Method of injection molding with down cavity detection

1. A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram, the method comprising:

injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities;

measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting, the measuring of the first process parameter comprising measuring a position of the injection molding screw or ram;

based on the first process parameter, determining whether one or more mold cavities of the plurality of mold cavities are non-operational; and

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.

2. The method of claim 1 , further comprising:

comparing the measured position to an expected position corresponding to all of the plurality of mold cavities being operational; and

when a difference between the measured position and the expected position is greater than a predetermined threshold, generating a signal indicative of at least one mold cavity of the plurality of mold cavities being non-operational.

3. The method of claim 1 , wherein automatically adjusting the first process parameter or the second process parameter comprises adjusting a melt pressure of the molten thermoplastic material.

4. The method of claim 3 , wherein automatically adjusting the melt pressure of the molten thermoplastic material comprises decreasing the melt pressure of the molten thermoplastic material.

5. The method of claim 1 , wherein automatically adjusting the first process parameter or the second process parameter comprises adjusting an end-of-fill transition point from a first pressure to a second pressure, the second pressure being lower than the first pressure.

6. The method of claim 5 , wherein automatically adjusting the end-of-fill transition point comprises adjusting a screw position set point or a time set point.

7. The method of claim 1 , wherein determining whether the one or more mold cavities are non-operational comprises determining whether the one or more mold cavities are non-operational without using any cavity pressure sensors within the plurality of mold cavities.

8. The method of claim 1 , wherein after the adjusting, further comprising injecting, via the injection molding screw or ram, the molten thermoplastic material into the plurality of mold cavities at the adjusted process parameter.

9. A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram, the method comprising:

determining an expected parameter of the injection molding apparatus at a pre-determined time during or after an injection molding cycle comprising injecting a molten thermoplastic material into the plurality of mold cavities;

injecting, via the injection molding screw or ram, the molten thermoplastic material into the plurality of mold cavities;

determining an actual parameter of the injection molding apparatus at the pre-determined time during or after the injection molding cycle;

based on determining the actual parameter, determining a parameter differential between the expected parameter and the actual parameter;

based on the parameter differential between the expected parameter and the actual parameter, determining whether one or more mold cavities of the plurality of mold cavities are non-operational; and

when it is determined that one or more mold cavities are non-operational, adjusting a process parameter of the injection molding apparatus based at least in part on the parameter differential.

10. The method of claim 9 , wherein determining the expected parameter comprises: simulating, using a flow model simulator, the injecting prior to the injecting; and determining the expected parameter at the pre-determined time based on the simulated injection.

11. The method of claim 9 , wherein adjusting the process parameter of the injection molding apparatus comprises adjusting a melt pressure of the molten thermoplastic material.

12. The method of claim 11 , wherein adjusting the melt pressure of the molten thermoplastic material comprises decreasing the melt pressure of the molten thermoplastic material based at least in part on the parameter differential.

13. The method of claim 9 , wherein adjusting the process parameter of the injection molding apparatus comprises adjusting an end-of-fill transition point from a first pressure to a second pressure, the second pressure being lower than the first pressure.

14. The method of claim 13 , wherein adjusting the end-of-fill transition point comprises adjusting a screw position set point or a time set point.

15. The method of claim 9 , wherein determining the expected parameter comprises determining an expected nozzle pressure of an injection nozzle of the injection molding apparatus at the pre-determined time, and wherein determining the actual parameter comprises determining an actual nozzle pressure of the injection nozzle of the injection molding apparatus at the pre-determined time via a sensor disposed proximate the injection nozzle.

16. The method of claim 9 , wherein determining the expected parameter comprises determining an expected position of the injection molding screw or ram of the injection molding apparatus, and wherein determining the actual parameter comprises determining an actual position of the injection molding screw or ram of the injection molding apparatus.

17. The method of claim 9 , wherein determining the expected parameter comprises determining an expected cushion of the molten thermoplastic material at the pre-determined time, measured from a front of the injection molding screw or ram to an end of a barrel of the injection molding apparatus, and wherein determining the actual parameter comprises determining an actual cushion of the molten thermoplastic material at the pre-determined time.

18. The method of claim 9 , wherein determining the expected parameter comprises determining an expected melt pressure at the pre-determined time, and wherein determining the actual parameter comprises determining an actual melt pressure at the pre-determined time via a sensor disposed proximate the injection molding screw or ram.

19. The method of claim 9 , wherein determining whether the one or more mold cavities are non-operational comprises determining whether the one or more mold cavities are non-operational without using any cavity pressure sensors within the plurality of mold cavities.

20. The method of claim 9 , wherein after the adjusting, further comprising injecting, via the injection molding screw or ram, the molten thermoplastic material into the plurality of mold cavities at the adjusted process parameter.

21. A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram, the method comprising:

determining an expected position of the injection molding screw or ram at a pre-determined time during or after an injection molding cycle comprising injecting a molten thermoplastic material into the plurality of mold cavities;

injecting, via the injection molding screw or ram, the molten thermoplastic material into the plurality of mold cavities;

determining an actual position of the injection molding screw or ram at the pre-determined time during or after the injection molding cycle;

based on a position differential between the expected position and the actual position, determining whether one or more mold cavities of the plurality of mold cavities are non-operational; and

when it is determined that one or more mold cavities are non-operational, adjusting a process parameter of the injection molding apparatus based at least in part on the position differential.

22. The method of claim 21 , wherein determining the expected position comprises: simulating, using a flow model simulator, the injecting prior to the injecting; and determining the expected position at the pre-determined time based on the simulated injection.

23. The method of claim 21 , wherein adjusting the process parameter of the injection molding apparatus comprises adjusting a melt pressure of the molten thermoplastic material.

24. The method of claim 23 , wherein adjusting the melt pressure comprises decreasing the melt pressure.

25. The method of claim 21 , wherein adjusting the process parameter of the injection molding apparatus comprises adjusting a velocity of the injection molding screw or ram during the injecting.

26. The method of claim 21 , wherein adjusting the process parameter of the injection molding apparatus comprises adjusting an end-of-fill transition point from a first pressure to a second pressure, the second pressure being lower than the first pressure.

27. The method of claim 26 , wherein adjusting the end-of-fill transition point comprises adjustments to a screw position set point or a time set point.

28. The method of claim 21 , further comprising issuing an alert when it is determined that the one or more mold cavities are non-operational.

29. The method of claim 21 , wherein determining whether the one or more mold cavities are non-operational comprises determining whether the one or more cavities are non-operational without using any cavity pressure sensors within the plurality of mold cavities.