Real-time measurement of the flow front - Precise. Non-contact. Process reliable.
MOLDFRONT measures the flow front without contact and independent of pressure, temperature or material properties - whether thermoplastics, thermosets, elastomers or other process materials.
Detect, measure, optimize -
Your solution for perfect reproducibility.
A look into the mold.
The sensor package MoldFront is a precise measuring hardware for reliable and highly dynamic flow front detection in injection molds or similar filling processes in the polymer sector. This enables
- the precise control of subsequent processes
- the detection of irregularities
- the determination of reproducibility
Easy assembly.
Robust sensor technology.
The sensor is mounted in a blind hole and has no contact with the filling medium. The associated sensor unit can be mounted on the mold or on the respective machine.
Applications
Sensor-based cascade control for maximum precision
Cascade injection molding requires maximum precision when opening the valve gate nozzles in order to avoid weld line defects and produce high-quality components. Our sensor technology enables reliable and precise control by analyzing relevant measurement data in real time.
Your benefit:
- Reduced rejects and error-free series production.
- Precise control of complex shapes and long flow paths.
- Greater process stability thanks to precise viscosity monitoring.
See for yourself: In the video, you can see how our sensor solution actively monitors the process parameters and automatically controls the hot runner nozzle to ensure optimum quality.
Flow front detection in injection molds - precise and contactless
Our innovative sensor solution measures the flow rate of the polymer melt stream directly in the injection mold - contact-free and highly precise. Two ultrasonic sensors, which are mounted in the mold, detect the exact filling times at different positions. Based on these measured values, the exact speed of the melt front is calculated - regardless of pressure, temperature or polymer type.
Ideal for:
- Comparison with simulation results: Verify your simulations with high-precision real-time measurements directly in the mold.
- Continuous monitoring of flow properties: Control and optimize your processes in real time for maximum product quality.
Your benefits at a glance:
- Maximum process control: Reliable determination of the flow rate in real time, regardless of external influences.
- Non-contact and wear-free: The sensors never come into contact with the melt and are protected against high pressures.
- Precise control: Exact switchover points and optimum holding pressure phases for error-free production.
- Increased process stability: Monitoring of several injection points to avoid errors and rejects.
Universal ultrasonic sensors for different material systems
In resin transfer molding (RTM), a proven resin injection process, a resin is injected under pressure into a closed mould, where it hardens through the application of heat and pressure. This process is often used for the production of highly resilient components.
Our innovative MoldFront sensor technology enables precise monitoring of the flow front movement - regardless of whether thermoplastics, thermosets or elastomers are involved. Thanks to the non-contact measurement, the filling process can be monitored in real time for a wide range of material systems - even at temperatures of over 200°C.
Why is MoldFront universal and temperature-resistant?
- Material-independent: Our sensor technology measures reliably even with thermosetting resins (such as epoxy resin) and elastic materials - regardless of pressure, temperature or viscosity.
- Temperature resistance: The ultrasonic sensors are designed so that they can be used in processes with temperatures of over 200°C without any problems and without losing accuracy.
-Non-contact and wear-free: As the sensor does not come into contact with the material, it is ideal for high-temperature processes and abrasive media.
- Precise process monitoring: Whether curing reactions in thermosets or complex flow processes in elastomers - the precise detection of the flow front ensures consistent product quality.
Blow molding - Precise process control with ultrasonic sensors
Blow molding is a process for producing hollow bodies from thermoplastics. An extruded tube or preform is pressed against the contours of the tool using compressed air and then cooled to obtain the desired shape.
The MoldFront non-contact ultrasonic sensor system can precisely detect when the plastic has fully reached the mold wall and is in contact with it. This enables:
- Precise monitoring of the process: The time of wall contact can be precisely detected to ensure that the deformation is uniform and complete.
- Prevention of errors: Detects deviations such as uneven application or insufficient material distribution at an early stage.
- No influence on the process: As the sensors have no contact with the plastic material, they are wear-free and do not influence the forming process.
Thanks to precise measurement, it is possible to ensure that hollow bodies - whether simple containers or complex structures - are always produced with a consistently tight seal and stable shape.
Receive customized advice for your application
We find the optimal sensor solution for your production
Questions and answers
What output signal do I get?
