Increasing Productivity in the Injection Molding Process

Part of calculating the productivity in an injection molding operation is to figure out the maximum number of items you’d be able to produce if everything worked perfectly. Unfortunately, “everything working perfectly” is not something you often see in manufacturing. How can you get closer to that ideal number? One answer lies in a little sensor which can monitor environmental conditions vital to your operation. With it you can reduce your machine downtime and the amount of scrap you produce.

Condition monitoring sensors seem to be taking the automation world by storm. These sensors take various measurements including temperature, ambient pressure, relative humidity, and vibration. They report the data digitally, which makes it easy to track performance. What used to require several sensors now requires only one.

Monitor humidity in plastic granule drying process

Following the plastic injection molding process from beginning to end we can see the usefulness of this one sensor. Plastic granules need to be dried before they go into the machine. If the moisture level is too high, it can cause splay marks to show up on the final product, which then has to be scrapped. This can be costly and can extend lead times if it is not detected early on. The condition monitoring sensor can track ambient humidity so you can stop that problem in its tracks before it creates waste and increases overhead.

Monitor temperature in the injection molding process

One of the biggest variables to any injection molding process is temperature. Some common temperature-related issues in injection molding include blistering, burn marks, degradation of the polymer used, stringiness, and warping. These are caused by temperature variations that cause the resin to be too hot or too cold. Condition monitoring sensors can detect swings in temperature to prevent products having to be scrapped.

Monitor vibration to detect mechanical wear

It’s clear that condition monitoring sensors can helpfully measure environmental factors, but what about mechanical wear? Vibration sensors can monitor mechanical wear on bearings, linear drives, gearboxes and much more by plotting vibration data. It’s even more effective if they measure vibration on more than one axis so you can see the direction of vibration and not just the overall amount. This way you can be proactive and plan your maintenance in advance instead of being in a constant reactive state, trying to patch problems as they come up. Using vibration data gathered by a condition monitoring sensor, you can avoid the costly consequences of unscheduled downtime.

In conclusion there are many different applications that condition monitoring sensors can be used for in injection molding operations. By tracking a variety of different measurements including vibration, temperature, and humidity, you will be able to improve the efficiency and productivity of your entire operation by using this one compact sensor. It provides a low-cost solution so that you can reduce the scrap that is cutting into your profits. And reduce the amount of downtime that causes so many unnecessary headaches. Put these smart sensors to work for you.

How Hot is Hot? – The Basics of Infrared Temperature Sensors

Detecting hot objects in industrial applications can be quite challenging. There are a number of technologies available for these applications depending on the temperatures involved and the accuracy required. In this blog we are going to focus on infrared temperature sensors.

Every object with a temperature above absolute zero (-273.15°C or -459.8°F) emits infrared light in proportion to its temperature. The amount and type of radiation enables the temperature of the object to be determined.

In an infrared temperature sensor a lens focuses the thermal radiation emitted by the object on to an infrared detector. The rays are restricted in the IR temperature sensor by a diaphragm, to create a precise measuring spot on the object. Any false radiation is blocked at the lens by a spectral filter. The infrared detector converts radiation into an electrical signal. This is also proportional to the temperature of the target object and is used for signal processing in a digital processor. This electrical signal is the basis for all functions of the temperature sensor.

There are a number of factors that need to be taken into account when selecting an infrared temperature sensor.

  • What is the temperature range of the application?
    • The temperature range can vary. Balluff’s BTS infrared sensor, for example, has a range of 250°C to 1,250°C or for those Fahrenheit fans 482°F to 2,282° This temperature range covers a majority of heat treating, steel processing, and other industrial applications.
  • What is the size of the object or target?
    • The target must completely fill the light spot or viewing area of the sensor completely to ensure an accurate reading. The resolution of the optics is a relationship to the distance and the diameter of the spot.

  • Is the target moving?
    • One of the major advantages of an infrared temperature sensor is its ability to detect high temperatures of moving objects with fast response times without contact and from safe distances.
  • What type of output is required?
    • Infrared temperature sensors can have both an analog output of 4-20mA to correspond to the temperature and is robust enough to survive industrial applications and longer run lengths. In addition, some sensors also have a programmable digital output for alarms or go no go signals.
    • Smart infrared temperature sensors also have the ability to communicate on networks such as IO-Link. This network enables full parameterization while providing diagnostics and other valuable process information.

Infrared temperature sensors allow you to monitor temperature ranges without contact and with no feedback effect, detect hot objects, and measure temperatures. A variety of setting options and special processing functions enable use in a wide range of applications. The IO-Link interface allows parameterizing of the sensor remotely, e.g. by the host controller.

For more information visit www.balluff.com