Injection Molding Control Using Volume Growth Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing injection molding processes require extensive expertise and are time-consuming due to complex settings and empirical value-based configurations, often necessitating a trial-and-error approach, which can lead to errors and inefficiencies.
Innovation Solution
A method that calculates setting data for the injection molding process using a known volume model of the molded part, incorporating expert knowledge and geometric information to generate a stepwise volume growth profile, allowing for simplified and rapid parameterization of the injection molding process, reducing the need for specialized expertise and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive expert knowledge and empirical settings are used for injection molding process configuration, then the quality of molded parts can be improved, but the setup time and complexity increase significantly
Solution Approach 1:
The system performs preliminary calculations of setting data for the injection molding process before actual production. By pre-calculating parameters such as injection pressure, temperature, and timing based on the volume model and geometric information, the system prepares optimal settings in advance, eliminating the need for time-consuming trial-and-error adjustments during setup
Solution Approach 2:
The system creates a digital volume model copy of the molded part geometry and uses this virtual representation to calculate all necessary process parameters. This digital twin approach allows virtual simulation and optimization of the injection molding process without requiring physical trial runs, thereby reducing setup time while maintaining quality
2Reliability
If complex settings and trial-and-error processes are used for injection molding parameter configuration, then accurate process parameters can be achieved, but the device complexity and operational difficulty increase
Solution Approach 1:
The system performs self-service by automatically calculating all injection molding setting data based on the volume model and geometric information of the molded part. The control unit independently determines optimal parameters for injection pressure, temperature, and timing without requiring external expert intervention or complex manual configuration, thereby simplifying the control system while ensuring parameter accuracy
Solution Approach 2:
The system automatically adjusts and optimizes multiple process parameters simultaneously based on the calculated volume growth profile. By changing parameters such as injection pressure, temperature, and timing in a coordinated manner derived from the geometric model, the system achieves accurate process parameters without requiring complex individual settings or trial-and-error adjustment of each parameter
3Reliability
If expert operators perform manual configuration of injection molding settings, then complex processes can be controlled, but the ease of operation decreases and specialized knowledge is required
Solution Approach 1:
The system replaces the mechanical system of manual expert operation with an automated computational system. Instead of relying on human operators to manually configure settings based on experience, the control unit automatically calculates optimal parameters using algorithms that process the volume model and geometric information, thereby maintaining reliable control while dramatically improving ease of operation
Solution Approach 2:
The system introduces a computational intermediary (the control unit with calculation algorithms) between the geometric model and the injection molding process. This intermediary automatically translates geometric information into optimal process parameters, eliminating the need for human experts to directly control complex settings while ensuring reliable process control through scientifically derived parameters
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to a method that serves to control a machine (10) for processing plastics and other plasticisable materials such as powdered and/or ceramic substances. The machine has a mould opening and closing unit (12) for opening and closing an injection mould (14) having at least one mould cavity (16) for producing an injection moulded part (18) corresponding to the shape of the mould cavity (16), an injection moulding unit (20) having means for plasticising and for injection of the plasticisable material in the mould cavity (16) and has a machine control (22) which is connected to an expert knowledge source (34) and if required can be operated by the operator by means of an interactive contact. Information concerning the geometry of the injection moulded part (18) and/or the mould cavity (16) and the sprue geometry (24) are provided to the machine control (22), in order to calculate at least one injection process taking the geometric information into consideration. Because an injection process is calculated, taking into consideration the geometric information, at least one progressive volume growth profile of the injection moulded part (18) in the filling direction of the mould cavity (16) is calculated, and taking into consideration the progressive volume growth profile at least one injection process is calculated, a simplified, fast and effective parameterisation of the injection moulding machine is made possible, the operator is relieved by the implemented expert knowledge and the quality of the injection moulded part (18) is improved.