A defect monitoring system and method for injection molds

Abstract

The present application belongs to the technical field of mold monitoring, and particularly relates to a defect monitoring system and method for an injection mold, comprising: a water gap cutting mechanism for starting to work when one or more defects of an injection molded part are detected, so that one or more injection molded parts of the whole mold product are less after injection; a material pulling assembly for pulling out the injection molded part from the fixed mold discharge port or removing the damaged hardware when one or more defects of the injection molded part are detected; and a control system for monitoring the injection molding of the hardware in the fixed mold, and removing the damaged hardware in the mold cavity when one or more defects of the injection molded part are detected. The present application has the advantages of reducing the utilization rate of good products of one mold, saving plastic materials, reducing the scrap rate of hardware, saving product cost, and improving efficiency.

Description

Technical Field

[0001] This invention relates to the field of mold monitoring technology, specifically a defect monitoring system and method for injection molds. Background Technology

[0002] Injection molds play a crucial role in the processing of plastic products, and their quality directly affects the appearance, function, and lifespan of the finished product. However, injection molds are prone to various defects during use, such as corrosion, wear, cracks, and deformation. These defects not only reduce product quality but also lead to production stoppages and economic losses. Therefore, real-time monitoring and early warning of injection mold defects are of significant practical importance.

[0003] Traditional methods for monitoring defects in injection molds primarily rely on manual inspection, which suffers from low efficiency, susceptibility to errors, and difficulty in timely detection of latent defects. In recent years, with advancements in sensor technology and the continuous development of artificial intelligence algorithms, sensor- and machine learning-based injection mold defect monitoring systems have gained increasing attention. These systems utilize sensors to collect various signals from both inside and outside the mold, such as temperature, pressure, and vibration, and then use machine learning algorithms to analyze and interpret these signals, thereby achieving real-time monitoring and early warning of mold defects.

[0004] Existing injection mold defect monitoring systems are mostly limited to monitoring a certain type of defect, such as abnormal temperature or vibration, and lack the ability to monitor specific defects individually. Furthermore, the real-time performance, reliability, and adaptability to environmental interference of existing systems need improvement. Therefore, to address the diversified and complex needs of injection mold defect monitoring, it is still necessary to continuously explore more effective, intelligent, and reliable monitoring methods and systems. For example, when existing molds lack a cutting mechanism, if the metal parts from the previous process are automatically pulled into the mold and detected by the in-mold monitor as one or more defects are present, the mold will not be injected and will be pulled away, resulting in a missing mold of molded parts.

[0005] To address the aforementioned technical deficiencies, a defect monitoring system and method solution for injection molds is proposed. Summary of the Invention

[0006] To address the above problems, the present invention provides the following technical solution:

[0007] A defect monitoring system for injection molds includes an upper mold plate, a lower mold plate, side mold plates, a mold cavity, a moving mold, and a fixed mold. The fixed mold is disposed between the upper mold plate and the lower mold plate. The moving mold is connected to an injection molding machine. The mold cavity is disposed between the upper mold plate and the lower mold plate and is used to install the fixed mold. The side mold plates are disposed outside the moving mold. The system also includes:

[0008] A sprue cutting mechanism is provided on the fixed mold and connected to the loading port and unloading port of the fixed mold. The sprue cutting mechanism is used to start working when one or more defects of the injection molded part are detected. After injection molding, one or more injection molded parts of the whole mold product are missing.

[0009] A material pulling assembly is disposed at the discharge port of the fixed mold. The material pulling assembly is used to pull out the molded injection parts from the discharge port of the fixed mold or to pull out and remove the damaged hardware parts from the current discharge port when one or more defects in the injection parts are detected.

[0010] The control system connects the sprue cutting mechanism and the material pulling assembly. The control system is used to monitor the injection molding of metal parts in the fixed mold. When one or more defects are detected in the injection molded part, the control system controls the sprue cutting mechanism and the material pulling assembly to pull out the damaged metal parts in the mold cavity, thereby reducing material waste.

