Abstract:
An injection molding system comprised of: an injection machine having a barrel and a screw for injecting an injection fluid, a distribution manifold, a valve associated with a corresponding one of one or more downstream gates, each valve comprising an actuator interconnected to and reciprocally driving a corresponding valve pin at one or more selectable upstream velocities including a maximum upstream velocity, a sensor adapted to sense and generate a signal indicative of pressure of the injection fluid in the barrel or an inlet that delivers injection fluid from the barrel to the manifold, and a controller receiving the signal generated from the sensor and including instructions that use the signal as a control value to adjust, during the course of an injection cycle, positioning or velocity of one or more of the valve pins such that the rate of flow of injection fluid into a corresponding one or more of the cavities is controlled, during the course of the injection cycle, based on the control value.
Abstract:
The present invention provides a method and system for controlling the quality of a product produced by an injection molding production process. The invention includes performing a multivariate analysis on injection molding process data collected real-time and determining whether the real-time data is within a predetermined production control limit. When the real-time production data exceeds the control limit, the process is considered out of control and product produced during the out of control condition is removed real-time from the injection molding production process.
Abstract:
A mold includes a controller and core actuators that may independently drive a plurality of mold cores positioned with the mold. Sensors may be included whereby the mold cores are positioned in the mold core responsive to the sensor feedback. The core actuators may be servomotors and may further include motor controllers, one for each servomotor, for use in actuating the mold cores.
Abstract:
An energy management control apparatus for a molding machine that includes a first electrically-driven prime mover configured to drive at least a first molding machine device, and a second electrically-driven prime mover configured to drive at least a second molding machine device, includes a common DC link configured to provide DC energy to the first electrically-driven prime mover and to the second electrically-driven prime mover. A slave axis is configured to supply and absorb energy from to/from the common DC link. A machine controller is configured to (i) communicate with the first electrically-driven prime mover, the second electrically-driven prime mover, the common DC link, and the slave axis, (ii) cause the slave axis to supply energy to the common DC link in response to input from at least one of the first electrically-driven prime mover and the second electrically-driven prime mover, and (iii) cause the slave axis to absorb energy from the common DC link in response to input from at least one of the first electrically-driven prime mover and the second electrically-driven prime mover.
Abstract:
A method for the automated optimization of an injection molding machine set-up process comprising injection molding one or more parts, inspecting the parts for defects, adjusting the injection stroke and/or the injection velocity and repeating the process until the defects are reduced. There is also disclosed a method comprising injection molding one or more parts, determining a mean injection pressure profile by measuring the injection pressure with the machine configured with a constant, desired injection velocity. Then the velocity profile is adjusted to reduce differences between the measured pressure and the mean pressure profile. A further method is disclosed wherein the kickback is calculated and adjusted from screw displacement, packing/holding time and pressure. Also disclosed is a method comprising injection molding one or more parts then determining the gate freeze time by incrementing the holding time and measuring the screw displacement.
Abstract:
A material characterization system and method for quantifying the characteristics of a flowing thermoplastic material is presented. The system comprises a tool comprising first and second tool halves, a plurality of flowing material characterization channels, and a feed runner. The tool is at a temperature that causes phase changes from fluid to solid in at least a portion of the characterized material and enables solidification of the material in the flowing material characterization channels. The feed runner is connectable to a single flowing material characterization channel. The tool is adjustable to disconnect the feed runner from one flowing material characterization channel and connect it to different flowing material characterization channels. A sensor quantifies the characteristics of the material under different flow conditions. The method comprises measuring the material characteristics as it flows through the flowing material characterization channel at multiple flow rates and repeating measurements for different flowing material characterization channels.
Abstract:
A method and apparatus of controlling commencement of an injection of a melt stream of moldable material from an auxiliary injection unit. A sensor is placed in an injection molding system to sense a condition related to an injection of a first melt stream of a first moldable material provided by a primary injection unit. Commencement of a second melt stream of a second moldable material from the auxiliary injection unit is initiated upon the sensed condition related to the injection of the first melt stream being detected at a preselected value. The sensed condition may be a pressure, velocity or temperature of the first melt stream as provided by a direct sensor, a force or strain on a hot runner component as provided by an indirect sensor or the occurrence of a function of the injection molding system as provided by a functional sensor.
Abstract:
A real time method and apparatus for indicating preventative maintenance in a molding system. The molding system could be a metal molding system or a plastics molding system. Real time threshold status data is compared to real time operational parameter data as measured by sensors located on the molding system. If an out of tolerance condition is detected and validated by a comparator, then an indicator is provided to notify the need for preventative maintenance.
Abstract:
Method and apparatus for controlling an injection molding machine having a first surface and a second surface includes a piezo-ceramic sensor configured to be disposed between the first surface and a second surface. The piezo-ceramic sensor is configured to sense a force between the first surface and the second surface, and to generate corresponding sense signals. Wiring structure is coupled to the piezo-ceramic sensor and is configured to carry the sense signals. Preferably, a piezo-ceramic actuator is also disposed between the first surface and a second surface, and is configured to provide an expansive force between the first surface and a second surface in accordance with the sense signals.
Abstract:
Molding assemblies and methods for dual side package molding are described. In an embodiment, a molding compound is injected into a front cavity with a first actuator, and a molding compound is injected into a back cavity with a second actuator, with the first and second actuator assemblies being independently controlled. In an embodiment, the molding compound flows through a through-hole in a molding substrate from a front side of the molding substrate to a back side of the molding substrate, and into the back cavity.