Solutions
Automotive Manufacturing
Resin Molding
- Improving the product quality by controlling the molding pressure in real time
- Reducing the defect rate by monitoring the mold condition to perform molding in an optimal condition
- Stabilizing the quality by preventing molding defects
Solutions to the Issues
| Issues | Solutions |
|---|---|
| Improving the product quality by controlling the molding pressure in real time | Perform a high-response pressure control with servo amplifiers supporting pressure control. |
| Reducing the defect rate by monitoring the mold condition to perform molding in an optimal condition | Inspect for molding defects (position deviation, resin sticking to the mold) by MELSENSOR. |
| Stabilizing the quality by preventing molding defects | Detect unusual trends with a real-time data analyzer. |
Issues
Improving the product quality by controlling the molding pressure in real time
Solutions
Perform high-response pressure control and improve product quality by pressure feedback control with pressure sensor signals directly input to the servo amplifiers.
- Generate optimal pressure commands and set gains easily by adjusting the pressure control through a test operation on engineering software.
Point
- A combination of a servo amplifier (MR-J4-B-LL) and a Motion CPU module (RnMTCPU) enable pressure control.
- The servo amplifier flexibly responds to load changes and maintains the constant pressure by directly receiving analog signals from the pressure sensor and the pressure commands from the Motion CPU.
Product Lineup
Issues
Reducing the defect rate by monitoring the mold condition to perform molding in an optimal condition
Solutions
Ensure a stable operation and reduce the defect rate with MELSENSOR inspecting for molding defects (position deviation, resin sticking to the mold) and enabling feedback control based on the results.
- Compare the image captured with a vision sensor to the pre-registered image without resin sticking to the mold and judge if they match.
- Detect position deviations of the upper mold in XY directions with a laser displacement sensor measuring the distance to the upper mold and a PLC calculating the measured value.
Point
- Prevent molding defects with a laser displacement sensor that monitors mold position deviation.
- Prevent equipment failures with a vision sensor that monitors resin sticking to the mold.
Product Lineup
Issues
Stabilizing the quality by preventing molding defects
Solutions
Monitor the condition of injection molding machines with a real-time data analyzer utilizing the collected data to detect and prevent the increasing trend of defects.
- Collect data of resin cylinder pressure measured with a pressure sensor and mold temperature measured with a thermal camera when pressure is applied.
- Monitor the condition of an injection molding machine by comparing the collected data with the normal condition data using a real-time data analyzer.
Point
- A thermal camera enables temperature measurement of an object on which a thermometer cannot be installed.
- The real-time data analyzer offers various analysis and diagnosis methods for various purposes and detects unusual data by analyzing data in real time.
