COMPUTER IMPLEMENTED METHOD OF DESIGNING A MOLDING PROCESS

Abstract

Disclosed herein are a computer-implemented method and a design system for designing a molding process for manufacturing at least one component. The computer-implemented method includes a) retrieving three-dimensional geometrical data describing a candidate shape of a mold cavity; b) analyzing the geometrical data; c) automatically interpreting at least one analysis result generated in step b) by subjecting the analysis result to at least one target specification; and d) outputting at least one interpretation result generated in step c), the interpretation result describing at least one quality of one or both of the molding process and a part design using the candidate shape of the mold cavity.

Claims

1. A computer-implemented method of designing a molding process for manufacturing at least one component, the method comprising a) retrieving three-dimensional geometrical data describing a candidate shape of a mold cavity; b) analyzing the geometrical data, the analyzing comprising: b1. analyzing a geometry of the mold cavity by automatically scanning the geometrical data for a plurality of predetermined criteria; and b2. simulating a use of the mold cavity by at least one of: a computer-implemented simulation of a filling of the mold cavity with a molten mass of at least one material; and a computer-implemented simulation of the component manufactured by using the mold cavity; c) automatically interpreting at least one analysis result generated in step b) by subjecting the analysis result to at least one target specification; d) outputting at least one interpretation result generated in step c), the interpretation result describing at least one quality of one or both of the molding process and a part design using the candidate shape of the mold cavity; and e) pre-processing the geometrical data retrieved in step a) by discretizing the geometrical data into a mesh comprising a finite number of mesh elements, wherein step e) is performed before performing step b), wherein step e) further comprises a file repair of defective parts of the geometrical data.

2. The method according to claim 1, wherein the method further comprises: f) retrieving at least one material to be used for the molding process wherein step f) is performed before step b).

3. The method according to claim 2, wherein step f) comprises: f1. retrieving at least one target property of at least one of: the material; the component; a manufacturing machine for manufacturing the component; and f2. automatically selecting at least one material from a database according to the target property.

4. The method according to claim 1, wherein step b1. comprises determining in the geometrical data at least one measured variable, and wherein step c) comprises comparing the at least one measured variable with at least one threshold value of the target specification.

5. The method according to claim 4, wherein the at least one measured variable is selected from the group consisting of: a length; an angle; and a thickness.

6. The method according to claim 1, wherein step c) comprises identifying critical geometrical properties of the candidate shape of the mold cavity, wherein step c) comprises using at least one process of artificial intelligence.

7. The method according to claim 1, wherein step b2. comprises determining at least one simulated variable, and wherein step c) comprises comparing the at least one simulated variable with at least one simulation threshold variable of the target specification.

8. The method according to claim 7, wherein the at least one simulated variable is a property selected from the group consisting of: a property of the molten mass of the at least one material used for filling the mold, a temperature of the molten mass of the at least one material; a property of the mold; a flow path length; a filling time for completely filling the mold with the molten mass of the at least one material; and a property of the at least one material of the component.

9. (canceled)

10. (canceled)

11. The method according to claim 1, wherein the at least one interpretation result generated in step c) comprises at least one item of recommendation information, wherein the at least one item of recommendation information comprises at least one recommendation selected from the group consisting of: a material adaption, a geometry adaption, and adaption of manufacturing parameters.

12. The method according to claim 11, wherein the method further comprises outputting at least one automatic report, wherein the automatic report comprises the at least one item of recommendation information.

13. The method according to claim 12, wherein step d) comprises outputting the at least one automatic report.

14. The method according to claim 12, wherein the outputting of the at least one automatic report comprises providing guidance for one or more of a material adaption, a geometry adaption and an adaption of manufacturing parameters.

15. The method according to claim 1, wherein the method further comprises g) retrieving at least one item of analysis information from the at least one interpretation result generated in step c) and using the at least one item of analysis in-formation in an automated learning process.

16. The method according to claim 1, wherein the method comprises using at least one requesting computer and at least one processing computer, wherein the processing computer retrieves the three-dimensional geometrical data from the requesting computer, performs at least steps b)-c), and outputs the interpretation result in step d) to the requesting computer, wherein the requesting computer and the processing computer communicate via at least one web interface.

17. The method according to claim 1, wherein the method further comprises h) outputting the interpretation result generated in step c) to at least one further computing device.

18. A design system for designing a molding process for manufacturing at least one component, the design system comprising at least one processor configured to perform the steps of the method according to claim 1.

19. The design system according to claim 18, wherein the design system comprises at least one processing computer and at least one requesting computer, wherein the processing computer is configured for retrieving the three-dimensional geometrical data from the requesting computer, for performing at least steps b)-c), and for outputting the interpretation result in step d) to the requesting computer.

20. The design system according to claim 19, wherein the design system further comprises at least one web interface for one or both of transmitting information from the requesting computer to the processing computer or vice versa.

