Apparatus and method for detecting a position of an actuator piston

1. A method of determining a position of an actuator piston driving a valve pin in an injection molding apparatus, the apparatus including an actuator comprising:

an actuator housing having a body portion, surrounding an axial bore, of a substantially non-magnetic and/or magnetically permeable material,

the piston, movable within the axial bore, for driving the valve pin,

a magnetic member, embedded in the piston, having a north N pole end and a south S pole end defining a N-S axis and generating a magnetic field such that axial movement of the piston in the bore modifies the magnetic field according to the axial position of the piston relative to a detection position,

a magnetic field detector comprising a hall effect sensor circuit mounted at the detection position on an exterior surface of the substantially non-magnetic and/or magnetically permeable body portion, wherein the sensor circuit detects the axial position of the piston relative to the detection position on the body portion by detecting the magnetic field of the magnetic member as modified by axial movement of the piston in the bore and generates a changing output signal that is unique to each axial position of the piston in the bore based on the detected modified magnetic field,

wherein the magnetic member's N-S axis is disposed transverse to the direction of axial movement of the piston in the bore and the sensor circuit is disposed at the detection position adjacent either the north N pole end or the south S pole end of the magnetic member, and

a drive mechanism for axially driving the piston in the bore,

the method comprising:

detecting a change in degree or quality of the magnetic field of the magnetic member with the hall effect sensor circuit upon axial movement of the piston in the bore,

determining the axial position of the piston in the bore according to the detected change in the degree or quality of the magnetic field, and

using the determined axial position of the piston to instruct the drive mechanism to drive the piston in a predetermined manner during the course of an injection cycle.

2. The method of claim 1 , including:

instructing the drive mechanism to drive the piston in the bore such that the piston travels upstream from a gate closed position to an intermediate upstream position at a first travel velocity and such that the piston further travels upstream from the intermediate position to a predetermined upstream position at a second travel velocity that is higher than the first travel velocity.

3. The method of claim 1 , including:

using the determined axial position of the piston to control movement of the valve pin along a predetermined path of withdrawal from a gate of a mold at one or more predetermined drive rates or one or more predetermined velocities of withdrawal.

4. The method of claim 1 , using the determined axial position of the piston in a closed loop control application.

5. The method of claim 1 , using the determined axial position of the piston in an open loop monitoring application.

6. The method of claim 1 , using the detected change to generate a control signal to the drive mechanism to control the piston position in the bore and receiving user input from a user interface for adjusting the control signal to control the piston position in the bore.

7. The method of claim 1 , using the detected change for continuous monitoring of a valve pin position.

8. The method of claim 1 , wherein the valve pin is driven by the piston to multiple positions with respect to a mold gate.

9. The method of claim 1 , wherein the valve pin is positionable between open and closed positions with respect to a mold gate.

10. The method of claim 1 , displaying for viewing on a user interface an indication of a valve pin position.

11. The method of claim 10 , wherein the displaying comprises displaying via one or more of: lights, LEDs, a graph of pin position versus time, and an indicator of pin open and pin closed.

12. The method of claim 1 , wherein the body portion is non-magnetic.

13. The method of claim 1 , wherein the magnetic member is a permanent magnet that produces its own persistent magnetic field.

14. The method of claim 1 , wherein the magnetic field comprises a vector field wherein a higher density of nearby field lines indicates a stronger magnetic field, and the magnetic field points towards the south pole S and away from the north pole N.

15. The method of claim 1 , wherein the magnetic member comprises a ferromagnetic material.

16. An apparatus for determining a position of an actuator piston driving a valve pin in an injection molding apparatus, the apparatus including an actuator comprising:

an actuator housing having a body portion, surrounding an axial bore, of a substantially non-magnetic and/or magnetically permeable material,

a piston, movable within the axial bore, for driving a valve pin,

a magnetic member, embedded in the piston, having a north N pole end and a south S pole end defining a N-S axis and generating a magnetic field such that axial movement of the piston in the bore modifies the magnetic field according to the axial position of the piston relative to a detection position,

a magnetic field detector comprising a hall effect sensor circuit mounted at the detection position on an exterior surface of the substantially non-magnetic and/or magnetically permeable body portion, wherein the sensor circuit detects the axial position of the piston relative to the detection position on the body portion by detecting a change in degree or quality of the magnetic field of the magnetic member as modified by axial movement of the piston in the bore and generates a changing output signal that is unique to each axial position of the piston in the bore based on the detected change in the degree or quality of the magnetic field,

wherein the magnetic member's N-S axis is disposed transverse to the direction of axial movement of the piston in the bore and the sensor circuit is disposed at the detection position adjacent either the north N pole end or the south S pole end of the magnetic member, and

an electronic controller processing the changing output signal of the sensor circuit to generate a control signal to drive the piston in a predetermined manner during the course of an injection cycle.

17. The apparatus of claim 16 , wherein the electronic controller generates the control signal to drive the piston in the bore such that the piston travels upstream from a gate closed position to an intermediate upstream position at a first travel velocity and such that the piston further travels upstream from the intermediate position to a predetermined upstream position at a second travel velocity that is higher than the first travel velocity.

18. The apparatus of claim 16 , wherein the electronic controller generates the control signal to control movement of the valve pin along a predetermined path of withdrawal from a gate of a mold at one or more predetermined drive rates or one or more predetermined velocities of withdrawal.

19. A method of determining a position of an actuator piston driving a valve pin in an injection molding apparatus, the apparatus including an actuator comprising:

an actuator housing having a body portion, surrounding an axial bore, of a substantially non-magnetic and/or magnetically permeable material,

the piston, movable within the axial bore, for driving the valve pin,

a magnetic member, embedded in the piston, having a north N pole end and a south S pole end defining a N-S axis and generating a magnetic field such that axial movement of the piston in the bore modifies the magnetic field according to the axial position of the piston relative to a detection position,

a magnetic field detector comprising a hall effect sensor circuit mounted at the detection position on an exterior surface of the substantially non-magnetic and/or magnetically permeable body portion, wherein the sensor circuit detects the axial position of the piston relative to the detection position on the body portion by detecting the magnetic field of the magnetic member as modified by axial movement of the piston in the bore and generates a changing output signal that is unique to each axial position of the piston in the bore based on the detected modified magnetic field,

wherein the magnetic member's N-S axis is disposed transverse to the direction of axial movement of the piston in the bore and the sensor circuit is disposed at the detection position adjacent either the north N pole end or the south S pole end of the magnetic member, and

a drive mechanism for axially driving the piston in the bore,

the method comprising:

detecting a change in degree or quality of the magnetic field of the magnetic member with the hall effect sensor circuit upon axial movement of the piston in the bore,

determining the axial position of the piston in the bore according to the detected change in the degree or quality of the magnetic field, and

instructing the drive mechanism to drive the piston in the bore such that the piston travels upstream from a gate closed position to an intermediate upstream position at a first travel velocity and such that the piston further travels upstream from the intermediate position to a predetermined upstream position at a second travel velocity that is higher than the first travel velocity.