Hot runner process controller

Abstract

A hot runner process controller is configured to monitor the status and operation of a hot runner system to autonomously generate information, thereby improving the injection molding process quality of the hot runner system, which has an inlet nozzle, one or more nozzles with or without actuators, one or more manifolds, and one or more heating elements. The hot runner process controller is self-operating and independent of the injection molding machine. The hot runner process controller includes: one or more sensors located on, within, or at the hot runner system to detect the status and / or operation of the hot runner system; a processing unit; and a memory. The processing unit is connected to one or more sensors, and the memory stores data and program code. The processing unit is configured to load and execute program code to compare sensor information with stored data and determine whether the hot runner system is in an operable state. If the hot runner system is in an operable state, it is configured to generate status information to activate one or more heating elements and / or one or more actuators, thereby enabling production operation of the injection molding machine. When the hot runner system is not in an operational state, it is configured to generate status information to disable one or more heating elements and / or shut down or disable one or more actuators, thereby preventing the injection molding machine from performing production operations.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Application No. 17 / 204,597, filed March 17, 2021, and to European Patent Application No. EP20215358.1, filed December 18, 2020, both of which are incorporated herein by reference in their entirety. Technical Field

[0003] This invention relates to a hot runner process controller configured to monitor the status and operation of a hot runner system. Background Technology

[0004] Typically, an injection molding machine is connected to a hot runner system, which in turn is connected to a mold. Molten plastic is forced from the injection molding system into the mold through the hot runner system. Generally, the hot runner system, injection molding machine, and mold are manufactured by different companies. These components work together during the injection molding process based on predetermined interfaces. However, the injection molding machine cannot adequately control and / or monitor the hot runner system to avoid errors or the production of low-quality products. The injection molding machine may control heating elements and actuators based on pre-programmed information, but this control is insufficient to detect suboptimal injection molding processes or application errors. In applications, the injection molding machine may have an integrated or external hot runner temperature controller, as well as internal or external hydraulic or pneumatic controllers, such as cascaded controls, which, as defined in this application, pertain to the injection molding machine.

[0005] For example, during the preheating of the mold and hot runner system in the preheating station, the injection molding machine has no physical connection with other components. In this situation, the injection molding machine cannot perform control solely through the preheating station and its surroundings.

[0006] A hot runner system includes: one or more manifolds having an inlet nozzle connected to an injection molding machine; and one or more nozzles connected to a plurality of manifolds in a hot runner system comprising an inlet nozzle, one or more nozzles with or without actuators, and one or more manifolds, and a heating element.

[0007] Therefore, there is a strong desire to provide an apparatus and method for monitoring hot runner systems and detecting errors or any quality loss in molded plastic products, with the potential to intervene before damage or quality loss occurs. The aim is to prevent damage to the hot runner system, mold, and molten plastic. Furthermore, one objective is to reduce scrap after the melting process begins. Additionally, the goal is to reduce cleaning work for molders, mold makers (and their service teams), and save significant service and repair costs. Another objective is to improve the mechanical stability of molded parts and enhance their surface finish. Another objective is to detect corrosive wear or excessive pressure before any damage, injury, fire, or explosion may occur. Furthermore, one objective is to provide preventative maintenance triggers, thereby reducing maintenance costs. This again reduces downtime of the injection molding machine and increases availability. Summary of the Invention

[0008] This invention provides a hot runner process controller that autonomously generates information independent of the injection molding machine to improve the quality of the injection molding process. In this context, "independent" means that the power supply and processing unit operate independently of the injection molding machine, allowing operation to be performed even when the injection molding machine is not running or connected. The hot runner process controller can centralize and optimize the monitoring and control of the hot runner system. In a possible implementation, the hot runner process controller includes a separate housing that can be attached to the hot runner system so that the unit can be transported together for the preheating process.

[0009] A hot runner process controller can be configured to monitor the status and operation of a hot runner system. A hot runner system includes an inlet nozzle, one or more nozzles with or without actuators and one or more manifolds with actuators, and heating elements.

[0010] The hot runner process controller is self-operating and independent of the injection molding machine.

[0011] In one aspect of this disclosure, the hot runner process controller includes connection to one or more sensors located on, within, or at the hot runner system to detect the state and / or operation of the hot runner system. The sensors can be of different types.

[0012] The memory stores information and exchanges information with the processing unit. The processing unit may be a central processing unit. The processing unit is connected to one or more sensors. The connection may be direct or through an analog-to-digital converter, an analog-to-digital interface, or an input / output port. The memory stores data and program code, which are loaded and executed by the processing unit. During the execution of the program code, sensor information is compared with the stored data to determine whether the hot runner system is in an operable state. If the hot runner system is in an operable state, the processing unit generates status information to enable the heating element and / or enable or turn on the actuator for operation. If the hot runner system is in an inoperable state, the processing unit generates status information to disable the heating element and / or turn off or disable the actuator. The status information may be provided to the interface (input and / or output) to directly or indirectly enable or disable the operation of the hot runner system.

[0013] The process controller determines whether normal control of the injection molding system is permitted or interrupted during operation. Operation is permitted when all parameters are normal; if a shutdown message is generated, the controller rejects operation and the process of the injection molding equipment to prevent damage.

[0014] In some implementations, the nozzle can be opened and closed by an actuator, which is typically controlled by the injection molding system. A hot runner process controller can directly or indirectly access the actuator to control the operation of the injection molding system. Direct access is provided by valves, relays, or switches directly connected to the processing unit. Indirect control can be performed through the communication interface of the injection molding system.

[0015] In a possible implementation, deactivation / enactivation is performed by triggering individual switches and valves to open / close, thereby enabling or disabling the operation of the hot runner system. These switches and / or valves are located in the connection / line between the injection molding machine and the hot runner system, allowing the operation of the injection molding machine to be interrupted. These switches and / or valves are operated by a processing unit via an interface based on status information generated using sensors to enable or disable control of the hot runner system via the injection molding machine.

[0016] In a possible implementation, the hot runner process controller includes switching units that spatially group switches and / or valves and provide connectors identical to those in standard hot runner systems. The switching units are positioned between the cable and the connectors so that the injection molding machine can be connected to the switching units without modifying the connectors. This allows for seamless integration of the invention into existing injection molding machines, as no connector (plug / receptacle) replacement is required. The switching units may also include separate cables with receptacles for connecting to plugs in standard hot runner systems.

[0017] In a possible implementation, the hot runner process controller includes a signal line output that can be connected to the injection molding machine to provide status information indicating the operating status of the hot runner system. This allows the injection molding machine to be controlled via the status information and may also disable its operation. The signal line can be any network or a single / multiple status lines. The status can be a packet containing several bytes or k bytes of information, or binary information.

[0018] In possible implementations, the hot runner process controller includes one or more sensors: a temperature sensor for detecting the temperature of one or more components of the hot runner system or the temperature of cutouts within a component of the hot runner system, or the temperature of cutouts within a manifold region or flow channel. These components may be nozzles, actuators or actuator parts, manifolds or areas of manifolds defined by heating elements.

[0019] Cutouts are defined within the hot runner system, particularly near components in or around the manifold, where leaks can be identified. Humidity sensors detect humidity around the hot runner system, which is an indication of cooling leaks.

