A remote controller can be provided on any apparatus that employs feedback control from a native controller to add functionality to the apparatus where the native controller is not capable of providing such functionality independently.

In order to reduce oscillations in process variables of an injection molding process, a variable-gain proportional-integral-derivative (PID) controller is utilized to control one or more of the process variables. The injection molding system may also include a tuning controller to automatically tune at least one of the proportional, integral, or derivative gains within a mold cycle. The tuning controller may obtain sensor data that monitors the operation of the injection molding machine to determine an adjustment to at least one of the proportional, integral, or derivative gains. The tuning controller may adjust the gains of the variable-gain PID controller in accordance with the determined adjustment to the at least one of the proportional, integral, or derivative gains.

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.

An injection molding machine includes a storage unit in which input information input via an operation unit and a molding condition under which molding is performed using a gain specified by the input information are stored in association with each other, and a control unit configured to generate a signal with a feedback-control, which uses a difference between a set value used to control an object to be controlled and an actual value measured from the object to be controlled and the gain specified by the input information associated with the molding condition, and to control a drive source using the signal to perform the molding, in a case where the molding indicated by the molding condition is performed.

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.

Systems and methods describe supplementing a native controller of an injection molding with a remote controller, via a retrofitting of the remote controller the injection molding machine. The remote controller may thereby modify control of an injection molding process based upon a control strategy of the remote controller, e.g., by providing a modified feedback signal to be used by a control algorithm of the native controller in lieu of a feedback signal previously used by the native controller. The remote controller may generate the modified feedback signal based upon its own control algorithm and control strategy. Furthermore, the remote controller may be configured to robustly account for behavior of the native controller so as to provide stable control of a control variable of the process according to a setpoint defined by the remote controller.

An injection molding machine uses a controller to effectively control its operation. The controller may determine and/or receive information regarding the machine's maximum load capacity, and may also determine a current operational load value of the machine. The controller also may determine a number of set points used to operate the machine. The controller may cause the machine to operate at these set points, thereby resulting in the machine operating at or below the maximum load value by adjusting any number of machine parameters associated with the injection molding machine.

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 remote controller can be provided on any apparatus that employs feedback control from a native controller to add functionality to the apparatus where the native controller is not capable of providing such functionality independently.

A remote controller can be provided on any apparatus that employs feedback control from a native controller to add functionality to the apparatus where the native controller is not capable of providing such functionality independently.