Patent Description:
Injection molding is a technology commonly used for high-volume manufacturing of parts made of thermoplastic material. During a repetitive injection molding process, a thermoplastic resin, most often in the form of small beads or pellets, is introduced to an injection molding apparatus that melts the resin beads under heat and pressure. The now-molten resin is forcefully injected into a mold cavity having a particular cavity shape. The injected plastic is held under pressure in the mold cavity, cooled, and then removed as a solidified part having a shape that essentially duplicates the cavity shape of the mold. The mold itself may have a single cavity or multiple cavities.

An injection molding cycle, as used herein, or simply "cycle", can include the steps of (<NUM>) melting a shot of polymeric material; (<NUM>) clamping together two (or more) portions of a mold, such as a mold core and a mold cavity plate, that together form the mold walls that define one or more mold cavities (typically while the mold walls are in a cool condition relative to the temperature to which the molten thermoplastic material is heated prior to injection into the mold cavity); (<NUM>) injecting molten polymeric material into the one or more mold cavities; (<NUM>) packing or holding the material, i.e., applying one or more set pressures to the material, after the mold is full, to ensure adequate densification within the cavity and wait for material solidification in the gate(s) or runner(s) to prevent the material from flowing in the opposite direction through the gate(s) or runner(s); (<NUM>) waiting some period of time until the molded polymeric material cools to a temperature sufficient to eject the part, i.e. a temperature below its melt temperature, so that at least outside surfaces of the molded part are sufficiently solid so that the part will maintain its molded shape once ejected; (<NUM>) opening the portions of the mold that define the one or more mold cavities; (<NUM>) ejecting the molded part(s) from the one or more mold cavities; and (<NUM>) closing the two (or more) mold sections (for a subsequent cycle).

<CIT> discloses a constant current power source, resistors and switches turned off and on responding to the conditions of resin in metal molds, constitute a monitoring system. With a metal mold filled with resin, the circuit including the resistor closes, thereby reducing to a <NUM>/<NUM> the current through the resistor. With metal molds are filled with resin, the circuits including the resistors close, reducing to a the current through the resistor. With a controlling unit operating on the current received through the resistor contained in a transfer mold forming machine or externally connected thereto, constant speed potting can be effected lasting until the last metal mold is filled up with resin.

<CIT> discloses injection molding at substantially constant pressure with the use of rapid heating techniques, such as induction heating, at strategic locations within a mold to heat molding surfaces in a manner that mitigates problems typically associated with flow filling challenges.

<CIT>discloses cavities corresponding to the shapes of a plurality of bottomed containers are formed between a stationary mold and a movable mold. In the stationary mold, a sprue, to which the nozzle of an injection molder is connected, is provided. Further, in an injection mold, in which runners extending from the sprue to the cavities, molten resin is poured by advancing the screw of the injection molder and, after that, dwelled for a certain period of time. By measuring the position of the screw after the release of dwelling, the abnormality in molding process is detected.

While the invention is defined in the independent claims, further aspects of the invention are set forth in the dependent claims, the drawings and the following description.

The present disclosure describes a method of detecting at least one non-operational cavity in a multi-cavity mold during an injection molding cycle and automatically adjusting a process parameter of the injection molding cycle to compensate for the at least one non-operational cavity.

The features of the present disclosure which are believed to be novel are set forth with particularity in the appended claims. The present disclosure may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the several figures, in which:.

Embodiments of the present invention generally relate to systems, machines, products, and methods of producing parts by injection molding and, more specifically, to systems, parts, and methods of detecting a non-operational cavity in a multi-cavity mold and automatically adjusting a process parameter to continue producing quality parts despite at least one cavity being non-operational.

