Note: Descriptions are shown in the official language in which they were submitted.
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METHOD AND APPARATUS FOR CONFIGURING, ORDERING AND MANAGING THE
FABRICATION IN A FACTORY OF AN INJECTION MOLDING MACHINE
APPARATUS USING A DISTRIBUTED COMPUTING SYSTEM
TECHNICAL FIELD
The Internet, which started in the late 1960s, is a vast
computer network consisting of many smaller networks that span
the entire globe. The Internet has grown exponentially, and
1o millions of users ranging from individuals to corporations now
use permanent and dial-up connections to use the Internet on a
daily basis worldwide. The computers, or networks of computers
connected within the Internet, known as "hosts", allow public
access to databases featuring information in nearly every field
of expertise and are supported by entities ranging from
universities and government to many commercial organizations.
BACKGROUND OF THE INVENTION
2o The information on the I~.ternet is made available to the
public through "servers". A server is a system running on an
Internet host for making available files or documents contained
within that host. Such files are typically stored on magnetic
storage devices, such as fixed disks, local to the host. An
Internet server may distribute information to any computer that
requests the files on a host. The computer making such a request
is known as the "client", which may be an Internet-connected
workstation, bulletin board system or home personal computer
(PC) .
TCP/IP (Transmission Control Protocol/Internet Protocol) is
one networking protocol that permi.ts..;:full use of the Internet.
All computers on a TCP/IP network need unique ID codes.
Therefore, each computer or host on the Internet is identified
by a unique number code, known as the IP (Internet Protocol)
number or address, and corresponding network and computer names.
In the past, an Internet user gained access to its resources
only by identifying the host computer and a path through
directories within the host's storage to locate a requested
4o file. Although various navigating tools have helped users to
search resources on the Internet without knowing specific host
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addresses, these tools still require a substantial technical
knowledge of the Internet.
The World-Wide Web (Web) is a method of accessing
information on the Internet which allows a user to navigate the
Internet resources intuitively, without IP addresses or other
technical knowledge. The Web dispenses with command-line
utilities which typically require a user to transmit sets of
commands to communicate with an Internet server. Instead, the
1o Web is made up of hundreds of thousands of interconnected
"pages", or documents, which can be displayed on a computer
monitor. The Web pages are provided by hosts running special
servers. Software which runs these Web servers is relatively
simple arid is available on a wide range of computer platforms
l5 including PC's. Equally available is a form of client software,
known as a Web "browser" , which is used to display Web pages as
well as traditional non-Web files on the client system. Today,
the Internet hosts which provide Web servers are increasing at a
rate of more than 300 per month, en route to becoming the
2o preferred method of Internet communication.
Created in the early 1990s, the Web is based on the concept
of "hypertext" and a transfer method known as "HTTP" (Hypertext
Transfer Protocol). HTTP is designed to run primarily over
25 TCP/IP and uses the standard Internet setup, where a server
issues the data and a client displays or processes it. One
format for information transfer is to create documents using
Hypertext Markup Language (HTML). HTML pages are made up of
standard text as well as formatting codes which indicate how the
3o page should be displayed.. The Web client, a browser, reads these
codes in order to display the page.
Each Web page may contain pictures and sounds in addition
to text. Hidden behind certain text, pictures or sounds are
35 connections, known as "hypertext links" ("links"), to other
pages within the same server or even on other computers within
the Internet. For example, links may be visually displayed as
words or phrases that may be underlined or displayed in a second
color. Each link is directed to a web page by using a special
40 name called a URL (Uniform Resource Locator) . URLs enable a Web
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browser to go directly to any file held on any Web server. A
user may also specify a known URL by writing it directly into
the command line on a Web page to jump to another Web page.
The URL naming system consists of three parts: the transfer
format, the host name of the machine that holds the file, and
the path to the file. An example of a URL may be:
http://www.sitename.com/Adir/Bdir/Cdir/page.html,
where "http" represents the transfer protocol; a colon and two
forward slashes (://) are used to separate the transfer format
from the host name; "www.sitename.com" is the host name in which
"www" denotes that the file being requested is a Web page;
"/Adir/Bdir/Cdir" is a set of directory names in a tree
structure, or a path, on the host machine; and "page.html" is
the file name with an indication that the file is written in
HTML.
