Preventative maintenance indicator system

• US 20070294040A1
• Filed: 06/16/2006
• Published: 12/20/2007
• Est. Priority Date: 06/16/2006
• Status: Abandoned Application

• Current Assignee: Husky Injection Molding Systems Limited
• Original Assignee: Husky Injection Molding Systems Limited
• Inventors: Galt, John Robert
• Application Number:
  US11/454,712
• Publication Number:
  US 20070294040A1
• Time in Patent Office: Days
• US Class Current: 702/34
• CPC Class Codes: B22D 17/32 Controlling equipment
• CPC Class Codes: B22D 46/00 Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons controlling or regulating in general G05
• CPC Class Codes: B29C 2945/76006 Pressure
• CPC Class Codes: B29C 2945/76033 Electric current or voltage
• CPC Class Codes: B29C 2945/7604 Temperature
• CPC Class Codes: B29C 2945/7611 Velocity
• CPC Class Codes: B29C 2945/7614 Humidity, moisture
• CPC Class Codes: B29C 2945/76147 Contaminants
• CPC Class Codes: B29C 2945/7616 Surface properties
• CPC Class Codes: B29C 2945/76943 compare with thresholds
• CPC Class Codes: B29C 45/768 Detecting defective moulding conditions B29C45/84 takes precedence

Abstract

A real time method and apparatus for indicating preventative maintenance in a molding system. The molding system could be a metal molding system or a plastics molding system. Real time threshold status data is compared to real time operational parameter data as measured by sensors located on the molding system. If an out of tolerance condition is detected and validated by a comparator, then an indicator is provided to notify the need for preventative maintenance.

Claims

1. A method for indicating preventative maintenance of a molding system comprising the steps of:

sampling at least one real time operational parameter from at least one sensor of a molding system;

comparing the at least one real time operational parameter with at least one real time threshold operational limit to indicate operational status;

if the operational status is either below a minimum real time threshold operational limit or above a maximum real time threshold operational limit, indicate an out of tolerance condition.

2. A method as in claim 1 further comprising the steps of;

when the operational status is below a minimum real time threshold operational limit, determine;

(a) if this is not allowed;

or

(b) if a maximum limit has been reached;

and, if this is not allowed or if the maximum limit has been reached, indicate preventative maintenance.

3. A method as in claims 1 [otherwise with claim 10 on 9 on 3, and the like, you have multiple on multiple] further comprising the steps of:

when the operational status is above a maximum threshold operational limit, determine;

(a) if this is not allowed;

or

(b) if a maximum limit has been reached;

and, if this is not allowed or if the maximum limit has been reached, indicate preventative maintenance.

4. A method as in claim 2 wherein the maximum amount is based upon units of time.

5. A method as in claim 2 wherein the maximum limit is based upon a frequency of occurrence.

6. A method as in claim 2 wherein the maximum limit is based upon a pre-defined parameter.

7. A method as in claim 3 wherein the maximum limit is based upon units of time.

8. A method as in claim 3 wherein the maximum limit is based upon a frequency of occurrence.

9. A method as in claim 3 wherein the maximum limit is based upon a predefined parameter.

10. A method as in claims 1, 4-9 further comprising the steps of:

storing historical values of the real time operational parameters of the molding system.

11. A method as in claims 1, 4-9 wherein:

the real time operational parameters are based upon at least one of the following types of data, and any combination or permutation thereof;

voltage;

current;

pressure;

temperature;

humidity;

acidity;

alkinity;

stress;

strain;

alignment;

viscosity;

or

molded part quality.

12. A method as in claim 1, 4-9 wherein:

the real time threshold operational limits are based upon at least one of the following types of data, and any combination and permutation thereof;

voltage;

current;

pressure;

temperature;

humidity;

acidity;

alkinity;

stress;

strain;

alignment;

viscosity;

or

molded part quality.

13. A method as in claim 12 wherein the real time threshold operational limits include at least one of:

(a) a normal operational range value of said threshold operational limit data,

(b) a minimum limit value of said threshold operational limit data;

or

(c) a maximum limit value of said threshold operational limit data.

14. A method as in claims 1, 4-9 wherein preventative maintenance is indicated for the molding system.

15. A method as in claims 1, 4-9 wherein preventative maintenance in indicated for a subsystem of the molding system.

16. A method as in claims 1, 4-9 wherein preventative maintenance is indicated for a component part of the molding system.

17. A method as in claims 1, 4-9 wherein preventative maintenance is indicated for an auxiliary or supply system to the molding system.

