US 8,165,714 B2
`(10) Patent No.:
`a2) United States Patent
`Mieretal.
`(45) Date of Patent:
`Apr. 24, 2012
`
`
`US008165714B2
`
`(54) CONTROLLER FOR CONTROLLING
`COMBINATION OF HOT-RUNNER SYSTEM
`AND MOLD ASSEMBLY
`
`(75)
`
`Inventors: Angelo Mier, Colchester, VT (US);
`Keith Carlton Caledon. CA (US);
`:
`°
`;
`;
`David Seott Rotondo, Thousand Oaks,
`(US)
`
`(*) Notice:
`
`(73) Assignee: Husky Injection Molding Systems
`Ltd., Bolton, Ontario (CA)
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 294 days.
`(21) Appl. No.: 12/692,916
`
`(22)
`
`Filed:
`
`Jan. 25, 2010
`
`(65)
`
`Prior Publication Data
`US2011/0184550 Al
`Jul. 28, 2011
`Int.Cl
`(51)
`(2006.01)
`B29C 39/00
`,
`(52) US.CI
`700/197: 425/145
`(58) Field °f ClassificationSearchue
`700,197
`rere 700200
`See application file for completesearch history.
`‘
`References Cited
`
`(56)
`
`U.S. PATENT DOCUMENTS
`
`5,795,511 A
`6,000,831 A
`6,421,577 Bl
`
`8/1998 Kalantzis et al.
`12/1999 Triplett
`7/2002 Triplett
`
`6,529,796 Bl
`6,589,039 BI*
`7,214,048 B2
`7,258,536 B2
`7,580,771 B2*
`2003/0154004 Al
`2006/0082009 Al*
`2008/0006955 AL*
`2008/0290541 Al
`
`............. 425/145
`
`3/2003 Kroegeretal.
`7/2003 Doughty et al.
`5/2007 Kim
`8/2007 Olaru etal.
`8/2009 Quail et al. oes 700/197
`8/2003 Kroeger et al.
`4/2006 Quailetal. o...c 264/40.1
`1/2008 Niewels ..cccccsecseenen 264/40.5
`11/2008 Baumann
`
`FOREIGN PATENT DOCUMENTS
`0967063
`6/1999
`EP
`* cited by examiner
`
`Primary Examiner — Albert DeCady
`Assistant Examiner — Anthony Whittington
`
`(57)
`
`ABSTRACT
`
`for controllin
`A single stand alone controller system (100)
`g
`g
`y'
`combination of hot-runner system (102) and mold assembly
`(104), assembly (104) connectable to system (102), controller
`system (100) comprising: processor (110); interface modules
`(112) configured to operatively couple to system (102) and
`assembly (104), processor (110) connected with modules
`(112); and controller-usable medium (114) embodying
`instructions (116) executable by processor (110), processor
`(110) connected with said medium (114), instructions (116)
`including: executable instructions for directing
`said proces-
`8
`8
`Pp
`sor (110) to control said system (102) and said assembly
`(104).
`
`7 Claims, 2 Drawing Sheets
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`Hunting Titan, Inc.
`Ex. 1027
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 001
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`

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`U.S. Patent
`
`Apr.24, 2012
`
`Sheet 1 of 2
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`US 8,165,714 B2
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`9995
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`997 eene
`OePOVAN,AIRBAS
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`906
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`thee
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`918
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`104
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`995
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`996
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`FIG.1
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`Apr.24, 2012
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`Sheet 2 of 2
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`U.S. Patent
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`100
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`US 8,165,714 B2
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`FIG.2
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`Hunting Titan, Inc.
`Ex. 1027
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 003
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`US 8,165,714 B2
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`1
`CONTROLLER FOR CONTROLLING
`COMBINATION OF HOT-RUNNER SYSTEM
`
`AND MOLD ASSEMBLY
`
`TECHNICAL FIELD
`
`5
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`An aspectofthe present invention generally relates to (but
`is not limited to) a controller for molding systems including
`(but notlimited to) a controller for controlling a combination
`of a hot-runner system and a mold assembly.
`
`BACKGROUND
`
`2
`providing material to a mold, such as in an injection molding
`system, wherein the settings for controlling the molding
`operation are retained in a non-volatile memory in a hot-half
`of the mold.
