WO2022217012A1

WO2022217012A1 - System containing multivariate sensors

Info

Publication number: WO2022217012A1
Application number: PCT/US2022/023947
Authority: WO
Inventors: Vito Galati; Jack Adoline
Original assignee: Barnes Group, Inc.
Priority date: 2021-04-08
Filing date: 2022-04-08
Publication date: 2022-10-13

Abstract

An apparatus in an injection molding system for monitoring, controlling or identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion, movement or position of any one or more of an actuator, a mold (25, 27), a heated manifold (15), a clamping or top clamp plate and an injection machine, comprising: a sensor assembly comprising two or more sensors (PS1, PS2, PS3, PS4, A1, A2, T1, T2, T3, 950, 951, 952) adapted to sense and generate a sensor signal, each sensor assembly being mounted on, to, within or in close physical proximity to one or the other of the cavity (5), the heated manifold (15), an inlet (13) to the heated manifold, one or more nozzles (21, 23) receiving fluid from the heated manifold (15) or a barrel of the injection machine, a communication module that includes: a separate or individual radio frequency signal transmitter (600) corresponding to each sensor adapted to send a wireless signal (S) corresponding to the received sensor signals to a processor, memory, display or user interface (16).

Description

SYSTEM CONTAINING MULTIVARIATE SENSORS SUMMARY OF THE INVENTION

[001] In accordance with the invention there is provided an apparatus comprising: at least one sensor assembly arranged for integration into an injection molding system (10, 10A), the injection molding system formed of an injection machine, a mold (25, 27, 42) having a cavity (5, 30), a clamping or top clamp plate (1) interconnected to the mold, a heated manifold (15) arranged to receive injection fluid (3) from the injection machine and deliver the injection fluid to at least one channel (13, 17, 18, 18A, 19, 20) that delivers the injection fluid to at least one respective gate (7, 9) of the cavity, each sensor assembly having: two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 , 952) contained within a housing; and a communication module interconnected to the two or more sensors, the communication module having a separate or individual radio frequency signal transmitter (600) corresponding to the respective sensor assembly wherein each separate or individual radio frequency signal transmitter is arranged to separately or individually receive a corresponding sensor signal from a corresponding one of the two or more sensors and wherein each separate or individual radio frequency signal transmitter is adapted to communicate a wireless signal (S) corresponding to the received sensor signals toward a processor, memory, display, or user interface (16) mounted or disposed in a location remote from the housing or the respective sensor assembly; and a controller (16A) arranged to direct a plurality of monitoring, controlling, and identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, and motion or movement or position of any one or more of an actuator (14, 940, 941, 942), the mold, the heated manifold, the clamping or top clamp plate, and the injection machine, wherein the two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951, 952) are each adapted to sense and generate a respective sensor signal indicative of one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, wherein each sensor assembly is mounted on, to, within or in close physical proximity to one or more of the cavity, the heated manifold, an inlet (13) to the heated manifold, one or more nozzles (21 , 22A, 22B, 22C, 23) arranged to receive the injection fluid from the heated manifold or a barrel of the injection machine.

[002] In such an apparatus each separate or individual radio frequency signal transmitter (600) is typically disposed in a location remote from its corresponding sensor.

[003] In such an apparatus each separate or individual radio frequency signal transmitter is mounted in one or more arrangements wherein: the separate or individual radio frequency signal transmitter is mounted in a location or disposition distal from its corresponding sensor assembly with the corresponding sensor assembly being more proximal to the mold, heated manifold or hotrunner than the separate or individual radio frequency signal transmitter, and the separate or individual radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated, or isolated from one or more of substantial interference with or shielding of transmission of the wireless signal (S) to a receiver by the mold, or from vibration or movement of the mold, or from heat communication with the mold.

[004] In such an apparatus each separate or individual radio frequency signal transmitter can be mounted in one or more arrangements wherein: the separate or individual radio frequency signal transmitter is mounted in a location or disposition distal from its corresponding sensor assembly with the corresponding sensor assembly being more proximal to the mold, heated manifold or hotrunner than the separate radio frequency signal transmitter, or the separate or individual radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated, or isolated from one or more of substantial heat communication with the heated manifold, substantial interference with or shielding of transmission of the wireless signal (S) by the heated manifold, or from vibration or movement of the heated manifold. [005] In such an apparatus at least one separate or individual radio frequency signal transmitter is typically interconnected to and receives a sensor signal from a corresponding sensor via a wire or cable (700) that extends to a location remote from the corresponding sensor.

[006] Such an apparatus can further include a battery (500) that is interconnected to and provides operative power to at least some of the two or more sensors, wherein the battery is one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iii) rechargeable via receipt of energy from an energy harvesting device that harvests energy from movement of one or more components of the injection molding system,

(iv) readily removable and replaceable,

(v) non rechargeable, and

(vi) mounted or disposed in a location remote from the housing or the sensor. [007] Such an apparatus can further include a battery (500) that is interconnected to and provides operative power to one or more radio frequency signal transmitters (600), wherein the battery is one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable, and

(vi) mounted or disposed in a location remote from the housing or the sensor. [008] Such an apparatus can further include a single battery (500) that is interconnected to and provides operative power to at least some of the two or more sensors and an ione or more radio frequency signal transmitters, wherein the battery is one or more of:

(i) rechargeable, (ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable, and

(VI) mounted or disposed in a location remote from the housing or the sensor. [009] In such an apparatus the processor, memory, display or user interface (16) is typically adapted to receive data embedded in the wireless signals (S) and further adapted, based on the data, to direct an adjustment or control during the course of an injection cycle one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, a valve pin, the mold, the heated manifold, the clamping or top clamp plate, and the injection machine.

[010] In such an apparatus at least one of the two or more sensors can be mounted in an arrangement for sensing fluid pressure or temperature within the cavity, or within a distribution channel (17, 19) within the heated manifold(15), or within a downstream channel (18, 20, 44) upstream of the gate (7, 9), or within a barrel of the injection machine, or within an inlet (13) to the heated manifold.

[011] In such an apparatus a battery that powers at least one of the two or more sensors can be readily manually accessible and replaceable.

[012] In such an apparatus at least one of the two or more sensors can be a thermocouple, an infrared sensor, and a thermistor.

[013] In such an apparatus at least one of the separate or individual radio frequency signal transmitters can be adapted to transmit a radio wave according to a protocol, wavelength, or signal compatible with one or more of Bluetooth, ZigBee, Z-Wave, 6L0WPAN, Thread, WiFi-ah (HaLow), WiFi, 2G, 3G, 4G, 5G, LTE Cat 0, 1, 3, NB-loT, NFC, RFID, SigFox, IR, and ANT & ANT+.

[014] In such an apparatus at least one of the separate or individual radio frequency signal transmitters can be adapted to transmit angle of arrival and angle of departure data. [015] In such an apparatus at least one of the separate or individual radio frequency signal transmitters can be adapted to be awakened or activated to transmit wireless signals (S) upon sensing, by an interconnected motion sensor, of movement or motion of the mold.

[016] In such an apparatus at least one of the two or more sensors includes a motion sensor arranged to generate signals that are indicative of one or more of an opening movement or closing movement of the mold, and wherein the controller is arranged execute an algorithm adapted to count cycles of one or more of mold opening movement and mold closing movement.

[017] In another aspect of the invention there is provided a method comprising: providing at least one sensor assembly arranged for integration into an injection molding system (10, 10A), the injection molding system formed of an injection machine, a mold (25, 27, 42) having a cavity (5, 30), a clamping or top clamp plate (1) interconnected to the mold, a heated manifold (15) arranged to receive injection fluid (3) from the injection machine and deliver the injection fluid to at least one channel (13, 17, 18, 18A, 19, 20) that delivers the injection fluid to at least one respective gate (7, 9) of the cavity, each sensor assembly having two or more sensors (PS1 , PS2, PS3, PS4,

A1, A2, T1, T2, T3, 950, 951, 952) contained within a housing; providing a communication module interconnected to the two or more sensors, the communication module having a separate or individual radio frequency signal transmitter (600) corresponding to the respective sensor assembly wherein each separate or individual radio frequency signal transmitter is arranged to separately or individually receive a corresponding sensor signal from a corresponding one of the two or more sensors and wherein each separate or individual radio frequency signal transmitter is adapted to communicate a wireless signal (S) corresponding to the received sensor signals toward a processor, memory, display, or user interface (16) mounted or disposed in a location remote from the housing or the respective sensor assembly; adapting each sensor to sense and generate a respective sensor signal indicative of one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine; programming a controller (16A) to direct a plurality of monitoring, controlling, and identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, and motion or movement or position of any one or more of an actuator (14, 940, 941, 942), the mold, the heated manifold, the clamping or top clamp plate, and the injection machine; mounting each sensor assembly on, to, within, or in close physical proximity to one or the other of the cavity, the heated manifold, an inlet (13) to the heated manifold or a barrel of the injection machine; and mounting each communication module in a location remote from its respective sensor.

[018] Such a method can further comprise: interconnecting one or more batteries (500) to one or more of each radio frequency signal transmitter (600) to provide power thereto, each battery adapted to be one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable, and

(vi) mounted or disposed in a location remote from the housing or the sensor. [019] Such a method can further comprise: interconnecting one or more batteries to at least some of the two or more sensors to provide power thereto, each battery adapted to be one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device, (iii) rechargeable via receipt of energy from an energy harvesting device that harvests energy from movement of one or more components of the injection molding system,

(iv) readily removable and replaceable,

(v) non rechargeable,

(vi) mounted or disposed in a location remote from the housing or the sensor. [020] Such a method can further comprise: adapting the processor, memory, display, or user interface (16) to receive data embedded in the wireless signals (S) and further adapting, based on the data, the processor, memory, display, or user interface to direct an adjustment or control during the course of an injection cycle of one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, a valve pin, the mold, the heated manifold, the clamping or top clamp plate, and the injection machine.

