A computer-implemented method for calculating a nominal profile for the movement of an injection actuator of a molding machine includes defining a simulation domain comprising at least one cavity of a mold installed on the molding machine. At least one simulation is performed in the simulation domain, and injection of a molding material into the at least one cavity of the mold is simulated by predefining at least one volume flow profile through an inlet face at the edge of the simulation domain and/or by predefining at least one pressure profile at the inlet face as boundary condition. A volume flow profile calculated using the simulation and/or the at least one volume flow profile is converted into a nominal profile for the movement of an injection actuator, in particular a plasticizing screw, and a compressibility of the molding material is taken into account in the conversion.

A system includes a cavity, an injection nozzle configured to inject material into the cavity, and a plurality of sensors at sensor locations. Each of the plurality of sensors is configured to measure parameters at one of the sensor locations. The system lacks a strain gauge. The system further includes a controller configured to control a flow rate of the injection of material into the cavity. The controller is configured to receive the measured parameters and compare the received information to predetermined curves. The controller is configured to control the flow rate when the measured parameters deviate from the predetermined curves.

An actuator system for an injection molding system includes a double acting pressurized fluid actuator having a piston drive movable in a cylinder space, a flow control valve for regulating a flow rate of pressurized fluid to and/or from the cylinder space, a flow sensor for detecting the flow rate of pressurized fluid to and/or from the cylinder space, and an electronic controller for controlling the flow control valve to regulate the flow rate of pressurized fluid to and/or from the cylinder space depending on the flow rate detected by the flow sensor.

An actuator system for an injection molding system includes a double acting pressurized fluid actuator having a piston drive movable in a cylinder space, a flow control valve for regulating a flow rate of pressurized fluid to and/or from the cylinder space, a flow sensor for detecting the flow rate of pressurized fluid to and/or from the cylinder space, and an electronic controller for controlling the flow control valve to regulate the flow rate of pressurized fluid to and/or from the cylinder space depending on the flow rate detected by the flow sensor.

A system includes a cavity, an injection nozzle configured to inject material into the cavity, and a plurality of sensors at sensor locations. Each of the plurality of sensors is configured to measure parameters at one of the sensor locations. The system lacks a strain gauge. The system further includes a controller configured to control a flow rate of the injection of material into the cavity. The controller is configured to receive the measured parameters and compare the received information to predetermined curves. The controller is configured to control the flow rate when the measured parameters deviate from the predetermined curves.

A system includes a cavity, an injection nozzle configured to inject material into the cavity, and a plurality of sensors at sensor locations. Each of the plurality of sensors is configured to measure parameters at one of the sensor locations. The system lacks a strain gauge. The system further includes a controller configured to control a flow rate of the injection of material into the cavity. The controller is configured to receive the measured parameters and compare the received information to predetermined curves. The controller is configured to control the flow rate when the measured parameters deviate from the predetermined curves.

A computer-implemented simulation method for use in a molding process by a computer process is disclosed. The method includes steps of specifying a simulating domain comprising a mold cavity and a barrel of an injection machine, wherein the barrel is configured to connect to the mold cavity; creating at least one mesh by dividing at least part of the simulating domain; specifying boundary conditions of the mesh by taking into consideration at least one motion of a screw in the barrel; and simulating a first injection-molding process of a molding material by using the boundary conditions to generate a plurality of molding conditions.

Injection molding system comprising at least one first actuator-system (D1, D2, D3), the first actuator system comprising: at least one piston drive having at least two pressure line connectors (CP2, CP3) to drive a piston to open or close a molding nozzle, pressure lines (L1, L2) connectable to a changeover valve (V) having a pressure line connector (P) and tank line connector (T) and at least two changeover pressure line connectors, wherein the first changeover valve pressure line connector (CV1) is connectable to a first pressure line (L1) and the second changeover valve pressure line connector (CV2) is connectable to a second pressure line (L2), wherein the second pressure line (L2) is connected to the second pressure line connector (CP2) of the piston drive, an electronically adjustable flow control valve having a first pressure line connector and a second pressure line connector, wherein the first pressure line connector of the adjustable flow control valve being connected to the first pressure line (L1) to allow a connection to the first pressure line connector (CV1) of the changeover valve (V), and the second pressure line connector is connected to a third pressure line (L3) which establishes a connection to the second pressure line connector (CP3) of the piston drive, at least one electronic flow sensor for (P1, P2, P3) sensing flow rate in the first, second and/or third pressure lines (L1, L2, L3), a controller connected to the adjustable flow control valve and to the at least one sensor, configured to electronically adjust the flow control valve, depending on information of the at least one sensor, controlling thereby the timing and the speed of the movement of the piston and the molding nozzle.

A computer-implemented simulation method for use in a molding process by a computer process is disclosed. The method includes steps of specifying a simulating domain comprising a mold cavity and a barrel of an injection machine, wherein the barrel is configured to connect to the mold cavity; creating at least one mesh by dividing at least part of the simulating domain; specifying boundary conditions of the mesh by taking into consideration at least one motion of a screw in the barrel; and simulating a first injection-molding process of a molding material by using the boundary conditions to generate a plurality of molding conditions.

A system includes a cavity, an injection nozzle configured to inject material into the cavity, and a plurality of sensors at sensor locations. Each of the plurality of sensors is configured to measure parameters at one of the sensor locations. The system lacks a strain gauge. The system further includes a controller configured to control a flow rate of the injection of material into the cavity. The controller is configured to receive the measured parameters and compare the received information to predetermined curves. The controller is configured to control the flow rate when the measured parameters deviate from the predetermined curves.