Note: Descriptions are shown in the official language in which they were submitted.
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TEMPERATURE REGULATING SYSTEM, METHOD AND APPARATUS
FIELD OF THE INVENTION
This invention relates to a temperature regulating system,
method and apparatus, and relates particularly to such system,
method and apparatus for cyclic processors. Such processors
typically have a pre-set repeating cycle time, and form standard
products from a hot melt material which solidifies in a mould.
Although the system is likely to find most application
utilising coolant flows to regulate against over-heating, we do
not exclude systems utilising heating flows to regulate against
over-cooling.
BACKGROUND TO THE INVENTION
Typical cyclic processors are injection moulding machines, blow
moulding machines and aluminium die casting machines. For
convenience the invention will be described in relation to
thermoplastic injection moulding.
In thermoplastic injection moulding machines the hot melt
material is introduced, typically injected, into a mould cavity,
which cavity is then cooled in order that the material will
solidify to form the product to a shape dictated by the mould
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cavity; the mould is thereafter opened, the formed product
ejected, the mould closed to re-make the cavity, and the cycle
repeated. For efficient working, the mould operating temperature
must be held within an acceptable range defined by specified
upper and lower temperature limits, since if the mould
temperature is too high the material is slow to solidify, and if
the mould temperature is too low some or all of the mould
material can solidify in the injection sprue leading to the
cavity i.e. premature solidification with a consequent increase
in the required injection pump pressure. Furthermore it is
considered good practice to maintain the mould within a
temperature range which allows the product the minimum shrinkage
and distortion during the setting or curing stage, both for
product quality and for uniformity amongst the replications of
the product being moulded.
The four variables which affect product quality are melt
temperature, melt flow rate, melt pressure (each a function of
the processor control systems and condition settings) and cooling
rate. It is normal practice to seek to maintain product quality
by repeated small adjustments of the processor machine controls,
usually in response to external changes "outside" the machine
controls. A reliable and accurate temperature regulating system
is necessary so that the operating temperature, and therefore the
cooling rate, can be held within a pre-determined range.
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DISCLOSURE OF THE PRIOR ART
In one known mould cooling system a liquid is circulated
continuously through channels fashioned in the walls of the
mould. One disadvantage of this system is that by using
continuously circulating liquid, the thermal mass of the system
is large, so that the response time to temperature change is
slow: also considerable skill is required on the part of the
operator to set the correct external heat input or cooling rate
for the liquid to maintain the mould within its working
temperature range. The manual adjustment needs to be effected
quickly and correctly if reject products are to be avoided.
In an alternative known continuous flow system, fluid is again
continuously circulated through the mould, by way of a control
system. The liquid temperature is less than that of the mould.
If the temperature of the mould increases, the rate of water
circulation is increased. This system has the disadvantages of
the above known system, including that the mould temperature may
vary due to ambient temperature changes, (with an unacceptable
level of product rejects until the water circulation rate is
Zp manually changed), that the operator needs considerable skill to
judge whether the rate needs to be increased or decreased and by
how much, and that the mould is being cooled during charge
injection, and even prior thereto.
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USA Patent 4,354,812 discloses another known arrangement, in
which intermittent fluid cooling is used in accordance with the
instantaneous temperature of the mould, with the flow being
turned "on" when the temperature recorded rises above a preset
value and "off" when the temperature recorded falls below a lower
pre-set value. In a typical production embodiment the
temperature of the mould adjacent the cavity is sensed by a
probe; thus the probe is located in a probe well, which should
extend close to the cavity to reduce the thermal lag time, but
not so close as to weaken the cavity wall. The probe signal is
monitored continuously.
Operating disadvantages of this known system are that there is
a significant lag time before a cavity temperature outside the
acceptable range is measured and responded to, so that the
corrective "on" or "off" coolant flow though intended to be
simultaneous with mould cavity temperature movements outside the
pre-determined acceptable range also lags and so requires a
correction, that the rate of heat transfer from the hot charge
material through the mould wall to the probe can change if the
2~ position of the probe in the mould alters (for instance upon
vibration as the mould opens and closes) so that the lag time can
alter, and that the the sensor may respond to ambient temperature
changes, heat spikes or heat troughs (i.e sudden rises or falls
in temperature respectively) to effect too early commencement of
coolant flow (with partial solidification in the injection sprue)
or too late commencement of coolant flow (with only partial
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solidification of the product before the mould is opened).
