WO2014082168A1

WO2014082168A1 - A device for optimizing a molding process

Info

Publication number: WO2014082168A1
Application number: PCT/CA2013/050825
Authority: WO
Inventors: Francois Styga; Douglas James Weatherall
Original assignee: Husky Injection Molding Systems Ltd.
Priority date: 2012-11-30
Filing date: 2013-10-31
Publication date: 2014-06-05

Abstract

Disclosed herein, amongst other things, is a device and related method for use with optimizing a molding process in a molding system. The device includes an imaging device that is positionable in the molding system for acquiring a sequence of images of at least one molded article being ejected from a mold of the molding system and a computer that is configured to receive the sequence of images and to analyze the sequence of images to evaluate an ejection trajectory of a selected molded article.

Description

A DEVICE FOR OPTIMIZING A MOLDING PROCESS

TECHNICAL FIELD

Non-Limiting embodiments disclosed herein generally relate to a device and a related method for optimizing a molding process of a molding system.

SUMMARY

In accordance with an aspect disclosed herein, there is provided a device for use with optimizing a molding process in a molding system. The device includes an imaging device that is positionable in the molding system for acquiring a sequence of images of at least one molded article being ejected from a mold of the molding system and a computer that is configured to receive the sequence of images and to perform an operation therewith.

In accordance with another aspect disclosed herein, there is provided a method for optimizing a molding process in a molding system. The method includes molding at least one molded article within a mold of the molding system; opening the mold; ejecting the at least one molded article from the mold; acquiring a sequence of images of the at least one molded article during the ejection thereof using an imaging device; and performing an operation with the sequence of images.

These and other aspects and features of non-limiting embodiments will now become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

The non-limiting embodiments will be more fully appreciated by reference to the accompanying drawings, in which:

FIG. 1 depicts a schematic plan view representation of a molding system according to a non-limiting embodiment;

FIGS. 2 to 6 depict a sequence of side views of the molding system of FIG. 1 that illustrate the ejection behavior of a group of molded articles being ejected from a mold therein; FIG. 7 depicts a section view representation of a portion of a mold that has been configured in accordance with a non-limiting embodiment;

FIG. 8 depicts a section view representation of a portion of a mold that has been configured in accordance with a further non-limiting embodiment;

FIG. 9 depicts a section view representation of a portion of the mold that has been configured in accordance with yet another non-limiting embodiment. The drawings are not necessarily to scale and may be illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to perceive may have been omitted. DETAILED DESCRIPTION OF THE NON-LIMITING EMBODIMENT(S)

Reference will now be made in detail to various non-limiting embodiment(s) of a device and a related method for optimizing a molding process in a molding system. It should be understood that other non-limiting embodiment(s), modifications and equivalents will be evident to one of ordinary skill in the art in view of the non-limiting embodiment(s) disclosed herein and that these variants should be considered to be within scope of the appended claims.

Furthermore, it will be recognized by one of ordinary skill in the art that certain structural and operational details of the non-limiting embodiment(s) discussed hereafter may be modified or omitted (i.e. non-essential) altogether. In other instances, well known methods, procedures, and components have not been described in detail.

Introduction

Ejection of molded article(s), such as, for example, closure(s) for the capping of bottle(s), from a mold (e.g. injection mold) is a large contributor to cycle time (i.e. the total time required for a molding system to complete one entire molding cycle) and cycle interruptions. Usually the distance that the parts (i.e. mold halves) of the mold need to be opened depends almost exclusively on how organized a group (cluster) of closures are during the ejection thereof. The kinetic energy at ejection of all the closures is very similar, but if some closures are tumbling they will not travel as far horizontally as others that are not tumbling. The broader the range of this behavior, the more scattered the group of closures will be when it is ejected and the further the mold will have to open to allow the parts to fall out without hitting the mold halves.

Disclosed herein is a device for use with a molding system having an imaging device for tracking a molded article during the ejection thereof from the mold. For example, a high-speed camera may be incorporated into a mold clamp area in order to observe mold movements and the ejection of a group of closures. The observations from the imaging device may then be correlated into formation of a 2D or 3D image of the group of closures in order that individual part trajectories may be tracked and adjustments made to a molding process to optimize the ejection thereof.

The results of the imaging may be reported to an operator of the molding system, such as, for example, via a display on an operator interface device of the molding system, in such a way that the operator may to track changes in the ejection of the closures.

Preferably the system is automated such that a computer (for instance the control structure of the molding system or a standalone device) analyzes the images during the cycle and applies a predetermined algorithm to make corrections to one or more molding parameters. Additionally this algorithm could be a learning type which modifies itself based on historical data and responses. For example, the control structure of the molding system may be configured to dynamically adjust mold closing (e.g. closing speed and/or time) to allow molded articles that are relatively slow moving to drop out of the mold before the closing thereof. In accordance with another example, adjustments could be made to a molding material distributor (e.g. hot runner), such as, for example, a temperature of a tip in a nozzle thereof, to affect change in the ejection behavior of the closure molded in fluid communication therewith. In yet another example, a temperature of the components of the mold that define the mold cavity may be adjusted to again affect change in the ejection behavior of the closure molded therewith. Such a change may be made, for example, by adjusting a heater that is incorporated into a mold cavity defining component to make slight modifications of the temperature effecting heat removal rates and thereby changing the ejection behavior.

