Injection Molding Front Tracking Through Pressure Curve Alignment

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Solution Overview

Problem

Current methods for determining the position of the moulding material front during injection-moulding processes are unreliable and non-reproducible, relying on manual detection of pressure features which are difficult to automate, and simulation alignment with real processes is operator-dependent and prone to inaccuracies.

Innovation Solution

A method and computer program product that calculate simulated and measured pressure progressions, apply transformations to minimize deviations, and determine the moulding material front positions using parameter adjustments, enabling reliable and reproducible tracking of the moulding material front and alignment of simulations with real processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual detection of pressure features is used to determine moulding material front positions, then detection capability is provided, but reliability and reproducibility deteriorate due to operator dependency and difficulty in automated implementation

Engineering Contradiction:

Improvemoulding material front position detection accuracyVSAvoiddetection reliability and reproducibility

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces manual visual detection of pressure features with automated mathematical analysis. Transformation functions are applied to pressure progression data to objectively identify moulding material front positions, eliminating operator dependency and enabling reliable automated implementation in series production machines.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transforms pressure progression data through mathematical transformations to reveal features that are not apparent in raw data. By changing the parameter representation (applying transformation functions), the system can reliably detect moulding material front positions automatically, improving both precision and reliability.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If simulation alignment is performed manually by operators, then simulation results can be matched to real processes, but automation and reproducibility deteriorate due to operator dependency

Engineering Contradiction:

Improvesimulation alignment accuracyVSAvoidautomation level of simulation alignment

Core Design Contradiction:

Manufacturing precisionVSExtent of automation

Solution Approach 1:

The patent replaces manual operator-based simulation alignment with automated computational methods. Mathematical transformation functions are applied to both simulation and measurement data to objectively determine alignment parameters, enabling full automation while maintaining or improving alignment accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses feedback from comparing transformed simulation pressure progressions with transformed measurement pressure progressions to iteratively optimize alignment parameters. This automated feedback loop enables reproducible alignment without operator intervention, improving both automation extent and manufacturing precision.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If features of pressure progression are analyzed closely with human eye, then detection capability is improved, but ease of operation and productivity deteriorate due to insurmountable obstacles to automatic implementation

Engineering Contradiction:

Improvepressure feature detection accuracyVSAvoidautomated implementation feasibility

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent replaces human visual inspection with automated mathematical transformation and analysis. Transformation functions are applied to pressure progression data to objectively identify features, making the process suitable for automated implementation in series production machines while maintaining detection accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transforms pressure progression data through mathematical functions to convert subtle features into clearly identifiable patterns. This parameter transformation enables automated systems to detect features with the same effectiveness as human experts, greatly improving ease of operation and automated implementation feasibility.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12064909B2Procedure for determining real molding fronts and aligning simulations

Publication Date: 2024.08.20 ENGEL AUSTRIA

AI summary

A method for determining positions of a real moulding material front during a process to be carried out with a moulding machine, whereina simulation progression (SV) of a variable characteristic of the process is calculated,positions of a simulated moulding material front are determined from the simulation,the real process is carried out, and at least one measurement progression (MV) of the at least one characteristic variable is measured directly or indirectly,a transformation is chosen, which has at least one parameter (ΔV, kp, Vunknown),the transformation is applied to the at least one simulation progression (SV), with the result that a transformed simulation progression (tSV) is formed, anda parameter value is determined for the parameter (ΔV, kp, Vunknown) such that a deviation between the measurement progression (MV) and the transformed simulation progression (tSV) is minimized according to a predetermined error measure or according to an operator input.