[0011] Furthermore, the sprue cutting mechanism includes a controller, a water pipe, a connecting pipe, and a sprue outlet. The controller is connected to the fixed mold and the water pipe is connected to the water pipe. The connecting pipe is connected to the water pipe and the sprue outlet is located on the connecting pipe. The controller is used to receive and control the water flow rate of the sprue outlet to stop the injection molding at that point when one or more defects in the injection molded part are detected.

[0012] Furthermore, the material pulling assembly includes a material pulling rod and a material pulling track. The material pulling track is disposed on the fixed mold, and the material pulling rod is disposed on the material pulling track. The material pulling rod is connected to the hardware. When one or more defects are detected in the injection molded part, the material pulling rod pulls out and cuts off the hardware to ensure the utilization rate of the material.

[0013] Furthermore, the control system includes:

[0014] The defect detection module is used to detect the quality of injection molded parts. It includes vision sensors, laser sensors, and temperature sensors. It processes the images or data acquired by the sensors to determine whether the injection molded parts have defects. It analyzes and makes decisions based on the sensor data to determine whether the cut-off mechanism needs to be activated.

[0015] The cutting mechanism control module receives signals from the defect detection module and controls the action of the cutting mechanism according to the set logic, controlling the sprue cutting mechanisms at both ends of the mold to cut off the injection runner.

[0016] The alarm and display module issues an alarm when a defect is detected or the cutting mechanism is activated, notifies the operator, and provides real-time system status, defect information, and operation prompts.

[0017] The data recording and analysis module records various data during the production process, including defect types, occurrence frequency, and number of shutdowns, and analyzes the recorded data to help find the root cause of problems and optimize the production process;

[0018] The communication module communicates with other production equipment or systems to transmit monitoring data and control commands;

[0019] The system power and backup module provides a stable power supply to the control module and sensors, ensuring that the system can still maintain basic functions in the event of power interruption or other failures.

[0020] Furthermore, the defect detection module includes a high-resolution visual sensor and a physical sensor for capturing the appearance information and physical characteristics of the injection molded part. An illumination unit is set up to provide sufficient illumination to ensure that the sensor can clearly capture images or detect physical states. The image data captured by the sensor is converted into digital signals processed by a computer, and an image processing algorithm is executed to process the captured image data and compare it with preset defect standards to determine whether there are defects in the injection molded part. Through machine learning and deep learning algorithms, the accuracy and speed of defect detection are improved.

[0021] Furthermore, the cutting mechanism control module includes a control unit for receiving signals transmitted by the defect detection module and controlling the action of the cutting mechanism according to preset logic and conditions. It performs complex logical operations and sequential control to ensure that the cutting mechanism performs the cutting operation at the correct time, controls the opening and closing state of the sprue, controls the cutting mechanism of the mold through pneumatic or hydraulic pressure, monitors the actual state of the cutting mechanism to ensure that it is in the correct position, confirms whether the cutting operation is successful through real-time feedback from the position sensor, checks the operating status of the cutting mechanism to ensure that it works normally, and issues an alarm when an abnormality occurs.

[0022] Compared with the prior art, the beneficial effects of the present invention are:

[0023] 1. In the defect monitoring system and method for injection molds of the present invention, a sprue cutting mechanism is used to start working at both ends of the mold when one or more defects in the injection molded part are detected, so that one or more injection molded parts are missing after injection molding; a material pulling assembly is used to pull out the molded injection molded parts from the sprue outlet of the fixed mold or to pull out the damaged hardware parts from the current sprue outlet when one or more defects in the injection molded part are detected; a control system is used to monitor the injection molding of hardware parts in the fixed mold, and when one or more defects in the injection molded part are detected, the sprue cutting mechanism and the material pulling assembly are controlled to pull out the damaged hardware parts in the mold cavity. This reduces the utilization rate of good products in a mold, saves plastic materials, reduces the scrap rate of hardware parts, and achieves the effects of saving product costs and improving efficiency.

