Dec 08,2025
Mold digitalization and intelligent mold base: transformation from“Experience-driven” to“Data-driven”
Mold digitalization and intelligent mold base: transformation from“Experience-driven” to“Data-driven”
On the wave of Industry 4.0, the mould is evolving from a“Mechanical unit” to an“Information node”. By embedding sensors and data systems in the mold, the intelligent mold base realizes the transparency, controllability and optimization of the production process, and opens a new era of mold intelligence.
The sensing layer of the intelligent mould base: the“Nerve endings” implanted in the mould
Pressure transducer of mould cavity
Position: directly installed in the cavity wall or the lower end of the thimble.
Function: real-time monitoring of filling, holding pressure, cooling three stages of cavity internal pressure changes.
Value: this is the most important process monitoring indicator. By analyzing the pressure curve, we can accurately judge whether the filling is balanced, whether the holding pressure is sufficient and whether the switching point is accurate, which is the basis of realizing“Quality closed-loop control”.
Mould temperature sensor
Location: multi-point layout in the cavity, core of the different key areas.
Features: real-time monitoring of the actual mold temperature, not just water temperature.
Value: with the mold temperature machine linkage, to achieve a true cavity temperature closed-loop control, to ensure process stability.
Sensor for mould condition
Types:
Displacement sensor: monitor the ejector stroke and confirm whether the ejector is in place.
Vibration Sensor: Monitoring Guide Pillar, slider movement is smooth, early warning abnormal wear.
RFID chip: storage mold identity information, maintenance records and process parameters.
Data-driven decision making and optimization
Objective definition of process window
The traditional method relies on the experience of engineers, but the intelligent mold base can directly correlate the cavity pressure data with the critical size/weight of the product through DOE experiments, and objectively find a robust process window.
Predictive maintenance
By continuously monitoring the changes in the thimble friction resistance, guide pillar vibration spectrum, the system can warn of“Thimble is about to break” or“Guide pillar lubrication is insufficient”, so as to arrange maintenance before the failure occurs, avoid unplanned downtime.
100% monitoring of production quality
Each mold cavity pressure curve is a“Quality fingerprint”. By setting the upper and lower limits of the qualified pressure curve, the nondestructive, on-line and 100% quality judgment of each mold product can be realized. Any defects that fall outside the tolerance range are automatically identified and eliminated.
III. Implementation Path and challenges
Implementation Path:
Start from the key mold: first in high value, large output, many problems on the mold implementation.
Sensor selection and installation: select high-temperature, high-pressure micro-sensor, and design a reasonable installation hole to ensure that it does not affect the strength of products and molds.
Data Integration Platform: sensor data is integrated into MES (manufacturing execution system) or cloud platform through gateway for visual display and analysis.
Challenges:
Initial investment: high cost of sensor and data systems.
Technical Threshold: need both mold technology, sensor technology and data analysis ability of compound talents.
Data Security: the security and confidentiality of production data need to be guaranteed.
Conclusion:
Intelligent mould base is the inevitable direction of mould technology evolution. It makes the“Black box” processes deep inside the molds visible, quantifiable, and optimized. It's not just about collecting data, it's about turning that data into knowledge and decision-making cycles. To invest in smart molds is to invest in a more efficient, reliable, and intelligent manufacturing future.
Latest News
1013 Min'an Avenue, Xiang'an District Xiamen City, Fujian Province, China
+86-13225990951
2605949828@qq.com
