Scientific Molding and Adaptive Process Quality Control with External Sensors for Injection Molding Process

This study established a real-time measurement system to monitor the melt quality in an injection molding process using a pressure sensor installed on the nozzle and a strain gauge installed on the tie bar. Based on the sensing curves from these two external sensors, the characteristic values of nozzle pressure and clamping force were used to optimize parameters. This study defined product weight as a quality indicator and developed a scientific molding parameter setup process. The optimization sequence of parameters is injection speed, V/P switchover point, packing pressure, packing time, and clamping force. Finally, an adaptive process control system was established based on the online quality characteristic values to maintain product quality consistency. Continuous production experiments were conducted at two sites to verify the system’s effectiveness. The results revealed that the optimized process parameters can ensure product weight stability during long-term production. Furthermore, using the adaptive process control system further enhanced product weight stability at both sites, reducing the standard deviation of product weight to 0.0289 g and 0.0148 g, and the coefficient of variation to 0.065% and 0.035%, respectively.