[0020] Flow sensors are used to detect the flow of fluids or melts. Flow sensors can be mechanically pressure-driven or ultrasonic sensors to determine if the cooling fluid, actuator pressure fluid, or melt is moving within the correct limits, or pressure sensors to detect the pressure in the fluid or melt. Based on pressure information, the status / cycle, time / cycle number of the injection molding process can be determined, and leaks or excessive pressure exceeding predetermined values ​​can be identified as erroneous indications. Leak sensors detect leaks in areas where leaks may occur, such as in fluid lines and / or inlet nozzles and / or manifolds, hot runner nozzles and / or actuators, and / or their junctions. Leak sensors can be mechanical sensors, temperature sensors, or pressure sensors. Temperature sensors can detect higher temperatures in manifold areas, indicating plastic leaks because hot plastic comes into contact with the temperature sensor, or if the leaking plastic insulates the temperature sensor, detecting a temperature drop. Furthermore, mechanical sensors may move or bend / become damaged due to plastic leaks. Potential leak areas can include fluid lines, pipes, hoses or joints for oil, water, and / or air, inlet nozzles to manifolds, nozzles to manifolds, manifolds to manifolds, end caps to handles or sleeve seals to manifolds, and bend sensors attached to the hot runner system to detect deformation. Bending sensors can be metallic, changing their electrical properties when bent, or, if the bend is too strong, a strain gauge indicating an abnormal state (workpiece detection, as the part may break), or a state within a cycle (cycle counter or cycle time detection), which results in different bending states when the mold is closed or open, or vibration sensors to detect movement in the hot runner system to detect state within a cycle. Different vibrations occur when the mold is open or closed, and acoustic sensors detect operating sounds associated with the hot runner system. Acoustic sensors can be microphones that record ambient sound and, based on a pre-stored sound pattern, determine operating conditions, states, or cycles; they can also detect ware in this way (e.g., the sound changes when a valve pin is slightly moved); or gyroscope sensors used to detect movement in the hot runner system. In addition, the sensor can also determine the repositioning and / or movement of the hot runner system; and potentiometers on hydraulic, pneumatic, or electric actuators to detect movement within the nozzle to determine the position and / or cycle time of the nozzle pin. In the case of actuators that drive the nozzle pin to open and close the nozzle, position and conditions should be determined. In the case of a broken nozzle pin, the pin's position deviates from the position determined by the potentiometer; and limit switches on hydraulic, pneumatic, or electric actuators are used to determine the position and / or cycle time of the hot runner nozzle needle.Limit switches are also used in combination with potentiometers and actuators; however, the information is binary. Optical sensors mounted on molds or hot runner systems detect light entering the parting line through holes in the mold when the mold is open or closed. Sensors for wear detection detect whether the walls or other components of the manifold have been washed away, whether heating elements have reached the end of their service life, or whether nozzle pins are damaged. These sensors can also be temperature sensors with a specific metal shielding layer. If the temperature sensor malfunctions due to the metal being washed away, the shielding status of the manifold can be determined.

[0021] In a possible implementation, the processing unit performs one or more of the following operations based on the sensor information:

[0022] The detection is performed by using flow and temperature sensors to determine whether the cooling and / or actuating fluid in one or more actuators of the hot runner system is operating at a minimum flow rate and preferably below the maximum temperature measured at the outlet of the cooling and / or actuating fluid; status information is generated to indicate that one or more heating elements of the hot runner system can be activated for heating. In this case, actuator overheating can be avoided, and information can be generated to open the heating element or open the valve. If the temperature of the cooling fluid becomes too high, the heating element can be interrupted / power reduced, or information can be generated to de-energize / shut down the heating element.

[0023] A temperature sensor detects that the temperature of the cooling and / or actuating fluid, preferably measured at the outlet, is higher than the maximum temperature, generating status information to indicate that the hot runner system is deactivated. In this case, as described above, the heating element can be interrupted / power reduced by switching on or by sending information to the injection molding system, or information can be generated to de-energize / shut down the heating element.

[0024] A status message is generated to indicate that the hot runner system is deactivated if insufficient pressure is detected by a pneumatic or hydraulic pressure sensor to operate the hot runner valve and / or one or more actuators. If the actuator operates under insufficient pressure, there may be a leak or the pressure pump may not be operating within specifications.

[0025] If an air or hydraulic pressure sensor detects that one or more actuators are under excessive pressure and cannot operate, the shut-off pin may damage the mold. This generates a status message indicating that the hot runner system should be shut down or that a pressure line has been closed. Shutting down a pressure line involves reducing the pressure in that line by opening a valve.

[0026] The system generates status information to indicate that the hot runner system is deactivated by detecting that one or more actuators of the hot runner nozzle are above a predetermined temperature using a temperature sensor.

[0027] A status message is generated to indicate that the hot runner system should be shut down if one or more heating element areas of the manifold, nozzle, or inlet nozzle fall below a specific temperature level after a certain time limit, detected by temperature sensors and timers. The heating element area is the area of ​​the manifold preferably heated by a single heating element. Each heating element area is monitored by a temperature sensor. If the temperature is outside the predetermined limit, the valve can be closed to avoid damage to the manifold or other components, such as the nozzle.

[0028] Temperature sensors and timers detect when heating time in one or more zones exceeds predetermined limits and no operating cycle is detected. This generates status information to trigger the hot runner system to be shut down, the heating element to be disconnected, or the temperature of the heating element to decrease. Some types of plastics can only be heated for specific time periods to avoid quality loss. If the time span is too long, the properties of the plastic will change, and the product will lose its performance.

[0029] The injection molding system is shut down by detecting when the temperature drops below a predetermined limit within a specific time using a temperature sensor and timer, generating status information to shut off the actuator before the melt solidifies. If the machine is powered off, the nozzle pin must be closed while the plastic / melt is still liquid; otherwise, the pin, gate, mold, and actuator may be damaged.

[0030] Temperature sensors and timers are used to detect when a temperature drop below a specific temperature occurs faster than a predetermined threshold indicating that the plastic material has solidified. This generates status information indicating that actuators should be deactivated to prevent movement and avoid the risk of damage. In this case, the melt has solidified and access to the actuators is interrupted by a switch or valve.

[0031] In the absence of detected circulation or when the production cycle is not running, the system detects that the processing temperature has been reached and the heating safety time has been exceeded via a temperature sensor. It then generates status information to indicate that the hot runner system or heating element should be shut down or that the temperature of the heating element should be reduced. Furthermore, this avoids prolonged exposure of the plastic to high temperatures. In this case, autonomous cycle detection is performed based on the received sensor information.

[0032] A humidity sensor detecting a humidity level higher than a predetermined level indicates a cooling leak. Based on this humidity information, a status message is generated to indicate that the hot runner system or heating element is being shut down, or that the temperature of the heating element is being reduced.

[0033] Coolant leaks are detected using flow or pressure sensors. If the flow rate or pressure falls below a certain level during circulation, the fluid driving the actuator or the cooling fluid may be leaking, which will trigger the generation of status information to indicate that the hot runner system is being shut down.

[0034] Melt leakage is detected by mechanical switches, electrical switches, temperature sensors, or pressure sensors in the risk areas of the hot runner system, and status information is generated to indicate that the hot runner system is to be shut down.

[0035] The viewing point within the flow channel of the hot runner system is detected using a temperature sensor; the cycle time and / or number of cycles are determined.

[0036] Cycle time and / or number of cycles are detected using motion or deformation sensors; and

[0037] A pressure sensor in the flow channel detects that the pressure is too high for the hot runner system; a valve pin driven by a hydraulic, electric, or pneumatic actuator will close the inlet nozzle to prevent damage.

[0038] In a possible implementation, the hot runner process controller of the processing unit is configured to detect the preheating status of the hot runner system preheating station and to select one or more of the aforementioned operations, performed via valves, that are different from the molding operation. Preheating is detected by values ​​transmitted from one or more sensors, requiring no additional input. In a possible implementation, manual input from the user may be allowed. Preheating can be detected by the physical location of the hot runner system, by the connectors used, by temperature profiles, and by circulation loss and pressure loss in the piping.

