ABOUT CAVITY EYE
Success for your critical injection moulding applications.
Zero defect in production to increase your profit!
What does Cavity Eye offer?
CAVITY EYE system consists on the one hand out of pressure sensors installed in the injection molding tool. The second part of the system includes hardware and software that evaluates information from the injection molding machine and the internal pressure curves of each cavity in the tool. Thus, a reliable quality statement for each produced part is possible.
In the conventional injection molding process, the flow of information ends at the end of the machine nozzle – what happens in the mould remains invisible to the user.
CAVITY EYE enables the visualization and evaluation of the internal pressure curves, a systematic process control for each individual cavity in your production. Our system looks directly into every cavity – this is CAVITY EYE.
The injection molding process is a complex process of interaction of many individual parameters, the mould, the raw material batches used and, of course, depending on the machine operator in adjusting settings during production.
The focus is ultimately on increasing product quality and improving profitability with the goal of zero defects to your customer.
Our CAVITY EYE process monitoring system observes and evaluates the quality of an injection molded part based on the internal pressure curve of each cavity. Evaluation elements and tolerance curves can be set or adjusted manually or automatically. These limits are defined as part of a DoE (Design of Experience) during the running-in process of the tool. Thus, an individual quality prediction for each individual produced part is possible, which the system evaluates as good or bad part and gives a corresponding selection signal to the periphery.
Your advantages when using CAVITY EYE with the aim of zero-defect production
- Reduction of quality costs
- Increase process efficiency and process reliability
- Saving of sorting costs
- Reduction of customer complaints
- Upgrade of already existing moulds with few efforts
- Increase plant efficiency and short payback period (ROI)
Best solution for mould instrumentation
Sensor Fixing Plates
Pressure Sensors (PC15,PC26)
1 kN, up to 40 kN
Mould Plug with Memory
CAVITY EYE pressure sensors are waterproof (IP67) and shock resistant. CAVITY EYE sensors provide a wide pressure range from 1 to 40 kN, which is suitable for almost any application. The necessary installation diameters are 15 or 26 mm.
CAVITY EYE uses only indirect sensors. According to investigations, the indirect measurement is as accurate as a direct measurement. A major advantage is that the sensors are usually mounted only once and do not need to be maintained or disassembled over the entire lifetime of the tool. Thus, the risk of damage to the wiring is excluded. Sensors and cables are reliably protected by pressure plates or stainless steel covers.
For the majority of the tools, the sensors are mounted in the clamping plate on ejector side. Pressure is transferred from the (existing) ejector pin via an additional transfer pin to the top of the sensor (measuring surface). Alternatively, we have also developed solutions for a measurement directly under a measuring pin.
Memory in mould (MiM)
In the Memory in Mould Plug (MiM), the wiring of the pressure sensors is carried out. The MiM is firmly connected to the tool. In each case 8 – or in a larger design – 32 sensors can be read out. If more sensors are required, several plugs can be used. Due to the built-in memory module, all important information about the tool is stored in the MiM (reference curves, tolerances, switching point, sensor identifiers, pin diameter, cavity identification, machine parameters). Thus, these data can be accessed immediately when changing the injection moulding machine and parameter adjustment can be done to the already made digital fingerprint (cavity pressure curve) of the respective injection molded part.
We gladly assist you in selecting the sensors and the right position. More information under TECHNICAL DETAILS
|Sensor Type||Max. Load [N]||Max. Mould Temperature [°C]||Diameter [mm]||Height [mm]||Max. Ejector Diameter / Area [mm] / [mm2]|
|PC15-1-AA||1.000||90||15||8||3 / 7|
|PC15-1-AA-MT||1.000||150||15||8||3 / 7|
|PC15-1-AA-HT||1.000||200||15||8||3 / 7|
|PC15-5-AA||5.000||90||15||8||6 / 28|
|PC15-5-AA-MT||5.000||150||15||8||6 / 28|
|PC15-5-AA-HT||5.000||200||15||8||6 / 28|
|PC26-20-AA||20.000||90||26||12||12 / 113|
|PC26-20-AA-MT||20.000||150||26||12||12 / 113|
|PC26-20-AA-HT||20.000||200||26||12||12 / 113|
|PC26-40-AA||40.000||90||26||12||20 / 314|
|PC26-40-AA-MT||40.000||150||26||12||20 / 314|
|PC26-40-AA-HT||40.000||200||26||12||20 / 314|
|Product Data Sheets|
|PC15 and PC26 Pressure sensors|
|MPM (Mould Plug with Memory)|
Best solution for measuring cavity pressure, control the molding machine and lot more.
Smart Measuring Plug (SMP)
Smart Control Plug (SCP)
Smart Control Socket (SCS)
Cavity Eye Base Unit
Cavity Eye measuring system for zero-defect production
The latest generation CAVITY EYE SMP Smart Measuring Plug is a robust, industrial-grade, IP 67 plug connected directly to the Smart Control Socket SCS and sends data to an integrated ARM-based measurement system. It therefore offers an industrial method for measuring the cavity pressure of single and multi-cavity moulds even under tough production conditions. The CAVITY EYE system unit is installed in the machine control cabinet of the injection molding machine. The Smart Control Plug provides the interface for signal transmission from and to the injection molding machine or to connected peripherals. Usually, no EUROMAP interface is required for selection of good and bad parts.
