WO2012159207A1

WO2012159207A1 - Integrated electrical cabinet for an injection unit

Info

Publication number: WO2012159207A1
Application number: PCT/CA2012/000523
Authority: WO
Inventors: Robert D. Schad; Marc RICKE
Original assignee: Athena Automation Ltd.
Priority date: 2011-05-26
Filing date: 2012-05-28
Publication date: 2012-11-29

Abstract

An injection molding machine includes a base; a first platen and a second platen supported by the base, the first and second platens moveable between mold open and mold closed positions and between clamped and undamped positions; a first electrical cabinet affixed to the base, the first electrical cabinet housing a plurality of stationary electrical components for operating the injection molding machine; and an injection unit mounted on the base, the injection unit movable relative to the base in at least one of an axial and rotational direction. A plurality of transducers may be mounted on the injection unit for monitoring at least one operating parameter of the injection unit, the plurality of transducers fixed relative to the injection unit and moveable with the injection unit relative to the base. An on-board electrical cabinet may be fixed to the injection unit and moveable with the injection unit relative to the base, the on-board electrical cabinet housing a plurality of on-board electrical components, each of the transducers in electrical communication with at least one of the on-board electrical components, and each of the on-board electrical components in electrical communication with at least one of the stationary electrical components.

Description

TITLE: INTEGRATED ELECTRICAL CABINET FOR AN INJECTION UNIT

FIELD

[0001] The teaching disclosed herein generally relates to injection molding machines, injection units for injection molding machines, and to one or more methods or apparatuses for providing electrical communication between a stationary base member and a sub-assembly moveable relative to the base member.

INTRODUCTION

[0002] U.S. Patent No. 7,316,553 (Teng et al.) discloses a drive assembly for rotating and translating a shaft comprising a hollow shaft motor and a fluid cylinder. The hollow shaft motor rotates the shaft and the fluid cylinder moves the shaft lengthwise. The drive is purported to be particularly useful in the injection unit of an injection-molding machine. In one preferred embodiment the injection unit includes a hollow electric motor and a hydraulic cylinder. A first cylinder wall of the hydraulic cylinder is joined to a rotor of the hollow motor. A second cylinder wall of the cylinder is connected to a stationary portion of the hollow motor. A piston has two end portions. One end portion of the piston engages the first cylinder wall and the other end portion of the piston engages the second cylinder wall. Means for rotating the piston are attached to the rotor. The means for rotating also permits the piston end portions to slide along the cylinder walls. One channel means provides hydraulic fluid to drive the piston in a forward direction and another channel means provides hydraulic fluid to drive the piston in a reverse direction. Means are provided for attaching an injection screw to the piston. In the preferred arrangement, the cylinder is at least partially situated within the hollow motor.

[0003] U.S. Patent No. 6,478,572 (Schad) discloses what is purported to be an energy efficient drive system is provided for use on typical injection molding machines whereby a single electric motor drives both the extruder screw and a hydraulic motor that continuously charges a hydraulic accumulator during the extrusion process. During the injection cycle, the charge in the accumulator is directed to stroke the extruder screw and inject melt into the mold cavities. Another embodiment utilizes a similar arrangement on the clamp mechanism of the injection molding machine whereby the charge in the accumulator is directed to hold the mold closed during the injection cycle.

[0004] U.S. Patent No. 5,747,076 (Jaroschek) discloses an electric drive with hydraulic assist for use in an injection molding machine, especially for screw advance during the injection process and/or in the dwell pressure phase. An electric motor is primarily used to produce the axial advance of the injection screw via an appropriate gear train. A piston that is moveable in a cylinder through pressure provided by a hydraulic fluid reservoir, can be used to supplement the axial movement produced by the electric motor. It is proposed according to the invention that pressurization occurs via the hydraulic fluid reservoir upon reaching a defined control quantity which corresponds to a defined load condition on the electric motor, such that the pressure rise in the cylinder is proportional to the load on the electric motor.

SUMMARY

[0005] The following summary is intended to introduce the reader to this specification but not to define any invention. In general, this specification discusses one or more examples of an injection molding machine having a first electrical component cabinet fixed relative to the base of the machine and a second electrical component cabinet which is integrated with the injection unit and is moveable relative to the base.