Facility disadvantages of this known system are that gateway
circuits are required to distinguish between "high" temperatures
which are above the upper pre-set temperature (so that coolant or
extra coolant is required) and those which are above the lower
temperature limit (so that the coolant valve is now to be closed
or is to remain closed). Similarly, the gateway circuit must
quickly distinguish throughout the cycle between "low"
temperatures which are below the lower pre-set threshold
requiring coolant valve closure, and those which are below the
upper threshold, so that the coolant valve is opened (or is to
remain open). Careful probe positioning is mandatory.
DISCLOSURE OF THE INVENTION
We have now realised that an intermittent coolant flow regime
need not be directly dependent upon a scrutiny of the current
mould temperature, but can instead and with advantage be made
indirectly dependent on mould temperature as by using the
"historic" average temperature of the mould (or of an equivalent
or related parameter such as the exhaust temperature of the
coolant) recorded during or over a previously completed cycle: or
additionally or alternatively by arranging coolant flow in
response to a temperature trend over a number of machine cycles.
The intermittent flow can be at a rate selected to ensure
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excess cooling, preferably with turbulent rather than laminar
flow through the mould coolant passageway(s), so that the
required cooling can be obtained by selecting the proportion of
the cycle over which the coolant will flow, and by varying the
proportion as necessary.
Furthermore, the optimum timing of the coolant flow can be
selected in accordance with the known temperature curve of the
mould e.g. with coolant flow when required always starting five
seconds after mould closure, or with the required coolant volume
for a long cycle time of perhaps ninety seconds being segmented
into short flow periods to better hold the mould within the
acceptable temperature range.
Other advantages of our system are that it no longer requires
sophisticated instrumentation coupling the probe to the on-off
valve for "direct instantaneous action", and that the probe
location in the mould or fluid exhaust line is not critical.
Preferably the average temperature is calculated over each
completed cycle from a succession of recorded temperature
readings during that cycle, but in an alternative embodiment
2o another mathematical derivative (e.g. root mean square value) can
be used, and in a further but less preferred embodiment one or
more temperature measurements over only a selected part of the
machine or mould cycle are recorded or used.
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We have also realised that the temperature measurements can
themselves be recorded continuously as in the known system
described above, but that the values to be summed can be taken
therefrom at specified intervals. alternatively the sensor can
itself average the temperature from the previous "inspection"
i.e. over the interval until the next take-off of the reading,
and so can achieve the' accuracy of more delicate sensors whilst
being better suited to a harsh enviranment.
We have further realised that a change in the coolant flow
regime can be made dependent upon the change in the average mould
or exhaust temperature either from cycle to cycle, or from the
trend over several cycles, so that the system is
difference-dependent. An advantage of this arrangement is that
the system does not "hunt" (with fast repeated coolant valve
actuation) if the mould temperature recorded by the probe hovers
about one or other end of the pre-set temperature range, nor is
the valve actuation required to react to short duration heat
spikes or heat troughs which are not representative of the
average cycle temperature.
2p We have furthermore realised that the coolant flow can be
effected over a predetermined part only of a cycle, rather than
randomly in direct (instantaneous) response to the high or low
temperature sensor measurements. Specifically we can arrange the
coolant regime so that there will be no coolant flow during
material injection i.e. the material is not cooled whilst it is
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being injected, or whilst the majority of the material is being
injected. The coolant flow is thereby concentrated in the period
after injection, as the mould warms in response to the hot
material input, and the mould temperature can thus be more
closely controlled, as well as the coolant being more effectively
used since it is circulated at the time it is most needed.
In a modified arrangement, the required coolant flow is
arranged to occur as~a number of "pulses", of a duration and
spacing related to the cycle time. Thus this coolant regime is
designed to avoid the problem of subsequent heat up of the mould
after the specified coolant volume has been all utilised (as in a
"single shot or pulse"), and which may be a problem with long
cycle times.
SCOPE OF THE INVENTION
The scope of the invention is defined in the appended claims.
SPECIFIC EMBODIMENTS OF THE INVENTION
The invention will be further described with reference to the
accompanying schematic drawings, in which .
Fig.1 is a block diagram indicating the basic functional
elements of the cyclic processor with a temperature
control system according to the invention:
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Fig.2 is an illustrative graph showing typical temperature
changes in a mould during successive injections of molten
thermoplastics material;
Fig.3 is an illustrative drawing of a cyclic processor fitted
with a three-zone control:
Fig.4 is a graph of heat input to the mould during a cycle,
from injected material, and the coolant time flow for
zone 1 of the mould;
Fig.5 is similar To Fig.4, but for zone 2 of the mould; and
Fig.6 is similar to Fig.4, but for zone 3 of the mould.