[0024] 2. In the defect monitoring system and method for injection molds of the present invention, defect judgment involves analyzing the collected data to determine whether a defect exists. Based on preset standards or thresholds, it is determined whether a cut-off mechanism needs to be activated to confirm the authenticity and severity of the defect, thereby avoiding false alarms or unnecessary cut-off operations. The cut-off mechanism is triggered by transmitting the defect detection results to the cut-off mechanism control module. Based on the detection results, it is determined whether to trigger the cut-off operation, issuing a cut-off signal to activate the sprue cut-off mechanisms at both ends of the mold. The cut-off mechanism executes the cut-off operation according to the control signal, cutting off the sprues at both ends of the mold and stopping the continued production of the injection molded parts. The system also inspects and processes the already injection-molded defective parts to ensure their removal from the production line, verifying the success of the cut-off operation and ensuring that no more defective parts are produced. The system is recalibrated and set to ensure the normal operation of the mold and production line. After confirming that the cut-off operation is correct, normal injection molding production is resumed. This system provides precise control over injection mold damage. Attached Figure Description

[0025] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings;

[0026] Figure 1 This is a schematic diagram of the overall structure of a defect monitoring system and method for injection molds according to the present invention;

[0027] Figure 2 This is a schematic diagram of the cross-sectional structure of the mold in the defect monitoring system and method for injection molds of the present invention;

[0028] Figure 3 This is a schematic diagram of the sprue cutting mechanism in the defect monitoring system and method for injection molds of the present invention;

[0029] Figure 4 This is a schematic diagram of the control system framework in the defect monitoring system and method for injection molds of the present invention;

[0030] Figure 5 This is a schematic diagram of the method steps in the defect monitoring system and method for injection molds of the present invention.

[0031] Reference numerals: 1. Upper template; 2. Lower template; 3. Mold cavity; 4. Fixed mold; 5. Sprue cutting mechanism; 51. Controller; 52. Water pipe; 53. Connecting pipe; 54. Sprue outlet; 6. Material pulling assembly; 61. Material pulling track; 62. Material pulling rod. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] like Figure 1-5 As shown, a defect monitoring system for injection molds includes an upper mold plate 1, a lower mold plate 2, side mold plates, a mold cavity 3, a moving mold, and a fixed mold 4. The fixed mold 4 is disposed between the upper mold plate 1 and the lower mold plate 2. The moving mold is connected to the injection molding machine. The mold cavity 3 is disposed between the upper mold plate 1 and the lower mold plate 2 and is used to install the fixed mold 4. The side mold plates are disposed outside the moving mold. The system also includes:

[0034] The sprue cutting mechanism 5 is set on the fixed mold 4 and connected to the loading port and unloading port of the fixed mold 4. The sprue cutting mechanism 5 is used to start working when one or more defects of the injection molded part are detected. After injection molding, one or more injection molded parts of the whole mold product are missing.

[0035] Pulling component 6 is set at the discharge port of fixed mold 4. Pulling component 6 is used to pull out the molded injection parts from the discharge port of fixed mold 4 or to pull out the damaged hardware parts from the current discharge port when one or more defects of the injection parts are detected.

[0036] The control system connects the sprue cutting mechanism 5 and the material pulling assembly 6. The control system is used to monitor the injection molding of metal parts in the fixed mold 4. When one or more defects are detected in the injection molded part, the control system controls the sprue cutting mechanism 5 and the material pulling assembly 6 to pull out the damaged metal parts in the mold cavity 3, thereby reducing material waste.

[0037] Specifically, the sprue cutting mechanism 5 includes a controller 51, a water pipe 52, a connecting pipe 53, and a sprue outlet 54. The controller 51 is connected to the fixed mold 4 and the water pipe 52 is connected to the connecting pipe 53. The sprue outlet 54 is located on the connecting pipe 53. The controller 51 is used to control the flow rate of the sprue outlet 54 when one or more defects in the injection molded part are detected, thereby stopping the injection molding at that point. The material pulling assembly 6 includes a material pulling rod 62 and a material pulling track 61. The material pulling track 61 is located on the fixed mold 4, and the material pulling rod 62 is located on the material pulling track 61. The material pulling rod 62 is connected to the hardware. When one or more defects in the injection molded part are detected, the material pulling rod 62 pulls out and cuts off the hardware, ensuring the utilization rate of the material.