[0006] According to some aspects, an injection molding machine comprises a base; a first platen and a second platen supported by the base, the first and second platens moveable between mold open and mold closed positions and between clamped and undamped positions; a first electrical cabinet affixed to the base, the first electrical cabinet housing a plurality of stationary electrical components for operating the injection molding machine; an injection unit mounted on the base, the injection unit movable relative to the base in at least one of an axial and rotational direction; a plurality of transducers mounted on the injection unit for monitoring at least one operating parameter of the injection unit, the plurality of transducers fixed relative to the injection unit and moveable with the injection unit relative to the base; and an on-board electrical cabinet fixed to the injection unit and moveable with the injection unit relative to the base, the on-board electrical cabinet housing a plurality of on-board electrical components, each of the transducers in electrical communication with at least one of the on-board electrical components, and each of the on^¬ board electrical components in electrical communication with at least one of the stationary electrical components.

[0007] In some examples, the machine may further comprise a quantity of electrical transducer connectors extending from the on-board cabinet to the transducers to provide the electrical communication between each transducer and the respective stationary components. The machine may comprise a base connector cable extending between the on-board cabinet and the base cabinet. The base connector cable may comprise at least one data conductor for providing data communication between the on-board cabinet and the base cabinet. The base connector cable may comprise fewer data conductors than the quantity of electrical transducer connectors. The base connector cable may comprise at least one power conductor for providing electrical power supply to the on-board components.

[0008] In some examples, the machine may comprise a first controller in electrical communication with one or more of the stationary components, the first controller operable to store and execute a first set of instructions for controlling a first plurality of operating functions of the injection molding machine, the first plurality of operating functions including mold opening and closing, and mold clamp and unclamp. The machine may comprise a Human Machine Interface coupled to the base, wherein the first controller is integrated with the Human Machine Interface. The first plurality of operating instructions may include at least one of injection screw rotation and screw translation. The first plurality of operating instructions may include substantially all of the operating functions used during normal operation of the machine.

[0009] In some examples, the machine may comprise a second controller in electrical communication with one or more of the on-board components, the second controller operable to store and execute a second set of instructions for controlling a second plurality of operating functions of the injection molding machine, the second plurality of operating functions including injection screw rotation and screw translation.

[0010] In some examples, the injection unit further comprises an injection screw translatable and rotatable within an injection barrel, and an actuator mounted in a drive housing and coupled to the screw for moving the screw within the barrel, the actuator responsive to a first electrical control signal transmitted from an output of one of the onboard electrical components.

[0011] According to some aspects, an injection unit for an injection molding machine comprises a drive housing; an injection barrel extending from the drive housing; and c) an electrical cabinet fixed to the drive housing.

[0012] In some examples, the injection unit may comprise a plurality of electrical components mounted in the electrical cabinet, the electrical components providing electrical inputs and outputs to facilitate operation of the injection unit. The injection unit may comprise an injection screw translatable and rotatable within the injection barrel, and an actuator mounted in the drive housing and coupled to the screw for moving the screw within the barrel, the actuator responsive to a first electrical control signal transmitted from a first one of the outputs. The actuator may comprise a solenoid operated valve, and the first electrical control signal moves the valve between open and closed positions.

[0013] In some examples, the injection unit may comprise a position sensor generating a first electrical feedback signal, the first electrical feedback signal responsive to an axial position of at least one of the screw and actuator, the first electrical feedback signal transmitted to a first one of the inputs.

[0014] In some examples, the injection unit may comprise a heating band assembly encasing at least a portion of the barrel for maintaining resin in the barrel in a sufficiently molten state. In some examples, the electrical components include a temperature control module, the temperature control module transmitting a second control signal from a second output, the heating band assembly generating thermal energy from a supply of electrical current that is responsive to the second control signal. In some examples, the injection unit may comprise a temperature sensor for generating a second feedback signal, the second feedback signal responsive to a temperature of at least one of the heating band and the barrel, the second feedback signal transmitted to a second one of the inputs.

