Injection molding machines and methods for accounting for changes in material properties during injection molding runs

1. A method of automatically adjusting an injection molding process to compensate for variations in the flowability of a molten plastic material, the method comprising:

providing an injection molding machine with at least one mold cavity;

providing an injection molding controller, which includes a pressure control output that is configured to generate a control signal, which, at least partially determines an injection molding pressure for the injection molding process of the injection molding machine;

measuring a first control signal generated from the pressure control output at a first time in an injection molding cycle;

measuring a second control signal generated from the pressure control output at a second time in the same injection molding cycle, subsequent to the first time;

comparing the first control signal generated from the pressure control output and the second control signal generated from the pressure control output to obtain a comparison result; and

determining a third control signal for the pressure control output, based at least in part on the comparison result, at a third time that is subsequent to the second time.

2. The method of claim 1 , wherein the determining includes determining the third control signal at a third time, which is within the same injection molding cycle as the second time.

3. The method of claim 1 , wherein the third time is located in a subsequent molding cycle from the second time.

4. The method of claim 1 , including:

determining a time difference between the first time and the second time; and

wherein the comparing includes comparing the first control signal and the second control signal, based, at least in part, on the time difference, to obtain the comparison result.

5. The method of claim 4 , wherein the comparison result is a flow factor (FF) that is used as a soft sensor melt viscosity input to by the controller.

6. The method of claim 5 , wherein the FF is determined by the formula:

FF=(CS1−CS2)/ T;

where CS1 is the first control signal;

CS2 is the second control signal; and

T is the time difference between CS1 and CS2.

7. The method of claim 6 , wherein the third control signal is proportional to the flow factor.

8. The method of claim 6 , wherein T is between 0.1 milliseconds and 10 milliseconds.

9. The method of claim 6 , wherein T is about 1 millisecond.

10. The method of claim 1 , wherein the comparison result is used as a basis for a viscosity change index (VCI) that is used as a soft sensor melt viscosity input to by the controller.

11. The method of claim 10 , wherein the VCI is determined by the following formula:

VCI=(CS1−CS2)/ S

where CS1 is a first control signal;

CS2 is a second control signal; and

S is the position difference for the a melt moving machine component.

12. The method of claim 11 , wherein the third control signal is proportional to the VCI.

13. The method of claim 11 , wherein S is between 0.5 microns and 10 microns.

14. The method of claim 11 , wherein S is about 1 micron.

15. The method of claim 11 , wherein the first control signal and the second control signal are measured before the molten plastic material fills more than 90% of a mold cavity.

16. The method of claim 1 , wherein the comparing of the first control signal and the second control signal includes comparing the first control signal and the second control signal to optimal control signals based on an optimal pressure curve.

17. The method of claim 1 , wherein the providing of the injection molding machine includes providing a melt moving machine component; and further comprising:

measuring a first position of the melt moving machine component at the first time;

measuring a second position of the melt moving machine component at the second time;

determining a position difference between the first position and the second position; and

wherein the comparing includes comparing the first control signal and the second control signal, based, at least in part, on the position difference, to obtain the comparison result.

18. The method of claim 1 , further comprising controlling the injection molding pressure by sending the third control signal to a melt pressure control device.

19. A controller configured to automatically adjust an injection molding process to compensate for variations in the flowability of a molten plastic material, the controller adapted to:

measure a first control signal generated from a pressure control output of the controller at a first time in an injection molding cycle using a control signal measurement device;

measure a second control signal generated from the pressure control output of the controller at a second time in the same injection molding cycle, subsequent to the first time using the control signal measurement device;

compare the first control signal generated from the pressure control output of the controller and the second control signal generated from the pressure control output of the controller to obtain a comparison result; and

determine a third control signal for the pressure control output, based at least in part on the comparison result, at a third time that is subsequent to the second time.

20. The controller of claim 19 , wherein the controller is adapted to be used with an injection molding machine.