A molding system and a method for operation of the molding system are provided. The method includes flowing a molten polymeric material into a shot tuning chamber from an upstream device, adjusting a temperature of and/or pressure applied to the molten polymeric material in the shot tuning chamber, and flowing the molten polymeric material from the shot tuning chamber into a mold cavity.

A hot runner process controller configured to monitor the status and operation of a hot runner system to autonomously generate information to improve the quality of injection molding process of a hot runner system having an inlet nozzle, one or more manifolds and one or more nozzles with actuator or without actuator, and one or more heating elements, the hot runner process controller is self-operating, and independent from the injection molding machine, includes: one or more sensors located on, in or at the hot runner system to detect the status and/or the operation of the hot runner system, and a processing unit and a memory. The processing unit is connected to the one or more sensors, wherein the memory stores data and program codes. The processing unit is configured to load and execute the program code to compare sensor information with the stored data and to determine if the hot runner system is in an operable status, and in case the hot runner system is in an operable status, configured to generate status information to activate the one or more heating elements and/or the one or more actuators enabling a production operation of the injection molding machine. In case the hot runner system is not in an operable status, configured to generate status information to deactivate the one or more heating elements and/or close or deactivate the one or more actuators disabling a production operation of the injection molding machine.

A hot runner process controller configured to monitor the status and operation of a hot runner system to autonomously generate information to improve the quality of injection molding process of a hot runner system having an inlet nozzle, one or more manifolds and one or more nozzles with actuator or without actuator, and one or more heating elements, the hot runner process controller is self-operating, and independent from the injection molding machine, includes: one or more sensors located on, in or at the hot runner system to detect the status and/or the operation of the hot runner system, and a processing unit and a memory. The processing unit is connected to the one or more sensors, wherein the memory stores data and program codes. The processing unit is configured to load and execute the program code to compare sensor information with the stored data and to determine if the hot runner system is in an operable status, and in case the hot runner system is in an operable status, configured to generate status information to activate the one or more heating elements and/or the one or more actuators enabling a production operation of the injection molding machine. In case the hot runner system is not in an operable status, configured to generate status information to deactivate the one or more heating elements and/or close or deactivate the one or more actuators disabling a production operation of the injection molding machine.

Systems and approaches for determining design of experiment parameters using largest empty area rectangle optimization for an injection molding system. The systems and methods include obtaining pressure versus time data sets indicative of fill step pressures and corresponding fill step times for a plurality of mold cycles and defining a low and high pressure versus time curves from the data sets, with the low and high pressure versus time curves being two surfaces of a geometric shape. The systems and methods further include identifying a top surface and a bottom surface of the geometric shape; identifying a rectangle having the largest area of all rectangles contained within the first geometric shape; and generating design of experiment parameters from the largest area rectangle.

Systems and approaches for determining design of experiment parameters using largest empty area rectangle optimization for an injection molding system. The systems and methods include obtaining pressure versus time data sets indicative of fill step pressures and corresponding fill step times for a plurality of mold cycles and defining a low and high pressure versus time curves from the data sets, with the low and high pressure versus time curves being two surfaces of a geometric shape. The systems and methods further include identifying a top surface and a bottom surface of the geometric shape; identifying a rectangle having the largest area of all rectangles contained within the first geometric shape; and generating design of experiment parameters from the largest area rectangle.

In order to improve the consistency of molded products as viscosity shifts throughout a run, a controller of an injection molding machine executes a calibration cycle in accordance with a mold cycle. The controller analyzes a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics. The controller then uses the calibration metrics when executing each mold cycle of the run. More particularly, during each mold cycle of the run, the controller detects a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle and compares the plurality of sensed melt pressures to the one or more calibration metrics to predict cavity pressure for a pack and hold phase of the mold cycle. The controller then adjusts a set point pressure for the pack and hold phase based on the predicted cavity pressure.

In order to improve the consistency of molded products as viscosity shifts throughout a run, a controller of an injection molding machine executes a calibration cycle in accordance with a mold cycle. The controller analyzes a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics. The controller then uses the calibration metrics when executing each mold cycle of the run. More particularly, during each mold cycle of the run, the controller detects a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle and compares the plurality of sensed melt pressures to the one or more calibration metrics to predict cavity pressure for a pack and hold phase of the mold cycle. The controller then adjusts a set point pressure for the pack and hold phase based on the predicted cavity pressure.

An additive injection system for use in injection molding machines to inject additive materials, such as fluids or powders, downstream of a nozzle of the injection molding machine. The additive injection unit has an additive tank to store or contain additive material and additive injectors that inject an additive material into an injection molding machine. A pump pumps the additive material from the tank through a common manifold connected to the additive injectors to be injected into the injection molding machine. A controller controls operation of the additive injection device and one or more sensors coupled to the additive injection device can provide feedback to the controller.

Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include extruding a molten polymer according to an extrusion profile and measuring at least one variable during the extrusion profile with a first sensor. At least one extrusion operational parameter is adjusted based on the measured variable. The extrusion profile is terminated upon the molten polymer exceeding a first threshold, and the molten polymer is injected into the mold cavity according to an injection profile via a screw that moves from a first position to a second position. Upon completion of the injection profile, a recovery profile commences in which the screw is moved to the first position.

Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include extruding a molten polymer according to an extrusion profile and measuring at least one variable during the extrusion profile with a first sensor. At least one extrusion operational parameter is adjusted based on the measured variable. The extrusion profile is terminated upon the molten polymer exceeding a first threshold, and the molten polymer is injected into the mold cavity according to an injection profile via a screw that moves from a first position to a second position. Upon completion of the injection profile, a recovery profile commences in which the screw is moved to the first position.