An ultrasound-based system for temperature distribution measurements in injection moulding: system design, simulations and off-line test measurements in water

The polymer melt temperature in the screw ante-chamber of an injection moulding machine influences a number of parameters during the polymer process and therefore the final product quality. For measurement of this temperature, a sensor must be non-invasive (because of the axial moved screw during the injection of the plasticized polymer into the mould) and withstand the high pressure (> 1000 bar) and temperature (> 200 degrees C) during the injection moulding process. It is well known that the temperature of the polymer melt in the screw ante-chamber is inhomogeneous, and for that reason the sensor system must be able to measure the temperature spatially resolved. Due to the fact that sound velocity is temperature dependent, we developed a non-invasive tomography system using the transit times of ultrasonic pulses along different sound paths for calculating the temperature distribution in a polymer melt. Simulation results and example experiments at a test measurement setup are shown. Moreover, different strategies for the ultrasonic probe design (buffer rods, generation of wide beam angle) are discussed. The results of the proposed system are important for the validation of numerical simulations, a better understanding of the plasticizing process and can be used for the input of a novel temperature control system.