Control-Oriented Modeling of an Injection Molding Machine Including the Fill-to-Pack Transition

2000 ◽  
Author(s):  
Danian Zheng ◽  
Andrew Alleyne ◽  
Heather Havlicsek
Keyword(s):  
Injection Molding ◽  
Controller Design ◽  
Flow Characteristics ◽  
Polymer Melt ◽  
Hydraulic Actuator ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
Digitally Controlled ◽  
Engineering Models ◽  
Injection Cycle

Abstract In this paper the modeling of a typical injection cycle for an injection molding machine (IMM) is examined. Both the mold filling and mold packing phases of the cycle are examined along with a critical fill-to-pack transition. The novelty in this modeling work is that the non-linear model considers both the machine hydraulic actuator and polymer flow characteristics in extensive detail. The resulting model will provide simulation capabilities to facilitate machine controller design; however the actual controller is not the focus of the current work. The modeling is based on (a) the characteristics of digitally controlled electrohydraulic valves, (b) the dynamics of the hydraulic actuator ram system, and (c) the gross polymer melt behavior determined from simple polymer engineering models. The simulation model is validated against experimental data and demonstrates the availability of a relatively accurate system model for full cycle control of this electrohydraulic system.

Modeling and Control of an Electro-hydraulic Injection Molding Machine With Smoothed Fill-to-Pack Transition*

2003 ◽  
Vol 125 (1) ◽  
pp. 154-163 ◽  
Author(s):  
Danian Zheng ◽  
Andrew Alleyne
Keyword(s):  
Injection Molding ◽  
Process Model ◽  
Flow Characteristics ◽  
Hydraulic Actuator ◽  
Molding Machine ◽  
Transfer Scheme ◽  
Injection Molding Machine ◽  
Modeling And Control ◽  
And Control ◽  
Injection Cycle

In this paper the modeling of a typical injection cycle for an injection-molding machine (IMM) is examined. Both the mold filling and mold packing phases of the cycle are examined along with a critical fill-to-pack transition. The novelty in this modeling work is that the nonlinear model considers both the machine hydraulic actuator and polymer flow characteristics in extensive detail. The simulation model is validated against experimental data and demonstrates the availability of a relatively accurate system model for full cycle control design of this electro-hydraulic system. The accurate process model is used in the design of a controller for the injection cycle including the fill-to-pack transition. The overall algorithm includes two Iterative Learning Controllers connected by a bumpless transfer scheme between them. The algorithm is successfully tested through model simulations and machine experiments. The simulation and experimental results presented demonstrate a significantly smoother control signal and pressure transient between the two learning controlled phases as well as overall tracking convergence for each phase.

Glass fiber–reinforced polypropylene composites fabricated by direct fiber feeding injection molding

2018 ◽  
Vol 38 (5) ◽  
pp. 461-467
Author(s):  
Xiaofei Yan ◽  
Lichao Yu ◽  
Hua Shen
Keyword(s):  
Mechanical Properties ◽  
Injection Molding ◽  
Glass Fiber ◽  
Process Parameters ◽  
Polymer Melt ◽  
Core Layer ◽  
Tensile Tests ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
Pp Composites

Abstract This article investigates the effect of process parameters on the mechanical properties of polypropylene-glass fiber (GF/PP) composites made using a new injection molding method known as direct fiber feeding injection molding (DFFIM). In the DFFIM process, continuous fibers are directly guided into the barrel of the injection molding machine through the designed vent and are fed into the polymer melt by the shearing motion of the screw of the injection molding machine during the plasticization process. The DFFIM process improves the fiber length and avoids excessive fiber attrition, resulting in enhanced mechanical properties in the composites. The effect of process parameters on the mechanical properties of manufactured composite specimens is discussed based on the results of tensile tests, three-point flexural tests, and Izod impact tests. Scanning electron microscopy was performed on the fracture surfaces to observe cross-section morphology. There is a fiber agglomeration phenomenon that occurs in the core layer of GF/PP composites made using DFFIM. The number of fiber rovings, number of fiber filaments, matrix feeding speed, and screw speed influence the GF content and distribution in the composites, ultimately affecting the mechanical properties.