The system and apparatus is described for Figs.l-2 in relation
to one mould zone, although it will be understood that the system
and apparatus can also be used to control a number of zones as in
Figs.3-6, one or more of which may be in the various separable
~5 sections which are joined to form a mould. Similar numbers are
used for similar parts in the various figures.
The mould 10 is part of a cyclic processor, in this embodiment
used to form thermoplastic products in an internal mould cavity 7
(Fig.3). The mould can be separated along split line il to allow
ejection or withdrawal of the formed product. In use hot product
liquid is fed to the mould cavity through conduit 8 and injection
sprue 6.
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The mould can be pre-heated to the operating temperature by
electric current through wires 9, preferably powered from an
adjustable power source and which are usefully disposed
internally of the mould but which in an alternative embodiment
5 are wrapped therearound. Subsequent to start-up, the current in
wires 9 can be selected for extra heating to maintain the mould
above the pre-set minimum operating temperature, for instance if
the ambient environment suddenly becomes cooler or if flow of the
hot thermoplastics liquid into the mould is interrupted. In an
1o alternative embodiment the mould pre-heating, and the extra
heating during moulding, can be effected by supplying pre-heated
liquid to the mould, the heating passageways usually being
different passageways from (but in specified embodiments the same
as) those used for coolant circulation.
In a typical mould design suitable for continuous cyclic
operation, the mould heat input 5 (Fig.4) during a machine cycle
introduced by injection of the hot product liquid is arranged to
equal or be slightly greater than the mould maximum heat losses
due to convection, conduction and radiation: thus forced cooling
is needed to ensure that the mould does not overheat,
particularly when the convection, conduction and radiation heat
losses are at a minimum.
In the single zone embodiment of Fig. l, mould 10 can be cooled
by coolant flow through conduit 12 and which therefore provides a
fluid supply means. In use, "on-off" valve 14 controls the
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supply of coolant from the supply means 12 to the connection
means 15 and internal passageway 1'7 and thus to exhaust 13. In
this embodiment the coolant is water at ambient temperature, but
in an alternative embodiment is pre-cooled to below ambient
temperature, and in another is pre-warmed above ambient.
Valve 14 is in either an open or a closed condition, as
determined by timer T2: in this embodiment the valve carries its
own driver, but the driver can be associated with or incorporated
in a powered timer drive unit.
The temperature of either the mould 10 or of the exhaust
coolant in conduit 13 is measured respectively by a sensor 16a or
16b at set intervals during each cycle. These temperatures are
summed and an average cycle temperature obtained by means of
calculator 20, which divides the summed value by the number of
inputs; in an alternative embodiment the RMS (root mean square)
temperature or other derivative indicative temperature is
obtained, and this can be shown on a display 22. Sensor 16a or
16b typically is a thermocouple, resistance thermometer or
thermistor probe, with associated known circuitry to produce a
signal representative of the instantaneous mould temperature.
The output from calculator 20 is transmitted to comparator or
error difference meter 30, which also has an input from datum
temperature unit 32. Meter 30 is responsive to the difference
between the inputs from calculator 20 and datum temperature unit
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32. Datum unit 32 can be manually adjusted to a predetermined
temperature setting, which can be changed for different operating
conditions, and different injected materials.
The difference signal from comparator 30 is fed to comparator
40, and also to memory 42. If this difference signal, analogue or
digital, is greater than a preset threshold value (as is most
likely at start up or after an interruption), the signal (or a
corresponding derived signal) is fed directly by comparator 40 to
mode generator 50.
If however, the difference signal is less than the threshold
value (as is most likely during normal running) it is not
accepted by comparator 40. Thus comparator 40 is used to insert a
"dead range", to help prevent the system "hunting" in response to
every difference signal. It will be understood that the complex
interaction between the mould normal heat losses and the heat
input from the product material might itself lead to a mould
temperature correction without need for two corrective changes to
valve 14: excessive valve 14 wear is avoided.
The system can always respond to a trend (increase or decrease)
2p in the difference between three or more successive difference
signals, to apply a necessary temperature correction: such
correction will usually be a "gentler" correction, with valve 14
being switched to and from "open" or "closed" for a smaller time
variation. Thus in this embodiment, comparator 40 addresses
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memory 42 to seek the last three difference signals recorded by
difference unit 30, though in an alternative embodiment a
different number of memory signals in memory 42 can be
addressed. If the memory signals show a consistent trend i.e.
an increasing or decreasing difference from one cycle to the
next, then an instruction signal is generated by comparator 40
and sent to mode generator 50; however, if the signals from
memory 42 do not show a consistent trend, for instance being
successively greater,and smaller, na memory-originating signal is
generated by comparator 40.
