Injection Molding Condition Modeling for Variable Resin Quality
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Solution Overview
Problem
Existing injection molding methods struggle to stabilize the quality of molded articles due to variations in resin material properties, particularly with recycled materials, leading to issues like short shots or appearance defects, and require specialized controllers and additional development efforts.
Innovation Solution
An injection molding condition generation system using a computer to generate optimal molding conditions based on accumulated data relating material properties, molding conditions, and quality parameters, without needing real-time control or connection to the molding machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is sequentially adjusted for each cycle during injection molding operation, then the injection molding condition can be controlled in consideration of material property changes, but a special controller and additional development are required, increasing man-hours
Solution Approach 1:
The patent creates a virtual model (relational expression) that copies and represents the complex relationship between material properties, molding conditions, and quality parameters. This virtual model allows the system to determine optimal conditions without requiring complex real-time control hardware, thereby resolving the contradiction between quality consistency and controller complexity.
Solution Approach 2:
The patent performs preliminary data collection and relational expression generation before actual production. By pre-establishing the relationship model between material properties and optimal molding conditions, the system eliminates the need for complex real-time adjustment controllers during production, reducing both device complexity and development man-hours while maintaining quality consistency.
2Reliability
If pressure control is based on change in control signal from controller, then adjustment according to material property change is achieved, but adjustment amount of pressure is increased when temperature property and fluidity greatly change, causing short shot or burr
Solution Approach 1:
The patent changes from controlling only pressure to controlling multiple injection molding parameters (temperature, pressure, injection speed, holding pressure) simultaneously. By adjusting multiple parameters in coordination based on material properties, the system achieves better adaptation without excessive pressure adjustments that cause defects like short shots or burrs.
Solution Approach 2:
The patent implements dynamic adjustment of multiple molding parameters based on real-time material property measurements. The system continuously monitors material properties and dynamically modifies the relational expression to determine optimal parameter combinations, enabling flexible adaptation to material variations while maintaining quality within specification limits.
3Productivity
If recycled plastic materials are used, then resource utilization is improved, but variation in material property becomes large due to thermal history, environmental deterioration, and contamination, resulting in larger quality variation
Solution Approach 1:
The patent implements a feedback mechanism where material properties are measured during injection molding, and the relational expression is updated based on these measurements. This feedback loop allows the system to adapt to variations in recycled materials by continuously learning the relationship between material properties and optimal molding conditions, thereby reducing quality variation despite using recycled materials with inconsistent properties.
Data Source
AI summary
An injection molding condition generation system improves the quality of injection molding. The injection molding condition generation system acquires a material property value of a resin material and an injection molding condition using the first resin material based on a target value of a quality parameter related to a quality of a molded article, the first material property value, and a predetermined relational expression. The predetermined relational expression indicates a relation among the material property value of the resin material, a plurality of injection molding conditions input to an injection molding machine, and a quality parameter related to the quality of the molded article molded by the injection molding machine based on the material property value and the injection molding conditions, and is generated based on data accumulated in the memory in association with the material property value of the resin material, the injection molding conditions, and the quality parameter.