MONITORING DEVICE FOR AN INJECTION MOLD

Abstract

The present disclosure is directed to a monitoring device for an injection mold. The monitoring device includes a first processing unit and a sensor interface by which during operation at least one sensor is interconnected to the first processing unit. A second processing unit is interconnected to the first processing unit via a data bus to exchange data with the first central processing unit. At least one user interface is interconnected to the second processing unit for exchanging information with a user.

Claims

1. A monitoring device for an injection mold comprising: a. a first processing unit; b. an sensor interface configured such that at least one sensor is interconnected to the first processing unit during operation; c. a second processing unit, interconnected to the first processing unit via a data bus, and configured to exchange data with the first processing unit; d. at least one user interface interconnected to the second processing unit configured to exchange information with a user.

2. The monitoring device according to claim 1, wherein the first processing unit is interconnected to a first power supply and the second processing unit is interconnected to a second power supply, wherein the first power supply comprises a first battery.

3. The monitoring device according to claim 1, wherein a data storage unit is interconnected to the first processing unit configured to record data received from the first processing unit.

4. The monitoring device according to claim 1, wherein a network interface unit configured to exchange data with the outside via a network connection is interconnected to the second processing unit.

5. The monitoring device according to claim 1, wherein the monitoring device comprises at least one of a GPS-module or a GSM-Module which is interconnected to the first processing unit.

6. The monitoring device according to claim 1, wherein the sensor interface is configured to interconnect to at least one sensor comprising a temperature sensor, a pressure sensor, a cycle counting sensor, an acceleration sensor, an acoustic sensor, an optical sensor, a vibration sensor, or a flow rate sensor.

7. The monitoring device according to claim 1, wherein the monitoring device comprises an interface to interconnect the monitoring device to a control unit of a mold press.

8. The monitoring device according to claim 1, wherein the monitoring device comprises a first housing and a second housing that is mechanically interconnectable to the first housing via at least one connector assembly.

9. The monitoring device according to claim 8, wherein the first housing comprises the first processing unit and the second processing unit.

10. The monitoring device according to claim 8, wherein the first housing comprises the first processing unit and the second housing comprises the second processing unit.

11. The monitoring device according to claim 8, wherein the second housing comprises at least one fastening means to fasten the second housing directly or indirectly to the injection mold.

12. The monitoring device according to claim 8, wherein the connector assembly comprises a linking sensor which indicates whether the first housing and the second housing are interconnected to each other.

13. The monitoring device according to claim 8, wherein the connector assembly comprises an interface for at least one of a temperature sensor, a cycle counter, and a pressure sensor.

14. The monitoring device according to claim 1, wherein the at least one sensor is interconnected directly to the first processing unit.

15. The monitoring device according to claim 1, wherein a temperature sensor and a valve are interconnected to the monitoring device, wherein the valve is interconnected to the actuator of a needle of a needle valve arranged in the injection mold to be monitored.

16. A safety device interconnected to a monitoring device according to claim 1, wherein the safety device comprises a processing unit interconnected to a temperature sensor arranged in an area of a nozzle tip of a hot runner nozzle and at least one valve or switch interconnected to an actuator of a needle of the hot runner nozzle configured to prevent harmful movement of the actuator by the processing unit as long as the temperature measured by the temperature sensor is below a preset temperature.

17. A mold comprising the monitoring device according to claim 1.

18. A method for monitoring of an injection mold comprising the following method steps: a. Providing a monitoring device comprising a first processing unit interconnected to at least one sensor arranged at the injection mold to measure at least one physical value of the injection mold; b. Providing a second processing unit interconnected to the first processing unit via a data bus; and c. Controlling the operation of the first processing unit via a program code executed on the second processing unit through the data bus.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present disclosure will be more fully understood from the detailed description given herein below and the accompanying drawings which should not be considered limiting to the disclosure described in the appended claims. The drawings show:

[0025] FIG. 1 a monitoring device in a perspective view from the front and above wherein a first and a second housing are interconnected to each other;

[0026] FIG. 2 the monitoring device according to FIG. 1 in a perspective view from behind and below;

[0027] FIG. 3 a monitoring device in a perspective view from the front and above wherein a first and a second housing are separated from each other;

[0028] FIG. 4 the monitoring device according to FIG. 3 in a perspective view from behind and below;

[0029] FIG. 5 a perspective, exploded view of the inside of a monitoring device;

[0030] FIG. 6 a safety device.