The Method of Improving Precision of Micro Injection Molding Machine Temperature Control

2013 ◽  
Vol 372 ◽  
pp. 354-359
Author(s):  
Sheng De Tang ◽  
Hong Xu ◽  
Da Ming Wu ◽  
Ya Jun Zhang
Keyword(s):  
Injection Molding ◽  
Temperature Control ◽  
Control Method ◽  
Polymer Melt ◽  
Molding Machine ◽  
Micro Injection Molding ◽  
Injection Molding Machine ◽  
Mathematical Algorithm ◽  
Accurate Temperature ◽  
Accurate Temperature Control

the temperature control accuracy of polymer melt is the main factor affecting quality precision of final products. In this paper, we study the method of improving the precision of temperature control based on control system of micro injection molding machine. In order to avoid big overshoot in the traditional PID control, we use gradual approximation control method based on gradual approximation mathematical algorithm to realize fast and accurate temperature control of the micro injection molding machine. Experiment results show that effective combination of the traditional PID and gradual approximation method can realize accurate temperature control of micro injection molding machine, and precision of temperature control can be improved up to±0.5°C.

Choice and Exchange of Lubricating Oil for Injection Molding Machine

2019 ◽  
Vol 12 (4) ◽  
pp. 378-382
Author(s):  
Shan Syedhidayat ◽  
Quan Wang ◽  
Al-Hadad M.A.A. Mohsen ◽  
Jinrong Wang
Keyword(s):  
Injection Molding ◽  
Dimensional Accuracy ◽  
Low Noise ◽  
Working Environment ◽  
Lubricating Oil ◽  
Lubrication System ◽  
Molding Machine ◽  
Oil And Grease ◽  
Injection Molding Machine ◽  
The Stability

Background: One of the most common manufacturing equipment for polymer product is injection molding machine. In order to ensure the precise, stable and continuous operation of the injection molding machine, the maintenance of the lubrication system must be done well. The stability, reliability, rationality and low noise performance of the lubrication system of injection molding machine directly affect the quality of injection products, dimensional accuracy, molding cycle, working environment and maintenance. Objective: The purpose of this study is to introduce the methods of choice, maintenance of lubricating oil for injection molding machine from many literatures and patents in the recent years, such as lubricating oil device, lubricating composite and structure. Methods: An example of the 260M5 automatic injection molding machine is introduced for the inspection and maintenance of the lubrication system including lubricating oil and lubricating grease. Results: To ensure the lubrication of the injection molding machine, it needs to strictly observe the lubrication time and modulus of the injection molding machine. It needs to strictly control the temperature rise of the lubricating oil and select the correct lubricating oil and grease to ensure the lubrication quality. Conclusion: In the operation of the injection molding machine, it is necessary to check that the lubricating oil is sufficient and the lubricating points are working properly. It ensures sufficient lubrication of the injection molding machine and strictly observes the lubrication time and modulus of the injection molding machine. The stored lubricating oil should be sealed well to prevent air pollution.

Analysis on vibration characteristics of screw in filling process of dynamic injection molding machine

2016 ◽  
Vol 36 (8) ◽  
pp. 861-866 ◽  
Author(s):  
Quan Wang ◽  
Zhenghuan Wu
Keyword(s):  
Injection Molding ◽  
Processing Parameters ◽  
Axial Vibration ◽  
Filling Process ◽  
Molding Machine ◽  
Lumped Mass ◽  
Injection Molding Machine ◽  
Injection Speed ◽  
And Performance ◽  
Injection Screw

Abstract This paper presents a study of the characteristics of axial vibration of a screw in the filling process for a novel dynamic injection molding machine. By simplifying a generalized model of the injection screw, physical and mathematic models are established to describe the dynamic response of the axial vibration of a screw using the method of lumped-mass. The damping coefficient of the screw is calculated in the dynamic filling process. The amplitude-frequency characteristics are analyzed by the simulation and experimental test of polypropylene. The results show that the amplitude of a dynamic injection molding machine is not only is related to structure parameters of the screw and performance of the material, such as non-Newtonian index, but also depends on the processing parameters, such as vibration intensity and injection speed.

Based on Vector Control of All-Electric Injection Molding Machine Control System Design

2012 ◽  
Vol 490-495 ◽  
pp. 2210-2214
Author(s):  
Ming Hui Li ◽  
Zheng Qi Li
Keyword(s):  
Control System ◽  
Injection Molding ◽  
Vector Control ◽  
System Design ◽  
High Reliability ◽  
Permanent Magnet Synchronous Motor ◽  
Control System Design ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
Machine Control

According to the all-electric injection molding machine control system requirements, the vector control applied to the permanent magnet synchronous motor control, we propose a fully electric injection molding machine control system design, through analysis and research that can further improve the program precise all-electric injection molding machine control, its stability, high reliability, to better meet the all-electric injection molding machine of precision and stability requirements.

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