Melt-IQ™
Melt-IQ™
Advanced Math Modeling & Control Logic
Proprietary algorithms that transform raw melt data into intelligent process decisions — enabling unmatched shot control and real-time quality prediction.
Learn the Work & Thermal Mass Density
The Melt-IQ™ is the first system of its kind to "Learn the Work" imparted into the polymer. Using high-speed ADC and proprietary math models, it calculates Thermal Mass Density to define shot weight with unprecedented accuracy — turning any IMM into a Decoupled II Phenom.
3 Critical Quality Variables
During the Fill Stage, the system analyzes Max Te (peak temperature), Power Factor (PF) (area under the integral), and Viscosity Rise (VR) (integral from injection start to Te). Statistical analysis of these variables sets alarm windows to determine Good/Bad part production with incredible accuracy.
Intelligent V-P Switch Control
By learning the work integral (F1) and time to reach the integral (F1T), the Melt-IQ™ bypasses the machine's native position/time sensors. A digital relay and mechanical toggle execute the switch, giving complete control of the fill stage to the Melt-IQ™ for superior part consistency.
Dual-Mode Intelligence
In Monitor Mode, the system learns applied work and statistically analyzes data for future alarm setup. In Control Mode, it actively manages the V-P switch point — a breakthrough that makes injection molding processes fundamentally better.
DON'T JUST TAKE OUR WORD WATCH TO SEE HOW IT WORKS
Technical Specifications at a Glance
Complete technical details of the Melt-IQ™ for comprehensive process monitoring and control.
Why Melt-IQ™?
The MELT-IQ™ system uses a proprietary embedded board with 24 bit precision ADC, powerful microchip processor, HMI display, its own power supply and industrial housing (see Fig. 2) to read our unique micro-bead Temp-Sense™ melt sensor that is placed into the distal end of the injection molding machines End Cap , Nozzle cylinder or last to fill cavity. The thermal-mechanical energy that is imparted into the polymer during the molding cycle is converted to work and measured in thermal units. Every mold-machine-polymer reveals a unique thermal template (see Fig. 1) and the mathematical relationships of PVT allow us to calculate the mass displacement for each shot. The speed of our processor is now capable of calculating an integral in milliseconds which allows us to learn the amount of work necessary to “Fill” the mold, then used to “Control” the Velocity Pressure (VP) switch point during the injection forward phase of the cycle. We have closed the loop between the mold and the machine by looking at the polymer melt, using the laws of physics and our advanced proprietary math models to make perfect parts!
The MELT-IQ™ system will operate in two modes, Monitor or Control. The control mode reads thermal energy at speeds never used before on an injection molding machine and by using our proprietary math models calculates Thermal Mass Density to define the shot weight for the first time. The MELT-IQ™ will be able to calculate our Thermal Mass Density Integral using our high speed ADC and powerful microprocessor by using Temp-Sense™ Sensors placed into the melt pool at the distal end of the barrel or into the last to fill control cavity of the mold. The program will offer versatility by reading and calculating the “Fill” integral in < a millisecond. The speed of the processor will allow us to “Learn” what work is applied to the polymer during the “Setup-Learning'' mode while statistically analyzing the data for future use in setting up alarms and or to “Control” the (VP) transfer points. Additional Temp-Sense™ Sensors can be placed into other Cavities, the Hopper and Water Manifold ...up to 6 places to monitor the injection molding machines ECOSystem.
Engineered for Superior Process Control
Transform your injection molding operation with advanced monitoring and control capabilities that ensure consistent quality and reduce waste.
Real-Time Temperature
Monitor melt temperature in real-time during the injection molding process, ensuring optimal processing conditions and consistent part quality through continuous temperature measurement and analysis.
Mass Displacement Control
Precisely measure mass displacement for each shot, providing accurate control over material flow and ensuring consistent fill patterns for uniform part dimensions and weight.
Quality Prediction
Advanced algorithms predict good or bad parts before completion, enabling proactive process adjustments and reducing scrap rates while maintaining high quality standards.
VP Switch Control
Controls the velocity-pressure switch point during injection forward phase, optimizing the molding process for improved part consistency and reduced cycle times.
Process Stability
Monitor and analyze process stability and consistency, detecting variations in polymer viscosity and thermal-mechanical energy to ensure repeatable manufacturing results.
Advanced Processing
Powered by a proprietary embedded board with 24-bit precision ADC and powerful microchip processor, delivering accurate measurements and reliable performance in industrial environments.
Frequently Asked Questions
What is the VP switch point control feature?
The VP switch point control manages the velocity-pressure transition during the injection forward phase. This optimization ensures better part consistency, reduces cycle times, and improves overall molding process efficiency by precisely controlling when the injection switches from velocity to pressure control.
Where is the Temp-Sense™ sensor installed?
The micro-bead Temp-Sense™ sensor is placed into the distal end of the injection molding machine's end cap, nozzle cylinder, or last to fill cavity. This strategic placement ensures accurate melt temperature readings at critical points in the process.
What power requirements does the system have?
The Melt-IQ™ comes with its own 120-230V -5V power supply and is housed in an industrial 10x8x8 enclosure. It features five digital type K thermocouple inputs and includes an HMI display for user interface and monitoring.
Are software upgrades included with the system?
Yes, the Melt-IQ™ includes free software upgrades to ensure your system stays current with the latest features and improvements. Md Plastics continuously enhances the system's capabilities and provides these updates at no additional cost.
Industries We Serve
Serving diverse sectors with specialized plasticating solutions for enhanced manufacturing performance.
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Automotive
Precision plasticating solutions for high-quality automotive components requiring consistent melt quality and performance.
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Medical Devices
Advanced plasticating technology ensuring purity and precision for critical medical device manufacturing applications.
Consumer Electronics
Innovative solutions for complex electronic housings and components requiring superior surface finish and dimensional accuracy.
Additive Manufacturing
Specialized plasticating systems for 3D printing and additive manufacturing, delivering consistent filament quality and material flow.
Plastic Processing
Comprehensive plasticating solutions for general plastic processing applications across various manufacturing sectors.
Automotive
Precision plasticating solutions for high-quality automotive components requiring consistent melt quality and performance.
Medical Devices
Advanced plasticating technology ensuring purity and precision for critical medical device manufacturing applications.
Consumer Electronics
Innovative solutions for complex electronic housings and components requiring superior surface finish and dimensional accuracy.
Additive Manufacturing
Specialized plasticating systems for 3D printing and additive manufacturing, delivering consistent filament quality and material flow.
Plastic Processing
Comprehensive plasticating solutions for general plastic processing applications across various manufacturing sectors.
Ready to Transform Your Injection Molding Process?
Get expert guidance on implementing the Melt-IQ™ in your manufacturing operation. Our team will work with you to ensure optimal setup and maximum ROI.
For immediate assistance, call us at (330) 482-5100 or email us at info@mdplastics.com
For immediate assistance, call us at (330) 482-5100 or email us at info@mdplastics.com