2o Therefore, with the click of the mouse, a user can be
presented with information as well as a chance to collaborate
with that information. The power of the web is the ability to
share information instantaneously around the world and to allow
users to interact with this data. Before the web, collaborative
communication was either by phone or face-to-face. The web
allows interactive collaboration at reduced cost and
considerable time savings. Many web sites exist today that
allow a user to search through an online catalog and order
common retail products like music CDs, books and flowers. These
3o sites are not truly collaborative because the product is already
fully configured and ready for purchase.
Within the plastics industry, a company that has developed
a new plastic product will need to purchase an injection molding
machine apparatus to injection mold this new product for the
product's release. Based on the plastic product's design, the
company establishes specific requirements that the molding
machine must meet. These requirements include not only machine
performance, but will also include machine cost, delivery time,
4o maintenance cost and the like.
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Matching the requirements the plastics company has
established to a machine is often a time consuming and laborious
process due to the many factors that must be analyzed to arrive
at a final machine configuration. For example, a typical set of
machine parameters that must be considered in choosing an
injection molding machine include part size, resin. type, mold
design, and desired machine throughput to name just a few.
1o Following what may be weeks of face-to-face and phone
collaboration between the injection molding machine manufacturer
and the customer, a machine configuration is agreed upon and a
machine is placed on order. Typical delivery times for an
injection molding machine can vary greatly depending on the size
and complexity of the machine. Specifically, according to the
prior art, custom hot runner systems can be delivered in 8-10
weeks. This long lead time is often not acceptable for many
customers and the industry is currently under pressure to reduce
this lead time to 3-4 weeks.
Once an order is placed, numerous documents are created to
facilitate the building of the machine. These documents are
typically stored both electronically in computer systems as well
as in hard copy format. These documents can include Computer
Aided Drawings (CAD) of the machine Configuration, sales
contract, schedules, bill of materials (BOM), inspection
reports, change reports, shipping records, etc. If the buyer of
the machine would like access to any of these documents,
typically they will contact the manufacturer and obtain hard
3o copies of the documents. This method of information sharing has
proven time consuming and prone to errors.
Following the placing of the order, changes may occur in
the machine configuration based on customer input. Due to the
disparate computing environments currently being used, managing
changes to the machine configuration is extremely difficult and
prone to error. Errors in the machine configuration often
result in rework and delays in delivery to the customer. Errors
can occur at many points along the communication chain. The
4o customer may provide erroneous information due to an internal
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error. The manufacturer may misinterpret the change request and
incorrectly change the configuration of the machine. Often a
change that was requested never made it into the machine
configuration paper work and therefore the requested change was
never implemented. There are many potential sources for error
due to the current mode of communication between manufacturer
and customer.
To track progress, a customer often requests periodic
updates of when the machine is expected to arrive at their
factory. Reporting status back to the customer is also very
time consuming and error prone. Tracking progress of an order
as it progress through the factory requires manually tracking
where the order is in the overall process.
Often, a customer may need CAD drawings of the machine they
have ordered so they may order other products that interface
with the machine. These CAD drawings are created by the machine
manufacturer and are provided to the customer some time after
2o the order is placed. Each time a change is made to the machine,
these drawings are manually updated and delivered to the
customer for approval and acceptance. This manual process
results in errors, delivery delays and increased cost.
Therefore, an improved system and method is needed that
utilizes the collaborative power of the web and other Internet
based technologies to facilitate the configuration, ordering and
tracking of an injection molding machine apparatus.
SUMMARY OF THE INVENTION
The primary objective of the invention is to provide an
online collaborative system for the configuring, ordering and
status reporting of an injection molding machine apparatus.
.Another object of the invention is to provide an online
means for communicating configuration changes to an injection
molding machine apparatus from a customer to the manufacturer.
4o A further object of the invention is to provide an
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interactive web site where a customer can configure and order an
injection molding machine apparatus without the need for offline
collaboration.
Still another object of the invention is to provide an
online system for requesting changes to an already ordered
injection molding machine apparatus.
Still a further object of the invention is to provide an
online system that allows customers to generate a set of CAD
drawings of an injection molding machine apparatus based on the
customers selected configuration.
Still another object of the invention is to provide an
online system for obtaining up-to-date status and delivery
information of a previously ordered injection molding machine
apparatus.
Yet another object of the invention is to provide an online
2o collaborative system that reduces errors in the communication of
changes to a machine configuration.
Still another object of the invention is to provide an
online collaborative system that reduces the time required to
fabricate an injection molding machine apparatus.
