Development and Validation of a 1D Dynamic Model of an Injection Moulding Process and Design of a Model-Based Nozzle Pressure Controller

Abstract

A 1D model describing the dynamics of an injection moulding machine and the injection process is presented. The model describes an injection cylinder actuated by a dual-pump electro–hydraulic speed-variable drive and the filling, holding and cooling phases of the injection moulding process utilising amorphous polymers. The model is suggested as the foundation for the design of model-based pressure controllers of, e.g., the nozzle pressure. The focus is on using material, mould and machine properties to construct the model, making it possible to analyse and design the dynamic system prior to manufacturing hardware or conducting experiments. Both the presented model and the developed controller show good agreement with experimental results. The proposed method is general in nature and enables the design, analysis and evaluation of the machine, material and mould dynamics for controller design based solely on the physical properties of the system.

Cycle-Based Control of Injection Moulding Process in Presence of Material Dual Sourcing Using Mass Feedback

“…The limit of experimental based models compared to theoretical models based on, e.g., physics is that it is only valid in the tested region. However, in this case, the experimental approach is preferred due to the simplicity of the test making it beneficial, compared to more complex models such as [16,20,21,34,[36][37][38]. Nine experiments are conducted, where the five ABS materials are moulded at three dif-ferent holding pressures.…”