Ultrasound sensors for process monitoring in injection moulding

Injection moulding is an extremely important industrial process, being one of the most commonly-used plastic formation techniques. However, the industry faces many current challenges associated with demands for greater product customisation, higher precision and most urgently a shift towards more sustainable materials and processing. Accurate real-time sensing of the material and part properties during processing is key to achieving rapid process optimisation and set-up, reducing downtimes, and reducing waste material and energy in the production of defective products. While most commercial processes rely on point measurements of pressure and temperature, ultrasound transducers represent a non-invasive and non-destructive source of rich information on the mould, the cavity, and the polymer melt and its morphology, which affect critical quality parameters such as shrinkage and warpage. In this paper, the relationship between polymer properties and the propagation of ultrasonic waves is described and the application of ultrasound measurements in injection moulding is evaluated. The principles and operation of both conventional and high-temperature ultrasound transducers are reviewed (HTUTs) together with their impact on improving the efficiency of the injection moulding process. The benefits and challenges associated with the recent development of sol-gel methods for HTUT fabrication are described together with a synopsis of further research and development needed to ensure greater industrial uptake of ultrasonic sensing in injection moulding

State estimators in soft sensing and sensor fusion for sustainable manufacturing

State estimators, including observers and Bayesian filters, are a class of model-based algorithms for estimating variables in a dynamical system given sensor measurements of related system states. They can be used to derive fast and accurate estimates of system variables which cannot be measured directly (’soft sensing’) or for which only noisy, intermittent, delayed, indirect or unreliable measurements are available, perhaps from multiple sources (’sensor fusion’). In this paper we introduce the concepts and main methods of state estimation and review recent applications in improving the sustainability of manufacturing processes. It is shown that state estimation algorithms can play a key role in manufacturing systems to accurately monitor and control processes to improve efficiencies, lower environmental impact, enhance product quality, improve the feasibility of processing more sustainable raw materials, and ensure safer working environments for humans. We discuss current and emerging trends in using state estimation as a framework for combining physical knowledge with other sources of data for monitoring and control of distributed manufacturing systems

Expressive interaction design using facial muscles as controllers

Here we describe a proof-of-concept case study focusing on the design and development of a novel computer interface that uses facial muscles to control interactivity within a virtual environment. We have developed a system comprised of skin-mounted electrodes that detect underlying muscle activity through electromyography. The signals from the electrodes are filtered and smoothed, then used as input data to an application that displays a virtual environment with a 3D animated avatar. The user’s expressions control the facial movements of the avatar, thus conveying user emotions through real-time animation of a representative face in a virtual scenario. To achieve this, we collaborated with our Public and Patient Involvement focus group to discuss concepts and design appropriate interactions, while simultaneously developing a prototype system. Programmers and 3D artists worked together to create a system whereby individual user facial muscles are connected to 3D animated models of the same muscle features represented in an avatar, providing the user with an option to receive visual and numerical feedback on the extent of their muscle control. Using the prototype system, people can communicate facial expressions virtually with each other, without the need for a camera. This research is part of an on-going project to develop a facial muscle rehabilitation system that can be optimized to help patients with conditions such as hypomimia

Comparison of intelligent approaches for cycle time prediction in injection moulding of a medical device product

Injection moulding is an important industry, providing a significant percentage of the demand for plastic products throughout the world. The process consists of many variables which directly or indirectly influence the part quality and cycle time. The first step in optimizing the process parameters is identifying the most significant variables affecting the desired output. For this purpose, various Design of Experiments methods (DOE) have been developed to investigate the effect of the experimental variables on the output and predict the required settings to achieve the optimal value of the output. In this study we investigate the application of DOE for a commercial injection moulded component which suffers from a long cycle time and high shrinkage. The Taguchi method has been used to analyze the effect of four input variables on the two output variables: cycle time and shrinkage. The component has been simulated in the Moldflow software to validate the predicted output and optimized settings of the variables from the DOE. Comparison of the simulation result and the predicted value from the DOE illustrated good accordance. The calculated optimal setting with the Taguchi method reduced the cycle time from 40s to about 23s and met the shrinkage criteria for this commercial part

Expressive Interaction Design Using Facial Muscles as Controllers

Here we describe a proof-of-concept case study focusing on the design and development of a novel computer interface that uses facial muscles to control interactivity within a virtual environment. We have developed a system comprised of skin-mounted electrodes that detect underlying muscle activity through electromyography. The signals from the electrodes are filtered and smoothed, then used as input data to an application that displays a virtual environment with a 3D animated avatar. The user’s expressions control the facial movements of the avatar, thus conveying user emotions through real-time animation of a representative face in a virtual scenario. To achieve this, we collaborated with our Public and Patient Involvement focus group to discuss concepts and design appropriate interactions, while simultaneously developing a prototype system. Programmers and 3D artists worked together to create a system whereby individual user facial muscles are connected to 3D animated models of the same muscle features represented in an avatar, providing the user with an option to receive visual and numerical feedback on the extent of their muscle control. Using the prototype system, people can communicate facial expressions virtually with each other, without the need for a camera. This research is part of an on-going project to develop a facial muscle rehabilitation system that can be optimized to help patients with conditions such as hypomimia

Designing a broad-spectrum integrative approach for cancer prevention and treatment.

Targeted therapies and the consequent adoption of "personalized" oncology have achieved notable successes in some cancers; however, significant problems remain with this approach. Many targeted therapies are highly toxic, costs are extremely high, and most patients experience relapse after a few disease-free months. Relapses arise from genetic heterogeneity in tumors, which harbor therapy-resistant immortalized cells that have adopted alternate and compensatory pathways (i.e., pathways that are not reliant upon the same mechanisms as those which have been targeted). To address these limitations, an international task force of 180 scientists was assembled to explore the concept of a low-toxicity "broad-spectrum" therapeutic approach that could simultaneously target many key pathways and mechanisms. Using cancer hallmark phenotypes and the tumor microenvironment to account for the various aspects of relevant cancer biology, interdisciplinary teams reviewed each hallmark area and nominated a wide range of high-priority targets (74 in total) that could be modified to improve patient outcomes. For these targets, corresponding low-toxicity therapeutic approaches were then suggested, many of which were phytochemicals. Proposed actions on each target and all of the approaches were further reviewed for known effects on other hallmark areas and the tumor microenvironment. Potential contrary or procarcinogenic effects were found for 3.9% of the relationships between targets and hallmarks, and mixed evidence of complementary and contrary relationships was found for 7.1%. Approximately 67% of the relationships revealed potentially complementary effects, and the remainder had no known relationship. Among the approaches, 1.1% had contrary, 2.8% had mixed and 62.1% had complementary relationships. These results suggest that a broad-spectrum approach should be feasible from a safety standpoint. This novel approach has potential to be relatively inexpensive, it should help us address stages and types of cancer that lack conventional treatment, and it may reduce relapse risks. A proposed agenda for future research is offered.Multiple funders. See acknowledgments within article for details.This is the final version of the article. It first appeared from Elsevier via http://dx.doi.org/10.1016/j.semcancer.2015.09.00