[0038] Specifically, the control system includes:

[0039] The defect detection module is used to detect the quality of injection molded parts. It includes vision sensors, laser sensors, and temperature sensors. It processes the images or data acquired by the sensors to determine whether the injection molded parts have defects. It analyzes and makes decisions based on the sensor data to determine whether the cut-off mechanism needs to be activated.

[0040] The cutting mechanism control module receives signals from the defect detection module and controls the action of the cutting mechanism according to the set logic, controlling the sprue cutting mechanisms at both ends of the mold to cut off the injection runner.

[0041] The alarm and display module issues an alarm when a defect is detected or the cutting mechanism is activated, notifies the operator, and provides real-time system status, defect information, and operation prompts.

[0042] The data recording and analysis module records various data during the production process, including defect types, occurrence frequency, and number of shutdowns, and analyzes the recorded data to help find the root cause of problems and optimize the production process;

[0043] The communication module communicates with other production equipment or systems to transmit monitoring data and control commands;

[0044] The system power and backup module provides a stable power supply to the control module and sensors, ensuring that the system can still maintain basic functions in the event of power interruption or other failures.

[0045] Specifically, the defect detection module includes a high-resolution visual sensor and a physical sensor to capture the appearance information and physical characteristics of the injection molded part. It is equipped with an illumination unit and provides sufficient illumination to ensure that the sensor can clearly capture images or detect physical states. The image data captured by the sensor is converted into digital signals processed by a computer, and an image processing algorithm is executed to process the captured image data and compare it with preset defect standards to determine whether there are defects in the injection molded part. Through machine learning and deep learning algorithms, the accuracy and speed of defect detection are improved.

[0046] Specifically, the cutting mechanism control module includes a control unit, which receives signals transmitted by the defect detection module and controls the action of the cutting mechanism according to preset logic and conditions. It performs complex logical operations and sequential control to ensure that the cutting mechanism performs the cutting operation at the correct time, controls the opening and closing state of the sprue, controls the cutting mechanism of the mold through air pressure or hydraulic pressure, monitors the actual state of the cutting mechanism to ensure that it is in the correct position, confirms whether the cutting operation is successful through real-time feedback from the position sensor, checks the operating status of the cutting mechanism to ensure that it works normally, and issues an alarm when an abnormality occurs.

[0047] Specifically, the alarm and display module includes an audible alarm to alert operators of system problems, a visual alarm to provide visual alarm signals, different alarm levels and thresholds to adjust alarm triggering conditions according to actual conditions, a touchscreen display of real-time system status, defect information, operation prompts, and alarm messages, touchscreen operation and configuration, display of historical fault records, detection data, and alarm events for operator fault analysis and trend monitoring, graphical data display to help operators understand abnormal situations in the production process, and allows operators to configure the system, adjust parameters, and start / stop detection operations, providing operation confirmation and error feedback to help operators understand operation results and system status in a timely manner. Alarm information and system status are sent to a remote monitoring center or management system via a network interface or communication protocol for remote monitoring and maintenance by management. System integration: Integration with other production systems or MES (Manufacturing Execution System) provides overall production line monitoring and management functions. The alarm and display module not only promptly informs operators of system anomalies but also helps them quickly locate and resolve problems, thereby improving production efficiency and reducing downtime.

