GOALI: Self-Energized Micro Sensors for Process Monitoring of Injection Molding

本研究的目的是使新一代的远程传感器注塑过程的监测和控制。本研究的动机是目前在制造过程中观察零件质量的限制，允许出现缺陷产品和成本效率低下。新的传感器将通过从聚合物熔体压力的增强和衰减中提取能量来产生和传输与成型过程变化相对应的信号脉冲，从而实现自供电。这种方法有望将能源消耗降低几个数量级。要研究的问题包括传感器设计、模拟、热传导、结构完整性、信号编码和最佳传输。这项研究代表了传感技术向前迈出的激进一步，并有可能通过实现更好的成型控制算法来改变工业成型实践。生产力的潜在增长估计为每年2亿美元。该研究项目是学院研究人员和他们在Dynisco仪器的工业合作伙伴之间的密切合作，可以为注塑成型以外的许多其他应用提供验证的过程传感技术。自激励和无线信号传输的概念有望大大减少制造过程中的信息瓶颈。最后，该研究有可能从根本上影响制造和设计课程，并最终影响研究人员所在机构的教育基础设施。

The objective of this research is to enable a new generation of remote sensors for injection molding process monitoring and control. This research is motivated by current limitations in observing part quality during manufacture that allow the occurrence of defective products and cost inefficiencies. The new sensors will be self-energized by extracting energy from the intensification and decay of polymer melt pressure to generate and transmit signal pulses that correspond to changes in the molding process. This approach promises to reduce the energy consumption by several orders of magnitude. Issues to be investigated include sensor design, simulation, heat conduction, structural integrity, signal encoding, and optimal transmission. The research represents a radical step forward in sensing technology, and has the potential to change industrial molding practice by enabling better algorithms for molding control. The potential increase on productivity is estimated to be $200 million/year.This research project, being a close collaboration between the faculty researchers and their industrial partner at Dynisco Instruments, may provide validated process sensing technology for many other applications beyond injection molding. The self-energizing and wireless signal transmission concept promises to greatly reduce the information bottleneck out of manufacturing processes. Finally, the research has a great potential to fundamentally impact the manufacturing and design curriculum and ultimately, the educational infrastructure the researchers' home institution.