As used herein, the phrase "process parameter" generally refers to a parameter of an injection molding apparatus that is at least partially responsible for the quality of a part created using a multi-cavity mold of that injection molding apparatus. For example, the "process parameter" can include, but is not limited to, a nozzle pressure of an injection nozzle of the injection molding apparatus, a position of a reciprocating screw disposed in the injection molding apparatus, a cushion of the molten thermoplastic material, a melt pressure of a molten thermoplastic material being injected into the multi-cavity mold of the injection molding apparatus, an expected travel of the reciprocating screw, a shot size of the thermoplastic material, an end-of-fill transition point such as a screw position set point and a time set point, or any other parameter that could affect the operation of the injection molding apparatus during the cycle or the quality of the product.

As used herein, the term "cavity percent fill" can refer to the percentage of the cavity that is filled on a volumetric basis, or the percentage of the cavity that is filled in relation to weight or mass of the molten material. For example, if a cavity is <NUM>% filled, then the total volume of the mold cavity that is filled is <NUM>% of the total volumetric capacity of the mold cavity. Alternatively, if a cavity is <NUM>% filled, then the total weight of the material in the mold is equal to <NUM>% of the weight specifications of a full part.

As used herein, the term "cushion" refers to a distance from a front of a check ring to an end of a barrel at an end of the injection molding cycle. The cushion is generally based on both the mold volume and the target shot size. For a given mold with constant volume, when the target shot size is increased, the cushion will increase as well. Conversely, when the target shot size is decreased, the cushion will decrease as well.

As used herein, the term "cycle time" is defined as a single iteration of an injection molding process that is required to fully form an injection molded part. Cycle time includes the collective time it takes to perform the steps of advancing molten thermoplastic material into a mold cavity, substantially filling the mold cavity with thermoplastic material, packing and/or holding pressure on the thermoplastic material within the cavity, cooling the thermoplastic material, separating first and second mold sides to expose the cooled thermoplastic material, removing the thermoplastic material, and closing the first and second mold sides.

As used herein, the terms "filled" and "full," when used with respect to a mold cavity including thermoplastic material, are interchangeable and both terms mean that thermoplastic material has reached the maximum volumetric capacity of the mold cavity.

As used herein, the phrase "flow front" refers to a leading edge of a shot of molten polymeric material, as experienced by the surfaces of the mold that define a mold cavity, as the molten polymeric material is progressing from a nozzle or gate of the mold cavity (i.e., a point or points of introduction of the molten polymeric material into the mold cavity) toward, and ultimately to, an end-of-fill location of the mold cavity.

As used herein, the phrase "flow rate" generally refers to the volumetric flow rate of polymer as measured at the injection nozzle. This flow rate can be calculated based on the injection rate, the compressibility of the thermoplastic material, the pressure experienced by thermoplastic material as measured at the injection nozzle, and the cross sectional area of the nozzle, or measured with a suitable sensor located in the injection nozzle.

As used herein, the phrase "melt temperature" generally refers to the temperature of the polymer that is maintained in the injection unit/barrel, and in the material feed system when a hot runner system is used, which keeps the polymer in a molten state. The melt temperature varies by material. However, a desired melt temperature is generally understood to fall within the ranges recommended by the material manufacturer.

As used herein, the term "mold simulator" is defined as a software simulator such as AUTODESK® MOLDFLOW® ADVISER (TRADEMARK) by AUTODESK, INC. , San Rafeal, California, used to simulate or model an injection molding cycle to determine a predicted or expected parameter of the injection molding apparatus during the subsequent actual injection molding cycle performed using the injection molding apparatus. The "mold simulator" may, for example, determine an expected position of the reciprocating screw or an expected location of a flow front of the molten thermoplastic material at fixed intervals of time. The "mold simulator" may also generate a pressure profile according to which an injection molding system might operate to achieve a selected flow front velocity profile. More specifically, the "mold simulator" may produce a model of a mold cavity with contour lines spaced along the length thereof, with the exact spacing depending on the selected profile. The contour lines may, for example, depict a flow front velocity throughout filling of the mold cavity that does not exceed a desired maximum or a flow front velocity that varies throughout filling of the mold cavity based on a custom flow front profile.

As used herein, the term "production version" refers to an injection molded part that is a "quality molded part.

