Visualizing the interior of molds | A measurement system that achieves quality improvement and cost reduction in injection molding.
The in-mold measurement system (Mold Marshalling System) is a measurement system for injection molding that converts the behavior of resin within the mold, which has traditionally been a black box, into signals or voltage using sensors and dedicated amplifiers installed inside the mold. It outputs this data in waveform form to a computer or various measuring instruments in real-time. By utilizing the quantified data, it can be applied to various purposes such as setting optimal molding conditions, automatic sorting of defective products, quality control, and mold evaluation. 【Features】 ■ Determine injection molding quality through waveforms By setting monitoring limits on the measurement waveforms during good product molding, it is possible to detect molding defects such as short shots and overpacking. ■ Digitalize the "intuition and know-how" of technicians It can digitalize the areas of intuition and know-how that were previously reliant on technicians, preventing personalization. ■ Reproduce quality even in different environments By setting molding conditions to match the measurement waveforms with those of good product molding, it is possible to produce products of equivalent quality even under different environments (machines, factories, countries, etc.).
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Reasons to Choose the Mold Marshalling System ■ Affordable Introduction of In-Mold Sensing To make in-mold sensing more accessible, we offer it at a price that is easy to adopt in research and development as well as mass production lines. ■ Achieving High-Speed Response of 8ms: Futaba's Resin Temperature Sensor Our developed resin temperature sensor, using the "fiber optic infrared method," can accurately measure the resin temperature that changes moment by moment within the mold. ■ Global Track Record Since starting sales in 1999, we have been adopted by many customers both domestically and internationally. We provide robust sales and support within Japan, and we also have sales bases overseas to fully support implementations abroad. ■ Comprehensive Support System To help you utilize in-mold sensing, we offer free webinars and sensing schools tailored to individual companies. *Please download the catalog or feel free to contact us. You can also check it from the dedicated website linked in the related links.
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Overview video of the in-mold measurement system https://youtu.be/BGB0zHnQLmk?si=gC0R1yiTs00GUwQ1 *Please feel free to download the catalog or contact us. You can also check it on the dedicated website linked below.*
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| Model number | overview |
|---|---|
| Mold Internal Resin Pressure Measurement System | It is possible to display the resin pressure inside the mold, measured by a pressure sensor, in real-time as a waveform using dedicated measurement software. By saving the waveform during good product molding as a "reference waveform," it can be utilized for setting conditions when starting molding under different environments. Additionally, by setting monitoring limits on the reference waveform, it can automatically detect waveforms that fall outside the limits in the event of molding defects such as short shots or burrs, and output an alarm signal. |
| Mold Internal Resin Temperature Measurement System | It is possible to display the resin temperature inside the mold, measured by a resin temperature sensor, in real-time as a waveform using commercially available measuring instruments and data loggers. Our resin temperature sensor adopts a fiber optic infrared method, achieving a high-speed response time of 8 ms, allowing it to track the constantly changing resin temperature within the mold. This contributes to the optimization of various conditions such as holding pressure, cooling, nozzle temperature, mold temperature, ejection temperature of molded products, and even the molding cycle. |
| Mold Surface Temperature Measurement System | It is possible to display the mold temperature measured by the surface temperature sensor in real-time as a waveform using commercially available measuring devices or data loggers. This can be utilized to improve the quality of molded products and enhance productivity by optimizing the temperature settings for resin curing, reducing the number of discard shots at the start of molding, and checking the temperature distribution for each cavity when using multi-cavity molds. |
| Injection Molding Monitoring System | By using the injection molding monitoring system, it is possible to connect to pressure sensors, resin temperature sensors, mold surface temperature sensors, and mold opening measurement sensors to measure various data, and it is also possible to integrate information from measurement devices and injection molding machines from other manufacturers. By performing multivariable composite monitoring, it can be utilized for a wide range of applications, such as confirming the correlation of each measurement element, establishing conditions for starting molding under different environments, and monitoring defects in mass production molding. |
| Flow velocity measurement system | The flow front speed of the resin flowing within the cavity, measured by a flow velocity sensor, can be displayed in real-time as a waveform using dedicated measurement software. The measurement can be easily performed with a single flow velocity sensor, regardless of the flow direction of the resin. Additionally, it is possible to output a signal when the resin flow front passes, which can be utilized for controlling the injection molding machine. |
| Flow front detection system | The flow front detection sensor detects the arrival of resin flow front and outputs control signals to the injection molding machine and external devices. The flow front detection sensor, which adopts a fiber optic infrared method, achieves a high-speed response time of 8 ms, making it suitable for precise control of injection molding machines and external devices. This enables applications such as V-P switching control of injection molding machines and valve gate opening and closing control of hot runners, contributing to the stabilization of the quality of molded products. |
| Injection Molding AI System | This is a system that supports the injection molding process using AI. The AI learns the state inside the mold during molding and can automatically determine the quality of the molded products and suggest conditions for producing good products. By combining it with our resin pressure measurement system, it demonstrates its capabilities and achieves efficient manufacturing. |
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Company information
Our company was established in 1948 (Showa 23) with the fundamental philosophy of "contributing to the development of the industrial world by supplying essential equipment as a member of industrial society." Over the past 70 years, we have continuously built our efforts and grown to offer a wide range of products, including electronic devices such as fluorescent display tubes, organic EL displays, touch sensors, composite modules, industrial remote control equipment, and hobby remote control equipment, as well as production equipment such as molds, plate products, and molding rationalization equipment, while continuing our global business expansion. Moving forward, we will consistently keep in mind our social responsibility as a company and strive for sustainable growth that anticipates global changes, ensuring the trust and satisfaction of all our stakeholders. The foundation of everything starts from one. Based on "a direct view of essence," we will create indispensable equipment and services for our customers and contribute to global development. We sincerely ask for your continued support.