SONICSCAN | ULTRASOUND MELT EVALUATION
Evaluate melt quality directly during processing
SonicScan supplements existing machine data with information obtained directly from the plastic melt. Ultrasonic measurements in the melt channel reveal both inhomogeneities and changes in the melt’s state during injection molding—thereby providing an additional basis for evaluating material and process variations.
THE CHALLENGE
What machine data doesn't reveal about the polymer melt
Modern injection molding machines measure numerous process parameters, such as pressure, temperature, and screw position. This data provides valuable information about machine and process operations—but only limited direct insight into the actual condition of the plastic melt.
Material variations, incompletely melted components, or other inhomogeneities may occur even though the standard process parameters appear normal. Such variations can affect the subsequent quality of the component.
The key question: In what condition does the polymer melt actually end up on mold?
THE SOLUTION
Ultrasonic measurement directly through the plastic melt
SonicScan uses ultrasound to assess the condition of the plastic melt directly in the melt channel. During the process, the transmission of the ultrasound is continuously monitored by the polymer melt.
Changes in the melt state affect the ultrasonic signal, making them measurable. SonicScan analyzes this information and translates it into understandable process parameters — as a supplement to existing machine data.
The sensors are integrated according to the specific application, for example in a measurement flange on an injection molding machine.
Melt evaluation in industrial applications
SonicScan is already in industrial use under real production conditions. The integration, implemented in collaboration with ENGEL, demonstrates how additional information about the melt condition can be incorporated directly into the existing process monitoring system.
Together with ENGEL: A fully integrated machine solution
ENGEL has fully integrated the SonicScan sensor technology into its injection molding machines. This has resulted in a practical, comprehensive solution that allows the condition of the plastic melt to be monitored during every production cycle.
The ultrasonic signals are continuously recorded and automatically converted into easily interpretable process parameters. These are available directly in the ENGEL machine control system and can be evaluated and monitored using the existing monitoring functions.
This transforms a complex ultrasonic measurement into an easy-to-use process monitoring tool that offers real added value in day-to-day production.
The fully integrated melt analysis system is available directly from ENGEL as a machine option.
Melt evaluation tailored to your needs
MACHINE OPERATORS & PROCESSORS
Melt quality monitor during the production process
Detect changes in the melt homogeneity, and melt state directly during the process. Use the additional measurement data for process monitoring and quality assurance.
Check Measurement Capabilities
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Integrating melt evaluation into machines
Enhance your machines with ultrasonic melt analysis and unlock new possibilities for process monitoring, quality assessment, and process optimization.
Discuss OEM Integration
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What You Should Know About SonicScan
What can SonicScan tell us about the plastic melt?
SonicScan reveals changes in the melt homogeneity , and melt state during the process. These include, for example, anomalies caused by incompletely melted components, foreign particles, or changes in material and process conditions.
Can SonicScan detect foreign particles and unmelted components?
Yes, SonicScan can detect such inhomogeneities based on changes in the ultrasonic signal. Detectability depends, among other factors, on the material, particle size, and acoustic properties, and must be evaluated for each specific application.
What measurements does SonicScan provide?
SonicScan calculates two key process parameters: the Melt Homogeneity Index (MHI) and the Relative Melt Density Level (MDL). The MHI describes anomalies in the signal curve, while the MDL highlights changes in the relative ultrasonic signal level compared to a reference state. Ultrasonic measurement curves are also available for detailed analysis.
Does the machine operator have to interpret the ultrasonic measurement curves?
No. SonicScan automatically converts the ultrasonic measurements into understandable process parameters. These can be integrated into the existing process monitoring system. The detailed measurement curves are available for further analysis as needed.
Is SonicScan only suitable for injection molding machines?
No. The ultrasonic measurement principle is also suitable for extrusion applications. The specific sensor integration and data analysis are tailored to the respective machine and measurement task.
Can SonicScan also be used as a standalone solution?
Yes. SonicScan can also be operated as a standalone solution, independent of a machine control system. The mechanical and control system integration is customized to suit each specific application.
If the melt evaluation is also to be used for automated quality monitoring or process control, it must also be determined how the measured values can be effectively integrated into an appropriate quality control loop.
Can SonicScan be integrated into existing machines?
Yes. Retrofitting SonicScan is relatively simple from a mechanical standpoint, since it essentially requires a suitable measuring flange with integrated ultrasonic sensors.
The integration with the machine control system and the use of the measured values are customized on a case-by-case basis. Alternatively, SonicScan can also be operated as a stand-alone solution.
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