[0048] Specifically, the data recording and analysis module includes collecting various data from the defect detection module, the cutting mechanism control module, and sensors, including defect type, frequency of occurrence, number of cuts, and production speed. The collected data is saved to a database, providing data processing and analysis functions such as statistical analysis, trend analysis, and anomaly detection. Through analysis of historical data, it identifies problems and trends in the production process, utilizes advanced analysis techniques to identify complex patterns and potential problems, and generates real-time production reports, including current production status, defect statistics, and cutting operations. It also generates periodic historical reports for reviewing and analyzing problems in the production process, helping to identify long-term trends and potential improvement points. The data is visualized in the form of charts, line graphs, and pie charts to help operators and management intuitively understand production data and trends. The module analyzes the data, automatically identifies abnormal situations or deviations from normal production ranges, and triggers alarms or notifications. The analysis results and suggestions are fed back to operators or engineers to help them adjust production parameters or perform maintenance in a timely manner.

[0049] The data analysis involves collecting real-time data from the molds and establishing a database, filtering the data in the database, selecting the best data, and creating a new dataset, including:

[0050]

[0051] Where Y(t) is the current median data, (X(t)+X(t-1)+…+X(t-M+1)) is the total number of data in the current database, and M is the number of data in the current database. By analyzing the output data at the current time point, the median of all data in the database is calculated based on the number of data. The median data is compared with the current output data, and the error range is used to determine whether the current data meets the inclusion requirements of the dataset and is recorded.

[0052] The data analysis uses a PID algorithm to control the stroke of the mold. The PID control algorithm is as follows:

[0053]

[0054] Where U(t) is the input at the current time, kp is the PID coefficient, and err(t) is the proportional term. For the integral term, T I The integral coefficient is... For the differential term, T D The differential coefficient is used to monitor the safety status of the mold injection molding process and provide real-time feedback through the PID control algorithm, ensuring that the injection molding machine can accurately locate and provide feedback on injection parts with internal problems during injection molding.

[0055] Data analytics can also be integrated with Manufacturing Execution Systems (MES), Enterprise Resource Planning (ERP) systems, or other production management systems for data sharing and collaborative work. API Interface: Provides an open API interface, facilitating the integration of data and analysis results with other systems or platforms. Data Backup System: Regularly backs up data to prevent loss or corruption. Data Security Measures: Includes access control and encryption to ensure data security and privacy. Through these functions, the data logging and analysis module helps production managers monitor production status in real time, identify and resolve problems, optimize production processes, and improve product quality and production efficiency.

[0056] Specifically, the system power supply and backup module provides a stable power supply to all components of the system, including controllers, sensors, actuators, and display devices. Through power regulation and protection functions, it provides overvoltage protection, overcurrent protection, and short-circuit protection to ensure that the system is not affected by power problems. When the main power supply fails, the UPS provides temporary power to ensure the system continues to operate and prevent data loss or equipment damage. By providing additional power support, it monitors the operating status of the power system in real time, including voltage, current, and power indicators, when long-term backup power is required, during UPS battery replacement or maintenance. The monitoring and control system detects power problems and issues alarms, regularly checks the health status of power components to prevent power failures from affecting the system, configures a regular automatic backup plan to ensure that the latest data and configuration files are saved and reduce the need for human intervention, provides data recovery function so that the system can quickly restore to the backup state in case of data loss or corruption, automatically switches to the backup power supply when the main power supply fails to ensure that the system does not shut down due to power interruption, and sets power priorities according to the needs of different components to ensure that critical components receive power first when power is insufficient.

[0057] The power system status, including power level, running time, and fault information, is displayed in real time via a screen or monitoring interface. The operation panel allows operators to manually control power switching, view power status, and configure power settings. Regular maintenance plans for the power system can be developed and implemented, including checking battery status, cleaning power equipment, and updating firmware. Service support is provided to ensure the power system operates efficiently and stably. Through these functions, the system power and backup modules ensure the reliability and stability of the injection mold defect monitoring system, reducing the risk of system downtime or data loss due to power problems, thereby guaranteeing smooth production processes.