The foregoing objects are achieved in an arrangement
comprising a plurality of computers connected to a digital
computer network, the network carrying and routing digital
3o information between the computers. At least one of the
computers is an Internet based server which contains a database
of injection molding machine apparatus design information. The
server communicates over the network to a plurality of buyer
computers to provide a collaborative computing environment where
a buyer can easily configure and order an injection molding
machine apparatus without the need for extensive person to
person collaboration. Once the customer has fully configured
the injection molding machine apparatus a purchase order for the
fully configured injection molding apparatus is generated by the
4o customer while online.
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Based on the customer's selected configuration, the server
generates a dataset that includes the ordered machine's CAD
files, financial information, bill of material and fabrication
status that may be easily viewed online by the customer. Each
order will be assigned a unique order number that will allow a
customer to securely review status and design documentation as
well as submit changes and/or questions to the machine
manufacturer using a computer connected to a server over a
1o computer network.
BRIEF' DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic diagram of the invention;
FIG. 2 is a simplified block diagram representing the
elements of a typical injection molding apparatus design
database, specifically directed towards a hot runner;
FIG. 3 is a simplified block diagram representing the
elements that comprise an order dataset;
FIG. 4, 4a, 4b, 4c, 4d is a series of simplified flow
diagrams of the online interactive computer system directed
towards a hot runner;
FIG. 5 is a simplified flow diagram showing the online
configuration and collaborative design process for an injection
molding machine apparatus directed towards a hotrunner
subsystem;
FIG. 5a is a continuation of the simplified flow diagram
showing the online configuration and ordering system;
FIG. 6 is a flow diagram of the off-line prior art method
of ordering a hot runner subsystem and its associated timeline;
FIG. 7 is a flow diagram of the online configuration and
ordering of a hot runner subsystem and its associated reduced
timeline over the prior art;
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FIG. 8 is a isometric view of a typical hot runner
subsystem.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(SZ
The present invention will be described in the context of
the exemplary Internet based hot runner design and ordering
system 10 shown in FIG. 1. Since the majority of the detailed
1.o specification will concentrate on the online design and
configuring of an injection molding hot runner subsystem, a
simplified view of a hot runner is provided in FIG 8.
The hot runner subsystem comprises a heated hot runner
manifold 158 sandwiched between an insulator board 146 and a
mold base 132. The subsystem further includes a plurality of
nozzle assemblies 142 which interface with melt channels within
the heated manifold 158 to deliver molten plastic to a mold or
cavity (not shown). A sprue bushing 150 is inserted through the
2o insulator board 146 and interfaces with the manifold 158 for
communication of molten plastic from the injection molding
machine (not shown). An electrical connector 130 is attached to
the mold base 132 to provide power to a manifold heater 160
which maintains the plastic in a molten state when flowing
through the manifold 158. The distance between nozzle
assemblies 142 is known as the nozzle pitch 138. A locating
ring 147 is mounted to a face of the insulator board 146 around
the sprue bushing 150 which helps maintain alignment between the
hot runner subsystem and the injection machine (not shown). A
3o plurality of locating pins 143 protrude from the face of the
mold base 132 to help maintain alignment of the hot runner
subsystem with the cavity mold (not shown) . A thermocouple 131
is mounted in the manifold 158 and measures the temperature of
the manifold 158 during the injection molding process. The
thermocouple's electrical power and the return signal are
provided through the electrical connector 130.
Referring to FIG. 8, the operation of a hot runner will now
be described. Molten plastic flows from the injection molding
4o machine (not shown) into the sprue bushing 150. The molten
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plastic flows through the sprue bushing 150 to the channels
located in the manifold 158. The manifold 158 is maintained at
an elevated temperature by a manifold heater 160 which is
embedded in the surface of the manifold 158 to maintain the
plastic in a molten state. As the molten plastic flows through
the channels of the manifold 158, the flow splits so that an
equal amount of molten material is delivered to each nozzle
assembly 142. The molten plastic then flows through each nozzle
assembly 142 and into a respective mold/cavity (not shown).
While FIG. 8 depicts a hot runner subsystem with two nozzle
assemblies 142, it is not uncommon to have much larger systems
that contain forty-eight o.r ninety-six such nozzle assemblies.
