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JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1871882007690693ADAPTIVESYSTEMFORELECTRICALLYDRIVENTHERMOREGULATIONOFMOULDSFORINJECTIONBNARDINA,BZAGARA,ASLOVENIA,ABSTRACTDITIONSMEANSMOULDITWPATENTONLINEINFLUENCECONTROL2006ELSEVIERBVALLRIGHTSRESERVEDKSIMULATIONS1DEVELOPMENTOFTECHNOLOGYOFCOOLINGMOULDSVIATHERMOELECTRICALTEMMEANSDERIVESOUTOFTHEINDUSTRIALPRAXISANDPROBLEMS,IEATDESIGN,TOOLMAKINGANDEXPLOITATIONOFTOOLSCURRENTCOOLINGTECHNOLOGIESHAVETECHNOLOGICALLIMITATIONSTHEIRFINITEPLETELYRETROLLABLEINGTECHNOLOGIESENINGONLYTIONAND11PRPLASTICPROCESSINGISBASEDONHEATTRANSFERBETWEENPLASTICMATERIALANDMOULDCAVITYWITHINCALCULATIONOFHEATTRANSFERONESHOULDCONSIDERTWOMAJORFACTSFIRSTISALLUSEDENERGY09240136/DOILIMITATIONSCANBELOCATEDANDPREDICTEDINADVANCEWITHELEMENTANALYSESFEASIMULATIONPACKAGESBUTNOTCOMAVOIDEDRESULTSOFADIVERSESTATEOFTHEARTANALYSESVEALEDTHATALLEXISTINGCOOLINGSYSTEMSDONOTPROVIDECONHEATTRANSFERCAPABILITIESADEQUATETOFITINTODEMANDTECHNOLOGICALWINDOWSOFCURRENTPOLYMERPROCESSINGPOLYMERPROCESSINGISNOWADAYSLIMITEDINTERMOFSHORTTHEPRODUCTIONCYCLETIMEANDWITHINTHATREDUCINGCOSTSWITHHEATCAPACITYMANIPULATIONCAPABILITIESOTHERPRODUCOPTIMIZATIONCAPABILITIESAREALREADYDRIVENTOMECHANICALPOLYMERPROCESSINGLIMITATIONS3CORRESPONDINGAUTHORSTEL3863490920FAX38634264612EMAILADDRESSBLAZNARDINTECOSSIBNARDINWHICHISBASEDONFIRSTLAWOFTHERMODYNAMICSLAWOFENERGYCONSERVATION1,SECONDISVELOCITYOFHEATTRANSFERBASICTASKATHEATTRANSFERANALYSESISTEMPERATURECALCULATIONOVERTIMEANDITSDISTRIBUTIONINSIDESTUDIEDSYSTEMTHATLASTDEPENDSONVELOCITYOFHEATTRANSFERBETWEENTHESYSTEMANDSURROUNDINGSANDVELOCITYOFHEATTRANSFERINSIDETHESYSTEMHEATTRANSFERCANBEBASEDASHEATCONDUCTION,CONVECTIONANDRADIATION112COOLINGTIMECOMPLETEINJECTIONMOULDINGPROCESSCYCLECOMPRISESOFMOULDCLOSINGPHASE,INJECTIONOFMELTINTOCAVITY,PACKINGPRESSUREPHASEFORCOMPENSATINGSHRINKAGEEFFECT,COOLINGPHASE,MOULDOPENINGPHASEANDPARTEJECTIONPHASEINMOSTCASES,THELONGESTTIMEOFALLPHASESDESCRIBEDABOVEISCOOLINGTIMECOOLINGTIMEININJECTIONMOULDINGPROCESSISDEFINEDASTIMENEEDEDTOCOOLDOWNTHEPLASTICPARTDOWNTOEJECTIONTEMPERATURE1SEEFRONTMATTER2006ELSEVIERBVALLRIGHTSRESERVED101016/JJMATPROTEC200611052ATECOS,TOOLANDDIEDEVELOPMENTCENTREOFBFACULTYOFELECTRICALENGINEERINGONEOFTHEBASICPROBLEMSINTHEDEVELOPMENTANDPRODUCTIONPROCESSINTHEMOULDPRECISESTUDYOFTHERMODYNAMICPROCESSESINMOULDSSUCHSYSTEMUPGRADESCONVENTIONALCOOLINGSYSTEMSWITHINTHEINTHEPAPER,THEAUTHORSWILLPRESENTRESULTSOFTHERESEARCHPROJECT,WHICHTHETESTINGSTAGE,THEPROTOTYPESTAGEANDTHEINDUSTRIALIZATIONPHASETHERMOREGULATIONOFTHEMOULDOVERTHECYCLETIMEANDOVERALLPRESENTEDAPPLICATIONCANPRESENTAMILESTONEINTHEFIELDOFMOULDTEMPERATUREEYWORDSINJECTIONMOULDINGMOULDCOOLINGTHERMOELECTRICMODULESFEMINTRODUCTION,DEFINITIONOFPROBLEMMOULDINGGLOJEKA,DKRIZAJBKIDRICEVACESTA25,3000CELJE,SLOVENIA,LJUBLJANA,SLOVENIAOFMOULDSFORINJECTIONMOULDINGISTHECONTROLOFTEMPERATURECONSHOWED,THATHEATEXCHANGECANBEMANIPULATEDBYTHERMOELECTRICALORCANBEASTANDALONEAPPLICATIONFORHEATMANIPULATIONWITHINASCARRIEDOUTINTHREEPHASESANDITSRESULTSAREPATENTEDINA6862006WILLBEPRESENTEDTHEMAINRESULTSOFTHEPROJECTWERETOTALANDRAPIDONQUALITYOFPLASTICPRODUCTWITHEMPHASISONDEFORMATIONANDPRODUCTQUALITYCONTROLDURINGTHEINJECTIONMOULDINGPROCESSTHERMALPROCESSESININJECTIONMOULDINGPLASTICOCESSINGBNARDINETAL/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1871882007690693691COOLINGFROMMOULDANDTEMPERATUREFROM2ENTMOSTIELINES,ACCUMULATEDTOITYINTOALTERLIKINTETHEERTIESWITHATUREINDEPENDENTDONEFROMSIMULATIONTEM21WTRICALTHEFIG2TEMBLOCKDIAGRAMNOWNEVERUSEDINTHEINJECTIONMOULDINGAPPLICATIONSTEMMODULESEEFIG2ISADEVICECOMPOSEDOFPROPERLYARRANGEDPAIRSOFPANDNTYPESEMICONDUCTORSTHATAREPOSITIONEDBETWEENTWOCERAMICPLATESFORMINGTHEHOTANDTHECOLDTHERMOELECTRICCOOLERSITESPOWEROFAHEATTRANSFERCANBEEASILYCONTROLLEDTHROUGHCURRENT22INTOUNITTRANSFERALLOSYSTEMMODULESPERATUREHEATCONSTANTTRICWITHTEMCHANNELSCONTROLLABLEMOULDFIG1MOULDTEMPERATUREVARIATIONACROSSONECYCLE2THEMAINAIMOFACOOLINGPROCESSISTOLOWERADDITIONALTIMEWHICHISTHEORETICALLYNEEDLESSINPRAXIS,ITEXTENDS45UPTO67OFTHEWHOLECYCLETIME1,4FROMLITERATUREANDEXPERIMENTS1,4,ITCANBESEEN,THATTHETEMPERATUREHASENORMOUSINFLUENCEONTHEEJECTIONTIMETHEREFORETHECOOLINGTIMECOSTSINJECTIONMOULDINGPROCESSISACYCLICPROCESSWHEREMOULDVARIESASSHOWNINFIG1WHERETEMPERATUREVARIESAVERAGEVALUETHROUGHWHOLECYCLETIMECOOLINGTECHNOLOGYFORPLASTICINJECTIONMOULDSASITWASALREADYDESCRIBED,THEREAREALREADYSEVERALDIFFERTECHNOLOGIES,ENABLINGTHEUSERSTOCOOLTHEMOULDS5THECONVENTIONALISTHEMETHODWITHTHEDRILLINGTECHNOLOGY,PRODUCINGHOLESINTHEMOULDTHROUGHTHESEHOLESCOOLINGTHECOOLINGMEDIAISFLOWING,REMOVINGTHEGENERATEDANDHEATFROMTHEMOULD1,2ITISALSOVERYCONVENIENTBUILDINDIFFERENTMATERIALS,WITHDIFFERENTTHERMALCONDUCTIVWITHTHEAIMTOENHANCECONTROLOVERTEMPERATURECONDITIONSTHEMOULDSUCHAPPROACHESARESOCALLEDPASSIVEAPPROACHESWARDSTHEMOULDTEMPERATURECONTROLTHECHALLENGINGTASKISTOMAKEANACTIVESYSTEM,WHICHCANTHETHERMALCONDITIONS,REGARDINGTOTHEDESIREDASPECTS,EPRODUCTQUALITYORCYCLESTIMEONEOFSUCHAPPROACHESISGRATINGTHERMALELECTRICALMODULESTEM,WHICHCANALTERTHERMALCONDITIONSINTHEMOULD,REGARDINGTHEDESIREDPROPWITHSUCHAPPROACH,THEONECANCONTROLTHEHEATTRANSFERTHETIMEANDSPACEVARIABLE,WHATMEANS,THATTHETEMPERCANBEREGULATEDTHROUGHOUTTHEINJECTIONMOULDINGCYCLE,OFTHEPOSITIONINTHEMOULDTHEHEATCONTROLISBYTHECONTROLUNIT,WHERETHEINPUTVARIABLESARERECEIVEDTHEMANUALINPUTORTHEINPUTFROMTHEINJECTIONMOULDINGWITHTHEOUTPUTVALUES,THECONTROLUNITMONITORSTHEMODULEBEHAVIOURTHERMOELECTRICMODULESTEMFORTHENEEDSOFTHETHERMALMANIPULATION,THETEMMODULEASINTEGRATEDINTOMOULDINTERACTIONBETWEENTHEHEATANDELECVARIABLESFORHEATEXCHANGEISBASEDONTHEPELTIEREFFECTPHENOMENONOFPELTIEREFFECTISWELLKNOWN,BUTITWASUNTILTHEMAGNITUDEANDTHEPOLARITYOFTHESUPPLIEDELECTRICAPPLICATIONFORMOULDCOOLINGTHEMAINIDEAOFTHEAPPLICATIONISINSERTINGTEMMODULEWALLSOFTHEMOULDCAVITYSERVINGASAPRIMARYHEATTRANSFERSUCHBASICASSEMBLYCANBESEENINFIG3SECONDARYHEATISREALIZEDVIACONVENTIONALFLUIDCOOLINGSYSTEMTHATWSHEATFLOWSINANDOUTFROMMOULDCAVITYTHERMODYNAMICDEVICEPRESENTEDINFIG3COMPRISESOFTHERMOELECTRICATHATENABLEPRIMARILYHEATTRANSFERFROMORTOTEMCONTROLLABLESURFACEOFMOULDCAVITYBSECONDARYTRANSFERISENABLEDVIACOOLINGCHANNELSCTHATDELIVERTEMPERATURECONDITIONSINSIDETHEMOULDTHERMOELECMODULESAOPERATEASHEATPUMPANDASSUCHMANIPULATEHEATDERIVEDTOORFROMTHEMOULDBYFLUIDCOOLINGSYSCSYSTEMFORSECONDARYHEATMANIPULATIONWITHCOOLINGWORKASHEATEXCHANGERTOREDUCEHEATCAPACITYOFAREATHERMALINSULATIONDISINSTALLEDBETWEENTHECAVITYFANDTHEMOULDSTRUCTUREPLATESEFIG3STRUCTUREOFTEMCOOLINGASSEMBLY692BNARDINETAL/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1871882007690693ATURESYSTEMINPUTANDINFORMATIONCUTIONRELATIONSORMEDIACURRENTOFOFFURTHERMORE,FILESDESCRIBEDRESEARCHTROLTHEORETICAL,ASPECTONEINTO3MOULDINGDESIGNDAYSMOLDFLOESPECIALLYDESIGNERSTIONUNRELIABLETIONTEM,BANDSIMULATIONSFIG5CROSSSECTIONOFAPROTOTYPEINFEMENVIRONMENT31PHYSICALMODEL,FEMANALYSISIMPLEMENTATIONOFFEMANALYSESINTODEVELOPMENTPROJECTWASDONEDUETOAUTHORSLONGEXPERIENCESWITHSUCHPACKAGES4ANDPOSSIBILITYTOPERFORMDIFFERENTTESTINTHEVIRTUALENVIRONMENTENINTHEMDECOMSOLIDENTICALPOSSIBLETAKINGFLUIDPHYSICSWIMPACTGOALINGTEMPERATUREFIG4STRUCTUREFORTEMPERATUREDETECTIONANDREGULATIONTHEWHOLEAPPLICATIONCONSISTSOFTEMMODULES,ATEMPERSENSORANDANELECTRONICUNITTHATCONTROLSTHECOMPLETETHESYSTEMISDESCRIBEDINFIG4ANDCOMPRISESOFANUNITINPUTINTERFACEANDASUPPLYUNITUNITFORELECTRONICPOWERELECTRONICSUPPLYHBRIDGEUNITTHEINPUTANDSUPPLYUNITSWITHTHETEMPERATURESENSORLOOPAREATTACHEDTOACONTROLUNITTHATACTSASANEXEUNITTRYINGTOIMPOSEPREDEFINEDTEMPERATE/TIME/POSITIONUSINGTHEPELTIEREFFECT,THEUNITCANBEUSEDFORHEATINGCOOLINGPURPOSESTHESECONDARYHEATREMOVALISREALIZEDVIAFLUIDCOOLINGSEENASHEATEXCHANGERINFIG4THATUNITISBASEDONCOOLINGTECHNOLOGIESANDSERVESASASINKORASOURCEAHEATTHISENABLESCOMPLETECONTROLOFPROCESSESINTERMSTEMPERATURE,TIMEANDPOSITIONTHROUGHTHEWHOLECYCLEITALLOWSVARIOUSTEMPERATURE/TIME/POSITIONPROWITHINTHECYCLEALSOFORSTARTINGANDENDINGPROCEDURESTECHNOLOGYCANBEUSEDFORVARIOUSINDUSTRIALANDPURPOSESWHEREPRECISETEMPERATURE/TIME/POSITIONCONISREQUIREDTHEPRESENTEDSYSTEMSINFIGS3AND4WEREANALYSEDFROMTHEASWELLASTHEPRACTICALPOINTOFVIEWTHETHEORETICALWASANALYSEDBYTHEFEMSIMULATIONS,WHILETHEPRACTICALBYTHEDEVELOPMENTANDTHEIMPLEMENTATIONOFTHEPROTOTYPEREALAPPLICATIONTESTINGFEMANALYSISOFMOULDCOOLINGCURRENTDEVELOPMENTOFDESIGNINGMOULDSFORINJECTIONCOMPRISESOFSEVERALPHASES3AMONGTHEMISALSOANDOPTIMIZATIONOFACOOLINGSYSTEMTHISISNOWAPERFORMEDBYSIMULATIONSUSINGCUSTOMIZEDFEMPACKAGESW4THATCANPREDICTCOOLINGSYSTEMCAPABILITIESANDITSINFLUENCEONPLASTICWITHSUCHSIMULATIONS,MOULDGATHERINFORMATIONONPRODUCTRHEOLOGYANDDEFORMADUETOSHRINKAGEASELLASPRODUCTIONTIMECYCLEINFORMATIONTHISTHERMALINFORMATIONISUSUALLYACCURATEBUTCANSTILLBEINCASESOFINSUFFICIENTRHEOLOGICALMATERIALINFORMAFORTHEHIGHQUALITYINPUTFORTHETHERMALREGULATIONOFITISNEEDEDTOGETAPICTUREABOUTTHETEMPERATUREDISTRIUTIONDURINGTHECYCLETIMEANDTHROUGHOUTTHEMOULDSURFACETHROUGHOUTTHEMOULDTHICKNESSTHEREFORE,DIFFERENTPROCESSARENEEDEDWHOLEPROTOTYPECOOLINGSYSTEMWASDESIGNEDINFEMVIRONMENTSEEFIG5THROUGHWHICHTEMPERATUREDISTRIBUTIONEACHPARTOFPROTOTYPECOOLINGSYSTEMANDCONTACTSBETWEENWEREEXPLOREDFORSIMULATINGPHYSICALPROPERTIESINSIDEAVELOPEDPROTOTYPE,ASIMULATIONMODELWASCONSTRUCTEDUSINGMULTIPHYSICSSOFTWARERESULTWASAFEMMODELTOREALPROTOTYPESEEFIG7THROUGHWHICHITWASTOCOMPAREANDEVALUATERESULTSFEMMODELWASEXPLOREDINTERMOFHEATTRANSFERPHYSICSINTOACCOUNTTWOHEATSOURCESAWATEREXCHANGERWITHPHYSICSANDATHERMOELECTRICMODULEWITHHEATTRANSFERONLYCONDUCTIONANDCONVECTIONWASANALYSED,RADIATIONASIGNOREDDUETOLOWRELATIVETEMPERATUREANDTHEREFORELOWONTEMPERATUREBOUNDARYCONDITIONSFORFEMANALYSESWERESETWITHTHETOACHIEVEIDENTICALWORKINGCONDITIONSASINREALTESTSURROUNDINGAIRANDTHEWATEREXCHANGERWERESETATSTABLEOF20CFIG6TEMPERATUREDISTRIBUTIONACCORDINGTOFEMANALYSISBNARDINETAL/