DETAILED DESCRIPTION

[0031] Reference will now be made in detail to certain embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all features are shown. Indeed, embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Whenever possible, like reference numbers will be used to refer to like components or parts.

[0032] FIG. 1 shows a monitoring device 1 according to the present disclosure in a perspective view from the front and above. FIG. 2 shows the monitoring device 1 in a perspective view from below and behind. The monitoring device 1 comprises a first housing 15 and a second housing 16 which are interconnected to each other by a connector assembly 14 which in the here shown interconnected position is arranged between the first and the second housing 15, 16.

[0033] FIG. 3 and FIG. 4 are showing the first and the second housing 15, 16 spaced apart from each other in a vertical direction (z-direction). The connector assembly 14 is shown in a disengaged manner. Interconnection is indicated by dotted lines. The monitoring device is foreseen to be interconnected to a mold which is not shown in detail. As visible in FIG. 5, which is showing an inside view of the monitoring device 1, the monitoring device 1 comprises a first processing unit 2 arranged on a PCB (printed circuit board) 23. The first processing unit 2 which is interconnected to a sensor interface 3 by which at least during operation at least one sensor 4 is interconnected to the first processing unit 2 by a cable 22. A second processing unit 6, interconnected to the first processing unit 2 via a data bus 7, to exchange data with the first central processing unit 2. At least one user interface 8, here in the form of a display 19, is interconnected to the second processing unit 6 for exchanging information with a user. Alternatively or in addition, the user interface 8 can comprise other elements alone or in combination, such as: At least one LED 20 indicating the status of the device, respectively specific parameters. At least one button 21, e.g. for resetting the device or a part thereof.

[0034] In the shown variation, the first processing unit 2 is interconnected to a first power supply 9 and the second processing unit 6 is interconnected to an external second power supply 10, wherein the first power supply 9 comprises a first battery 11. When not connected to an external power supply the monitoring device 1 is supplied with electrical power at least by the first battery, which is preferably arranged inside the first housing 15. The first battery 11 is preferably dimensioned, such that the monitoring device can be operated in a standalone manner over a certain period of time, e.g. up to 10 years. When not connected to the second power supply, the second processing unit is not activated, i.e. is switched-off completely or is set into a sleep mode.

[0035] A data storage unit 5 is interconnected to the first processing unit 2 for recording data received from the first processing unit 2.

[0036] The monitoring device 1 comprises one or several network interface units 13 (Wi-Fi, Bluetooth, LAN, GSM) for exchanging data with the outside via a network connection. The at least one network interface 13 is preferably interconnected to the second processing unit 6. However, it can be interconnected, at least under certain operating conditions, to the first processing unit 2. Depending on the field of application, the monitoring device 1 comprises a GPS-module 23, which is normally interconnected to the first processing unit 2 to determine the position of the mold interconnected to the monitoring device 1 during time. The monitoring device 1 may be interconnected to at least one sensor, including, but not limited to, a temperature sensor, pressure sensor, cycle counting sensor, acceleration sensor, acoustic sensor, optical sensor, vibration sensor, or flow rate sensor. If appropriate, several sensors can be interconnected to a combined sensor. The monitoring device 1 may comprise at least one external interface 24 e.g. to interconnect the monitoring device 1 to a control unit of the mold press (both not shown in detail). If appropriate, the monitoring device 1 comprises a USB-Interface 25 to exchange data with the monitoring device 1.