[021] In another aspect of the invention there is provided in an injection molding system (10) comprised of an injection machine, a clamping or top clamp plate (1) interconnected to a mold (25, 27) having a cavity (5), a heated manifold (15) that receives injection fluid (3) from the injection machine (10) and delivers the injection fluid (3) to a downstream channel (18, 20) that delivers the injection fluid to a gate (7, 9) of the cavity (5), an apparatus for monitoring, controlling or identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, the apparatus comprising: a sensor assembly comprising two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1, T2, T3, 950, 951, 952) contained within a housing and a communication module interconnected to the two or more sensors, wherein the two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 , 952) are adapted to sense and generate a sensor signal indicative of one or the other of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, wherein each sensor assembly is mounted on, to, within or in close physical proximity to one or the other of the cavity (5), the heated manifold (15), an inlet (13) to the heated manifold, one or more nozzles (21 , 23) receiving fluid from the heated manifold (15) or a barrel of the injection machine, wherein the communication module includes: a separate or individual radio frequency signal transmitter (600) corresponding to each sensor wherein each separate or individual radio frequency signal transmitter separately or individually receives a corresponding sensor signal from a corresponding one of the two or more sensors, wherein each separate or individual radio frequency signal transmitter is adapted to send a wireless signal (S) corresponding to the received sensor signals to a processor, memory, display or user interface (16) mounted or disposed in a location remote from the housing or the sensor.

[022] In such an apparatus each separate or individual radio frequency signal transmitter (600) can be disposed in a location remote from its corresponding sensor. [023] In such an apparatus, each separate radio frequency signal transmitter can be mounted in one or more arrangements wherein: the radio frequency signal transmitter is mounted in a location or disposition distal from the sensor assembly with the sensor assembly being more proximal to the mold, heated manifold or hotrunner than the radio frequency signal transmitter, the radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial interference with or shielding of transmission of the wireless signal (S) to the receiver by the mold, or from vibration or movement of the mold, or from heat communication with the mold.

[024] In such an apparatus each separate radio frequency signal transmitter can be mounted in one or more arrangements wherein: the radio frequency signal transmitter is mounted in a location or disposition distal from the sensor assembly with the sensor assembly being more proximal to the mold, heated manifold or hotrunner than the radio frequency signal transmitter, the radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial heat communication with the heated manifold, substantial interference with or shielding of transmission of the wireless signal (S) by the heated manifold, or from vibration or movement of the heated manifold.

[025] In such an apparatus each separate or individual radio frequency signal transmitter is preferably interconnected to and receives a sensor signal from a corresponding sensor via a wire or cable that extends to the location remote from the corresponding sensor.

[026] Such an apparatus can include a battery (500) that is interconnected to and provides operative power to the sensors, wherein the battery is one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable,

(vi) mounted or disposed in a location remote from the housing or the sensor. [027] Such an apparatus can further include a battery (500) that is interconnected to and provides operative power to a corresponding radio frequency signal transmitter (600), wherein the battery is one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable,

(vi) mounted or disposed in a location remote from the housing or the sensor. [028] Such an apparatus can further include a single battery (500) that is interconnected to and provides operative power to both a sensor and an interconnected radio frequency signal transmitter, wherein the battery is one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable,

(VI) mounted or disposed in a location remote from the housing or the sensor. [029] In such an apparatus the processor, memory, display or user interface (16) is preferably adapted to receive the wireless signals (S) and include instructions for using data corresponding to the wireless signals (S) to adjust or control during the course of an injection cycle one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator (14), a valve pin (32), the mold (25, 27), the heated manifold (15), the clamping or top clamp plate (1) and the injection machine.

[030] In such an apparatus one or more of the sensors can be mounted in an arrangement for sensing fluid pressure or temperature within the cavity (5) or within a distribution channel (17, 19) within the heated manifold(15) or within a downstream channel (18, 20) upstream of the gate (7, 9) or within a barrel of the injection machine or within an inlet (13) to the heated manifold.

[031] In such an apparatus the battery (500) can be adapted to be readily manually accessible and replaceable.

[032] In such an apparatus the sensors can comprise one or more of a thermocouple, an infrared sensor and a thermistor.

[033] In such an apparatus the radio frequency signal transmitter is typically adapted to transmit a wireless signal (S) according to a protocol, wavelength or signal comprising one or more of Bluetooth, ZigBee, Z-Wave, 6L0WPAN, Thread, WiFi-ah (HaLow), WiFi, 2G, 3G, 4G, 5G, LTE Cat 0, 1 , 3, NB-loT, NFC, RFID, SigFox, IR, ANT & ANT+ and radio waves.

[034] In such an apparatus the radio frequency signal transmitter can be adapted to transmit angle of arrival and angle of departure data.

[035] In such an apparatus the radio frequency signal transmitter can be adapted to be awakened or activated to transmit wireless signals (S) upon sensing by an interconnected motion sensor of movement or motion of the mold.

[036] In such an apparatus one or more of the sensors can comprise a motion sensor that generates signals sent as the wireless signal (S) to the processor, memory, display or user interface (16) that are indicative of one or more of an opening movement or closing movement of the mold, the to the processor, memory, display or user interface (16) including an algorithm adapted to count cycles of one or more of mold opening movement and mold closing movement.

[037] In another aspect of the invention there is provided a method of performing an injection cycle in an injection molding system comprising an injection machine, a clamping or top clamp plate (1) interconnected to a mold (25, 27) having a cavity (5), a heated manifold (15) that receives injection fluid (3) from the injection machine (10) and delivers the injection fluid (3) to a downstream channel (18, 20) that delivers the injection fluid to a gate (7, 9) of the cavity (5), the system including an apparatus for monitoring, controlling or identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, the method comprising: forming a sensor assembly comprised of two or more sensors contained within a housing and a communication module interconnected to the two or more sensors, adapting the two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 , 952) to sense and generate a sensor signal indicative of one or the other of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, mounting the sensor assembly on, to, within or in close physical proximity to one or the other of the cavity (5), the heated manifold (15), an inlet (13) to the heated manifold or a barrel of the injection machine, mounting the communication module in a location remote from the housing or the sensor, forming the communication module to include an individual or separate radio frequency signal transmitter (600) corresponding to each of the two or more sensors, adapting each of the separate or individual radio frequency signal transmitters (600) to separately or individually receive a corresponding sensor signal sent by each of the two or more sensors and to separately or individually send a wireless signal (S) corresponding to each of the sensor signals to a to the processor, memory, display or user interface (16) mounted or disposed in a location remote from the housing.

[038] Such a method can further comprise:

Interconnecting one or more batteries to one or more of each radio frequency signal transmitter (600) to provide power thereto, and adapting each battery to be one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable,

(vi) mounted or disposed in a location remote from the housing or the sensor. [039] Such a method can further comprise:

Interconnecting one or more batteries to one or more of each sensor (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 , 952) to provide power thereto, and adapting each battery to be one or more of:

(i) rechargeable,

(iv) readily removable and replaceable,

(v) non rechargeable,

(vi) mounted or disposed in a location remote from the housing or the sensor. [040] Such a method can further comprise: adapting the to the processor, memory, display or user interface (16) to receive the wireless signals (S) and to use data corresponding to the wireless signals (S) according to a predetermined set of instructions to adjust or control during the course of an injection cycle one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator (14), a valve pin (32), the mold (25, 27), the heated manifold (15), the clamping or top clamp plate (1) and the injection machine.

[041] In another aspect of the invention there is provided in an injection molding system (10) comprised of an injection machine, a clamping or top clamp plate (1) interconnected to a mold (25, 27) having a cavity (5), a heated manifold (15) that receives injection fluid (3) from the injection machine (10) and delivers the injection fluid (3) to a downstream channel (18, 20) that delivers the injection fluid to a gate (7, 9) of the cavity (5), an apparatus for monitoring, controlling or identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, the apparatus comprising: a sensor assembly comprising two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1, T2, T3, 950, 951, 952) contained within a housing and a communication module interconnected to the two or more sensors, the two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 ,

952) being adapted to sense and generate a sensor signal indicative of one or the other of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, wherein each sensor assembly is mounted on, to, within or in close physical proximity to one or the other of the cavity (5), the heated manifold (15), an inlet (13) to the heated manifold, one or more nozzles (21 , 23) receiving fluid from the heated manifold (15) or a barrel of the injection machine, wherein the communication module comprises: a separate or individual radio frequency signal transmitter (600) corresponding to each sensor wherein each separate or individual radio frequency signal transmitter separately or individually receives a corresponding sensor signal from a corresponding one of the two or more sensors, each separate or individual radio frequency signal transmitter sending a wireless signal (S) corresponding to the received sensor signals to a to the processor, memory, display or user interface (16) mounted or disposed in a location remote from the housing or the sensor.

[042] In such an apparatus each separate or individual radio frequency signal transmitter (600) is preferably disposed in a location remote from its corresponding sensor.

[043] In such an apparatus, each separate radio frequency signal transmitter is preferably mounted in one or more arrangements where: the radio frequency signal transmitter is mounted in a location or disposition distal from the sensor assembly or sensor with the sensor assembly being more proximal to the the mold, heated manifold or hotrunner than the radio frequency signal transmitter, the radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial interference with or shielding of transmission of the wireless signal (S) by the mold, or from vibration or movement of the mold, or from heat communication with the mold, the radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial heat communication with the heated manifold, substantial interference with or shielding of transmission of the wireless signal (S) by the heated manifold, or from vibration or movement of the heated manifold.

[044] In such an apparatus each separate or individual radio frequency signal transmitter is typically interconnected to and receives a sensor signal from a corresponding sensor via a wire or cable that extends to the location remote from the corresponding sensor.

[045] Such an apparatus can include a battery (500) that is interconnected to and provides operative power to the sensors, the battery being mounted or disposed in a location remote from the housing or the sensor.

[046] Such an apparatus can include a battery (500) that is interconnected to and provides operative power to a corresponding radio frequency signal transmitter (600), the battery being mounted or disposed in a location remote from the housing.

