Intelligent molding environment and method of configuring a molding system

• US 7,580,771 B2
• Filed: 10/19/2004
• Issued: 08/25/2009
• Est. Priority Date: 10/19/2004
• Status: Active Grant

• Current Assignee: Husky Injection Molding Systems Limited
• Original Assignee: Husky Injection Molding Systems Limited
• Inventors: Quail, John P., Saggese, Stefano M., Dearling, Bruce C.
• Primary Examiner(s): Bahta; Kidest
• Application Number:
  US10/968,610
• Publication Number:
  US 20060082009A1
• Time in Patent Office: 1,771 Days
• Field of Search: 700/197, 700/200, 700/204, 425/162, 425/143, 425/445, 425/434, 425/526, 425/547, 717/188, 717/123, 715/200, 164/456, 264/40.1, 264/328.14
• US Class Current: 700/197
• CPC Class Codes: B22D 17/007 Semi-solid pressure die casting
• CPC Class Codes: B22D 17/32 Controlling equipment
• CPC Class Codes: B29C 2045/1796 Moulds carrying mould related information or codes, e.g. bar codes, counters
• CPC Class Codes: B29C 2945/76006 Pressure
• CPC Class Codes: B29C 2945/76066 Time
• CPC Class Codes: B29C 2945/7611 Velocity
• CPC Class Codes: B29C 2945/76418 Ejection
• CPC Class Codes: B29C 2945/76498 Pressure
• CPC Class Codes: B29C 2945/76551 Time
• CPC Class Codes: B29C 2945/76785 hydraulic fluids
• CPC Class Codes: B29C 2945/76869 Mould clamping, compression of the cavity
• CPC Class Codes: B29C 2945/76936 The operating conditions are corrected in the next phase or cycle
• CPC Class Codes: B29C 2945/76939 Using stored or historical data sets
• CPC Class Codes: B29C 45/27 Sprue channels ; Runner channels or runner nozzles
• CPC Class Codes: B29C 45/766 the setting or resetting of moulding conditions, e.g. before starting a cycle
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/253 Preform

Abstract

An injection molding machine, including: a human machine interface being configured to provide graphical representation of a status of the injection molding machine; a machine controller being configured to: (i) provide operational control of the injection molding machine, (ii) operationally couple with the human machine interface, the machine controller having; (i) a machine-controller processor; and (ii) machine-controller memory being coupled with the machine-controller processor; an injection unit being configured to plasticizing and inject a molding material; a tie-bar clamping mechanism being associated with the injection unit; and a mold assembly being supported by the tie-bar clamping mechanism, the mold assembly being coupled with the injection unit, the mold assembly being adapted to receive the molding material from the injection unit so that a molded article may be molded, and the mold assembly including: a mold assembly body; and a mold memory device being coupled with the mold assembly body, and being operatively coupled with the machine controller so that data being stored in the mold memory device may be accessed by the machine controller, the mold memory device including; mold set-up data being related with the molded article to be molded in the mold assembly.

Claims

1. An injection molding machine, comprising:

a human machine interface being configured to provide graphical representation of a status of the injection molding machine;

a machine controller being configured to;

(i) provide operational control of the injection molding machine, (ii) operationally couple with the human machine interface, the machine controller having;

(i) a machine-controller processor; and

(ii) machine-controller memory being coupled with the machine-controller processor;

an injection unit being configured to plasticizing and inject a molding material;

a tie-bar clamping mechanism being associated with the injection unit; and

a mold assembly being supported by the tie-bar clamping mechanism, the mold assembly being coupled with the injection unit, the mold assembly being adapted to receive the molding material from the injection unit so that a molded article may be molded, and the mold assembly including;

a mold assembly body; and

a mold memory device being coupled with the mold assembly body, the mold memory device being readable by the machine controller, and the mold memory device including;

data being associated with the mold assembly.

2. The injection molding machine according to claim 1, wherein:

the data includes;

mold set-up data being related with the molded article to be molded in the mold assembly.

3. The injection molding machine according to claim 1, wherein:

the data includes;

mold set-up data being related with the molded article to be molded in the mold assembly, and the mold set-up data defines the molded article in terms of a plurality of zones having differing thicknesses and geometries.

4. The injection molding machine according to claim 1, wherein:

the data includes;

mold set-up data being related with the molded article to be molded in the mold assembly, and the mold set-up data defines the molded article in terms of a plurality of zones having differing thicknesses and geometries, and the mold set-up data includes;

a plurality of weighting factors designed to at least partially compensate for differing cooling and flow characteristic within the molded article.

5. The injection molding machine according to claim 1, wherein:

the data includes;

mold set-up data being related with the molded article to be molded in the mold assembly, the mold set-up data defines the molded article in terms of a plurality of zones having differing thicknesses and geometries, and the mold set-up data defines the molded article in terms of a fill rate for each of the plurality of zones, and the fill rate defining a substantially constant speed or flow for a melt front that is expected to flow within each of the plurality of zones.

6. The injection molding machine of claim 1, wherein:

the data includes;

mold configuration information, and the machine controller, based on the mold configuration information, allows an operator to modify selected operating conditions associated with machine operation.

7. The injection molding machine of claim 1, wherein:

the data includes;

technical data being associated with the molded article.

8. The injection molding machine of claim 1, wherein:

the data includes;

a user instruction manual being accessed by the machine controller to allow display of the user instruction manual on the human machine interface.

9. The injection molding machine of claim 1, wherein:

the data includes;

a component identity number being configured to allow the machine controller to cross-reference a database having component-identity numbers to obtain configuration information.

10. The injection molding machine of claim 1, wherein:

the data includes;

a component identity number providing a point of recognition which can be cross-referenced into a database of operating parameters made available to the machine controller.

11. The injection molding machine of claim 1, wherein:

the data includes;

a bar-code strip identifying a component being associated with the mold memory device.

12. The injection molding machine of claim 1, wherein:

the data includes;

an authentication code that establishes component compatibility and origin, mold operation is enabled.

13. The injection molding machine of claim 1, wherein:

the data includes;

a predefined pressure drop model for a configuration of the injection molding machine.

14. The injection molding machine of claim 1, wherein:

the data includes;

an indication indicating whether the machine controller may apply any one of;

(i) minimum closure tonnage based on pressure measurements, and (ii) variation of closure tonnage over time based on either measured physical parameters of a mold or the molded article.

15. The injection molding machine of claim 1, wherein:

the data includes;

information pertaining to at least one of;

a fill profile for the molded article to be molded; and

set point control for a mold.

16. The injection molding machine of claim 1, wherein:

the mold assembly body includes;

a mold being coupled with the mold memory device.

17. The injection molding machine of claim 1, wherein:

the mold assembly body includes;

a hot runner being coupled with the mold memory device.

18. The injection molding machine of claim 1, wherein:

the mold memory device includes;

an electronic memory;

a data interface being coupled with the electronic memory, and being configured to couple with the machine controller; and

a memory-device microprocessor being coupled with the data interface.

19. The injection molding machine of claim 1, further comprising:

a mold sensor being coupled with the mold assembly body, the mold sensor being coupled with the mold memory device, the mold memory device being configured to store the data being provided by the mold sensor, the mold sensor being configured to measure a variable parameter being associated with a mold operation of the injection molding machine.

20. The injection molding machine of claim 1, wherein:

the machine controller is configured to communicate with a database, and the database containing operational parameters associated with the injection molding machine, and

the data includes;

a network address pointer being usable by the machine controller to access a set-up parameter being located in the database.

21. The injection molding machine according to claim 1, wherein:

the data includes;

an identification tag identifying the mold assembly.