As used herein, the term "quality molded part" refers to a molded part that satisfies one or more predetermined dimensional, performance, and/or aesthetic requirements within a defined tolerance range and is generally free of defects. Such dimensional requirements can include, but are not limited to, part lengths, widths, path lengths or perimeters, thickness, eccentricity, flatness or warp, parallelism, perpendicularity, and/or concentricity. Such performance requirements can include, but are not limited to, surviving and/or absorbing loads, such as tensile loads, compressive loads, torsional loads; exposure to vibration, surviving and/or absorbing electrical loads, and withstanding environmental exposures for a rated period of time. Additional performance requirements may include acoustic properties, such as, resonant frequencies, harmonics, and dampening behavior; and optical performance, such as percent transmission, dispersion, specularity, reflectance, and allowable aberrations. Aesthetic requirements can include, but are not limited to color, texture, surface texture, knit lines, blush, gap trap vestiges, markings, such as burn markings or freedom from undesired markings, and visible sink. Quality parts are also substantially free of defects, including, but not limited to lacking internal voids or containing only internal voids that do not compromise mechanical, electrical, or optical performance, substantially free of mold-in stress or have mold-in stress within a given tolerance, and substantially free of defects resulting from short shot or freeze-f during the molding process. Other requirements or part specification specified by a part customer are also within the contemplation of this definition. For example, the customer may require the molded part to have a given tensile and/or flexural moduli, impact resistance, hardness, chemical resistance and/or compatibility, abrasion resistance, thermal conductivity and/or resistivity, electrical conductivity and/or resistivity, reflectivity, specularity, clarity, percent transmission, index of refraction, and/or coefficient of friction.

As used herein, the term "shot size" generally refers to the volume of polymer to be injected from the injection unit/barrel to completely fill the mold cavity or cavities. The shot size is determined based on the temperature and pressure of the polymer in the injection unit/barrel just prior to injection. In other words, the shot size is a total volume of molten plastic material that is injected in a stroke of an injection molding screw or ram at a given temperature and pressure. Shot size may include injecting molten plastic material into one or more injection cavities through one or more gates. The shot of molten plastic material may also be prepared and injected by one or more injection units/barrels.

Referring to the figures in detail, <FIG> illustrates an exemplary injection molding apparatus <NUM> that generally includes an injection system <NUM> and a clamping system <NUM>. A thermoplastic material may be introduced to the injection system <NUM> in the form of thermoplastic pellets <NUM>. The thermoplastic pellets <NUM> may be placed into a hopper <NUM>, which feeds the thermoplastic pellets <NUM> into a heated barrel <NUM> of the injection system <NUM>. The thermoplastic pellets <NUM>, after being fed into the heated barrel <NUM>, may be driven to the end of the heated barrel <NUM> by a reciprocating screw <NUM>. The heating of the heated barrel <NUM> and the compression of the thermoplastic pellets <NUM> by the reciprocating screw <NUM> causes the thermoplastic pellets <NUM> to melt, forming a molten thermoplastic material <NUM>.

The reciprocating screw <NUM> forces the molten thermoplastic material <NUM> toward a nozzle <NUM> to form a shot of thermoplastic material, which will be injected into a mold cavity <NUM> of a mold <NUM> via one or more gates <NUM>, preferably three or less gates, that direct the flow of the molten thermoplastic material <NUM> to the mold cavity <NUM>. In other embodiments the nozzle <NUM> may be separated from one or more gates <NUM> by a feed system (not shown). The mold cavity <NUM> is formed between a first mold side <NUM> and a second mold side <NUM> of the mold <NUM> and the first and second mold sides <NUM>, <NUM> are held together under pressure by a press or clamping unit <NUM>. The press or clamping unit <NUM> applies a clamping force during the molding process that is greater than the force exerted by the injection pressure acting to separate the two mold halves <NUM>, <NUM>, thereby holding the first and second mold sides <NUM>, <NUM> together while the molten thermoplastic material <NUM> is injected into the mold cavity <NUM>. To support these clamping forces, the clamping system <NUM> may include a mold frame and a mold base.

