Method and apparatus for injection molding machine operation

Abstract

Injection molding machines and control systems are disclosed. Sensors are configured to measure operating conditions of the injection molding machine such as heats, pressures and component positions. A human interface includes a graphical display with a schematic representation of the injection molding machine, which may be animated to depict operating conditions measured by the sensors. Selectable icons are presented on the graphical display, each representing a corresponding stage of a startup process of the injection molding machine. Each of the icons is operable to cause the machine to perform operations of a respective stage. The icons are animated to represent progress through the respective stages.

Description

[0001] METHOD AND APPARATUS FOR INJECTION MOLDING MACHINE OPERATION

[0002] FIELD OF THE TECHNOLOGY

[0003] This relates to injection molding; in particular, to startup and operation controls for injection molding machines.

[0004] BACKGROUND

[0005] Modem injection molding machines are very complex. Machines (including molds installed in machines) are often designed to produce complex parts, at high production rates and efficiencies. Many molds are designed for simultaneous production of multiple parts in each molding cycle. For example, blanks (preforms) for plastic containers may be produced in multi-cavity molds capable of producing tens of preforms per cycle.

[0006] In order to produce such parts efficiently and in high quantities, machines may have complications such as molds with movable molding surfaces, complex hot runner, injection nozzle and gate design, active heating systems for melters and hot runners, and active cooling systems for molds. In addition, machine components and melt feedstocks may frequently be changed. For example, a single melter and injection unit may be used with multiple different molds (e.g. to produce different parts) or with multiple different molding materials (e.g., to produce parts with different colours or different strength or quality levels).

[0007] In addition, quality expectations for injection molded parts are high. Part characteristics such as prominent parting lines, density or thickness variations, variations in opacity, are examples of defects that may not be accepted. Such defects can be created when actual molding conditions deviate from actual design conditions. For example, defects may be introduced by temperature variations in temperature, e.g. localized areas reaching excessively high or excessively low temperatures; discontinuities in molding material, such as by contamination from previous molding activity or by formation of bubbles in the melt flow.

[0008] Accordingly, injection molding machines are typically started up and shut down according to detailed specifications. Successful molding operations rely on correct execution of start up and shut down procedures. These procedures may be performed by human operators with varying degrees of skill and experience. Such operators may have differing preferences for control interfaces and may require differing amounts of guidance. SUMMARY

[0009] An example injection molding machine comprises: a plurality of sensors configured to measure operating conditions of the injection molding machine; a graphical display comprising a schematic representation of the injection molding machine and the operating conditions; a plurality of selectable icons on the graphical display, each representing a corresponding stage of a startup process of the injection molding machine and operable to cause the machine to perform operations of the respective stage; the icons having associated animations representing progress through the respective stages.

[0010] In some embodiments, the sensors comprise a clamp position sensor and an injection piston position sensor.

[0011] In some embodiments, the sensors comprise a first thermal sensor configured to measure a temperature in a mold and a second thermal sensor configured to measure a temperature in a melter of the machine.

[0012] In some embodiments, the associated animations are based on inputs from the sensors.

[0013] In some embodiments, the schematic representation is animated based on the operating conditions.

[0014] In some embodiments, the stages include a heating stage, and wherein the control system is configured to coordinate heating of the mold and the machine.

[0015] In some embodiments, the icons have a plurality of segments, each representing an operation of the corresponding stage, and the associated animations comprise animation of the segments.

[0016] In some embodiments, the animation of the segment comprises shading.

[0017] In some embodiments, the icons have status indicators, the status indicators animated to represent whether an operation of the corresponding stage is in progress.

[0018] Injection molding machines according to the disclosure herein may include the foregoing features in any operable combination.

[0019] An example control system for an injection molding machine comprises: a plurality of sensors configured to measure operating conditions of the injection molding machine; a graphical display comprising a schematic representation of the injection molding machine and the operating conditions; a plurality of selectable icons on the graphical display, each representing a corresponding stage of a startup process of the injection molding machine and operable to cause the machine to perform operations of the respective stage; the icons having associated animations representing progress through the respective stages.

[0020] In some embodiments, the sensors comprise a clamp position sensor and an injection piston position sensor.

[0021] In some embodiments, the sensors comprise a first thermal sensor configured to measure a temperature in a mold and a second thermal sensor configured to measure a temperature in a melter of the machine.

[0022] In some embodiments, the associated animations are based on inputs from the sensors.

[0023] In some embodiments, the schematic representation is animated based on the operating conditions.

[0024] In some embodiments, the stages include a heating stage, and wherein the control system is configured to coordinate heating of the mold and the machine.

[0025] In some embodiments, the icons have a plurality of segments, each representing an operation of the corresponding stage, and the associated animations comprise animation of the segments.

[0026] In some embodiments, the animation of the segment comprises shading.

[0027] In some embodiments, the icons have status indicators, the status indicators animated to represent whether an operation of the corresponding stage is in progress.

[0028] Control systems according to the disclosure herein may include the foregoing features in any operable combination.

[0029] Other aspects will be apparent from the description and drawings.