[0015] According to some aspects, an injection molding machine includes a base and at least one platen mounted to the base for supporting a mold. The injection molding machine also includes an injection unit movably mounted on the base. The injection unit may be slidable between a first position, in which the injection unit engages the platen, and a second position, in which the injection unit is spaced apart from the platen. The injection molding machine may also include a first electrical component cabinet fixedly mounted to the base. The first electrical component cabinet can include a first controller operable to control at least one injection molding machine function. A plurality of transducers can be mounted on the injection unit to monitor at least one characteristic or operating paratmeter of the injection unit. The plurality of transducers may be moveable in unison with the injection unit between the first and second positions. A second electrical component cabinet can be fixed to the injection unit and can be movable with the injection unit between the first and second positions. The second electrical component cabinet can be communicably linked to the first electrical component cabinet and may include a plurality of electrical components communicably linked to the plurality of transducers so that the plurality of transducers are communicably linked to the first electrical component cabinet via the second electrical component cabinet.

[0016] The plurality of transducers may be communicably linked to the second electrical component cabinet by a respective plurality of transducer connectors. The second electrical component cabinet may be communicably linked to the first electrical component cabinet by at least one cabinet connector. The number of cabinet connectors can be less than the number of transducer connectors.

[0017] The plurality of electrical components can include a second controller operable to at least partially control operation of the injection unit. The second controller can be in two-way communication with at least one of the plurality of transducers, and can be operable to control the operation of the at least one transducer. [0018] The at least one cabinet connector can include a single communication cable extending between a first transmitter in the first electrical component cabinet and a receiver in the second electrical component.

[0019] The second electrical component cabinet can include a second transmitter that is connectable to at least one auxiliary device.

[0020] The second controller can include a plurality of transducer control modules. Each transducer control module can be communicably linked to a corresponding one of the plurality of transducers. The second controller can be at least partially remotely controllable by the first controller.

[0021] The injection molding machine can also include a human machine interface apparatus communicably linked to the first controller in the first electrical component cabinet. The human machine interface can allow an operator to control the injection molding machine. The human machine interface apparatus can be communicably linked to the second controller via the first controller.

[0022] The second electrical component cabinet can be disposed on an operator- side of the injection unit to be accessible to a machine operator.

[0023] The second electrical component cabinet can include a cabinet door. The cabinet door can openable to provide access to the interior of the second electrical component cabinet. Optionally, the cabinet door can be openable when the injection unit is in both the first and second positions.

[0024] The injection unit can be swivelable relative to the base between an inline position and a service position. The second electrical component cabinet can be swivelable with the injection unit.

[0025] The first electrical component cabinet and the second electrical component cabinet can be accessible from different sides of the injection molding machine.

[0026] The at least one characteristic of the injection unit controlled by the second controller can include at least one of heater band temperature, injection pressure, injection unit translation, injection unit swivel, nozzle operation, injection screw operation and hopper operation.

[0027] The plurality of transducers can include at least one of a sensor and an actuator.

[0028] The first controller can include a processor in communication with a computer readable memory. The memory can include software to configure the processor to control the at least one injection molding machine function.

[0029] The at least one injection molding machine function controlled by the first controller can be at least one of opening the mold, closing the mold, ejecting molded articles from the mold, plasticizing feed material and operating an injection molding machine hydraulic system.

[0030] Other aspects and features of the present specification will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific examples of the specification.

DRAWINGS

[0031] The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:

[0032] Figure 1 is a side elevation view of the operator side of an injection molding machine;

[0033] Figure 2 is a side elevation view of the non-operator side of the injection molding machine of Figure 1 ;

[0034] Figure 3 is a perspective view of the non-operator side of the injection molding machine of Figure 1 , with the base cabinet doors in an open position;

[0035] Figure 4 is a perspective view of the operator side of the injection molding machine of Figure 1 , with the protective enclosure removed and with the injection unit swiveled to a service position; [0036] Figure 5 is the perspective view of Figure 4, with the on-board cabinet doors in an open position;

[0037] Figure 6 is a side view of a portion of the injection unit of Figure 4, with the injection cabinet doors removed; and

[0038] Figure 7 is a schematic representation of an injection unit, base cabinet, HMI and on-board cabinet for use with the injection molding machine of Figure 1.

DETAILED DESCRIPTION

[0039] Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.

