A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram includes injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities. The method includes measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting. The method also includes determining, based on the first process parameter, whether one or more mold cavities of the plurality of mold cavities are non-operational. Then, when it is determined that one or more mold cavities are non-operational, the method includes automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus.

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 injecting a molten polymer into the mold cavity according to a startup profile. A first sensor is used to measure at least one variable during the startup profile. The startup profile is terminated upon the at least one variable exceeding a first threshold. The molten polymer is then injected into the mold cavity according to a primary injection profile.

A monitoring apparatus for molds includes a control unit connectable to a first and second sensor associable with the mold and configured for emitting respective signals representative of a deformation parameter and temperature parameter of the mold. The control unit, in order to define an alert condition, is configured for: defining a value of a threshold parameter as a function of the temperature of the mold and comparing such value of the deformation parameter with a value of a threshold parameter defined as a function of the temperature of the mold; or normalizing, at a reference temperature, the value of the deformation parameter determined at the temperature of the mold and comparing a value of a threshold parameter, defined at the reference temperature, with the value of the normalized deformation parameter at the same reference temperature. Also forming the object of the present invention is a monitoring method and a data medium.

There are provided a molding conditions determination assist device and a resin state estimation device including: a quality estimation unit which estimates quality of the mold products by a machine learning on the basis of a detection data; a quality transition storage unit which accumulates the estimated quality of the mold products and stores a quality transition with respect to the accumulated quality of the mold products; a tendency evaluation unit which evaluates a quality change tendency with respect to a prescribed standard quality on the basis of the quality transition; a relationship storage unit which stores a relationship between the quality change tendency and a modification amount of the molding conditions for returning the quality to the standard quality; and a modification conditions determination unit which determines the modification amount of the molding conditions on the basis of the quality change tendency and the relationship.

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.

An insert molding includes a lithium-ion battery, temperature measurement element and a pressure measurement element disposed close to the lithium-ion battery to sense temperature and pressure around the lithium-ion battery during insert molding; and a molding resin that covers the lithium-ion battery, the temperature measurement element, the pressure measurement element and a cover member.

A controller for an injection molding system is in communication with a melt flow control unit, a gas assist control unit, and a gas counter pressure control unit. The controller can effect real-time adjustments to gas assist pressure and/or gas counter pressure as a function of melt pressure or flow front position.

A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram includes injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities. The method includes measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting. The method also includes determining, based on the first process parameter, whether one or more mold cavities of the plurality of mold cavities are non-operational. Then, when it is determined that one or more mold cavities are non-operational, the method includes automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus.

A method for determining an actual volume Vr of an injection-moldable compound during an injection-molding process is disclosed. The injection-moldable compound is introduced into at least one cavity of the mould. The method includes the steps of: a) determining a theoretical volume Vt from process variables at least during a filling phase of the injection-molding process, b) determining and/or measuring at least one value for at least one compound pressure pM, c) selecting a material-specific compression k (p), corresponding to the value of pM, of the injection-moldable compound, and d) calculating an actual volume Vr by taking into account the compression k (p).