`European patent Number 0967063 (Inventor: Moss et al.;
`Filed: 24 Jun. 1999) discloses a pressure transducer used to
`sense the pressure in the manifold bore downstream of the
`valve pin head.
`USS. Pat. No. 6,000,831 (Inventor: TRIPLETT; Filed: 14
`Dec. 1999) discloses injection mold hot runner control
`devices and more particularly to an injection molding control
`device which eliminates the conventional control cables to
`
`improve the quality of feedback signals received by the con-
`troller and the safety of the environment in which such sys-
`tems are used.
`
`USS. Pat. No. 6,529,796 (Inventor: Kroeger,et al.; Filed: 21
`Jul. 1999) discloses an injection mold apparatus having mul-
`tiple injection zones, each zone havingat least one heater and
`at least one temperature sensor generating a temperature indi-
`cating signal.
`USS. Pat. No. 6,421,577 (Inventor: TRIPLETT; Filed: 15
`Oct. 1999) discloses injection mold hot runner control
`devices and more particularly to an injection molding control
`device which eliminates the conventional control cables to
`improve the quality of feedback signals received by the con-
`troller and the safety of the environment in which such sys-
`tems are used.
`
`U.S. Pat. No. 6,589,039 (Inventor: DOUGHTY et al.;
`Filed: 2000-10-30) discloses a system and method in which
`the rate of material flow to a plurality of gates can be con-
`trolled by a single controller.
`United States Patent Publication Number 20030154004
`
`Thefirst man-madeplastic was invented in Britain in 1851
`by Alexander PARKES. He publicly demonstrated it at the
`1862 International Exhibition in London,calling the material
`Parkesine. Derived from cellulose, Parkesine could be heated,
`molded, and retain its shape when cooled. It was, however,
`expensive to produce, prone to cracking, and highly flam-
`mable. In 1868, American inventor John Wesley HYATT
`developed a plastic material he named Celluloid, improving
`on PARKES’ invention so that it could be processed into
`finished form. HYATT patented the first injection molding
`machine in 1872. It workedlike a large hypodermic needle,
`using a plungerto inject plastic through a heated cylinder into
`a mold. The industry expandedrapidly in the 1940s because
`World War II created a huge demand for inexpensive, mass-
`produced products. In 1946, American inventor James Wat-
`son HENDRYbuilt the first screw injection machine. This
`machine also allowed material to be mixed before injection,
`so that colored or recycled plastic could be added to virgin
`material and mixed thoroughly before being injected. In the
`1970s, HENDRY went on to develop the first gas-assisted
`(Inventor: KROEGER,et al.; Filed: 23 Jan. 2003) discloses an
`injection molding process.
`injection mold apparatus having multiple injection zones,
`Injection molding machines consist of a material hopper,
`each zonehavingat least one heater andat least one tempera-
`an injection ram or screw-type plunger, and a heating unit.
`ture sensor generating a temperature indicating signal.
`They are also knownas presses, they hold the molds in which
`USS. Pat. No. 7,214,048 (Inventor: KIM; Filed: 25 May
`the components are shaped. Presses are rated by tonnage,
`2004) discloses control for a valve pin through a linear motor
`which expresses the amount of clamping force that the
`controlled by a pulse signal and through a cooling block, so
`machine can exert. This force keeps the mold closed during
`that an opening/closing amount of a gate can be precisely
`the injection process. Tonnage can vary from less than 5 tons
`managed.
`to 6000 tons, with the higher figures used in comparatively
`USS. Pat. No. 7,258,536 (inventor: OLARY,etal.; Filed:
`few manufacturing operations. The total clamp force needed
`21 Jun. 2004) discloses a control module attached to a
`is determinedby the projected area ofthe part being molded.