[0030] BRIEF DESCRIPTION OF THE DRAWINGS

[0031] A better understanding of the embodiments of the present technology (including alternatives and / or variations thereof) may be obtained with reference to the detailed description of the nonlimiting embodiments along with the following drawings, in which:

[0032] In the drawings, which depict example embodiments:

[0033] FIG. 1 is a perspective view of an injection molding machine; FIG. 2 is a block diagram showing stages of a startup process of the machine of FIG. 1 ;

[0034] FIG. 3 is a block diagram showing a computing device associated with the machine of FIG. 1;

[0035] FIG. 4 depicts an example screen of a human interface of the machine of FIG. 1;

[0036] FIG. 5 depicts an example information overlay of the screen of FIG. 3;

[0037] FIGS. 6A-6F depict example buttons of the screen of FIG. 3; and

[0038] FIGS. 7A-7E are enlarged views of machine representations of the screen of FIG. 3, showing animation states.

[0039] DETAILED DESCRIPTION

[0040] Reference will now be made in detail to various non-limiting embodiment(s) of a molding system and a related method for the operation thereof. It should be understood that other non-limiting embodiment(s), modifications and equivalents will be evident to one of ordinary skill in the art in view of the non-limiting embodiment(s) disclosed herein and that these variants should be considered to be within scope of the appended claims.

[0041] Furthermore, it will be recognized by one of ordinary skill in the art that certain structural and operational details of the non-limiting embodiment(s) discussed hereafter may be modified or omitted (i.e. non-essential) altogether. In other instances, well known methods, procedures, and components have not been described in detail.

[0042] FIG. 1 depicts a schematic view of an example injection molding machine 100. The depicted machine includes a raw material supply 102, namely, a hopper with pelletized molding material such as polyethylene terephthalate (PET). The raw material supply 102 provides raw material to a melter unit 104, namely, a screw-type extruder configured to heat and melt the raw material by application of pressure.

[0043] Molding material is directed to a barrel 106, in which a piston is housed, and is configured to reciprocate to thereby push molten molding material towards a mold 110. Molding material is supplied to a hot runner (not shown), which serves as a manifold to direct material to the multiple mold cavities of mold 110.

[0044] Heating devices are provided, for example, for the barrel 106, hot runner and mold 110. For example, the heating devices may comprise electric heaters. Machine 100 includes an associated human interface unit 113. The human interface unit may, for example, comprise a touch screen with a graphical user interface configured to present information and controls for operation of the machine.

[0045] During operation, solid (e.g. granulated) molding material is provided to the melter unit 104, e.g. from a hopper positioned above the melter unit. The molding material is heated by heating devices, along with application of pressure by an extruder screw in the melter unit. Such heating melts the molding material into a flowable state. The piston 108 reciprocates to displace molten material through the hot runner and into the cavities of mold 110.

[0046] As molding material flows through the hot runner and fills the mold cavities, the temperature of the molding material is tightly controlled to maintain consistent quality of molded parts. Accordingly, the hot runner and mold may be actively heated and / or cooled to maintain the respective structures at a desired temperature. Thermal sensors 114 may be installed at one or more locations within the machine 100 to verify temperatures of respective machine components. For example, sensors may be provided for measuring temperature at the mold 110 (in some embodiments; independently at multiple locations in the mold), at the hot runner 112, and at the barrel 106 and extruder 108. Such components may have substantial thermal mass and thus, a control system may regulate heating and cooling to avoid thermal overshoot.

[0047] The mold 110 has a core plate and a cavity plate. The core plate includes surfaces for forming the inner surfaces of molded articles. The cavity plate includes surfaces for forming the outer surfaces of molded articles. During molding in the closed position, the mold plates are clamped together by the platens.

[0048] The cavity and core plates are removably mounted to a pair of platens of the machine 100. During molding, the platens reciprocated between a closed position in which the plates cooperatively define molding cavities for receiving molding material and forming parts, and an open position for removal of molded parts.

[0049] Machine 100 comprises a part removal robot (not shown in FIG. 1). The part removal robot may remove molded parts when the mold and clamp are in the open position and may cool removed parts before releasing them for further handling (e.g. delivery, packaging or further processing).

[0050] In the depicted example, the part removal robot includes a tooling plate operable to move between the mold cavity and core plates when the mold is opened, and physically remove molded parts from mold cores. The part removal robot further includes a cooling device. In the depicted example, the cooling device is a combined dehumidification and blower unit, e.g. a CoolPikTM device made by Husky Technologies.

[0051] Machine 100 may be used to produce multiple different types of parts. For example, machine 100 may be used with molding materials of different composition, quality or colour, to produce parts of different composition, quality or colour. In addition, machine 100 may be used with any one of multiple different molds to produce parts, for example, of different shapes or sizes.

[0052] Machine 100 may not be continuously operated. For example, machine 100 may be shut down for maintenance, for changing of molding material and / or mold 110, between work shifts or outside working hours.

[0053] Following a shut down of machine 100, start-up procedures may be followed to ensure that the machine, mold and molding material are prepared to produce parts of sufficient quality.

[0054] FIG. 2 depicts an example start-up procedure for machine 100. As depicted, the start-up procedure comprises a plurality of stages. In the depicted example, the start-up procedure includes heat stage 202 for bringing machine 100 to operating heat conditions, purge stage 204 for clearing old molding material from the melter unit 104, and barrel 106, charge stage 206 for filling the machine’s hot runner with fresh molding material, semi-freedrop stage 208 in which old molding material is cleared from the hot runner of machine 100 and mold 110, and molded parts are freely released from the mold and discarded while fresh molding material is brought to production condition, semi with robot stage 210 in which molded parts are removed with the part removal robot, and auto-cycle stag 211 in which the machine 110 is cycled automatically.