Once the shot of molten thermoplastic material <NUM> is injected into the mold cavity <NUM>, the reciprocating screw <NUM> stops traveling forward. The molten thermoplastic material <NUM> takes the form of the mold cavity <NUM> as the material fills the mold cavity <NUM>. The molten thermoplastic material <NUM> cools inside the mold cavity <NUM> until the thermoplastic material <NUM> solidifies. Once the thermoplastic material <NUM> has solidified, the press <NUM> releases the first and second mold sides <NUM>, <NUM>, the first and second mold sides <NUM>, <NUM> are separated from one another, and the finished part may be ejected from the mold <NUM>. The mold <NUM> may include a plurality of mold cavities <NUM> (e.g., eight, sixteen, <NUM>, <NUM>, <NUM> mold cavities) to increase overall production rates. For ease of reference, a mold <NUM> having a plurality of mold cavities <NUM> may be referred to as a "multi-cavity mold. " The shapes of the cavities of the plurality of mold cavities <NUM> may be identical, similar or different from each other. (The latter may be considered a family of mold cavities <NUM>).

A controller <NUM> is communicatively connected with a sensor <NUM>, located in the vicinity of the nozzle <NUM>, and a screw control <NUM>. The controller <NUM> may include a microprocessor, a memory having at least one database stored thereon, and one or more communication links. The sensor <NUM> may provide an indication of when the thermoplastic material is approaching the end of fill in the mold cavity <NUM>. The sensor <NUM> may sense the presence of thermoplastic material optically, acoustically, pneumatically, mechanically, electro-mechanically, or by otherwise sensing pressure and/or temperature of the thermoplastic material. When pressure or temperature of the thermoplastic material is measured by the sensor <NUM>, this sensor <NUM> may send a signal indicative of the pressure or the temperature to the controller <NUM> to provide a target pressure for the controller <NUM> to maintain in the mold cavity <NUM> (or in the nozzle <NUM>) as the fill is completed. This signal may generally be used to control the molding process, such that variations in material viscosity, mold temperatures, melt temperatures, and other variations influencing filling rate, are adjusted by the controller <NUM>. These adjustments may be made immediately during the molding cycle, or corrections can be made in subsequent cycles. Furthermore, several signals may be used in calculations over a number of cycles and then used by the controller <NUM> to calculate adjustments to the molding cycle. The controller <NUM> may be connected to the sensor <NUM> and the screw control <NUM> via wired connections <NUM>, <NUM>, respectively. In other embodiments, the controller <NUM> may be connected to the sensors <NUM> and screw control <NUM> via a wireless connection, a mechanical connection, a hydraulic connection, a pneumatic connection, or any other type of communication connection known to those having ordinary skill in the art that will allow the controller <NUM> to communicate with the sensors <NUM> and the screw control <NUM>.

In the embodiment of <FIG>, the sensor <NUM> is a pressure sensor that measures (directly or indirectly) melt pressure of the molten thermoplastic material <NUM> in vicinity of the nozzle <NUM>. The sensor <NUM> generates an electrical signal that is transmitted to the controller <NUM>. The controller <NUM> then commands the screw control <NUM> to advance the screw <NUM> at a rate that maintains a desired melt pressure of the molten thermoplastic material <NUM> in the nozzle <NUM>. While the sensor <NUM> may directly measure the melt pressure, the sensor <NUM> may also indirectly measure the melt pressure by measuring other characteristics of the molten thermoplastic material <NUM>, such as temperature, viscosity, flow rate, etc., which are indicative of melt pressure. Likewise, the sensor <NUM> need not be located directly in the nozzle <NUM>, but rather the sensor <NUM> may be located at any location within the injection system <NUM> or mold <NUM> that is fluidly connected with the nozzle <NUM>. As an example, the sensor <NUM> may be located in the barrel <NUM> to measure the position of the reciprocating screw <NUM>, the travel of the reciprocating screw <NUM>, the cushion, or another process parameter. If the sensor <NUM> is not located within the nozzle <NUM>, appropriate correction factors may be applied to the measured characteristic to calculate an estimate of the melt pressure in the nozzle <NUM>. The sensor <NUM> need not be in direct contact with the injected fluid and may alternatively be in dynamic communication with the fluid and able to sense the pressure of the fluid and/or other fluid characteristics. In yet other embodiments, the sensor <NUM> need not be disposed at a location that is fluidly connected with the nozzle. Rather, the sensor <NUM> could measure clamping force generated by the clamping system <NUM> at a mold parting line between the first and second mold parts <NUM>, <NUM>. In one aspect, the controller <NUM> may maintain the pressure according to the input from sensor <NUM>. Alternatively, the sensor <NUM> could measure an electrical power demand by an electric press, which may be used to calculate an estimate of the pressure in the nozzle.

