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ORIGINALARTICLEMODULARDESIGNAPPLIEDTOBEVERAGECONTAINERINJECTIONMOLDSMINGSHYANHUANGMINGKAIHSURECEIVED16MARCH2010/ACCEPTED15JUNE2010/PUBLISHEDONLINE25JUNE2010SPRINGERVERLAGLONDONLIMITED2010ABSTRACTTHISWORKAPPLIESMODULARDESIGNCONCEPTSTODESIGNATINGBEVERAGECONTAINERINJECTIONMOLDSTHISSTUDYAIMSTODEVELOPAMETHODOFCONTROLLINGCOSTSANDTIMEINRELATIONTOMOLDDEVELOPMENT,ANDALSOTOIMPROVEPRODUCTDESIGNTHISINVESTIGATIONCOMPRISESTWOPARTSFUNCTIONALITYCODING,ANDESTABLISHINGASTANDARDOPERATIONPROCEDURE,SPECIFICALLYDESIGNEDFORBEVERAGECONTAINERINJECTIONMOLDDESIGNANDMANUFACTURINGFIRST,THEINJECTIONMOLDISDIVIDEDINTOSEVERALMODULES,EACHWITHASPECIFICFUNCTIONEACHMODULEISFURTHERDIVIDEDINTOSEVERALSTRUCTURALUNITSPOSSESSINGSUBFUNCTIONORSUBSUBFUNCTIONNEXT,DIMENSIONSANDSPECIFICATIONSOFEACHUNITARESTANDARDIZEDANDACOMPATIBLEINTERFACEISCONSTRUCTEDLINKINGRELEVANTUNITSTHISWORKEMPLOYSACUPSHAPEDBEVERAGECONTAINERTOEXPERIMENTALLYASSESSTHEPERFORMANCEOFTHEMODULARDESIGNAPPROACHTHEEXPERIMENTALRESULTSINDICATETHATTHEMODULARDESIGNAPPROACHTOMANUFACTURINGINJECTIONMOLDSSHORTENSDEVELOPMENTTIMEBY36ANDREDUCESCOSTSBY1923COMPAREDWITHTHECONVENTIONALAPPROACHMEANWHILE,THEINFORMATIONONMODULARITYHELPSDESIGNERSINDIVERSEPRODUCTSDESIGNADDITIONALLY,THEFUNCTIONALITYCODEHELPSEFFECTIVELYMANAGEANDMAINTAINPRODUCTSANDMOLDSKEYWORDSBEVERAGECONTAINERINJECTIONMOLDMODULARDESIGNPRODUCTFAMILY1INTRODUCTIONRECENTLY,GROWINGMARKETCOMPETITIONANDINCREASINGLYDIVERSECUSTOMERDEMANDHASFORCEDCOMPETITORSTOINCREASETHESPEEDATWHICHTHEYDELIVERNEWPRODUCTSTOTHEMARKETHOWEVER,DEVELOPINGAMOLDFORMASSPRODUCTIONREQUIRESCONSIDERINGNUMEROUSFACTORS,INCLUDINGPRODUCTGEOMETRY,DIMENSIONS,ANDACCURACY,LEADINGTOLONGPRODUCTDEVELOPMENTTIMEINTRODUCINGMODULARDESIGNCONCEPTSINTOPRODUCTDESIGNAPPEARSAKEYMEANOFFACILITATINGPRODUCTDEVELOPMENT,SINCEITINCREASESDESIGNFLEXIBILITYANDSHORTENSDELIVERYTIME14MEANWHILE,AHIGHLEVELOFPRODUCTMODULARITYENHANCESPRODUCTINNOVATIVENESS,FLEXIBILITY,ANDCUSTOMERSERVICES5MODULARITYISTOSUBDIVIDEACOMPLEXPRODUCTINTOMODULESTHATCANBEINDEPENDENTLYCREATEDANDTHENAREEASILYUSEDINTERCHANGEABLY6,7THEREARETHREEGENERALFIELDSWHEREMODULARITYCOULDBEIMPLEMENTEDINCLUDINGMODULARITYINDESIGNMID,MODULARITYINUSEMIU,ANDMODULARITYINPRODUCTIONMIP8MIDINVOLVESSTANDARDIZINGBASICSTRUCTURALUNITSWHICHPERFORMSPECIFICFUNCTIONS,THUSFACILITATINGFLEXIBLEASSEMBLYOFVARIOUSPRODUCTS9,10MIDCANREVEALPRODUCTSTRUCTURE,NAMELYTHERELATIONSHIPAMONGDIFFERENTPRODUCTSRELATEDPRODUCTSARETERMEDPRODUCTFAMILYANDINCLUDEBOTHBASICANDSPECIFICFUNCTIONSDEVELOPINGPRODUCTFAMILIESOFFERSBENEFITSINTERMSOFMULTIPURPOSEDESIGNANDTHUSREDUCESPRODUCTIONCOSTS11,12MIUISCONSUMERDRIVENDECOMPOSITIONOFAPRODUCTWITHAVIEWTOSATISFYINGTHEEASEOFUSEANDINDIVIDUALLYMIPENABLESTHEFACTORYFLOORTOPRECOMBINEALARGENUMBEROFCOMPONENTSINTOMODULESANDTHESEMODULESTOBEASSEMBLEDOFFLINEANDTHENBROUGHTONTOTHEMAINASSEMBLYLINETOBEINCORPORATEDINTOASMALLANDSIMPLESERIESOFTASKSMSHUANGMKHSUDEPARTMENTOFMECHANICALANDAUTOMATIONENGINEERINGANDGRADUATEINSTITUTEOFINDUSTRIALDESIGN,NATIONALKAOHSIUNGFIRSTUNIVERSITYOFSCIENCEANDTECHNOLOGY,2JHUOYUEROAD,NANZIH,KAOHSIUNGCITY811,TAIWAN,REPUBLICOFCHINAEMAILMSHUANGCCMSNKFUSTEDUTWINTJADVMANUFTECHNOL201153110DOI101007/S001700102796YMIDHASBEENBROADLYAPPLIEDTONUMEROUSAREASANDHASEXERTEDSIGNIFICANTEFFECTSINTERMSOFCOSTREDUCTIONANDDESIGNDIVERSITY13,14HOWEVER,THEREISLIMITEDEMPIRICALRESEARCHTHATHASAPPLIEDMODULARDESIGNTOMOLDS1518THISSTUDYTHUSAIMSTOREDUCEMOLDDEVELOPMENTTIMEBYAPPLYINGMODULARDESIGNANDDEVELOPASTANDARDOPERATIONPROCEDUREFORDESIGNINGBEVERAGECONTAINERINJECTIONMOLDS,WHICHARECHARACTERIZEDBYSCORESOREVENHUNDREDSOFCOMPONENTS2GENERALPROCEDURESOFDESIGNINGINJECTIONMOLDSBASICALLY,ANINJECTIONMOLDSETCONSISTSOFTWOPRIMARYCOMPONENTS,THEFEMALEMOLDANDTHEMALEMOLDTHEMOLTENPLASTICENTERSTHECAVITYTHROUGHASPRUEINTHEFEMALEMOLDTHESPRUEDIRECTSTHEMOLTENPLASTICFLOWINGTHROUGHRUNNERSANDENTERINGGATESANDINTOTHECAVITYGEOMETRYTOFORMTHEDESIREDPARTSIDESOFTHEPARTTHATAPPEARPARALLELWITHTHEDIRECTIONOFTHEMOLDOPENINGARETYPICALLYANGLEDSLIGHTLYTOEASEREJECTIONOFTHEPARTFROMTHEMOLDTHEDRAFTANGLEREQUIREDFORMOLDRELEASEISPRIMARILYDEPENDENTONTHEDEPTHOFTHECAVITYANDTHESHRINKAGERATEOFPLASTICMATERIALSTHEMOLDISUSUALLYDESIGNEDSOTHATTHEMOLDEDPARTRELIABLYREMAINSONTHEMALEMOLDWHENITOPENSEJECTORPINSOREJECTORPLATEISPLACEDINEITHERHALFOFTHEMOLD,WHICHPUSHESTHEFINISHEDMOLDEDPRODUCTORRUNNERSYSTEMOUTOFAMOLDTHESTANDARDMETHODOFCOOLINGISPASSINGACOOLANTTHROUGHASERIESOFHOLESDRILLEDTHROUGHTHEMOLDPLATESANDCONNECTEDBYHOSESTOFORMACONTINUOUSPATHWAYTHECOOLANTABSORBSHEATFROMTHEMOLDANDKEEPSTHEMOLDATAPROPERTEMPERATURETOSOLIDIFYTHEPLASTICATTHEMOSTEFFICIENTRATETOEASEMAINTENANCEANDVENTING,CAVITIESANDCORESAREDIVIDEDINTOPIECES,CALLEDINSERTSBYSUBSTITUTINGINTERCHANGEABLEINSERTS,ONEMOLDMAYMAKESEVERALVARIATIONSOFTHESAMEPARTGENERALMOLDDESIGNPROCESSCONTAINSTWOPARTS19PARTDESIGNANDMOLDDESIGNTHEPARTDESIGNPROCESSCONTAINSFIVEMAJORPROCEDURESDEFININGMAINPULLINGDIRECTION,DEFININGCOREANDCAVITY,CALCULATINGSHRINKAGERATE,DEFININGDRAFTANGLE,ANDTHENDEFININGPARTINGLINETHEMOLDDESIGNPROCESSMAINLYINCLUDESCHOOSINGAMOLDBASE,POSITIONINGTHEMOLDEDPART,DESIGNINGCOREANDCAVITY,DESIGNINGCOMPONENTS,DESIGNINGCOOLANTCHANNELS,CREATINGRETURNINGPIN,ADDINGEJECTORPIN,CREATINGGATEANDRUNNER,ADDINGLOCATINGRINGANDSPRUEBUSHINGINSEQUENCE3APPLYINGMODULARDESIGNFORBEVERAGECONTAINERSTHISSTUDYAPPLIESMODULARDESIGNTOBEVERAGECONTAINERINJECTIONMOLDSVIAAFIVESTAGEPROCESS,ASFOLLOWS1PRODUCTCLASSIFICATIONANDMACHINESPECIFICATIONS,2DIVISIONOFINJECTIONMOLDSINTOMODULESBASEDONFUNCTIONALITY,3DIVISIONOFINDIVIDUALMODULESINTOMULTIPLEUNITSWITHSUBFUNCTIONS,ANDTHERELATIONSHIPBETWEENDESIGNANDASSEMBLYFOREACHUNIT,4STANDARDIZATIONOFSTRUCTURALUNITS,AND5CODINGOFSTANDARDSTRUCTURALUNITSTHESEINDIVIDUALPROCESSESAREDETAILEDBELOWABEVERAGECONTAINERHOTRUNNERINJECTIONMOLDCLAMPINGMODULEHOTRUNNERMODULEMOLDINGMODULEEJECTINGMODULEGUIDINGMODULECLAMPINGPLATEFEMALEMOLDBASEMALEMOLDBASEMANIFOLDHOTTIPBUSHINGHOTTIPFEMALEMOLDINSERTCUPBASEFEMALEMOLDINSERTMALECOOLINGBASEMALEMOLDINSERTAIREJECTOREJECTORPLATELEADERPINLEADERPINBUSHINGFIG1MODULARITYCLASSIFICATIONOFABEVERAGECONTAINERINJECTIONMOLD2INTJADVMANUFTECHNOL20115311031PRODUCTCLASSIFICATIONANDMACHINESPECIFICATIONSTHISSTEPCLASSIFIESALLOFTHEBEVERAGECONTAINERSBASEDONTHEIRGEOMETRYANDDIMENSIONS,ANDSELECTSTHEMACHINEWITHTHEMOSTSUITABLESPECIFICATIONSFORPRODUCTIONTHEREAREFIVEMAJORQUALIFICATIONSFORANINJECTIONMOLDINGMACHINE,INCLUDINGSUFFICIENTMOLDCLAMPINGFORCE,SUFFICIENTTHEORETICALSHOTVOLUME,SUFFICIENTDISTANCEBETWEENTIEBARS,SUFFICIENTRANGEOFMOLDTHICKNESS,ANDSUFFICIENTMOLDCLAMPINGSTROKE32DIVISIONOFINJECTIONMOLDSINTOMODULESBASEDONFUNCTIONALITYTHISSTEPDIVIDESAMOLDSETINTOSEVERALMODULESWITHINDIVIDUALFUNCTIONSTHEPRINCIPLESOFDIVISIONINCLUDEGENERALRULE,DIVISIONRULE,APPLICABILITYRULE,ANDINTERCHANGERULEINGENERALRULE,MODULESMUSTCONTAINALLTHEFUNCTIONSOFBEVERAGECONTAINERINJECTIONMOLDSINDIVISIONRULE,EACHFUNCTIONALMODULEMUSTCONTAINATLEASTONEFUNDAMENTALFUNCTIONANDEACHUNITMUSTFULFILLITSOWNSPECIFICFUNCTIONSASTOAPPLICABILITYRULE,UNITSFULFILLINGASINGLEFUNCTIONAREPREFERREDFORINTERCHANGERULE,FUNDAMENTALUNITSSHOULDBEINTERCHANGEABLEAMONGMODULESAFTERDIVIDINGMOLDSINTOPRODUCTFAMILIES33DIVISIONOFAMODULEINTOMULTIPLEUNITSWITHSUBFUNCTIONANDTHERELATIONSHIPBETWEENDESIGNANDASSEMBLYFOREACHUNITFIGURE1ILLUSTRATESTHESTRUCTUREOFABEVERAGECONTAINERMOLDTHATINCLUDESSEVERALFUNCTIONALMODULESTHEFUNCTIONSOFINDIVIDUALMODULESAREFURTHEREXTENDEDTOTHESTRUCTURALUNITVIASUBFUNCTIONSORSUBSUBFUNCTIONSTHEDIVIDEDMODULESINCLUDECLAMPINGMODULE,HOTRUNNERMODULE,MOLDINGMODULE,EJECTINGMODULE,ANDGUIDINGMODULETHECLAMPINGMODULEFUNCTIONSFORPRECISELYPOSITIONINGINDIVIDUALUNITSANDMODULESONANINJECTIONMOLDINGMACHINETHEHOTRUNNERMODULEISTOMAINTAINTHEFLOWABILITYOFMOLTENPLASTICSVIAHEATINGTHEMOLDINGABCUPTYPECONTAINERRECTANGLESHAPEATCROSSSECTIONCUBOIDSHAPEDMOLDINSERTDESIGNROUNDSHAPEATCROSSSECTIONCYLINDERSHAPEDMOLDINSERTDESIGNBASINTYPECONTAINERFIG3DESIGNOFGEOMETRICALSTRUCTURALUNITACUPTYPECONTAINER,BBASINTYPECONTAINERCOSTHIGHLYEFFICIENTPROCESSMODULARMOLDDEVELOPMENTPROCESSREDUCTIONOFWORKINGHOURSCONVENTIONALMOLDDEVELOPMENTPROCESSDURATIONOFCONVENTIONALMOLDDEVELOPMENTPROCESSCOSTDOWNMATERIALSDELIVERYCNCMACHININGMILLINGTURNINGHEATTREATMENTEDMWIRECUTTINGPOLISHINGTEXTUREPRODUCTSEMIPRODUCTTIMEDURATIONOFMODULARMOLDDEVELOPMENTPROCESSFIG2COMPARISONOFCONVENTIONALANDMODULARMOLDDEVELOPMENTPROCESSESINTJADVMANUFTECHNOL2011531103MODULECONTROLSTHEGEOMETRYANDDIMENSIONALACCURACYOFINJECTIONMOLDEDPARTSTHEEJECTINGMODULEEJECTSINJECTIONMOLDEDPARTSFROMTHEMOLDCAVITYTHEGUIDINGMODULEWORKSFORACCURATELYPOSITIONINGTHEFEMALEANDMALEMOLDSDURINGMOLDCLOSING331GEOMETRICALDESIGNOFSTRUCTURALELEMENTSSTANDARDSTRUCTURALELEMENTSAREPREPAREDINTOSEMIFINISHEDPRODUCTSTHATFULFILLTHEGEOMETRICALOUTLINESOFFINISHEDPRODUCTS,THUSSIGNIFICANTLYSHORTENINGMANUFACTURINGMOLDDELIVERYTIMEFIGURE2ILLUSTRATESTHECOMPARISONBETWEENTHEMODULARITYDESIGNMOLDDEVELOPMENTPROCESSANDTHECONVENTIONALPROCESSSTANDARDSTRUCTURALELEMENTSAREFASTTOPRODUCESINCETHEYAREPREMANUFACTUREDINTOGENERALSHAPESANDREQUIREMINIMALMANUFACTURINGTOYIELDAFINISHEDPRODUCTFIGURE3SHOWSTHEGEOMETRICALDESIGNOFTHEBEVERAGECONTAINERSEXAMINEDINTHISSTUDYTHEMOLDINSERTTHATBESTCORRESPONDENTSWITHTHEPRODUCTSHAPEHASASIMPLEGEOMETRICALSHAPEFOREXAMPLE,THECYLINDERANDTHECUBOIDREPRESENTCUPTYPEANDBASINTYPECONTAINERS,RESPECTIVELYTHEREMAININGCOMPONENTSAREMODULARIZEDTOFACILITATETHEIREFFECTIVEINTEGRATIONINTOACOMPLETESETOFINJECTIONMOLDSINAMANNERSIMILARTOSTACKINGPLAYINGBLOCKSA1SINGLESPIRAL2DOUBLESPIRAL3BLOCKPLATE4FOUNTAINB1LINEARSHAPE2USHAPE3MULTISEGMENT4BLOCKPLATEFIG4DESIGNOFCOOLINGSYSTEMATHEMALEPORTIONOFTHEMOLDCOOLINGUNIT,BTHEFEMALEPORTIONOFTHEMOLDCOOLINGUNIT4INTJADVMANUFTECHNOL201153110332ASSEMBLYDESIGNOFSTRUCTURALUNITHUNDREDSOFSTRUCTURALELEMENTSAREINVOLVEDINNEWPRODUCTDEVELOPMENT,EACHCONTAININGNUMEROUSDIMENSIONSASSEMBLINGSUCHASOPHISTICATEDSYSTEMMAYFREQUENTLYFAILBECAUSEOFSMALLMISTAKESOCCURRINGINDIMENSIONSTHISSTUDYDEFINESDIMENSIONSINVOLVINGSTRUCTURALELEMENTSWITHMUTUALASSEMBLYRELATIONSHIPSASUNIONDIMENSIONSTHESEDIMENSIONSARESIMPLIFIEDTOAFOOLPROOFINGEFFECTPROCEDURESFORASSEMBLINGSTRUCTURALELEMENTSAREINTRODUCEDBELOW1DIRECTIONOFMODULEASSEMBLYTWOLINESAREUSEDTOSEPARATEAMOLDINTOFOURASSEMBLYMODULESTHEFIRSTLINEISTHEPARTINGLINEDEFININGTHEFEMALEANDMALEMOLDSTHESECONDLINEDEFINESTHEBOUNDARYBETWEENTHEFRONTANDREARHOTRUNNERPLATESTHESEQUENCEOFASSEMBLYFOLLOWSTHEORDEROFMALEMOLD,FEMALEMOLD,FRONTHOTRUNNERPLATE,ANDREARHOTRUNNERPLATE2DIRECTIONOFASSEMBLYUNITSEACHUNITBELONGINGTOTHEABOVEMENTIONEDFOURASSEMBLINGMODULESISASSEMBLEDINASEQUENCE,NAMELY,CONFIRMINGTHEAPPEARANCEDIMENSIONSOFINJECTIONMOLDEDPARTS,FURTHERCONFIRMINGTHEPRODUCTRELATEDDIMENSIONSOFTHEMOLDINSERTANDMOLDCAVITY,FIXINGTHEMOLDINSERTWITHTHECLAMPINGMODULE,IDENTIFYINGTHEDIMENSIONOFTHEHOTRUNNERMODULEUSINGTHESTRUCTURALCOMPONENTSOFTHEFEMALEMOLD,CALCULATINGTHEPRECISEDIMENSIONSOFTHECLAMPINGPLATES,ANDFINALLYSELECTINGTHEINJECTIONMOLDINGMACHINESPECIFICATIONSTHEASSEMBLINGSEQUENCEPRIMARILYFOLLOWSPRODUCT,MOLDINSERT,CLAMPINGPLATE,ANDINJECTIONMOLDINGMACHINE34STANDARDIZATIONOFSTRUCTURALUNITASFORTHESTRUCTURALUNITSOFBEVERAGECONTAINERINJECTIONMOLDS,THECONCEPTOFPRODUCTFAMILIESISFURTHERINTRODUCEDTOINCREASETHECOMMONALITYANDEXCHANGEABILITYAMONGVARIOUSFUNCTIONALUNITSFIGURE4ILLUSTRATESANEXAMPLEOFMUTUALLYSUBSTITUTABLECOOLINGSYSTEMSFURTHERMORE,FIG5SHOWSTHEDESIGNOFVARIOUSEJECTIONSYSTEMSUSEDFORPRODUCTFAMILIES341DESIGNOFCOOLINGSYSTEMTHECOOLINGSYSTEMCOMPRISESTWOUNITSMALEMOLDCOOLINGUNITANDFEMALEMOLDCOOLINGUNITTHEMALEMOLDCOOLINGUNITINCLUDESFOUNTAIN,DOUBLESPIRAL,SINGLESPIRAL,BCOREX4EJECTORPLATEEJECTORRINGX4ALINETYPELTYPELINETYPELTYPEAIROUTLETLTYPEAIRINLETFIG5DESIGNOFEJECTORAAIREJECTOR,BEJECTORPLATEINTJADVMANUFTECHNOL2011531105ANDBLOCKPLATETYPESLISTEDINDESCENDINGSEQUENCEOFCOOLINGEFFICIENCYBASEDONMANUFACTURINGCOSTANDCOOLINGEFFECT,THEDOUBLESPIRALTYPEISPRIORITIZEDASTOTHEFEMALEMOLDCOOLINGUNIT,ITINCLUDESMULTISEGMENT,BLOCKPLATE,USHAPE,ANDLINEARTYPESLISTEDINDESCENDINGSEQUENCEOFCOOLINGEFFICIENCYBASEDONMANUFACTURINGCOSTANDCOOLINGEFFECT,BLOCKPLATEISPRIORITIZED342DESIGNOFEJECTIONMECHANISMTHEBEVERAGECONTAINERISNORMALLYTHINWALLEDANDTHEIDEALEJECTIONMECHANISMISANAIREJECTOR,BASEDONTHEDESIRABILITYOFPREVENTINGDAMAGETOINJECTIONMOLDEDPARTSASFORINJECTIONMOLDINGMATERIALSWITHHIGHSHRINKAGE,THEEJECTORPLATECANBESELECTEDTOSMOOTHLYSEPARATETHEPRODUCTSANDMOLDTHEAIREJECTORDESIGNINCORPORATESTWOAIROUTLETSAROUNDTHEMOLDINSERT,NAMELY,ONELTYPEOUTLETANDONELINETYPEOUTLETTHEAIRINTHELTYPEOUTLETENTERSTHEPERIPHERYOFTHEMOLDINSERTANDSEPARATESTHEINJECTIONMOLDEDPARTSFROMTHEMOLDINSERTTHEAIRINTHELINETYPEOUTLETISTHENINJECTEDINTOTHEBOTTOMOFTHEPARTSTOEJECTTHEMFROMTHEMOLDCAVITYEJECTORPLATEISTOPUSHAMOLDEDPARTOFFACOREOROUTOFACAVITYMOLDITISATTACHEDTOACOREANDMOVESLINEARLYALONGLEADERS35CODINGOFSTANDARDSTRUCTURALUNITSAFTERSPECIFYINGSTRUCTURALUNITDIMENSIONS,THISINVESTIGATIONINTRODUCESACODINGSYSTEMTOASSISTINMANAGINGTHESECOMPONENTSANDUNITS351STRUCTURALUNITCODESTHISSTUDYUSESTHREEDIGITSTOCODEALLOFTHESTRUCTURALUNITSFIG6ATHEFIRSTDIGITISTHEMAINFUNCTIONCODE,WHICHREPRESENTSPRODUCTGEOMETRYANDDIMENSIONS,ANDSYMBOLIZESSTANDARDIZEDSTRUCTURALUNITSTHESECONDDIGITISTHESUBFUNCTIONCODE,WHICHREPRESENTSMATERIALS,ANDISWIDELYUSEDINBILLSOFMATERIALSBOMFORSTRUCTURALUNITSTHETHIRDDIGITREPRESENTSTHECHARACTERISTICSOFEACHSTRUCTURALUNIT,ANDINCLUDESTHECODESFORPRODUCTSFAMILIESANDDIMENSIONS352PRODUCTIDENTIFICATIONCOMPLEXCODETHISCODEISDESIGNEDFORRAPIDLYSEARCHINGSTRUCTURALUNITSWHICHAREMUTUALLYEXCHANGEABLEDURINGPRODUCTDEVELOPMENTTHISCODEINTEGRATESALLSTRUCTURALUNITSCORRELATEDWITHTHEMANUFACTUREOFASPECIFICCONTAINER,ANDALSOREVEALSINFORMATIONONMOLDGEOMETRYANDDIMENSIONS,ANDPRODUCTCHARACTERISTICS,ASSHOWNINFIG6BMODULARDESIGNOFINJECTIONMOLDSPRODUCTANDUNITCODINGMANUFACTURINGFACILITYANALYSISCONFIRMATIONOFPRODUCTSPECIFICATIONSISAPROPERDESIGNYESNOYESNOSTRUCTURALUNITMANUFACTURINGMOLDASSEMBLYANDINSPECTIONCOMPONENTDRAWINGLISTOFMODULAROBJECTSMOLDTESTINGMASSPRODUCTIONISINSPECTIONOKFIG7STANDARDOPERATIONPROCEDUREFORDEVELOPINGBEVERAGECONTAINERINJECTIONMOLDSABMAINFUNCTIONGEMOETRYDIMENSIONS123SUBFUNCTIONMATERIALSMODULECODECLAMPINGMODULEHOTRUNNERMODULEMOLDINGMODULE78CHARACTERISTICCODEPRODUCTFAMILYDIMENSIONSINJECTIONMOLDINGMACHINEPRODUCTCLASSIFICATIONEJECTORTYPECLAMPINGPLATEHOTTIPBUSHINGFEMALEMOLDMALEMOLDFEMALEMOLDBASEMALEMOLDBASEHOTTIPMANIFOLDGUIDINGMODULEEJECTORUNIT213456910111213FIG6CODEOFMODULARFUNCTIONALITYASTRUCTURALUNITCODES,BPRODUCTIDENTIFICATIONCOMPLEXCODE6INTJADVMANUFTECHNOL2011531104PROCEDUREFORDEVELOPINGCONTAINERPRODUCTSBASEDONTHEABOVEMENTIONEDMODULARDESIGNAPPROACH,ASTANDARDOPERATIONPROCEDUREFORDESIGNINGBEVERAGECONTAINERINJECTIONMOLDSCANBEGENERATEDTHUS,MERELYFOLLOWINGTHEPROCEDURECANEASILYDESIGNMOLDSFORNEWPRODUCTSANDIDENTIFYINTERCHANGEABLESTRUCTURALUNITSWHICHCANHELPEFFECTIVELYMANAGEANDMAINTAINPRODUCTSANDMOLDSFIGURE7SHOWSTHESTANDARDOPERATIONPROCEDUREFORDESIGNINGBEVERAGECONTAINERINJECTIONMOLDSTHEPROCEDURECOMPRISESNINESTEPSANDISILLUSTRATEDASFOLLOWSSTEP1CONFIRMATIONOFPRODUCTSPECIFICATIONSINORDERTOEXACTLYDESCRIBETHEGEOMETRY,DIMENSIONALACCURACY,ANDQUALITYCHARACTERISTICSOFPRODUCTS,THISSTEPDEFINESTHEPRODUCTWITHITSGEOMETRICALCHARACTERISTICS,SUCHASWIDTH,HEIGHT,PROJECTIONAREA,ANDWEIGHTSTEP2MANUFACTURINGFACILITYANALYSISBASEDONTHEINFORMATIONFROMSTEP1,THEMOSTSUITABLEINJECTIONMOLDINGMACHINEISDETERMINEDBYCHECKINGSPECIFICATIONSSUCHASCLAMPINGFORCE,SHOTVOLUME,RANGEOFMOLDTHICKNESS,ANDDAYLIGHTSTEP3MODULARDESIGNOFINJECTIONMOLDSTHROUGHTHEDIVISIONOFMOLDFUNCTIONINTOSEVERALFUNCTIONALMODULES,THEINJECTIONMOLDOFASPECIFICCONTAINERCANBERAPIDLYANDEASILYDEVELOPEDBYMODULESTACKINGMODULESTOBEDESIGNEDINCLUDEMALEMOLDMODULE,FEMALEMOLDMODULE,HOTRUNNERMODULE,ANDOTHERSSTEP4PRODUCTANDUNITCODINGEACHSTRUCTURALUNITISASSIGNEDACOMPONENTCODE,WHICHISTHENINTEGRATEDWITHTHEPRODUCTCHARACTERISTICSTOYIELDAPRODUCTCOMPLEXIDENTIFICATIONCODECONSEQUENTLY,MUTUALLYEXCHANGEABLEUNITSAREAVAILABLEINTHEPRODUCTDEVELOPMENTSTAGEFURTHERMORE,NOTITLECODESPECIFICATIONSMATERIALSAMOUNTAUXILIARY1CUPSHAPEDMALEMOLDBASE62NL450H450T60S55C1HEATTREATMENT2CUPSHAPEDFEMALEMOLDBASE192NL450H450T130S55C1HEATTREATMENT3CLAMPINGPLATE32NL450T50120S55C14MANIFOLD42NL330H90T43SKD6115HOTTIP21N14L90BERYLLIUMCOPPER46HOTTIPBUSHINGS23N