[0055] Each stage includes one or more discrete operations and may have one or more associated operating parameters. The operating parameters may define conditions which must be achieved in order to complete the associated stage or operation.

[0056] Generally, the heat stage 202 may include activating heaters to increase temperatures at specific locations in machine 100. Different components of machine 100 may be heated independently. For example, heat may be applied to the melter unit 104, barrel 106 and associated components such as an extruder and shooting pot (“machine heats”). Heat may separately be applied to mold 110 (“mold heats”) In some embodiments, mold heats may be separately controlled at nozzle tips and manifolds.

[0057] Operating temperatures required at different components of the machine may vary. Each component may need to be maintained at an operating temperature for a fixed duration of time, referred to as a soak time. The soak time may ensure that heat is conducted throughout the machine, so that all parts of the machine are sufficiently warm. Soak times may vary by component. For example, soak times may differ for mold 110 and melter unit 104.

[0058] Different components of the machine 100 may change temperature at different rates. For example, heat input from heaters may not be uniformly distributed. Moreover, heat capacity may vary from position to position. Components formed out of solid (or near-solid) steel may have differing heat capacity from components with large voids (e.g. mold 110 and barrel 106).

[0059] Ideally, heats should be applied such that the mold and machine reach their respective temperature presents and complete their respective soak times at approximately the same time. This may guard against degradation of molding material that can occur if material is held at a high temperature for an excessively long period of time.

[0060] Achieving coordination of heats may be difficult for human operators, for example, because of differential heating rates and variability of starting temperatures.

[0061] Purge stage 204 involves purging of old molding material from the melter unit 104 and barrel 106 of the machine. Purging may be achieved by cycling of machine 100 to displace old mold material with fresh molding material. Multiple such cycles may be required to fully purge old material. The number of cycles required may vary. For example, the number of purge cycles required may depend on the volume of molding material present in the melter unit, and on characteristics (e.g. density and viscosity) of the old molding material and fresh molding material, and the amount of time for which the machine or the installed mold was idle. Typically, purge progress is visually assessed by an operator based on the appearance of discharged material, which may rely on the experience of the operator.

[0062] Additional heats may be applied during the purge stage 204. For example, nozzle tip and booster heats may be activated in preparation for injection of material into the hot runner and mold during subsequent stages.

[0063] Hot runner charge stage 206 includes operations carried out to fill the hot runner with molten molding material that is ready for injection to the mold. Hot runner charging may be performed by cycling the piston and extruder of machine 100 with the mold 110 clamped in a closed position, until the hot runner is filled. A full charge may be indicated by backpressure on the piston and by the piston reaching the end of its travel, i.e. an injection piston stop position. Semi freedrop stage 208 includes cycling of the machine 100 semi-automatically state in order to discharge old molding material from mold 110 and prepare melt for production and test that parts being produced meet specifications. As used herein, “semi-automatic” cycling of machine 100 refers to an operating state in which molding cycles are manually initiated by an operator, but each molding cycle is controlled automatically, once started. Molding parameters may be set (e.g., automatically) during the semi freedrop stage. Such parameters may include injection pressure and part cooling time.

[0064] Semi with robot stage 210 involves cycling of machine 100 in a semi-automatic state with part removal robot enabled, to verify that molded parts are successfully removed from the mold.

[0065] Auto-cycle stage 211 involves fully automatic cycling of machine 100 to verify successful part production. During the auto cycle stage, operating parameters may be tuned. For example, part cooling time may be progressively reduced.

[0066] Typically, controls for startup of an injection molding machine are presented to a human user in a linear, “wizard” interface. That is, startup is broken into a plurality of discrete operations interface screens are presented serially for each of the discrete options. Such interfaces are neither optimal for experienced operators, nor for inexperienced operators.

[0067] For example, the number of options available for operators during startup is very large. At each startup, only a subset of options may need to be changed from default values. The options which need to be changed in any given case may be readily apparent to a skilled operator. Accordingly, a linear interface that presents all of the options may be inefficient. Experienced operators may wish to input only those settings the operator knows to be important. Additionally, or alternatively, experienced operators may wish to input settings asynchronously with operation of the machine, or out of the expected order.

[0068] Inexperienced operators may also have difficulties with linear wizard-based interfaces. For example, such operators may not intuitively appreciate which settings need adjustment during a given startup. Therefore, presentation of a large number of options may make it difficult to identify those settings which are most significant. In addition, presenting options in a series of discrete display scenes may tend to reduce emphasis on how such options interact with one another.

[0069] Linear start-up interfaces may force operators to adhere to automated, pre-set steps. In some instances, experienced operators may wish to deviate from such steps. For example, operators may heuristically adopt corrective steps to be taken in response to certain start-up behaviours, such as melt quality. Taking such corrective steps may be difficult in a start-up wizard interface that presents a linear sequence of screens.

[0070] Referring to FIG. 3, a computing device 200 may be part of or associated with machine 100. The computing device may be configured to control operations of the machine, and to present a user interface on human interface unit 113. The user interface may be, for example, a touch-based graphical user interface. Graphical interfaces built for other types of inputs are also possible, as will be apparent.

[0071] Computing device 200 comprises a processor 201, a memory 203, a storage 205, and one or more input / output (I / O) interfaces 207.

