Injection Molding Controller Digital Twin for Offline Setup
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Solution Overview
Problem
Existing methods for configuring and operating injection molding machines are inefficient and require significant user intervention, leading to downtime and potential production of faulty parts.
Innovation Solution
A digital twin of the machine control system is created using a hardware-independent app, allowing settings datasets to be generated or modified offline, enabling seamless adaptation to a target system without a postprocessor or virtual model, and facilitating immediate operation of the injection molding machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If configuration and operation of injection molding machines is done using existing methods, then user intervention is required for settings, but this leads to significant downtime and potential production of faulty parts
Solution Approach 1:
The patent applies preliminary action by creating and configuring a digital twin of the injection molding machine before the actual production process. All settings, parameters, and configurations are prepared in advance on the digital twin system, allowing validation and optimization before transferring to the physical machine. This eliminates the need for time-consuming on-machine adjustments and reduces the risk of faulty production.
Solution Approach 2:
The patent uses copying by creating a digital twin - a virtual replica of the injection molding machine that mirrors all physical characteristics, components, and operational parameters. This digital copy allows for configuration, testing, and optimization without affecting the actual production machine, thereby reducing downtime and ensuring reliability when settings are transferred back to the physical system.
2Productivity
If a digital twin is created using a hardware-independent app, then settings datasets can be generated offline, but this requires additional system complexity
Solution Approach 1:
The patent applies universality by developing a hardware-independent application that can run on various platforms (cloud systems, local servers, or embedded devices). This single software solution performs multiple functions: creating the digital twin, configuring parameters, validating settings, and transferring data back to the physical machine. This multi-functionality reduces the need for multiple specialized systems while maintaining productivity benefits.
3Ease of operation
If configuration is done on the actual machine, then immediate operation is possible, but user intervention is required and downtime increases
Solution Approach 1:
The patent applies self-service by enabling the digital twin system to automatically configure, validate, and optimize settings without requiring continuous user intervention. The system can independently adjust parameters, simulate production scenarios, and identify optimal configurations. Users only need to initiate the process and review final results, significantly reducing setup time while maintaining ease of operation through automated intelligent systems.
Data Source
AI summary
An operating system of a machine controller for an injection molding machine for processing plastics is provided on a target system having a processor. Information about an operating system of a machine controller of an injection molding machine is provided. The operating system can be configured to the characteristics of the injection molding machine by means of configuration data of a first machine configuration. The operating system is installed with all the configuration data as a digital twin, using a hardware-independent app to convert the information for the target system. On the target system, a new setting dataset is created or an existing setting dataset for producing injection-molded parts is changed, the setting dataset being able to run on the injection molding machine. The setting dataset created or changed on the target system is transferred to the injection molding machine and the injection molding machine is operated therewith.