Let the Mold Think for Itself.

Since the mold is the heart of the injection molding process, it should control more of the process rather than be just a passive object. That's the philosophy behind the new Interactive Process Manager (IPM) from moldmaker Caco Pacific Corp., Covina, Calif. It's designed particularly for complex hot-runner molds and tools with moving cores and slides. The IPM is a box that sits permanently on top of the mold like a standard junction box. It contains a computer and software that can be programmed to monitor and control a wide variety of functions, from hot-runner nozzle temperatures and valve-gate actuation to cavity pressure. With appropriate sensors, IPM could control cooling based on actual steel (not just coolant) temperature. It could also sense the contact pressure between mold faces (essential for proper venting of some parts like floppy-disk cases) or parting of the mold faces that could cause flash. It could prevent injection before all hot-runner zones are up to temperature. Or it could confirm prop er positioning of ejectors, slides, and cores before allowing robot and clamp movements that could damage the mold.

One big advantage of this system is that it eliminates the need for a separate hot-runner controller, thereby saving floor space, and it also does away with cumbersome cables dangling from the mold. The IPM reportedly also provides more accurate temperature control because fewer power-cable junctions mean less degradation of thermocouple readings.

The IPM can be configured to communicate with a laptop computer, central supervisory computer, or the machine controller. Caco Pacific technicians could even use the IPM to troubleshoot a molding problem remotely via modem. Cost of a system is comparable to that of a standard hot-runner controller.