[0072] The processor may be a general-purpose processor, such as an AMD or Intel x86 processor, an ARM-based processor, or any other suitable type of processor. Computer-readable instructions are stored on storage 205 for execution by the processor 201 of computing device 200. I / O interfaces 207 may include, for example, network interfaces (e.g. wi-fi or Ethernet interfaces), parallel ports, serial ports such as universal serial bus (USB) interfaces, or the like.

[0073] The computing device may be, for example, an industrial PC. The PC may comprise virtualized programmable logic controllers (PLCs) coupled to actuators within the machine 100. Suitable industrial computers include Beckhoff GmbH series C6930 PCs based on multi-core intel CPUs and Microsoft Windows 10 operating system. Virtualized PLCs may be implemented in the Beckhoff TwinC AT 3 PLC runtime.

[0074] A plurality of sensors 209 may be installed at machine 100 and connected to computing device 200 via I / O interfaces 207. The sensors provide signals indicative of operating conditions of machine 100. The sensors may include, for example, thermal sensors 209-1 positioned at one or more locations such as in the melter unit 104, barrel 106, hot runner, mold or part removal robot. In an example, a plurality of thermal sensors is placed at locations along the length of barrel 106 and a plurality of thermal sensors are placed at locations of interest in mold 110 and the hot runner.

[0075] The sensors may further include position sensors 209-2 for movable components of the machine, such as extruder, piston, mold, mold clamp and robot position sensors. Sensors may further include pressure sensors 209-3 for measuring force or pressure experienced at various locations. For example, force or pressure sensors may be installed to measure force exerted by the piston, clamping force exerted on the mold, or pressure of molding material at one or more positions of interest in the extruder, hot runner or mold. Software instructions stored at the computing device 200 include instructions for presenting a human interface on interface unit 113 for performing start-up procedures for machine 100. The human interface allows easy access to settings and communicates status information and alarm information to operators. The human interface provides guidance to operators by presenting such status and alarm information, and also by hint or guideline text included in elements of the interface.

[0076] In some embodiments, the computing device 200 is configured to calculate operating characteristics to automatically define settings for the various startup stages.

[0077] For example, the computing device 200 may be configured to measure an idle time, i.e., a duration of time elapsed since the machine 100 was last used for producing parts. In some embodiments, measurement of the idle time may be started by an operator explicitly providing a control input indicating the end of a production run. Alternatively, measurement of idle time may be automatic. For example, measurement of idle time may begin when thermal sensors 209-1 measure a temperature below a defined threshold; when position sensors 209-2 measure movement of a machine component, such as the piston, below a defined threshold in a period of time; or when pressure sensors 209-3 measure pressure on a component below a defined threshold in a period of time.

[0078] Measurement of idle time may stop in response to an explicit control input by an operator (e.g. powering on of machine 100 in a startup mode).

[0079] The computing device 200 may also be configured to compute one or estimated heat times. Separate estimated heat times may be computed for one or more individual machine components. For example, a heat time may be computed for mold 110, for the machine hot runner, melter unit 104 and barrel 106. In some embodiments, a machine heat time may be computed based on any combination of times calculated for the hot runner, melter unit 104 and barrel 106.

[0080] Heat time may be calculated based on a measured temperature at the time startup is initiated; a target operating temperature (temperature setpoint), a heat input rate (e.g. a heater wattage), and the mass, volume, specific heat capacity and / or void volume of a component, or the like.

[0081] Computing device 200 may be configured to track progress of machine 100 through its startup procedures. Specifically, the computing device may log completed stages of startup procedures, and completed operations within stages, and may track the current stage and operation being performed. Initiation and completion of operations and stages may be determined based on explicit control inputs by an operator or may be inferred based on a combination of control inputs and measurements by sensors 209.

[0082] FIG. 4 depicts a human interface screen 400 of the machine 100, representative of aspects of the present disclosure. The human interface screen 400 is presented by computing device 200 on interface unit 113. In the depicted example, the interface unit is a touch-sensitive display. However, other types of display and other input types are possible. References herein to “touches” of graphical elements such as “buttons” may alternatively be implemented as other types of selection of the described graphical elements, e.g. by clicking with a mouse or similar pointing device, operation of physical buttons, or the like.

[0083] Human interface screen 400 includes a schematic representation of machine 100. In the depicted embodiment, the schematic representation is divided into two parts, namely a melter section graphic 404 and a mold section graphic 406. The melter section graphic 404 generally includes cross-sectional depictions of the raw material supply 102, melter unit 104, which in the depicted embodiment includes a screw-type extruder 410, piston 412 within the barrel 106, and a first depiction of clamp stationary 415.

[0084] The mold section graphic 406 includes a second depiction of the clamp stationary 415, and depictions of hot runner 414, a core plate 416 and cavity plate 418 of the mold 110, a movable platen 420 to which the mold core plate is mounted, and a part removal robot 422.

[0085] Melter section graphic 404 and mold section graphic 406 may be discontinuous. That is, they may be discrete representations of subassemblies or portions of the machine 100. Some components of machine 100, e.g., the clamp stationary, may be shown in both the melter section and mold section graphics.

[0086] In the depicted embodiment, the melter section and mold section graphics depict parts of the machine from different perspectives. For example, the melter section graphic 404 shows a simplified partial cross-section view of machine 100 from a side perspective. In other words, the melter section depiction generally shows a simplified vertical cross section. Mold section graphic 406 shows a simplified partial view from a top perspective. In other words, the mold section depiction generally shows a simplified plan view of a portion of the machine.