21. The design system according to claim 18, wherein the design system is a client-server-system, wherein the at least one processing computer is selected from the group consisting of: a server; and at least one web-server.

Description

[0147] In the Figures:

[0148] FIG. 1: shows a part of an embodiment of a three-dimensional geometrical data describing a candidate shape of a mold cavity and a component manufactured by using the mold cavity;

[0149] FIG. 2: shows an embodiment of a design system in a perspective view; and

[0150] FIGS. 3 to 9: show flow charts of different embodiments of a computer-implemented method of designing a molding process for manufacturing at least one component.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0151] In FIG. 1 an embodiment of a three-dimensional geometrical data 110 describing a candidate shape of a mold cavity 112 is partially illustrated in a perspective view. Further, a component 114 manufactured by using the mold cavity 112 is shown in FIG. 1.

[0152] An embodiment of a design system 116 for designing a molding process for manufacturing at least one component 114 is illustrated in a perspective view in FIG. 2. The design system 116 comprises at least one processor 118 configured to perform a computer implemented method 120 of designing a molding process for manufacturing at least one component 114 as for example illustrated in FIGS. 3 to 9. The design system 116 may further comprise at least one processing computer 122 and at least one requesting computer 124. Specifically, the processing computer 122 may be configured for retrieving the three-dimensional geometrical data 110 from the requesting computer 124. Further, the processing computer 122 may be configured for outputting and interpretation result generated in the computer implemented method 122 the requesting computer 124. In particular, the processing computer 122 may comprise a memory 126 for storing a database, such as a material database or a partner database. As an example, the design system 116 may comprise at least one web interface 128 four one or both of transmitting information from the requesting computer 124 to the processing computer 122 and vice versa.

[0153] In particular, the requesting computer 124 of the design system 116 may for example be or may comprise at least one front-end or front-end computer, such as at least one client computer. As an example, the requesting computer 124 may be configured for illustrating the interpretation result of step d) of the designing method to a user.

[0154] The processing computer 122 of the design system 116 may for example be or may comprise at least one back-end or back-end computer, such as at least one server, for example at least one of at least one web-server, e.g. configured for providing a web-platform. In particular, the processing computer 122 may be configured for processing the three-dimensional geometrical data 110. In detail, in order to process the three-dimensional geometrical data 110, the processing computer 122 may make use of at least one application programming interface (API) for performing steps b)-c) of the designing method.

[0155] In FIGS. 3 to 9 flow charts of different embodiments of the computer implemented method 120 of designing a molding process for manufacturing at least one component 114 are illustrated. The computer implemented method 120 of designing a molding process for manufacturing at least one component 114, specifically the designing method 120, comprises the following steps, which may specifically be performed in the given order. Still, a different order may also be possible. It may be possible to perform two or more of the method steps fully or partially simultaneously. It may further be possible to perform one, more than one or even all of the method steps once or repeatedly. The method may comprise additional method steps which are not listed herein. Method steps of the designing method 120 are the following: [0156] step a) (denoted with reference number 130) retrieving three-dimensional geometrical data 110 describing a candidate shape of a mold cavity 112; [0157] step b) (denoted with reference number 132) analyzing the geometrical data 110, the analyzing comprising: [0158] step b1. (denoted with reference number 134) analyzing a geometry of the mold cavity 112 by automatically scanning the geometrical data 110 for a plurality of predetermined criteria; and [0159] step b2. (denoted with reference number 136) simulating a use of the mold cavity 112 by at least one of: [0160] a computer-implemented simulation of a filling of the mold cavity 112 with a molten mass of at least one material (denoted with reference number 138); and [0161] a computer-implemented simulation of the component 114 manufactured by using the mold cavity 112 (denoted with reference number 140); [0162] step c) (denoted with reference number 142) automatically interpreting at least one analysis result generated in step b) by subjecting the analysis result to at least one target specification; and [0163] step d) (denoted with reference number 144) outputting at least one interpretation result generated in step c), the interpretation result describing at least one quality of one or both of the molding process and a part design using the candidate shape of the mold cavity 112.

[0164] As an example, the geometry of the mold cavity 112 analyzed in step b1. 134 may be or may comprise at least one geometrical data of a part, such as of a plastic part, e.g. at least one geometry of the component 114, wherein the geometry of the mold cavity 112 may specifically be or may comprise a negative geometry, such as an inverse geometrical shape, of the component 114.

[0165] In particular, as illustrated in FIG. 3, step b2. 136 of the designing method 120 may comprise only the first substep of b2. 138 of simulating the use of the mold cavity 112 by a computer implemented simulation of a filling of the mold cavity 112 with a molten mass of at least one material. Alternatively, as illustrated in FIG. 4, step b2. 136 of the designing method 120 may comprise only the second substep of b2. 140 of simulating the use of the mold cavity 112 by a computer implemented simulation of the component 114 manufactured by using the mold cavity 112. Alternatively, as illustrated in FIG. 5, step b2. 136 of the designing method 120 may comprise both the first substep 138 and the second substep 140.

