本研究主要在探討完全電器驅動的立式射出機(Fully Electric Vertical Injection Molding Machine)，首先使用3D繪圖軟體SolidWorks98，以模組化的設計程序，就一般30噸射出機的規格提出一個包含射出、計量與射座單元的馬達傳動機構設計，包含動力系統的分析與設計、伺服馬達容量大小的選定以及機械結構的有限元素應力應變分析與設計(使用SolidWorks外掛之FEM模組：COSMOS4.0)。
Due to the rapid growth of the electronic industry, the requirements for the functions and quality of the processing machines have been greatly raising up as well. Those precision products such as IC not only require the machines to be very accurate and steady, but also emphasize the production speed as well as the pollution of the working environment. Therefore, in order to satisfy those requirements, the injection molding machines which are used to pack those products have to make some improvements.
It is an obvious trend that a fully electric-drive system is going to replace the conventional hydraulic-drive system. The reason is pretty clear that the motor-drive system would not cause the environment’s pollution, and the response speed as well as the controllability is better than that of the conventional hydraulic-drive. However, the fully electric-drive system has some inherent disadvantages at this current stage, for example, the output-force control of the motor is more complicated than that of the hydraulic system. Besides that, the measurement of the clamping force and the injecting force is the another problem needs to take care.
This study is aimed to develop the injection system of a vertical-type fully electric injection-molding machine. A design of the motor-drive mechanism for a 30-ton injection-molding machine, which includes injection unit, measurement unit and screw-holding unit, is presented. The modularized design method is applied in this design with the 3D CAD software—SolidWorks 98. The new design has been verified by the stress analysis through the finite-element analysis software—COSMOS 4.0.
All the machine elements of each module have the descriptions of their functions, stress analysis, material selection and the guidelines for assembling, Especially for the load cell, a new assembly design has been presented to decrease the error in accuracy caused by the pre-load and the friction force.
This study has also developed the drive system and the structure for the high-speed fully electric molding machines according to the specifications of the current advanced molding machines as well as the practical design experience from the industry. This could include three major parts: material, mold and machine itself. For the machine part, an optimum drive mechanism with low inertia is designed through COSMOS. A plunger-type injection mechanism with high-speed and high-response is also presented. It has the advantages of economical drive unit and good stability of the structure. The results could provide the future research in this area as a reference.
This study also emphasizes on the prepared work for the development of a
new product for industry and academia, especially on the completed study of the
related patents in the world. Not only it could fill the gap between the theory
and the applicability, but also could prepare to file the patent application for
the new technology during the development in order to protect the intellectual
property as well as to increase the additional value of the product.