The output signal of our MoldFront ultrasonic sensor system is a digital signal. In the standard version, the signal level is 0 volts or 24 volts. The signal behavior is binary:
- 0 Volt: No medium is detected at the sensor.
- 24 volts: A medium (e.g. plastic melt) is detected.
There is also a special version with an output signal of 0 to 10 volts, which has been specially developed for customer-specific applications.
Important properties of the digital output signal:
- Reliable detection: The signal switches immediately on contact with the medium and ensures precise control.
- Seamless integration: The digital signal (24V) can be easily integrated into industrial control systems and process monitoring systems.
- Real-time response: Switching between 0 and 24 volts takes place in real time and provides immediate feedback on the process status.
How many sensors can be connected to one electronic unit?
Up to two sensors can be connected to one electronic unit of the MoldFront ultrasonic sensor system. This configuration enables precise monitoring of the flow front at several positions in the mold.
Details of the connection:
- Two sensors: Enables the flow velocity of the medium to be determined by precisely recording the time difference between the measuring points.
- Synchronized data processing: Both sensors work in sync to ensure consistent and accurate measurement in real time.
- Flexible expansion: If required, several electronic units can be used to cover more complex processes with more measuring points.
In which temperature range can MoldFront be used?
The MoldFront ultrasonic sensor system can be operated in different temperature ranges:
- Standard version: Suitable up to 120°C, ideal for typical applications in plastic injection molding.
- Special high-temperature variant: Suitable for temperatures up to 250°C, specially developed for high-temperature applications, e.g. for thermosets, elastomers or RTM processes.
The electronic unit can withstand an operating temperature of 60°C permanently.
Does the sensor need to be serviced or calibrated?
The MoldFront ultrasonic sensor is basically calibration- and maintenance-free. Once installed, the sensor works reliably without regular adjustments or calibrations, which reduces operating costs and increases efficiency.
Maintenance recommendation:
However, to ensure smooth operation even in demanding applications, we recommend one to two functional checks per year, depending on the operating environment. These checks include:
- Check the sensor function and the electronic unit.
- Visual inspection for possible contamination or mechanical damage in the vicinity of the sensor.
- Check the installation, especially in applications with high pressures or temperatures.
Complete service from Moldsonics:
Moldsonics will be happy to carry out these regular inspections for you. Our service team will provide you with comprehensive expertise and ensure that your system runs smoothly at all times.
Contact us if you are interested in an individual consultation!
What are the dimensions of the sensor system?
Sensor:
∅ 10 x 8 mm, with a standard cable length of 300 mm (individual lengths and plug-in cable extensions are optionally available)
Electronic unit: 100 x 98.5 x 33 mm
When the electronic unit is attached using magnetic holders, the product dimensions are 100 x 98.5 x 42 mm.
How is the sensor system electrically supplied?
The MoldFront ultrasonic sensor system is supplied electrically via a standard voltage supply of 24 volts DC. This supply voltage is widely used in industry and enables simple integration into existing control systems.
Details of the power supply:
- Voltage range: 24 V DC ±10 %
- Power consumption: Low power consumption for energy-efficient operation.
- Suitable for industrial use: Protection against voltage peaks and interference ensures safe operation even under demanding conditions.
How is the signal set back to 0 or to the initial state?
The output signal of the MoldFront ultrasonic sensor is reset to 0 volts by an external trigger signal. The trigger signal must remain high (24 volts) during the measurement and then change to low (0 volts) so that the sensor system is reset to the initial state and is ready for the next detection.
Sequence of the signal behavior:
- High signal (24 volts): While the external trigger signal is high (24 volts), the sensor system is in active measuring mode and can detect a medium.
- Change to low (0 volts): The trigger signal must go low (0 volts) for a brief moment to reset the output signal of the sensor system to 0 volts.
- Ready for next measurement: After resetting, the sensor system can start the next detection process as soon as the trigger signal changes back to high.
Example trigger sources:
- Mold open/close: A signal from the mold that indicates the status of mold opening or closing.
- Start of the injection process: A control signal that marks the start of a new cycle.
- Proximity sensor: An external sensor that emits a corresponding signal when it detects a certain position in the process sequence.