[047] In such an apparatus, a single battery (500) can be interconnected to and provide operative power to both a sensor and an interconnected radio frequency signal transmitter.

[048] In such an apparatus the p processor, memory, display or user interface (16) can be adapted to receive the wireless signals (S) and includes instructions for using data corresponding to the wireless signals (S) to adjust or control during the course of an injection cycle one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator (14), a valve pin (32), the mold (25, 27), the heated manifold (15), the clamping or top clamp plate (1) and the injection machine.

[049] In such an apparatus one or more of the sensors can be mounted for sensing fluid pressure or temperature within the cavity (5) or within a distribution channel (17,

19) within the heated manifold(15) or within a downstream channel (18, 20) upstream of the gate (7, 9) or within a barrel of the injection machine or within an inlet (13) to the heated manifold.

[050] In such an apparatus the battery (500) is preferably readily manually accessible and replaceable.

[051] In such an apparatus, the sensors typically comprise one or more of a thermocouple, an infrared sensor and a thermistor. [052] In such an apparatus the radio frequency signal transmitter can be adapted to transmit the wireless signal (S) according to a protocol, wavelength or signal comprising one or more of Bluetooth, ZigBee, Z-Wave, 6L0WPAN, Thread, WiFi-ah (HaLow), WiFi, 2G, 3G, 4G, 5G, LTE Cat 0, 1 , 3, NB-loT, NFC, RFID, SigFox, IR, ANT & ANT+ and radio waves.

[053] In such an apparatus the radio frequency signal transmitter can be adapted to transmit angle of arrival and angle of departure data.

[054] In such an apparatus the radio frequency signal transmitter can be adapted to be awakened or activated to transmit wireless signals (S) upon sensing by an interconnected motion sensor of movement or motion of the mold.

[055] In such an apparatus one or more of the sensors can comprise a motion sensor that generates the wireless signals (S) sent to the to the processor, memory, display or user interface (16) that are indicative of one or more of an opening movement or closing movement of the mold, the processor, memory, display or user interface (16) including an algorithm adapted to count cycles of one or more of mold opening movement and mold closing movement.

[056] In such an apparatus the receiver can be configured and adapted to receive and process one or more of the received signals to determine one or more actual process parameters including one or more of an actual pin opening time and an actual pin opening velocity.

[057] In such an apparatus the reciver can include a display that displays one or more of pin position, cavity pressure, fluid pressure and fluid temperature in real time.

[058] In such an apparatus the communications module can include control circuitry that controls the wireless signal sending sensor, the control circuitry having a top side and a bottom side, the communications module being mounted on said sensor and said sensor being disposed under the bottom side of said control circuitry.

[059] Such an apparatus can include a plurality of connector pins, wherein the bottom side of the control circuitry is spaced above a top surface of the sensor, the plurality of connection pins being connected to the control circuitry and the sensor and facilitating in supporting the control circuitry above said sensor, one or more of the plurality of connection pins transmitting data, signals, and/or power between the control circuitry and the sensor.

[060] In another aspect of the invention there is provided a method of performing an injection cycle in an injection molding system comprising an injection machine, a clamping or top clamp plate (1) interconnected to a mold (25, 27) having a cavity (5), a heated manifold (15) that receives injection fluid (3) from the injection machine (10) and delivers the injection fluid (3) to a downstream channel (18, 20) that delivers the injection fluid to a gate (7, 9) of the cavity (5), the system including an apparatus for monitoring, controlling or identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, the method comprising: forming a sensor assembly comprised of two or more sensors contained within a housing and a communication module interconnected to the two or more sensors, adapting the two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 , 952) to sense and generate a sensor signal indicative of one or the other of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, mounting the sensor assembly on, to, within or in close physical proximity to one or the other of the cavity (5), the heated manifold (15), an inlet (13) to the heated manifold or a barrel of the injection machine, mounting the communication module in a location remote from the housing or the sensor, forming the communication module to include an individual or separate radio frequency signal transmitter (600) corresponding to each of the two or more sensors, adapting each of the separate or individual radio frequency signal transmitters (600) to separately or individually receive a corresponding sensor signal sent by each of the two or more sensors and to separately or individually send a wireless signal (S) corresponding to each of the sensor signals to a processor, memory, display or user interface (16) mounted or disposed in a location remote from the housing.

[061] In another aspect of the invention there is provided an injection molding system comprising an injection machine (10), a clamping or top clamp plate (1) interconnected to a mold (25, 27) having a cavity (5), a heated manifold (15) that receives injection fluid (3) from the injection machine and delivers the injection fluid (3) to a downstream channel (18, 20) that delivers the injection fluid to a gate (7, 9) of the cavity (5), the system (10) including: two or more sensor assemblies mounted on, to or within the system for sensing one or more selected properties or parameters of one or more of the injection fluid (3) and a physical component of the system, each sensor assembly comprising a sensor (PS1 , PS2, PS3, PS4, A1 , A2, T 1 ,

T2, T3, 950, 951 , 952) adapted to sense the one or more selected properties or parameters and a transmitter (600) that individually or separately sends a wireless radio frequency signal indicative of each of the one or more selected properties or parameters to a receiver mounted remotely from the two or more sensor assemblies, the receiver receiving a separate or individual wireless radio frequency signal from each transmitter of each sensor assembly.

[062] In such a system, the transmitter can be mounted remotely from the two or more sensor assemblies.

[063] In such a system the transmitter can comprise separate or individual transmitters corresponding to each sensor that separately and individually receive sensor signals from separate and individual sensors.

[064] Alternatively the transmitter can comprise a bus antenna that receives signals from two or more sensors.

[065] In such a system, each transmitter is preferably mounted in one or more arrangements where: the transmitter is mounted in a location or disposition distal from the sensor assembly or sensor with the sensor assembly being more proximal to the the mold, heated manifold or hotrunner than the radio frequency signal transmitter, the transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial interference with or shielding of transmission by the mold of a wireless radio frequency signal to the receiver, or from vibration or movement of the mold, or from heat communication with the mold, the transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial heat communication with the heated manifold, substantial interference with or shielding of transmission by the heated manifold of a wireless radio frequency signal to the receiver, or from vibration or movement of the heated manifold.

[066] In such a system one or more of the sensor assemblies can comprise a housing that houses a sensor and the transmitter, and a battery (500) mounted externally of the housing, the battery being interconnected to the sensor or transmitter or both via a wire or cable (700) extending externally of the housing between the battery and the one or more sensor assemblies.

[067] In such a sytem, the battery (500) can be adapted to provide operative power to the sensors, the transmitter or both.

[068] In such a system the battery can be mounted or disposed in a location remote from the housing or the sensor.

[069] In such a system, a single battery can be interconnected to and provide operative power to a sensor or an interconnected radio frequency signal transmitter or both.

[070] In such a system one or more of the sensors are operable to sense one or more of injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[071] In such a system one or more of the sensors can be mounted for sensing fluid pressure or temperature within the cavity (5) or within a distribution channel (17, 19) within the heated manifold(15) or within a downstream channel (18, 20) upstream of the gate (7, 9) or within a barrel of the injection machine or within an inlet (13) to the heated manifold. [072] In such a system the receiver can comprise one or more of a processor, memory, display or user interface (16) that stores, displays or processes one or more of the sensed injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[073] In such a system the sensor assembly can include two or more sensors each sensor separately sensing a selected property or parameter and generating a sensor signal corresponding to the sensed property or parameter, the transmitter transmitting a wireless signal (S) corresponding to each sensor signal.

[074] In such an apparatus the battery (500) is preferably readily manually accessible and replaceable.

[075] In such a system, the sensors typically comprise one or more of a thermocouple, an infrared sensor and a thermistor.

[076] In such a system the radio frequency signal transmitter can be adapted to transmit a wireless signal (S) according to a protocol, wavelength or signal comprising one or more of Bluetooth, ZigBee, Z-Wave, 6L0WPAN, Thread, WiFi-ah (HaLow), WiFi, 2G, 3G, 4G, 5G, LTE Cat 0, 1 , 3, NB-loT, NFC, RFID, SigFox, IR, ANT & ANT+ and radio waves.

[077] In such a system the radio frequency signal transmitter can be adapted to transmit angle of arrival and angle of departure data.

[078] In such a system the radio frequency signal transmitter can be adapted to be awakened or activated to transmit wireless signals (S) upon sensing by an interconnected motion sensor of movement or motion of the mold.

[079] In such a system one or more of the sensors can comprise a motion sensor that generates signals sent wirelessly to the processor, memory, display or user interface (16) that are indicative of one or more of an opening movement or closing movement of the mold, the processor, memory, display or user interface (16) including an algorithm adapted to count cycles of one or more of mold opening movement and mold closing movement. [080] In such a system the receiver can be configured and adapted to receive and process one or more of the received signals to determine one or more actual process parameters including one or more of an actual pin opening time and an actual pin opening velocity.

[081] In such a sytem the reciver can include a display that displays one or more of pin position, cavity pressure, fluid pressure and fluid temperature in real time.

[082] In such an apparatus the sensor assembly can include control circuitry that controls the wireless signal (S) sending, the control circuitry having a top side and a bottom side, the trasmitter being mounted on the sensor, the sensor being disposed under the bottom side of the control circuitry.

[083] Such an apparatus can include a plurality of connector pins, wherein the bottom side of the control circuitry is spaced above a top surface of the sensor, the plurality of connection pins being connected to the control circuitry and the sensor and facilitating in supporting the control circuitry above said sensor, one or more of the plurality of connection pins transmitting data, signals, and/or power between the control circuitry and the sensor.