A networked design and configuration system 10 as shown in
FIG. 1 employs a communications network 18 to interconnect a
plurality of buyer computers 12a, 12b, and 12c for example to at
least one merchant computer 14. The merchant computer 14
contains a hot runner design database 16 and the digital storage
of unique customer datasets 20. A user of the system employs a
2o buyer computer 12 to retrieve information from the hot runner
design database 16 and create a new unique customer dataset 20
for storage on the merchant computer 14. The unique customer
dataset 20 contains a complete set of digital documents that
would comprise and define a hot runner configuration and
purchase request.
Now referring to FIG. 2, in a hot runner design database
16, various design parameters are stored separately for
selection by a customer. In a typical hot runner subsystem, the
design parameters that must be configured so that it interfaces
with the overall injection molding machine include as a minimum
a locating ring interface 32, a sprue bushing interface 30, a
platen mounting method 28, nozzle locations 26, mold plate
compatibility parameters 24, a valve gate style parameter 22 and
an electrical connection interface 21. With the selection of
the above design. parameters, the design and configuration of a
hot runner subsystem can be fully designed and the merchant
computer 14 may initiate the creation and storage of the unique
customer dataset 20.
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Referring to FIG. 3, a unique customer dataset 20 is
generated by the merchant computer 14 based on the selections
transmitted by at least one buyer computer 12. In a typical
customer dataset 20 a digital CAD file 50 is stored that
describes the engineering design of the instant hot runner for
downloading or online viewing. Also included in the customer
dataset 20 is a digital bill of materials 52 which lists the
quantities and descriptions of every discrete part that make up
the instant hot runner. Once the customers hot runner is
configured, it is possible to prepare a schedule 54 which shows
each discrete step and the estimated time duration for each step
in the hot runner manufacturing process. This schedule 54 may
be continually updated based upon changes that may occur
following the original order entry. The schedule 54 may be
stored in a digital file thereby allowing easy online viewing,
downloading or printing.
In the event a customer or the merchant needs to request a
change to the hot runner Configuration, a change request 56
2o would be generated which would document the specifics
surrounding the required change. Managing the changes that
occur to a specific order has always been a troublesome process
due to the many opportunities for mis-communication of the
requested change. Providing a central location and the digital
storage of these change request 56 will insure instant and
consistent communication of the required change.
Other digital documents that make up a customer dataset 20
further comprise a purchase order 58, a sales Contract 60, a
3o sales agreement 62, and a statement of work 72. Each of these
digital documents are used to define the legally specific
relationship arid agreement between the merchant and the b-ia.yer.
These documents will be automatically generated based upon the
buyer's selections during the ordering process. With recent US
laws enacted that allow for legally binding contracts to be
entered using digital signature technology, optionally a buyer
could employ such technology to sign and consummate the order of
the hot runner completely online. In the alternative, the
documents may be printed out, signed and then computer scanned
4o and saved as computer readable image files.
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During the manufacturing of the hot runner subsystem,
buyers frequently require status updates to determine if
everything is on schedule. Included in the customer dataset 20
is a status report 64 that is constantly updated to show the
current status of the item placed on order as it goes through
the various stages of the manufacturing process. This status
report 64 may be readily compared to the original schedule 54 to
determine if corrective action is required due to a schedule
1o slip. The status report 64 may be updated by shop floor
personnel as the hot runner subsystem goes from manufacturing
process to process. The online status report 64 provides
instant feedback to the customer and reduces the burden placed
on the merchant who, based on the prior art, must constantly
prepare these status reports manually and are often out of date.
Through the course of manufacturing the hot runner
subsystem, various inspections are performed to insure the item
is manufactured in accordance with a product specification 70.
Available on line for viewing, downloading or printing is a
series of inspection reports 66 which indicate inspections that
have been performed as well as any out of specification
measurements or occurrences. Tn the event an inspection reveals
an unacceptable condition, corrective action must be performed
to place the item back into an acceptable condition. A
corrective action report 68 would be generated and made
available online if this occurs. The corrective action report
68 will include the methods employed to remedy the situation as
well as the outcome of the corrective action.
Also include in the customer dataset 20 will be digital
documents that indicate the financial status of the order. A
financial account statement 74 will indicate payments received
by the merchant from the buyer relative to that particular
order. The financial account statement 74 may also include
adjustments to the buyer account based on other events during
the fabrication of the hot runner subsystem.