If difference meter 30 is not fitted or is inoperative, the
memory unit receives signals directly from calculator 20, with
the system then only reacting to trend signals, after a delay to
eliminate or ignore "start-up" temperature readings; the memory
unit will issue a signal to comparator 40 based on a trend which
averages readings from least two preceding cycles. If calculator
is omitted, the memory unit may receive individual temperature
signals, including perhaps one from the present cycle e.g if
single readings at a specified cycle time are interrogated by
20 memory unit 42. The memory unit 42 thus interposes a delay before
the control signal is issued for valve alteration.
Mode generator 50 is therefore activated if there is an above
threshold difference signal from difference unit 30, or if there
is a trend signal from memory 42. Unless mode generator 50 is
activated, no signal is transmitted to initiating unit 54, so
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that the coolant regime for mould 10 is unchanged. If however
mode generator 50 is activated, a signal is despatched by line
52, by way of initiating unit 54, to timer T2 to alter the
duration of the open condition of valve 14.
In this embodiment, the valve opening signal from timer T2 is
timed with respect to a particular stage of a cycle by mode
generator 50, with the signal from line 52 varying the "duration
before change" or closure time set in unit 54, and thus the
period during which the valve 14 remains open.
In the normal arrangement, valve 14 will remain open
continuously for the specified period, during a single cycle.
However, in an alternative embodiment, the required valve open
period can be divided into a plurality of open periods, so as
better to encompass the duration of the cycle. This alternative
may be particularly appropriate for the longer cycles) typically
of up to 300 seconds, and for which a single coolant shot or flow
may not be best suited because of initial overcooling the mould
and subsequent over-heating. For coolant flow division, the mode
select unit 56 can be pre-set manually or automatically to divide
the period of the valve opening 14 into a plurality of equal (or
disparate) open-closed periods, for example three equal-time open
periods or five equal-time open periods during each cycle, with
intervening valve closed periods.
As described above, mode generator 50 controls the timing of
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the first opening of valve 14 during a particular cycle, so that
valve 14 is only opened for instance after the hot material has
been injected or mostly injected into mould 10. The initiating
unit 54 needs to be re-set or triggered every cycle, to prevent
drift in the opening time of valve 14 over a series of cycles
i.e. a change in the duration from cycle commencement to coolant
valve opening. Thus mode generator 50 receives a cycle time
repeat-interval pulse through line 60 from repeat cycle timer T1.
In one embodiment, the re-setting or triggering of timer T2 is
repeated every 14 seconds, corresponding to the cycle time of T1,
set on the manual set point indicator 62 to correspond to the
mould 10 automatic timing cycle.
In an alternative arrangement, to cater for changes in the
repeat interval, for instance if the moulding machine is manually
cycled, or its operating arrangement is subject to fluctuations
in the electrical supply, timer T1 can inspect a signal from an
external source which it receives by way of line 72, for instance
an externally generated sychronising trigger signal: this trigger
signal may be derived directly from closure movement of the
mould, or from pressure generation at the pump feeding the hot
(liquid) product material, or from the machine control system.
Timer T1 defines for mode generator 50, memory unit 42 and
calculator 20 each completed cycle, to permit proper calculation
of the respective error differences and average cycle
temperatures, and prompts mode generator 50 to trigger timer T2
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for initial opening for that cycle of valve 14.
We also provide a comparator 80 with a first output line 81 to
a "high temperature" alarm indicator, and a second output line 82
to a "low temperature" alarm indicator. To permit a simple check
that comparator 80 is operative, we also provide an output line
83 which energises a "normal" indicator, for mould temperatures
within an acceptable range. As one example, if for any reason
valve 14 jammed in the closed condition, and did not respond to
the consequent difference-signals from comparator 40 as mould 10
overheated, a visual or audible warning to the machine operator
would be given by the "high temperature" alarm from a signal
through line 81, and/or this signal could act to shut down the
machine.
In this embodiment, comparator 80 compares the input derived
from the average temperature generator 20 with upper and lower
preset values from respective input units 84, 85; a normal
temperature or temperature range is pre-set in unit 86. The
actual pre-set values will be altered in conjunction with an
alteration to set point indicator 32.
The variable heater control 90 responds to inputs from output
lines 81,82,83 or the associated indicators, to adjust the
electrical current in wiring 9, leading to mould l0. Greater
current will be fed to mould 10 if there is for instance a
significant drop in the ambient temperature, perhaps to such a
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degree that timer T2 is not reduired i.e. the heat input from
the hot thermoplastic material is insufficient to counter
environmental losses. A high electrical current is also used for
mould pre-heating on start-up, instead of injected material.
