Sensory mould insert monitors the injection moulding process

Real-time monitor Sensory mould insert monitors the injection moulding process

2024-03-28 Source: Fraunhofer IST 1 min Reading Time

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Injection moulding of plastic parts is one of the most tightly controlled manufacturing processes. But Fraunhofer researchers are now going one better in terms of monitoring...

With this sensor, which was developed at the Fraunhofer IST, the injection moulding of plastic parts in the mould can be recorded in real time in order to initiate corrections if necessary. The system can be seen at the upcoming Hannover Messe.(Source: Fraunhofer IST / U. Balhorn) — With this sensor, which was developed at the Fraunhofer IST, the injection moulding of plastic parts in the mould can be recorded in real time in order to initiate corrections if necessary. The system can be seen at the upcoming Hannover Messe.
(Source: Fraunhofer IST / U. Balhorn)

The economical and ecological production of plastic parts using injection moulding machines and appropriate tools requires a high level of process reliability. This requires precise recording and monitoring of relevant parameters such as temperature and pressure curves. At the Hannover Messe from 22 to 26 April 2024, the Fraunhofer Institute for Surface Engineering and Thin Films IST will therefore be presenting a real-time data acquisition system that can be used directly in the running process by means of integrated and wear-resistant thin-film sensors. The special feature is that the tribologically resistant multifunctional sensor systems are deposited directly on the tool surface, enabling measurement in the main load zones.

Real-time recording of component geometry during the development process

One example is the development of a multifunctional thin-film sensor system that is applied to an exchangeable mould insert. As the IST researchers explain, a specially adapted sensor design with a total of 13 measuring points enables spatially resolved measurement of the entire flow front of the plastic melt when it is pressed through the mould cavity. The thermoresistive sensors are distributed in such a way that they can map the component geometry metrologically. The measurement data obtained is read out in real time by an electronic unit specially adapted to the sensors and processed directly. This enables faults and potential weak points to be recognised immediately and corrections and adjustments to be implemented quickly. Machine learning algorithms implemented on an edge device also make it possible to reliably determine the component quality. The results of the data analysis are then output as a colour signal on the system - even before the mould opens again after the injection process to eject the component.

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