The online use of the customer dataset 20 is advantageous
4o because it creates a central location or repository for all the
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information that comprises an order, and allows quick and easy
access for the buyer and the merchant. Using well known
information management techniques, a buyer or merchant can also
quickly parse out specific data from each customer dataset 20
and create a report to show status and items on a larger scale.
For example, a customer who has multiple orders at the same
time may wish to see an overall status report for all of these
open orders in one convenient document. Database manipulation
techniques may easily be employed while the buyer is online to
generate such a report and provide the report to the buyer for
online viewing, downloading or printing.
Ref erring to FIG. 4, 4a, 4b, 4c, and 4d, the online design
and configuration process of a hot runner subsystem will now be
described. A buyer computer 12 will connect with a merchant
computer 14 over a communications network 18 (FIG. 4, item 300).
The buyer computer 12 will typically employ a client browser
program to view the data available on the merchant computer 14.
The merchant computer 14 will typically employ an Internet
2o server program to respond to requests by the client browser
program. The buyer computer 12 will have displayed a menu of
choices which may be selected by the buyer, typically by the
click of a mouse which is connected to the buyer computer 22.
Tn the present invention, these menu of choices include a create
new account option (FIG. 4, item 302), a place order/configure
hot runner option (FIG. 4, item 318), a review orders option
(FIG. 4, item 332) and a request change option (FIG. 4, item
348 ) .
The first time a user connects to the merchant computer 14,
they must create an account so they may enter an order.
Selecting the create new account option (FIG. 4, item 302), the
user is presented with a series of steps as shown in FIG. 4a. A
new user will be required to submit basic contact information
about themselves as well as the company they represent (FIG 4a,
item 304). This information will be stored and used for all
subsequent orders placed by this user and will include at a
minimum a full name, company name, address, phone number, fax
number and email address. The new user must select a unique
4o u.sername and password (FIG. 4a, item 306), which will be used to
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identify the user and allow them to place orders, review orders
and make change requests. The merchant computer 14 will verify
that the username selected is not already in use and that the
password is acceptable (FIG 4a, item 308). If the information
provided is not acceptable, an error will be presented (FIG 4a,
item 310a) to the buyer computer 12 and the user will be
requested to try a different username and/or password. If the
information is verified as acceptable, the new account will be
created (FIG 4a, item 312) and the user will be presented with a
1o confirmation screen (FIG 4a, item 314) to indicate that the
username and password has been approved. In addition, and to
create a more tangible record of the new account being created,
a confirmation email (FIG 4a, item 316) will be sent to the
user. Contained in the email will be the contact information
the user provided while creating the new account. Once the
account has been created, the user will be returned to the
merchant computer's home page (FIG. 4, item 300)..
Once an account is created, a buyer may now configure and
2o design a complete hot runner subsystem online. Selecting the
configure hot runner option (FIG. 4, item 318) will cause the
merchant computer 14 to generate and communicate with the buyer
computer 12 a collection of steps which leads the buyer through
a process to design and configure a hot runner subsystem.
Referring to FIG. 4b, the buyer must sign in using the username
and password previously created (FIG 4b, item 320). The
merchant computer 24 will then validate an account exists for
that username and the password is correct. The buyer may then
start the steps of configuring a hot runner online (FIG 4b, item
322). The detailed steps required to design and configure a hot
runner subsystem is described in FIG. 5 and FIG. 5a, and will be
described hereinafter.
Once the design and configuration process as shown in FIG.
5 and 5a (described hereinafter)is completed, the order
information is analyzed by the merchant computer (FIG 4b, item
324) to ensure all the necessary information has been provided
and meets predetermined guidelines. If an error or problem is
encountered during this analysis, an error screen is presented
(FIG 4b, item 310b) and the buyer is requested to take
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corrective action. Upon verification of the order information,
an order ID will be generated and the data provided by the buyer
will be used to generate the customer dataset 20 for this order.
The customer dataset 20 will be generated almost instantly
while the buyer is online and connected to the merchant computer
14. Once the customer dataset 20 is created, a confirmation of
order screen will be presented to the user (FIG. 4b, item 328)
which will identify the order number associated with this order
as well as the pertinent information required to help the buyer
1o identify this order. A confirmation email will also be sent to
the buyer (FIG 4b, item 330) which will contain a set of
predetermined order information. Upon completion of the
ordering process, the user will be returned to the merchant
computer's home page (FIG 4, item 300).
