Methods, systems, and apparatus, including medium-encoded computer program products, for injection molding warp prediction include: obtaining a mold model and measured shrinkage data for at least one material, predicting an amount of warpage for a part manufactured using the mold by computational simulation of an injection molding process, where the computational simulation uses an internal residual stress model for the part that uses calibrated values for both a coefficient of thermal expansion and an elastic modulus and/or a Poisson's ratio of the at least one material, in at least one direction, for at least thermal stress due to cooling and pressure compensation during and/or after a packing phase of the injection molding process, in accordance with the measured shrinkage data for the at least one material, and providing the amount of warpage predicted for the part manufactured using the mold.

An injection molding machine includes a cylinder that accommodates a molten resin, a discharging nozzle, a piston that discharges the molten resin from the discharging nozzle, and one or more processors configured to execute the following functions. The functions include calculating a target pressure at which a flow rate of the molten resin discharged from the discharging nozzle becomes an indicated flow rate, controlling a pressure of the molten resin in the cylinder such that the pressure becomes the target pressure, acquiring a temperature of the molten resin in the cylinder, and acquiring a pseudo-plastic viscosity corresponding to the temperature of the molten resin. The target pressure is calculated based on the indicated flow rate, the temperature of the molten resin, the pseudo-plastic viscosity, and the size of the discharging nozzle.

An injection molding includes: a clamping mechanism (conversion mechanism and toggle mechanism) for moving a fixed platen that retains a fixed die toward a fixed platen that retains a fixed die to bring the fixed die and the movable die into contract, and generating a clamping force therebetween; a drive source (mold opening/closing motor) for driving the clamping mechanism; a clamping force detection unit for detecting the clamping force; an elongation value detection unit for detecting an elongation value indicating the amount of elongation of a tie bar that extends as the clamping force is generated; and an abnormality determination unit for determining an abnormality in the injection molding machine on the basis of the ratio of the elongation value and the clamping force.

Systems and approaches for controlling an injection molding machine and a mold forming a mold cavity and being controlled according to an injection cycle. The systems and methods include analyzing a model of at least one of the injection molding machine, the mold, and a molten material to determine initial values for one or more control parameters of the injection molding machine, and executing a run of injection cycles at the injection molding machine; measuring operation of the injection molding machine during a particular injection cycle of the run of injection cycles; determining one or more operational parameters exceed a threshold; and upon determining that the one or more operational parameters exceed the threshold, adjusting the one or more control parameters for subsequent injection cycles of the run of injection cycles.

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.

The invention relates to the use of polyamide 6 for reduction of the melt viscosity, to be determined at 260° C. to ISO 11443, and/or of the fill pressure, to be determined according to EN ISO 294-1, of compositions and moulding compounds in which there are 10 to 115 parts by mass of glass fibres per 100 parts by mass of poly-C.sub.1-C.sub.6-alkylene terephthalate.

A method and system for co-injection molding of two molten plastic materials that allows monitoring and utilization of injection pressure and optionally melt pressure and/or flow front pressure during an injection run. A controller alters the injection pressure so as to achieve and maintain optimal or desired ratios of injection pressure, and optionally melt pressure and/or flow front pressure, of the two molten plastic materials. This allows for more precise part manufacture, including reducing the thickness of a skin or shell layer compared to a core layer of a molded part.

When an injection molding machine performs molding, the mold clamping force on the mold is adjusted on the basis of a mold displacement of the mold or the injection peak pressure and injection foremost position so that the molding is performed without causing flash and by an appropriate mold clamping force with which energy can be reduced. The amount of mold displacement and also the injection peak pressure and the injection foremost position are monitored during automatic operation. If there occurs no mold displacement change exceeding a threshold or if there occurs no injection peak pressure anomaly or injection foremost position anomaly exceeding thresholds, the automatic operation is continued. If the mold displacement change occurs or if the injection peak pressure anomaly and the injection foremost position anomaly occur, the operation of the injection molding machine is stopped.

An LED luminaire and potting method having the following steps: introducing a configured luminaire into an at least partly optically transparent potting mold (16), such that the luminaire does not come into contact with the walls of the potting mold; introducing an optically transparent potting compound (18) into the potting mold (16) until at least the luminaire is surrounded; and detecting a quantity of bubbles by an optical sensor or image detector (14), wherein the pressure in the vacuum chamber (11) is controlled in order to influence the bubbles and/or a pivot/inclination device (12) is controlled in order to move the vacuum chamber (11) and/or the potting mold (16) in order to expel detected gas/air bubbles (19) out of the optically transparent potting compound (18).

An injection molding machine is provided with a nozzle touch mechanism configured to press a nozzle attached to an injection device against a mold, a drive unit configured to move the injection device, a drive compression member connected to the drive unit, an injection compression member connected to the injection device, at least one resilient member interposed preloaded between the drive compression member and the injection compression member, and at least one strain sensor mounted on the drive compression member.