Brian F Burns

US Patent:

20220332029, Oct 20, 2022

Filed:

Jul 1, 2022

Appl. No.:

17/856238

Inventors:

- Hamilton OH, US
Brian Matthew Burns - Mason OH, US

International Classification:

B29C 45/77
B29C 45/78
B29C 45/76

Abstract:

In order to reduce oscillations in process variables of an injection molding process, an injection molding machine may be operatively connected to a model database that stores models of injection molding machines and molds. A tuning controller may set initial gain values of a variable-gain proportional-integral-derivative (PID) controller. To set the initial gains, the tuning controller may be configured to obtain, from the model database, a model for a first and second injection molding machines and a model for a mold. The tuning controller may analyze the models to determine a correlation between injection molding machine parameters and mold cycle performance for the mold. Accordingly, the tuning controller may apply the correlation to determine an initial gain value for a least one of the first, second, and third gains of the PID controller. The tuning controller may then set the initial gain values for the PID controller.

US Patent:

20220266493, Aug 25, 2022

Filed:

May 11, 2022

Appl. No.:

17/741754

Inventors:

- Hamilton OH, US
Gene Michael Altonen - West Chester OH, US
Brandon Michael Birchmeier - Morrow OH, US
Brian Matthew Burns - Mason OH, US

International Classification:

B29C 45/77

Abstract:

In order to improve the consistency of molded products as viscosity shifts throughout a run, a controller of an injection molding machine executes a calibration cycle in accordance with a mold cycle. The controller analyzes a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics. The controller then uses the calibration metrics when executing each mold cycle of the run. More particularly, during each mold cycle of the run, the controller detects a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle and compares the plurality of sensed melt pressures to the one or more calibration metrics to predict cavity pressure for a pack and hold phase of the mold cycle. The controller then adjusts a set point pressure for the pack and hold phase based on the predicted cavity pressure.

US Patent:

20230041317, Feb 9, 2023

Filed:

Oct 20, 2022

Appl. No.:

17/970217

Inventors:

- Hamilton OH, US
Ethan David Stiefel - Masom OH, US
Gene Michael Altonen - West Chester OH, US
Brandon Michael Birchmeier - Morrow OH, US
Brian Matthew Burns - Mason OH, US

International Classification:

B29C 45/77
B29C 45/03

Abstract:

Systems and approaches for controlling an injection molding machine having a first configuration and a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for a portion of an injection cycle of an injection molding machine having a second configuration and operating the injection molding machine having the first configuration to inject a molten material into the mold cavity. While operating the injection molding machine having the first configuration, the obtained pattern is used to control a portion of the injection cycle.

US Patent:

20230031650, Feb 2, 2023

Filed:

Oct 5, 2022

Appl. No.:

17/960739

Inventors:

- Hamilton OH, US
Bryler Collins - Maineville OH, US
Gene Michael Altonen - West Chester OH, US
Brian Matthew Burns - Mason OH, US
Brandon Michael Birchmeier - Morrow OH, US

International Classification:

B29C 45/77
B29C 45/03

Abstract:

Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for the injection cycle, operating the injection molding machine to inject a molten material into the mold cavity , and measuring a cavity pressure value of the mold cavity during the mold cycle. Upon measuring a nominal cavity pressure value, a pattern recognition portion of the injection cycle that is at least partially dependent on the obtained pattern commences where a driving force being exerted on the molten material is adjusted such that the measured cavity pressure matches the obtained pattern for the injection cycle.

US Patent:

20210387390, Dec 16, 2021

Filed:

May 21, 2021

Appl. No.:

17/326597

Inventors:

- Hamilton OH, US
Brian Matthew Burns - Mason OH, US
Gene Michael Altonen - West Chester OH, US

International Classification:

B29C 45/76
B29C 45/46
B29C 45/47

Abstract:

Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity include feeding a molten polymer into a barrel containing a screw disposed in a first position, advancing the screw a first instance, from the first position to a second position, to inject the molten polymer into the mold cavity to form a molded part, and ejecting a first molded part or a first set of molded parts from the mold cavity. Further, the screw is advanced a second instance, from the second position to a third position, to inject the molten polymer into the mold cavity to form an additional molded part. A second molded part or a second set of molded parts is ejected from the mold cavity. After the second advancing instance, a recovery profile is commenced in which the screw is returned to the first position.

US Patent:

20210387391, Dec 16, 2021

Filed:

May 21, 2021

Appl. No.:

17/326538

Inventors:

- Hamilton OH, US
Brian Matthew Burns - Mason OH, US
Gene Michael Altonen - West Chester OH, US

International Classification:

B29C 45/76
B29C 45/77

Abstract:

Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include injecting a molten polymer into the mold cavity according to a startup profile. A first sensor is used to measure at least one variable during the startup profile. The startup profile is terminated upon the at least one variable exceeding a first threshold. The molten polymer is then injected into the mold cavity according to a primary injection profile.

US Patent:

20210387393, Dec 16, 2021

Filed:

May 19, 2021

Appl. No.:

17/324299

Inventors:

- Hamilton OH, US
Brian Matthew Burns - Mason OH, US
Gene Michael Altonen - West Chester OH, US
Brandon Michael Birchmeier - Morrow OH, US
Matthew Craver - Cincinnati OH, US

International Classification:

B29C 45/77
B29C 45/80
B29C 45/50
B29C 45/26

Abstract:

A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram includes injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities. The method includes measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting. The method also includes determining, based on the first process parameter, whether one or more mold cavities of the plurality of mold cavities are non-operational. Then, when it is determined that one or more mold cavities are non-operational, the method includes automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus.

US Patent:

20200108538, Apr 9, 2020

Filed:

Dec 10, 2019

Appl. No.:

16/708628

Inventors:

- Hamilton OH, US
Rick Alan Pollard - Moscow OH, US
Gene Michael Altonen - West Chester OH, US
Brian Matthew Burns - Mason OH, US

International Classification:

B29C 45/78
B29C 45/77
B29C 45/27
B29C 45/17

Abstract:

A hot runner injection molding apparatus, and method of use, is disclosed in which strain gauges are provided in the temperature zones of the hot runner injection molding apparatus and a hot runner controller creates a target strain profile, detects deviations from the target strain profile in any temperature zone based on the strain readings provided by the strain gauges in each temperature zone, and instructs correction of deviations from the target strain profile in any deviating temperature zone by adjusting the heat produced by a heater or heaters in the deviating temperature zone. The target strain profile may be based on a median or average of strain readings provided over time by the strain gauges in each temperature zone. A hollow installation tube for placing the strain gauges in the hot runner injection molding apparatus is also disclosed.