`This projected area is multiplied by a clampforce of from 2 to
`machineplaten of an injection molding machine. The control
`
`8 tons for each square inch of the projected areas. Asarule of module is coupled to at least one sensorthat reports a value of
`thumb, 4 or 5 tons per square inch can be used for most
`a processing condition associated with an injection mold and
`products. If the plastic material is very stiff, it will require
`is disposed within the injection mold. The control module is
`more injection pressure to fill the mold, thus more clamp
`also coupledto at least one controllable device that varies the
`tonnageto hold the mold closed. The required force can also
`processing condition of the injection mold and is disposed
`be determined by the material used and the size ofthe part,
`within the injection mold. The control module collects and
`larger parts require higher clamping force. With Injection
`processes sensor output, and provides a control signal to at
`Molding, granularplastic is fed by gravity from a hopperinto
`least one controllable device. A display interface module is
`a heated barrel. As the granules are slowly moved forward by
`linked to the control module. The display interface module
`ascrew-type plunger, the plastic is forced into a heated cham-
`accepts user-entered data set-points, provides the user-en-
`ber, where it is melted. As the plunger advances, the melted
`tered data set-points to the control module, and collects the
`plastic is forced through a nozzle that rests against the mold,
`processed sensor output from the control module for display
`to a user.
`allowingit to enter the mold cavity through a gate and runner
`United States Patent Publication Number 20060082009
`system. The mold remainscold so the plastic solidifies almost
`as soon as the moldis filled.
`Mold assembly ordie are termsused to describe the tooling
`used to produceplastic parts in molding. The mold assembly
`are used in mass production where thousands ofparts are
`produced. Molds are typically constructed from hardened
`steel, etc.
`USS. Pat. No. 5,795,511 (Inventor: KALANTZIS, et al.;
`Filed: 6 Jun. 1995) discloses an apparatus and method for
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`(Inventor: Quail, et al; Filed: 19 Oct. 2004) discloses an
`intelligent molding system that makes use of data directly
`associated with a molding environmentorparticular mold.
`United States Patent Publication Number 2008/0290541
`
`(Inventor: BAUMANN;Filed: 25 May 2007) discloses an
`injection molding system including a hot runner comprising a
`memory device configured to contain at least one process
`control parameter.
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 004
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 004
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`US 8,165,714 B2
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`3
`United States Patent Publication Number 2008/0006955
`
`(Inventor: NIEWELS; filed: 5 Jul. 2007) discloses a piezoce-
`ramic actuator actuated so as to supply the force to seal the
`side acting core insert against the core insert during a molding
`operation. Sensors are used to detect pressure between mold
`components andto transmit sense signals to a controller.
`
`SUMMARY
`
`It is understood that the scope of the present invention is
`limited to the scope provided by the independentclaims, and
`it is also understoodthat the scope of the present invention is
`not limited to: (i) the dependent claims, (ii) the detailed
`description of the non-limiting embodiments, (111) the sum-
`mary, (iv) the abstract, and/or (v) description provided out-
`side of this document(that is, outside of the instant applica-
`tion as filed, as prosecuted, and/or as granted).
`It
`is
`understoodthat “comprising” means “including but not lim-
`ited to the following”.
`According to one aspect, there is provided a single stand
`alone controller system (100) for controlling a combination
`of a hot-runner system (102) and a mold assembly (104), the
`mold assembly (104) being connectable to the hot-runner
`system (102), the single stand alone controller system (100)
`comprising: a processor (110); interface modules (112) being
`configured to operatively couple to the hot-runner system
`(102) and the mold assembly (104),the processor (110) being
`connected with the interface modules (112); and a controller-
`usable medium (114) embodying instructions (116) being
`executable by the processor (110), the processor (110) being
`connected with the controller-usable medium (114),
`the
`instructions (116)
`including: executable instructions for
`directing the processor (110) to control the hot-runner system
`(102) and the mold assembly (104).
`Other aspects and features of the non-limiting embodi-
`ments will now become apparent to those skilled in the art
`upon review ofthe following detailed description of the non-
`limiting embodiments with the accompanying drawings.
`
`DETAILED DESCRIPTION OF THE DRAWINGS
`
`The non-limiting embodiments will be more fully appre-
`ciated by reference to the following detailed description ofthe
`non-limiting embodiments when taken in conjunction with
`the accompanying drawings, in which:
`FIG. 1 depicts a schematic representation of the single
`stand alone controller system (100); and
`FIG. 2 depicts another schematic representation of the
`single stand alone controller system (100).
`The drawings are not necessarily to scale and may be
`illustrated by phantom lines, diagrammatic representations
`and fragmentary views. In certain instances, details not is
`necessary for an understanding of the embodiments (and/or
`details that renderother details difficult to perceive) may have
`been omitted.