In an injection molding system, the location of the flow front of the molten polymeric material can be detected at desired locations within the mold cavity <NUM>. As described above, the fact that the flow front has reached a particular location in the mold cavity <NUM> may be detected by a sensor <NUM>. For instance, the sensor <NUM> may take the form of a pressure transducer and may use vacuum pressure. One or more temperature sensors, such as thermal resistors, could be used instead of or in addition to a pressure sensor to determine or verify that the flow front has reached a given location of a mold cavity <NUM>. Such a sensor <NUM> may operate by either sensing temperature or pressure, or by sensing a lack thereof. For instance, the sensor could sense a flow of air, and upon interruption, the sensor <NUM> may detect that interruption and communicate to the controller <NUM> that the air flow has been interrupted. Alternatively, or additionally, the location of the flow front may be determined based on time, screw position (e.g., monitored using a potentiometer), hydraulic pressure, the velocity of the flow front, or some other process characteristic. As an example, the location of the flow front can be determined by monitoring the screw position, which when analyzed over time, can be used to calculate the volume of thermoplastic material in the mold <NUM>. As illustrated in <FIG>, the pressure injection molding apparatus <NUM> further includes a check ring <NUM> coupled (e.g., attached) to a portion of the reciprocating screw <NUM> within the barrel <NUM>. In the example illustrated in <FIG>, the check ring <NUM> is coupled to the reciprocating screw <NUM> at a position proximate to an end <NUM> of the reciprocating screw <NUM>. The check ring <NUM> is generally configured to prevent, or at least limit, a backflow of the molten thermoplastic material <NUM>, i.e., the molten thermoplastic material <NUM> from flowing in a direction from the nozzle <NUM> toward the hopper <NUM>. As an example, the check ring <NUM> may be configured to allow a backflow of to less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, or less than <NUM>% of the target shot size for the molten thermoplastic material <NUM>.

During operation of the pressure injection molding apparatus <NUM>, it is possible that one or more cavities <NUM> in a multi-cavity mold <NUM> may become non-operational (e.g., blocked). For example, the molten thermoplastic material <NUM> entering the multi-cavity mold <NUM> may cool quicker than expected and solidify before the entire cavity is filled with the molten thermoplastic material <NUM>. As a result, the molten thermoplastic material <NUM> may cool and solidify in the gate of one of the cavities <NUM> or in an area within one of the cavities <NUM> proximate the gate, thereby blocking that cavity <NUM>. However, some conventional multi-cavity molds <NUM> do not include a feedback mechanism that is disposed within the non-operational cavity <NUM> and indicates that the cavity <NUM> is non-operational. For this reason, some conventional multi-cavity molds <NUM> do have such a feedback mechanism, in the form of a sensor disposed in each cavity <NUM> of the multi-cavity mold <NUM>. However, disposing a sensor in each cavity <NUM> of the multi-cavity mold <NUM> is quite costly to install, maintain, and repair.