A technical effect or benefit of the foregoing may include molding process optimization that is characterized by cycle time reduction (increased molding system output) and increased overall equipment effectiveness by reducing cycle interruptions caused by erratic ejection. Non-limiting embodiment(s): With reference to FIG. 1 there is depicted a schematic representation of a molding system 100 in accordance with a non-limiting embodiment. In particular, the molding system 100 is configured as an injection molding system that broadly includes a mold clamp 110, a mold 120, a molding material preparation device 130, a system controller 140, and a molding material distributor 170.

The mold 120 includes a first part 122 and a second part 124 that when closed together define a plurality of molding cavities within which molded articles, depicted as a group of molded articles (e.g. a group of closures of the type for capping bottles and the like), are moldable. The first part 122 is mounted to a moving platen 114 of the mold clamp 110. The second part 124 is mounted to the molding material distributor 170 which in turn is mounted on a stationary platen 116 of the mold clamp 110. In operation, the first part 122 is reciprocated relative to the second part 124 for opening and closing the mold 120 through relative movement between the moving platen 114 and the stationary platen 116. The molding material preparation device 130 is configured to prepare (e.g. melt) molding material (not shown) and to inject the molding material through the melt distributor 170 and into the plurality of molding cavities of the mold 120.

Also shown is a device 180 in accordance with a non- limiting embodiment that is configured to aid with optimizing the operation of the molding system 100. In particular, the device 180 includes an imaging device 150 (or multiple such imaging devices) and a computer 152 that is associated therewith.

The imaging device 150 is positionable within the molding system 100 for acquiring a sequence of images of the group closures being ejected from the mold 120 of the molding system (as may be appreciated by contrasting the sequence of views shown in FIGS. 2 to 6). In particular, the imaging device 150 may be a high-speed digital camera, that is able to grab, for example, and without specific limitation, about 60 to 500 frames per second, that is positioned beside the mold clamp 110 with a clear view of a region between the first part 122 and the second part 124 of the mold 120.

The computer 152 may be a standalone device or otherwise implemented within the system controller 140 of the molding system 100. Furthermore, the computer 152 may be configured to cooperate with the system controller 140. The computer 152 is configured to receive the sequence of images and to perform an operation therewith.

For example, the operation performed by the computer 152 may involve displaying one or more of the sequence of images on an operator interface 106 of the molding system 100. This information may be useful to the operator of the molding system 100 with which to make manual adjustments to a molding parameter thereof.

Alternatively, or in addition thereto, the operation may involve analyzing the sequence of images to evaluate an ejection trajectory of each of the group of molded articles 160 or a selected molded article 160-1 (FIG. 2) thereof the at least one molded article. Such an analysis may be performed using commercially available software such as the i-speed software suite from Olympus (www.olympus- ims.com). The selected molded article 160-1 may be identified from a group of molded articles 160 being ejected on the basis of having an ejection trajectory that is an outlier. For example, and as may be appreciated with reference to FIGS. 2 to 6, the selected molded article 160-1 is identified on the basis of having an ejection trajectory that is outside of a pre-determined bound 232. Likewise, other outliers, such as molded article 160-2 may be identified.

The operation may further include correlating the selected molded article 160-1 to a mold cavity of the mold 120 and evaluating an adjustment to a molding parameter appropriate to alter the ejection trajectory of another molded article molded in the mold cavity in a subsequent molding cycle. The adjustment may be implemented manually by the operator or the operation may further include automatically adjusting the molding parameter.

In a non-limiting embodiment, the molding parameter may relate to the operation of a clamp actuator 112 of the mold clamp 110 (FIG. 1) that is operable, in use, to open and close the mold 120, and wherein the adjustment to the molding parameter affects closing of the mold 120 to allow the selected molded article 160-1 to drop out thereof before the complete closing thereof.

In a further non-limiting embodiment, the molding parameter may relate to the operation of the molding material distributor 170 (FIG. 1) and wherein the adjustment to the molding parameter affects a temperature of the molding material entering the mold 120. In particular, and as shown with reference to FIG. 7, the molding parameter more specifically relates to the control of a nozzle heater 174 that is associated with a nozzle 172 of the molding material distributor 170.

In yet another non-limiting embodiment, as shown with reference to FIG. 8, the molding parameter may relate to the control of an air valve 193 for selectively dispensing air in the mold 120 during ejection of the molded article 160-1. In particular, the air valve 193 is configured to selectively control a flow of air from a source 191 through a passageway that is defined between an inner core 194 and an outer core 196 of the core 192.