[0039] In a possible implementation, if preheating is detected and if the preheating temperature is reached and the predetermined time allowed for melt residence in the processing unit is exceeded, information is configured to be generated to deactivate the heating element or reduce the temperature. As mentioned above, certain types of plastics cannot be heated for too long without losing their properties.

[0040] In a possible implementation, the hot runner process controller is configured to detect the production cycle of the injection molding machine solely by using sensor values, and to select different stored data and program code for the aforementioned operation compared to preheating. Therefore, the present invention is capable of autonomously detecting both modes based on sensor-generated values.

[0041] In a possible implementation, the hot runner process controller includes one or more of the following components: a network interface for transmitting status information over a network; a display for indicating status information to a user; a keyboard for allowing user input; output relays for providing status information; and a serial interface for providing status information. This allows network messages to be sent to the user or other devices, such as injection molding machines, which can be addressed to provide the corresponding information.

[0042] In a possible implementation, the hot runner process controller includes means for providing bypass functions to bypass one or more of the operations described above and forcibly enable or disable the hot runner system. If an error is detected, the user may want to re-enable the hot runner system. In this case, the user can force the hot runner process controller to disable or bypass certain functions, thereby preventing the injection molding process.

[0043] In one possible implementation, the hot runner process controller includes means for recording the activation of the bypass function and continuing to record incoming sensor data. In another possible implementation, an input device is required to enter a password to enable the bypass function.

[0044] In a possible implementation, the power supply is provided by a connector for the hot runner system, preferably by a connector for at least one heating zone in manual mode. This allows for easy integration using standard connectors used with the heating elements. Furthermore, legacy systems can also be integrated.

[0045] In possible implementations, additional switching devices are used to switch one or more of the following: switching the power supply to one or more heating elements; switching one or more solenoid valves or switching valves to close or open one or more actuators; switching one or more solenoid valves or switching valves to interrupt the flow of actuating fluid from the injection molding machine to one or more actuators; and switching sensor cables and / or thermocouples to provide analog values ​​to control one or more heating elements to allow the use of the same sensors as the injection molding system. The two systems share the same sensors; disconnecting sensor cables and / or thermocouples simulates a broken sensor line and forces the injection molding machine to stop heating the heating elements; detecting pressure sensors in the flow channel where the pressure is higher than a predetermined value that is too high for a hot runner system; and valve pins driven by hydraulic, electric, or pneumatic actuators closing the inlet nozzles to prevent damage.

[0046] Another aspect of the invention is a method for monitoring the status and operation of a hot runner system. The hot runner system includes: an inlet nozzle; one or more nozzles with or without actuators and one or more manifolds; and one or more heating elements. The method is performed by a self-operating hot runner process controller independent of the injection molding machine. The hot runner process controller can access information from one or more sensors located on, within, or at the hot runner system to detect the status and / or operation of the hot runner system. The hot runner process controller includes a processing unit and a memory, wherein the processing unit is connected to one or more sensors, and the memory stores data and program code, comprising the following steps: the processing unit loads and executes program code to compare sensor information with stored data to determine whether the hot runner system is in an operable state, and if the hot runner system is in an operable state, generates status information to enable one or more heating elements and / or turn on one or more actuators; if the hot runner system is in an inoperable state, generates status information to deactivate one or more heating elements and / or turn off the actuators. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the preheating process of the hot runner system in the preheating station.

[0048] Figure 2 The diagram illustrates a heating process with an initial stage, using a mold from a preheating station and installed and connected in an injection molding machine with production and production end stages.

[0049] Figure 3 A heating process with a start-up phase and without the use of a preheating station with production and production end phases is shown.

[0050] Figure 4 This indicates whether the loop is confirmed, the loop is interrupted, or the loop has not started.

[0051] Figure 5 A hot runner system is shown, which has hydraulic or pneumatic actuators and solenoid valves or switching valves to open or close the actuators to open or close the valve pins contained in the hot runner system.

[0052] Figure 6 A hot runner system is shown, which has hydraulic or pneumatic actuators and actuators (solenoid valves) to open or close valve pins driven by the injection molding machine, and additional solenoid valves in the hot runner system to interrupt pressure lines driven by the injection molding machine.

[0053] Figure 7 A hot runner system with wiring diagrams or de-enabled is shown.

[0054] Figure 8 A hot runner system with an electric actuator and a hot runner process controller is shown to open or close the valve pins provided by the hot runner system.

[0055] Figure 9 The frictional forces in the flow channel used to determine the circulation are shown.

[0056] Figure 10 The image shows an item detection process using a covered thermocouple.

[0057] Figure 11 The concept of closing the inlet nozzle is illustrated so that high pressure does not occur in the flow channel, and can occur in the open position if the pressure is acceptable.

[0058] Figure 12 The detection of a damaged valve pin is shown. Detailed Implementation

[0059] This invention also allows for control of the hot runner system in the preheating station. Figure 1 The temperature is displayed over a period of time. After a soft start initially reaches a certain temperature level, a steeper temperature rise is triggered until the preheating temperature is reached. This temperature can be measured by temperature sensors at various components such as the manifold, actuator, and nozzle. After reaching the preset preheating temperature, a certain time elapses until the temperature stabilizes. The preheating temperature is lower than the temperature set for material handling. Based on this mode, the hot runner process controller can determine that the hot runner system is in the preheating station. The temperature mode can be defined by the slope over time or time intervals. The interface can also indicate that the hot runner process controller system is in the preheating station.

[0060] For example, when the hot runner process controller is activated (energized) and connected to the hot runner system, and the cooling water is running (e.g., at minimum flow rate and maximum outlet temperature, e.g., 50°C), the hot runner system can be heated. In this case, a message is generated to activate the heating element. Activation of the heating element can be performed by actively shutting down a relay or switch that allows current to flow to the heating element, or by sending a message to the injection molding system. This means that the heating phase can begin when the coolant is running and if the cooling temperature or actuator temperature does not exceed a preset maximum temperature. For example, if the temperature exceeds the upper limit, a message is generated to automatically deactivate the heating element. It is then shut down by the hot runner process controller. Shutdown can be performed by a permanent or temporary switch or relay until the temperature drops below the preset maximum temperature.

[0061] When the hot runner process controller is enabled (powered on and connected to all relevant sensors correctly), the actuator can be enabled and preheated if the actuator does not exceed a predetermined temperature, the plastic material in the flow channel is melted, and the (fluid) air or oil pressure is above a predetermined lower limit and below a predetermined upper limit.

[0062] A temperature sensor in the actuator is used to measure the temperature on or within the actuator (pneumatic, hydraulic, or electric). This temperature should be below a specific temperature (e.g., 80°C) to protect the actuator and / or seals and / or hydraulic oil and / or lubricant so that the heating element can remain enabled.

[0063] All heating elements in all zones / areas require preheating. This is measured by temperature sensors on / at the manifold in the zone / area. If one heating element fails to operate or falls below a predetermined temperature, a shutdown message is provided to all heating elements and / or actuators.

[0064] If the heating time exceeds a predetermined time limit, for example, more than 20 minutes in one or more zones without detecting one or more cycles, a message is generated to disable the heating element and stop or set the power supply to all heated zones to a lower temperature. The predetermined time and temperature limits depend on the plastic material. If the hot runner process controller detects that one or more heated zones have not reached the preset temperature (which may occur if the heating element or thermocouple fails during or after the activation phase), a message to disable the system is generated.

