Performance Evaluation of Purely Mechanical Wireless In-Mould Sensor for Injection Moulding
In this paper, the influencing parameters of a novel
purely mechanical wireless in-mould injection moulding sensor
were investigated. The sensor is capable of detecting the melt
front at predefined locations inside the mould. The sensor comprises
a movable pin which acts as the sensor element generating
structure-borne sound triggered by the passing melt front. Due to
the sensor design, melt pressure is the driving force. For pressure
level measurement during pin movement a pressure transducer
located at the same position as the movable pin. By deriving
a mathematical model for the mechanical movement, dominant
process parameters could be investigated towards their impact
on the melt front detection characteristic. It was found that the
sensor is not affected by the investigated parameters enabling it
for reliable melt front detection. In addition, it could be proved
that the novel sensor is in comparable range to conventional melt
front detection sensors.
<p>[1] K. K. Wang, J. Zhou, and Y. Sakurai, “An Integrated Adaptive Control
for Injection Molding,” in Proceedings of ANTEC 1999, New York City,
1999.
[2] Z. Chen and L.-S. Turng, “A review of current developments in
process and quality control for injection molding,” Advances in Polymer
Technology, vol. 24, no. 3, pp. 165–182, 2005.
[3] J. Giboz, T. Copponnex, and P. M´el´e, “Microinjection molding of
thermoplastic polymers: a review,” Journal of Micromechanics and
Microengineering, vol. 17, no. 6, pp. 96–109, 2007.
[4] D. O. Kazmer, S. P. Johnston, R. Gao, and Z. Fan, “Feasibility Analysis
of an In-mold Multivariate Sensor,” International Polymer Processing
The Journal of the Polymer Processing Society, vol. XXVI, no. 01, pp.
63–72, 2011.
[5] D. O. Kazmer, Plastics manufacturing systems engineering: [a systems
approach]. M¨unchen: Hanser Verlag, 2009.
[6] D. O. Kazmer, S. Velusamy, S. Westerdale, S. Johnston, and R. Gao, “A
comparison of seven filling to packing switchover methods for injection
molding,” Polymer Engineering and Science, vol. 50, no. 10, pp. 2031–
2043, 2010.
[7] C. Bader, “Das kleine Einmaleins der Werkzeug-Sensorik,” Kunststoffe
International, no. 6, pp. 114–117, 2006.
[8] T. Hirano, “Automated Switchover in Injection Molding,” Journal of the
Japan Society of Polymer Processing, vol. 9, no. 11, p. 843, 1997.
[9] M.-S. Huang, “Cavity pressure based grey prediction of the filling-topacking
switchover point for injection molding,” Journal of Materials
Processing Technology, vol. 183, no. 2-3, pp. 419–424, 2007.
[10] B. Sheth, C. M. Barry, N. R. Scott, R. D. Higdon, and B. Davison,
“Improved part quality using cavity pressure switchover,” in Proceedings
of ANTEC 2001, Dallas, 2001.
[11] F. Johannaber and W. Michaeli, Handbuch Spritzgiessen, 2nd ed.
M¨unchen: Hanser, 2004.
[12] C. Collins, “Monitoring cavity pressure perfects injection molding,”
Assembly Automation, vol. 19, no. 3, pp. 197–202, 1999.
[13] A. Kelly, M. Woodhead, and P. Coates, “Comparison of injection molding
machine performance,” Polymer Engineering & Science, vol. 45,
no. 6, pp. 857–865, 2005.
[14] L. Zhang, C. B. Theurer, R. Gao, and D. O. Kazmer, “Design of
ultrasonic transmitters with defined frequency characteristics for wireless
pressure sensing in injection molding,” IEEE Transactions on Ultransonics
Ferroelectrics and Frequency Control, vol. 52, no. 8, pp. 1360–1371,
2005.
[15] L. Zhang, C. B. Theurer, R. Gao, and D. O. Kazmer, “DEVELOPMENT
OF A WIRELESS PRESSURE SENSOR WITH REMOTE ACOUSTIC
TRANSMISSION,” Transaction North American Manufacturing
Research Institute, vol. 30, pp. 573–580, 2002.
[16] Z. Fan, R. Gao, and D. O. Kazmer, “Design of a self-energized wireless
sensor for simultaneous pressure and temperature measurement,” Advanced
Intelligent Mechatronics (AIM), 2010 IEEE/ASME International
Conference on Advanced Intelligent, Montreal, 2010.
