Provided is an injection molding support system and method that can support searching for suitable materials. This injection molding support system 1 comprises: a process 35 of acquiring a production result using a combination of a mold and a predetermined material and material information on a predetermined material; a process 36 of acquiring the production result, the material information on a predetermined material, and material information on a plurality of previously acquired materials, and selecting at least one candidate material from among the plurality of materials on the basis of the acquired information; a process 43 of creating a correction molding condition for injection molding using a combination of the selected candidate material and the mold; and a process 34 of providing, to a user, the created correction molding condition and the output candidate material.

In order to reduce oscillations in process variables of an injection molding process, an injection molding machine may be operatively connected to a model database that stores models of injection molding machines and molds. A tuning controller may set initial gain values of a variable-gain proportional-integral-derivative (PID) controller. To set the initial gains, the tuning controller may be configured to obtain, from the model database, a model for a first and second injection molding machines and a model for a mold. The tuning controller may analyze the models to determine a correlation between injection molding machine parameters and mold cycle performance for the mold. Accordingly, the tuning controller may apply the correlation to determine an initial gain value for a least one of the first, second, and third gains of the PID controller. The tuning controller may then set the initial gain values for the PID controller.

A method of determining melt flow front travel in a molding apparatus includes setting a sensor threshold, receiving a sensor amount as an output from a sensor monitoring a nozzle of the molding apparatus, and determining that the sensor amount exceeds the sensor threshold. The method further includes receiving a screw location, calculating a travel distance of the screw from the screw location, and calculating melt flow front travel based on the travel distance of the screw. The method further includes receiving, via an interface, an operator generated value for the desired melt flow front travel to be reached, and sending, via an interface, an analog or digital output after the operator generated value has been reached. A method of detecting a leaking condition of a check valve is also included.

In order to reduce oscillations in process variables of an injection molding process, an injection molding machine may be operatively connected to a model database that stores models of injection molding machines and molds. A tuning controller may set initial gain values of a variable-gain proportional-integral-derivative (PID) controller. To set the initial gains, the tuning controller may be configured to obtain, from the model database, a model for a first and second injection molding machines and a model for a mold. The tuning controller may analyze the models to determine a correlation between injection molding machine parameters and mold cycle performance for the mold. Accordingly, the tuning controller may apply the correlation to determine an initial gain value for a least one of the first, second, and third gains of the PID controller. The tuning controller may then set the initial gain values for the PID controller.

The present disclosure provides a method of measuring a true shear viscosity profile of a molding material in a capillary and a molding system performing the same. The method includes the operations of: determining a setpoint temperature of the molding material before injecting into the capillary; obtaining an initial shear viscosity profile at the setpoint temperature with respect to a shear rate of the molding material; fitting an initial temperature profile with respect to the shear rate according to the initial shear viscosity based on Cross William-Landel-Ferry model; fitting a first shear viscosity profile and a first temperature profile with respect to the shear rate according to the initial temperature profile based on the Cross-WLF model; and setting the first shear viscosity profile as the true shear viscosity profile when a difference between the first temperature profile and the initial temperature profile is not greater than a threshold.

The present disclosure provides a method of measuring a true shear viscosity profile of a molding material in a capillary and a molding system performing the same. The method includes the operations of: determining a setpoint temperature of the molding material before injecting into the capillary; obtaining an initial shear viscosity profile at the setpoint temperature with respect to a shear rate of the molding material; fitting an initial temperature profile with respect to the shear rate according to the initial shear viscosity based on Cross William-Landel-Ferry model; fitting a first shear viscosity profile and a first temperature profile with respect to the shear rate according to the initial temperature profile based on the Cross-WLF model; and setting the first shear viscosity profile as the true shear viscosity profile when a difference between the first temperature profile and the initial temperature profile is not greater than a threshold.

An injection molding system comprising: a first selected valve, one or more downstream valves, delivering a fluid to a mold cavity, at least one fluid property sensor that detects a flow front of fluid material flowing downstream through the mold cavity at a trigger location within the cavity disposed between the first gate and at least one selected downstream gate, a controller instructing an actuator associated with the downstream gates to open the gates at a predetermined open gate target time on a first injection cycle, each valve associated with a position sensor that detects opening of a gate at an actual open gate time to the controller, the controller automatically adjusting time of instruction to open the gates on a subsequent injection cycle by an adjustment time equal to any delay in time between the predetermined open gate target time and the actual open gate time.

Apparatus (3) for detecting a leak of molten plastics material in a hot runner mould (1) comprises a detecting circuit (28) which in turn comprises a plurality of tubular detecting elements (30) connected in series by connecting conduits (32). The detecting circuit (28) is located in galleries (25) in the hot runner mould (1) with the tubular detecting elements (30) located adjacent locations in the galleries (25) where leaks are likely to occur. A compressed air source (40) delivers compressed air at a regulated pressure through the detecting circuit (28) at a controlled flow rate controlled by a flow controller (45). A first pressure sensor (43) at the upstream end of the detecting circuit (28) and a second pressure sensor (44) at a downstream end of the detecting circuit (28) monitors the pressure upstream of the detecting circuit (28). The tubular detecting elements (30) are of heat stabilised silicone rubber material of deformable transverse cross-section, which is deformable by molten plastics material leaking into the gallery (25) adjacent the corresponding one of the tubular detecting elements (30). A microcontroller (47) monitors signals from the first and second pressure sensors (43) and (44) and on detecting an increase in the pressure read from the second pressure sensor (44) above a stored normal pressure value, the microcontroller (47) operates a sounder (52) and a relay (54) to activate a visual alert and to deactivate the moulding machine.

An injection molding temperature control device according to an aspect of the present disclosure controls output of a heater that heats a target site, based on a detection value of a temperature sensor which detects temperature of the target site of an injection molding machine that injects resin into a mold using an injection machine, the injection molding temperature control device including: a temperature control unit which controls output of the heater so as to make the detection value of the temperature sensor approach a predetermined set temperature; a supplied heat amount calculation unit which calculates a supplied heat amount to the target site based on at least one of a drive voltage, a duty ratio and an electrical current value of the heater; and an abnormality detection unit which detects abnormality in temperature control of the target site, based on the detection value of the temperature sensor, and a supplied heat amount calculated by the supplied heat amount calculation unit.

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.