Systems and approaches for controlling an injection molding machine

Abstract

Systems and approaches for controlling an injection molding machine having a first configuration and a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for a portion of an injection cycle of an injection molding machine having a second configuration and operating the injection molding machine having the first configuration to inject a molten material into the mold cavity. While operating the injection molding machine having the first configuration, the obtained pattern is used to control a portion of the injection cycle.

What is claimed is: 
     
         1 . An injection molding machine comprising:
 a first injection unit having a mold forming a mold cavity, the first injection unit adapted to receive and inject a molten plastic material into the mold cavity to form a molded part;   a controller adapted to control operation of the injection molding machine according to an injection cycle having a first portion and a second portion;   a first sensor coupled to the injection molding machine and the controller;   a second sensor coupled to the injection molding machine and the controller, the second sensor adapted to measure a different characteristic than the first sensor;   wherein in the first portion of the injection cycle, the controller controls the injection unit at least partially based on measurements obtained from the first sensor, and upon an event occurring, the second portion of the injection cycle commences whereby the controller further controls the injection unit at least partially based on measurements obtained from the second sensor, wherein the second portion operates according to a previously obtained pattern derived from a second injection unit.   
     
     
         2 . The injection molding machine of  claim 1 , wherein the second injection unit has a different configuration than the first injection unit. 
     
     
         3 . The injection molding machine of  claim 1 , wherein the previously obtained pattern comprises a cavity pressure setpoint curve for an injection cycle of the second injection unit. 
     
     
         4 . The injection molding machine of  claim 3 , wherein the second injection unit has a different number of mold cavities than the first injection unit. 
     
     
         5 . The injection molding machine of  claim 3 , wherein the second injection unit comprises a pilot tooling. 
     
     
         6 . The injection molding machine of  claim 1 , wherein the first sensor is adapted to measure a melt pressure value of the injection unit. 
     
     
         7 . The injection molding machine of  claim 1 , wherein the second sensor is adapted to measure a cavity pressure value of the injection unit. 
     
     
         8 . The injection molding machine of  claim 1 , wherein the event comprises a measured nominal cavity pressure value. 
     
     
         9 . The injection molding machine of claim  18 , wherein the nominal cavity pressure value is approximately 50 psi. 
     
     
         10 . The injection molding machine of  claim 1 , wherein the controller controls the first injection unit at least partially based on measurements obtained from the second sensor and a pattern captured via the second injection unit. 
     
     
         11 . The injection molding machine of  claim 10 , wherein the pattern comprises an ideal cavity pressure setpoint curve.