[0065] All this information can be transmitted as instructions to the injection molding machine via an electronic interface (e.g., via an industrial x.0 (4.0) connection like OPC UA between the hot runner process controller and the injection molding machine) to stop the heating of the hot runner system. Information exchange can be performed via cable, LAN, Bluetooth, USB, WLAN, 3G, 4G, 5G, etc. If connected, the hot runner process controller can control the injection molding machine (e.g., issue an alarm or send a request to reduce the hot runner system temperature). If the preheating temperature is reached and falls below the allowed predetermined time, and the melt residence time exceeds (e.g., 20 minutes), the heating elements in the heating zone will be deactivated to shut off or set to a lower temperature. In this case, information about deactivation / temperature reduction can be sent to the customer (e.g., via screen / display, email, or an app message). If the hot runner process controller is standalone, meaning no connection to the injection molding machine is provided, deactivation occurs via a protective switch / relay installed between the plug interface and the heating elements of the hot runner system. If the hot runner process controller is connected to the injection molding machine, a stop message will be sent to the injection molding machine to reject the process running on the injection molding machine.

[0066] Figure 2 The diagram illustrates a heating process with an initial phase, utilizing a mold from a preheating station and mounted and connected to the injection molding machine, having both a production start and a production end. After heating the mold and hot runner at the preheating station, the hot runner system is connected to the injection molding machine. During connection, the temperature drops. Once connected to the injection molding machine, the temperature of the injection molding process reaches a higher level than during the preheating phase. The temperature must stabilize before production begins. The invention monitors all these phases. Following the heating phase, until the processing temperature on the injection molding machine is reached, the invention also monitors a safety time to ensure the melt has uniformly reached the set temperature. The hot runner system is activated for heating when the hot runner process controller is enabled (powered on and properly connected to all relevant sensors) and connected to the hot runner system, and if there are actuators on the hot runner system, cooling water is running at a defined minimum flow rate and a defined maximum temperature (e.g., 50°C) at the outlet. The heating phase is performed by activating the heating elements and can only begin when the cooling fluid is running and the cooling temperature or actuator temperature does not exceed a predetermined temperature. If the temperature exceeds the preset limit, the heating element will automatically stop and shut down.

[0067] Figure 3 This illustrates a heating process with a start-up phase, production phase, and production end phase, without the use of a preheating station. The injection molding machine can be activated when the hot runner process controller is enabled (powered on and properly connected to all relevant sensors), the actuator does not exceed the predetermined temperature, the plastic material in the flow channel melts, and the fluid (air or oil) pressure is above a predetermined level. Furthermore, temperature is monitored to prevent the actuator from being used by the injection molding machine. The actuator is activated when the preset temperature is reached and stabilized, meaning the injection molding machine can begin its operation. Additionally, the temperature measured by sensors on / in the actuator (pneumatic, hydraulic, or electric) should be below a specific temperature (e.g., 80°C). The injection molding machine is capable of being activated and / or can begin its operation when the preset temperature of the plastic material used is reached (the plastic material needs to melt, otherwise the system may be damaged) and after sufficient additional time (depending on the plastic material) to ensure that the temperature is stable in all required areas (e.g., 5 minutes).

[0068] When the sensor does not detect any production cycle and the heating time exceeds a predetermined limit, such as more than 20 minutes in one or more areas, the component is deactivated. This means that the power supply to all heating elements and actuators is deactivated or triggered to close the valve by moving the valve pin, or if a connection to the injection molding machine is provided that allows external temperature control, the temperature is reduced to a lower predetermined temperature.

[0069] In a possible implementation, the invention detects that one or more heating zones are not at the preset temperature. This may be caused by damage to the heating elements or thermocouples during or after the activation phase. The injection molding machine should not operate. A warning message is sent to the operator via screen, email, or application. If all of the above conditions are not met, a message is sent to the injection molding machine via the (Industry x.0) interface to disable the injection molding process. However, if the predetermined processing temperature has been reached and the predetermined heating safety time has been exceeded without any production cycle running (cycle not detected), the invention will generate a message to shut down all heating elements, or, depending on the type of plastic material, reduce the temperature via the interface.

[0070] exist Figure 4 In this context, the second temperature or lower temperature indicates this condition. If the hot runner process controller does not interface with the injection molding machine, a shutdown can be performed using an electrical switch installed between the plug interface and the heating element. If the hot runner process controller is connected to the injection molding machine, a shutdown message will be sent to the injection molding machine.

[0071] The following prerequisites must be met to enable the molding process: (1) The hot runner system can continue to operate when the hot runner process controller is enabled (powered on and properly connected to all relevant sensors) and connected to the hot runner system and the cooling water is running (at minimum flow rate and maximum outlet temperature, e.g., 50°C). Heating can only continue to operate if the coolant is running and the cooling temperature or actuator temperature does not exceed the predetermined temperature. If the temperature exceeds the mentioned upper limit, the heating element can be automatically deactivated; (2) The hot runner system can continue to operate when the hot runner process controller is enabled (powered on and properly connected to all relevant sensors) and connected to the hot runner system and the heating element is running; (3) The hot runner system can continue to operate when the hot runner process controller is enabled (powered on and properly connected to all relevant sensors) and connected to the hot runner system and the air or oil pressure is correct; (4) The temperature on / inside the (pneumatic, hydraulic, or electric) actuator is below a certain value. (5) The hot runner system can continue to operate when the preset temperature is reached for the plastic material used (which needs to melt or the system will be damaged; it also needs to be below a certain temperature to avoid damaging the material); and (6) If the plastic material dependence time is exceeded without running the production cycle (no cycle detected), shutdown information will be automatically generated for all heating areas; or the plastic material information will be sent to the injection molding machine through the interface to reduce the temperature, or the power supply of the heating element will be modulated to reduce the temperature.

[0072] If the hot runner process controller is independent, shutdown is performed via a protective switch installed between the customer plug interface and the hot runner system heating element. If the hot runner process controller is connected to the injection molding machine and / or an external hot runner system controller, shutdown information is sent to one of the aforementioned devices.

[0073] Figure 3 An example is shown below: where the valve pin needs to be closed before the plastic material cures. After production stops, the temperature drops. This invention detects the production drop and stoppage caused by the lack of circulation and the drop in temperature. The hot runner process controller receives information about the valve and valve pin status. Sensors that detect valve pin position or line pressure, etc., can determine the valve pin position. If a connection to the injection molding machine is provided, a message is sent to close the valve pin as long as the material has not solidified. If the material has solidified, a message is sent to not close the valve pin. If no connection is available, this invention can trigger valves with full-open or full-close functions (such as check valves; proportional valves), servos, etc., to directly drive actuators, or to interrupt the operation of the injection molding machine in the event of material solidification.

[0074] Figure 5 A hot runner system 1 is shown, comprising an inlet nozzle, manifold b, actuator 3, and nozzle c. The nozzle includes a gate 2 that is opened or closed by a valve pin. The valve pin is driven by actuator 3 (hydraulic or pneumatic) to actuate its opening or closing. The actuator is fluid-driven, with a valve pin closing pipe / hose / line 4 and a valve pin opening pipe / hose / line 5 present. An additional valve 6 is configured as a change-over valve or a solenoid valve. In lines 4 and / or 5, a sensor 7 is positioned to detect any movement of the actuating medium. Lines 5 and 4 are connected via a connecting plate or block 8 to a fluid tank T and a pump or pressure P and an exhaust valve. An additional cooling circuit 9 is established to cool the valves and / or actuators, also connected via the connecting plate or block 8. A sensor 10 is used to detect the movement of the cooling medium. In a possible implementation, the sensor is used to detect the movement of the cooling fluid and the amount each time. A temperature sensor 11 is used to detect whether the actuator temperature exceeds a preset value. Additional sensor 12 is used to detect the temperature of the cooling medium at the cooling outlet and inlet of the cooling line. Sensor 13 is used to detect valve pin position, which can be used to determine the current state of a cycle or process. Sensor 14 is used to detect air humidity (e.g., to detect cooling water leaks). Vibration sensor 15 is used to detect movement or vibration in the hot runner system. This sensor can be used to detect cycles (e.g., as a cycle counter and / or cycle time). Strain gauge or bending sensor 16 is used to detect bending in the hot runner or mold.