Once an order is placed by a buyer, that buyer may wish to
review the order details that are contained in the customer
dataset 20. Selecting the review orders option (.FIG 4, item
332) will present the buyer with a series of steps as shown in
2o FIG 4c. To review an order, the buyer must have already
established an account (FIG 4, item 302) and placed an
acceptable order (FIG 4, item 318). Selecting the review orders
option (FIG 4, item 332), the buyer will be requested to sign in
by entering their username and password (FIG 4c, item 334). The
merchant computer 14 will verify the account information (FIG.
4c, item 336) and present the buyer with a list of open orders
(FIG. 4c, item 338). If the password and username and not
verified, an error will be displayed (FIG 4c, item 310c) and the
user will be prompted to enter the correct information.
Optionally, the list of open orders would include all the orders
placed by this buyer rather than just the open orders. This
would allow a buyer to search through historical information of
previous orders which may be necessary for various technical and
business related reasons.
The buyer may select the order they wish to review (FIG.
4c, item 340) by simply clicking on one of the items in the list
of orders by using a mouse connected to the buyer computer 12.
The merchant computer 14 would then transmit to the buyer
4o computer 22 a list of available documents available for online
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viewing (FIG 4c, item 342) that are associated with that order.
The user selects the document for viewing (FIG 4c, item 344) by
clicking on the item using the mouse. The merchant computer 14
then transmits to the buyer computer 12 the selected document
where the user may further view online, download or print it
(FIG. 4c, item 346). Following this, the buyer may choose to
return to any of the earlier steps of displaying all open orders
(FIG 4c, item 338), selecting an order to review (FIG 4c, item
340), or to display the order dataset (FIG 4c, item 342).
l0 Alternatively, the buyer can be returned to the merchant
computer home page (FIG 4, item 300).
A buyer may need to make changes to the hot runner
subsystem they have ordered. In the prior art, which uses a
manual entry and response system, the management of these change
requests is prone to costly errors. It is therefore
advantageous to provide an online system that allows a buyer to
make a change request online so that each change is easily
tracked and implemented, thereby reducing the opportunity for
error.
Referring to FIG. 4, a buyer who has previously created an
account and placed an order for a hot runner subsystem may
select a request change option (FIG. 4, item 348). This option
will present the buyer with a series of steps that allow them to
review the specifics of an order by reviewing the dataset 20,
and then selectively requesting a change to the configuration of
the hot runner subsystem. Referring to FIG. 4d, the buyer must
first sign-in using their username and password (FIG 4d, item
334a). If the username and password is not verified, an error
screen is displayed (FIG. 4d, item 310d) and the buyer is
returned to the sign in screen (FIG. 4d, item 334a). The
merchant computer 14, upon validating the username and password
presents the buyer with a list of current open orders associated
with their account (FIG 4d, item 338a). The buyer then selects
the order that they wish to review by clicking on it with the
mouse (FIG. 4d, item 340a). The dataset 20 associated with this
order is then displayed which contains all the documents
associated with the selected order (FIG. 4d, item 342a). The
4o buyer may then request a change to the configuration of the hot
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runner subsystem (FIG. 4d, item 350). To submit a change
request, the buyer must supply detailed information that
adequately describes the change. A buyer then submits the
change request information to the merchant computer 14, and the
merchant computer assigns a unique change request number and
confirms receipt of the change request to the buyer (FIG. 4d,
item 352).
The manufacturer will need to determine the impact to cost
and schedule as a result of the change, and provide that
information to the buyer for approval. Only if the buyer agrees
with the cost and schedule impact will the change be
implemented. Upon approval, the dataset 20 associated with this
change will be updated to reflect the requested change. For
historical record keeping, the original dataset 20 will remain
in the online database in a separate dataset 20 in the event
previous revisions need to be reviewed.
Now referring to FIG. 5, the steps required to configure
2o and design a complete hot runner subsystem will be described.
Selecting the configure hot runner option (FIG. 4, item 318)
will present the buyer with a series of choices that will
capture the design information for a typical hot runner
subsystem (FIG 5, item 200). The first item the buyer must
select is the number of drops, or nozzles the hot runner
subsystem will need (FIG 5, item 202). Once the number of drops
is determined, the pattern of the drops must then be selected
(FIG. 5, item 204). In an effort to simplify the design process
of the hot runner subsystem, a series of discrete patterns is
3o made available. A graphical representation of each pattern is
displayed on the buyer's computer 12 to facilitate the selection
of the drop pattern. The drop pattern can range from a simple
inline configuration to a more complex pattern with multiple
branches.
