SST/Collaborative Research: Self-Powered Wireless Sensor Array for Pressure, Volume, and Temperature Monitoring of Injection Molding

这个小型传感器团队(SST)/合作研究项目的目标是通过在模腔内多个位置提供压力、温度、流速和其他过程状态的反馈，以实现实时过程和质量控制，从而显著提高聚合物加工操作的可观察性。这一目标将通过同时模内压力-温度传感、多域信号处理和注射成型过程分析来实现。这项研究的好处是，它将引入新一代的微型传感器，可以放置在模具腔内的任何地方，这是以前不可能的，而且比以前修改模具放置传统传感器所需的时间要短得多。这项研究的广泛影响有三个方面：1)它代表了从目前已经使用了几十年的有线传感器向前迈出的激进一步，并且有可能显着提高成型生产率，其中每一个百分点的改进相当于每年节省超过4000万美元的成本；2)新的传感技术不仅适用于注塑成型，也适用于其他高能制造工艺；3)该研究将对多学科教育和研究生及本科生的培训作出重大贡献，并加强pi院校的制造课程发展。

The objective of this Small Sensor Team (SST)/Collaborative Research project is to significantly improve the observability in polymer processing operations by providing feedback of pressure, temperature, flow rate, and other process states at multiple locations within the mold cavity, for real-time process and quality control. This objective will be achieved through simultaneous in-mold pressure-temperature sensing, multi-domain signal processing, and injection molding process analysis.The benefit of this research is that it will introduce a new generation of miniaturized sensors that can be placed at practically anywhere within the mold cavity that are previously not possible, and in much less time than previously required to modify a mold for placing a conventional sensor. The broader impact of this research is three-fold: 1) it represents a radical step forward from the current wired sensors that have been used for decades, and has the potential to significantly improve molding productivity wherein each percentage point improvement corresponds to cost savings over $40 million per year, 2) the new sensing technique will not only be applicable to injection molding, but also to other high-energy manufacturing processes, and 3) the research will contribute substantially to multidisciplinary education and training of graduate and undergraduate students and enhance manufacturing curriculum development at the PIs' institutions.