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This paper proposes a turbo injection mode (TIM) for an axial flux motor to apply onto injection molding machine. Since the injection molding machine requires different speed and force parameters setting when finishing a complete injection process. The interleaved winding structure in the motor provides two different injection levels to provide eno...
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Citations
... With the discovery of the dramatically continuous warpage of a large thin-walled workpiece during the free-cooling stage after ejection [71], Wen et al. [72] investigated the combined effect of processing parameters on warpage in injection and free-cooling stages of a type of motorcycle seat support made of polypropylene (PP) with the combination of the Taguchi method and finite element modeling (FEM) analysis. In the same way, an approach of manufacturing a hard mold with micro-features for microplastic injection molding was proposed, which significantly reduced a new optical element development cycle time [73]. In order to raise the persuasiveness and confidence, multiple criteria including practicality, efficacy, ease of construction, and adequate accuracy were considered collectively to favor the Taguchi method. ...
... In addition, particle swarm optimization (PSO) [60,61,73,104,[115][116][117][118][119], model-free optimization (MFO) [120,121], support vector machines (SVM) [122], simulated annealing, and hill-climbing are all advanced and effective ways to conduct the optimization design of process parameters. These models can be used to construct a mathematical approximation to replace expensive finite element analyses. ...
The quality control of plastic products is an essential aspect of the plastic injection molding (PIM) process. However, the warpage and shrinkage deformations continue to exist because the PIM process is easily interfered with by several related or independent process parameters. Thus, great efforts have been devoted to optimizing process parameters to minimize the warpage and shrinkage deformations of products during the last decades. In this review, we begin by introducing the manufacturing process in PIM and the cause of warpage and shrinkage deformations, followed by the mechanism about how process parameters, like mold temperature, melt temperature, injection rate, injection pressure, holding pressure, holding and cooling duration, affect those defects. Then, we summarize the recent progress of the design of experiments and four advanced methods (artificial neural networks, genetic algorithm, response surface methodology, and Kriging model) on optimizing process parameters to minimize the warpage and shrinkage deformations. In the end, future perspectives of quality control in injection molding machines are discussed.
... Kuo and Chang suggested a turbo injection mode (TIM) for a pivotal transition engine that can provide specific injection force onto a compactly designed IM machine. Figure 3 illustrates the two-wyewye winding structure of such a machine, and it can be operated in two distinct levels of speed range (Kuo & Chang, 2015). Composites fabricated by injection molding IM process is a popular manufacturing method for mass production. ...
... Axial-flux motor (on the left-hand side) in the plastic injection-molding machine (adapted fromKuo & Chang, 2015) ...
For the last couple of decades, researchers have been trying to explore eco-friendly materials which would significantly reduce the dependency on synthetic fibers and their composites. Natural fiber-based composites possess several excellent properties. They are biodegradable, non-abrasive, low cost, and lower density, which led to the growing interest in using these materials in industrial applications. However, the properties of composite materials depend on the chemical treatment of the fiber, matrix combination, and fabrication process. This study gives a bibliographic review on bio-composites specially fabricated by the injection-molding method. Technical information of injection-molded natural fiber reinforcement-based composites, especially their type and compounding process prior to molding, are discussed. A wide variety of injection-molding machines was used by the researchers for the composite manufacturing. Injection-molded composites contain natural fiber, including hemp, jute, sisal, flax, abaca, rice husk, kenaf, bamboo, and some miscellaneous kinds of fibers, are considered in this study.
... The multiobjective optimization problem (MOP) has been widely used in the optimization of injection molding process and machine. For injection molding machine, Kuo and Chang [14] proposed a turbo injection mode (TIM) for an axial flux motor, and the particle swarm optimization (PSO) was used to find out the multiobjective optimal design solution. The product quality, energy-saving efficiency, and molding efficiency were optimized, and the corresponding multiple-objective Pareto-optimal set was obtained. ...
It is still a challenge to achieve the polymer replication of high aspect ratio micro-structured surface especially when the completed and unified replication quality is required. This paper shows a new method for the replication named ultrasonic vibration micro-injection mold (μUVIM) technology which combines the micro-injection mold (μIM) with ultrasonic vibration. An experimental mold that integrates micro-injection compression mold (μICM) and μUVIM has been designed. In this paper, the effect of important process parameters on the replication quality of microstructure was studied via μUVIM experiment, and the process parameters were optimized through the response surface method (RSM). Compared with replication methods based on μICM technology, the μUVIM technology discussed in this paper can increase the average height of the microstructure by 14.6% and increase the production efficiency by three times. Moreover, it has been found that the μUVIM technology is insensitive to the thickness of the polymer substrate, so it can widen the processing scope of microstructure with high aspect ratio.
