Meaning
Automated sorting systems evaluate every cycle in an injection moulding process to identify parts that fall outside established parameters. When the machine detects a deviation in peak pressure or cycle time, real time rejection triggers a diverter gate to separate the suspect part from the good production stream. This prevents the contamination of a batch with defective components without stopping the machinery.
Scrap Reduction
In-process monitoring equipment compares every shot against a master profile stored in the controller memory. A real time rejection occurs if the cavity pressure curve deviates from the validated range by more than a pre-set percentage. This immediate action reduces the need for secondary manual inspection of the entire lot.
Quality Threshold
Defining the limits for an automated sort requires a balance between scrap costs and customer requirements. If the thresholds for real time rejection are too narrow, the system may discard functional parts due to minor process noise. Reliable sensors and stable hydraulic systems are necessary to make the automated sort effective.
The logic must be based on the specific dimensions or properties that are most sensitive to the measured variable.
Waste Prevention
Removing defects at the point of origin lowers the total cost of quality for a moulding plant. Because a real time rejection identifies the specific cycle that failed, the operator can investigate the cause of the drift immediately.