[084] In another aspect of the invention there is provided a method for performing an injection cycle in an injection molding system comprising an injection machine, a clamping or top clamp plate interconnected to a mold having a cavity, a heated manifold that receives injection fluid from the injection machine and delivers the injection fluid to a downstream channel that delivers the injection fluid to a gate of the cavity, the method comprising: mounting two or more sensor assemblies on, to or within the system forming the two or more sensor assemblies to comprise a sensor and a transmitter, adapting the sensor of the two or more sensor assemblies to sense one or more selected properties or parameters of one or more of the injection fluid and a physical component of the system, individually sending from each sensor assembly a wireless signal (S) from the transmitter indicative of the one or more selected properties or parameters to a receiver mounted remotely from two or more sensor assemblies, adapting the receiver to separately receive the wireless signal (S) from each transmitter of each sensor assembly.

[085] In another aspect of the invention there is provided an injection molding system (10) comprising an injection machine, a clamping or top clamp plate (1) interconnected to a mold (25, 27) having a cavity (5), a heated manifold (15) that receives injection fluid (3) from the injection machine and delivers the injection fluid (3) to a downstream channel (18, 20) that delivers the injection fluid to a gate (7, 9) of the cavity (5), the system including: two or more sensor assemblies mounted on, to or within the system, each sensor assembly comprising a sensor (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 ,

952) interconnected to a transmitter that wirelessly sends a wireless signal (S) indicative of the sensed one or more selected properties or parameters to a receiver mounted remotely from the two or more sensor assemblies, the receiver receiving the wireless signals (S), wherein one or more of the sensor assemblies comprises a housing that houses the sensor (PS1, PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 , 952) and the transmitter, and a battery (500) mounted externally of the housing, the battery being interconnected to the sensor or transmitter or both via one or more wires or cables (700) extending externally of the housing between the battery and the one or more sensor assemblies.

[086] In such a system the battery (500) is typically mounted or disposed in a location remote from the housing or the sensor.

[087] In such a system, the battery is typically mounted in one or more arrangements where: the battery is mounted in a location or disposition distal from the sensor assembly or sensor with the sensor assembly being more proximal to the the mold, heated manifold or hotrunner than the battery, the battery is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial vibration or movement of the mold, or from substantial heat communication with the mold, the battery is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial heat communication with the heated manifold, or from substantial vibration or movement of the heated manifold.

[088] In such a system the battery (500) can be adapted to provide operative power to the sensors, the transmitter or both.

[089] In such a system, a single battery can be interconnected to and provide operative power to a sensor or an interconnected radio frequency signal transmitter or both.

[090] In such a system one or more of the sensors can be adapated to sense one or more of injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[091] In such a system one or more of the sensors can be mounted for sensing fluid pressure or temperature within the cavity (5) or within a distribution channel (17, 19) within the heated manifold(15) or within a downstream flow channel (18, 20) or at a position disposed at or around or upstream (47) of the gate (7, 9) or within a barrel of the injection machine or within an inlet (13) to the heated manifold.

[092] In such a system the receiver can comprise one or more of a processor, memory, display or user interface (16) that stores, displays or processes one or more of the sensed injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[093] In such a system the sensor assembly can include two or more sensors each sensor separately sensing a selected property or parameter and generating a sensor signal corresponding to the sensed property or parameter, the transmitter transmitting a wireless signal (S) corresponding to each sensor signal.

[094] In such an apparatus the battery (500) is preferably readily manually accessible and replaceable.

[095] In such a system, the sensors typically comprise one or more of a thermocouple, an infrared sensor and a thermistor. [096] In such a system the radio frequency signal transmitter can be adapted to transmit a wireless signal (S) according to a protocol, wavelength or signal comprising one or more of Bluetooth, ZigBee, Z-Wave, 6L0WPAN, Thread, WiFi-ah (HaLow), WiFi, 2G, 3G, 4G, 5G, LTE Cat 0, 1 , 3, NB-loT, NFC, RFID, SigFox, IR, ANT & ANT+ and radio waves.

[097] In such a system the radio frequency signal transmitter can be adapted to transmit angle of arrival and angle of departure data.

[098] In such a system the radio frequency signal transmitter can be adapted to be awakened or activated to transmit wireless signals (S) upon sensing by a motion sensor of movement or motion of the mold.

[099] In such a system one or more of the sensors can comprise a motion sensor that generates signals sent wirelessly to the processor, memory, display or user interface (16) that are indicative of one or more of an opening movement or closing movement of the mold, the processor, memory, display or user interface (16) including an algorithm adapted to count cycles of one or more of mold opening movement and mold closing movement.

[0100] In such a system the transmitter of each sensor assembly can be adapted to wirelessly send an individual wireless signal (S) indicative of the one or more selected properties or parameters to the receiver, the receiver receiving a separate wireless signal (S) from each transmitter of each sensor assembly.

[0101] In such a system the sensor can be adapted to sense one or more of injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, movement of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[0102] In such a system, the sensor can be mounted for sensing fluid pressure or temperature within the cavity (5) or within a distribution channel (17, 19) within the heated manifold (15) or within a downstream channel (18, 20) or within a barrel of the injection machine or within an inlet to the heated manifold.

[0103] In such a system, the receiver typically comprises a processor, memory, display or user interface (16) that stores, displays or processes one or more of the sensed injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[0104] In such a system the receiver can be configured and adapted to receive and process one or more of the received signals to determine one or more actual process parameters including one or more of an actual pin opening time and an actual pin opening velocity.

[0105] In such a sytem the reciver can include a display that displays one or more of pin position, cavity pressure, fluid pressure and fluid temperature in real time.

[0106] In such a system, a sensor assembly can include two or more sensors each sensor separately sensing a selected property or parameter and generating a sensor signal corresponding to the sensed property or parameter, the transmitter transmitting a separate or individual wireless signal (S) corresponding to each sensor signal.

[0107] In such an apparatus the sensor assembly can include control circuitry that controls the wireless signal (S) sending, the control circuitry having a top side and a bottom side, the trasmitter being mounted on the sensor, the sensor being disposed under the bottom side of the control circuitry.

[0108] Such an apparatus can include a plurality of connector pins, wherein the bottom side of the control circuitry is spaced above a top surface of the sensor, the plurality of connection pins being connected to the control circuitry and the sensor and facilitating in supporting the control circuitry above said sensor, one or more of the plurality of connection pins transmitting data, signals, and/or power between the control circuitry and the sensor.

[0109] In another aspect of the invention there is provided, a method for performing an injection molding cycle in an injection molding system comprising an injection machine, a clamping or top clamp plate interconnected to a mold having a cavity, a heated manifold that receives injection fluid from the injection machine and delivers the injection fluid to a downstream channel that delivers the injection fluid to a gate of the cavity, the method comprising: mounting two or more sensor assemblies on, to or within the system, forming each sensor assembly to comprise a housing that houses a sensor and a transmitter interconnected to the sensor, sending a wireless signal (S) from the transmitter indicative of the sensed one or more selected properties or parameters, to a receiver mounted remotely from the two or more sensor assemblies, adapting the receiver to wirelessly receive the wireless signal (S) sent by each sensor, mounting a battery externally of the housing, interconnecting the sensor assembly to the battery via a wire extending externally of the housing between the battery and the one or more sensor assemblies. [0110] In another aspect of the invention there is provided an injection molding system comprising an injection machine, a clamping or top clamp plate interconnected to a mold having a cavity, a heated manifold that receives injection fluid from the injection machine and delivers the injection fluid to a downstream channel that delivers the injection fluid to a gate of the cavity, the system including: one or more sensor assemblies mounted on, to or within the system, each sensor assembly comprising one or more sensors each generating a sensor signal indicative of a sensed condition, property or position of the injection fluid or a component of the system, and a transmitter that receives the sensor signal, the transmitter sends a wireless signal (S) corresponding to the received sensor signal to a receiver mounted remotely from the sensor assembly, wherein the one or more sensors are adapted to sense one or more of: injection fluid pressure or temperature flowing through any one or the other of: a channel within the heated manifold, a channel within a nozzle, a channel within a barrel of the injection machine, a channel within an inlet to the heated manifold, a position of a drive member of an actuator, angle of arrival, angle of departure, vibration of the mold or the heated manifold or the top clamp plate, deflection of the mold or the heated manifold or the top clamp plate, magnetic field emitted by a magnetic device.

[0111] Such a system can include a battery (500) mounted or disposed in a location remoted from the sensors, the battery being interconnected to the sensor or transmitter or both via one or more wires or cables (700) extending externally of the housing between the battery and the one or more sensor assemblies.

[0112] In such a system the battery (500) can be adapted to provide operative power to the sensors, the transmitter or both.

[0113] In such a system, a single battery can be interconnected to and provide operative power to a sensor or an interconnected radio frequency signal transmitter or both.

[0114] In such a system one or more of the sensors can be adapated to sense one or more of injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[0115] In such a system one or more of the sensors can be mounted for sensing fluid pressure or temperature within the cavity (5) or within a distribution channel (17, 19) within the heated manifold(15) or within a downstream flow channel (18, 20) or at a position disposed at or around or upstream (47) of the gate (7, 9) or within a barrel of the injection machine or within an inlet (13) to the heated manifold.

[0116] In such a system the receiver can comprise one or more of a processor, memory, display or user interface (16) that stores, displays or processes one or more of the sensed injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[0117] In such a system the sensor assembly can include two or more sensors each sensor separately sensing a selected property or parameter and generating a sensor signal corresponding to the sensed property or parameter, the transmitter transmitting a wireless signal (S) corresponding to each sensor signal. [0118] In such an apparatus the battery (500) is preferably readily manually accessible and replaceable.

[0119] In such a system, the sensors typically comprise one or more of a thermocouple, an infrared sensor and a thermistor.

[0120] In such a system the radio frequency signal transmitter can be adapted to transmit a wireless signal (S) according to a protocol, wavelength or signal comprising one or more of Bluetooth, ZigBee, Z-Wave, 6L0WPAN, Thread, WiFi-ah (HaLow), WiFi, 2G, 3G, 4G, 5G, LTE Cat 0, 1 , 3, NB-loT, NFC, RFID, SigFox, IR, ANT & ANT+ and radio waves.

[0121] In such a system the radio frequency signal transmitter can be adapted to transmit angle of arrival and angle of departure data.