[17] C. Theurer, Li Zhang, D. O. Kazmer, R. Gao, and R. Jackson, “Passive
charge modulation for a wireless pressure sensor,” IEEE Sensors
Journal, vol. 6, no. 1, pp. 47–54, 2006.
[18] L. Zhang, C. B. Theurer, and R. Gao, “A SLEF-ENERGIZED SENSOR
FOR WIRELESS INJECTION MOLD CAVITY PRESSURE MEASUREMENT:
DESIGN AND EVALUATION,” Journal of dynamic
systems, measurement, and control, vol. 126, no. 2, pp. 309–318, 2004.
[19] F. Muller, G. Rath, T. Lucyshyn, C. Kukla, M. Burgsteiner, and
C. Holzer, “Presentation of a novel sensor based on acoustic emission in
injection molding,” Journal of Applied Polymer Science, vol. 127, no. 6,
pp. 4744–4749, 2013.
[20] F. M¨uller, P. O’Leary, G. Rath, M. Harker, T. Lucyshyn, and C. Holzer,
“Resonant Acoustic Sensor System for the Wireless Monitoring of
Injection Moulding,” in Sensornets 2013, 2nd International Conference
on Sensor Networks, Barcelona, 2013.
[21] B. Heißing, Fahrwerkhandbuch. Wiesbaden: Springer Fachmedien,
2008.
[22] I. N. Bronˇstejn, Taschenbuch der Mathematik, 19th ed. Thun and
Frankfurt/Main: Deutsch, 1981.
[23] C. Bader and S. C. Zeller, “Die Entdeckung der Schmelzefront: Sensortechnik,”
Kunststoff Magazin Online, no. 6, pp. 2–6, 2010.
[24] M. Pahl, W. Gleissle, and H.-M. Laun, Praktische Rheologie der
Kunststoffe und Elastomere, 4th ed. D¨usseldorf: VDI-Verl., 1995.
[25] Priamus System Technologies AG, “Datasheet 4007B / 4008B,” Schaffenhausen
and Switzerland, 2013.</p>
<p>[1] K. K. Wang, J. Zhou, and Y. Sakurai, “An Integrated Adaptive Control
for Injection Molding,” in Proceedings of ANTEC 1999, New York City,
1999.
[2] Z. Chen and L.-S. Turng, “A review of current developments in
process and quality control for injection molding,” Advances in Polymer
Technology, vol. 24, no. 3, pp. 165–182, 2005.
[3] J. Giboz, T. Copponnex, and P. M´el´e, “Microinjection molding of
thermoplastic polymers: a review,” Journal of Micromechanics and
Microengineering, vol. 17, no. 6, pp. 96–109, 2007.
[4] D. O. Kazmer, S. P. Johnston, R. Gao, and Z. Fan, “Feasibility Analysis
of an In-mold Multivariate Sensor,” International Polymer Processing
The Journal of the Polymer Processing Society, vol. XXVI, no. 01, pp.
63–72, 2011.
[5] D. O. Kazmer, Plastics manufacturing systems engineering: [a systems
approach]. M¨unchen: Hanser Verlag, 2009.
[6] D. O. Kazmer, S. Velusamy, S. Westerdale, S. Johnston, and R. Gao, “A
comparison of seven filling to packing switchover methods for injection
molding,” Polymer Engineering and Science, vol. 50, no. 10, pp. 2031–
2043, 2010.
[7] C. Bader, “Das kleine Einmaleins der Werkzeug-Sensorik,” Kunststoffe
International, no. 6, pp. 114–117, 2006.
[8] T. Hirano, “Automated Switchover in Injection Molding,” Journal of the
Japan Society of Polymer Processing, vol. 9, no. 11, p. 843, 1997.
[9] M.-S. Huang, “Cavity pressure based grey prediction of the filling-topacking
switchover point for injection molding,” Journal of Materials
Processing Technology, vol. 183, no. 2-3, pp. 419–424, 2007.
[10] B. Sheth, C. M. Barry, N. R. Scott, R. D. Higdon, and B. Davison,
“Improved part quality using cavity pressure switchover,” in Proceedings
of ANTEC 2001, Dallas, 2001.
[11] F. Johannaber and W. Michaeli, Handbuch Spritzgiessen, 2nd ed.
M¨unchen: Hanser, 2004.
[12] C. Collins, “Monitoring cavity pressure perfects injection molding,”
Assembly Automation, vol. 19, no. 3, pp. 197–202, 1999.