`
`DETAILED DESCRIPTION OF THE
`
`NON-LIMITING EMBODIMENT(S)
`
`Thesingle stand alone controller system (100) may include
`components that are knownto persons skilled in theart, and
`these known components will not be described here; these
`known components are described, at least in part, in the
`following reference books (for example): (i) “/njection Mold-
`ing Handbook’ authored by OSSWALD/TURNG/GRA-
`MANN (SBN: 3-446-21669-2),
`(ii) “Injection Molding
`Handbook” authored by ROSATO AND ROSATO (ISBN:
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`0-412-99381-3), (ii) “Injection Molding Systems” 3"@ Edi-
`tion authored by JOHANNABER (ISBN 3-446-17733-7)
`and/or (iv) “Runner and Gating Design Handbook”authored
`by BEAUMONT(ISBN 1-446-22672-9).
`FIG. 1 depicts the schematic representation of the single
`stand alone controller system (100). The single stand alone
`controller system (100) maybe hereafter referred, from time
`to time, as the “controller system (100). An injection mold-
`ing system (999) is depicted as having the single stand alone
`controller system (100). The injection molding system (999)
`includes (but is not limited to): an extruder assembly (997)
`and a clamping assembly (996). The extruder assembly (997),
`which is also called an injection unit, includes (but is not
`limited to): a barrel assembly (902), a heater assembly (904),
`ascrew assembly (906), a drive assembly (907) for driving the
`screw assembly (906), a machine nozzle (908) connected to
`an exit end of the barrel assembly (902), and a hopper (910)
`connected to an entrance end of the barrel assembly (902).
`The clamping assembly (996) includes(but is notlimitedto):
`a movable platen (912), a stationary platen (914), tie bars
`(916), clamp units (918), lock units (920). A machine con-
`troller (not depicted, but known) is connected to the compo-
`nents of the injection molding system (999). The injection
`molding system (999), also knownas an injection press, is a
`machine for manufacturing plastic products by the injection
`molding process. The injection molding system (999) can
`fasten the mold assembly (104)in either a horizontal or ver-
`tical position. Usually, the mold assembly (104) is horizon-
`tally oriented. Vertical orientation ofthe mold assembly (104)
`is used in some niche applications such as insert molding,
`allowing the machineto take advantage of gravity.
`FIG. 2 depicts another schematic representation of the
`single stand alone controller system (100). The single stand
`alone controller system (100) is used for controlling a com-
`bination of a hot-runner system (102) and a mold assembly
`(104). The mold assembly (104) is connectable to the hot-
`runner system (102). The single stand alone controller system
`(100) includes(but is not limitedto): (1) a processor (110); (11)
`interface modules (112), and (111) a controller-usable medium
`(114).
`The processor (110) may bereferred to as a central pro-
`cessing unit (CPU), which is an electronic circuit that can
`execute computer programs. The CPU orprocessor is the
`portion of a computer system that carries out the instructions
`of a computer program, and is the primary element carrying
`out the computer’s functions. This term has been in use in the
`computer industry at least since the early 1960s. The form,
`design and implementation of CPUs have changedsince the
`earliest examples, but their fundamental operation remains
`much the same. The fundamental operation of most CPUs,
`regardless of the physical form they take,
`is to execute a
`sequence of stored instructions called a program. The pro-
`gram is represented by a series of numbers that are kept in
`some kind of computer memory. There are four steps that
`nearly all CPUsuse in their operation: fetch, decode, execute,
`and writeback. The first step, fetch, involves retrieving an
`instruction (which is represented by a numberor sequence of
`numbers) from program memory. The location in program
`memory is determined by a program counter (PC), which
`stores a number that identifies the current position in the
`program.In other words, the program counter keeps track of
`the CPU’s place in the current program.After an instruction is
`fetched, the PC is incrementedby the lengthofthe instruction
`word in terms of memory units. Often the instruction to be
`fetched mustbe retrieved from relatively slow memory, caus-
`ing the CPUto stall while waiting for the instruction to be
`returned. This issue is largely addressed in modern processors
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`US 8,165,714 B2
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`6
`interface modules (112). The interface modules (112) are
`connections between different elements of the controller sys-
`tem (100) and elements that exist outside of the controller
`system (100). The interface modules (112) are also called
`electrical connectors (for example), which are a conductive
`device for joining electrical circuits together. The connection
`maybe temporary, as for portable equipment, or may require
`a tool for assembly and removal, or may be a permanent
`electrical joint between two wires or devices. There are hun-
`dreds of types of electrical connectors. In computing, an
`electrical connector can also be knownas a physical interface
`(compare Physical Layer in OSI model of networking). Con-
`nectors may join two lengthsof flexible wire or cable, or may
`connect a wire or cable to an electrical terminal.
