Method of injection molding using one or more strain gauges as a virtual sensor

1. A method of injection molding, comprising:

measuring, using at least one strain gauge sensor provided on an exterior of a mold surface, a change in strain in a mold side of a mold cavity under both a closing force exerted by a clamping unit and an opening force exerted by thermoplastic molten material as it is injected into the mold cavity;

approximating, by a controller, a pressure within the mold cavity based on the change in strain;

comparing, by the controller, the approximated pressure to a pre-set trigger point, wherein the pre-set trigger point occurs when the change in strain is a relaxing tensile strain;

determining, by the controller, that the approximated pressure equals or exceeds the pre-set trigger point;

in response to the determining, via the controller, that the approximated pressure equals or exceeds the pre-set trigger point, activating, by the controller, a virtual cavity sensor having an optimal pre-defined pressure-time curve, wherein upon activation, the virtual cavity sensor tracks approximated pressures calculated from the change in strain measurements measured by the at least one strain gauge sensor over time and compares the results of the approximated pressure tracking to the optimal pre-defined pressure-time curve.

2. The method of claim 1 , further comprising:

determining, by the virtual cavity sensory, that the comparison of the results of the approximated pressure tracking to the optimal pre-defined pressure-time curve indicates that the optimal pre-defined pressure-time curve is not being followed; and

adjusting, by the controller, an injection molding process executed by an injection molding system.

3. The method of claim 2 , wherein adjusting an injection molding process comprises causing, by the controller, the injection molding system to inject additional molten thermoplastic material.

4. The method of claim 2 , wherein adjusting an injection molding process comprises causing, by the controller, the injection molding system to increase the rate of extrusion of molten thermoplastic material.

5. The method of claim 2 , wherein adjusting an injection molding process comprises causing, by the controller, the injection molding system to decrease the rate of injection of molten thermoplastic material.

6. The method of claim 2 , wherein adjusting an injection molding process comprises causing, by the controller, the injection molding system to increase a pressure at injection of molten thermoplastic material.

7. The method of claim 2 , wherein adjusting an injection molding process comprises causing, by the controller, the injection molding system to decrease a pressure at injection of molten thermoplastic material.

8. The method of claim 1 , wherein upon activation, the virtual cavity sensor determines the viscosity of molten thermoplastic material being injected into the mold cavity.

9. The method of claim 1 , where upon activation, the virtual cavity sensor determines the percentage of the mold cavity that has been filled with molten thermoplastic material.

10. The method of claim 1 , comprising:

measuring, using at least one traditional cavity sensor, a change in mold cavity pressure in the mold cavity.

11. The method of claim 1 , comprising:

measuring, using a plurality of strain gauge sensors, a change in strain in a plurality of mold sides of a plurality of mold cavities; and

wherein upon activation, the virtual cavity sensor determines the percentage of mold cavity that has been filled with molten thermoplastic material for each of the plurality of mold cavities.

12. The method of claim 11 , comprising:

measuring, using at least one traditional cavity sensor, a mold cavity pressure in each of the plurality of mold cavities.

13. The method of claim 12 , comprising:

ensuring through use of the at least one strain gauge sensor that none of the mold cavity pressures measured by the at least one traditional cavity sensor exceed a maximum mold cavity pressure.

14. The method of claim 1 , comprising:

approximating, by the controller, a pressure at a melt flow front based on the change in strain.

15. A method of injection molding, comprising:

providing a first strain gauge sensor on an exterior surface of a first mold side of a mold cavity near a parting line between the first mold side and a second mold side of the mold cavity;

providing a second strain gauge sensor on an exterior surface of the second mold side;

measuring, using the first strain gauge sensor and the second strain gauge sensor, a change in strain in the first mold side and the second mold side of a mold cavity under both a closing force exerted by a clamping unit and an opening force exerted by thermoplastic molten material as it is injected into the mold cavity;

approximating, by a controller, a pressure within the mold cavity based on the change in strain in the first mold side and the second mold side;

comparing, by the controller, the approximated pressure to a pre-set trigger point, wherein the pre-set trigger point occurs when the change in strain is a relaxing tensile strain;

determining, by the controller that the approximated pressure equals or exceeds the pre-set trigger point; and

in response to the determining, via the controller, that the approximated pressure equals or exceeds the pre-set trigger point, activating, by the controller, a virtual cavity sensor having an optimal pre-defined pressure-time curve, wherein upon activation, the virtual cavity sensor tracks approximated pressures calculated from the change in strain measurements measured by the at least one strain gauge sensor over time and compares the results of the approximated pressure tracking to the optimal pre-defined pressure-time curve.

16. An injection molding system comprising:

at least one strain gage on an exterior of a mold surface configured to measure a change in strain in a mold side of a mold cavity under both a closing force exerted by a clamping unit and an opening force exerted by thermoplastic molten material as it is injected into the mold cavity;

a controller operatively connected to the at least one strain gage, the controller configured to:

approximate a pressure within the mold cavity based on the change in strain measured by the at least one strain gage,

compare the approximated pressure to a pre-set trigger point, wherein the pre-set trigger point occurs when the change in strain is a relaxing tensile strain,

determine that the approximated pressure equals or exceeds the pre-set trigger point, and

in response to the determination, activate a virtual cavity sensor; and

the virtual cavity sensor, wherein the virtual cavity sensor is operatively connected to the controller, has an optimal pre-defined pressure-time curve, and, upon activation, is configured to:

track the approximated pressure based on the change in strain measurements measured by the at least one strain gauge sensor over time, and

compare the results of the approximated pressure tracking to the optimal pre-defined pressure-time curve.

17. The injection molding system of claim 16 , wherein the virtual cavity sensor is further configured to:

determine that the comparison of the results of the approximated pressure tracking to the optimal pre-defined pressure-time curve indicates that the optimal pre-defined pressure-time curve is not being followed; and

adjust an injection molding process.

18. The injection molding machine of claim 17 , wherein to adjust the injection molding process, the virtual cavity sensor is configured to:

signal the controller to take a corrective action.