, the radial surface 1155 of the tip 1142 of the pins 1041, 1042 may be a cylindrical structure and the gate may have a complementary cylindrical surface 1254; tip surface 1155 cooperates with cylindrical surface 1254 to close gate 34 when pin 1041 is in the downstream gate closed position. The outer radial surface 1155 of the tip 1142 of the pin 1041 forms a restricted flow channel 1154 over the length of travel of the tip 1142 through and along the restricted flow path RP; the restricted flow channel 1154 limits or reduces the volume of the fluid material 1153, or the restricted flow channel 1154 limits or reduces the flow rate of the fluid material 1153 relative to the flow rate when the pins 1041, 1042 are in the gate fully open position (i.e., the flow rate when the tip 1142 of the pin 1041 has traveled to or beyond the length of the restricted flow path RP).

In one embodiment, as the tip 1142 of the pin 1041 continues to travel upstream from the gate-off GC position (e.g., as shown in fig. 9-11) through the length of the RP path (i.e., the path traveled a predetermined amount of time), the rate of material fluid flow 1153 through the gate 34 into the cavity 30 by the restricted gap 1154 continues to increase from 0 at the gate-off GC position to a maximum flow rate when the tip 1142 of the pin reaches the position FOP (fully open position); in this position FOP, the pin no longer restricts the flow of injection molding material through the gate. In such an embodiment, when the pin tip 1142 reaches the FOP (fully open) position, upon expiration of the predetermined amount of time, the pin 1041 may be immediately driven by the actuator system at a maximum speed FOV (fully open speed), typically causing the limiting valve 600 to open to 100% fully open.

In various embodiments, where tip 1142 has reached the end of restricted flow path RP2 and tip 1142 is not necessarily in a position where fluid flow 1153 is still unrestricted, fluid flow 1153 may still be restricted to less than maximum flow when the pin has reached transition position COP 2; in the transition position COP2, the pin 1041 is driven at a higher speed (typically the maximum upstream speed FOV). In the example of fig. 9B, 10B, when the pin has traveled a predetermined path length at a reduced speed and tip 1142 has reached the transition point COP, tip 1142 of pin 1041 (and its radial surface 1155) no longer restricts the flow rate of fluid material 1153 through gap 1154, as gap 1154 has increased to a size that no longer restricts fluid flow 1153 below the maximum flow rate of material 1153. In one example shown in fig. 9B, the maximum fluid flow rate of the injected material 1153 is reached at the upstream location COP of the tip 1142. In another example shown in fig. 9B, the pin 1041 may be driven at a reduced speed on a shorter path RP2 (the shorter path RP2 being less than the overall length of the constrained mold material flow path RP) and switched to a higher speed or maximum speed FOV at the end COP2 of the shorter constrained path RP 2.

In another alternative embodiment, as shown in fig. 10B, pin 1041 may be driven and indicated: driven at a reduced speed or a speed less than the maximum speed over a longer path length RP3 having an upstream portion UR; at this upstream portion UR, the flow of injection fluid mold material is not restricted for a given injection mold system, but flows through gate 34 at a maximum rate. In this example, the speed or drive rate of the pin 1041 is not changed until the end of the pin 1041 or actuator 941 has reached the transition position COP 3. In this embodiment, the position sensor senses that the valve pin 1041 or related component has traveled the path length RP3 or reached the end COP3 of the selected path length; and the controller receives and processes this information and instructs the drive system to drive pin 1041 upstream at a higher, typically maximum, speed. In another alternative embodiment, the pin 1041 may be driven at a speed less than the maximum speed throughout the pin travel path during an injection cycle from the gate closed position GC to the end of travel EOS position, the actuator controller 16 being programmed to instruct the drive system to: driving the actuator at a reduced speed for an initial path length or time period and driving the actuator at another speed less than the maximum speed after the initial reduced speed path or time period for the remainder of the injection cycle; thus, the actuator/valve pin travels at a speed less than maximum speed throughout the closed GC to fully open EOS cycle.