[0040] Referring to Figure 1 , an example of an injection molding machine 100 includes a base 102, with a moving platen 104 and a stationary platen 106 mounted to the base 102 and coupled together via tie bars 108. A mold is formed between the platens 104, 106, the mold defined at least in part by a first mold half mounted to the moving platen 104, and a second mold half mounted to the stationary platen 106. When the injection molding machine 100 is in use, the platens 104, 106 can be surrounded by a protective enclosure 110, as shown in Figures 1 and 2. Figures 4 and 5 show the machine without the protective enclosure 110. [0041] The injection molding machine 100 comprises a first electrical component cabinet (also called a base cabinet 112) fixed relative to the base. The first cabinet 112 may be fixedly mounted on or within the base 102. In the illustrated example, the first cabinet 112 is integrated with the machine base 102. Alternatively, the first cabinet 112 can be separate from the base. The injection molding machine 100 also includes a fluid power cabinet or pump compartment 114 that can enclose motors 116, hydraulic pumps 118 and other components of the machine's hydraulic systems, or other fluid systems (Figure 5).

[0042] Referring to Figures 2 and 3, the interior of the first cabinet 112 is enclosed by operable cabinet doors 120. The cabinet doors 120 are moveable between a closed position (Figure 2) and an open position (Figure 3). Opening the cabinet doors 120 can provide access to the interior of the first cabinet 112. In the illustrated example, the base cabinet doors 120 are accessible from the back or non-operator side 122 of the injection molding machine 100. Alternatively, the first cabinet 112 can be configured so that the base cabinet doors 120 are accessible from the front or operator side 124 of the injection molding machine 100. In the example illustrated, the base cabinets 112 is connected to an electrical supply line 125 for providing electrical power to the machine 100.

[0043] Referring to Figure 3, a plurality of electrical components (stationary components) 126 can be installed within the first cabinet 1 2. The plurality of stationary components 126 may include, for example, controllers, drives, switches, amplifiers, relays, or other components. The stationary components 126 may include a device for storing and executing a set of instructions, such as a computer, CPU, or PLC. In the example illustrated, the stationary components 126 include, among other things, a plurality of servo drives 126a, an electrical filter 126b, a programmable safety relay (safety PLC) 126c, and a transformer 126d. Machine functions controlled by the stationary components 126 can include, for example, opening the mold, closing the mold, ejecting molded articles from the mold, and operating an injection molding machine hydraulic system.

[0044] Referring to Figure 2, an injection unit 130 is mounted to the base 102 for injecting resin into the mold to form a molded article. The injection unit 130 generally includes a drive housing 132 and a barrel 134 extending from the housing 132 towards the stationary platen 106. The injection unit 130 also includes, in the example illustrated, a feed hopper 136 for receiving a meltable, plastic feed stock. An injection screw is housed within the barrel 134. The injection screw is urged to rotate and to translate within the barrel 134 by one or more actuators housed in the drive housing 132. In the illustrated example, the actuators for the injection screw include a hydraulic motor and a hydraulic piston/cylinder. Hydraulic fluid is supplied to the injection unit 130 via hydraulic supply lines 138 (Figure 3), which are connected to the hydraulic pump 118 and form part of a machine hydraulic system.

[0045] The injection unit 130 is movably mounted on the base 102. By sliding the housing 132 relative to the base 102, the barrel 134 can be advanced toward, and retracted from the stationary platen 106. The housing 132 can be advanced to a first position, in which the tip 140 (Figure 4) of the barrel 134 of the injection unit 130 engages a sprue hole on the stationary platen 106. When the barrel 134 is engaged with the sprue hole, molten plastic can be injected into the mold.

[0046] The housing 132 can be retracted to a second position, in which the injection unit 130 is moved away from the stationary platen 106 and the tip 140 of the barrel 134 is spaced apart from the stationary platen 106. When the tip 140 of the barrel 134 is removed from the sprue hole, a valve provided toward the tip 140 of the barrel can be closed. Closing the valve may help prevent leakage of molten plastic from the barrel 134.