In any event, when the controller <NUM> of the injection system <NUM> lacks any indication that one or more of the cavities <NUM> is non-operational, the reciprocating screw <NUM> of the injection system <NUM> continues to inject the same amount of molten thermoplastic material <NUM> into each cavity <NUM> of the multi-cavity mold <NUM>, even though one or more of these cavities <NUM> is non-operational. Consequently, the reciprocating screw <NUM> continues to advance toward the forward most position of the reciprocating screw <NUM> thereby injecting, or attempting to inject, the material into the remaining operational cavities <NUM>. This can, in turn, lead to an excess amount of material being injected into one or more of the operational cavities <NUM>, thereby resulting in flashing to one or more parts produced by the multi-cavity mold <NUM>. The present disclosure aims to prevent this problem by detecting when one or more cavities <NUM> are non-operational without the use of sensors disposed in each of the cavities <NUM> or without the use of sensors disposed in any of the cavities <NUM> in the multi-cavity mold <NUM>, and automatically adjusting a process parameter of the injection system <NUM> to compensate for the non-operational cavity, thereby maintaining the quality of the products and limiting downtime for repairs.

<FIG> illustrates an example of a method <NUM> respectively, of detecting and compensating for one or more non-operational mold cavities in the injection molding apparatus <NUM>. The method <NUM> generally includes the steps of: (<NUM>) injecting, via the reciprocating screw <NUM>, the molten thermoplastic material into the mold cavities <NUM> (block <NUM>), (<NUM>) measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting (block <NUM>), (<NUM>) based on the first process parameter, determining whether one or more mold cavities <NUM> are non-operational (block <NUM>), and (<NUM>) when it is determined that one or more mold cavities are non-operational, automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus <NUM> (block <NUM>).

In some examples, the method <NUM> includes determining (e.g., calculating, recording), using the controller <NUM>, or another computing device, one or more expected (or desired) process parameters at one or more pre-determined times during the injecting. The expected process parameters are generally determined based on the specifications of the part to be produced, such as, for example, the type of thermoplastic material from which the part is to be made, the overall dimensions of the product (e.g., height, width, length, radius, diameter, etc.), the amount of parts to be made (i.e., the amount of cavities in the multi-cavity mold), the specifications of the injection molding apparatus <NUM>, one or more previous injection cycles performed using the injection molding apparatus <NUM> (or another injection molding apparatus) to produce quality molded parts, simulated injection cycles performed using a mold simulator, or combinations thereof. For example, the controller <NUM> may determine the expected (or desired) melt pressure of the molten thermoplastic material <NUM> in the nozzle <NUM> during the injecting. As another example, the controller <NUM> may determine the expected (or desired) position of the reciprocating screw <NUM> prior to the beginning of the injecting and at another point in time during or after the injecting. As yet another example, the controller <NUM> may determine the expected cushion (i.e., the amount of molten thermoplastic material <NUM> that should be disposed between the check ring <NUM> and an end of the barrel <NUM> at the end of the injecting). The process parameter may also be an end-of-fill transition point, such as a screw position set point or a time set point. For example, adjusting the process parameter can involve adjusting the end-of-fill transition point from a first pressure to a second pressure. The second pressure being lower than the first pressure.

Once the expected process parameters are determined, the expected process parameters may be stored in an expected parameters database stored in the memory of the controller <NUM> (or another computing device), to be later accessed by the controller <NUM>. In some cases, it may be beneficial to populate the expected parameters database with a plurality of different expected process parameters and/or a plurality of expected values for one or more process parameters. For example, the expected parameters database may be populated with a plurality of expected cushion values. Doing so may provide an operator, programmer, or the controller <NUM> with a range of acceptable or expected parameters for various process parameters. In some cases, the controller <NUM> may associate a timestamp with each expected parameter.

