USOO8165714B2
`
`(12) Unlted States Patent
`(10) Patent No.:
`US 8,165,714 B2
`
`Mier et al.
`(45) Date of Patent:
`Apr. 24, 2012
`
`(54) CONTROLLER FOR CONTROLLING
`COMBINATION OF HOT-RUNNER SYSTEM
`AND MOLD ASSEMBLY
`
`6,529,796 B1
`6,589,039 B1 *
`7,214,048 B2
`7,258,536 B2
`
`3/2003 Kroeger et al.
`7/2003 Doughty et a1.
`5/2007 Kim
`8/2007 Olaru et al.
`
`.............. 425/ 145
`
`(75)
`
`Inventors: Angelo Mier, Colchester, VT (US);
`-
`Keith Cam”: Called“: CA (Us);
`22211188?“ Romndo’ Thousand oaks’
`
`7,580,771 B2 *
`88888883888 21*
`2008/0006955 A1*
`2008/0290541 A1
`
`8/2009 Quail et 31' """""""""" 700/197
`113.1 e a .
`..................
`.
`88888 88°88 ‘8 81'
`264/401
`1/2008 Niewels ....................... 264/405
`11/2008 Baumann
`
`(73) Assignee: Husky Injection Molding Systems
`Ltd., Bolton, Ontario (CA)
`
`EP
`
`FOREIGN PATENT DOCUMENTS
`0967063
`6/1999
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U'S'C' 15403) by 294 days.
`(21) Appl. No.: 12/692,916
`
`* cited by examiner
`
`Primary Examiner 7 Albert DeCady
`Assistant Examiner 7 Anthony Whittington
`
`(22)
`
`Filed:
`
`Jan. 25, 2010
`
`(65)
`
`Prior Publication Data
`
`US 2011/0184550A1
`
`Jul. 28, 2011
`
`(51)
`
`Int. Cl.
`(2006.01)
`329C 39/00
`52 US. Cl.
`........................................ 700/197; 425/145
`E58; Field of Classification Search
`700/197
`""""""""" 700/206
`S
`1't'
`filf
`1t
`hh't.
`ee app lca lon
`e or comp e e searc
`ls ory
`References Cited
`
`(56)
`
`U.S. PATENT DOCUMENTS
`5,795,511 A
`8/1998 Kalantzis et al.
`6,000,831 A
`12/1999 Triplett
`6,421,577 B1
`7/2002 Triplett
`
`(57)
`
`ABSTRACT
`
`A single stand alone controller system (100) for controlling
`combination of hot-runner system (102) and mold assembly
`(1 04), assembly (1 04) connectable to system (1 02), controller
`.
`.
`.
`system (100) comprlslng: processor (110); 1nterface modules
`.
`(112) configured to operatlvely couple to system (102) and
`.
`assembly (104), processor (110) connected w1th 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-
`sor (110) to control said system (102) and said assembly
`(104).
`
`7 Claims, 2 Drawing Sheets
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`100
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`104
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`995
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`920
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`912
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`916
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`914
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`918
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`997
`T_T_T_T_T_‘
`996 <4 999
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 001
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 001
`
`

`

`US. Patent
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`Apr. 24, 2012
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`Sheet 1 of2
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`US 8,165,714 B2
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` 912916
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`920
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`917
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`919
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`104
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`995
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`100
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`997
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`999
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`996
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`FK3.1
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 002
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 002
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`

`

`US. Patent
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`Apr. 24, 2012
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`Sheet 2 of2
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`US 8,165,714 B2
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`100
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`FIG.2
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 003
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`Hunting Titan, Inc.
`Ex. 1027
`Pg. 003
`
`

