Plastic injection molding processes

Condition-based maintenance for your injection molds

In-line measurement system

Permanent and force-locked connection of the QASS vibration sensor on the tool (no sensor infeed necessary). Processes can be monitored by the
Optimizer4D in real time. 

Maintenance forecast & wear history

The optimizer consistently records the wear of a tool via HFIM and sequences the obtained data to the individual moving components. Learn when and why a tool needs to be serviced. 

Process understanding

Use Optimizer4D to look inside the mold and immediately detect quality variations and maintenance needs.

Maintenance cycle optimization

QASS offers the possibility of condition-based maintenance with the Optimizer4D and can therefore save customers several maintenance cycles a year, and thus a lot of money.

Tool monitoring in plastic injection molding

When is a plastic injection molding tool due for maintenance? The Optimizer4D makes it possible to carry out maintenance at the right time, instead of relying on maintenance in fixed cycles: Condition-based instead of interval-based maintenance.

The QASS system provides an image of the spray process via high-frequency impulse measurement (HFIM). This image varies depending on the degree of wear of the mold. A worn mold produces a significantly different image than a brand-new one.

This inspection occurs in real time, non-destructively and with 100 percent accuracy. At the same time, the system performs process monitoring and can detect sluggish bolts and worn ejectors. ​

Measurement method HFIM  Condition Monitoring

Venting control: Injection molds often struggle with venting problems. Over time, they 
often become clogged, as various additives can outgas. If the vent is blocked, the air in the mold cannot escape during injection - therefore it is strongly compressed and very hot. This can lead to "burn-marks" on the plastic parts. Optimizer4D is able to detect the blockage of the detect the clogging of the venting channels. 

Tool monitoring with the Optimizer4D

Closed tools have a simple disadvantage. You cannot perceive what is happening inside. QASS, however, has a reliable method of displaying the processes in a mold with microsecond precision using structure-borne sound, thus enabling an evaluation of each individual process step. The installation of a structure-borne sound sensor is very easy and does not influence the production in any way, as it can be measured inline. The sensor is simply applied to the mold by means of a small hole. The spectral analysis reveals even the smallest process irregularities.

More about Optimizer4D

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