pps proceeding - Abstract Preview
pps proceeding
Symposium: S04 - Injection Molding and Molds
Oral Presentation
 
 

Analysis of the Filling Cycle and Automated Determination of the Change-over point with Sensor Systems on the Machine and Comparison with Conventional Switchover Methods in Injection Molding

Kruppa Stefan (1)*, Schiffers Reinhard (1), Hämmerl Severin (2), Krampe Erhard (2), Wintermantel Erich (2)

(1) KraussMaffei Technologies GmbH - Munich - Germany, (2) Institute of Medical and Polymer Engineering, Lehrstuhl für Medizintechnik, TUM - Munich - Germany

The mold cavity is not constantly volumetrically filled during the filling cycle due to disturbances such as batch changes, or residual moisture in the material and the associated performance of the non-return valve. On this account, five velocity-controlled filling to pressure-controlled packing switchover methods in injection molding that are placed on the market are analyzed and evaluated: (1) conventional screw position, (2) cavity pressure near the gate, (3) cavity pressure away from the gate, and two gradient methods that interpret the melt pressure – one using a force transducer at the end of the screw (4), and one using a pressure transducer inside the nozzle (5). The methods for analyzing the mold pressure (force transducer at the end of the screw and pressure transducer in the nozzle) are based upon the rapidly increasing mold pressure when the mold cavity is volumetrically filled. This results in a prompt increase of the pressure curve, which is detected by its second derivative with respect to the screw displacement (d2p/ds2). The threshold for the switchover signal is dynamically generated by a multiple of the standard deviation of the curvature. This switchover method is analyzed and benchmarked in respect to its fitness to automatically determine the correct change-over point from filling to packing. The molded parts were injection-molded with and without packing pressure in order to differentiate and evaluate the effects. The weight of the molded parts was chosen as the primary target size for evaluating their consistency and quality. Long-term malfunctions of the viscosity were simulated by three materials (different MFRs).