Meaning
Standardized multi stage injection control separates the filling phase from the packing and holding phases to improve part consistency. Implementing a decoupled moulding process ensures that the high speed filling of the cavity is governed by velocity, while the consolidation of the plastic is controlled by pressure. This separation reduces the sensitivity of the process to changes in polymer viscosity.
Machine Stage
Separating these phases prevents the machine from packing the mould while still injecting at high speed. The decoupled moulding process utilizes a velocity to pack switchover point based on screw position or cavity pressure to transition to the holding phase. This prevents flash and reduces residual stress in the molded parts.
Cavity Performance
Cavity pressure sensors provide the feedback needed to control the transition point with high precision. By focusing on the conditions inside the mould rather than the machine hydraulics, the decoupled moulding process delivers parts with highly consistent weight and dimensions. This consistency is maintained even when using recycled resins with variable melt flow rates.
Quality Control
By monitoring the peak cavity pressure during each cycle, the system can automatically sort parts into accept or reject bins. This automated inspection reduces the reliance on manual quality checks and prevents defective parts from reaching the customer. Consistent execution of this process lowers production scrap and improves the overall efficiency of the moulding operation, especially during long production runs where material variations and temperature drifts would otherwise lead to part defects.