The current through wires 9 can be of a constant amperage, but
for variable periods, or the current can flow for preset periods
but be of variable amperage.
The mould for which the graph of Fig.2 is representative has no
pre-heating, so that the injection flows for the first few
start-up cycles from cold are used only to heat up the mould to
operating temperature and the formed products are rejected.
Subsequently cooling is effected, and the instantaneous
temperature of the respective part of the mould repeats during
each cycle in a common pattern; if however the average
temperature shows a consistent rise over a pre-set number of
cycles e.g. three, so that a rise indicated by line "A" ensues,
then the valve 14 is opened at the predetermined stage in the
cycle, and for either a pre-set time or a time dependent on the
rate of "average cycle-temperature" rise, whereby the next cycle
2.) 100 with concurrent coolant flow, has lower instantaneous
temperatures and thus a lower average temperature, bringing the
average closer to the ideal line "B".
Thus the system of the invention provides for effective and
efficient timing of coolant flow through the mould during each
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cycle, to extract the excess process heat (from cooling of the
hot product material.); and also allows for minor. environmental
changes from cycle to cycle (e.g. slight ambient cooling if a
door is opened) without the need f.or valve 14 opening time period
to be altered. Thus we have recognised that small temperature
fluctuations will be evened out by the thermal mass and inertia
of the system, so that only cumulative changes either positive or
negative need to be identified and responded to, with the
potential for a simplified and robust system, suited to the
control of cyclic processors subject to repeated thermal
stressing.
As also indicated in Fig.3, it is common for moulds of the type
described to have at least two separable sections, each section
forming part of the cavity into which the thermoplastic material
~5 is injected. Furthermore, each section may have more than one
tone, these zones each requiring a different operating
' temperature regime for optimum moulding, as is more particularly
seen in Figs.4-6. Thus the coolant flow (if required) starts a
specified time after hot liquid injection, and continues longer
for zones 2,3 (core and hot runners respectively) than for zone 1
(cavity); the pulsed flow to zone 3 is segmented.
Shown dotted on Fig.3 are the temperature sensors for zones 2,3
fitted in the return water manifold. A calculated temperature
obtained from comparator 20 of a part of a zone of mould l0 is
shown at indicator 70, and the units (Celsius or Fahrenheit) at
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71: the respective zone is indicated ut 72. The valve state
(on,off) for each respective zone is shown at 73. The zone
respective zone temperature condition (high, normal, low) is
visually indicated at 74. Panel 75 is a keyboard for setting the
desired temperatures.
One system constructed and operated according to the invention
may be used to control a number. of valves, each valve regulating
coolant flow to a respective mould zone: in an alternative system
the signals from the temperature sensor 16a,16b can be "sliced"
into time segments, with signals from one or more other moulds or
mould zones fitting in the time spaces therebetween, so that the
microprocessor comprising components 20 to 90 of rig.l separately
processes signals to a plurality of timers T2, on a mark-space
basis so that differing instructions can be given from each time
segment.
We have also disclosed a cyclic processor with a cooling system
designed to over-cool the part, in which the cooling system is
pulsed and made to complement the hot material injection (to
permit "set and forget"), in which the mould is the largest
"restriction" to coolant flow in the system (valve fully open),
and which utilises a "feed back" loop from the mould to vary the
fluid received by the internal coolant passageway of the mould.
Although we prefer to vary the fluid received by the passageway
by altering the duration of full fluid flow (valve fully open),
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since full fluid flow reduces the thermal gradient across the
mould, we do not exclude alternatively or in addition altering
the rate of fluid flow, or altering the fluid to one of different
temperature or composition whereby to permit a different heat
take up from the mould by the same volume of fluid, for instance
water at one of 5,15,25 degrees Celsius. Thus valve 14 can be a
four position valve (off,5,15,25 positions); or three "on-off"
valves can connect to an inlet manifold.
We prefer to control the flow of fluid to the passageways)
upstream of the mould, with in the preferred embodiment the fluid
being allowed to dwell in the mould before all or some is
expelled to exhaust be the next fluid shot, in accordance with
the fluid volume of that shot. Usefully the mould fluid exhaust
is ata height above that of the mould fluid inlet. In an
alternative embodiment fluid dwelling in the mould is caused to
exhaust (or allowed to exhaust under gravity) upon opening of one
or more downstream valves whereby to allow a corresponding volume
of fresh temperature regulating fluid to enter the passageway, to
fill the passageway; the valve will be opened for a period
determined from one or more earlier cycles as above described.
