Ultrasonic Phased Array In-Situ Imaging for Injection Melt Flow
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Solution Overview
Problem
Existing ultrasonic online measurement methods for injection molding rely on single ultrasonic probes, which can only provide melt information from a single site, limiting the measurement range and primarily offering qualitative characterization.
Innovation Solution
An ultrasonic phased array-based in-situ imaging method is developed, which collects full matrix capture (FMC) data during injection molding, calculates propagation displacement and time delay, and performs total focusing imaging to obtain high-resolution melt flow images and velocity measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single ultrasonic probe is used, then the device complexity is low, but the measurement range is limited and only single-site melt information can be provided
Solution Approach 1:
The single ultrasonic probe is segmented into multiple ultrasonic elements (e.g., 64 elements arranged in a matrix) that can be independently controlled. Each element acts as an independent sensor, allowing the system to measure melt flow at multiple sites simultaneously across the entire mold cavity, thereby expanding the measurement range without proportionally increasing overall system complexity
Solution Approach 2:
The measurement approach transitions from a single-point measurement (0D) to a two-dimensional array of measurement points (2D) by arranging ultrasonic elements in a matrix configuration. This dimensional expansion enables comprehensive coverage of the melt flow field across the entire mold cavity, providing spatial distribution of melt flow velocity and front position
2Measurement precision
If qualitative characterization methods are used, then the analysis is simpler, but the measurement precision is insufficient for quantitative melt flow analysis
Solution Approach 1:
The patent replaces qualitative mechanical measurement approaches with quantitative ultrasonic measurement techniques. By measuring the ultrasonic velocity of sound waves through the melt, the system obtains precise quantitative data on melt flow velocity, density, and front position, enabling rigorous analysis of injection molding process parameters
Solution Approach 2:
The system continuously monitors ultrasonic signals during the injection process and provides real-time feedback on melt flow characteristics. This feedback mechanism enables dynamic adjustment of process parameters and provides quantitative data for process optimization, transforming qualitative observation into measurable, controllable parameters
3Measurement precision
If total focusing method (TFM) is applied to multi-layer structure, then the imaging ability and resolution are high, but the calculation time is excessive and imaging efficiency is limited
Solution Approach 1:
The patent performs preliminary calculations of ultrasonic propagation paths and time delays before the actual imaging process. By pre-computing the ray tracing paths through the multi-layer mold structure and storing the propagation time data, the system eliminates the need for time-consuming real-time calculations during imaging, significantly reducing processing time while maintaining high resolution
Solution Approach 2:
The system applies TFM selectively to specific regions of interest within the mold cavity rather than processing the entire measurement volume. By identifying and focusing computational resources on critical areas where melt flow information is most needed, the system achieves high imaging resolution in key regions while reducing overall calculation time
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
This method enables accurate, high-resolution, and dynamic monitoring of melt flow in injection molding, providing quantitative measurements of melt flow velocity and imaging the melt flow front process, thereby improving imaging efficiency and measurement accuracy.
Implementation Method 1
Ultrasound is a widely used nondestructive testing technology, which can penetrate a melt mold and provide abundant melt information feedback
Implementation Method 2
Cheng et al. measured the ultrasonic velocity of the melt in the cavity to characterize different injection stages in injection molding
Implementation Method 3
He distinguished fusible materials from immiscible materials by measuring the change of an attenuation coefficient
Implementation Method 4
A total focusing method (TFM) is as highly accepted as the gold standard of ultrasonic imaging, which focuses all sound beams on each pixel in the measurement region through a time delay operator
Data Source
AI summary
Provided by the present disclosure is an ultrasonic phased array-based in-situ imaging method for melt flow in injection molding. The ultrasonic phased array is used for the detection of an injection molding process for the first time, and an effective dynamic monitoring imaging method for a melt front position is developed. A melt flow process in a mold cavity is dynamically monitored by collecting an FMC (Full matrix capture) dataset online. A mapping relationship between an incident angle and a target pixel point is established to rapidly determine time delay of each point in a measurement target region, and a melt bottom image is acquired using TFM (Total focusing method) imaging conditions, from which the melt front can be localized. The provided method is high in measurement accuracy, short in imaging time, and capable of effectively improving imaging efficiency of online measurement.