`

`US 8,165,714 B2
`
`1
`CONTROLLER FOR CONTROLLING
`COMBINATION OF HOT-RUNNER SYSTEM
`
`AND MOLD ASSEMBLY
`
`TECHNICAL FIELD
`
`An aspect of the present invention generally relates to (but
`is not limited to) a controller for molding systems including
`(but not limited to) a controller for controlling a combination
`of a hot-runner system and a mold assembly.
`
`BACKGROUND
`
`The first man-made plastic 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 worked like a large hypodermic needle,
`using a plunger to inject plastic through a heated cylinder into
`a mold. The industry expanded rapidly in the 1940s because
`World War II created a huge demand for inexpensive, mass-
`produced products. In 1946, American inventor James Wat-
`son HENDRY built 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
`injection molding process.
`Injection molding machines consist of a material hopper,
`an injection ram or screw-type plunger, and a heating unit.
`They are also known as presses, they hold the molds in which
`the components are shaped. Presses are rated by tonnage,
`which expresses the amount of clamping force that the
`machine can exert. This force keeps the mold closed during
`the injection process. Tonnage can vary from less than 5 tons
`to 6000 tons, with the higher figures used in comparatively
`few manufacturing operations. The total clamp force needed
`is determined by the projected area of the part being molded.
`This projected area is multiplied by a clamp force of from 2 to
`8 tons for each square inch of the projected areas. As a rule of
`thumb, 4 or 5 tons per square inch can be used for most
`products. If the plastic material is very stiff, it will require
`more injection pressure to fill the mold, thus more clamp
`tonnage to hold the mold closed. The required force can also
`be determined by the material used and the size of the part,
`larger parts require higher clamping force. With Injection
`Molding, granular plastic is fed by gravity from a hopper into
`a heated barrel. As the granules are slowly moved forward by
`a screw-type plunger, the plastic is forced into a heated cham-
`ber, where it is melted. As the plunger advances, the melted
`plastic is forced through a nozzle that rests against the mold,
`allowing it to enter the mold cavity through a gate and runner
`system. The mold remains cold so the plastic solidifies almost
`as soon as the mold is filled.
`
`Mold assembly or die are terms used to describe the tooling
`used to produce plastic parts in molding. The mold assembly
`are used in mass production where thousands of parts are
`produced. Molds are typically constructed from hardened
`steel, etc.
`US. Pat. No. 5,795,511 (Inventor: KALANTZIS, et al.;
`Filed: 6 Jun. 1995) discloses an apparatus and method for
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`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.
`US. 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.
`
`US. 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 having at least one heater and
`at least one temperature sensor generating a temperature indi-
`cating signal.
`US. 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.
`
`US. 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
`
`(Inventor: KROEGER, et al.; Filed: 23 Jan. 2003) discloses an
`injection mold apparatus having multiple injection zones,
`each zone having at least one heater and at least one tempera-
`ture sensor generating a temperature indicating signal.
`US. Pat. No. 7,214,048 (Inventor: KIM; Filed: 25 May
`2004) discloses control for a valve pin through a linear motor
`controlled by a pulse signal and through a cooling block, so
`that an opening/closing amount of a gate can be precisely
`managed.
`US. Pat. No. 7,258,536 (Inventor: OLARU, et al.; Filed:
`21 Jun. 2004) discloses a control module attached to a
`machine platen of an injection molding machine. The control
`module is coupled to at least one sensor that reports a value of
`a processing condition associated with an injection mold and
`is disposed within the injection mold. The control module is
`also coupled to at least one controllable device that varies the
`processing condition of the injection mold and is disposed
`within the injection mold. The control module collects and
`processes sensor output, and provides a control signal to at
`least one controllable device. A display interface module is
`linked to the control module. The display interface module
`accepts user-entered data set-points, provides the user-en-
`tered data set-points to the control module, and collects the
`processed sensor output from the control module for display
`to a user.
`United States Patent Publication Number 20060082009
`
`(Inventor: Quail, et al; Filed: 19 Oct. 2004) discloses an
`intelligent molding system that makes use of data directly
`associated with a molding environment or particular 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
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 004
`
`

`

`US 8,165,714 B2
`
`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 and to 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 independent claims, and
`it is also understood that the scope of the present invention is
`not limited to: (i) the dependent claims, (ii) the detailed
`description of the non-limiting embodiments, (iii) 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
`understood that “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 of the 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 render other details difficult to perceive) may have
`been omitted.
`
`DETAILED DESCRIPTION OF THE
`
`NON-LIMITING EMBODIMENT(S)
`
`The single stand alone controller system (100) may include
`components that are known to persons skilled in the art, 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) “Injection Mold-
`ing Handbook” authored by OSSWALD/TURNG/GRA-
`MANN (ISBN: 3-446-21669-2),
`(ii) “Injection Molding
`Handbook” authored by ROSATO AND ROSATO (ISBN:
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`0-412-99381-3), (iii) “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) may be 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),
`a screw 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 not limited to):
`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 known as 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 machine to 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 limited to): (i) a processor (110); (ii)
`interface modules (112), and (iii) a controller-usable medium
`(114).
`The processor (110) may be referred to as a central pro-
`cessing unit (CPU), which is an electronic circuit that can
`execute computer programs. The CPU or processor 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 changed since 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 CPUs use in their operation: fetch, decode, execute,
`and writeback. The first step, fetch, involves retrieving an
`instruction (which is represented by a number or 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 incremented by the length ofthe instruction
`word in terms of memory units. Often the instruction to be
`fetched must be retrieved from relatively slow memory, caus-
`ing the CPU to stall while waiting for the instruction to be
`returned. This issue is largely addressed in modern processors
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 005
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 005
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`