[0122] In such a system the radio frequency signal transmitter can be adapted to be awakened or activated to transmit wireless signals (S) upon sensing by a motion sensor of movement or motion of the mold.

[0123] In such a system one or more of the sensors can comprise a motion sensor that generates signals (S) sent wirelessly to the processor, memory, display or user interface (16) that are indicative of one or more of an opening movement or closing movement of the mold, the processor, memory, display or user interface (16) including an algorithm adapted to count cycles of one or more of mold opening movement and mold closing movement.

[0124] In such a system the transmitter of each sensor assembly can be adapted to wirelessly send an individual wireless signal (S) indicative of the one or more selected properties or parameters to the receiver, the receiver receiving a separate wireless signal (S) from each transmitter of each sensor assembly.

[0125] In such a system the sensor can be adapted to sense one or more of injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, movement of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[0126] In such a system, the sensor can be mounted for sensing fluid pressure or temperature within the cavity (5) or within a distribution channel (17, 19) within the heated manifold (15) or within a downstream channel (18, 20) or within a barrel of the injection machine or within an inlet to the heated manifold.

[0127] In such a system, the receiver typically comprises a processor, memory, display or user interface (16) that stores, displays or processes one or more of the sensed injection fluid pressure, injection fluid temperature, injection fluid velocity, position of a valve pin driven by an actuator, position of a piston of an actuator, position of an actuator motor, deflection of the mold, vibration of the mold, angle of arrival, angle of departure and magnetic field.

[0128] In such a system the receiver can be configured and adapted to receive and process one or more of the received signals to determine one or more actual process parameters including one or more of an actual pin opening time and an actual pin opening velocity.

[0129] In such a sytem the reciver can include a display that displays one or more of pin position, cavity pressure, fluid pressure and fluid temperature in real time.

[0130] In such a system, a sensor assembly can include two or more sensors each sensor separately sensing a selected property or parameter and generating a sensor signal corresponding to the sensed property or parameter, the transmitter transmitting a separate or individual wireless signal (S) corresponding to each sensor signal.

[0131] In such a system one or more of the sensor assemblies can comprise a housing that houses the sensor and the transmitter and a battery mounted externally of the housing, the battery being interconnected to the sensor or transmitter or both via a wire extending externally of the housing between the battery and the one or more sensor assemblies.

[0132] In such a system, a sensor assembly can include two or more sensors each sensor separately sensing a selected property or parameter and generating a sensor signal corresponding to the sensed property or parameter, the transmitter transmitting a wireless signal (S) corresponding to each sensor signal.

[0133] In such a system the receiver can be configured and adapted to receive and process one or more of the received signals to determine one or more actual process parameters including one or more of an actual pin opening time and an actual pin opening velocity. [0134] In such a sytem the reciver can include a display that displays one or more of pin position, cavity pressure, fluid pressure and fluid temperature in real time.

[0135] In such a system the sensor assembly can include control circuitry that controls the wireless signal (S) sending, the control circuitry having a top side and a bottom side, the trasmitter being mounted on the sensor, the sensor being disposed under the bottom side of the control circuitry.

[0136] Such a system can include a plurality of connector pins, wherein the bottom side of the control circuitry is spaced above a top surface of the sensor, the plurality of connection pins being connected to the control circuitry and the sensor and facilitating in supporting the control circuitry above said sensor, one or more of the plurality of connection pins transmitting data, signals, and/or power between the control circuitry and the sensor.

[0137] In such a system the wireless signal (S) typically comprises a radio frequency wireless signal.

[0138] In such a system each sensor assembly is preferably mounted on, to, within or in close physical proximity to one or the other of the cavity (5), the heated manifold (15), an inlet (13) to the heated manifold or a barrel of the injection machine, each transmitter individually sending a wireless signal (S) corresponding to a sensor signal to a processor, memory, display or user interface (16) mounted or disposed in a location remote from the housing or the sensor.

[0139] In such a system each transmitter (600) is preferably disposed in a location remote from its corresponding sensor.

[0140] In such a system, each transmitter is preferably mounted in one or more arrangements where: the radio frequency signal transmitter is mounted in a location or disposition distal from the sensor assembly or sensor with the sensor assembly being more proximal to the the mold, heated manifold or hotrunner than the radio frequency signal transmitter, or the radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial interference with or shielding of transmission by the mold of a wireless radio frequency signal to the receiver, or from vibration or movement of the mold, or from heat communication with the mold, or the radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial heat communication with the heated manifold, substantial interference with or shielding of transmission by the heated manifold of a wireless radio frequency signal to the receiver, or from vibration or movement of the heated manifold.

[0141] In another aspect of the invention there is provided a method of performing an injection cycle in an injection molding system comprising an injection machine, a clamping or top clamp plate interconnected to a mold having a cavity, a heated manifold that receives injection fluid from the injection machine and delivers the injection fluid to a downstream channel that delivers the injection fluid to a gate of the cavity, the method comprising: mounting a sensor assembly on to or within the system, forming the sensor assembly to comprise a sensor and a transmitter, adapting the sensor to sense one or more of: injection fluid pressure or temperature flowing through any one or the other of: a channel within the heated manifold, a channel within a nozzle, a channel within a barrel of the injection machine, a channel within an inlet to the heated manifold, a position of a drive member of an actuator, angle of arrival, angle of departure, vibration of the mold or the heated manifold or the top clamp plate, deflection of the mold or the heated manifold or the top clamp plate, magnetic field emitted by a magnetic device, adapting the sensor to generate a sensor signal indicative of a sensed condition or property of the system, sending a signal corresponding to the sensor signal wirelessly via the transmitter, adapting a receiver mounted remotely from the sensor assembly to receive the wireless signal (S) from the transmitter.

[0142] In another aspect of the invention, one or more sensors of the system can comprise a heat sensor or thermocouple that senses the temperature of a nozzle that is controllably heated by a band heater. The band heater typically includes a heating element that is controllably heated by the processor (16) that receives wireless signals (S) from the heat sensor to use in a heat control algorithm or program Such a band heater is preferably comprised of a sheet of highly heat conductive metal material, the sheet or jacket having opposing sheet edges, the sheet or jacket being bendable or formable into a heating cylinder having a central channel having an interior circumferential wall surface (14is) and a selected longitudinal length extending from a downstream end to an upstream end of the heating cylinder, the central channel being formed into a configuration wherein a selected nozzle is received within the central channel and the interior circumferential wall surface of the channel directly engages without intermediary element an outer circumferential wall surface of the selected nozzle, the sheet having opposing sheet edges that are disposed in a select arrangement or position relative to each other upon bending or forming of the sheet into the cylinder and reception of the selected nozzle within the central channel, a stabilization ring or cylinder having a central ring channel having an inner

circumferential ring surface, the stabilization ring or cylinder being adapted to receive a selected longitudinal portion of the downstream or distal end of the heating cylinder, the stabilization ring or cylinder being adapted to engage or mate the inner fia§ circumferential ring surface with an outer surface of the heating cylinder extending along the selected longitudinal portion of the downstream or distal end of the heating cylinder. [0143] In another aspect of the invention there is provided an apparatus comprising: at least one sensor assembly arranged for integration into an injection molding system (10, 10A), the injection molding system formed of an injection machine, a mold (25, 27, 42) having a cavity (5, 30), a clamping or top clamp plate (1) interconnected to the mold, a heated manifold (15) arranged to receive injection fluid (3) from the injection machine and deliver the injection fluid to at least one channel (13, 17, 18, 18A, 19, 20) that delivers the injection fluid to at least one respective gate (7, 9) of the cavity, each sensor assembly having: two or more position sensors (950, 951 , 952) contained within a housing; and a communication module interconnected to the two or more sensors, the communication module having a separate or individual radio frequency signal transmitter (600) corresponding to the respective sensor assembly wherein each separate or individual radio frequency signal transmitter is arranged to separately or individually receive a corresponding sensor signal from a corresponding one of the two or more sensors and wherein each separate or individual radio frequency signal transmitter is adapted to communicate a wireless signal (S) corresponding to the received sensor signals to a controller (16, 16A) mounted or disposed in a location remote from the housing or the respective sensor assembly; wherein the two or more sensors (950, 951 , 952) are each adapted to sense and generate a respective sensor signal indicative of motion, movement or position of an actuator or a valve pin interconnected to and driven by the actuator, wherein each sensor assembly is mounted on, to, within or in close physical proximity to one or more of the cavity, the heated manifold, an inlet (13) to the heated manifold, one or more nozzles (21 , 22A, 22B, 22C, 23) arranged to receive the injection fluid from the heated manifold or a barrel of the injection machine. and wherein the controller (16, 16A) includes an algorithm that instructs the actuators to move the actuator or the valve pin initially from a gate closed position upstream at a reduced, less than maximum rate of movement or at reduced velocity such that fluid flow through the gate at the beginning of an injection cycle is reduced relative to a maximum rate of fluid flow and to instruct the actuator to subsequently move the valve pin at a higher rate of upstream velocity when the position sensor senses that the valve pin has reached a predetermined position upstream of the gate closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0144] Fig. 1 is a schematic representation of the mounting location of a pair of sensors being disposed within the perimeter or within the temperature, vibration, or movement environment of a mold or hotrunner (heated injection fluid manifold) relative to a location that is outside the perimeter or outside the temperature, vibration, or movement environment of the mold or hotrunner. The sensors shown in part P1 without wires each have a wireless signal transmitter 600 individually incorporated within a housing that houses both the sensor and the transmitter, such a system typically being used in conjunction with aluminum molds. The sensors shown in part P2 have wires 700 interconnected to the sensors, the wires extending outside the perimeter and being interconnected to an antenna disposed outside the perimeter, the antenna typically comprising a bus antenna that wirelessly transmits, via a wireless signal transmitter 600, signals indicative of the conditions or properties sensed by the sensors to a remote processor, memory, display or user interface (16), such a system typically being used in conjunction with steel molds. The sensors shown in part P3 have wires 700 interconnected to the sensors, the wires being interconnected to a module comprised of a replaceable battery 500 for powering the sensors and an antenna typically a bus antenna for transmitting, via a wireless signal transmitter 600, a wireless signal (S) to a remotely located or disposed receiver that routes the signal CS to a processor, memory, display or user interface (16).