In yet further non-limiting embodiment, as shown with reference to FIG. 9, the molding parameter may relate to the operation of the mold 120. Specifically, and without limitation, the molding parameter may relate to temperature control of a mold cavity defining component of the mold 120 such as, for example, a core 192 that defines an interior of the mold cavity. More particularly, the molding parameter relates to the control of a core heater 197 that is associated with the core 192 of the mold 120.

It is noted that the foregoing has outlined some of the more pertinent non-limiting embodiments. It will be clear to those skilled in the art that modifications to the disclosed non-embodiment(s) can be effected without departing from the spirit and scope thereof. As such, the described non-limiting embodiment(s) ought to be considered to be merely illustrative of some of the more prominent features and applications. Other beneficial results can be realized by applying the non-limiting embodiments in a different manner or modifying them in ways known to those familiar with the art. This includes the mixing and matching of features, elements and/or functions between various non- limiting embodiment(s) is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one embodiment may be incorporated into another embodiment as skill in the art would appreciate from this disclosure that features, elements and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise, above. Although the description is made for particular arrangements and methods, the intent and concept thereof may be suitable and applicable to other arrangements and applications.

Claims

WHAT IS CLAIMED IS:

A device (180) for use with optimizing a molding process in a molding system (100):

an imaging device (150) that is positionable in the molding system (100) for acquiring a sequence of images of at least one molded article being ejected from a mold (120) of the molding system; and

a computer (152) that is configured to receive the sequence of images and to perform an operation therewith.

The device (180) of claim 1, wherein:

the operation involves displaying one or more of the sequence of images on an operator interface (106) of the molding system (100).

The device (180) of claim 1, wherein:

the operation involves analyzing the sequence of images to evaluate an ejection trajectory of a selected molded article (160-1) of the at least one molded article.

The device (180) of claim 3, wherein:

the selected molded article (160-1) is identified from a group of molded articles (160) being ejected on a basis of having the ejection trajectory that is an outlier.

The device (180) of claim 3, wherein the

the selected molded article (160-1) is identified on a basis of having the ejection trajectory that is outside of a pre-determined bound (232).

The device (180) of claim 3, wherein:

the operation further includes correlating the selected molded article (160-1) to a mold cavity of the mold (120) in which it was molded.

The device (180) of claim 6, wherein:

the operation further involves evaluating an adjustment to a molding parameter to alter an ejection trajectory of another molded article molded in the mold cavity in a subsequent molding cycle.

8. The device (180) of claim 7, further comprising: the operation further includes automatically adjusting the molding parameter in accordance with the adjustment.

9. The device (180) of claim 7, wherein:

the adjustment is evaluated using a predetermined algorithm of a learning type.

10. The device (180) of claim 7, wherein:

the molding parameter relates to the operation of a clamp actuator (112) that is operable, in use, to open and close the mold (120), and wherein the adjustment to the molding parameter affects closing of the mold (120) to allow the selected molded article (160-1) to drop out thereof before a complete closing thereof.

11. The device (180) of claim 7, wherein:

the molding parameter relates to the operation of a molding material distributor (170) that is operable, in use, to distribute molding material to the mold (120), and wherein the adjustment to the molding parameter affects a temperature of the molding material entering the mold (120).

12. The device (180) of claim 11, wherein:

the molding parameter more specifically relates to a control of a nozzle heater (174) that is associated with a nozzle (172) of the molding material distributor (170).

13. The device (180) of claim 7, wherein:

the molding parameter relates to the operation of the mold (120).

14. The device (180) of claim 13, wherein:

the molding parameter relates to temperature control of a component of the mold (120).

15. The device (180) of claim 14, wherein:

the molding parameter relates to the control of a core heater that is associated with a core (192) of the mold (120).

16. The device (180) of claim 13, wherein:

the molding parameter relates to a control of an air valve for selectively dispensing air in the mold (120) during ejection of the selected molded article (160-1).

17. The device (180) of claim 16, wherein:

the air is dispensable through a core (192) of the mold (120).

18. A method for optimizing a molding process in a molding system (100):

molding at least one molded article within a mold (120) of the molding system (100); opening the mold (120);

ejecting the at least one molded article from the mold (120);

acquiring a sequence of images of the at least one molded article during ejection thereof using an imaging device (150); and

performing an operation with the sequence of images.

19. The method of claim 18, wherein:

20. The method of claim 18, wherein:

21. The method of claim 20, wherein:

22. The method of claim 20, wherein the

23. The method of claim 20, wherein:

24. The method of claim 23, wherein:

25. The method of claim 24, further comprising:

the operation further includes automatically adjusting the molding parameter in accordance with the adjustment.

26. The method of claim 24, wherein:

the adjustment is evaluated using a predetermined algorithm of a learning type.

27. The method of claim 24, wherein:

28. The method of claim 24, wherein:

29. The method of claim 28, wherein:

30. The method of claim 24, wherein:

the molding parameter relates to the operation of the mold (120).

31. The method of claim 30, wherein:

32. The method of claim 31 , wherein:

33. The method of claim 30, wherein:

4. The method of claim 33, wherein:

the air is dispensed through a core (192) of the mold (120).