In a typical example, the FOV is 100 mm/s. Typically, when the time period or path length for driving the pin 1041 at a reduced speed has expired or reached, and the pin tip 1142 has reached the position COP, COP2, the limiting valve 600 opens to a 100% fully open speed FOV position such that the pins 1041, 1042 are driven at a maximum speed or travel rate at which the pneumatic system is capable of driving the actuators 941, 942. Alternatively, the pins 1041, 1042 may be driven at a preselected FOV speed less than the maximum speed at which the pins can be driven when the limiting valve 600 is fully open, but which is still greater than the reduced speed selected by the pins to be driven into the COP, COP2 positions during the RP, RP2 path.

At the expiration of the predetermined reduced speed drive time, the pins 1041, 1042 are typically driven further upstream past the COP, COP2 positions to the end of maximum travel EOS position. The upstream COP, COP2 position is downstream of the maximum upstream end of travel EOS open position of pin tip 1142. The length of the path RP or RP2 is typically between about 2mm and about 8mm, more typically between about 2mm and about 6mm, and most typically between about 2mm and about 4 mm. In practice, the maximum upstream (end of travel) open position EOS of the pins 1041, 1042 is in the range of about 8mm to about 18 inches upstream from the closed gate position GC.

An embodiment includes the following configuration: valve pins 1040, 1041, 1042 are driven downstream from a fully upstream gate open position at one or more reduced downstream speeds at least a later portion of the downstream path of pin travel toward the gate; the tip 1142 of the pin 1041 restricts the flow of injection fluid through the gates RP, RP2, RP3 for at least a later portion of the downstream path the pin travels toward the gates, such as shown in fig. 9-10. Reduced downstream velocity actuation of valve pin 1041 may be used to reduce the extent of downward force DF exerted by pin tip 1142 on injection fluid 1153 f; as the tip of the valve pin travels downstream to a position where the tip closes the gate, injection fluid 1153f is forced through the gate and into cavity 1153c. This reduced force DF is exerted on the injection fluid 1153g at the inlet 34 of the mold cavity at the extreme end portions of the strokes RP, RP2 of the injection cycle, thus reducing the likelihood of flaws or artifacts forming on the part formed in the cavity at the gate region 34.

In one embodiment of the method, the electric actuator is drivably interconnected to valve pins 1040, 1041, 1042 in one arrangement; in this arrangement, the actuator drives the valve pin along axis a of the valve pin and drives the tip 1142 of the valve pin between the first position, the second position upstream of the first positions RP, RP2, RP3, and the third maximum upstream position FOP; in the first position, the tip of the valve pin blocks gate 34 to prevent injection fluid from flowing into the cavity; in the second position, the tip 1142 of the valve pin restricts the flow 1153 of injection fluid along at least a portion of the length of the drive path extending between the first and second positions; in the third maximum upstream position FOP, the injected fluid material is free to flow unrestricted from the pin tip 1142 through the first gate.

The electric actuator is further operable to drive the valve pin at one or more intermediate rates of upstream and downstream travel extending between zero and a maximum upstream travel rate and a maximum downstream travel rate, the method comprising: selecting a travel length between a maximum upstream position and a predetermined third position, the third position being downstream of the maximum upstream position and upstream of the first downstream position; and controllably operating the actuator to drive the associated valve pin at one or more high downstream travel rates that are equal to or less than a maximum downstream travel rate of the valve pin when in a maximum upstream position during an injection cycle; sensing the position of the valve pin to determine when the tip of the valve pin reaches a preselected downstream position during downstream travel; and controllably operating the actuator to drive the valve pin at one or more intermediate downstream travel rates to continuously drive the tip end of the valve pin downstream from the downstream position to the closed position when it has been determined in the sensing step that the tip end of the valve pin has reached the downstream position, wherein the one or more intermediate downstream travel rates are less than the one or more high downstream travel rates.