[13] A. Kelly, M. Woodhead, and P. Coates, “Comparison of injection molding
machine performance,” Polymer Engineering & Science, vol. 45,
no. 6, pp. 857–865, 2005.
[14] L. Zhang, C. B. Theurer, R. Gao, and D. O. Kazmer, “Design of
ultrasonic transmitters with defined frequency characteristics for wireless
pressure sensing in injection molding,” IEEE Transactions on Ultransonics
Ferroelectrics and Frequency Control, vol. 52, no. 8, pp. 1360–1371,
2005.
[15] L. Zhang, C. B. Theurer, R. Gao, and D. O. Kazmer, “DEVELOPMENT
OF A WIRELESS PRESSURE SENSOR WITH REMOTE ACOUSTIC
TRANSMISSION,” Transaction North American Manufacturing
Research Institute, vol. 30, pp. 573–580, 2002.
[16] Z. Fan, R. Gao, and D. O. Kazmer, “Design of a self-energized wireless
sensor for simultaneous pressure and temperature measurement,” Advanced
Intelligent Mechatronics (AIM), 2010 IEEE/ASME International
Conference on Advanced Intelligent, Montreal, 2010.
[17] C. Theurer, Li Zhang, D. O. Kazmer, R. Gao, and R. Jackson, “Passive
charge modulation for a wireless pressure sensor,” IEEE Sensors
Journal, vol. 6, no. 1, pp. 47–54, 2006.
[18] L. Zhang, C. B. Theurer, and R. Gao, “A SLEF-ENERGIZED SENSOR
FOR WIRELESS INJECTION MOLD CAVITY PRESSURE MEASUREMENT:
DESIGN AND EVALUATION,” Journal of dynamic
systems, measurement, and control, vol. 126, no. 2, pp. 309–318, 2004.
[19] F. Muller, G. Rath, T. Lucyshyn, C. Kukla, M. Burgsteiner, and
C. Holzer, “Presentation of a novel sensor based on acoustic emission in
injection molding,” Journal of Applied Polymer Science, vol. 127, no. 6,
pp. 4744–4749, 2013.
[20] F. M¨uller, P. O’Leary, G. Rath, M. Harker, T. Lucyshyn, and C. Holzer,
“Resonant Acoustic Sensor System for the Wireless Monitoring of
Injection Moulding,” in Sensornets 2013, 2nd International Conference
on Sensor Networks, Barcelona, 2013.
[21] B. Heißing, Fahrwerkhandbuch. Wiesbaden: Springer Fachmedien,
2008.
[22] I. N. Bronˇstejn, Taschenbuch der Mathematik, 19th ed. Thun and
Frankfurt/Main: Deutsch, 1981.
[23] C. Bader and S. C. Zeller, “Die Entdeckung der Schmelzefront: Sensortechnik,”
Kunststoff Magazin Online, no. 6, pp. 2–6, 2010.
[24] M. Pahl, W. Gleissle, and H.-M. Laun, Praktische Rheologie der
Kunststoffe und Elastomere, 4th ed. D¨usseldorf: VDI-Verl., 1995.
[25] Priamus System Technologies AG, “Datasheet 4007B / 4008B,” Schaffenhausen
and Switzerland, 2013.</p>
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:53120", author = "Florian Müller and Christian Kukla and Thomas Lucyshyn and Clemens Holzer", title = "Performance Evaluation of Purely Mechanical Wireless In-Mould Sensor for Injection Moulding", abstract = "In this paper, the influencing parameters of a novel
purely mechanical wireless in-mould injection moulding sensor
were investigated. The sensor is capable of detecting the melt
front at predefined locations inside the mould. The sensor comprises
a movable pin which acts as the sensor element generating
structure-borne sound triggered by the passing melt front. Due to
the sensor design, melt pressure is the driving force. For pressure
level measurement during pin movement a pressure transducer
located at the same position as the movable pin. By deriving
a mathematical model for the mechanical movement, dominant
process parameters could be investigated towards their impact
on the melt front detection characteristic. It was found that the
sensor is not affected by the investigated parameters enabling it
for reliable melt front detection. In addition, it could be proved
that the novel sensor is in comparable range to conventional melt
front detection sensors.
", keywords = "Injection Moulding, In-Mould Sensor,
Structure-Borne Sound, Wireless Sensor", volume = "7", number = "9", pages = "1782-6", }
