Injection Actuator Profile Calculation via Cavity Simulation
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Solution Overview
Problem
Current methods for simulating the injection process in molding machines require in-depth machine-specific knowledge and are inefficient for optimization, as they need to simulate the movement of the injection actuator and molding material, making them complex and resource-intensive.
Innovation Solution
A computer-implemented method that simplifies the simulation by defining a simulation domain comprising only the mold cavity, allowing for the simulation of molding material injection without simulating the injection actuator's movement, and converting the volume flow profile into a nominal profile for the actuator's movement, which can be used to optimize the molding process independently of the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the entire injection process including injection actuator movement is simulated, then the simulation accuracy is improved, but the device complexity and computational resources increase
Solution Approach 1:
The simulation domain is segmented into two parts: the injection actuator (screw) and the mold cavity. The patent applies segmentation by simulating only the mold cavity portion while using measured volume flow data from the actuator as boundary conditions, thereby reducing simulation complexity while maintaining accuracy in the critical casting process.
Solution Approach 2:
The injection actuator is extracted from the simulation domain. Instead of simulating the actuator's movement and its interaction with the molding material, the patent measures the volume flow directly at the actuator outlet and uses this as a boundary condition for the cavity simulation, eliminating the need to model the actuator itself.
2Loss of information
If the entire injection process is simulated, then the process understanding is improved, but the simulation time and computational resources increase
Solution Approach 1:
The simulation process is segmented into two independent stages: (1) measuring/obtaining volume flow characteristics from the injection actuator, and (2) simulating the molding material flow in the cavity using this volume flow as boundary conditions. This segmentation reduces simulation time while preserving essential process information.
Solution Approach 2:
The volume flow characteristics are determined in advance through separate measurements or simplified simulations before the main cavity simulation. This preliminary action allows the complex cavity simulation to use pre-prepared boundary conditions, significantly reducing the computational time required for the main simulation process.
3Measurement precision
If machine-specific parameters are included in the simulation, then the simulation accuracy for specific machines is improved, but the adaptability to different machines decreases
Solution Approach 1:
Instead of simulating the actual injection actuator for each machine, the patent creates a simplified representation by measuring the volume flow characteristics and using these as boundary conditions. This copying approach preserves the essential flow characteristics needed for accurate cavity simulation while eliminating machine-specific complexities, enabling the same simulation methodology to be applied to different machines.
Solution Approach 2:
The patent changes the simulation parameters from machine-specific geometric and mechanical parameters to flow-based parameters (volume flow rate, pressure) that can be measured or obtained for different machines. This parameter transformation maintains accuracy while improving adaptability, as the same simulation framework can accommodate different machines by simply changing the boundary condition parameters.
Data Source
AI summary
A computer-implemented method for calculating a nominal profile for the movement of an injection actuator of a molding machine includes defining a simulation domain comprising at least one cavity of a mold installed on the molding machine. At least one simulation is performed in the simulation domain, and injection of a molding material into the at least one cavity of the mold is simulated by predefining at least one volume flow profile through an inlet face at the edge of the simulation domain and/or by predefining at least one pressure profile at the inlet face as boundary condition. A volume flow profile calculated using the simulation and/or the at least one volume flow profile is converted into a nominal profile for the movement of an injection actuator, in particular a plasticizing screw, and a compressibility of the molding material is taken into account in the conversion.