[0087] The differing perspectives allows depiction of features with different orientations. For example, the melter section graphic 404 shows operation of an extruder and a piston which act in a horizontal axis, and the molding material supply, which vertically feeds molding material. Conversely, the mold section graphic 406 shows operation (e.g. opening and closing) of the mold 110 along a first horizontal axis, and extension and retraction of the part removal robot 422 along a different horizontal axis.

[0088] In the depicted embodiment, machine 100 is represented in two discrete sections. However, in other embodiments, a machine may be depicted in more or fewer discrete sections.

[0089] As will be described in greater detail, in the depicted embodiment, the machine representation is animated to depict operation of the machine in real-time. For example, the extruder 410 and piston 412 may be animated to reflect movement of the respective components of machine 100. In addition, molding material may be shown with animated shading to represent charging of components with material.

[0090] Computing device 430 may animate human interface 400 in real time based on signals from the sensors 209 (FIG. 3). For example, the image of the mold may be animated between open and closed states based on the measured mold position. Likewise, the piston and part removal robot may be animated in real time according to position signals.

[0091] Human interface screen 400 also includes a plurality of selectable graphical controls that are each associated with a respective stage of startup. In the depicted embodiment, the selectable graphical controls include a heats button 440, a purge button 442, a hot runner charge button 444, a semicycle freedrop button 446, a semi-cycle with robot button 448, and an auto cycle button 450 (collectively, “the buttons”).

[0092] Each of the buttons is associated with a respective stage of the machine startup process.

[0093] Each button is animated to depict progress within the respective part of the setup process. In particular, each button is animated in a plurality of segments which progressively indicate completion of operations.

[0094] Each button has an associated detailed information shortcut 452 positioned proximate the button. The detailed information shortcuts may, for example, be touch-sensitive controls such as graphical buttons. Upon activation (e.g. when touched or when automatically invoked as part of the startup process), each detailed information shortcut may open an overlay window containing details of the associated startup stage.

[0095] FIG. 5 depicts an example overlay window 454 associated with the heating operations 202. The overlay window includes a list of names 456 of a sequence of operations included in the heating stage. An indicator is provided to identify a current operation being performed. In the depicted embodiment, the indicator comprises highlighted text. However, in other embodiments, other types of indicators may be used, such as icons, animations or pointers or the like. The overlay window further includes instructional content 458 for assisting operators. As depicted, the overlay window includes text matter descriptive of the operations and / or images representative of the operations, and the text matter for any of the operations can be displayed by selection (e.g. touching) of the corresponding operation name 456.

[0096] Referring again to FIG. 4, the detailed information shortcuts 452 may be transformed to context- dependent activated prompts 460. In particular, based on the current start-up stage of machine 100, the information shortcut 452 corresponding to that stage may be changed to an activated prompt 460 to indicate the stage in progress and to draw attention to the availability of further detailed information for that stage. In the depicted embodiment, activated prompt 460 comprises enlarged, highlighted text. However, in other embodiments, activated prompt may include icons, animations, pointers or the like.

[0097] FIGS. 6A-6E depict further detail of the startup stage buttons. Each of the startup stage buttons includes a plurality of graphical segments representative of individual operations within the respective startup stage. The graphical segments may be animated to indicate whether the corresponding stage has been completed, based on any combination of user inputs and measurements of sensors installed at machine 100. Each of the startup stage buttons may further comprise a status indicator, which may be animated to indicate whether the machine is (1) not ready for an operation of the respective stage; (2) performing an operation of the respective stage; or (3) ready to perform an operation of the respective stage. Each stage button also includes an activation control for initiating the next operation of the stage.

[0098] FIG. 6A depicts heats button 440. Heats button 440 has a status indicator 440-1, two progress segments 440-2, 440-3 and an activation control 440-4. The status indicator is a graphical element that has a first state, namely a white rectangle, to indicate that machine 110 is not ready for a heat operation; a second state, namely, a shaded rectangle, indicating that a heat operation is in progress, and a third state, namely a rectangle that blinks between white and shaded. The third state indicates a standby position in which machine 110 is ready to begin a heat operation.

[0099] The progress segment 440-3 represents heating of the hot runner and mold 110 of the machine 110 (also referred to as “mold heat”) and the progress segment 440-2 represents heating of the melter unit 104 and barrel 106 of machine 100 (also referred to as “machine heat”). The mold heat and machine heat may be measured with thermal sensors 209-1. In an example, heating is completed when all measured locations are at or above the threshold setpoint temperature for the defined soak time. In other examples, the heating threshold may be based on an algorithm combining discrete measured locations. For example, a threshold may be defined as an average of temperatures measured by thermal sensors 209-1 at a plurality of locations.

[0100] The progress segments likewise have three states. Each segment may be white, indicating that the corresponding operation has not been performed, shaded, indicating that the corresponding operation has been performed, or blinking between white and shaded, indicating that the corresponding operation is in progress. Thus, during an operation, the status indicator 440-1 is shaded and one or more of the progress segments blink.

[0101] In some embodiments, mold heats and machine heats may be initiated at different times, based on heating times calculated by computing device 200 for the mold heats and machine heats.

[0102] Heat stage 202 may therefore be broken into multiple separate operations. The first operation is activation of a first heater, associated with the machine component expected to require greater heating time. In order to coordinate completion of heating, heaters for subsequent components may be activated at later times, based on the difference between the calculated heating times.

