Injection molding machine having a vector controlled AC drive system

Claim 2

An injection molding machine for producing a molded part by injecting a molten material into mold elements forming a mold cavity defining the molded part, the machine comprising: (a) clamp means for supporting and moving the mold elements between open and closed positions; (b) injection means for injecting the molten material into the mold cavity, said injection means including a screw member rotatably and translatably carried in a tubular barrel having an end in communication with the mold cavity; (c) first drive means mechanically coupled to the clamp means for imparting relative motion to the mold elements; (d) second drive means mechanically coupled to the injection means for rotating the screw member; (e) third drive means mechanically coupled to the injection means for translating the screw member within the tubular barrel; (f) wherein at least one of the first drive means, the second drive means, and the third drive means further includes (1) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor, and (2) vector controller means for controlling the AC induction motor in response to a motor command signal, the vector controller means being connected to the AC induction motor and including (i) a CPU for calculating torque and flux producing components of current passing through the stator windings, (ii) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (iii) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor; and (g) machine control means connected to the vector controller means for producing the motor command signal.

Claim 3

The apparatus of claim 1 wherein at least another of the first drive means, the second drive means and the third drive means comprises: (a) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor; and (b) vector controller means connected to the AC induction motor for controlling the motor, the vector controller means including (1) a CPU for calculating torque and flux producing components of current passing through the stator windings, (2) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (3) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor.

Claim 4

The apparatus of claim 2 wherein the vector controller means of each drive means shares a common CPU connected to multiplexing means for switching the pulse width modulated trigger signals produced by the current controller means to the power amplifier means for each AC induction motor based on an external command input signal.

Claim 5

The apparatus of claim 1 wherein each of the first drive means, the second drive means and the third drive means comprises: (a) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor; and (b) vector controller means connected to each AC induction motor for controlling each motor, the vector controller means including (1) a CPU for calculating torque and flux producing components of current passing through the stator windings, (2) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (3) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor.

Claim 6

The apparatus of claim 1 further comprising: (a) ejector means for ejecting the molded part from the mold cavity; (b) die height means for adjusting the clamp means relative to the mold elements; (c) injection sled means for positioning the injection means relative to the mold elements; (d) fourth drive means mechanically coupled to the ejector means for imparting motion to the molded part; (e) fifth drive means mechanically coupled to the die height means for adjusting the position of the clamp means; (f) sixth drive means mechanically coupled to the injection sled means for imparting relative motion to the injection sled means; (g) wherein at least one of the fourth drive means, the fifth drive means, and the sixth drive means further includes (1) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor, and (2) vector controller means for controlling the AC induction motor in response to a motor command signal, the vector controller means being connected to the AC induction motor and including (i) a CPU for calculating torque and flux producing components of current passing through the stator windings, (ii) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (iii) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor; and (h) machine control means connected to the vector controller means for producing the motor command signal.

Claim 7

The apparatus of claim 5 wherein the vector controller means of each drive means shares a common CPU connected to multiplexing means for switching the pulse width modulated trigger signals produced by the current controller means to the power amplifier means for each AC induction motor based on an external command input signal.

Claim 8

The apparatus of claim 1 wherein the commutation effect creating a torque on the rotor produces periodic torque pulsations thereby causing deviations in a process variable in response to the torque pulsations, and wherein the machine control means further comprises means for controlling the process variable by modifying the motor command signal in response to the deviations in the process variable caused by the torque pulsations.

Claim 9

The apparatus of claim 1 wherein the commutation effect creating a torque on the rotor produces periodic torque pulsations thereby causing deviations in a process variable in response to the torque pulsations, and wherein the machine control means further comprises: (a) means for producing a process feedback signal representing the process variable changing in response to the torque pulsations; (b) means for providing a set point signal representing a predetermined value of the process variable; and (c) means responsive to the set point signal and the process feedback signal for modifying the motor command signal in response to changes in the process variable from the predetermined value thereby reducing the deviations in the process variable caused by the torque pulsations.