[0145] Fig. 2 is a side sectional schematic of an injection molding system showing multiple sensors having wireless signal (S) transmitters mounted or disposed at various locations within the perimeter of a mold, a heated manifold, a downstream nozzle flow channel and an inlet from the barrel of an injection machine to a heated manifold.

[0146] Fig. 3 is a schematic of an embodiment of the invention utilizing position sensors to monitor the position of the apparatus actuators and to send signals to a wireless signal transmitter that in turn sends a wireless signal (S) indicative of the position of the actuator to a processor or controller 16 as described more fully herein.

DETAILED DESCRIPTION

[0147] The sensors shown in Fig. 1 , part P1 are without wires, each sensor having a wireless signal transmitter 600 individually incorporated within a housing that houses both the sensor and the transmitter. The housing being mounted or disposed within the perimeter of the mold or hotrunner (heated manifold) or both, such a system typically being used in conjunction with aluminum molds. [0148] The sensors shown in Fig. 1 , part P2 have wires 700 interconnected to the sensors, the wires 700 extending outside the perimeter and being interconnected to an antenna or radio frequency signal transmitter 600 that is disposed up to or slightly beyond the perimeter of the mold or heated manifold, the antenna or radio frequency signal transmitter 600 can comprise separate or individual transmitters that are individually mounted. The radio frequency signal transmitter 600 can comprise a bus antenna that wirelessly transmits signals indicative of the conditions or properties sensed by the sensors to a remotely located or mounted processor, memory, display or user interface (16), such a system typically being used in conjunction with steel molds. Batteries are typically housed within a protective housing that houses the sensors. In the Fig. 1 , part P2 embodiment, the batteries that power each sensor can be mounted remotely from the mold or other system component (hotrunner, top clamp plate, inlet, barrel) in the same manner that the radio frequency transmitters 600 are mounted remotely and interconnected via wires or cables (similar to the wires or cables shown) to the two (or more) sensors as shown. In such an embodiment the battery can comprise a single battery unit that is interconnected to and provides power to both sensors. Further in such an embodiment, the batteries or battery can be interconnected to a recharging device such as an energy harvester or kinetic energy generator disposed outside the perimeter, typically up to or slightly beyond the perimeter, the energy harvester typically generating energy from vibration or other movement (such as opening or closing) of the mold or from another selected source of energy generation. [0149] The sensors and embodiment shown in Fig. 1, part P3 have wires 700 interconnected to the sensors, the wires being interconnected outside the perimeter to a module disposed outside the perimeter of the mold or heated manifold, the module containing typically a replaceable battery 500 for powering the sensors and an antenna typically a bus antenna for transmitting, via a wireless signal transmitter 600, a wireless signal (S) to a remotely located or disposed receiver that routes the signal to a remotely disposed processor, memory, display or user interface (16). The battery or batteries 500 in such an embodiment can be interconnected to an energy harvester that recharges the batteries contained within the module, a typical energy harvester being a device that captures and utilizes vibration of the mold to generate electrical power. [0150] The processor, memory, display or user interface (16) can include or be interconnected to a device that enables sending a wireless control signal (CS) containing control data or instructions that are routed to the control elements of one or more operational components of the apparatus such as to the actuators, the heaters, the valves, the drive valves, the directional valves, the servo valves, the electric power receiving or distribution components of an electric actuator such an electric drive, an electromagnet, an electric power receiving coil, a stator or an armature. Such control elements of the apparatus can be interconnected to a wireless signal receiver similar to or same as the wireless signal receiver that receives the wireless signals (S) and routes those signals (S) to the processor, memory, display or user interface (16).

[0151] Fig. 2 shows show one embodiment of an injection molding system according to the present invention having two nozzles 21 , 23 the plastic flow through which are to be controlled according to a predetermined algorithm as described below. Although only two nozzles are shown in Fig. 2 the invention contemplates simultaneously controlling the material flow through one or more and typically a plurality of nozzles. In the embodiment shown, the injection molding system 10 is a multi-gate single cavity system in which injection fluid 3 (e.g., any suitable melt material) is injected into a cavity 5 from the two gates 7 and 9. Injection fluid 3 is injected from an injection molding machine through an extended inlet 13 and into the channels of a heated manifold 15. Manifold 15 distributes the injection fluid 3 through channels 17 and 19. Although a hot runner (a/k/a heated manifold) system is shown in which plastic melt is injected, the invention is applicable to other types of injection systems in which it is useful to control the rate at which a material (e.g., metallic or composite materials) is delivered to a cavity.

[0152] Mounting or disposition of a component, signal transmitter, battery, antenna or the like outside the perimeter of the mold (or the perimeter of the hotrunner) or in a location remote from the sensor assembly or sensors refers to any one or more of:

(i) mounting of the a component, signal transmitter, battery, antenna or the like distal from the sensor assembly or sensor with the sensor assembly being more proximal to the mold, heated manifold or hotrunner than the subject component, signal transmitter, battery, antenna or the like, (ii) a mounting arrangement or configuration where the component, signal transmitter, battery, antenna or the like is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial interference by the mold with transmission of a wireless radio frequency signal to the receiver, or from vibration or movement of the mold, or from heat communication with the mold,

(iii) a mounting arrangement or configuration where the component, signal transmitter, battery, antenna or the like is mounted in a location or disposition that is removed, insulated or isolated from one or more of substantial heat communication with the heated manifold, substantial interference by the heated manifold with transmission of a wireless radio frequency signal to the receiver, or from vibration or movement of the heated manifold.

[0153] Injection fluid 3 is distributed by the manifold 15 through upstream channels 17 and 19 disposed within the heated manifold 15 and into the downstream flow channels or bores 18 and 20 of the two nozzles 21 and 23, respectively. The rate of flow of injection fluid 3 through the gates 7, 9 and into cavity 5 is typically controlled via controlled axial positioning of valve pins 41, 102 within the flow channels 18, 20 of nozzles 21 and 23. The cavity is defined and formed by mold plates 25 and 27. In the embodiment shown the valve pins 41 , 102 have an upstream protrusion 43, 45 that has an outer circumferential surface adapted to interact with a complementary interior surface 47 of the nozzle channels 18, 20 the channel surface 47 being disposed upstream and away from the gate 7, 9. Depending on the precise axial positioning of the protrusions relative to the surfaces 47, the rate of fluid flow through the nozzle channel and the gates 7, 9 can be controllably varied during the course of an injection cycle as described for example in U.S. Patent No. 6,769,896 and U.S. Publication No. 2002/0086086 the disclosures of which are incorporated herein by reference. Although a multigate 7, 9 single-cavity 5 system is shown, the invention is not limited to this type of system, and is also applicable to, for example, multi-cavity systems.

[0154] The injection nozzles 21 and 23 are received in respective wells 28 and 29 formed in the mold plate 27. The nozzles 21 and 23 are each seated in support rings 31 and 33. The support rings serve to align the nozzles with the gates 7 and 9 and insulate the nozzles from the mold. The manifold 15 sits atop the rear end of the nozzles and maintains sealing contact with the nozzles via compression forces exerted on the assembly by clamps (not shown) of the injection molding machine. An O-ring is typically provided to prevent melt leakage between the nozzles and the manifold. A dowel 2 centers the manifold on the mold plate 27. Dowels prevent the nozzles 21 , 23 and support rings respectively, from rotating with respect to the mold 27.

[0155] Other valve pin and downstream channel configurations can be employed for controlling fluid flow rate such as disclosed in WO2012074879 and WO2012087491 the disclosures of which are incorporated herein by reference. In such systems fluid flow rate is controlled by controlled axial positioning of the tip ends of the valve pins relative to the interior surfaces of the gate areas of the mold cavities.

[0156] The sensor assembly systems and methods described herein can be used to implement systems and methods that utilize sensed cavity pressure data and signals such as described for example in W02014172100 and W02017100575 and U.S.

Patent No. 9908273, the disclosures of all of which are incorporated herein by reference.

[0157] In the Fig. 2 system an electric band heater for heating the nozzles can be employed as disclosed in PCT/US2019/040920 (published as WO 2020/204980) the disclosures of which are incorporated herein by reference in their entirety as if fully set forth herein. The sensor component of such a band heater can be interconnected to a radio frequency signal transmitter (600) as described herein with reference to heat sensors T1 , T2, T3 or A1 , A2 to effect transmission of a wireless signal (S) to a processor, memory, display or user interface (16) mounted or disposed in a location remote from the housing or the sensor as described herein.

[0158] Such a band heater includes a temperature sensor and is typically comprised of a sheet of highly heat conductive metal material, the sheet or jacket having opposing sheet edges, the sheet or jacket being bendable or formable into a heating cylinder having a central channel having an interior circumferential wall surface and a selected longitudinal length extending from a downstream end to an upstream end of the heating cylinder, the central channel being formed into a configuration wherein a selected nozzle is received within the central channel and the interior circumferential wall surface of the channel directly engages without intermediary element an outer circumferential wall surface of the selected nozzle, the sheet having opposing sheet edges that are disposed in a select arrangement or position relative to each other upon bending or forming of the sheet into the cylinder and reception of the selected nozzle within the central channel, a stabilization ring or cylinder having a central ring channel having an inner fin§ circumferential ring surface, the stabilization ring or cylinder being adapted to receive a selected longitudinal portion of the downstream or distal end of the heating cylinder, the stabilization ring or cylinder being adapted to engage or mate the inner ring circumferential ring surface with an outer surface of the heating cylinder extending along the selected longitudinal portion of the downstream or distal end of the heating cylinder. [0159] In other embodiments, heat pipes, such as those disclosed in U.S. Pat. No. 4,389,002, the disclosure of which is incorporated herein by reference may be disposed in a nozzle and used alone or in conjunction with a band heater. The heater is used to maintain the injection fluid 3 (e.g., any suitable plastic, metal, composite, or other melt material) at its processing temperature as far up to the point of exit through/into gates 7 and 9 as possible. The manifold is heated to elevated temperatures sufficient to maintain the plastic or other fluid which is injected into the manifold distribution channels 17, 19 at a preferred preselected flow and processing temperature.