[0103] In the depicted example, the estimated heating time for machine heats is greater than that for mold heats. Accordingly, when actuation control 440-4 is first touched, machine heating commences. Status indicator 440-1 is shaded and progress segment 440-2 blinks. After a period of delay, the mold heats are activated and progress segment 440-3 blinks. When the machine heat is completed, progress segment 440-2 is shaded. When the mold heat is completed, progress segment 440-3 is shaded.

[0104] In some embodiments, the mold and machine heats may both be manually initiated, i.e., by touching actuation control 440-4.

[0105] FIG. 6B depicts purge button 442. Purge button 442 has a status indicator 442-1, progress segments 442-2 through 442-5, actuation control 442-6.

[0106] Status indicator 442-1 changes from white to blinking between white and shaded upon completion of heat stage 202. Nozzle tip heats are activated, and each time actuation control 442-6 is touched, a purge cycle is performed. During the purge cycle, status indicator 442-1 is shaded and a progress segment blinks. When a purge cycle is completed, a corresponding progress segment is shaded. Another purge cycle may be started automatically. Alternatively, actuation control 442-6 can then be touched to initiate another purge cycle.

[0107] The number of progress segments of purge button 442 corresponds to the required number of purge cycles. In the depicted embodiment, four purge cycles are required. However, more or fewer cycles may be required, in which case more or fewer progress segments may be displayed.

[0108] The number of purge cycles required, and thus, the number of progress segments presented, may be automatically set by computing device 200 dependent on conditions of machine 100. For example, the number of purge cycles may be dependent on the temperature measured by thermal sensors 209-1 of barrel 106 or hot runner 414 when startup is initiated, or on the idle time measured by computing device 200. If the temperature is below a threshold value or if the idle time is above a threshold value, a “full purge” may be performed, whereas if the starting temperature is above a threshold value or idle time below a threshold value, a partial purge may be performed, with fewer cycles.

[0109] After a pre-set number of purge cycles are completed, all of the progress segments are shaded. Status indicator 442-1 changes to a half white, half shaded state, indicating that the next stage may be started, or the operator may choose to perform additional purge cycles by touching actuation control 442-6. An operator may, for example, choose to perform additional purge cycles if old molding material is present in the purged material, or if the quality of purged melt is not acceptable.

[0110] In some embodiments, purging may discharge melt material into a receptacle such as a purge tray. The purge tray may have finite capacity. Thus, the purge tray may need to be periodically emptied. In the depicted embodiment, purging may be automatically paused when the purge tray needs to be emptied. Status indicator 442-1 may change from shaded to blinking, indicating a step to be taken to resume purging. A visual cue to empty the purge tray may be presented on human interface screen 400. For example, a purge tray icon 417 (FIG. 4) may be shown, and may blink or be shown as filled, indicating that the purge tray is to be emptied. Presence of the purge tray may be detected by a sensor at machine 110, and after the purge tray is removed and replaced, the purge tray icon may indicate that emptying has occurred, e.g., it may stop blinking. The operator may then resume purging by selection of actuation control 442-6.

[0111] In some embodiments, the state of the purge tray may be automatically determined. For example, an operator may be prompted to periodically empty the purge tray based on a volume of material discharged in each purge cycle and the capacity of the purge tray, or based on a measurement of how much material is in the purge tray (e.g. by weight). In other embodiments, an operator may define the times at which the purge tray is emptied.

[0112] FIG. 6C depicts charge button 444. Charge button 444 has a status indicator 444-1, a single progress segment 444-2, and an actuation control 444-3. Status indicator 444-1 changes from white to blinking after purging is completed and the nozzle and sprue are cleaned, and nozzle heats are ready. When actuation control 444-3 is touched, the status indicator is shaded and progress segment 444-2 blinks while charging is carried out. The hot runner is charged by advancing the piston to force molding material into mold 110 after closing the mold under clamping pressure. Charging is complete when either the piston cannot advance to the end of its travel and backpressure measured by pressure sensors 209-3 against the piston is at or above a threshold value, indicating the mold (and thus, the hot runner) are filled with material. Status indicator 444- 1 and progress segment 444-2 then stop blinking and are shaded.

[0113] FIG. 6D depicts semi with freedrop button 446. The semi with freedrop button has a status indicator 446-1, four progress segments 446-2 through 446-5, and an actuation control 446-6. The number of progress segments corresponds to the number of freedrop cycles required.

[0114] In some embodiments, the number of freedrop cycles is automatically determined by computing device 200 based on the idle time measured by computing device 200. If the idle time is above a threshold (long idle), a full freedrop stage may be performed. If the idle time is below a threshold, a shorter freedrop stage, may be performed, with fewer cycles.

[0115] Status indicator 446-1 changes from white to blinking when charge stage 204 is completed, and mold and nozzle heats are ready. When actuation control 446-6 is touched, a freedrop molding cycle is performed. Startup molding settings may be automatically selected. That is, mold 110 is closed, molding material is injected, and a set of parts produced.