`
`5
`by cachesandpipeline architectures (see below). Theinstruc-
`tion that the CPU fetches from memory is used to determine
`what the CPU is to do. In the decode step, the instruction is
`broken upintoparts that have significanceto other portions of
`the CPU.The wayin which the numerical instruction value is
`interpreted is defined by the CPU’s instruction set architec-
`ture (ISA). Often, one group of numbers in the instruction,
`called the opcode, indicates which operation to perform. The
`remaining parts of the number usually provide information
`required for that instruction, such as operandsfor an addition
`operation. Such operands may be given as a constant value
`(called an immediate value), or as a place to locate a value: a
`register ora memory address, as determined by some address-
`ing mode. In older designs the portions of the CPU respon-
`sible for instruction decoding were unchangeable hardware
`devices. However, is in more abstract and complicated CPUs
`and ISAs, amicroprogram isoften used to assist in translating
`instructions into various configuration signals for the CPU.
`This microprogram is sometimes rewritable so that it can be
`modified to change the way the CPU decodes instructions
`even after it has been manufactured.
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`The controller-usable medium (114) embodies a grouping
`of instructions (116), hereafter referred to as the “instructions
`(116)”, which are executable by the processor (110). The
`processor (110)
`is connected with the controller-usable
`medium (114). The controller-usable medium (114) is a
`material on which data are recorded, such as, but not limited
`to: CD-RWs (compact discs), DVDs (digital video disk),
`external hard drives, magnetic tape,etc.
`After the fetch and decodesteps, the execute step is per-
`In computing, an executable file, such as instructions
`formed. During this step, various portions of the CPU are
`(116), causes the controller system (100) to perform indicated
`connected so they can perform the desired operation.If, for
`25
`
`instance, an addition operation was requested, an arithmetic tasks according to encodedinstructions, as opposedtoafile
`logic unit (ALU)will be connectedto a set of inputs and a set
`that only contains data. Files that contain instructions for an
`of outputs. The inputs provide the numbers to be added, and
`interpreter or CPU or virtual machine may be considered
`the outputs will contain the final sum. The ALU contains the
`executables, but are more specifically called scripts or byte-
`code. Executables are also called “binaries” in contrast to the
`circuitry to perform simple arithmetic and logical operations
`on the inputs (like addition and bitwise operations). If the
`program’s source code. In computer science, source code
`addition operation producesa result too large for the CPU to
`(commonly just source or code) is any collection of state-
`ments or declarations written in some human-readable com-
`handle, an arithmetic overflow flag in a flags register may also
`be set.
`puter programming language. Source code is the mechanism
`most often used by programmersto specify the actions to be
`performed by a computer. The source code which constitutes
`a program is usually held in one or moretextfiles, sometimes
`stored in databasesas stored procedures and mayalso appear
`as code snippets printed in books or other media. A large
`collection of source code files may be organized into a direc-
`tory tree, in which case it may also be knownasa sourcetree.
`A computer program’s source codeis the collectionis offiles
`needed to convert from human-readable form to some kind of
`
`Thefinal step, writeback, simply “writes back”the results
`of the execute step to some form of memory. Very often the
`results are written to some internal CPU register for quick
`access by subsequentinstructions. In other cases results may
`be written to slower, but cheaper and larger, main memory.
`Sometypes of instructions manipulate the program counter
`rather than directly produce result data. These are generally
`called “jumps”andfacilitate behaviorlike loops, conditional
`program execution (through the use of a conditional jump),
`and functions in programs. Many instructions will also
`changethestate of digits in a “flags” register. These flags can
`be used to influence how a program behaves, since they often
`indicate the outcomeof various operations. For example, one
`type of “compare”instruction considers two values andsets a
`numberin the flags register according to which oneis greater.