[0047] Optionally, the injection unit 130 can be swivelable relative to the base 102, about a swivel axis, between an inline position (Figures 1-3) and a service position (Figures 4 and 5). Swiveling the injection unit 130 into the service position may help facilitate access to the barrel 134 and other components of the injection unit 130 for inspection and/or maintenance.

[0048] In the example illustrated, the injection unit 130 can swivel about a generally vertical swivel axis 141 (Fig. 6) so that the barrel 134 swings toward the operator side 124 of the injection molding machine 100. Swiveling the barrel 134 toward the operator side 124 of the machine may help facilitate inspection and maintenance of the injection unit 130 from the operator side of the machine, instead of requiring a machine operator to access the opposite, back side 122 of the injection molding machine 100.

[0049] In the example illustrated, a plurality of transducers are mounted on the injection unit 130 to monitor, and optionally modify, at least one characteristic or operating parameter of the injection unit. Characteristics of the injection unit that can be monitored and/or modified via the transducers may include, for example heater band temperature, injection pressure, injection unit translation, injection unit swivel, nozzle operation, injection screw operation and hopper operation.

[0050] The transducers may be mechanical, electrical, or electro-mechanical in nature, and may generally convert electrical energy to or from another form of energy. Some transducers may comprise actuators and related sensors that can be used to monitor and/or alter the operation of the injection unit 130. The plurality of transducers may include, for example, a plurality of barrel heater bands 144 (Figure 2) and related barrel temperature sensors, plasticizing screw injection and/or back pressure sensors, injection screw position monitoring sensors, injection unit translation sensors (configured to measure displacement of the injection unit along the machine axis), injection unit swivel sensors, hopper status sensors, hopper control actuators, and/or nozzle flow control valve position sensors and valve actuators 146, including solenoid actuated valves, (Figure 5). Schematic representations of transducers 142 are shown in Fig. 7 to help illustrate an exemplary configuration of the transducers relative to other machine components.

[0051] In the illustrated example, the plurality of transducers 142, 144, 146 are moveable in unison with the injection unit 130 relative to the base 102, including at least one of translation between the first and second positions, and swiveling between an in-line position and a maintenance position.

[0052] In known injection molding machines, the plurality of injection unit transducers are typically directly connected to the stationary components in the base cabinet. To facilitate this connection, known injection molding machines may include one or more electrical connectors (e.g. wires or cables) running from each transducer to the base cabinet. Such a plurality of individual cables running from the transducers to the base cabinet can increase the complexity of the control system of an injection molding machine, and can require a relatively large quantity of relatively long connecting cables.

[0053] Running a plurality of cables from the injection unit to the machine base may also interfere with, or complicate the configuration of, the translatable and swivelable connection between the injection unit and the base. Relatively long communication cables may also be prone to tangling or other damage when the injection molding machine is in use, may be relatively expensive (particularly if the cables are shielded, insulated or otherwise enhanced) and may be prone to relatively high line signal loss or noise introduced between the transducers and the base cabinet.

[0054] Referring again to Figures 1-5, the injection molding machine 100 comprises, in the example illustrated, a second electrical component cabinet (also called an on-board cabinet 148) mounted on the injection unit 130. The on-board cabinet 148 is, in the example illustrated, fixedly connected to the injection unit housing 132 and is moveable in unison with the injection unit 130, an contains a plurality of on-board electrical components 159. In the illustrated example, the injection unit 130 is also swivelable relative to the base 102, and the on-board cabinet 148 can swivel in unison with the injection unit 130.

[0055] In the example illustrated, the on-board cabinet 148 includes a pair of openable cabinet doors 150, which are moveable between a closed position (Figures 1-4) and an open position (Figure 5). Opening the cabinet doors 150 may help facilitate inspection, maintenance and/or replacement of the on-board electrical components 159 located within the on-board cabinet. In the illustrated example, the cabinet doors 150 are hingedly coupled to the cabinet housing 152, and includes a cabinet locking mechanism 154. Use of a cabinet locking mechanism 154 may allow a machine operator to limit access to the interior of the on-board cabinet 148. Air circulation fans 156 (and/or an optional air conditioning unit) may be provided in the cabinet body 152, and may help facilitate cooling the air within the interior of the on-board cabinet 148.

