Injection Moulding Simulation for Hydraulic Valve-Actuator System Controller Design

1999 ◽  
Author(s):  
Paul K. Guerrier ◽  
Kevin A. Edge
Keyword(s):  
Injection Moulding ◽  
Controller Design ◽  
Experimental Testing ◽  
Effective Control ◽  
Hardware In The Loop ◽  
Moulding Process ◽  
Moulding Machine ◽  
Actuator System ◽  
Loop Technique ◽  
System Controller

Abstract In the development of advanced injection controllers and more effective control valves, full scale testing is often too expensive. This paper is concerned with virtual testing using simulation and experimental testing using a ‘hardware-in-the-loop’ technique in which a servovalve-actuator system emulates the moulding process. Simulation results for the purely simulated load and a ‘hardware-in-the-loop’ emulated load are compared with experimental data. Good agreement is achieved. Although the particular case of an hydraulic injection moulding machine has been considered, the model of the moulding process would be equally valid for studies of an all-electric machine.

Hydraulic Emulation of Injection Moulding

2001 ◽  
Author(s):  
Paul K. Guerrier ◽  
Kevin A. Edge
Keyword(s):  
Injection Moulding ◽  
Controller Design ◽  
Control Strategies ◽  
Full Scale ◽  
Active Area ◽  
Hardware In The Loop ◽  
Moulding Process ◽  
Advantages And Disadvantages ◽  
Hydraulic Load ◽  
Loop Technique

Abstract The control of injection moulding is an active area for research. The inject phase of the moulding process which includes filling and packing is of particular importance. New control strategies have traditionally been evaluated either in simulation or through full scale testing. Both methods have advantages and disadvantages. This paper details the hydraulic load emulation of the filling and packing phases using the hardware-in-the-loop technique which is a compromise between these two methods. With suitable controller design successful load emulation is demonstrated.

Evaluation of P-Q Controllers for an Injection Moulding Machine

2000 ◽  
Author(s):  
Paul K. Guerrier ◽  
Kevin A. Edge
Keyword(s):  
Injection Moulding ◽  
Adaptive Controller ◽  
Pi Controller ◽  
Hardware In The Loop ◽  
Model Reference ◽  
Industry Standard ◽  
Moulding Machine ◽  
Single Controller ◽  
Pressure Controller ◽  
Model Reference Adaptive

Abstract There are a number of problems surrounding traditional velocity and pressure controllers used on injection moulding machines. Injection moulding machines are also very expensive and full scale testing is often not appropriate at the beginning of new controller evaluation. This paper presents results for a half scale ‘hardware-in-the-loop’ load emulation of the filling and packing phases of injection moulding, suitable for controller evaluation. The problems linked to the current industry standard velocity and pressure controller are discussed along with alternative strategies. Schemes including single controller fuzzy logic and neural network solutions are discussed and ruled out in favour of ones containing separate velocity and pressure controllers. Results for a model reference adaptive pressure controller are presented and compared with those obtained using a closed loop PI controller experimentally and in simulation. Experimentally the model reference adaptive controller outperforms the PI controller but does suffer from gain drift.

Simulation of the micro-injection moulding process: effect of the thermo-rheological status on the morphology

2011 ◽  
Vol 225 (4) ◽  
pp. 224-238 ◽  
Author(s):  
T Nguyen-Chung ◽  
C Löser ◽  
G Jüttner ◽  
T Pham ◽  
M Obadal ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Process Conditions ◽  
Transfer Coefficients ◽  
Moulding Process ◽  
Micro Injection Moulding ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Simulation Results ◽  
Micro Cavity

The software package Moldflow Plastics Insights was used to simulate the filling of a micro-cavity by considering precise material data and accurate boundary conditions. Experiments were carried out on an accurately controlled micro-injection moulding machine (formicaPlast) for providing important parameters to verify the simulation results and improve the accuracy of the simulation. Based on the relationship between the cavity pressure and the mould-filling ratio, the heat transfer coefficients can be appropriately determined for different process conditions. Finally, the transient thermo-rheological results were analysed with regard to their influence on the morphology of semi-crystalline (PP) micro-injection moulded parts, which not only give rise to the mechanisms of the morphological formation but also verify the quality of the simulation results.

Injection Moulding Simulation Analysis of Handle Shell

2013 ◽  
Vol 798-799 ◽  
pp. 286-289
Author(s):  
Wei Li
Keyword(s):  
Process Parameters ◽  
Injection Moulding ◽  
Simulation Analysis ◽  
Final Analysis ◽  
Moulding Process ◽  
Technical Requirements ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Final Analysis Result

This thesis first made an introduction to the functional and technical requirements of this product, and then determined its moulding process. After that, the injection moulding process parameters of the selected injection moulding machine were set, besides, it applied Moldflow software to make simulation analysis to multiple schemes of injection moulding process, and finally, the best mold structure was determined according to the final analysis result.

Optimization of Injection Moulding Process from the View of Cavity Filling Time and Product Cooling Time

2014 ◽  
Vol 621 ◽  
pp. 208-213
Author(s):  
Katarina Monkova ◽  
Slavomir Hric
Keyword(s):  
Injection Moulding ◽  
3D Model ◽  
Cooling System ◽  
Moulding Process ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Filling Time ◽  
Moulding Machine ◽  
Mould Cavity ◽  
Cavity Filling

The article deals with the mould cooling system design. The goal of design presented in the article was to propose the mould form so to be achieved the shortest time for both mould filling and product cooling. Studied product is intended to serve as a stopper in the automotive spotlight. After filling of mould cavity, the melt has to cool at 100 ° C, only then it is possible to accede to the next phase, which is final pressure. So the cooling and filling time is directly proportional to the reduction of production cost. 3D model of the mould was created in Autodesk Inventor Proffesional software and then solidification of material was simulated in Autodesk Moldflow Insight software. There were considered four types of cooling system in the article and the best one from the view of time was manufactured and placed into the injection moulding machine Arburg Allrounder 320 C.