Claim 10

An injection molding machine for producing a molded part by injecting a molten material into a mold cavity defining the molded part, the machine comprising: (a) injection means for injecting the molten material into the mold cavity, said injection means including a screw member rotatably and translatably carried in a tubular barrel, the tubular barrel having an end in communication with the mold cavity; (b) first drive means mechanically coupled to the injection means for translating the screw member within the tubular barrel, the first drive means including; (1) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings and means for detecting angular positions of the rotor; and (2) vector controller means for controlling the AC induction motor in response to a velocity command signal, the vector controller means being connected to the AC induction motor and including (i) a CPU for calculating torque and flux producing components of current passing through the stator windings, (ii) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (iii) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor with periodic torque pulsations; (c) means for producing a process feedback signal representing a non-velocity variable changing in response to the torque pulsations; and (d) machine control means connected to the vector controller means and the means for producing the process feedback signal for controlling the machine, the machine control means including (1) means for producing the velocity command signal representing a predetermined motor velocity, (2) means for providing a set point signal representing a predetermined value of the non-velocity variable, (3) means responsive to the set point signal and the process feedback signal for generating an error signal for representing the difference between the set point signal and the process feedback signal, and (4) means responsive to the error signal for modifying the velocity command signal as a function of the error signal thereby reducing changes in the non-velocity variable caused by the torque pulsations.

Claim 11

An injection molding machine for producing a molded part by injecting a molten material into a mold cavity defining the molded part, the machine comprising: (a) injection means for injecting the molten material into the mold cavity, said injection means including a screw member rotatably and translatably carried in a tubular barrel, the tubular barrel having an end in communication with the mold cavity; (b) first drive means mechanically coupled to the injection means for translating the screw member within the tubular barrel, the first drive means including; (1) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings and means for detecting angular positions of the rotor; and (2) vector controller means for controlling the AC induction motor in response to a velocity command signal, the vector controller means being connected to the AC induction motor and including (i) a CPU for calculating torque and flux producing components of current passing through the stator windings, (ii) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (iii) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor with periodic torque pulsations; (c) means for producing a process feedback signal representing a non-velocity variable changing in response to the torque pulsations; and (d) machine control means connected to the vector controller means and the means for producing the process feedback signal for controlling the machine, the machine control means including (1) means for producing the velocity command signal representing a predetermined motor velocity, (2) means for providing a set point signal representing a predetermined value of the non-velocity variable, (3) means responsive to the set point signal and the process feedback signal for generating an error signal for representing the difference between the set point signal and the process feedback signal, and (4) means responsive to the error signal for modifying the velocity command signal as a function of the error signal thereby reducing changes in the non-velocity variable caused by the torque pulsations.

Claim 12

The apparatus of claim 9 wherein the means for producing a process feedback signal further comprises means for producing a pressure feedback signal representing a pressure exerted against the screw member by the molten material.

Claim 13

An injection molding machine for producing a molded part by injecting a molten material into a two-part mold having a cavity defining the molded part, the machine comprising: (a) injection means for injecting the molten material into the mold cavity, said injection means including a screw member rotatably and translatably carried in a tubular barrel, the tubular barrel having an end in communication with the mold cavity; (b) first drive means mechanically coupled to the injection means for rotating the screw member to provide a quantity of molten material at one end of the screw member; (c) second drive means mechanically coupled to the injection means for translating the screw member within the tubular barrel, the second drive means including; (1) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor; and (2) vector controller means for controlling the AC induction motor in response to a velocity command signal, the vector controller means being connected to the AC induction motor and including (i) a CPU for calculating torque and flux producing components of current passing through the stator windings, (ii) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (iii) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor with periodic torque pulsations; (d) means connected to the injection means for producing a pressure feedback signal representing a pressure exerted against the screw member by the molten material, the pressure feedback signal changing in response to the torque pulsations; and (e) machine control means connected to the first and second drive means and the means for producing the pressure feedback signal for controlling the machine, the machine control means including (1) means for commanding the first drive means to rotate the screw member to provide a quantity of molten material at one end of the screw member, (2) means for producing the velocity command signal for commanding the vector controller means to maintain the AC induction motor and screw member at a zero translational velocity, (3) means for providing a pressure limit signal representing a desired pressure force between the screw member and the quantity of molten material, (4) comparing means responsive to the pressure limit signal and the pressure feedback signal for comparing the signals, and (5) means responsive to the comparing means for modifying the velocity command signal thereby reducing changes in the pressure feedback signal caused by the torque pulsations.