`This flag could then be used by a later jump instruction to
`determine program flow.After the execution ofthe instruction
`and writeback ofthe resulting data, the entire process repeats,
`with the next instruction cycle normally fetching the next-in-
`sequenceinstruction because of the incremented value in the
`program counter. Ifthe completed instruction was a jump, the
`program counter will be modified to contain the address ofthe
`instruction that was jumpedto, and program execution con-
`tinues normally.
`In more complex CPUs than the one
`described here, multiple instructions can be fetched, decoded,
`and executed simultaneously. This section describes whatis
`generally referred to as the “Classic RISC pipeline,’ which in
`fact is quite common among the simple CPUs used in many
`electronic devices (often called microcontroller). It largely
`ignores the important role of CPU cache, andtherefore the is
`access stage ofthe pipeline.
`Theinterface modules (112) are configured to operatively
`couple to the hot-runner system (102) and couple to the mold
`assembly (104). The processor (110) is connected with the
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`computer-executable form. The source code may be con-
`verted into an executablefile by a compiler, or executed on the
`fly from the humanreadable form with the aid of an inter-
`preter. The code base of a programmingproject is the larger
`collection of all the source code of all the computer programs
`which make up the project. The instructions (116) include
`(but are not limited to) executable instructions for directing
`the processor (110) to control the hot-runner system (102)
`and the mold assembly (104). More specifically, the instruc-
`tions (116) include(but are not limited to) executable instruc-
`tions for directing the processor (110) to control: (1) a set of
`thermal-managementdevices (105), and (ii) a group ofelec-
`trically-actuated devices (106). The set of thermal-manage-
`mentdevices (105) is mountedto the hot-runner system (102)
`and is also mounted to the mold assembly (104). The group of
`electrically-actuated devices (106) is mounted to the hot-
`runner system (102) and is also mounted to the mold assem-
`bly (104). It will be appreciated that the set of thermal-man-
`agement devices (105) may include(butis not limited to: (i)
`a set of heaters (known but not depicted), (i1) a set of cooling
`devices (knownbut not depicted) with cooling conduits with
`associated cooling support structures and cooling fluid,etc, or
`the combination of(i) and(ii).
`According to a variationofthe single stand alone controller
`system (100), the group of electrically-actuated devices (106)
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`Hunting Titan, Inc.
`Ex. 1027
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`Ex. 1027
`Pg. 006
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`7
`includes a collection of hot-runner valve stems (107). The
`hot-runnervalve stems (107) maybeeither individually actu-
`atedor plate actuated.
`Theinstructions (116) further include additional (or more)
`executable instructions for directing the processor (110) to
`control the collection of hot-runner valve stems (107).
`According to another variation of the single stand alone
`controller system (100), the group of electrically-actuated
`devices (106)
`includes moving-mold components (108).
`Examples of the moving-mold components (108) include
`(but are not limited to): core pulls, and/or slides, etc. The
`instructions (116)
`further
`include additional executable
`instructions for directing the processor (110) to control the
`moving-mold components (108).
`According to yet anothervariation ofthe single stand alone
`controller system (100), the group of electrically-actuated
`devices (106) includes molded-part ejection components
`(109). Examples of the molded-part ejection components
`(109) include (but are not limited to): ejector pins, and/or
`stripper plates, etc. The instructions (116) further include
`additional executable instructions for directing the processor
`(110) to control the molded-part ejection components (109).
`According to a yet again variation of the single stand alone
`controller system (100), the group of electrically-actuated
`devices (106)
`include molded-part removal components
`(111). An example of the molded-part removal components
`(111) includes(but is not limited to): swing chutes, etc. The
`instructions (116)
`further
`include additional executable
`instructions for directing the processor (110) to control the
`molded-part removal components (111).
`The technical effect of the controller system (100) is by
`controlling all electrified functions (such as, heating zones,
`motorized and/or solenoid valve stem control, core pull con-
`trol, ejector control, swing chute control, etc) of the combi-
`nation of the hot-runner system (102) and the mold assembly
`(104) from the controller system (100), the cost, required
`floor space, and complexity are minimized while maximizing
`potential performance andefficiency.
`Theelectrically-actuated devices (106) each require some
`form of controller in addition to a standard temperature con-
`troller (known but not depicted) used for the hot-runner sys-
`tem (102). Advantageously, the controller system (100) com-
`bines the knownindividual controllers (not depicted) with the
`known temperature controller (not depicted) into the control-
`ler system (100) with one centralized processor/control point.