20L60FDAC47CUPSHAPEDMALEMOLDINSERT191N150H130SUS42048COOLINGUNITOFMALEMOLD192T90H130SDK114HEATTREATMENT9CUPSHAPEDBASEFEMALEMOLDINSERT191N150H110SUS420410CUPSHAPEDFEMALEMOLDINSERT192N130H20SKD114HEATTREATMENT11LEADERPIN611540L260SK3412LEADERPINBUSHING612155L100SK34FIG8BOMOFACUPSHAPEDINJECTIONMOLDINTJADVMANUFTECHNOL2011531107THECODESYSTEMSIMPLIFIESMOLDMAINTENANCEANDPRODUCTMANAGEMENTSTEP5LISTOFMODULAROBJECTSACCORDINGTOTHESTRUCTURALSPECIFICATIONSFROMSTEP3,ALLCOMPONENTSOFANINJECTIONMOLDARELISTEDINBOMFORINSTANCE,THEBOMOFACUPSHAPEDINJECTIONMOLDASANEXAMPLEISILLUSTRATEDINFIG8THISSTEPFACILITATESEASEOFHANDLINGDURINGTHESUBSEQUENTQUOTATIONANDPRODUCTIONSCHEDULINGPROCESSSTEP6COMPONENTDRAWINGSINCEDIMENSIONSOFSTRUCTURALUNITSAREFORSEMIPRODUCTS,THEBOMINFORMATIONLISTEDINSTEP5SIMPLYISTHEINITIALSTAGEOFMOLDDESIGNTHEREBY,ALLSTRUCTURALUNITSOFANINJECTIONMOLDDESIGNEDFORCUSTOMERREQUIREMENTANDSPECIFICATIONHAVETOBEDRAWNINTHEFORMATOFENGINEERINGDRAWINGFORENGINEERINGPURPOSESSTEP7STRUCTURALUNITMANUFACTURINGFOLLOWINGTHEINFORMATIONOFBOMANDCOMPONENTDRAWINGGENERATEDINSTEPS5AND6,RESPECTIVELY,THISSTEPENABLESTHEFACTORYFLOORTOFURTHERMANUFACTURETHEINJECTIONMOLDSTEP8MOLDASSEMBLYANDINSPECTIONTHISSTEPINSPECTSEACHUNITMANUFACTUREDINSTEP7TOASSUREMOLDQUALITYBASEDONTHEASSEMBLYDRAWINGOFAMOLD,THELOCATIONOFRELATEDMODULESANDSTRUCTURALUNITSISACCURATELYASSEMBLEDFORINSTANCE,FIG9PRESENTSTHEASSEMBLYDRAWINGOFACOFFEECUPINJECTIONMOLD,WHICHISUSEDTOCONFIRMTHERELATIONSHIPOFEACHCOMPONENTSTEP9MOLDTESTINGANDMASSPRODUCTIONAFTERCOMPLETINGTHEABOVEEIGHTSTEPS,THISFINALSTEPISPERFORMEDTOTESTTHEMOLDONTHEINJECTIONMOLDINGMACHINEANDIMPLEMENTMASSPRODUCTION5VERIFICATIONANDDISCUSSIONTHISSTUDYEMPLOYSACUPSHAPEDBEVERAGECONTAINERTOEXPERIMENTALLYASSESSTHEPERFORMANCEOFTHEMODULARDESIGNAPPROACHSINCETHESPECIFICATIONOFSTRUCTURALUNITSENABLESPREPROCESSINGOFTHEINITIALUNITSHAPEANDONLYREQUIRESLOCALPREPROCESSINGTOOBTAINPRECISEDIMENSIONSDURINGMOLDDEVELOPMENT,THETOTALMOLDDEVELOPMENTTIMEWILLBESIGNIFICANTLYREDUCEDTABLE1LISTSMOLDDEVELOPMENTFORACUPSHAPEDCONTAINERANDREVEALSTHATTHEMOLDDEVELOPMENTTIMEEMPLOYINGAMODULARDESIGNISSOME36LESSTHANWITHTHECONVENTIONALPROCESSWHEREASTHESTANDARDIZATIONOFCOMPONENTSPECIFICATIONSENABLINGBATCHPURCHASINGOFMATERIALSWHICHARECOMBINEDWITHEFFICIEN
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