I. Immediate Filling Synchronisation Verification: Compare the filling length of all cavities by performing a short shot with a stroke of 70% to 80%. Initially, the efficacy of parameter optimisation should be confirmed by the filling length deviation of the original slow-filling cavity from other cavities, which should be ≤2%.
Gather the pressure curves for each cavity in the mould. The filling synchronisation meets the standards with a quantitative confirmation that the filling time difference ∆t of the original slow-filling cavity is ≤0.03s, the peak filling pressure difference is <5%, and the pressure curve overlap with other cavities is ≥95%.
II. Verification of Short-Term Product Consistency: Consistently sample 20 complete moulded products and weigh each cavity individually. In order to confirm the product's consistent weight after parameter optimisation, the coefficient of variation (CV) of the complete batch should be ≤2%, and the weight deviation of the product from the original slow-filling cavity from the average weight of other cavities should be ≤1.5%.
Initially verify the actual effect of parameter optimisation by inspecting the appearance of all sampled products to ensure that the original slow-filling cavity is free of defects, including missing material, shrinkage marks, or burning.
III. Verification of Short- to Medium-Term Stability: Fifty mould samples were collected to evaluate the critical assembly dimensions of the slow-filling cavity products that were initially produced in continuous production for 1-2 hours. The stability of short- to medium-term production was confirmed by the fact that mechanical property fluctuations were ≤5% and dimensional deviations were maintained within 1/3 of the product tolerance zone following parameter optimisation.
The effectiveness of the parameter-reserved redundancy was confirmed by three simulations of minor parameter fluctuations, such as a 5% decrease in injection speed or a 2°C temperature reduction, which demonstrated that the cavity that was initially slow to fill would not experience filling lag again.
IV. Long-Term Mass Production Reliability Verification: The cumulative production of three production batches was continuously monitored (≥100,000 mould cycles). The long-term anti-recurrence effect of parameter optimisation was verified by the statistical analysis of filling time and product weight data for the originally slow-filling cavity, which confirmed the absence of any progressive drift or decline in filling speed.
The complete effectiveness of parameter optimisation was confirmed by the fact that the proportion of defective products caused by the original slow filling decreased to 0 when the defect rate data was compared before and after parameter optimisation.
This verification method is optimally adapted for the precision hot runner multi-cavity mould production line that you are currently operating. It is capable of accurately determining the actual impact of parameter optimisation without the necessity of substantial investments in testing equipment, thereby preventing the recurrence of similar faults as a result of incomplete optimisation.
