How cavity sensors improve quality
Injection moulding is a temperamental process, particularly when materials such as plastics are involved. To achieve parts with a consistent quality for their customers, manufacturers have to pay close attention to the parameters of the process
Cavity sensors
The cavity is one half of the mould that is used to create the part. During injection moulding, plastic or metal is injected into the mould and the cavity is compressed together with a clamp to create the final part.
Cavity sensors make it much easier for manufacturers to monitor and analyse the parameters of the process. This enables remote control over temperature, pressure and material volume and helps to create a high-quality, consistent product.
Temperature sensors
Monitoring the temperature of the molten material is extremely important to ensure the stability of the final product. Particularly in thermoplastics, just a slight change in temperature can make the difference between the final product being stable or it warping.
Temperature sensors help manufacturers to monitor and carefully control the temperature of the material. Reducing the chance of warpage or other aesthetic imperfections.
Pressure sensors
Getting the pressure right inside the cavity of the mould is essential to avoiding shrinkage, sinks and voids in the final product. Having sensors inside the cavity will make sure the pressure isn’t too high, which could cause potential defects in the product, or too low, meaning that the spread of the plastic isn’t effective enough to create a stable part.
It will also help to predict and identify potential faults in the mould or in the injection moulding machine. For example, a drop in pressure may suggest there is a lack of tolerance in the mould or that the gate of the machine isn’t sealed properly, which a manufacturer can then work to identify and fix.
Volume sensors
Making sure the right volume of material is in the cavity ensures there’s an equal spread of material across the whole mould and, therefore, the whole part. Volume sensors can help to make sure there is enough plastic to fill the mould and doesn’t turn into a short shot.
They can also ensure there isn’t too much plastic and, consequently, a less refined product, or an excess of material that turns into flash: an aesthetic defect that has to be removed. Volume sensors can also reduce the likelihood of a prominent parting line, which will need to be polished, causing extra time and money in the process. This can help to improve the efficiency and cost-effectiveness of the process, as can all of the cavity sensors.