Method for simultaneous closed loop control of gas assist and gas counter pressure in an injection molding process relative to plastic melt pressure and plastic melt flow position

1. A control system configured to automatically adjust operation of an injection molding apparatus, the control system comprising:

a melt pressure sensing device;

a melt flow front position sensing device;

a gas assist control unit; and

a gas counter-pressure control unit,

the control system being adapted to:

cause the injection molding apparatus to inject a molten thermoplastic material into a mold cavity;

inject a first gas at an initial pressure into a portion of the mold cavity downstream of a flow front of the injected molten thermoplastic material;

determine a melt pressure of the injected molten thermoplastic material using the melt pressure sensing device;

determine a flow front position of the injected molten thermoplastic material using the melt flow front position sensing device;

inject, after the flow front has reached a first part specific position in the mold cavity, a second gas at an initial pressure into a portion of the mold cavity upstream of the flow front of the injected molten thermoplastic material;

increase the pressure of the second gas until the melt flow front reaches a second part specific position of the mold cavity;

use the gas assist control unit to change, in real-time during a single injection molding filing cycle, a gas assist pressure of the second gas at least in part based on the determined melt pressure of the injected molten thermoplastic material or the determined flow front position of the injected molten thermoplastic material; and

use the gas counter-pressure control unit to change, in real-time during the single injection molding filing cycle, a gas counter-pressure of the first gas at least in part based on the determined melt pressure of the injected molten thermoplastic material or the determined flow front position of the injected molten thermoplastic material.

2. The control system of claim 1 , further comprising a melt pressure control unit adapted to change the melt pressure at least in part based on the determined melt pressure.

3. The control system of claim 1 , further comprising a melt travel control unit adapted to change the melt pressure at least in part based on the determined flow front position.

4. The control system of claim 1 , further comprising a virtual cavity sensor.

5. The control system of claim 1 , wherein:

the injection molding apparatus comprises a screw for injecting the molten thermoplastic material into the mold cavity; and

the melt flow front position sensing device comprises a screw position sensor.

6. The control system of claim 1 , further comprising a cavity pressure transducer.

7. The control system of claim 1 , wherein the melt flow front position sensing device comprises one of: (i) a thermocouple or (ii) a strain gauge.

8. The control system of claim 1 , the control system being further adapted to adjust two or more of the melt pressure, the gas assist pressure, and the gas counter pressure in response to the melt flow front position sensing device detecting proximity of the melt flow front to a change in geometry of the mold cavity, the change in geometry being at least one of a change in thickness, a change in direction, or a change in angle.

9. The control system of claim 1 , wherein:

the injection molding apparatus comprises a screw for injecting the molten thermoplastic material into the mold cavity, the screw actuated with an electrical drive comprising a motor or a hydraulic drive comprising a piston, and

the melt pressure sensing device senses pressure at one of: (i) a back of the piston; (ii) a load cell at a back of the screw; or (iii) in a melt stream at a location downstream of a tip of the screw.

10. The control system of claim 1 , further adapted to:

use the gas assist control unit to change the gas assist pressure at least in part based on a detected mold cavity condition trigger event during a molding cycle; and

use the gas counter-pressure control unit to change the gas counter-pressure at least in part based on the detected mold cavity condition trigger event during the molding cycle.