Injection Mold Sensor Module for Temperature and Vibration Monitoring
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Solution Overview
Problem
Existing technologies face challenges in accurately monitoring the quality of injection-molded products due to inefficiencies in temperature measurement and vibration signal analysis, leading to difficulties in recognizing temperature variations and analyzing product quality effectively.
Innovation Solution
A system that includes magnetic sensors for counting shots, temperature sensors for real-time temperature measurement, and acceleration sensors or vibration sensors for analyzing vibration signals, all integrated into a sensor module fixedly installed on the mold. This setup minimizes heat loss and ensures accurate transmission of vibration signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a temperature sensor is installed on the mold through existing sensing devices, then temperature measurement is enabled, but heat loss occurs and accurate temperature recognition is impossible
Solution Approach 1:
The patent introduces a thermal conductor as an intermediary component between the mold and the temperature sensor. This thermal conductor has high thermal conductivity and is in direct contact with the mold, serving as a mediator to transfer heat efficiently from the mold to the temperature sensor without significant heat loss, thereby enabling accurate temperature measurement.
Solution Approach 2:
The patent replaces conventional mechanical or electrical sensing methods with a thermal conduction-based measurement system. By using a thermal conductor with known thermal properties in direct contact with the mold, the system substitutes complex sensing mechanisms with a simpler thermal conduction principle, achieving more accurate and reliable temperature measurement.
2Measurement precision
If vibration sensors are installed to measure vibration signals, then quality analysis capability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensing functions (temperature measurement, vibration detection, and shot counting) into a single integrated sensor system mounted on the mold. By merging these functions into one unified device, the system achieves comprehensive quality monitoring capability while reducing the overall complexity compared to using separate independent sensing systems.
Solution Approach 2:
The patent designs a universal sensor system that can perform multiple functions simultaneously - measuring temperature, detecting vibration signals, and counting injection shots. This multi-functional approach allows a single device to replace multiple specialized sensors, improving measurement precision across different parameters while keeping the device complexity manageable through integrated design.
3Reliability
If multiple sensors are installed for comprehensive quality monitoring, then quality management capability is improved, but ease of operation deteriorates
Solution Approach 1:
The patent merges multiple sensors (temperature sensor, vibration sensor, shot counter) into a single integrated mounting system on the mold. This consolidation allows all sensors to be installed and operated together as one unit, improving quality management reliability through comprehensive monitoring while maintaining ease of operation by reducing the number of separate installation and operation steps.
Solution Approach 2:
The integrated sensor system is designed to automatically perform multiple measurement functions simultaneously without requiring separate operation for each sensor. The system self-manages temperature monitoring, vibration detection, and shot counting in an integrated manner, improving reliability through comprehensive data collection while simplifying operation by eliminating the need for manual coordination of multiple independent sensors.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances the efficiency and reliability of product quality management by providing accurate real-time data on temperature and vibration, enabling timely process management and improved productivity.
Implementation Method 1
measuring whether temperature of a mold is maintained within a set range by measuring the temperature in real time by installing a temperature sensor on the mold
Implementation Method 2
measuring and analyzing in real time the amplitude magnitude and generation interval of vibration signals that are generated by pressure variation of resin that is injected into the mold by fixedly installing an acceleration sensor or a vibration sensor on the mold
Implementation Method 3
counting the number of injection-molded molds by attaching and installing magnetic sensors to a moving side and a fixed side
Data Source
AI summary
Provided is an injection-molded product quality analysis and monitoring system for injection-molded product quality management, the system having magnetic sensors attachably provided on a movable-side part and a fixed-side part so as to count the number of times molds have opened for injection molding, and managing the quality of products during molding-manufacturing by fixedly providing a temperature sensor at the mold so as to measure the temperature of the mold in real time, and thus measure whether the temperature is maintained within a set range, and fixedly providing an acceleration sensor or a vibration sensor at the mold so as to measure and analyze the amplitude of vibration signals, generated because of the pressure of resin injected into the mold, and the generation intervals of the vibration signals.