Abstract: The invention is directed to a two-stage, all-electric injection unit. More specifically, an injection unit in which the feed screw is preferably used only for plastication and the injection of the plasticized material is accomplished by a separate accumulator having an electrically driven linear actuator, such as a ball screw mechanism. The plunger of the accumulator is configured with a helical flight and is rotatable by way of a one-way clutch interposed between the plunger and the ball screw.

Abstract: A method and apparatus for verification of the linear position of a machine element driven by a motor is provided. The actual position of the element is detected and compared to an expected position. When the two positions differ from each other by more than a predetermined tolerance value for a predetermined amount of time, an error signal is generated which deactivates the motor and generates an alarm for the machine operator. Preferably, the linear position of the axis is detected by a transducer and the expected position is determined by detecting the rotary position of the motor through the use of a resolver, which is then converted to a linear equivalent through the use of the gearing ratio. The method and apparatus can detect faulty machine conditions and thereby prevent machine malfunction and/or machine damage. Preferably, the method and apparatus are used to verify the position of machine elements in an injection molding machine.

Abstract: A method and apparatus for detecting an aberrant velocity of a motor used to drive an element in a plastics processing machine, such as an injection molding machine, for example. The velocity of the motor is detected by a first sensor and a machine parameter associated with the machine operation is provided. A velocity limit is determined based upon the machine parameter and an error signal is generated when the motor velocity exceeds the velocity limit by more than a predetermined tolerance value. Preferably, the machine parameter comprises the position of the element driven by the motor, which is sensed by a sensor, such as a linear displacement transducer. The velocity limit can be based upon this measured element position as well as data entered for the particular machine, such as a minimum element position, a maximum element position, and a maximum motor velocity, such that a desired motor operating envelope is defined.

Abstract: An electro-mechanical drive apparatus uses a single variable speed motor, two one-way clutches, and a hydraulic accumulator to provide both hydraulic power for the linear motion axes and rotation of the plasticizing screw in an injection molding machine. When engaged, the first one-way clutch couples the drive motor to the pump stack, while the second one-way clutch couples the motor to the feed screw. During rotation of the drive motor in a forward direction; (a) the first one-way clutch engages, rotating the shaft of the hydraulic pump stack to power the machines hydraulic systems and charge the accumulator; and (b) the second one-way clutch slips. When the drive motor is rotated in a reverse direction, (a) the second one-way clutch engages, rotating the feed screw, and (b) the first one-way clutch slips. Preferably, the drive apparatus is associated with a double shaft motor mounted adjacent separate drive couplings for the feed screw and hydraulic pump stack.

Abstract: An accumulator head is convertible to alternate capacity ranges by providing a construction that has a segmented barrel with a matching ram in the purging system. More specifically, the accumulator barrel is divided into upper and lower segments so that the accumulator chamber is bounded by the lower barrel segment. The inner diameter of the lower barrel segment matches the outer diameter of the ram, and the length of the lower barrel segment corresponds roughly to the range of movement of the ram. With this accumulator construction, it is possible to change the working volume of the internal accumulator chamber by simply changing two parts, i.e., the lower barrel segment (inner diameter) and the ram (outer diameter). In addition, the two piece accumulator barrel design facilitates a more economical construction since the lower segment (where most of the wear occurs) can be made of a wear resistant grade of steel, while the upper segment can be manufactured from a lower cost, more easily machined material.

Abstract: A two-platen injection molding machine without tie bars has a platen fixed relative to the machine frame and a platen that moves relative to it, a traverse mechanism that operates the movable platen, a device for generating clamping force and a device to compensate for the deformation forces occurring during generation of the clamping force. The traverse mechanism and the device for generating clamping force are decoupled. Preferably, the device for generating clamping force has at least one connecting rod that passes through both the fixed and movable platens beneath the mold space. The connecting rod is detachably fastened to one of the platens and can be locked to the other platen by means of a clamping device that produces the clamping force. The device to compensate for the deformation forces includes at least one rigid spacer detachably fastened at one end to one platen, while the other end of the spacer is forced against the other platen.

Abstract: A method and apparatus for measuring a misting property of fluids, the method and apparatus simulating mist generation of fluids in machining processes. Fluid is supplied to mist generating means in an enclosure and energy input to the fluid by the mist generating means is controlled. Mist laden gas flows from the vicinity of mist generation to a mist concentration measuring means. Droplets of relatively large mass are removed from the mist prior to the flow of gas reaching the mist concentration measuring means. To further simulate machining processes, the fluid of interest is recirculated from a reservoir through the mist generating means. Mist concentration measurements produced under the same conditions for fluids of different compositions are compared to characterize the misting properties of fluids.

Abstract: An aqueous machining fluid admixture comprises water, a sulfurized oil and a water soluble salt of a dimercaptothiadiazole wherein the weight ratio of the sulfurized oil to the water soluble salt of dimercaptothiadiazole is in the range of from about 15:1 to about 45:1. A method employs the fluid by applying the fluid at the interface between tool and workpiece in shaping or working operations of metallic and solid non-metallic workpieces. The fluid is particularly effective in grinding operations to produce improved grinding ratios.