[0075] Figure 6An embodiment is shown in which a drive valve 17 (conversion) is introduced, which is powered by the injection molding machine to operate the actuator. To interrupt actuator operation by means of the present invention, valves 18 and / or 18' can be driven by a solenoid and introduced into the pipeline to block media flow. This allows the present invention to stop fluid flow and actuator operation.

[0076] Figure 7 An embodiment is shown in which the valve is driven by an electric actuator. Figure 7 A power cable 19 for the heating element is shown. A sensor cable 20, acting as a thermocouple cable (+;-), is connected to a switch or contactor or one or more relays to switch the thermocouple cable or to modify sensor values ​​affecting the injection molding machine. When an additional cable 21 from an additional thermocouple is introduced to monitor temperature, it is not possible to use the thermocouple / sensor in parallel with the injection molding machine if separate monitoring with a single thermocouple is not feasible. Interface 22 is used to provide power to the invention.

[0077] Interface 23 is used to connect to the injection molding machine to allow temperature control (to a temperature sensor, which may also be wired together on one or more powered plugs). The hot runner process controller 24 is connected to switch 26 to interrupt or switch the thermocouple and to switch 27 to interrupt the power supply to the heating element, thereby enabling or disabling the heating element. This connection is established by line 25 to switch the thermocouple / temperature sensor to an interrupted position or a voltage position, in which the injection molding machine interprets the value as higher than permissible, triggering the injection molding machine to lower the temperature. Line 25' is used to switch the power line to a disconnected position. Switch 26 is used to switch the thermocouple / temperature sensor connection. Switch 27 is used to interrupt the power line. The temperature sensor 28, which may be a thermocouple, is located in the flow channel. Switching the power cable to the heating element via an electrical conductor may also lower the temperature if the hot runner process controller determines that certain parameters are out of range.

[0078] exist Figure 7In this configuration, if the hot runner process controller generates information indicating that certain parameters are out of range, it will switch the thermocouple connection via a relay. Thermocouple communication with the injection molding machine is interrupted. The injection molding machine should display a faulty thermocouple / temperature sensor and stop supplying power to the heating element. In a possible implementation, the hot runner process controller simulates the voltage on the thermocouple / temperature sensor, indicating that a certain temperature has been exceeded, which causes the injection molding machine to react by reducing the heat at the heating element. The injection molding machine will then reduce the voltage on the heating element, resulting in a temperature drop. Using a direct connection to the injection molding machine will result in a temperature drop or a shutdown triggered by the injection molding machine itself. Switching of the thermocouple / temperature sensor connection to the injection molding machine can also be used, depending on the plastic material and without a running / determined cycle to protect the plastic material from degradation within a given time. Another option is to interrupt communication between the thermocouple / temperature sensor and the injection molding machine. The injection molding machine should display a faulty thermocouple / temperature sensor and stop supplying power to the heating element.

[0079] If none of these conditions are met and the temperature drops (e.g., 10°C) below a preset temperature, the invention generates information to prevent the valve pin from closing. This is to prevent the valve pin from closing and being damaged by the plastic material becoming too cold (hardened). If the temperature does drop rapidly below a certain temperature (when the plastic material solidifies), the valve pin should not be allowed to move because there is a risk of damage.

[0080] In a possible implementation, the hot runner process controller has a bypass function that allows production to continue by bypassing one or more of the aforementioned deactivation messages. Enabling of the bypass function should be logged. The bypass function is only enabled after a password is entered, and all data during the bypass period is logged.

[0081] Hot runner process controllers feature extensive leak detection to prevent damage (e.g., overheating or electrical short circuits), achieved through plastic leak detectors that indicate whether plastic material is in areas it shouldn't be in. The contents of this application (U.S. Application No. 16 / 802,874) are incorporated herein by reference. Flow sensors for cooling water or oil are used to determine the derivation of standard flow rates. If a certain amount is exceeded, a leak may occur, and information must be generated to shut down the system. The same method can be used for air or other fluids. Pressure sensors can be used for leak detection. Furthermore, predetermined information patterns can be used to determine leaks. Sudden, repetitive pressure drops may indicate the presence of a leak.

[0082] Figure 9A cycle counter thermocouple / temperature sensor in the flow channel is shown, which measures the melt temperature deviation generated during short-duration dynamic injection (shear heating) to calculate the number of cycles. Along with a timer, cycle time can also be detected because the injected melt temperature, after the injection drops, can be determined from the time the shear heating ceases. Figure 9 The invention is capable of determining the number of cycles, cycle length, and combinations of other sensors, such as pressure sensors and / or position sensors, in the actuator. Cycle counting also allows for the generation of information to suggest maintenance after a certain number of cycles. For this purpose, limit switches on hydraulic, pneumatic, or electric actuators, or potentiometers or Hall effect sensors, inductive sensors, piezoelectric sensors, ultrasonic sensors, and optical sensors on hydraulic, pneumatic, or electric actuators, can be used as cycle counters. Optical sensors mounted on a sealed cable channel to detect light entering the parting line through holes in the mold can also be used to determine cycles and cycle times if the mold opens or closes. Bending sensors (e.g., resistance wire strain) that detect deformation (e.g., deformation of the manifold when a machine nozzle strikes the inlet nozzle of the manifold) can also be used to determine cycles and cycle times. Vibration sensors can detect the opening or closing movement of the mold, indicating vibrations on the pipes or hoses by opening or closing valve pins using oil or hydraulic pressure. Furthermore, this information can be used to determine cycles and cycle times. When using pressure sensors, the pressure changes with each injection cycle in the flow channel. Acoustic sensors can also be used. In addition, acoustic sensors can be used (for example, the closing of a mold can be detected acoustically). All of these sensors can be used individually or in combination to determine the cycle and cycle time.

[0083] All these sensors can be used to determine if the cycle time is inconsistent or if a pause has been exceeded. If it has, the system needs to (generate an alarm) reduce the heat of certain plastic materials (risk of plastic deterioration or even explosion). Information should be generated to warn the operator or shut down the injection molding machine.

[0084] Figure 10 The image shows the item detection process. After a period of time, a thermocouple / temperature sensor placed in the flow channel with an additional protective wall thickness or coating will not detect any temperature if it is washed away by a plastic material (e.g., fiberglass filler). This information, alone or together with the cycle count, can be used to generate a message indicating that all flow channels, valve pins, and gates are worn. This information can be used to shut down the system or allow production to continue for a predetermined number of cycles.

[0085] according to Figure 12Limit switches on hydraulic, pneumatic, or electric actuators can be used to detect damaged valve pins. In this case, the piston can still move its full stroke, but the valve pin cannot move to prevent damage. Other motion sensors (e.g., Hall effect sensors, inductive sensors, piezoelectric sensors, ultrasonic sensors, optical sensors) can also be used individually or in combination to detect damaged valve pins. Thermocouples on heating elements can be tracked to detect peak heat and usage time from each heating zone or a single heating zone. After a predetermined number of peak heat and usage times, information is generated to recommend replacement of the heating element. The ampere life of the heating element can be determined by a current sensor, which is used to recommend replacement. Excessive molten plastic pressure can damage parts in a hot runner system. Information is generated to indicate this error, either by shutting down the injection molding machine or switching the valve at the inlet nozzle to protect the manifold.