[0116] The mold is subsequently opened. Detailed information shortcut 452 may be automatically activated to prompt the operator to visually inspect the molded parts. Status indicator 446-1 blinks and the next touch of actuation control 446-6 causes parts to be ejected. Detailed information shortcut 452 may again be automatically activated to prompt the operator to visually verify that no parts failed to eject. Status indicator 446-1 blinks and the next touch of actuation control 446-6 causes the part ejector to reset, a progress segment is then shaded. The next touch of actuation control 446-6 initiates another cycle. After a pre-set number of cycles are completed, all of the progress segments are shaded. Status indicator 446-1 changes to a half white, half shaded state, indicating that the next stage may be started, or the operator may choose to perform additional freedrop cycles by touching actuation control 446-6. An operator may, for example, choose to perform additional freedrop cycles if defects are present in molded parts, or if all parts are not ejected successfully.

[0117] FIG. 6E depicts semi with robot button 448. The number of semi with robot cycles required is determined in the same manner as freedrop cycles. That is, computing device 200 determines if machine 100 has been idle for a long idle, in which case a full number of cycles is performed or a short idle, in which case fewer cycles are performed. In the depicted example, five semi with robot cycles are required. Accordingly, semi with robot button 448 has a status indicator 448-1, four progress segments 448-2 through 448-6 and an actuation control 448-6.

[0118] Status indicator 448-1 changes from white to blinking upon completion of freedrop stage 206, with mold and machine heats remaining activated. When actuation control 448-6 is touched, a full, semi-automatic molding cycle is performed. That is, mold 110 is closed, molding material is injected, and a set of parts produced. The mold is subsequently opened. Part removal robot 422 is moved into the open mold and parts are transferred to the robot. During the cycle, status indicator 448-1 is shaded and a corresponding progress segment blinks. Once parts are transferred, status indicator 448-1 is shaded and a progress segment is shaded. The operator visually verifies that parts were successfully transferred from the mold to the robot. The next touch of actuation control 448-6 initiates another cycle.

[0119] After a pre-set number of cycles are completed, all of the progress segments are shaded. Status indicator 448-1 changes to a half white, half shaded state, indicating that the next stage may be started, or the operator may choose to perform additional semi with robot cycles by touching actuation control 448-6. An operator may, for example, choose to perform additional semi with robot cycles if parts are not successfully transferred to the part removal robot.

[0120] FIG. 6F depicts auto cycle button 450. The auto cycle button has a status indicator 450- 1 , progress segments (as depicted, four progress segments 450-2 through 450-5), and actuation control 450-8. Status indicator 450-1 changes from white to blinking upon completion of semi with robot stage 210. When actuation control 450-6 is touched, a pre-set number of molding cycles are automatically performed. In the depicted embodiment, four molding cycles are performed. However, more or fewer molding cycles may be performed. Through the automatic molding cycles, status indicator 450-1 is shaded and corresponding progress segment 450-2 to 450-5 blinks. During auto-cycling, process settings may be automatically adjusted from startup settings to production settings. For example, part cooling times may be reduced in production relative to startup values, in order to maximize the rate of production. Such adjustment may be performed in steps, to allow verification that the adjustments do not introduce part or process defects. The required number of auto-cycles and progress segments may therefore correspond to a number of steps over which such adjustment is to be made. The number of steps may, for example, be determined automatically based on the magnitude of adjustment. After each cycle (and each adjustment step), a progress segment is shaded.

[0121] Each of buttons 440, 442, 444, 446, 448, 450 is designed to pictorially represent operations performed in the respective startup stage. Specifically, in the depicted embodiment, the pictorial representations are on the actuation controls.

[0122] Referring again to FIG. 3, human interface screen 400 further includes an iconic alarms panel 462. The iconic alarms panel displays icons representative of alarm (problem) conditions present in the machine 100. The alarm conditions may be presented using a series of icons associated with alarm classifications. For example, alarms may be categorized as safety system, power pack, machine heats, mold heats, clamp, mold, injection, robot and auxiliaries. Each alarm classification has a corresponding icon which visually represents the alarm type. Alarm conditions may be based on measurements from sensors at machine 100 and may be context-sensitive to an operating state of the machine. For example, heats alarms may be triggered when one or more thermal sensors at machine 100 measures a temperature outside a set acceptable range. The set range may be dependent, e.g. on which stage of startup the machine 100 is in. For example, the set temperature range during purging may differ from the set temperature range during semi-freedrop molding.

[0123] As noted above, the representation of machine 100 in human interface screen 400 may be animated to depict the status of operations of the machine.

[0124] FIGS. 7A-7E depict the melter section graphic 404 and mold section graphic 406 during different startup stages, showing example animations.

[0125] FIG. 7A depicts the mold portion and melter portion graphics during heating stage 202. The piston 412 within barrel 106 and the extruder 410 of melter unit 104 are retracted. The mold 110 is open and part removal robot 422 is at vertical position.

[0126] FIG. 7B depicts the mold portion and melter portion representations during purge stage 204. The mold is in an open position. Piston 412 and extruder 410 are animated to show reciprocating movement as they extend and retract for each shot of molding material. A purge guard 470 is shown adjacent the hot runner, and mold material is animated flowing into the purge tray.

[0127] FIG. 7C depicts the mold portion and melter portion representations during charge stage 206. The mold 110 is in a closed position. The piston 410 and extruder 412 are animated to show them extending to inject molding material into the mold.

[0128] FIG. 7D depicts the mold portion and the melter portion representations during the semi with freedrop stage. During this stage, all of the mold 110, piston 412 and extruder 410 are animated to depict movement in real time based on their respective measured positions. The mold 110 moves between open and closed positions. In addition, a stripper plate 472 of mold 100 reciprocates away from and towards the mold cavity plate during ejection of parts.