Once the nozzle pattern is selected, the buyer will then select
the nozzle type (FIG. 5, item 206). There are numerous nozzle
types that are typically used on hot runner subsystems. Nozzle
types include hot tip, valve gated, and sprue gating. Each type
4o has its specific application and operating parameters and the
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buyer will make this selection based on the design of the
overall injection molding machine.
Once the nozzle type is selected, the buyer will then
select the desired spacing between the nozzles (FIG. 5, item
208). The spacing between the nozzles is known as the nozzle
pitch (FIG. 8, item 138) and a range of acceptable spacings are
available to the buyer to interface with their mold design. The
selected nozzle spacing must fall within a minimum and a maximum
1o distance based upon the nozzle type selected. For example,
using a hot tip type nozzle, the nozzles must be at least 2.362"
apart. The merchant computer 14 will perform a check of the
selected parameters to verify that the selected spacing is
within the allowable limits (FTG. 5, item 210). If the selected
nozzle spacing is not within the specified limits, the buyer
will be returned (FIG. 5, item 218) to the nozzle selection
screen (FIG. 5, item 206) and/or the drop spacing screen (FIG.
5, item 208). The next step for the buyer is to select the
nozzle L-dimension (FIG. 5, item 211). The L-dimension is the
2o distance the nozzle (FIG. 8, item 142) protrudes from the mold
base (FIG. 8, item 132). The buyer is free to choose any L
dimension that may be required to interface with their mold
design. The selection of this item in combination with the
selection of the nozzle type (FIG. 5, item 206) will determine
the thickness of the mold base (FIG. 8, item 132).
The buyer will now be required to select the mold base
manufacturer from a pre-determined list (FIG. 5, item 212).
Selecting the mold base manufacturer is required because each
manufacturer follows their own specific design guidelines.
Knowing the mold base manufacturer is required by the hot runner
manufacturer in order to determine various mechanical interfaces
between the mold base and the hot runner subsystem. The buyer
is not required to know the specifics between the different mold
base manufacturers because the merchant computer 14 stores this
information and automatically configures the hot runner
subsystem to interface with the mold base selected by the buyer.
In the preferred embodiment, the mold base manufacturer is
selected by a click of the buyer's mouse on a drop down list.
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The next step in the online design process is for the buyer
to select the units of measure used in the design of their
injection molding system (FIG. 5, item 214). Since buyers of
hot runner subsystems exist all over the world, some buyers will
prefer their designs be represented in english units, and other
buyers will prefer their designs be represented in metric units.
The CAD files 50 will be generated using the units selected
during this step.
The next step in the process requires the buyer to provide
the length and width of the mold base they intend to use with
the hot runner subsystem (FIG. 5, item 220). Since the
available plate sizes are dependent on the mold base
manufacturer previously selected (FIG. 5, item 212), a list of
pre-determined plates sizes will be presented to the buyer that
match those made by the selected mold base manufacturer. In the
preferred embodiment, the buyer will select the plate size by
clicking on an item in a drop down list.
Now referring to FIG. 5a, the next step in the online
design process is the entering of various injection molding
machine parameters (FIG. 5a, item 222). Typical inputs which
adequately describe the injection molding machine will include
the electrical interface details and mechanical interface
details. Electrical interface details typically include the
electrical connector interface (FIG. 8, item 130), the voltage
of the machine which the hot runner subsystem will be connected
to, and the thermocouple type (FIG 8, item 131).
3o The mechanical interface information will typically include
the machine nozzle orifice diameter, the machine nozzle
interface radius, the locating ring diameter (FIG. 8, item 247)
and the thread type of the machine nozzle.
The next item the buyer must input is the mounting details
of the hot runner subsystem to the injection molding machine
(FIG. 5a, item 226). Currently there are two industry standard
mount designs to attach a hot runner subsystem to the injection
molding machine. The buyer selects this option based on the
4o design of the injection molding machine and the hot runner
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subsystem is configured to interface with the chosen design.
