CPC B29C 44/3446 (2013.01) [B29C 45/77 (2013.01); B29C 44/348 (2013.01); B29C 45/78 (2013.01); B29C 2945/76006 (2013.01); B29C 2945/7604 (2013.01); B29C 2945/76257 (2013.01); B29C 2945/76381 (2013.01); B29K 2105/04 (2013.01)] | 11 Claims |
1. An automated method for injection molding using an automated injection device that comprises a heating device, a temperature sensor, a screw, a barrel coupled to a nozzle, a pressure sensor, a closed-pressure sensing loop, a flow-rate control valve and a controller connected to the heating device, the temperature sensor, the pressure sensor, and the flow-rate control valve, the method comprising: continuously monitoring, by the controller, both a temperature and a pressure of a polymeric material in the barrel using signals received from the temperature sensor and the pressure sensor; implementing, by the controller, a condition indicator that dynamically adjusts multiple parameters based on real-time feedback, wherein the automated method performs the following: automatically adjusting, by the controller, and in response to a first temperature signal from the temperature sensor that is higher than a desired temperature, operation of the heating device to thereby decrease a temperature of a polymeric material in the barrel; automatically adjusting, by the controller, and in response to a second temperature signal from the temperature sensor that is lower than the desired temperature, operation of the screw to delay injection of the polymeric material to thereby increase the temperature of the polymeric material in the barrel; automatically adjusting, by the controller, a flow rate of the polymeric material through the nozzle using the closed-pressure sensing loop in response to real-time data from the pressure sensor to ensure consistent injection flow; determining, by the controller, that the polymeric material has reached the desired temperature as determined from a third temperature signal received from the temperature sensor, and generating a control signal to synchronize the injection process with the desired flow rate and temperature profile; and injecting the polymeric material at the desired temperature and optimal flow rate as determined by the controller from the injection device into a mold.
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