In an alternative pin movement protocol shown in fig. 11A-11B, the tips of pins 1040, 1041, 1042 are driven continuously upstream or continuously downstream, wherein the tips of the pins are held or maintained in a reduced or restricted flow position between fully open and gate closed positions for a selected period of time during travel between the fully open and gate closed positions, typically in a restricted flow "fill" or "fill pressure" position after the mold cavity has been substantially filled with injection fluid 18, typically after injection fluid 18 has been filled 90% or more of the volume of the cavity. For example, in the example of fig. 11A, the pin is held in an intermediate reduced or restricted flow of 4 millimeters upstream of the gate closed position for about 0.15 to about 0.26 seconds. Preferably, the actuator controller 16 instructs the valve pins 1041, 1042, 1040: or (a) continuously travel upstream during an upstream portion of the cycle, rather than following a driving fluid pressure, pin position, or injection fluid pressure curve in which a pin may travel in a downstream direction during the upstream portion of the injection cycle; or (b) continuously travels downstream during the downstream portion of the cycle, rather than following a curve in which the pin travels upstream during the downstream portion of the injection cycle.

While particular embodiments of the present invention have been shown and described, it will be obvious that numerous modifications may be made thereto without departing from the scope of the invention. Accordingly, the invention is not limited by the foregoing description.

Claims

1. An electric actuator control system comprising:

a wireless communication device programmed to: displaying synchronized control of valve pin positioning during injection molding and accepting user input related to preconfigured synchronization of valve pin positioning in real time during injection molding, enabling a user to monitor and communicate changes to such control via an electrically actuated synchronization controller; the electrically actuated synchronous controller communicates with a plurality of electrical actuator assemblies that are inaccessible during the molding process, and wherein the preconfigured synchronization is reconfigured based on real-time changes in the delivery of molten plastic material from the barrel screw of the IMM to the actuator assemblies and associated gates of the mold cavity.

2. The system of claim 1, comprising:

a housing including the electric actuator synchronization controller and one or more input interfaces configured to receive: a) A control signal (VS) generated by an Injection Molding Machine (IMM), the control signal (VS) adapted to instruct an actuator to begin driving a valve pin along a travel path from a gate closed position upstream toward a gate end-of-travel position, and to begin driving a valve pin from the end-of-travel position downstream toward the gate closed position; and b) a valve pin Position Signal (PS) indicative of a valve pin position between a gate closed position and an end-of-travel position;

The synchronous controller includes a processor and a computer readable medium having a program of instructions for preconfigured actuation control of valve pin position by an electric actuator assembly during an injection cycle; wherein the processor generates an output control signal based on an input signal (VS, PS) and a command, the output control signal being used by the electric actuator assembly to controllably drive the electric actuator assembly during an injection cycle; and

a wireless communication device comprising a processor, a user interface, an interface adapted for wireless communication with a synchronization controller, and a computer readable medium having a program of instructions for generating an output signal based on user selectable data entered via the user interface for synchronization with preconfigured actuation control of valve pin position by an electric actuator assembly, and for displaying valve pin position along a travel path during an injection cycle via the user interface.

3. The system of any preceding claim, wherein the program of instructions is configured to calibrate a set of valve pin settings stored in a junction box in communication with the electric actuator assembly and the synchronous controller.

4. The system of any preceding claim, wherein the synchronization controller is configured to be mounted to an outer surface of a housing of an injection molding machine.

5. The system of any preceding claim, wherein the synchronous controller is configured to generate valve pin opening and closing signals at a maximum speed (e.g., 50 millimeters/second) throughout a stroke, the maximum speed determined by the electrical actuator assembly.

6. The system of any preceding claim, wherein the synchronous controller is configured to generate the valve pin opening signal at a reduced rate that is less than a maximum rate, thereby allowing a user time to adjust the flow rate of fluid material into the mold cavity during an injection cycle.

7. The system of any preceding claim, wherein the synchronization controller is configured to: when the actuator assembly and the valve pin are positioned in the hot runner assembly, a valve pin arrangement for the closed position is created.

8. The system of any preceding claim, wherein the synchronization controller is configured to: valve pin settings are generated for a predetermined slow opening rate and travel distance to stabilize the flow front rate of the fluid material in the mold cavity.

9. The system of any preceding claim, wherein the synchronous controller is configured to generate a valve pin setting at an intermediate pin position between a port closed and end-of-travel position, for example to control filling of fluid material in a mold cavity.

10. The system of any preceding claim, wherein the preconfigured actuation control is a recipe stored in a junction box in communication with the electrical actuator assembly and the synchronous controller.