... The multiobjective optimization problem (MOP) has been widely used in the optimization of injection molding process and machine. For injection molding machine, Kuo and Chang [14] proposed a turbo injection mode (TIM) for an axial flux motor, and the particle swarm optimization (PSO) was used to find out the multiobjective optimal design solution. The prod- uct quality, energy-saving efficiency, and molding efficiency were optimized, and the corresponding multiple-objective Pareto-optimal set was obtained. ...
... The multiobjective optimization problem (MOP) has been widely used in the optimization of injection molding process and machine. For injection molding machine, Kuo and Chang [14] proposed a turbo injection mode (TIM) for an axial flux motor, and the particle swarm optimization (PSO) was used to find out the multiobjective optimal design solution. The product quality, energy-saving efficiency, and molding efficiency were optimized, and the corresponding multiple-objective Pareto-optimal set was obtained. ...
Injection molding process parameters (IMPP) have a significant effect on the optical performance and surface waviness of precision plastic optical lens. This paper presents a set of procedures for the optimization of IMPP, with haze ratio (HR) reflecting the optical performance and peak-to-valley 20 (PV 20) reflecting the surface waviness as the optimization objectives. First, the orthogonal experiment was carried out with the Taguchi method, and the results were analyzed by ANOVA to screen out the IMPP having a significant effect on the objectives. Then, the 3 4 full-factor experiment was conducted on the key IMPP, and the experimental results were used as the training and testing samples. The BPNN algorithm and the M-SVR algorithm were applied to establish the mapping relationships between the IMPP and objectives. Finally, the multiple-objective optimization was performed by applying the nondominated sorting genetic algorithm (NSGA-II), with the built M-SVR models as the fitness function of the objectives, to obtain a Pareto-optimal set, which improved the quality of plastic optical lens comprehensively. Through the experimental verification on the optimization results, the mean prediction error (MPE) of HR and PV 20 is 7.16% and 9.78%, respectively, indicating that the optimization method has high accuracy.
... The multiobjective optimization problem (MOP) has been widely used in the optimization of injection molding process and machine. For injection molding machine, Kuo and Chang [14] proposed a turbo injection mode (TIM) for an axial flux motor, and the particle swarm optimization (PSO) was used to find out the multiobjective optimal design solution. The product quality, energy-saving efficiency, and molding efficiency were optimized, and the corresponding multiple-objective Pareto-optimal set was obtained. ...
Injection molding process parameters (IMPP) have a significant effect on the optical performance and surface waviness of precision plastic optical lens. This paper presents a set of procedures for the optimization of IMPP, with haze ratio (HR) reflecting the optical performance and peak-to-valley 20 (PV 20 ) reflecting the surface waviness as the optimization objectives. First, the orthogonal experiment was carried out with the Taguchi method, and the results were analyzed by ANOVA to screen out the IMPP having a significant effect on the objectives. Then, the 3 ⁴ full-factor experiment was conducted on the key IMPP, and the experimental results were used as the training and testing samples. The BPNN algorithm and the M-SVR algorithm were applied to establish the mapping relationships between the IMPP and objectives. Finally, the multiple-objective optimization was performed by applying the nondominated sorting genetic algorithm (NSGA-II), with the built M-SVR models as the fitness function of the objectives, to obtain a Pareto-optimal set, which improved the quality of plastic optical lens comprehensively. Through the experimental verification on the optimization results, the mean prediction error (MPE) of HR and PV 20 is 7.16% and 9.78%, respectively, indicating that the optimization method has high accuracy.
Injection molding is one of the most significant material processing methods for mass production of plastic products. It is widely used in various industry sectors, and its products are ubiquitous in our daily life. The settings and optimization of the injection molding process dictate the geometric precision and mechanical properties of the final products. Therefore, sensing, optimization, and control of the injection molding process have a crucial influence on product quality and have become an active research field with abundant literature. This paper defines the concept of intelligent injection molding as the integral application of these three procedures—sensing, optimization, and control. This paper reviews recent studies on methods for the detection of relevant physical variables, optimization of process parameters, and control strategies of machine variables in the molding process. Finally, conclusions are drawn to discuss future research directions and technologies, as well as algorithms worthy of being explored and developed.
This study focused on the development a comprehensive design optimisation framework for line-start permanent magnet synchronous machines (LS PMSM) that could effectively consider both steady-state and transient synchronisation performance objectives. The use of Taguchi method for robust design was adopted and improvements were implemented to be suited for use in an iterative design optimisation. An analytical synchronisation criterion was defined and used as a quantifiable performance objective in the design optimisation. The proposed framework effectively realised a balanced, robust design for the most commonly used LS PMSM rotor topologies.
There has been a considerable amount of research work on using the Taguchi method for
electrical machine design in recent years. However, for the large community of electrical machine
designers, this method is still less known. The purpose of this paper is to summarise the past and
current research work of applying the Taguchi method in electrical machine designs. We attempt to
give readers some insight into the advantages and disadvantages, challenges, current status and future
perspective of the method.
