Energy management apparatus and method for injection molding systems

An injection molding system control apparatus, comprising:

• a first electrically-driven prime mover configured to drive at least a first molding machine device;
• a second electrically-driven prime mover configured to drive at least a second molding machine device;
• a common DC link configured to provide DC energy to said first electrically-driven prime mover and to said second electrically-driven prime mover;
• a slave axis configured to supply and absorb energy from to/from said common DC link;
• a non-electrical energy accumulation structure configured to supply energy to said common DC link, and to absorb energy from said common DC link;
• and
• a machine controller configured to (i) communicate with said first electrically-driven prime mover, said second electrically-driven prime mover, said common DC link, and said slave axis, (ii) cause said slave axis to supply energy to said common DC link in response to input from at least one of said first electrically-driven prime mover and said second electrically-driven prime mover, and (iii) cause said slave axis to absorb energy from said common DC link in response to input from at least one of said first electrically-driven prime mover and said second electrically-driven prime mover.

An injection molding system control apparatus, comprising:

• a first electrically-driven prime mover configured to drive a hydraulic molding machine device;
• a second electrically-driven prime mover configured to drive at least another molding machine device;
• a common DC link configured to provide DC energy to said first electrically-driven prime mover and to said second electrically-driven prime mover;
• a slave axis configured to supply and absorb energy from to/from said common DC link;
• a machine controller configured to (i) communicate with said first electrically-driven prime mover, said second electrically-driven prime mover, said common DC link, and said slave axis, (ii) cause said slave axis to supply energy to said common DC link in response to input from at least one of said first electrically-driven prime mover and said second electrically-driven prime mover, and (iii) cause said slave axis to absorb energy from said common DC link in response to input from at least one of said first electrically-driven prime mover and said second electrically-driven prime mover;
• and
• a hydraulic energy accumulation structure, coupled to said first electrically-driven prime mover, and configured to store and release energy through receipt and release of hydraulic fluid.

An injection molding system control apparatus, comprising:

• a first electrically-driven prime mover configured to drive a mechanical molding machine device;
• a second electrically-driven prime mover configured to drive at least another molding machine device;
• a common DC link configured to provide DC energy to said first electrically-driven prime mover and to said second electrically-driven prime mover;
• a slave axis configured to supply and absorb energy from to/from said common DC link;
• a machine controller configured to (i) communicate with said first electrically-driven prime mover, said second electrically-driven prime mover, said common DC link, and said slave axis, (ii) cause said slave axis to supply energy to said common DC link in response to input from at least one of said first electrically-driven prime mover and said second electrically-driven prime mover, and (iii) cause said slave axis to absorb energy from said common DC link in response to input from at least one of said first electrically-driven prime mover and said second electrically-driven prime mover;
• and
• a flywheel, coupled to said first electrically-driven prime mover, and configured to store and release energy through movement of said flywheel.

Energy management apparatus for a molding machine having (i) a first motor configured to drive a first molding machine device, and (ii) a second motor configured to drive a second molding machine device, said apparatus comprising:

• an electrical link coupled to the first motor and to the second motor;
• non-electrical energy storage structure configured to (i) store excess energy from at least one of the first motor and the second motor, and (ii) provide stored excess energy to at least one of the first molding machine device and the second molding machine device;
• and
• processing structure configured to cause (i) excess energy from the first motor to be stored in said energy storage structure, and (ii) excess energy stored in said energy storage structure to be used to drive at least the first molding machine device.

An injection molding machine, comprising:

• a mold;
• a mold clamp having a mold clamp actuator;
• a mold screw having a mold screw actuator;
• an electrical link coupling said mold clamp actuator and said mold screw actuator;
• an non-electrical energy accumulator coupled to at least one of said mold clamp actuator and said mold screw actuator;
• and
• energy management processing structure configured to cause (i) excess energy from at least one of said mold clamp actuator and said mold screw actuator to be stored in said energy accumulator, and (ii) energy stored in said energy accumulator to be provided to at least one of said mold clamp actuator and said mold screw actuator.

A method for managing energy in a molding machine having a first actuator for driving a first molding device and a second actuator for driving a second molding device, said method comprising the steps of:

• receiving from the first actuator an input signal corresponding to the energy status of the first actuator;
• receiving from the second actuator an input signal corresponding to the energy status of the second actuator;
• calculating an excess energy condition of any of the first actuator and the second actuator based on the received input signals;
• calculating an insufficient energy condition of any of the first actuator and the second actuator based on the received input signals;
• based on the calculation, providing excess energy from at least one of the first actuator and the second actuator to an energy accumulation device;
• and
• based on the calculation, providing excess energy from the energy accumulation device to at least one of the first actuator and the second actuator.

A computer readable medium containing instructions which cause a processing structure in a molding machine that has (i) a first actuator for driving a first molding device and (ii) a second actuator for driving a second molding device, to perform the following steps:

• receiving from the first actuator an input signal corresponding to the energy status of the first actuator;
• receiving from the second actuator an input signal corresponding to the energy status of the second actuator;
• calculating an excess energy condition of any of the first actuator and the second actuator based on the received input signals;
• calculating an insufficient energy condition of any of the first actuator and the second actuator based on the received input signals;
• based on the calculation, causing excess energy from at least one of the first actuator and the second actuator to be provided to an energy accumulation device;
• and
• based on the calculation, causing excess energy from the energy accumulation device to be provided to at least one of the first actuator and the second actuator.