Tool Monitoring For Plastic Injection Molding

When does a plastic injection molding tool have to be maintained? Optimizer4D paves the way for maintenance at the right time – evaluating the actual condition of the machine, instead of trusting in interval based service.

The QASS-system delivers an image of the injection process via HFIM (High-Frequency-Impulse-Measurement). This image varies according to the tools degree of wear. A worn out tool generates a very different image than a new one.

This test is non-destructive and takes place in real-time. Simultaneously, the system runs a process monitoring and in many cases detects sluggish bolts and worn out ejectors.

With the QASS Optimizer4D it is also possible to do subsequent quality control. A few examples are movable plastic parts for speakers, ashtrays, navigation systems or similar components. The measuring system sorts out faulty components by detecting abnormal sound emissions.

Tool installing: The HFIM system Optimizer4D from QASS helps installing a plastic injection mold correctly. If the tool is not fitted in correctly this will show up in the HFIM display.

Ventilation control: Plastic injection molds often have problems with ventilation. From time to time ventilation channels get clogged, often due to outgassing additives. If the ventilation fails, the air cannot escape when the tool is closing, causing it to compress and become extremely hot. Optimizer4D enables users to detect clogged ventilation channels.

Check for wear

HFIM images below: This is a plastic injection molding process. The area marked green shows the injection phase. The tool used in the process on the left has shortly been maintained,  the image on the right shows the same tool after 5000 shots. The high amplitudes indicate that the air is compressed and material and tool might be damaged.

Flawless process. It shows the tool shortly after maintenance

This depiction shows the same tool after 5000 shots. The air is compressed and material and tool might be damaged.