Cavity pressure dynamics and self-tuning control for filling and packing phases of thermoplastics injection molding

Because of its versatility, cost effectiveness, and ability to produce intricate shapes to tight specifications, the injection molding process is widely used in plastics processing. Mold cavity pressure plays an important role in determining the quality of the molded articles. The dynamic behavior and control of cavity pressure were studied for the filling and packing phases. The dynamics of cavity pressure during filling were investigated and found to be both nonlinear and time-varying in relation to the hydraulic servo-valve opening, which is the manipulated variable. A self-tuning control system was designed and tested for a wide range of conditions. The transition from filling to packing was best detected by the change in the derivative of cavity pressure. The dynamics of cavity pressure during packing were studied and modeled similarly as for filling. The self-tuning technique was successfully extended and implemented in the packing phase.