11. The system of claim 10, wherein the recipe is automatically transferred to the synchronization controller upon connection of the synchronization controller to the junction box.

12. The system of claim 11 wherein the recipe includes a set of valve pin settings displayed on a wireless user interface.

13. The system of claim 11 wherein the output signal is generated for preconfigured actuation control of valve pin positions by the plurality of electrical actuator assemblies.

14. The system of any preceding claim, wherein the wireless communication device is a handheld wireless computing device, such as a telephone or tablet.

15. An electric actuator control system comprising:

A sensor that senses and generates a signal indicative of a position of a valve pin driven by the electric actuator assembly through a downstream flow channel of a gate leading to a mold cavity during an injection cycle;

a controller having a processor and instructions for instructing the electric actuator assembly to drive the valve pin through the downstream flow channel between a gate closed position and an injection cycle end position or end-of-travel position; the controller receives signals from the sensors, and the instructions instruct the plurality of electric actuator assemblies to drive each of the plurality of valve pins along a predetermined travel path at one or more predetermined travel rates or speeds during an injection cycle based on receipt of one or more received signals;

16. The system of claim 15 wherein the instructions are configured to instruct the electric actuator assembly to drive the valve pin upstream to a predetermined position at a first rate or speed of travel and to drive the valve pin between a predetermined intermediate position and an end-of-travel position at a second rate or speed that is higher than the first rate or speed. The predetermined position is intermediate the gate closing position and the end-of-travel position.

17. A method of controlling an electric actuator of an electric actuator control system, the method comprising:

a housing including an electric actuator synchronization controller and one or more input interfaces configured to receive: a) A control signal (VS) generated by an Injection Molding Machine (IMM), the control signal (VS) adapted to instruct an actuator to begin driving a valve pin along a travel path from a gate closed position upstream toward a gate end-of-travel position, and to begin driving a valve pin from the end-of-travel position downstream toward the gate closed position; and b) a valve pin Position Signal (PS) indicative of a valve pin position between a gate closed position and an end-of-travel position;

a synchronous controller comprising a processor and a computer readable medium having instructions for preconfigured actuation control of valve pin positions by a plurality of electric actuator assemblies during an injection cycle; wherein the processor generates an output control signal based on an input signal (VS, PS) and a command, the output control signal being used by the electric actuator assembly to controllably drive the electric actuator assembly during an injection cycle; and

Providing a wireless communication device comprising a processor, a user interface, an interface adapted for wireless communication with a synchronization controller, and a computer readable medium having a program of instructions for generating an output signal based on user selectable data entered via the user interface for synchronization with a preconfigured actuation control of valve pin position by an electric actuator assembly, and for displaying the valve pin position along a travel path during an injection cycle via the user interface; and

the user provides user selectable data inputs to the user interface to adjust control of the electrical actuator assembly in real time during the injection molding process.

18. The method of claim 17, the program of instructions configured to calibrate a set of valve pin settings stored in a junction box in communication with the electric actuator assembly and the synchronous controller.

19. The method of any of claims 17-18, wherein the synchronization controller is mounted to an outer surface of a housing of an injection molding machine.

20. The method of any of claims 17-19 wherein the synchronization controller generates the valve pin opening and closing signals at a maximum speed (e.g., 50 millimeters/second) throughout the stroke, the maximum speed determined by the electrical actuator assembly.

21. The method of any of claims 17-20 wherein the synchronization controller generates the valve pin opening signal at a reduced rate that is less than a maximum rate, thereby allowing a user time to adjust the flow rate of fluid material into the mold cavity during an injection cycle.

22. The method of any of claims 17-21 wherein the synchronous controller generates a valve pin setting for the closed position when the actuator assembly and the valve pin are positioned in the hot runner assembly.

23. The method of any of claims 17-22 wherein the synchronous controller generates valve pin settings for a preset slow opening speed and travel distance to stabilize a flow front speed of the fluid material in the mold cavity.

24. The method of any of claims 17-23, wherein the synchronization controller generates a valve pin setting for a middle pin position between a gate closed position and an end-of-travel position, for example, to control filling of a fluid material in a mold cavity.