Abstract: The invention is directed to a two-stage, all-electric injection unit. More specifically, an injection unit in which the feed screw is preferably used only for plastication and the injection of the plasticized material is accomplished by a separate accumulator having an electrically driven linear actuator, such as a ball screw mechanism. The accumulator is configured so that the ratio of the piston stroke to the piston diameter is preferably in the range of ten to fifteen. In the preferred embodiment there are separate motors for rotation of the screw and operation of the accumulator. An alternate embodiment is disclosed wherein the system is driven with a single motor and one-way clutches.

Abstract: An apparatus for heating and blending thermoplastic material prior to delivering the material into the barrel of an extruder. The apparatus, has an elongated housing which contains two intermeshing feed screws that are driven to rotate in the same direction. Controlled heating is provided by electric band heaters which encircle the exterior of the housing, and electric cartridge heating elements fitted into aluminum cores that are received by an axial bore in each of the feed screws.

Abstract: The accumulator of an extrusion blow molding machine is constructed so that the programming cylinder and die adjustment rod have axially aligned bores to receive a die pin retaining rod. The retaining rod holds the die pin in place by means of a lower split ring that nests inside the die pin and a lock nut combined with an upper split ring associated with the programming cylinder. When the lock nut is loosened and the upper split ring is removed, the retaining rod is moved down (while the die pin is held in place) and the lower split ring is removed. The die pin is then free to slide off the retaining rod and be removed from the accumulator head.

Abstract: Grinding and regulating wheels are carried on opposed feed slides on a machine base. A workrest is fixed to the base between the opposed wheels. Wheel dressers are mounted to cross-slides on the base, behind the wheels, independent of the feed slides. CNC dressing occurs through combined transverse motions of feed slide (with wheel) and cross slide (with dresser).

Abstract: An apparatus for heating and blending thermoplastic material prior to delivering the material into the barrel of an extruder has an elongated housing which contains two intermeshing feed screws that are driven to rotate in the same direction. Controlled heating is provided by electric band heaters which encircle the exterior of the housing, and electric cartridge heating elements fitted into aluminum cores that are received by an axial bore in each of the feed screws.

Abstract: A head is positionable close to a supported composite material. A compactor on the head is movable relative to the head by a fluid actuator. A programmable valve means ports air into the actuator at several different pressures to provide variable compaction force.

Abstract: A machine tool spindle is supported at its spindle nose in a front, rolling element mechanical anti-friction thrust and radial support bearing means. The middle and rear end of the spindle is supported in a magnetic radial rear bearing and further supported at a generally mid-position of the spindle by magnetic radial mid bearing. The two magnetic radial bearings provide radial suspension of the spindle and permit the spindle to slide freely. A spindle flange is axially forced by a magnetic axial thrust bearing to vary the pre-load of the mechanical anti-friction thrust and radial support bearing.

Abstract: An aqueous machining fluid composition having improved resistance to microorganisms is provided. The fluid composition comprises in admixture: a) water, b) a water insoluble organic lubricant, c) a surface active agent selected from the group consisting of nonionic, anionic having up to and including 12 carbon atoms, and cationic surfactants and mixtures thereof and d) a water soluble polyquaternary cationic biocide. Machining processes comprising the step of supplying said aqueous machining fluid to the interface between the tool and the workpiece are also provided.

Abstract: The present invention provides a dual flow divider for use on an extruder. The flow divider is configured to separate the melt stream received from the extruder at a central entry into two flow channels, the respective channels being formed as nearly to identical (mirror image) as is practically possible. The relative flow in the respective channels can be varied by rotating a diverter valve that extends to a position adjacent the central entry of the flow divider, i.e., where the flow begins to divide. The flow channels and control end of the diverter valve are specially configured to avoid any shape or surface conditions that would impose heat-generating restrictions to material flow, and/or allow areas of stagnation in the flow stream. More specifically, the flow channels are machined to provide smooth, streamlined transitions at all points along the flow path.

Abstract: A simple, convenient method is provided for measuring the concentration of a constituent of an aqueous fluid composition (e.g. aqueous machining fluid composition) and for measuring total alkalinity thereof.

Abstract: A single-phase method for quantitatively measuring the anionic surfactant content of an aqueous machining fluid is provided. The method is carried out at a pH value of from about 1.5 to about 3.0 and from about 9.5 to about 10.6 and involves the addition of an excess of a standardized aqueous solution of 1,3-didecyl-2-methylimidazolium chloride to the sample of aqueous machining fluid and then back titrating the excess 1,3-didecyl-2-methylimidazolium chloride with a standardized aqueous solution of polyvinylsulfuric acid potassium salt in the presence of toluidine blue indicator. Values of the amount of 1,3-didecyl-2-methylimidazolium chloride amount corresponding to anionic surfactant concentration are produced by conducting the method using a series of standard aqueous solutions containing anionic surfactant at known concentrations.

Abstract: There is provided a metalworking process, such as for example a punching process, wherein a shaping tool (eg. punch) contacts and applies a non-chip forming shaping force to a metallic workpiece (eg. blank) and there is supplied to the interface between the shaping tool and the metallic workpiece an aqueous fluid composition, having an alkaline pH, comprising water, a tall oil fatty acid, sulfurized lard oil, a sulfurized olefin, an oxyethylene/oxypropylene random or block copolymer diol having an average molecular weight in the range of from about 1000 to 8000 and an organic phosphate ester such as for example poly (1,2-ethanediyl) alpha-isodecyl-omega hydroxy phosphate. Reduced forces, lower friction and improved tool life are observed.