[0058] According to another aspect of the present invention, a defect monitoring method for injection molds is provided, comprising the defect monitoring system for injection molds as described in any one of the preceding claims, including:

[0059] S1: Defect judgment. Analyze the collected data to determine whether a defect exists. Based on preset standards or thresholds, determine whether a cutoff mechanism needs to be activated. Confirm the authenticity and severity of the defect to avoid false alarms or unnecessary cutoff operations.

[0060] S2: Trigger the cutting-off mechanism, transmit the defect detection results to the cutting-off mechanism control module, decide whether to trigger the cutting-off operation based on the detection results, send a cutting-off signal, and start the sprue cutting-off mechanism at both ends of the mold.

[0061] S3: The cutting mechanism performs a cutting operation according to the control signal, and the sprue at both ends of the mold is cut off, stopping the continued production of the injection molded part;

[0062] S4: Inspect and handle defective parts that have already been injection molded, ensure they are removed from the production line, verify that the cutting operation was successful, and ensure that no more defective parts are produced;

[0063] S5: Recalibrate and set up the system to ensure the normal operation of the mold and production line. After confirming that the cutting operation is correct, resume normal injection molding production.

[0064] By recording detailed information about the cutting operation, including triggering conditions, number of cuts, and defect type, a report is generated to analyze the causes of defects and the effectiveness of the cutting operation, providing data support for subsequent improvements. In-depth analysis of the defect data identifies potential production problems or equipment malfunctions. Based on the analysis results, production parameters are adjusted or equipment maintenance is performed to reduce future defects. The key to this process is timely and accurate defect detection and effective control of the cutting mechanism to avoid producing more defective products, ensuring production stability and product quality.

[0065] The working principle of the defect monitoring system and method for injection molds of this invention is as follows: A sprue cutting mechanism is used to cut off the sprues at both ends of the mold when one or more defects are detected in the injection molded part, resulting in one or more fewer injection molded parts after injection molding. A material pulling assembly is used to pull out the molded injection molded part from the sprue outlet of the fixed mold, or to pull out and remove damaged parts from the current sprue outlet when one or more defects are detected. A control system monitors the injection molding of parts within the fixed mold. When one or more defects are detected, the sprue cutting mechanism and the material pulling assembly are controlled to pull out and remove damaged parts from the mold cavity. This reduces the utilization rate of good products in a single mold, saves plastic material, reduces the scrap rate of parts, and achieves cost savings and efficiency improvement. Defect judgment is used to collect... The system analyzes the received data to determine if defects exist. Based on preset standards or thresholds, it determines whether a cut-off mechanism needs to be activated to confirm the authenticity and severity of the defects, thus avoiding false alarms or unnecessary cut-off operations. The cut-off mechanism is triggered by transmitting the defect detection results to the cut-off mechanism control module. Based on the detection results, the module decides whether to trigger the cut-off operation, sends a cut-off signal, and activates the sprue cut-off mechanisms at both ends of the mold. The cut-off mechanism executes the cut-off operation according to the control signal, cutting off the sprues at both ends of the mold and stopping the continued production of the injection molded parts. The system inspects and processes the already molded defective parts, ensuring their removal from the production line and verifying the success of the cut-off operation to ensure no more defective parts are produced. The system is recalibrated and set to ensure the normal operation of the mold and production line. After confirming the cut-off operation is correct, normal injection molding production resumes, providing precise control over injection mold damage.