[0160] The mold plate or body 27 is typically cooled to a preselected temperature and maintained at such cooled temperature relative to the temperature of the manifold 15 via cooling ducts through which water or some other selected fluid is pumped during the injection molding process in order to effect the most efficient formation of the part within the mold cavity.

[0161] As shown in Fig. 2, the injection nozzle(s) is/are mounted within wells 28, 29 so as to be held in firmly stationary alignment with the gate(s) 7, 9 which lead into the mold cavities. The mounting of the heated nozzle(s) is/are arranged so as to reduce contact of the nozzle(s) body and its associated components with the cooled mold plate 27 but at the same time form a seal against fluid leakage back into an insulative air space in which the nozzle is disposed thus maintaining the fluid pressure within the flow bore or channel against loss of pressure due to leakage. [0162] As shown in Fig. 2, the system 10 includes plurality of sensor assemblies PS1, PS2, PS3, PS4, A1, A2, T1, T2, T3 each of which is interconnected to a wireless signal transmitter that sends a signal indicative of the condition or property sensed by the sensor component of the assembly. PS1 and PS2 include at least a pressure sensor that senses pressure and are mounted and arranged to sense the pressure of the injection fluid 3 flowing through the downstream channels 18, 20 of nozzles 21 , 23 at a position upstream and away from the gates 7, 9. PS3 and PS4 include at least a pressure sensor that senses fluid pressure within the cavity of the mold at or near the point of entry of the injection fluid 3 through the gates 7, 9. A1 includes at least a temperature sensor that is mounted and arranged to sense temperature of the heated manifold 7. A2 includes at least a temperature sensor that is mounted and arranged to sense temperature of the injection fluid at a selected position within the mold cavity 5. Sensor assemblies T1 and T2 include at least a temperature sensor that is mounted and arranged to sense temperature of the nozzle bodies 21 , 23. T3 includes at least a temperature sensor mounted and arranged to sense temperature of the inlet body 13. Each of the sensor assemblies PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3 can include more than one sensor. Each of the sensor assemblies typically include a protective housing that houses one or more selected sensors. Each of the sensor assemblies PS1, PS2, PS3, PS4, A1, A2, T1, T2, T3 as described above include at least one and can include two or more sensors that sense one or the other of pressure, temperature, deflection such as measured by a gyroscope, mold vibration such as measured by an accelerometer, Angle of arrival (AoA), Angle of departure (AoD), position (e.g., position, such local position of one structure relative to another structure in the system or position geographically such as by a global positioning system (GPS) sensor), or one or more magnetic properties.

[0163] The receiver of any of the systems described herein can be configured and adapted to receive and process one or more of the received signals to determine one or more actual process parameters including one or more of an actual pin opening time and an actual pin opening velocity. Such recivers can include a display that displays one or more of pin position, pin speed, cavity pressure, fluid pressure and fluid temperature in real time as described in U.S. patent no. US 10166710, the disclosure of which is incorporated herein by reference.

[0164] Where a position sensor such as shown in Fig. 3 is included in the system 10A to measure or monitor the position of a valve pin, the processor, memory, display or user interface (16) is typically configured to include an algorithm that controls the position of the valve pin based on received wireless signals (S) that correspond to the position of the valve pin. The processor 16A of such a user interface 16 utilizes the received wireless signals S in an algorithm that instructs the actuators to move the valve pin initially from a gate closed position upstream at a reduced, less than maximum rate of movement or at reduced velocity such that the fluid flow at the beginning of an injection cycle is reduced relative to a maximum rate of fluid flow and then to subsequently instruct the actuator to move the valve pin at a higher rate of upstream velocity when the position sensor senses that the valve pin has reached a predetermined position upstream of the gate closed position.

[0165] In such a system 10A as shown in Fig. 3 a central nozzle 22B feeds molten material from an injection molding machine through a main inlet 18A to a distribution channel 19 of a manifold 40. The distribution channel 19 commonly feeds three separate nozzles 22A, 22B, 22C which all commonly feed into a common cavity 30 of a mold 42. One of the nozzles 22B is controlled by actuator 940 and arranged so as to feed into cavity 30 at an entrance point or gate that is disposed at about the center 32 of the cavity. As shown, a pair of lateral nozzles 22A, 22C feed into the cavity 30 at gate locations that are distal 34, 36 to the center gate feed position 32. As shown in Fig. 3, position sensors 950, 951 , 952 are included for sensing the position of the actuator cylinders 940, 941, 942 and their associated valve pins (such as 1040, 1041, 1042) and feed such position information via wireless signal (S) to processor 16A (e.g., controller, microcontroller, microprocessor, or the like). The position sensors 950, 951, 952 are each interconnected to a separate wireless signal transmitter that is mounted in one or more arrangements as described herein to send a wireless signal indicative of pin position to a processor 16A.

[0166] As shown in the Fig. 3 embodiment, fluid material is injected from an injection machine into a distribution channel 19 (e.g., a manifold runner) and further downstream into the bores 44, 46 of the lateral nozzles 22A, 22C and ultimately downstream through the gates at the center and distal gate positions 32, 34, 36. When the pins 1041 , 1042 are withdrawn upstream to a position where the tip end of the pins 1041 are in a fully upstream open position, the rate of flow of fluid material through the lateral gates at distal gate positions 34, 36 is at a maximum for the particular system. However when the pins 1041, 1042 are initially withdrawn beginning from the closed gate position to intermediate upstream positions, a gap 1154, 1156 that restricts the velocity of fluid material flow is formed between the outer surfaces 1155 of the tip end of the pins 1040, 1041 , 1042 and the inner surfaces 1254, 1256 of the gate areas of the nozzles 22A,

22C. The restricted flow gap 1154, 1156 remains small enough to restrict and reduce the rate of flow of fluid material 1153 through lateral gates at distal gate positions 34, 36 to a rate that is less than maximum flow velocity over a travel distance RP in a direction FO of the tip end of the pins 1041 , 1042 going from closed to upstream.

[0167] In the Fig. 3 embodiment, the injection cycle is a cascade process where injection is effected in a sequence from the center nozzle 22B first and at a later predetermined time from the lateral nozzles 22A, 22C. The injection cycle is started by first opening the pin 1040 of the center nozzle 22A and allowing the fluid material (typically, but not always, polymer or plastic material) to flow up to a position 100a in the cavity just before the distally disposed entrance into the cavity (e.g., distal gate positions 34, 36) of the gates of the lateral nozzles 22A, 22C. After an injection cycle is begun, the gate of the center injection nozzle 22B and pin 1040 is typically left open only for so long as to allow the fluid material to travel to a position just past the distal gate positions 34, 36. Once the fluid material has travelled just past the distal gate positions 34, 36, the center gate at center gate position 32 of the center nozzle 22B is typically closed by pin 1040. The lateral gates at distal gate positions 34, 36 are then opened by upstream withdrawal of lateral nozzle pins 1041 , 1042. As described herein, the rate of upstream withdrawal or travel velocity of lateral pins 1041 , 1042 is a controlled process.

[0168] In alternative embodiments, the gate at center gate position 32 and associated actuator 940 and valve pin 1040 can remain open at, during and subsequent to the times that the lateral gates at distal gate positions 34, 36 are opened such that fluid material flows into cavity 30 through both the gate at center gate position 32 and one or both of the lateral gates at distal gate positions 34, 36 concurrently.

[0169] When the lateral gates at distal gate positions 34, 36 are opened and fluid material is allowed to first enter the mold cavity into the stream that has been injected from center nozzle 22B past distal gate positions 34, 36, the two streams mix with each other. If the velocity of the fluid material is too high, such as often occurs when the flow velocity of injection fluid material through lateral gates at distal gate positions 34, 36 is at maximum, a visible line or defect in the mixing of the two streams will appear in the final cooled molded product at the areas where lateral gates at distal gate positions 34, 36 inject into the mold cavity. By injecting at a reduced flow rate for a relatively short period of time at the beginning when the lateral gates at distal gate positions 34, 36 are first opened and following the time when fluis first enters the flow stream, the appearance of a visible line or defect in the final molded product can be reduced or eliminated.

[0170] The rate or velocity of upstream withdrawal of pins 1041 , 1042 starting from the closed position is controlled via controller 16A, which controls the rate and direction of flow of hydraulic fluid from the drive system to the actuators 940, 941 , 942.

[0171] Although the Fig. 3 system 10A shows a hydraulic or pneumatic actuator, the actuators 940, 941 , 942 can alternatively comprise electric actuators, rotary or linear. The position of the valve pins to which the electric actuators are interconnected can similarly be monitored by a suitable position sensor that senses either the position of the valve pin directly or senses the rotary or linear position of the drive member of the electric actuator to which the valve pin is drivably interconnected. A pin position program for controlling the position and rate of drive of the electric actuator can be included in the controller 16A in the same manner as a program for controlling the rate and position of the hydraulic or pneumatic actuators shown in Fig. 3.

[0172] A controller 16A as used herein, refers to electrical and electronic control apparati that comprise a single box or multiple boxes (typically interconnected and communicating with each other) that contain(s) all of the separate electronic processing, memory and electrical signal generating components that are necessary or desirable for carrying out and constructing the methods, functions and apparatuses described herein. Such electronic and electrical components include programs, microprocessors, computers, PID controllers, voltage regulators, current regulators, circuit boards, motors, batteries and instructions for controlling any variable element discussed herein such as length of time, degree of electrical signal output and the like. For example a component of a controller, as that term is used herein, includes programs, controllers and the like that perform functions such as monitoring, alerting and initiating an injection molding cycle including a control device that is used as a standalone device for performing conventional functions such as signaling and instructing an individual injection valve or a series of interdependent valves to start an injection, namely move an actuator and associated valve pin from a gate closed to a gate open position. In addition, although fluid driven actuators are employed in typical or preferred embodiments of the invention, actuators powered by an electric or electronic motor or drive source can alternatively be used as the actuator component.

