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MOLDWATCHER™

With each cycle, mold presses run a high risk of experiencing extreme damage due to molded parts or slides sticking. Standard mold protection options only detect the problem as it occurs. Vision mold protection prevents the problem before it occurs. Avalon’s patented MoldWatcher™ system will alert operators and stop the press before any hazardous force can be put on the mold using non-contact vision technology. This prevents severe mold damage in addition to the related down-time, which can often be more expensive and troubling than the mold damage itself.

MoldWatcher™ can be installed on horizontal and vertical shuttle or rotary injection molding machines and die-casting machines. It also works on Metal Injection Molding (MIM) Processes

In the case of a horizontal press, MoldWatcher™ automatically inspects for inserts or quality of the part while in the mold and the empty cavity, cores and slides after the part is ejected. This insures that no stray parts are left behind to damage the mold during the next cycle.

While on a vertical press, it ensures that all inserts are properly placed prior to permitting the table to index and the mold to close. The system will also detect miscellaneous items that may have been left on the lower mold half. After ejection, the system checks to ensure all parts have left the upper mold half.

Harsh environment molding processes require specialized camera cooling and enclosures. See our NightHawk™ product offering.

Contact us to see how you can Save Thousands by protecting your molds with MoldWatcher™.

Easy Setup

The MoldWatcher™ machine vision design has been optimized over thousands of installations and incorporates features such as:
  • Customizable Toolbar in user interface
  • Archives setup files for easy job retrieval
  • Touchscreen for easy operator interface
  • Single touch “Teach” updates the system
  • Two inspections per cycle ensure protection
  • Multiple, high resolution camera support
  • Communicates with all injection machines
  • SPI/EUROMAP 12 or 67 Interface Modules which eliminates wiring
  • Works with the NightHawk 2™
  • Multiple camera options up to 4.92 megapixels

NIGHTHAWK™

MoldWatcher™ with NightHawk™ 2 is an automated vision system for Injection Molding machines that features a camera with electronically controlled zoom, focus, and aperture.

Our harsh environment NightHawk II cameras include sealed, forced air cooled cameras that allow the MoldWatcher system to be used in high temperature applications like die- casting & metal injection molding.

  • Electronically controlled motorized zoom, aperture, & focus
  • Save zoom, aperture, & focus settings for each setup
  • Rugged construction with industrial connectors
  • Integrated cooling and lens protection system using pressurized air
  • Near-IR, 720 x 480 image sensor
  • Two inspections per cycle ensure protection
  • 18x optical zoom 12VDC – 24VDC operation
  • USB 2.0 Interface

What is included?

Patented Near-IR Lighting
Avalon’s patented near infrared (NIR) camera/light technology solves potential problems that can occur due to visible ambient plant lighting. Unlike incandescent lighting, DarkLight-IR is not affected by press vibration.
USB 3.0 Camera
The USB 3.0 camera is a multi-resolution design up to 2560 x 1920 (4.92 MP) for high-resolution inspection of part and mold details where cycle time permits.
MoldWatcher Software
Our powerful MoldWatcher software powers the entire process. It was created specifically for the injection molding industries and is fully supported by our developer and tech staff. Available in 14 languages and counting.
Vision Controller
Your MoldWatcher system includes a easy to use, touch screen 12" (1-2 cameras) or 15" (1-4 cameras) vision controller that runs on Windows7 Embedded.
Interface Module
SPI/EUROMAP 12 or 67 Interface Modules eliminates wiring and seamlessly integrates with your press. An E-Net module is available for presses without a SPI/EUROMAP.
Alarm Tower
The alarm tower alerts engineers when the molding process stops due to a failed image.
Power Supply
It's tiny, but powerful.
Mounts
The camera and light can be mounted with a magnetic or bold on flex mount. The controller can be mounted on a swing arm or on a mobile stand.

ProcessRx

Avalon’s optional ProcessRx™ for MoldWatcher is an important addition to the powerful inspection system. The process documentation module with image database, event logging and statistical reports is the most advanced and easy to use process documentation system available. The Internet Explorer web browser permits remote access using the LAN, however most problems are exposed when the user can see an actual image of the inspection. ProcessRx™ can be configured to save all the Failed images, all of the Passed images, or both.

This powerful configuration technique allows the user to define exactly what data they need to capture. Data is stored in an SQL database and can be easily exported to other file types and databases, including other process monitoring applications.

A medium sized Tier I supplier to the one of the big three US automotive companies was able to stop Charge Backs and Corrective Action Requests by implementing ProcessRX™ into their Quality Station inspection stations performing Sequencing. Inspection stations with ProcessRX™ kept track of each final assembly by serial number and were able to print PDF reports showing the product had left their plant fully assembled with no further damage. The actual PDF image reports of the final product were reviewed by the customer and all disputes were immediately settled. This was an incredible cost savings.
Injection Molders use Image Event data to determine exactly which cavity has problems with parts or slides sticking in the mold half or with non-filled material. When the mold comes out for repair they know exactly where the problem occurs and can repair the proper area of the mold. Engineers of molding companies know exactly when the MoldWatcher system is being used and under what conditions. This is a time saving feature to determine root causes of problems.

Ready for superior vision mold protection?