[0056] In the illustrated example, the base cabinet 112 and on-board cabinet 148 are accessible from opposite sides 122, 124 of the injection molding machine 100. Alternatively, injection molding machine 100 may be configured so that the base cabinet 1 12 and on-board cabinet 148 may be accessible from the same side of the injection molding machine 100, so that both the base cabinet 1 12 and on-board cabinet 148 can be opened and accessed from the same side of the injection molding machine 100.

[0057] Referring also to Figure 7, the plurality of transducers 142, 144, 146 are each connected to the on-board cabinet 148 by an electrical transducer connector 158. The connectors 158 may be, for example communication cables and/or power cables, and/or any other suitable connectors to facilitate one way, and optionally two-way, communication between the transducers 142, 144, 146 and the onboard cabinet 148. The on-board cabinet 148 is connected to the base cabinet 112 by at least one cabinet connector 160. In the illustrated example, each transducer connector 158 represents a discrete physical conduit extending between a transducer and the on-board cabinet 148. Each connector 158 may include more than one separate signal conductor and/or power conductor. Similarly, each cabinet connector 160 represents a discrete physical conduit extending between the onboard cabinet 148 and the base cabinet 160. Each connector 160 may include more than one separate signal conductor and/or power conductor. Preferably, the quantity of cabinet connectors 160 used is fewer than the quantity of transducer connectors 158.

[0058] Using a relatively smaller quantity of cabinet connectors 160 to link the onboard cabinet 148 and base cabinet 1 12 may help reduce the complexity and/or cost of the injection molding machine control system. Reducing the number of communication and/or power cables running between the on-board cabinet 148 and the base cabinet 1 12 may help reduce the number of cables running through the movable connection between the injection unit 130 and the base 102, and may help reduce the total length of cabling used to connect the plurality of transducers 142, 144, 146. This configuration may also help reduce the length of the transducer connectors 158.

[0059] Referring to Figure 7, in the illustrated example, all of the transducers 142, 144, 146 mounted on the injection unit 130 are communicably linked to the on-board cabinet 148, instead of being directly connected to the base cabinet 1 12. Signals to and from the transducers 142, 144, 146 (including, for example, control signals and sensor data) are routed to and collected in the on-board cabinet 148, and then optionally transferred to the base cabinet 1 12 via the cabinet connector 160, and vice versa, and may be transferred between the base cabinet 112 and a first controller 179a.

[0060] In the example illustrated, the cabinet connector 160 extending between the on-board cabinet 148 and the base cabinet 1 12 is a single conduit housing a power supply cable 160a and a single cabinet communication cable 160b. The power supplied to the onboard cabinet 148 can include, for example 24V for inputs and/or controller power, 120V for the cabinet fans and auxiliary batch mixers, 240V for the nozzle heater bands, and 460V for the barrel heater bands. Alternatively, an alternative connection configuration can be used. For example, the power cable 160a may be physically spaced apart from the communication cable 160b.

[0061] Referring to Figure 6, the on-board cabinet 148 is configured to enclose a plurality of on-board electrical components 159. In the illustrated example, the plurality of electrical components 159 includes a grounding bar 159a, a power distribution block 159b, terminal blocks 159c, circuit breakers 159d and fuses 159e. Optionally, the on-board electrical components 159 can include a relay station or router that may be operable to receive data from the plurality of transducers 142, 144, 146 and relay the data to the first controller 179a via the cabinet connector 160, and/or relay control signals from the first controller 179a to the appropriate transducer 142, 144, 146.

[0062] Alternatively, or in addition, the on-board electrical components 159 can include a second controller 159f that is operable to control at least some of the functions of the injection unit 130. The second controller 159f can be operable to locally process at least a portion of the data received from the plurality of transducers 142, 144, 146 and generate a corresponding control signal.

[0063] For example, the second controller 159f can be configured to monitor the operating temperature of the barrel 134 using temperature sensors, and to automatically adjust the operating temperature as needed, using a temperature control actuator, without engaging the first controller 179a. [0064] Referring still to Figure 7, a schematic representation of the base cabinet 112 includes exemplary stationary electrical components 126, including for example a transmitter module 126f (for example a fieldbus transmitter) for transmitting control signals to a corresponding receiver module 159g (for example a fieldbus receiver) in the on-board cabinet 148, via the cabinet connectors 160 (for example fieldbus communication cables 160b). Optionally the transmitter module 126f and receiver module 159g can be configured as transceiver modules, to help facilitate two-way communication between the base cabinet 12 and the on-board cabinet 148.

