Optimize Injection-Molding Process Parameters and Build an Adaptive Process Control System Based on Nozzle Pressure...

Area of Science:

• Manufacturing Engineering
• Materials Science
• Process Control

Background:

• Injection molding is a complex, non-linear process.
• Product quality and production stability are influenced by multiple factors.
• Variability in process parameters leads to inconsistent product quality.

Purpose of the Study:

• To stabilize product quality in injection molding.
• To establish a standard process parameter setup procedure.
• To develop an adaptive process control system for real-time adjustments.

Main Methods:

• Utilized nozzle pressure sensor and tie-bar strain gauge data.
• Sequentially optimized process parameters (V/P switchover, injection speed, packing pressure, clamping force) based on pressure profiles.
• Defined standard quality characteristics using optimized parameters.

Main Results:

• Successfully implemented an adaptive process control system.
• Achieved significant reductions in product weight variation for different viscosity materials (0.106%, 0.092%, 0.079%).
• Demonstrated the effectiveness of the optimization procedure and control system.

Conclusions:

• The developed system ensures automatic machine adjustment for consistent high-quality production.
• The adaptive control system effectively mitigates the impact of process variations.
• Optimized process parameters and adaptive control are crucial for stable injection molding.