Claim 14

An injection molding machine for producing a molded part by injecting a molten material into a two-part mold having a cavity defining the molded part, the machine comprising: (a) injection means for injecting the molten material into the mold cavity, said injection means including a screw member rotatably and translatably carried in a tubular barrel, the tubular barrel having an end in communication with the mold cavity; (b) first drive means mechanically coupled to the injection means for rotating the screw member to provide a quantity of molten material at one end of the screw member; (c) second drive means mechanically coupled to the injection means for translating the screw member within the tubular barrel, the second drive means including; (1) an AC induction motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor; and (2) vector controller means for controlling the AC induction motor in response to a velocity command signal, the vector controller means being connected to the AC induction motor and including (i) a CPU for calculating torque and flux producing components of current passing through the stator windings, (ii) current controller means for producing pulse width modulated trigger signals based on the CPU calculations to regulate the current, and (iii) power amplifier means for receiving the pulse width modulated trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the AC induction motor with periodic torque pulsations; (d) means connected to the injection means for producing a pressure feedback signal representing a pressure exerted against the screw member by the molten material, the pressure feedback signal changing in response to the torque pulsations; and (e) machine control means connected to the first and second drive means and the means for producing the pressure feedback signal for controlling the machine, the machine control means including (1) means for commanding the first drive means to rotate the screw member to provide a quantity of molten material at one end of the screw member, (2) means for producing the velocity command signal for commanding the vector controller means to maintain the AC induction motor and screw member at a zero translational velocity, (3) means for providing a pressure limit signal representing a desired pressure force between the screw member and the quantity of molten material, (4) comparing means responsive to the pressure limit signal and the pressure feedback signal for comparing the signals, and (5) means responsive to the comparing means for modifying the velocity command signal thereby reducing changes in the pressure feedback signal caused by the torque pulsations.

Claim 15

An injection molding machine for producing a molded part by injecting a molten material into mold elements forming a mold cavity defining the molded part, the machine comprising: (a) clamp means for supporting and moving the mold elements between open and closed positions; (b) injection means for injecting the molten material into the mold cavity, said injection means including a screw member rotatably and translatably carried in a tubular barrel having an end in communication with the mold cavity; (c) first drive means mechanically coupled to the clamp means for imparting relative motion to the mold elements; (d) second drive means mechanically coupled to the injection means for rotating the screw member; (e) third drive means mechanically coupled to the injection means for translating the screw member within the tubular barrel; (f) wherein more than one of the first drive means, the second drive means, and the third drive means further includes (1) a motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor, and (2) electronic controller means for controlling the motor in response to a motor command signal, the electronic controller means being connected to the motor and including (i) a CPU for determining the characteristics of current to be applied to the motor, (ii) current controller means for producing trigger signals to regulate the current, and (iii) power amplifier means for receiving the trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the motor; (3) the electronic controller having a CPU connected to multiplexing means for switching the trigger signals produced by the current controller means to the power amplifier means for each electronically controlled motor based on an external command input signal; and (g) machine control means connected to the electronic controller means for producing the motor command signal.

Claim 16

An injection molding machine for producing a molded part by injecting a molten material into mold elements forming a mold cavity defining the molded part, the machine comprising: (a) clamp means for supporting and moving the mold elements between open and closed positions; (b) injection means for injecting the molten material into the mold cavity, said injection means including a screw member rotatably and translatably carried in a tubular barrel having an end in communication with the mold cavity; (c) first drive means mechanically coupled to the clamp means for imparting relative motion to the mold elements; (d) second drive means mechanically coupled to the injection means for rotating the screw member; (e) third drive means mechanically coupled to the injection means for translating the screw member within the tubular barrel; (f) wherein more than one of the first drive means, the second drive means, and the third drive means further includes (1) a motor having a rotor, a stator comprised of a plurality of sets of three phase windings, and means for detecting angular positions of the rotor, and (2) electronic controller means for controlling the motor in response to a motor command signal, the electronic controller means being connected to the motor and including (i) a CPU for determining the characteristics of current to be applied to the motor, (ii) current controller means for producing trigger signals to regulate the current, and (iii) power amplifier means for receiving the trigger signals and applying a controlled current to the stator windings to produce a commutation effect thereby creating a controlled torque and speed for the motor; (3) the electronic controller having a CPU connected to multiplexing means for switching the trigger signals produced by the current controller means to the power amplifier means for each electronically controlled motor based on an external command input signal; and (g) machine control means connected to the electronic controller means for producing the motor command signal.