[0065] In the illustrated example, the first controller 179 is integrated with the HMI 178 may include a processor 179b in communication with a computer readable memory 179c. The memory 179c may be configured to store software that can configure the processor 179b to control at least one injection molding machine 100 function.

[0066] Optionally, the plurality of on-board electrical components 159 in the on-board cabinet 148 may include a plurality of transducer control modules 59i that are connected one or more of the plurality of transducers 142, 144, 146. The transducer control modules 159i can be selected based on the type of transducer they are connected to, and optionally can be in two-way communication with the transducers 142, 144, 146 to send and receive data from the transducers 142, 144, 146 (including, for example, state information), provide power to the transducers (if required) and send control signals to the transducers 142, 144, 146.

[0067] In the illustrated example, each of the transducer control modules 159i are connected to the second controller 159f. Optioanlly, the second controller 159f is operable to perform at least some local processing and decision making based on the data received from the transducers 142, 144, 146, and control the operation of a corresponding transducer 142, 144, 146 (via the transducer control modules 159i). While illustrated as separate components for clarity, the transducer control modules 159i can be integrated with the second controller 159f. The second controller 159f may be connected to the receiver module 159g. [0068] The second controller 159f can be any suitable type of controller that can be communicably linked to the first controller 179a, including, for example, a PLC or a computer.

[0069] Optionally, the second controller 159f can be configured to have lower processing power than the first controller 179a, and can be at least partially remotely controllable by the first controller 179a.

[0070] Optionally, the on-board cabinet 148 can include an auxiliary transmitter 159j (or transceiver) that is connectable to an auxiliary device 176. Providing an auxiliary transmitter 159j may allow the second controller 159f to interface with, and optionally control an auxiliary device 176 that is used in combination with the injection molding machine 100, in addition to the plurality of transducers 142, 144, 146.

[0071] Referring also to Figure 1 , in the illustrated example, the injection molding machine 100 includes a human machine interface apparatus (HMI) 178 that is communicably linked to the first controller 179a, and in the illustrated example the controller 179a is integrated with the HMI 178. The HMI 178 ay be operable to allow an operator to control the injection molding machine 100. The HMI can be any suitable apparatus, including, for example, a keyboard, push buttons, a display monitor and a touch screen interface. In the illustrated example, the HMI apparatus 178 and first controller 179a are directly connected to the base cabinet 112, and is connected to the second controller 159f, via the base cabinet 112. In this configuration, injection unit related operator inputs received via the HMI 178 can be transmitted to the transducers 142, 144, 146 via the first controller 179a and second controller 59f.

[0072] In the illustrated example, the injection molding machine 100 is a two platen molding machine equipped to use a single mold. Alternatively, the injection molding machine can be of a different configuration, including, for example, a three platen machine, a toggle machine and a stack mold machine. [0073] Optionally, instead of a single stage injection unit 130 as illustrated above, the injection molding machine 100 can include a multi-stage injection unit or other suitable injection apparatus.

[0074] Optionally, an on-board cabinet 148 can be provided on electric injection units, hydraulic injection units, and hybrid hydraulic-electric injection units. In some configurations, hydraulic injection units may include electronic sensors and electrically powered actuators and heaters, which may be connected to the on-board cabinet.

[0075] Optionally, instead of providing a physical communication link between the base cabinet 112 and the on-board cabinet 148, the base and on-board cabinets 112, 148 may be communicably linked using another suitable system, including, for example, a wireless or radio communication link.

[0076] The first controller 179a, second controller 159f, transducer control modules 159i and other electrical components described herein can be formed from any suitable combination of hardware, software and firmware.