[0129] FIG. 7E depicts the mold section graphic 406 and the melter section graphic 404 during the semi with robot stage 210. The mold 110, piston 412 and extruder 410 are animated as in the freedrop stage. Additionally, a tooling plate of the part removal robot 422 is animated to show moving into the open mold and moving out from the mold for parts transfer from the cores, the CoolPik of robot 422 moving with the mold stroke to pick up parts from the tooling plate, and rotation of the CoolPik for dropping the parts (e.g., onto a conveyor).

[0130] The representation of machine 100 may also include icons to provide detailed status information in addition to that depicted by animation of the components. Example icons are shown in FIG. 7 A. In the depicted example, the icons include mold heat icon 480 and nozzle heat icon 482 depicting status of the respective heats (e.g. on, off or standby status); valve gate icon 484 depicting the status of the valve gate as open, closed or neutral; conveyor icon 486, depicting a part removal conveyor as not running, running or running in a reverse direction; a mold air icon 491 that appears when mold air is active; and a cooling time icon 490, which appears when cooling time is greater than a pre-set production value. The icons may present information by any combination of pictorial representation of the system or parameter being shown, colour coding, arrows, text or numerical matter or the like. Other icons are possible.

[0131] Referring again to FIG. 4, the human interface screen 400 further comprises a detailed settings panel 474. Detailed settings panel comprises a plurality of additional buttons, each of which can be touched to display an overlay window of detailed settings and status information associated with an associated subsystem of machine 100. Conveniently, the human interface described herein provides real-time feedback and contextual information that can be readily interpreted by machine operators, regardless of experience level. In particular, animations provided in the interface depict conditions that could not readily be visually observed, such as heats of various components and the positions of internal components such as the extruder and piston. Moreover, control elements of configured in a manner to portray information about the respective steps of the startup process and progress of the machine through the startup process. Accordingly, operators may be reminded of stages and operations that have been completed, and stages and operations yet to be completed.

[0132] In addition, the interface allows ready access to detailed settings and information such as guidelines. However, display of such settings is responsive to user selections, rather than being presented in a static linear progression of screens.

[0133] When introducing elements of the present invention or the embodiments thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0134] The term "comprise", including any variation thereof, is intended to be open-ended and means "include, but not limited to," unless otherwise specifically indicated to the contrary.

[0135] When a set of possibilities or list of items is given herein with an "or" before the last item, any one of the listed items or any suitable combination of two or more of the listed items may be selected and used.

[0136] The above described embodiments are intended to be illustrative only. Modifications are possible, such as modifications of form, arrangement of parts, details and order of operation. The examples detailed herein are not intended to be limiting of the invention. Rather, the invention is defined by the claims.

Claims

AMENDED CLAIMS received by the International Bureau on 09 January 2026 (09.01 .2026)What is claimed is1. An injection molding machine, comprising: a plurality of sensors configured to measure operating conditions of said injection molding machine; a graphical display comprising a schematic representation of said injection molding machine and said operating conditions; a plurality of selectable icons on said graphical display, each representing a corresponding stage of a startup process of said injection molding machine and operable to cause said machine to perform operations of the respective stage; said icons having associated animations representing progress through said respective stages, wherein said icons have a plurality of segments, each representing an operation of the corresponding stage, and said associated animations comprise animation of said segments.2 The injection molding machine of claim 1, wherein said sensors comprise a clamp position sensor and an injection piston position sensor.3 The injection molding machine of claim 1, wherein said sensors comprise a first thermal sensor configured to measure a temperature in a mold and a second thermal sensor configured to measure a temperature in a melter of said machine.4 The control system of claim 1, wherein said associated animations are based on inputs from said sensors.5 The control system of claim 1, wherein said schematic representation is animated based on said operating conditions.6 The control system of claim 1 , wherein said stages include a heating stage, and wherein said control system is configured to coordinate heating of said mold and said machine.7 The control system of claim 1, wherein said animation of said segment comprises shading.

8. The control system of claim 1, wherein said icons have status indicators, said status indicators animated to represent whether an operation of the corresponding stage is in progress.

9. A control system for an injection molding machine, comprising: a plurality of sensors configured to measure operating conditions of said injection molding machine; a graphical display comprising a schematic representation of said injection molding machine and said operating conditions; a plurality of selectable icons on said graphical display, each representing a corresponding stage of a startup process of said injection molding machine and operable to cause said machine to perform operations of the respective stage; said icons having associated animations representing progress through said respective stages, wherein said icons have a plurality of segments, each representing an operation of the corresponding stage, and said associated animations comprise animation of said segments.

10. The control system of claim 9, wherein said sensors comprise a clamp position sensor and an injection piston position sensor.

11. The control system of claim 9, wherein said sensors comprise a first thermal sensor configured to measure a temperature in a mold and a second thermal sensor configured to measure a temperature in a melter of said machine.

12. The control system of claim 9, wherein said associated animations are based on inputs from said sensors.

13. The control system of claim 9, wherein said schematic representation is animated based on said operating conditions.

14. The control system of claim 9, wherein said stages include a heating stage, and wherein said control system is configured to coordinate heating of said mold and said machine.

15. The control system of claim 9, wherein said animation of said segment comprises shading.

16. The control system of claim 9, wherein said icons have status indicators, said status indicators animated to represent whether an operation of the corresponding stage is in progress.

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