[0086] exist Figure 11 In the inlet nozzle, valve pin 36 is in the closed position, which stops the flow of plastic. However, valve pin 37 is in the open position, allowing the plastic to flow. Figure 12 The diagram illustrates the detection of a damaged valve pin. Typically, the valve pin breaks off in the head region, where it hangs in the actuator's piston rod. If the valve pin head is damaged, the piston can still move, but the valve pin will not. To find a solution to this problem between the actuator and the manifold, a sensor can be placed to monitor whether the valve pin is still moving. This can be achieved through an extension leading to a cooler area, thus protecting the sensor. If there is sufficient space or by moving the actuator away from the manifold (a longer support), the sensor can be placed directly on the valve pin.

[0087] The above description is illustrative and not limiting. The scope of the invention should be determined by referring to the appended claims and their full scope. Future developments in the art are expected and anticipated, and the disclosed apparatuses, kits, and methods will be incorporated into such future embodiments. Therefore, modifications and variations are possible with respect to the invention, and it is limited only by the appended claims.

[0088] Reference tag list

[0089] 1 = Hot runner system (inlet nozzle, manifold, actuator, nozzle)

[0090] a = inlet nozzle

[0091] b = manifold

[0092] c = nozzle

[0093] 2 = Gate that is opened or closed by a valve pin

[0094] 3 = Actuator (hydraulic or pneumatic) to drive the valve pin to open or close.

[0095] 4= Valve pin shuts off pipes / hose

[0096] 5 = Valve pin opens pipe / hose

[0097] 6=Solenoid valve

[0098] 7 = Sensor for detecting movement of the actuating medium

[0099] 8 = Connected to customer drive power (air, oil, electricity) and cooling

[0100] 9 = Cooling circuit

[0101] 10 = A sensor used to detect the movement of cooling medium or a sensor used to detect the movement and the amount of each movement.

[0102] 11 = Temperature sensor used to detect whether the actuator temperature exceeds the limit.

[0103] 12 = Sensors used to detect the temperature of the cooling medium at the cooling outlet and inlet.

[0104] 13 = Sensor used to detect valve pin position

[0105] 14 = Sensors that detect air humidity (e.g., to detect coolant leaks).

[0106] 15 = Vibration sensor used to detect movement or vibration. Can be used to detect cycles (e.g., as a cycle counter).

[0107] 16 = Strain gauges or sensors used to detect bending in hot runners or dies

[0108] 17 = Customer-driven solenoid valve; 18 and / or 18' = Solenoid valve driven to block media flow.

[0109] 19 = Heater power cable

[0110] 20 = Thermocouple cable (+; -)

[0111] 21. If separate monitoring from the original thermocouple is not possible, the cable from the additional thermocouple is used to monitor the temperature.

[0112] 22 = Interface for connecting to the customer's power plug

[0113] 23 = Customer plug interface for temperature control (can also be mixed on one or more powered plugs)

[0114] 24 = Hot runner process controller

[0115] 25 = Switch the thermocouple / temperature sensor to the interrupt position or the position where the customer controller determines the system temperature is higher than the allowable voltage.

[0116] 25' = Switch the power line to an open line.

[0117] 26 = One or more contactors or one or more relays used for switching thermocouple / temperature sensor connections.

[0118] 27 = One or more contactors used to interrupt power lines

[0119] 28 = Thermocouple in the fluid channel

[0120] 29 = Electronic actuator that drives the opening or closing of a valve pin.

[0121] 30 = Power lines used for electronic actuators

[0122] 31 = Sensor circuitry for electronic actuators

[0123] 32 = Connected to customer cooling

[0124] 33 = Controller for electronic actuators

[0125] 34 = Power line from the customer (e.g., 230V)

[0126] 35 = Signal line from the injection machine, for example, used for the injection start signal.

[0127] 36 = Valve pin in the inlet nozzle in the closed position => Plastic flow stops / is impossible

[0128] 37 = Valve pin in the inlet nozzle in the open position => Allows plastic flow.

Claims

1. A hot runner system, the hot runner system comprising: One or more manifolds; Inlet nozzle leading to the manifold; One or more outlet nozzles exiting the manifold; One or more heating elements; One or more actuators that control the flow exiting the outlet nozzle; One or more sensors, located in or at the hot runner system, are used to detect the state or operation of the hot runner system. A process controller having a processing unit and a memory, wherein the processing unit is connected to the one or more sensors, wherein the processing unit is configured to: load and execute program code to compare sensor information with data stored in the memory to determine whether the hot runner system is in an operable state, and, if the hot runner system is in an operable state, enable the one or more heating elements and one or more actuators to enable production operation; In the event that the hot runner system is not in an inoperable state, the processing unit is configured to generate status information to disable one or more heating elements and shut down or deactivate one or more actuators, thereby preventing the injection molding machine from performing production operations. The processing unit is configured to perform one or more of the following operations: (a) Detecting whether the cooling and / or actuating fluid in one or more actuators of the hot runner system is operating at a predetermined minimum flow rate and below a predetermined maximum temperature measured at the outlet of the cooling and / or actuating fluid using flow and temperature sensors, and generating status information to indicate that the one or more heating elements of the hot runner system should not be deactivated; (b) The temperature of the cooling and / or actuating fluid measured at the outlet is detected by a temperature sensor as being higher than a predetermined maximum temperature, and a status message is generated to indicate that the hot runner system should be shut down; (c) The hot runner valve and / or one or more actuators are driven to operate below a predetermined minimum pressure by means of an air or oil pressure sensor, and status information is generated to indicate that the hot runner system should be deactivated; (d) The actuators are operated by detecting pressures above a predetermined limit by a pneumatic or hydraulic pressure sensor, such that the valve pins can damage the mold and generate status information indicating that the hot runner system should be deactivated or the pressure line should be shut down. (e) Detecting that one or more actuators of the hot runner nozzle are above a predetermined temperature using a temperature sensor, and generating status information to indicate that the hot runner system should be shut down; detecting that one or more heating element areas of one or more manifolds or nozzles or inlet nozzles are below a specific temperature level after a specific time limit using a temperature sensor and a timer, and generating status information to indicate that the hot runner system should be shut down. (f) Detecting that the heating time in one or more areas exceeds a predetermined limit and no operating cycle is detected by temperature sensors and timers, and generating status information to disable the hot runner system or the heating element or temporarily disable the heating element to reduce the temperature or enable a predetermined lower temperature; (g) If the temperature drops below a predetermined limit within a specific time period, the shutdown of the injection molding system is detected by a temperature sensor and a timer, and the following status information is generated: one or more actuators should be enabled to shut down one or more actuators before the melt solidifies; (h) Detecting a temperature drop below a specific temperature faster than a predetermined threshold indicating solidification of the plastic material using a temperature sensor and timer, and generating status information that one or more actuators should be deactivated; (i) If no cycle is detected, the temperature sensor detects that the processing temperature has been reached and the heating safety time has been exceeded while the production cycle is not running, and generates status information to indicate that the hot runner system or the one or more heating elements should be shut down, or the temperature of the one or more heating elements should be reduced. (j) The humidity sensor detects that the humidity is higher than a predetermined level, thereby indicating the presence of a cooling leak and generating status information to indicate that the hot runner system or one or more heating elements should be shut down; (k) Detect leakage of cooling water and / or fluid used to drive the one or more actuators by means of a flow sensor or pressure sensor, and generate status information to indicate that the hot runner system should be shut down; (l) Detection is performed by mechanical switches, electrical switches, temperature sensors or pressure sensors in areas of the hot runner system where melt leakage may occur, and status information is generated to indicate that the hot runner system should be shut down if leakage occurs; (m) The viewing point in the flow channel of the hot runner system is detected by a temperature sensor to determine the circulation time and / or the number of cycles; (n) Detecting cycle time and / or number of cycles using a motion sensor or deformation sensor; and (o) If a pressure sensor in the flow channel detects that the pressure is higher than a predetermined value that is excessively high for the hot runner system, a valve pin driven by a hydraulic, electric, or pneumatic actuator will close the inlet nozzle to prevent damage. The processing unit is configured to detect the preheating of the preheating station of the hot runner system and is configured to select one or more operations (a) to (o) performed by a valve that are different from the injection molding operation.

2. A hot runner system, the hot runner system comprising: One or more manifolds; Inlet nozzle leading to the manifold; One or more outlet nozzles exiting the manifold; One or more heating elements; One or more sensors, located in or at the hot runner system, are used to detect the state or operation of the hot runner system. as well as A process controller having a processing unit and a memory, wherein the processing unit is connected to the one or more sensors, wherein the processing unit is configured to: load and execute program code to compare sensor information with data stored in the memory to determine whether the hot runner system is in an operable state, and, if the hot runner system is in an operable state, enable the one or more heating elements and / or one or more actuators to enable production operation; In the event that the hot runner system is not in an inoperable state, the processing unit is configured to generate status information to disable one or more heating elements and shut down or deactivate one or more actuators, thereby preventing the injection molding machine from performing production operations. The hot runner further includes a switching unit that spatially groups switches and / or temperature sensors and / or valves for the heating zone, wherein one or more switches are placed between the cables from the heating zone and / or temperature sensors and / or valves and the hot runner connector.

3. The hot runner system according to claim 2, further comprising a signal line connected to the injection molding machine to provide the status information, thereby indicating the operating status of the hot runner system and enabling the injection molding machine to be controlled by the status information.

4. The hot-duct system of claim 3, wherein, The sensor includes at least one of the following: a temperature sensor, the temperature sensor being used to detect the temperature of one or more components of the hot runner system or the temperature of a cut in a component of the hot runner system or in a flow channel of the hot runner. A humidity sensor for detecting humidity around the hot runner system; a flow sensor for detecting the flow rate of the fluid or melt; a pressure sensor for detecting pressure in the fluid or melt; and a leak sensor for detecting leaks in fluid lines and / or areas where plastic leakage is possible and / or in the inlet nozzle and / or one or more manifolds, one or more hot runner nozzles and / or actuators. A bending sensor, attached to the hot runner system, for detecting deformation; and a vibration sensor, used to detect the movement of the hot runner system. An acoustic sensor for detecting sounds associated with operations related to the hot runner system; a gyroscope sensor for detecting motion of the hot runner system; a potentiometer or encoder located on a hydraulic, pneumatic, or electric actuator for detecting motion within the nozzle to determine the position and / or cycle time and / or number of cycles of the nozzle pin; a limit switch located on a hydraulic, pneumatic, or electric actuator for determining the position and / or cycle time and / or number of cycles of the needle of the hot runner nozzle; and an optical sensor mounted on the mold or the hot runner system to detect light entering the parting line through holes in the mold when the mold is open or closed. And a sensor for wear detection, the sensor for wear detection being used to detect whether other parts or walls of the one or more manifolds have been flushed away, or whether the one or more heating elements have reached the end of their service life, or whether the nozzle pins are damaged.

5. The hot runner system of claim 2, further comprising one or more switches and / or valves located at the connection between the injection molding machine and the hot runner system to allow interruption of operation of the injection molding machine or closure of the inlet nozzle having a valve pin, wherein the switches and / or valves are operated by the processing unit based on the status information generated using the one or more sensors to enable or disable control of the hot runner system via the injection molding machine.

6. The hot runner system according to claim 2, wherein, The processing unit is configured to perform one or more of the following operations: (a) Detecting whether the cooling and / or actuating fluid in one or more actuators of the hot runner system is operating at a predetermined minimum flow rate and below a predetermined maximum temperature measured at the outlet of the cooling and / or actuating fluid using flow and temperature sensors, and generating status information to indicate that the one or more heating elements of the hot runner system should not be deactivated; (b) The temperature of the cooling and / or actuating fluid measured at the outlet is detected by a temperature sensor as being higher than a predetermined maximum temperature, and a status message is generated to indicate that the hot runner system should be shut down; (c) The hot runner valve and / or one or more actuators are driven to operate below a predetermined minimum pressure by means of an air or oil pressure sensor, and status information is generated to indicate that the hot runner system should be deactivated; (d) The actuators are operated by detecting pressures above a predetermined limit by a pneumatic or hydraulic pressure sensor, such that the valve pins can damage the mold and generate status information indicating that the hot runner system should be deactivated or the pressure line should be shut down. (e) Detecting that one or more actuators of the hot runner nozzle are above a predetermined temperature using a temperature sensor, and generating status information to indicate that the hot runner system should be shut down; Detecting that one or more heating element areas of one or more manifolds or nozzles or inlet nozzles are below a specific temperature level after a specific time limit using a temperature sensor and a timer, and generating status information to indicate that the hot runner system should be shut down; (f) Detecting that the heating time in one or more areas exceeds a predetermined limit and no operating cycle is detected by temperature sensors and timers, and generating status information to disable the hot runner system or the heating element or temporarily disable the heating element to reduce the temperature or enable a predetermined lower temperature; (g) If the temperature drops below a predetermined limit within a specific time period, the shutdown of the injection molding system is detected by a temperature sensor and a timer, and the following status information is generated: one or more actuators should be enabled to shut down one or more actuators before the melt solidifies; (h) Detecting that the temperature drop below a certain temperature is faster than a predetermined threshold indicating that the plastic material has solidified by using a temperature sensor and a timer, and generating status information that the one or more actuators should be deactivated; (i) If no cycle is detected, the temperature sensor detects that the processing temperature has been reached and the heating safety time has been exceeded while the production cycle is not running, and generates status information to indicate that the hot runner system or the one or more heating elements should be shut down, or the temperature of the one or more heating elements should be reduced. (j) The humidity sensor detects that the humidity is higher than a predetermined level, thereby indicating the presence of a cooling leak and generating status information to indicate that the hot runner system or one or more heating elements should be shut down; (k) Detect leakage of cooling water and / or fluid used to drive the one or more actuators by means of a flow sensor or pressure sensor, and generate status information to indicate that the hot runner system should be shut down; (l) The hot runner system is detected by mechanical switches, electrical switches, temperature sensors or pressure sensors in the area where melt leakage can occur, and status information is generated to indicate that the hot runner system should be shut down if leakage occurs; (m) The viewing point in the flow channel of the hot runner system is detected by a temperature sensor to determine the circulation time and / or the number of cycles; (n) Detecting cycle time and / or number of cycles using motion sensors or deformation sensors; as well as (o) If a pressure sensor in the flow channel detects that the pressure is higher than a predetermined value that is too high for the hot runner system, a valve pin driven by a hydraulic actuator, electric actuator or pneumatic actuator will close the inlet nozzle to avoid damage.

7. The hot runner system of claim 2 further comprises at least one of the following: a network interface for transmitting status information over a network; a display for indicating status information to a user; a keyboard for allowing user input; an output relay for providing status information; and a serial interface for providing status information.

8. The hot runner system of claim 2, further comprising switches for: switching the power supply to the one or more heating elements; switching one or more solenoid valves or switching valves to close or open one or more actuators; switching one or more solenoid valves or switching valves to interrupt the actuation oil flow from the injection molding machine to the one or more actuators; switching sensor cables and / or temperature sensors to provide analog values ​​for controlling the one or more heating elements; and / or Disconnect the sensor cable and / or temperature sensor to simulate a disconnected sensor line and force the injection molding machine to stop heating the heating element.