[0037] As visible in the drawings, the shown variation of the monitoring device 1 comprises a first housing 15 and a second housing 16, which are mechanically interconnectable to each other via a connector assembly 14. Depending on the field of application, different configurations are possible. The connector assembly comprises at least one electrical connector 27. Furthermore, a locking means is present to lock the first with respect to the second housing 15, 18. Alternatively or in addition, the data transmission can be done by at least one optical connector (not shown in detail).

[0038] In a variation, the second housing 6 is designed as a base for the first housing 2. The second housing is attached to the mold (not shown in detail), for example, on the nozzle side as mentioned above, and interconnected via at least one electrical cable 22 of a sensor 4. In this situation, the first housing 15, which is interconnected to the second housing 6 in a detachable manner via the connector assembly 14, may comprise the second processing unit 6 (and the thereto related elements necessary for operation, e.g. power supply etc.) and the second housing 16 comprises the first processing unit 2 (and the thereto related elements necessary for operation). Thereby it can be guaranteed that the monitoring device 1 remains operable even when the first housing 2 is separated from the second housing. To attach the second housing 16 to a mold, the second housing comprises at least one fastening means 17 to fasten the second housing 16 directly or indirectly to a mold. Alternatively or in addition, a mounting adapter can be foreseen.

[0039] The connector assembly 14 may further comprise a linking sensor 18 which indicates whether the first and the second housing 15, 16 are interconnected to each other or not. The connector assembly 14 comprises a sensor interface for at least one temperature sensor and/or a cycle counter and/or a pressure sensor.

[0040] FIG. 6 is showing in a schematic manner a hot runner apparatus 54 in a section view as typically used in an injection mold 50. A safety device 68 as already described hereinabove will now be addressed in more detail based on a sample arrangement as described hereinafter. In the shown variation, two hot runner nozzles 51 are visible each interconnected to a cavity block 52. The hot runner apparatus 54 comprises a hot runner manifold 53. Each nozzle 51 comprises a needle 55 which is guided inside of a nozzle body 56. A rear end of the needle 55 is interconnected to an actuator, here in the form of a pneumatic cylinder 57, for linear displacement of the needle in axial direction (z-direction). The nozzle 51 is separated in three thermal zones, which can be summarized as follows: A first zone includes the hot runner manifold 53 which can be heated via a heating element 58. The temperature is measured via a first temperature sensor 59. A second zone comprises at least one rear end 60 of a nozzle body 56, which can be heated via a thermally connected heating element 61. The temperature in the second zone is measured via a second temperature sensor 62. A third zone covers a tip 63 of a nozzle body 56, which is heating via heating element 64. The respective temperature of the tip 63 is measured by a third temperature sensor 65. The heating elements 58, 61, 64 are interconnected to a heating element control panel 67. To avoid damage of the hot runner apparatus 54, namely the hot runner nozzles 51, due to premature start of the production process, the safety device 68 is implemented as follows. The safety device 68 comprises a separate temperature sensor or is interconnected to an existing temperature sensor 65 which is arranged sufficiently close to the needle 55, respectively the nozzle tip 63 of the needle valve to measure a temperature which corresponds to or is related to the temperature of the plastic material surrounding the needle in the area of a needle valve 69.

[0041] The third temperature sensor 65 is interconnected to a supplementary processing unit 70 which is here not forming part of the normal arrangement found in the injection molding device. In the shown variation, for each nozzle 51 (respectively per direction of movement) at least one additional valve 71 is foreseen arranged in the course of the pneumatic for actuating the actuators 57. The additional valves 71 are normally closed when a preset condition (temperature) is not achieved. In this condition, the actuator cannot be actuated although the control unit or the injection molding machine sends a command to actuate the actuators 57. The same normally applies for the situation when no power supply is connected to the safety device 68. Thereby it can be prevented that the safety device can be overruled. The valves 71 are interconnected to the actuator 57 of the needle 55 of the hot runner nozzle 51 to prevent harmful movement of the actuator 57 by the processing unit 70 before the temperature measured by the temperature sensor 65 is below a preset temperature. The herein shown variation of the safety device is implemented as a separate (standalone) device not depending on other devices, beside power supply, of the molding system (mold, mold press, etc.).