[0066] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A defect monitoring system for injection molds, characterized in that, The injection mold comprises an upper mold plate (1), a lower mold plate (2), a side mold plate, a mold cavity (3), a movable mold and a fixed mold (4), the fixed mold (4) is arranged between the upper mold plate (1) and the lower mold plate (2), the movable mold is connected to an injection molding machine, the mold cavity (3) is arranged between the upper mold plate (1) and the lower mold plate (2) and is used for mounting the fixed mold (4), the side mold plate is arranged outside the movable mold, and the injection mold further comprises: a water port cutting mechanism (5) arranged on the fixed mold (4) and connected to an upper feeding port and a discharging port of the fixed mold (4), the water port cutting mechanism (5) is used for starting the water port cutting mechanism (5) at both ends of the mold when one or more defective injection molded parts are detected, and the injection molded part is less than one or more after injection; a material pulling assembly (6) arranged at the discharging port of the fixed mold (4), the material pulling assembly (6) is used for pulling out the formed injection molded part at the discharging port of the fixed mold (4) or removing the damaged hardware when one or more defective injection molded parts are detected. The water port cutting mechanism (5) comprises a controller (51), a water pipe (52), a connecting pipe (53) and a water outlet (54), the controller (51) is connected to the fixed mold (4), the controller (51) is connected to the water pipe (52), the connecting pipe (53) is connected to the water pipe (52), the water outlet (54) is arranged on the connecting pipe (53), and the controller (51) is used for receiving the water outlet (54) to control the water outlet (54) when one or more defective injection molded parts are detected, so that the mold is stopped from being injected. The material pulling assembly (6) comprises a material pulling rod (62) and a material pulling track (61), the material pulling track (61) is arranged on the fixed mold (4), the material pulling rod (62) is arranged on the material pulling track (61), the material pulling rod (62) is connected to the hardware, and the material pulling rod (62) pulls out the hardware when one or more defective injection molded parts are detected, so that the use rate of the material is ensured.

2. The defect monitoring system for injection molds according to claim 1, characterized in that, A control system is connected to the water port cutting mechanism (5) and the material pulling assembly (6), and is used for monitoring the injection molding of the hardware in the fixed mold (4), controlling the water port cutting mechanism (5) and the material pulling assembly (6) to remove the damaged hardware in the mold cavity (3) when one or more defective injection molded parts are detected, and reducing material waste.

3. A defect monitoring system for injection molds according to claim 2, characterized in that, The control system comprises: a defect detection module for detecting the quality of the injection molded part, comprising a visual sensor, a laser sensor and a temperature sensor, processing the image or data obtained by the sensor, judging whether the injection molded part has defects, analyzing and deciding the sensor data, and determining whether the cutting mechanism needs to be started; a cutting mechanism control module receiving the signal of the defect detection module and controlling the action of the cutting mechanism according to the set logic, controlling the water port cutting mechanism at both ends of the mold to cut the injection flow channel.

4. The defect monitoring system for injection molds according to claim 3, characterized in that The alarm and display module sends an alarm when a defect is detected or the cutting mechanism is activated, notifying the operator and providing real-time system status, defect information, and operation prompts. The data recording and analysis module records various data during production, including defect types, occurrence frequencies, and cutting frequencies, and analyzes the recorded data to help identify problem sources and optimize production processes. The communication module communicates with other production equipment or systems to transmit monitoring data and control instructions. The system power and backup module provides stable power to the control module and sensors, ensuring that the system can maintain basic functions in the event of power interruptions or other failures.

5. A defect monitoring system for injection molds according to claim 4, characterized in that The defect detection module includes high-resolution visual sensors and physical sensors to capture appearance information and physical characteristics of the injection molded parts. The lighting unit is set to provide sufficient illumination to ensure that the sensors can clearly capture images or detect physical states. The captured image data is converted into digital signals processed by the computer, and image processing algorithms are executed to process the captured image data and compare it with pre-set defect standards to determine whether the injection molded parts have defects. Machine learning and deep learning algorithms are used to improve the accuracy and speed of defect detection.

6. The defect monitoring system for injection molds according to claim 5, characterized in that The cutting mechanism control module includes a control unit that receives signals from the defect detection module and controls the action of the cutting mechanism based on pre-set logic and conditions. It performs complex logical operations and sequence control to ensure that the cutting mechanism operates correctly at the right time. It controls the opening and closing of the water gap and monitors the actual state of the cutting mechanism to ensure that it is in the correct position. Position sensors provide real-time feedback to confirm whether the cutting operation is successful. The module checks the running state of the cutting mechanism to ensure its normal operation and sends an alarm if an abnormality occurs.

Images