It was noticed that the mold separation event occurred about 4 seconds into the molding process, and would very quickly separate the mold to 3 thousandths of an inch. Because the injection was fixed, and process variation may cause under or over filling. Cyclops was set to bypass the boost timer, and stop injection when the mold separated to .4 thous. This produced in effect a variable timer, that cut off boost not after a predetermined number of seconds, but after the mold cavity was full. The remainder of the run was completed under Cyclops control with ZERO rejects.
Injection is controlled by a boost timer.
Twenty more cycles were allowed to run, then 5 more consecutive samples were taken. The 10 samples taken before Cyclops control had an average weight of 1.19835 lbs. The average cycle time to produce these parts was 38.3 seconds, and the average mold separation was .173 thous. The Cyclops 2000 controller was then allowed to control the process, switching off boost injection at .05 thous. The controlled parts averaged 1.187 lbs.