MoldWatcher™

How MoldWatcher™ Works

1. The Mold Opens Before Ejector Image Is Taken

Presence of all parts on “B” side (moving) verifies the absence of parts from “A” side. Part quality and insert placement can also be verified. If good, ejectors are permitted to proceed.

2. Ejection is Enabled

If all parts are not present, the press is stopped. If bad parts are detected, the response is programmable by stopping the press or re-routing the bad product by reversing a conveyor, etc. If all parts are present and good, ejection is allowed.

3. Ejection is Complete

Absence of all parts on “B” is verified. This can also verify slides, ejector pins, cores, etc. If good, the mold is permitted to close for the next cycle. If problems are detected, the press is stopped.

Superior Vision Mold Protection

 

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.

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:

  • Setup on new molds in 5-10 minutes with our new AutoWindows™ programming
  • 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

Setting up for a new mold or running an existing setup is very straight-forward. A new mold setup can be implemented in just minutes and if a change is made to an existing job, the “Teach” function captures and updates the reference image with the touch of a button.

Once a setup has been completed, it can be saved to disk and the job can be run by executing a single “Teach” cycle. The “Presence/Absence” mold inspection tool is extremely robust and easy to use. The “Live Score” mode allows the user to instantly see the variance caused by problematic features so they can be confident the sensitivity adjustment will be optimal and the system will respond only to valid problems.

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.

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.

                   

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     Click the image above to download the MoldWatcher brochure.