[0173] Such an apparatus as shown in Fig. 3 comprises: a manifold receiving the injected fluid mold material, the manifold having a delivery channel that delivers the injected fluid material to a first gate leading to the mold cavity; an actuator interconnected to a valve pin having a tip end drivable along a drive path that extends between a first position where the tip end of the valve pin obstructs the first gate to prevent the injection fluid material from flowing into the cavity, a second position upstream of the first position wherein the tip end of the valve pin restricts flow of the injection fluid through the first gate along at least a portion of the length of the drive path extending between the first position and the second position, and a third position upstream of the second position where the injection fluid material flows freely through the first gate without restriction from the tip end of the pin, the actuator and the valve pin being translationally driven at a controllable rate of travel by a valve system that is controllably adjustable between a start position, one or more intermediate drive rate positions and a high drive rate position, the actuator being driven upstream at one or more intermediate rates of travel when the valve system is in the one or more intermediate drive rate positions and at a higher rate of travel than the one or more intermediate rates of travel when the valve system is in the high drive rate position; a position sensor and a controller, the position sensor 950, 951, 952 sensing the position of the valve pin and sending a signal indicative of the position of the pin to the controller; the controller instructing the valve system to drive the actuator and the valve pin continuously upstream from the start position to the second position to the third position; the controller including instructions that instruct the valve system to move from the start position to the one or more intermediate drive rate positions and subsequently from the one or more intermediate drive rate positions to the high drive rate position on receipt by the controller of a signal from the position sensor that is indicative of the valve pin having reached the second position.

Claims

What is claimed is:

1. An apparatus comprising: at least one sensor assembly arranged for integration into an injection molding system (10, 10A), the injection molding system formed of an injection machine, a mold (25, 27, 42) having a cavity (5, 30), a clamping or top clamp plate (1) interconnected to the mold, a heated manifold (15) arranged to receive injection fluid (3) from the injection machine and deliver the injection fluid to at least one channel (13, 17, 18, 18A, 19, 20) that delivers the injection fluid to at least one respective gate (7, 9) of the cavity, each sensor assembly having: two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951 , 952) contained within a housing; and a communication module interconnected to the two or more sensors, the communication module having a separate or individual radio frequency signal transmitter (600) corresponding to the respective sensor assembly wherein each separate or individual radio frequency signal transmitter is arranged to separately or individually receive a corresponding sensor signal from a corresponding one of the two or more sensors and wherein each separate or individual radio frequency signal transmitter is adapted to communicate a wireless signal (S) corresponding to the received sensor signals toward a processor, memory, display, or user interface (16) mounted or disposed in a location remote from the housing or the respective sensor assembly; and a controller (16A) arranged to direct a plurality of monitoring, controlling, and identifying one or more of injection fluid pressure, injection fluid temperature, magnetic field, and motion or movement or position of any one or more of an actuator (14, 940, 941, 942), the mold, the heated manifold, the clamping or top clamp plate, and the injection machine, wherein the two or more sensors (PS1 , PS2, PS3, PS4, A1 , A2, T1 , T2, T3, 950, 951, 952) are each adapted to sense and generate a respective sensor signal indicative of one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, the mold (25, 27), the heated manifold, the clamping or top clamp plate and the injection machine, wherein each sensor assembly is mounted on, to, within or in close physical proximity to one or more of the cavity, the heated manifold, an inlet (13) to the heated manifold, one or more nozzles (21 , 22A, 22B, 22C, 23) arranged to receive the injection fluid from the heated manifold or a barrel of the injection machine.

2. An apparatus according to claim 1 wherein each separate or individual radio frequency signal transmitter (600) is disposed in a location remote from its corresponding sensor.

3. An apparatus according to any of the foregoing claims wherein each separate or individual radio frequency signal transmitter is mounted in one or more arrangements wherein: the separate or individual radio frequency signal transmitter is mounted in a location or disposition distal from its corresponding sensor assembly with the corresponding sensor assembly being more proximal to the mold, heated manifold or hotrunner than the separate or individual radio frequency signal transmitter, and the separate or individual radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated, or isolated from one or more of substantial interference with or shielding of transmission of the wireless signal (S) to a receiver by the mold, or from vibration or movement of the mold, or from heat communication with the mold.

4. An apparatus according to any of the foregoing claims wherein each separate or individual radio frequency signal transmitter is mounted in one or more arrangements wherein: the separate or individual radio frequency signal transmitter is mounted in a location or disposition distal from its corresponding sensor assembly with the corresponding sensor assembly being more proximal to the mold, heated manifold or hotrunner than the separate radio frequency signal transmitter, and the separate or individual radio frequency signal transmitter is mounted in a location or disposition that is removed, insulated, or isolated from one or more of substantial heat communication with the heated manifold, substantial interference with or shielding of transmission of the wireless signal (S) by the heated manifold, or from vibration or movement of the heated manifold.

5. An apparatus according to any of the foregoing claims wherein at least one separate or individual radio frequency signal transmitter is interconnected to and receives a sensor signal from a corresponding sensor via a wire or cable (700) that extends to a location remote from the corresponding sensor.

6. An apparatus according to any of the foregoing claims further including a battery (500) that is interconnected to and provides operative power to at least some of the two or more sensors, wherein the battery is one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable, and

(vi) mounted or disposed in a location remote from the housing or the sensor.

7. An apparatus according to any of the foregoing claims further including a battery (500) that is interconnected to and provides operative power to one or more radio frequency signal transmitters (600), wherein the battery is one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable, and

(vi) mounted or disposed in a location remote from the housing or the sensor.

8. An apparatus according to any of the foregoing claims further including a single battery (500) that is interconnected to and provides operative power to at least some of the two or more sensors and an ione or more radio frequency signal transmitters, wherein the battery is one or more of:

(iv) readily removable and replaceable,

(v) non rechargeable, and

(VI) mounted or disposed in a location remote from the housing or the sensor.

9. An apparatus according to any of the foregoing claims wherein the processor, memory, display or user interface (16) is adapted to receive data embedded in the wireless signals (S) and further adapted, based on the data, to direct an adjustment or control during the course of an injection cycle one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, a valve pin, the mold, the heated manifold, the clamping or top clamp plate, and the injection machine.

10. An apparatus according to any of the foregoing claims at least one of the two or more sensors is mounted in an arrangement for sensing fluid pressure or temperature within the cavity, or within a distribution channel (17, 19) within the heated manifold(15), or within a downstream channel (18, 20, 44) upstream of the gate (7, 9), or within a barrel of the injection machine, or within an inlet (13) to the heated manifold.

11. An apparatus according to any of the foregoing claims wherein a battery that powers at least one of the two or more sensors is readily manually accessible and replaceable.

12. An apparatus according to any of the foregoing claims wherein at least one of the two or more sensors is a thermocouple, an infrared sensor, and a thermistor.

13. An apparatus according to any of the foregoing claims wherein at least one of the separate or individual radio frequency signal transmitters is adapted to transmit a radio wave according to a protocol, wavelength, or signal compatible with one or more of Bluetooth, ZigBee, Z-Wave, 6L0WPAN, Thread, WiFi-ah (HaLow), WiFi, 2G, 3G, 4G,

5G, LTE Cat 0, 1 , 3, NB-loT, NFC, RFID, SigFox, IR, and ANT & ANT+.

14. An apparatus according to any of the foregoing claims wherein at least one of the separate or individual radio frequency signal transmitters is adapted to transmit angle of arrival and angle of departure data.

15. An apparatus according to any of the foregoing claims wherein at least one of the separate or individual radio frequency signal transmitters is adapted to be awakened or activated to transmit wireless signals upon sensing, by an interconnected motion sensor, of movement or motion of the mold.

16. An apparatus according to any of the foregoing claims wherein at least one of the two or more sensors includes a motion sensor arranged to generate signals that are indicative of one or more of an opening movement or closing movement of the mold, and wherein the controller is arranged execute an algorithm adapted to count cycles of one or more of mold opening movement and mold closing movement.

17. A method comprising: providing at least one sensor assembly arranged for integration into an injection molding system (10, 10A), the injection molding system formed of an injection machine, a mold (25, 27, 42) having a cavity (5, 30), a clamping or top clamp plate (1) interconnected to the mold, a heated manifold (15) arranged to receive injection fluid (3) from the injection machine and deliver the injection fluid to at least one channel (13, 17,

18. 18A, 19, 20) that delivers the injection fluid to at least one respective gate (7, 9) of the cavity, each sensor assembly having two or more sensors (PS1 , PS2, PS3, PS4,

18. A method according to claim 17 further comprising: interconnecting one or more batteries (500) to one or more of each radio frequency signal transmitter (600) to provide power thereto, each battery adapted to be one or more of:

(i) rechargeable,

(ii) rechargeable via receipt of energy from an energy harvesting device,

(iv) readily removable and replaceable,

(v) non rechargeable, and

(vi) mounted or disposed in a location remote from the housing or the sensor.

19 A method according to any of claims 17 to 18 further comprising: interconnecting one or more batteries to at least some of the two or more sensors to provide power thereto, each battery adapted to be one or more of:

(i) rechargeable,

(iv) readily removable and replaceable,

(v) non rechargeable,

(vi) mounted or disposed in a location remote from the housing or the sensor. 20. A method according to any of claims 17 to 19 further comprising: adapting the processor, memory, display, or user interface (16) to receive data embedded in the wireless signals (S) and further adapting, based on the data, the processor, memory, display, or user interface to direct an adjustment or control during the course of an injection cycle of one or more of injection fluid pressure, injection fluid temperature, magnetic field, motion or movement or position of any one or more of an actuator, a valve pin, the mold, the heated manifold, the clamping or top clamp plate, and the injection machine.