`

`US 8,165,714 B2
`
`5
`by caches and pipeline architectures (see below). The instruc-
`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 up into parts that have significance to otherportions of
`the CPU. The way in 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 operands for 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 or a 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, a microprogram is often 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.
`
`After the fetch and decode steps, the execute step is per-
`formed. During this step, various portions of the CPU are
`connected so they can perform the desired operation. If, for
`instance, an addition operation was requested, an arithmetic
`logic unit (ALU) will be connected to a set of inputs and a set
`of outputs. The inputs provide the numbers to be added, and
`the outputs will contain the final sum. The ALU contains the
`circuitry to perform simple arithmetic and logical operations
`on the inputs (like addition and bitwise operations). If the
`addition operation produces a result too large for the CPU to
`handle, an arithmetic overflow flag in a flags register may also
`be set.
`
`The final 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 subsequent instructions. In other cases results may
`be written to slower, but cheaper and larger, main memory.
`Some types of instructions manipulate the program counter
`rather than directly produce result data. These are generally
`called “jumps” and facilitate behavior like loops, conditional
`program execution (through the use of a conditional jump),
`and functions in programs. Many instructions will also
`change the state of digits in a “flags” register. These flags can
`be used to influence how a program behaves, since they often
`indicate the outcome of various operations. For example, one
`type of “compare” instruction considers two values and sets a
`number in the flags register according to which one is 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-
`sequence instruction 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 jumped to, 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 what is
`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, and therefore the is
`access stage of the pipeline.
`The interface 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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`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
`may be 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 known as a physical interface
`(compare Physical Layer in OSI model of networking). Con-
`nectors may join two lengths of flexible wire or cable, or may
`connect a wire or cable to an electrical terminal.
`
`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.
`In computing, an executable file, such as instructions
`(116), causes the controller system (100) to perform indicated
`tasks according to encoded instructions, as opposed to a file
`that only contains data. Files that contain instructions for an
`interpreter or CPU or virtual machine may be considered
`executables, but are more specifically called scripts or byte-
`code. Executables are also called “binaries” in contrast to the
`
`program’s source code. In computer science, source code
`(commonly just source or code) is any collection of state-
`ments or declarations written in some human-readable com-
`
`puter programming language. Source code is the mechanism
`most often used by programmers to specify the actions to be
`performed by a computer. The source code which constitutes
`a program is usually held in one or more text files, sometimes
`stored in databases as stored procedures and may also 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 known as a source tree.
`A computer program’s source code is the collection is of files
`needed to convert from human-readable form to some kind of
`
`computer-executable form. The source code may be con-
`verted into an executable file by a compiler, or executed on the
`fly from the human readable form with the aid of an inter-
`preter. The code base of a programming project 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: (i) a set of
`thermal-management devices (105), and (ii) a group of elec-
`trically-actuated devices (106). The set of thermal-manage-
`ment devices (105) is mounted to 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 (but is not limited to: (i)
`a set of heaters (known but not depicted), (ii) a set of cooling
`devices (known but not depicted) with cooling conduits with
`associated cooling support structures and cooling fluid, etc, or
`the combination of (i) and (ii).
`According to a variation ofthe single stand alone controller
`system (100), the group of electrically-actuated devices (106)
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 006
`
`Hunting Titan, Inc.
`Ex. 1027
`Pg. 006
`
`

`

`US 8,165,714 B2
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`10
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`includes a collection of hot-runner valve stems (107). The
`hot-runner valve stems (107) may be either individually actu-
`ated or plate actuated.
`The instructions (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 another variation 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 and efiiciency.
`The electrically-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 known individual 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 known art 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 Runner is 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 that the enduser 65
`only needs the one piece of control equipment on the shop
`floor, one supply power feed, one location for the operator to
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`make process adjustments, and all of the ideal interfaces/
`interlocks to prevent any equipment damage and ensure opti-
`mum system performance.
`The controller system (100) provides a single piece of
`auxiliary equipment that will control hot-runner system tem-
`peratures as well as any or all 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 not limited to, 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 some sort
`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 equipment for control of 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 power supply, 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-management devices (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 when it 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 against solidified 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
`invention is suitable and applicable to other arrangements and
`applications. Modifications to the non-limiting embodiments
`can be effected without departing from the scope the inde-
`pendent claims. It is understood that the non-limiting embodi-
`ments are merely is illustrative.
`What is claimed is:
`
`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 instructions for directing the processor (110)
`to control the hot-runner system (102) and the mold
`assembly (104)
`wherein:
`the grouping of instructio