Claims

CLAIMS:

1. An injection molding machine comprising:

a) a base;

b) a first platen and a second platen supported by the base, the first and second platens moveable between mold open and mold closed positions and between clamped and undamped positions;

c) a first electrical cabinet affixed to the base, the first electrical cabinet housing a plurality of stationary electrical components for operating the injection molding machine;

d) an injection unit mounted on the base, the injection unit movable relative to the base in at least one of an axial and rotational direction;

e) a plurality of transducers mounted on the injection unit for monitoring at least one operating parameter of the injection unit, the plurality of transducers fixed relative to the injection unit and moveable with the injection unit relative to the base; and f) an on-board electrical cabinet fixed to the injection unit and moveable with the injection unit relative to the base, the on-board electrical cabinet housing a plurality of on-board electrical components, each of the transducers in electrical communication with at least one of the on-board electrical components, and each of the on-board electrical components in electrical communication with at least one of the stationary electrical components.

2. The machine of claim 1 , further comprising a quantity of electrical transducer connectors extending from the on-board cabinet to the transducers to provide the electrical communication between each transducer and the respective stationary components.

3. The machine of claim 2, further comprising a base connector cable extending between the on-board cabinet and the base cabinet.

4. The machine of claim 3, wherein the base connector cable comprises at least one data conductor for providing data communication between the on-board cabinet and the base cabinet.

5 The machine of claim 4, wherein the base connector cable comprises fewer data conductors than the quantity of electrical transducer connectors.

6. The machine of any one of claims 3-5, wherein the base connector cable comprises at least one power conductor for providing electrical power supply to the on-board components.

7. The machine of any one of claims 1-6, further comprising a first controller in electrical communication with one or more of the stationary components, the first controller operable to store and execute a first set of instructions for controlling a first plurality of operating functions of the injection molding machine, the first plurality of operating functions including mold opening and closing, and mold clamp and unclamp.

8. The machine of claim 7 further comprising a Human Machine Interface coupled to the base, wherein the first controller is integrated with the Human Machine Interface.

9. The machine of any one of claims 7-8, wherein the first plurality of operating instructions further includes at least one of injection screw rotation and screw translation.

10. The machine of any one of claims 7-8, wherein the first plurality of operating instructions includes substantially all of the operating functions used during normal operation of the machine.

1 1. The machine of claim 7, further comprising a second controller in electrical communication with one or more of the on-board components, the second controller operable to store and execute a second set of instructions for controlling a second plurality of operating functions of the injection molding machine, the second plurality of operating functions including injection screw rotation and screw translation.

12. The machine of any one of claims 1-11 , wherein the injection unit further comprises an injection screw translatable and rotatable within an injection barrel, and an actuator mounted in a drive housing and coupled to the screw for moving the screw within the barrel, the actuator responsive to a first electrical control signal transmitted from an output of one of the on-board electrical components.

13. An injection unit for an injection molding machine, comprising:

a) a drive housing;

b) an injection barrel extending from the drive housing; and

c) an electrical cabinet fixed to the drive housing.

14. The injection unit of claim 13, further comprising a plurality of electrical components mounted in the electrical cabinet, the electrical components providing electrical inputs and outputs to facilitate operation of the injection unit.

15. The injection unit of claim 14, further comprising an injection screw translatable and rotatable within the injection barrel, and an actuator mounted in the drive housing and coupled to the screw for moving the screw within the barrel, the actuator responsive to a first electrical control signal transmitted from a first one of the outputs.

16. The injection unit of claim 15, wherein the actuator comprises a solenoid operated valve, and the first electrical control signal moves the valve between open and closed positions.

17. The injection unit of any one of claims 15-16, further comprising a position sensor generating a first electrical feedback signal, the first electrical feedback signal responsive to an axial position of at least one of the screw and actuator, the first electrical feedback signal transmitted to a first one of the inputs.

18. The injection unit of any one of claims 14-17, further comprising a heating band assembly encasing at least a portion of the barrel for maintaining resin in the barrel in a sufficiently molten state.

19. The injection unit of claim 18, wherein the electrical components include a temperature control module, the temperature control module transmitting a second control signal from a second output, the heating band assembly generating thermal energy from a supply of electrical current that is responsive to the second control signal.

20. The injection unit of claim 19, further comprising a temperature sensor for generating a second feedback signal, the second feedback signal responsive to a temperature of at least one of the heating band and the barrel, the second feedback signal transmitted to a second one of the inputs.