The Simulation as a Tool for Technical Devices Design and Optimization

2014 ◽  
Vol 718 ◽  
pp. 122-127
Author(s):  
Slavomir Hric ◽  
Dominika Lehocka ◽  
Jan Carach ◽  
Filip Murgas ◽  
Peter Pastucha
Keyword(s):  
Injection Moulding ◽  
3D Model ◽  
Cooling System ◽  
Moulding Process ◽  
Design And Optimization ◽  
Running System ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Mould Cavity

The article deals with the research of the pressures originated inside the cooling system and also in the mould cavity during the injection moulding process. The simulations were realized for three designed types of running system and for four versions of cooling system. 3D model of the mould was created in Autodesk Inventor Proffesional software and then solidification of material was simulated in Autodesk Moldflow Insight software. The results were compared and the best version from the view of pressure was manufactured and placed into the injection moulding machine Arburg Allrounder 320 C.

scholarly journals Robust Part Quality by Controlling the Injection Moulding Process with 24 Fraction Factorial Design: A Case Study

2011 ◽  
Vol 383-390 ◽  
pp. 1032-1038 ◽  
Author(s):  
S. Rajalingam
Keyword(s):  
Factorial Design ◽  
Injection Moulding ◽  
Digital Camera ◽  
Moulding Process ◽  
Part Quality ◽  
Horizontal Length ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Process Factors

The author wants to use a case study to investigate the injection moulding machine parameters which will affect the horizontal length dimension of a plastic component used in digital camera. Currently the injection moulding machine process setting caused variations in the diameter exceeding the specification limit. Therefore the experiment is needed to identify the process factors that could be set to maintain the horizontal length dimension closest to the target value and smallest possible variation. The experimental model is used to investigate four factors to identify the factors having large effect by using the Full Factorial Design of Experiment (DOE). The experiment has emphasized the use of these designs in identifying the subset of factors that are active and provide some information about the interaction.

Hardware-in-the-loop environment for servo system controller design, tuning and testing

2000 ◽  
Vol 24 (1) ◽  
pp. 13-21 ◽  
Author(s):  
M Linjama ◽  
T Virvalo ◽  
J Gustafsson ◽  
J Lintula ◽  
V Aaltonen ◽  
...  
Keyword(s):  
Controller Design ◽  
Servo System ◽  
Hardware In The Loop ◽  
System Controller

scholarly journals Transfer and Optimisation of Injection Moulding Manufacture of Medical Devices Using Scientific Moulding Principles

2021 ◽  
Vol 5 (4) ◽  
pp. 113
Author(s):  
Aimee Fitzgerald ◽  
Paul McDonald ◽  
Declan Devine ◽  
Evert Fuenmayor
Keyword(s):  
Cycle Time ◽  
Injection Moulding ◽  
Endovascular Aneurysm Repair ◽  
Original Process ◽  
Injection Speed ◽  
Moulding Process ◽  
Hold Temperature ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Dimensional Measurements

Scientific moulding, also known as decoupled injection moulding, is a production methodology used to develop and determine robust moulding processes resilient to fluctuations caused by variation in temperature and viscosity. Scientific moulding relies on the meticulous collection of data from the manufacturing process, especially inputs of time (fill, pack/hold), temperature (melt, barrel, tool), and pressure (injection, hold, etc.). This publication presents a use case where scientific moulding was used to enable the transfer and optimisation of an injection moulding process from an Arburg 221M injection moulding machine to an Arburg 375 V model. The part was an endovascular aneurysm repair dilator device where a polypropylene hub was moulded over a high-density polyethylene dilator insert. Upon transfer, multiple studies were carried out, including material rheology study during injection, gate freeze study, cavity balance of the moulding tool, and pressure loss analysis. A design of experiments was developed and carried out on the process with a variety of effects and responses. The developed process cycle time was compared to that achieved theoretically using mathematical modelling and the original process cycle time. The studies resulted in the identification of optimum parameters for injection speed, holding time, holding pressure, cooling time, and mould temperature. The process was verified by completing a 32-shot study and recording part weights and dimensional measurements to confirm repeatability and consistency of the process. The output from the study was a reduction in cycle time by 12.05 s from the original process. A cycle time of 47.28 s was theoretically calculated for the process, which is within 6.6% of the practical experiment results (44.15 s).

Application of the Taguchi method for consistent polymer melt production in injection moulding

1998 ◽  
Vol 212 (8) ◽  
pp. 611-620 ◽  
Author(s):  
N Khoshooee ◽  
P D Coates
Keyword(s):  
Injection Moulding ◽  
Polymer Melt ◽  
Acrylonitrile Butadiene Styrene ◽  
Melt Temperature ◽  
Factors Affecting ◽  
Moulding Process ◽  
Control Factors ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Noise Factors

The consistency of polymer melt production in the injection-moulding process has been studied using a Taguchi design-of-experiment method for acrylonitrile butadiene styrene (ABS) and high-density polyethylene. Systematic experimentation with injection-moulding machine settings helped to establish both qualitative and quantitative process understanding in attempting to control the melt quality, assessed here by the shot weight variability. Optimum machine settings were determined which gave the lowest variations in the shot weight. In the case of ABS, uncontrollable influences (noise factors; here the injection stroke and moisture content) were incorporated in the study in such a way that the optimum levels recommended by the analysis make the process (i.e. shot weight) insensitive to variations caused by the noise factors. The set melt temperature and screw-back pressure were observed to be the most influential control factors affecting the shot weight variability for both polymers.

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