[0166] The designing method 120 may further comprise step e) (denoted with reference number 146) of retrieving at least one material to be used for the molding process, wherein step e) 146 may be performed before step b) 132, as for example illustrated in FIGS. 6 to 9. In particular, step e) may comprise: [0167] e1. (denoted with reference number 148) retrieving at least one target property of at least one of: the material; the component 114; a manufacturing machine for manufacturing the component 114; and [0168] e2. (denoted with reference number 150) automatically selecting at least one material from a database according to the target property.

[0169] Specifically, step e2. 150 may comprise using at least one process of artificial intelligence, in particular the at least one neuron network.

[0170] Further, the designing method 120 may comprise step f) (denoted with reference number 152) of pre-processing the geometrical data 110 retrieved in step a) 130 by discretizing the geometrical data 110 into a mesh comprising a finite number of mesh elements. Specifically, step f) may further comprise a file repair of defective parts of the geometrical data 110. In particular, as for example illustrated in FIG. 7, step f) may be performed before performing step b).

[0171] Specifically, the designing method 120 may further comprise, for example as a further step as illustrated in FIGS. 7 to 9, outputting at least one automatic report 154. In particular, the automatic report may comprise at least one item of recommendation information, for example comprised by the interpretation result generated in step c) 142.

[0172] Further, the designing method 120 may comprise step g) (denoted with reference number 156) of retrieving at least one item of analysis information from the at least one interpretation result generated in step c) 142 and using the at least one item of analysis information in an automated learning process, as for example illustrated in FIGS. 8 and 9. As an example, the automated learning process may further make use of information on the material retrieved in step e) 146, as is illustrated in FIG. 9 by an arrow pointing from step e) 146 to step g) 156.

[0173] Specifically, the designing method 120 may comprise using the at least one requesting computer 124 and the at least one processing computer 122. In particular, the processing computer 122 may retrieve the three-dimensional geometrical data 110 from the requesting computer 124. Further the processing computer 122 may perform at least step b) 132 and step c) 142 and may further output the interpretation result in step d) 144 to the requesting computer 124. Specifically, as illustrated in FIG. 2, the processing computer 122 and the requesting computer 124 may communicate via the at least one web interface 128.

[0174] The designing method 120 may further comprise step h) (denoted with reference number 158) of outputting the interpretation result generated in step c) to at least one further computing device, as for example illustrated in FIGS. 7 to 9. In particular, step h) 158 may further comprise, for example as a further substep as illustrated in FIG. 9, identifying matching collaborators or partners 160, such as tool manufacturers, mold designers, mechanical engineers, injection molders and material suppliers. As an example, the designing method 120 may comprise performing step h) 158 twice, as illustrated in FIG. 9. In particular, the computing device to which the interpretation result generated in step c) may be output, may be configured for translating the interpretation result into at least one process parameter. Thus, the designing method 120, may comprise as an additional step, as it is illustrated in FIG. 9, translating the interpretation result into at least one process parameter 159. Subsequently to performing step 159, the designing method 120 may further comprise a transferring step 161, wherein the process parameters may be transferred to a suitable manufacturing machine. Subsequently to performing step 161, the designing method 120 may further comprise evaluating a manufacturing outcome 163, such as for example the component.

[0175] As further steps, the designing method 120 may comprise a registration step 162 and a subsequently performed login step 164. As for example illustrated in FIG. 9, the registration step 162 and the login step 164 may be performed before performing step a). Further, matching collaborators or partners may also have to be registered and logged in as may exemplarily be illustrated in FIG. 9 by an arrow pointing from the login step 164 to step h) 158.

LIST OF REFERENCE NUMBERS

[0176] 110 geometrical data [0177] 112 mold cavity [0178] 114 component [0179] 116 design system [0180] 118 processor [0181] 120 computer-implemented method of designing a molding process [0182] 122 processing computer [0183] 124 requesting computer [0184] 126 memory [0185] 128 web interface [0186] 130 step a) [0187] 132 step b) [0188] 134 step b1. [0189] 136 step b2. [0190] 138 first substep of b2. [0191] 140 second substep of b2. [0192] 142 step c) [0193] 144 step d) [0194] 146 step e) [0195] 148 step e1. [0196] 150 step e2. [0197] 152 step f) [0198] 154 outputting at least one automatic report [0199] 156 step g) [0200] 158 step h) [0201] 159 translating the interpretation result into at least one process parameter [0202] 160 identifying matching collaborators or partners [0203] 161 transfer step [0204] 162 registration step [0205] 163 evaluating a manufacturing outcome [0206] 164 login step