`The controller system (100) can be treated as one single
`integrated master system controller.
`Electrically-actuated devices (106) used in the combina-
`tion of the hot-runner system (102) and the mold assembly
`(104) each require some form of controller in addition to the
`standard temperature controller used for the hot-runner sys-
`tem (102). This arrangement of the knownart negatively
`impacts the end user as the known arrangement occupies
`valuable extra floor space, requires costly and inconvenient
`multiple supply power feeds, has multiple locations for the 55
`operator to make process adjustments, and the various con-
`trollers often do not interface with each other in a practical
`manner which allows for situations resulting in equipment
`damage (e.g., actuating hot runner valve stems when the
`temperature controller is off or the Hot Runneris cold) or 60
`poor overall molding system performance.
`The controller system (100) combines the functions of the
`individual known controllers (not depicted) with a known
`temperature controller (not depicted) into one integrated
`single stand alone controller system (100), so thatthe enduser 65
`only needs the one piece of control equipment on the shop
`floor, one supply powerfeed, one location for the operator to
`
`40
`
`45
`
`50
`
`8
`make process adjustments, and all of the ideal interfaces/
`interlocks to prevent any equipment damage andensure opti-
`mum system performance.
`The controller system (100) provides a single piece of
`auxiliary equipmentthat will control hot-runner system tem-
`peratures as well as any orall electrically actuated devices
`and/or axis on the combination ofthe hot-runner system (102)
`and the mold assembly (104). Examples of these additional
`devices include,but are notlimitedto, electrically actuated or
`motorized valve stem (or stems), electrically actuated or
`motorized core pulls, and electrically actuated or motorized
`ejector/stripper pins/plates, each of which require somesort
`of controller. The controller system (100) would take the
`hardware components, methods, and software (or similar
`capable of performing the same control function) typically
`used for each of these controllers and incorporate them
`together into one piece of equipmentfor controlof the entire
`system. As an example, the controller system (100) integrates
`control of a servo-motor driven valve stem plate and a core
`pull actuator with a temperature control. The servo drive, line
`filter, relays, DC powersupply,fuses/circuit breakers, wiring,
`etc, used to control the servo motor would be assembled
`together with the components that make up a temperature
`controller (solid state switching devices, thermocouple moni-
`toring devices, central processor and its required compo-
`nents, operator interface device, etc) into the controller sys-
`tem (100). The controller system (100) contains the necessary
`software/firmware to be able to control both the set of ther-
`
`mal-managementdevices (105) of the hot-runner system and
`the valve stem motor positioning, and this arrangement
`ensures(or interlocks) the operation of the valve stem motor
`to occur only whenit is appropriate to do so (that is, when the
`hot-runner system (102) is at the required temperature) thus
`preventing potential equipment damage (valve stem damage
`from pushing againstsolidified resin) and optimizing perfor-
`mance.
`
`It is noted that the foregoing has outlined the non-limiting
`embodiments. Thus, although the description is made for
`particular non-limiting embodiments, the scope ofthe present
`inventionis suitable and applicable to other arrangements and
`applications. Modifications to the non-limiting embodiments
`can be effected without departing from the scope the inde-
`pendentclaims. It is understood that the non-limiting embodi-
`ments are merelyis illustrative.
`Whatis claimedis:
`
`1. A single stand alone controller system (100) for control-
`ling a combination of a hot-runner system (102) and a mold
`assembly (104), the mold assembly (104) being connectable
`to the hot-runner system (102), the single stand alone con-
`troller system (100) comprising:
`a processor (110);
`Interface modules (112) being configured to operatively
`couple to the hot-runner system (102) and the mold
`assembly (104), the processor (110) being connected
`with the interface modules (112); and
`a controller-usable medium (114) embodying a grouping
`of instructions (116) being executable by the processor
`(110), the processor (110) being connected with the
`controller-usable medium (114),
`the grouping of
`instructions (116) including:
`executable instructionsfor directing the processor (110)
`to control the hot-runner system (102) and the mold
`assembly (104)
`wherein:
`the grouping ofinstructions (116) further includes:
`additional executable instructions for directing the pro-
`cessor (110) to control:
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 007
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 007
`
`

`

`US 8,165,714 B2
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`6. Th