During the injecting, which may, for example, be performed based on substantially constant low pressure, the molten thermoplastic material <NUM> is injected into the cavities <NUM>, one or more of which may be non-operational. During or after the injecting, the controller <NUM> measures a plurality of process parameters of the injection molding apparatus <NUM> at the one or more pre-determined times, which in some cases will correspond to the pre-determined times associated with the expected process parameters stored in the expected parameter database. The controller <NUM> measures the plurality of process parameters using the sensor <NUM> and any other sensors employed in the injection molding apparatus <NUM>. The controller <NUM> can, for example, measure the actual position of the reciprocating screw <NUM> at one or more pre-determined times during or after the injecting (e.g., at each timestamp that the controller <NUM> determined the expected position of the reciprocating screw <NUM>). The controller <NUM> can measure the actual cushion <NUM> of the molten thermoplastic material <NUM> at one or more pre-determined times during or after the injecting (e.g., at each timestamp that the controller <NUM> determined the expected cushion <NUM> of the molten thermoplastic material <NUM>). The controller <NUM> can likewise measure the actual melt pressure of the molten thermoplastic material <NUM> toward the nozzle <NUM> at one or more pre-determined times during or after the injecting (e.g., at each timestamp that the controller <NUM> determined the expected melt pressure of the molten thermoplastic material <NUM>. Finally, the controller <NUM> can measure the actual travel of the reciprocating screw <NUM> at one or more pre-determined times during or after the injecting (e.g., at each timestamp that the controller <NUM> determined the expected travel of the reciprocating screw <NUM>).

Unlike conventional injection molding processes, which, as discussed above, may not include a feedback system or have a feedback system that is malfunctioning, the injection molding apparatus <NUM> of the present disclosure may determine whether one or more cavities <NUM> in the plurality of cavities <NUM> are non-operational without the use of any sensors disposed in the cavities <NUM>. More particularly, the controller <NUM> (or another computing device) determines whether one or more cavities <NUM> are non-operational based on the measured process parameters. In some cases, this determination may be based solely on the measured process parameters. As an example, this determination may be made by comparing one of the measured process parameters at several different points in time during the injecting, whereby a deviation in the values between the measured process parameters may be indicative of one or more cavities <NUM> being non-operational. As an example, during the injecting, the melt pressure of the molten thermoplastic material <NUM> should be steady or consistent throughout the injecting; thus, fluctuations in the melt pressure values at various pre-determined times during the injecting may indicate that at least one cavity <NUM> is non-operational. In other cases, this determination may be based on a comparison between one or more expected parameters stored in the expected parameter database to one or more corresponding actual process parameters measured by the controller <NUM>. In particular, the controller <NUM> compares the one or more expected parameters to the one or more corresponding actual parameters measured, and based on that comparison, determines whether there exists a difference, between the expected parameter(s) and the corresponding actual parameter(s). In some cases, a difference of any amount will indicate that one or more cavities <NUM> are non-operational. As an example, when the actual cushion <NUM> is greater than the expected cushion <NUM>, the controller <NUM> determines that one or more cavities <NUM> are non-operational. Notably, when the actual cushion <NUM> is greater than the expected cushion <NUM>, the difference between the two may be indicative of how many cavities <NUM> are non-operational. In other cases, the controller <NUM> may compare the difference to a threshold difference; when the difference exceeds the threshold difference, the controller <NUM> determines that one or more cavities <NUM> are non-operational, whereas when the difference is less than the threshold difference, the controller <NUM> determines that all of the cavities <NUM> are operational.

When the controller <NUM> determines that one or more of the cavities <NUM> are non-operational, the controller <NUM> (or another computing device) automatically adjusts one or more process parameters (e.g., the melt pressure of the molten thermoplastic material <NUM>) of the injection molding apparatus <NUM> to compensate for the non-operational cavity(ies) <NUM> without slowing down production or sacrificing quality of the molded part. The controller <NUM> may, in some cases, automatically adjust the same parameter(s) used to determine that the one or more of the cavities <NUM> are non-operational in the first place. In other cases, however, the controller <NUM> may automatically adjust one or more different parameters than the parameters used to determine that the one or more of the cavities <NUM> are non-operational.

<FIG> illustrate examples of how the injection molding apparatus <NUM> described above can be used to determine whether one or more cavities <NUM> are non-operational and, in response to the detecting, to adjust a process parameter to compensate for at least one non-operational cavity. <FIG> illustrate an actual position of the reciprocating screw <NUM> and an expected position of the reciprocating screw <NUM>, respectively. <FIG> illustrate an actual cushion <NUM> of the molten thermoplastic material <NUM> and an expected cushion <NUM> of the molten thermoplastic material <NUM>, respectively.