The software offers the possibility to set an automatic adjustable tolerances over time and pressure axis, alternatively individual monitoring strategies can be defined.
The CAVITY EYE system is ideally suited for balancing of multi-cavity moulds, fast start-up of production, detection of material variations and even easy mould transfers.
|Smart Measuring Plug|
|Plug type and size||Harting HAN 16A||Harting HAN 16B|
|Number of channels||8||32|
|Resolution||32 bit||32 bit|
|Sampling rate||200…2000 Hz||200…2000 Hz|
|Operation temperature||10…85 °C||10…85 °C|
|Power supply||6…9 V (7,5 V standard)||6…9 V (7,5 V standard)|
|Measuring cable length||5…15 m||5…15 m|
|Control software||Cavity Eye Base 25.x||Cavity Eye Base 25.x|
SMART MOULDING CONTROL
The next generation of cavity pressure control for 0 ppm scrap, on-line quality and process control for 24 hours and 7 days
Industry 4.0 Connection of external devices in real time
We create individual software solutions for the combination of machine data, cavity pressure curves and communication with external devices or signals.
Transparency and efficiency in your production – data integration into your system. Available online at any time.
The Smart Moulding Control is an online and real-time injection moulding quality and process control system, including:
- (SMP) Smart Measuring Plug;
- (MSC) Monitor, Switch, Computer;
- (SCP) Smart Control Plug
The Smart Measuring Plug provides the measurement and based on the pressure curve, the control signal is sent to the SCP which communicates with the injection moulding machine and controls the selector, the robot the transfer (switch over) or stops the machine by 24 V digital signals. One, two or more SMP plug can be connected to the router so the maximum number of the sensors are unlimited. The system is fixed to the injection moulding machine.
Our support is the pillar of your success
Moulding, training, consulting and cavity pressure control
Cavity Eye provides services to guarantee the success. We believe that the cavity pressure application is easy, but the new customers have to understand and study the basic rules of this technology.
The best way is to make the first projects together, from design to DOE. If you need more training, we train injection moulding from beginners to experts.
First project – let’s start together
3 days service in plant. The preparation of the project is online. We consult about the goal of the project, former production failures and statistics, instrumentation, sensor positions, design, modification and manufacturing
After the online preparation we visit the production plant of the customers and install the sensors together, then test the mould in toolshop. After the mould clamp, we optimize the process by cavity pressure.
A Cavity Eye engineer gives a training of “curve reading” and DOE analysis based on cavity pressure. The software and other applications also the part of the training. After the training, one-two days production will be analyzed. Stability and production restart also based on cavity pressure. During the first project, the Customer gets enough experience to handle the second one on his own.
Design and design review
The designers of the Cavity Eye can modify and make review of the 3D designs after signing the NDA. The review is free of charge and takes 1…3 days, the design has service charge.
If the customer has any kind of difficulties of the application of Cavity Eye, after invitation we can connect to the Cavity Eye instrument and give online support (mould analysis, production analysis, statistical analysis, software update etc). Thanks to this online service, you do not have to wait for a service engineer and the problem can be solved in a day.
Personal support, Consulting
A Cavity Eye service engineer visits the production plant of the customer to help personally in the following tasks:
Sensor installation, and dry test in the tool shop (mould preparation)
Production and failure analysis by DOE
Basic training of injection moulding (10-15 days)
This training is recommended to beginners who has no or has minimal experiences in injection moulding. The length of the training can be 10 or 15 days, depending on the knowledge of the participants.The goal of the training is to study and practice the steps of mould changing. After the training they will be able to clamp the mould and prepare the machine for productionm, but they will not be able to start the production alone.
After the training they need a mentor for a month to get more experience and study the local rules. The training is organized at the customer’s plant by two trainers.
The training is organized at the customer’s plant by two trainers.
Intermediate training for machine setters and technologies (5 days)
This five-day-training focuses for the theoretical background of injection moulding, but all the theory can be verified during the training in practice too (60% theory and 40% practice). The program is focusing on:
Material properties and material preparation
Material tests and measurement (MFI, moisture, mechanical properties…)
Parameter set (material temp. mould temp, speed, pressure…)
Mould trial (how to prepare a mould for the first test, first shot)
Process analysis, DOE (to determine the optimal machine parameters and define the mould failures, necessary modifications)
Cavity pressure analysis
Production failure analysis (understand, reproduce, modify, eliminate)
The training can be organized at the customer’s plant or in the research centre.
Cavity Eye training (3 days)
This training is for customers who need complex program for study the application of the Cavity Eye system.
Mould design and sensor installation
Measuring instrument installation
Machine set up and fine tune by cavity pressure
In case of any question do not hesitate to contact us
Attila SZŰCS Email: email@example.com
Éva DOBÓVÁRI Tel: +36-30/703-6058 Email: firstname.lastname@example.org
András SZŰCS PhD Tel: +36-30/313-8675 Email: email@example.com
Business Name: Cavity Eye Hungary Kft. Business Address: Szellő utca 1., Kecskemét, Hungary H-6000 VAT Number: HU-23921292-2-04 Email: firstname.lastname@example.org Foundation: 2012 Area of business: Cavity pressure measurement solutions for plastic industries, services and training for the plastic industries Target groups: Automotive industries (plastic processing), Plastic product manufacturing companies (precision engineering), Other industries