The next series of inputs by the buyer will describe the
finished plastic part that is to be molded using the hot runner
subsystem as well as the plastic resin that is to be used and
the processing parameters such as molding temperature and
pressure (FIG. 5a, item 224). The merchant computer 14 uses
these inputs to calculate the diameter of the melt channel
within the manifold (FIG. 8, item 158) and the nozzle (FIG. 8,
1o item 142 ) . For example, the buyer will need to supply the melt
temperature, the mold temperature, the injection. time, the
injection pressure, the diameter of the nozzle outlet, and the
melt flow index. All of these parameters in combination will be
used by the merchant computer 14 to calculate the optimum
diameter of the melt channel in the manifold (FIG. 8, 142).
This calculated diameter will then be used in generating the CAD
files (FIG. 3, item 50). Calculating an optimum diameter for
the melt channel reduces pressure loss in the hot runner
subsystem and helps to produce a superior quality part.
This is the last piece of design. information necessary to
design and configure a complete hot runner subsystem. The buyer
will be presented with a one page datasheet that lists all the
parameters they entered previously (FIG. 5a, item 230). At this
point the buyer is given an opportunity to review and change any
of the parameters entered. If the buyer would like to change
the configuration, a simple point and click is all that is
required to be taken back to that particular entry screen (FIG.
5a, item 240), and enter new values for those design parameters.
Once the buyer verifies all the information provided during
the online design process, the buyer will confirm the order
(FIG. 5a, item 232) and the merchant computer 14 will generate
the dataset 20 for this particular hot runner subsystem (FIG.
5a, item 234) which will be identified by a unique order number.
An email confirmation will be delivered to the buyer (FIG.
5a, item 236) to acknowledge receipt of the order by the
merchant computer 14. Tn addition, an email will be sent to the
4o hot runner manufacturer (FIG. 5a, item 238)to notify them that a
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hot runner subsystem has been. designed anal placed on order. The
dataset 20 associated with this order will be immediately
available for online viewing, downloading or printing.
Thus the reader can see that the present invention provides
an improved online design system which reduces overall Cycle
time as well as reduces the chance for design and configuration
errors of a machine designed online. Referring to FIG. 6 and
FIG. 7, a comparison in cycle time of the present invention over
1o the prior art is shown. FIG. 6 shows the prior art method of
designing and ordering a typical hot runner subsystem. The
first step in the process of designing a hot runner subsystem is
mold concepts are developed by the buyer(FIG. 6 item 102 and
FIG. 7 item 102a). This process usually requires at least 1-2
weeks of design activity by buyer's engineers to arrive at a
final mold concept design. The present invention doesn't reduce
the time for this process because it is largely done by the
buyer as they are designing the finished part which is to be
molded.
Based on the prior art, once the mold concept is developed,
the buyer will spend several days supplying their mold design to
the hot runner manufacturer in the form of CAD files and hard
copies that describe the interface to the hot runner subsystem
(FIG. 6, item 104). Usually transmission of this information is
through the mail after all the documentation has been printed
out and compiled. In comparison, the present invention reduces
this time to the time it takes to click through the simple
online process to define the hot runner subsystem interfaces
(FIG.7, item 104a).
According to the prior art, following submission of the
interface information to the hot runner supplier, and after some
preliminary data checking (FIG. 6, item 208), the fabrication of
that hot runner can begin(FTG. 6, item 110). According to the
prior art, it is not uncommon for the fabrication of the hot
runner to take 4 to 6 weeks due to errors and omissions that
occur when the buyer supplies incorrect or confusing design
information to the hot runner manufacturer. In contrast, the
4o present invention provides all the pertinent design information
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to the hot runner manufacturer in a concise and familiar format,
thereby reducing errors which results in a cycle time of only 3
1/z weeks to fabricate the entire hot runner subsystem (FIG. 7,
item 110a). Similarly, data verification, in accordance with the
present invention is reduced to just seconds because it is
performed online by the merchant computer 24 while the buyer is
designing the hot runner (FIG. 7, item 110a). Once the hot
runner has been fabricated it is shipped to the customer (FIG 6,
item 112 and FIG. 7, item 112a) . As shown by the comparison of
to the total cycle time of the prior art of 8-14 weeks (FIG. 6,
item 114) to the present invention of 4-6 weeks (FIG. 7, item
114a), significant time savings can be realized by the present
invention over the prior art.
It is to be understood that the invention is not limited to
the illustrations described and shown herein, which are deemed
to be merely illustrative of the best modes of carrying out the
invention, and which are susceptible of modification of form,
sine, arrangement of parts and details of operation. The
2o invention rather is intended to encompass all such modifications
which are within its spirit and scope as defined by the claims.
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