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1871882007690693693ATUREFIGINRESPONSEVTEMPERATUREWHATPROBLEMSMOUNTING,INTELLIGENT32TESTEDTIONSCONTROLMOULDWLATEDSIMULATINGMOULDINGSORS,TEMPERATUREREPRESENTSMOULDING4NECTIONMILESTONEINCOOLINGAPPLICATIONSITSINTRODUCTIONINTOMOULDSFORINJECTIONMOULDINGWITHITSPROBLEMATICCOOLINGCONSTRUCTIONANDPROBLEMATICPROCESSINGOFPRECISEANDHIGHQUALITYPLASTICPARTSREPRESENTSHIGHEXPECTATIONSTHEAUTHORSWEREASSUMINGTHATTHEUSEOFTHEPELTIEREFFECTCANBEUSEDFORTHETEMPERATURECONTROLINMOULDSFORINJECTIONMOULDINGWITHTHEAPPROACHBASEDONTHESIMULATIONWORKANDTHEREALPRODUCTIONOFLABORATORYEQUIPMENTPROVED,THEASSUMPTIONSWERECONFIRMEDSIMULATIONRESULTSSHOWEDAWIDEAREAOFPOSSIBLEAPPLICATIONOFTEMMODULEINTHEINJECTIONMOULDINGPROCESSWITHMENTIONEDFUNCTIONALITYOFATEMPERATUREPROFILEACROSSCYCLETIME,INJECTIONMOULDINGPROCESSCANBEFULLYCONTROLLEDINDUSTRIALPROBLEMS,SUCHASUNIFORMCOOLINGOFPROBLEMATICAANCESOLVMORE,OFREFLOITYOFPRODUCTICANTLYTHEOFCONTROLOFERANCESMOULDINGANDREFER123FIG7PROTOTYPEINREALENVIRONMENTRESULTSOFTHEFEMANALYSISCANBESEENINFIG6,IETEMPERDISTRIBUTIONTHROUGHTHESIMULATIONAREASHOWNINFIG56REPRESENTSSTEADYSTATEANALYSISWHICHWASVERYACCURATECOMPARISONTOPROTOTYPETESTSINORDERTOSIMULATETHETIMEALSOTHETRANSIENTSIMULATIONWASPERFORMED,SHOWINGERYPOSITIVERESULTSFORFUTUREWORKITWASPOSSIBLETOACHIEVEADIFFERENCEOF200CINASHORTPERIODOFTIME5S,COULDCAUSESEVERALPROBLEMSINTHETEMSTRUCTURETHOSEWERESOLVEDBYSEVERALSOLUTIONS,SUCHASADEQUATECHOOSINGAPPROPRIATETEMMATERIALANDAPPLYINGELECTRONICREGULATIONLABORATORYTESTINGASITWASALREADYDESCRIBED,THEPROTOTYPEWASPRODUCEDANDSEEFIG7THERESULTSARESHOWING,THATTHESETASSUMPWERECONFIRMEDWITHTHETEMMODULEITISPOSSIBLETOTHETEMPERATUREDISTRIBUTIONONDIFFERENTPARTSOFTHETHROUGHOUTTHECYCLETIMEWITHTHELABORATORYTESTS,ITASPROVEN,THATTHEHEATMANIPULATIONCANBEPRACTICALLYREGUWITHTEMMODULESTHETESTWEREMADEINTHELABORATORY,THEREALINDUSTRIALENVIRONMENT,WITHTHEINJECTIONMACHINEKRAUSSMAFFEIKM60C,TEMPERATURESENINFRAREDCAMERASANDTHEPROTOTYPETEMMODULESTHERESPONSEIN18SVARIEDFORM5UPTO80C,WHATAWIDEAREAFORTHEHEATCONTROLWITHINTHEINJECTIONCYCLECONCLUSIONSUSEOFTHERMOELECTRICMODULEWITHITSSTRAIGHTFORWARDCONBETWEENTHEINPUTANDOUTPUTRELATIONSREPRESENTSA45CLASSSURFACESANDITSCONSEQUENCEOFPLASTICPARTAPPEARCANBESOLVEDPROBLEMSOFFILLINGTHINLONGWALLSCANBEEDWITHOVERHEATINGSOMESURFACESATINJECTIONTIMEFURTHERWITHSUCHAPPLICATIONCONTROLOVERRHEOLOGICALPROPERTIESPLA
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