<FIG> illustrates an example actual parameter in the form of an actual position of the reciprocating screw <NUM> at a pre-determined time during the injecting. In other words, the reciprocating screw <NUM> is actually in the location illustrated in <FIG> at this pre-determined time during the injecting. In turn, the controller <NUM> compares the actual position of the reciprocating screw <NUM> to the expected position of the reciprocating screw <NUM> at the same pre-determined time during the injecting, which is illustrated in <FIG>. As evidenced by <FIG>, the expected position of the reciprocating screw <NUM> is different from the actual position of the reciprocating screw <NUM> illustrated in <FIG>. In fact, the actual position of the reciprocating screw <NUM> is further from the end of the barrel <NUM> than expected. Accordingly, the controller <NUM> may determine that one or more cavities <NUM> is non-operational and may respond by adjusting a process parameter of the plurality of process parameters to compensate for the non-operational cavity(ies). The controller <NUM> may use a machine learning algorithm to, based on the process parameter to be adjusted, adjust operation of the injection molding apparatus to compensate for the non-operational cavity(ies).

<FIG> illustrates an example actual cushion <NUM> of the molten thermoplastic material <NUM>, which is measured by the distance from a front end <NUM> of the reciprocating screw <NUM> to an end <NUM> of the barrel <NUM> of the injection molding apparatus <NUM>, at a pre-determined time during the injecting. The cushion <NUM> of the molten thermoplastic material <NUM> is expected to have the particular length illustrated in <FIG> at this pre-determined time during the injecting. In turn, the controller <NUM> compares the actual cushion <NUM> of the molten thermoplastic material <NUM> to the expected cushion <NUM> of the molten thermoplastic material <NUM> during the injecting, which is illustrated in <FIG>. As evidenced by <FIG>, the actual cushion <NUM> of the molten thermoplastic material <NUM> is different from the expected cushion <NUM> of the molten thermoplastic material <NUM> illustrated in <FIG>. In fact, the actual cushion <NUM> of the molten thermoplastic material <NUM> is greater than expected. Accordingly, the controller <NUM> may determine that one or more cavities <NUM> is non-operational and may respond by adjusting a process parameter of the plurality of process parameters to compensate for the non-operational cavity(ies). The controller <NUM> may use a machine learning algorithm to, based on the process parameter to be adjusted, adjust operation of the injection molding apparatus to compensate for the non-operational cavity(ies).

It will be appreciated from the foregoing that in spite of the fact that at least one cavity <NUM> of the multi-cavity mold <NUM> may be or become non-operational, the injection molding apparatus <NUM> described herein can continue to perform the current injection molding cycle and subsequent injection molding cycles as part of the same injection molding run, all while continuing to make or yield production versions of the same injection molded part in the remaining operational cavities <NUM>.

Claim 1:
A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus (<NUM>) having a plurality of mold cavities and an injection molding screw (<NUM>) or ram, the method comprising:
injecting, via the injection molding screw (<NUM>) or ram, a molten thermoplastic material into the plurality of mold cavities (<NUM>);
measuring a first process parameter of the injection molding apparatus (<NUM>) at a pre-determined time during or after the injecting;
based on the first process parameter, determining whether one or more mold cavities of the plurality of mold cavities (<NUM>) are non-operational; and
when it is determined that one or more mold cavities (<NUM>) are non-operational, automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus (<NUM>);
wherein measuring the first process parameter comprises measuring a nozzle pressure of an injection nozzle (<NUM>) of the injection molding apparatus (<NUM>) via a sensor disposed in the injection molding apparatus (<NUM>);
characterized by comparing the measured nozzle pressure to an expected nozzle pressure corresponding to all of the plurality of mold cavities (<NUM>); and
when a difference between the measured nozzle pressure and the expected nozzle pressure is greater than a predetermined threshold, generating a signal indicative of at least one mold cavity of the plurality of mold cavities (<NUM>) being non-operational.