9. A method for monitoring the status and operation of a hot runner system to automatically generate information to improve the quality of an injection molding process, the hot runner system including an inlet nozzle, one or more nozzles with or without actuators and one or more manifolds, and one or more heating elements, the method being performed by a self-operating hot runner process controller independent of the injection molding machine, the hot runner process controller being able to access information from one or more sensors located in or at the hot runner system to detect the status and / or operation of the hot runner system; The hot runner process controller includes: A processing unit and a memory, wherein the processing unit is connected to the one or more sensors, and wherein the memory stores data and program code, the method comprising the steps of: the processing unit loading and executing the program code to compare sensor information with the stored data and determine whether the hot runner system is in an operable state; and, if the hot runner system is in an operable state, generating status information to enable the one or more heating elements and / or turn on one or more actuators, thereby enabling the injection molding machine to perform production operations; or, if the hot runner system is not in an operable state, generating status information to deactivate the one or more heating elements and / or turn off or deactivate the one or more actuators, thereby preventing the injection molding machine from performing production operations, wherein the sensor information is obtained through one or more of the following steps: The temperature of the cooling line at the end of one or more actuators and / or in the flow channel and / or cut and / or one or more components of the hot runner system is detected by a temperature sensor. The humidity around the hot runner system is detected; The flow of fluids or melts is detected using flow sensors; Pressure is detected in fluids or melts using pressure sensors; Leakage is detected in fluid lines and / or areas where plastic leakage is possible, and / or in the inlet nozzle and / or one or more manifolds, one or more hot runner nozzles and / or one or more actuators and / or their joints, using a leak sensor. Deformation is detected by a deformation or bending sensor attached to the hot runner system; The motion of the hot runner system is detected by a vibration sensor; Operations related to the hot runner system are detected using acoustic sensors; The motion of the hot runner system is detected by a gyroscope sensor; The movement within the nozzle is detected by a potentiometer or encoder of one or more actuators, so as to detect the position of the nozzle pin and / or the cycle time and / or the number of cycles; The position and / or cycle time of the needle of the hot runner nozzle are determined by limit switches on one or more of the actuators; If the mold is opened or closed via an optical sensor installed in the hot runner system or the mold, light entering the parting line through holes in the mold is detected; and The wear detection sensor detects whether other components or walls of the one or more manifolds have been washed away, or whether one or more of the heating elements have reached the end of their service life, or whether the nozzle pins are damaged.

10. The method of claim 9, further comprising: The operation of the injection molding machine is interrupted by triggering a valve and / or switch located at the connection between the injection molding machine and the hot runner system, wherein the processing unit operates the switch and / or valve based on the status information generated using the sensor, thereby enabling or disabling control of the hot runner system via the injection molding machine.

11. The method of claim 9, further comprising: Provide status information including signal lines that can be connected to the injection molding machine, thereby indicating the operating status of the hot runner system, so that the injection molding machine can be additionally controlled by the status information.

12. The method according to claim 9, wherein, The processing unit performs one or more of the following operations: (a) Detecting whether the cooling and / or actuating fluid in one or more actuators of the hot runner system is operating at a predetermined minimum flow rate and below a predetermined maximum temperature measured at the outlet of the cooling and / or actuating fluid using flow and temperature sensors, and generating status information to indicate that the one or more heating elements of the hot runner system should not be deactivated; (b) If the temperature of the cooling and / or actuating fluid measured at the outlet is higher than a predetermined maximum temperature by a temperature sensor, a status message is generated to indicate that the hot runner system should be shut down. (c) Detecting by air or oil pressure sensors that the hot runner valve and / or one or more actuators are driven to operate below a predetermined minimum pressure, generating status information to indicate that the hot runner system is deactivated; (d) Detecting one or more actuators being exposed to pressures above a predetermined limit via a pneumatic or hydraulic pressure sensor, causing valve pins to damage the mold, generating status information to indicate that the hot runner system should be deactivated or the pressure line should be deactivated to be shut down; (e) If the temperature sensor detects that one or more actuators of the hot runner nozzle are above a predetermined temperature, a status message is generated to indicate that the hot runner system should be deactivated. (f) If, by means of a temperature sensor and a timer, one or more heating element areas of one or more manifolds, nozzles, or inlet nozzles are found to be below a specific temperature level after a specific time limit, status information is generated to indicate that the hot runner system should be shut down; (g) If the heating time of one or more areas exceeds a predetermined limit and no operating cycle is detected by temperature sensor and timer, generate status information to disable the hot runner system or disable the heating element or temporarily disable the heating element to reduce the temperature or enable a predetermined lower temperature; (h) If the temperature drops below a predetermined limit within a specific time period by a temperature sensor and a timer, the system is shut down, and the following status information is generated: one or more actuators should be enabled to shut down one or more actuators before the melt solidifies; (i) When the temperature drop below a certain temperature is detected by a temperature sensor and a timer and is faster than a predetermined threshold, the plastic material is indicated to solidify, and the following status information is generated: one or more actuators should be deactivated so that they cannot move, thereby avoiding the risk of damage; (j) If no cycle is detected and the production cycle is not running, the temperature sensor detects that the processing temperature has been reached and the heating safety time has been exceeded, and generates status information to indicate that the hot runner system or the one or more heating elements should be shut down, or the temperature of the one or more heating elements should be reduced. (k) If the humidity is detected by a humidity sensor as being higher than a predetermined level, thereby indicating the presence of a cooling leak, status information is generated to indicate that the hot runner system or one or more heating elements should be deactivated; (l) Detect leakage of cooling water and / or fluid used to drive the one or more actuators by means of a flow sensor or pressure sensor, and generate status information to indicate that the hot runner system should be shut down; (m) Leakage detection is performed by mechanical switches, electrical switches, temperature sensors or pressure sensors in the area where melt leakage can occur through the hot runner system, and status information is generated to indicate that the hot runner system should be shut down if a leak occurs; (n) The viewing point in the flow channel of the hot runner system is detected by a temperature sensor to determine the cycle time and / or the number of cycles; (o) Detecting the cycle time and / or the number of cycles using a motion sensor or deformation sensor; as well as (p) If a pressure sensor in the flow channel detects that the pressure is higher than a predetermined value that is too high for the hot runner system, a valve pin driven by a hydraulic, electric or pneumatic actuator will close the inlet nozzle to avoid damage.

13. The method according to claim 12, wherein, The processing unit detects the preheating of the preheating station of the hot runner system and selects one or more operations (a) to (p) through the valve that are different from the injection molding operation.

14. The method according to claim 13, wherein, If preheating is detected and if the preheating temperature is reached and a predetermined time for the melt to remain in the state is exceeded, the processing unit generates information to deactivate one or more heating elements.

15. The method of claim 12, further comprising detecting the production cycle of the injection molding machine to select different stored data and program codes for operations (a) to (p) compared to the preheating element.

16. The method according to claim 12, wherein, Allows the user to enable bypass functionality to bypass one or more of operations (a) to (p) to force the activation of the hot runner system.

17. The method according to claim 16, wherein, The processing unit records the activation of the bypass function and the incoming sensor data.

18. The method according to claim 16, wherein, After entering the password, the bypass function will be enabled.

19. The method according to claim 9, wherein, Perform one or more of the following steps: Switch the power supply to one or more heating elements; Switch one or more solenoid valves or switching valves to close or open one or more actuators; Switch one or more solenoid valves or switching valves to interrupt the actuation oil flow from the injection molding machine to the one or more actuators; Switch sensor cables and / or thermocouples to provide analog values ​​for controlling one or more heating elements; as well as Disconnect the sensor cable and / or heating element to simulate a disconnected sensor line and force the injection molding machine to stop heating the heating element.

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