18. A method as in claim 1, 4-9 wherein:

preventative maintenance is indicated for the injection unit.

19. A method as in claim 1, 4-9 wherein:

preventative maintenance is indicated for the power pack.

20. A method as in claim 1, 4-9 wherein:

preventative maintenance is indicated for the clamp.

21. A method as in claim 1, 4-9 wherein:

preventative maintenance is indicated for the mold.

22. A method as in claim 21 wherein:

the mold is a hot half.

23. A method as in claim 21 wherein:

the mold is a cold half.

24. A method as in claim 1, 4-9 wherein:

preventative maintenance is indicated for the hot runner.

25. A method as in claim 1, 4-9 wherein:

the real time threshold operational limits pertain to a particular customer.

26. A method as in claim 1, 4-9 wherein:

the real time threshold operational limits pertain to a geographic location.

27. A method as in claim 1, 4-9 wherein:

the real time threshold operational limits pertain to multiple customers.

28. A method as in claim 1, 4-9 wherein:

the real time threshold operational limits pertain to multiple geographic locations.

29. An apparatus for indicating preventative maintenance of a molding system comprising:

a comparator;

at least one real time threshold operational limit data;

sensors;

said sensors providing at least one real time operational parameter data about the molding system;

said comparator comparing the at least one real time operational parameter with said at least one real time threshold operational limit data to indicate operational status of the molding system; and

said comparator indicating an out of tolerance condition if the operational status is either below a minimum real time threshold operational limit or above a maximum real time threshold operational limit for indicating preventative maintenance.

30. An apparatus as in claim 29 wherein:

said operational status is below a minimum real time threshold operational limit, said comparator further determines if this is not allowed, or if a maximum limit has been reached, and indicates preventative maintenance.

31. An apparatus as in claims 29 or 30 wherein:

said operational status is above a maximum real time threshold operational limit, said comparator further determines if this is not allowed, or if a maximum limit has been reached, and indicates preventative maintenance.

32. An apparatus as in claim 30 wherein said threshold operational limit data includes at least one maximum limit based upon units of time.

33. An apparatus as in claim 30 wherein said threshold operational limit data includes at least one maximum limit based upon frequency of occurrence.

34. An apparatus as in claim 30 wherein said threshold operational limit data includes at least one maximum limit based upon a pre-defined parameter.

35. An apparatus as in claim 30 wherein said threshold operational limit data includes at least one maximum limit based upon units of time.

36. An apparatus as in claim 30 wherein said threshold operational limit data includes at least one maximum limit based upon frequency of occurrence.

37. An apparatus as in claim 30 wherein said threshold operational limit data includes at least one maximum limit based upon a pre-defined parameter.

38. An apparatus as in claims 29, 32-37 further comprising:

historical data of real time operational parameters of the molding system.

39. An apparatus as in claims 29, 32-37 wherein said real time operational parameter data includes at least on of the following types of data, and any combination or permutation thereof:

voltage;

current;

pressure;

temperature;

humidity;

acidity;

alkinity;

stress;

strain;

alignment;

viscosity;

or molded part quality.

40. An apparatus as in claims 29, 32-37 wherein said real time threshold operational limit data includes at least on of the following types of data, and any combination or permutation thereof:

voltage;

current;

pressure;

temperature;

humidity;

acidity;

alkinity;

stress;

strain;

alignment;

viscosity;

or molded part quality.

41. An apparatus as in claim 40 wherein said real time threshold operational limit data includes at least one of, and any combination or permutation thereof:

(a) a normal operational range value of said real time threshold operational limit data,

(b) a minimum limit value of said real time threshold operational limit data, or

(c) a maximum limit value of said real time threshold operational limit data.

42. An apparatus as in claims 29, 32-37 wherein said comparator indicates preventative maintenance for at least one of, and any combination or permutation thereof:

molding system;

subsystem of the molding system;

component part of the molding system;

auxiliary or supply system to the molding system;

injection unit;

power pack;

clamp;

mold;

hot half of said mold;

cold half of said mold;

or

hot runner.

43. An apparatus as in claims 29, 32-37 wherein said real time threshold limit data pertains to at least one of the following, and any combination or permutation thereof:

a particular customer;

a geographic location,

multiple customers, or

multiple geographic locations.

44. An apparatus as in claims 29, 32-37 wherein said apparatus is located with one of the following, and any combination or permutation thereof:

molding system;

power pack;

injection unit;

clamp;

mold;

hot half;

cold half;

hot runner;

control system;

a molding system component.