How to choose mold protector screen?

一、Reasons for the appearance of injection molding machine mold protector

In recent years, due to the sharp increase in the price of plastic raw materials, the labor cost has increased year by year, and the competition in the industry has become increasingly fierce. If coupled with poor management, it is easy to lead to a series of problems such as low production efficiency, out-of-control yield, huge loss of raw materials, frequent batch scrapping or customer returns, mold problems affecting normal production, failure to deliver on time and production safety accidents, resulting in no profit at all.

When the injection molding machine is running, the expensive molds may be damaged in each cycle due to residue or slider misalignment, causing irreparable losses to the company. In addition, the mold accounts for a large proportion of the injection molding production cost, and its service life directly affects the company’s production cost. In the actual production process, companies often encounter the following problems:

1. The ejector pin often gets stuck or sticks to the mold during the injection molding process, which affects production efficiency;
2. The molds frequently fail, requiring special personnel to maintain and overhaul them, increasing labor costs;
3. The machine is shut down to repair the mold, which takes 2-3 days or even longer, and the repair costs are as high as several thousand yuan to tens of thousands of yuan or even hundreds of thousands of yuan;
4. The delivery period is extended, and there is a risk of compensation for liquidated damages, up to 30%;
5. Defective products are outflowed, customers complain, and products are returned, affecting the company’s credit.

Therefore, it is extremely necessary to monitor the mold during the injection molding production process!

二、What is a mold protector?

Mold monitors, also known as mold protectors and electronic eyes, are mainly mold protection systems that monitor, control and detect the operation of various injection molding machines in real time. Because in the industrial manufacturing process, many companies suffer serious losses in molds. In view of the irregularities and particularities of different products, despite the adoption of many mold protection measures, mold damage is still unavoidable, resulting in economic losses and personal injury. Mold monitors use the machine vision comparison function and the powerful computing speed of the computer CPU to perform real-time computing and processing of image data. By analyzing the images captured during the operation of the machine, it can intelligently monitor the operation of the injection molding machine, effectively detect whether the product is qualified, and check for residues before closing the mold to prevent mold damage.模具监测器，也称为霉菌保护器和电子眼睛，主要是霉菌保护系统，可实时监视，控制和检测各种注射型机器的操作。因为在工业制造过程中，许多公司在模具中遭受了严重的损失。鉴于不同产品的不规则性和特殊性，尽管采用了许多霉菌保护措施，但仍然不可避免地会造成霉菌损害，从而导致经济损失和人身伤害。模具监视器使用机器视觉比较功能和计算机CPU的强大计算速度来执行图像数据的实时计算和处理。通过分析机器操作过程中捕获的图像，它可以智能监视注入模制机的操作，有效地检测到产品是否有资格，并在关闭模具之前检查残留物以防止霉菌损坏。

三、Working principle and composition structure of mold monitor

When the injection molding machine opens the mold, the output signal triggers the mold protector, which continuously takes images of the mold cavity to monitor whether the ejector ejects the molded workpiece and drops it.

When the workpiece is completely dropped, the mold monitor sends a confirmation signal to the injection molding machine to start the next cycle. If the workpiece does not fall within the set time or there are debris between the molds, the mold monitor sends an abnormal signal, stops the injection molding machine and alarms.

The mold monitor usually consists of the following parts:

• Camera: used to capture the running image of the mold.
• Sensor: used to detect the temperature, pressure and other parameters of the mold.
• Controller: used to process images and sensor data, and make judgments and alarms according to the set rules.
• Display: used to display the running image and alarm information of the mold.

四、Why do we need an mold protector screen?

• Display and operation convenience

Real-time image display: When the mold protector is working, it is necessary to take images after demoulding and compare them with the stored standard mold cavity images to check whether there are residual products on the mold, whether the inserts are in place, etc. The LCD screen can display these images taken in real time and various pictures during the comparison process. The operator can intuitively see the actual situation of the mold and find problems in time. For example, in the mold monitoring of the injection molding machine, the images of the plastic parts on the moving mold and the mold after demoulding can be clearly seen, which is convenient for accurately judging the mold status.

Interactive operation interface: The control host integrates image acquisition, image processing, quick operation system (panel), control output and other functions, and the LCD screen can be used as the carrier of the operation interface. The operator can complete the inspection and other operations on the LCD screen by simply pressing a few buttons, and can easily set various parameters, such as how much product residue should be checked and alarmed, how much difference between two images is considered to be a problem, etc. This intuitive operation method makes the use of the mold protector more convenient and reduces the difficulty of operation.

• Information display integrity

System status display: The mold protector has a variety of status information during operation, such as power status, detection status, alarm information, etc. The LCD screen can clearly display this information, allowing operators to understand the working status of the system at any time. For example, when it is detected that there is residual product on the mold or the insert is not in place, the LCD screen can display the corresponding alarm information in time to remind the operator to deal with it.

Parameter setting and display: When setting the detection parameters, such as checking only the changes that are brighter than the standard image, only checking the parts that are darker than the standard image, or checking all of them, the LCD screen can display these detailed parameter settings, which is convenient for operators to adjust and confirm, ensuring the accuracy and effectiveness of the detection.

• Improve detection accuracy

Image comparison reference: When performing image comparison, the LCD screen can display the standard image and the currently captured image at the same time, so that the operator can observe the difference between the two more clearly, which helps to accurately determine whether there is a problem and avoid misjudgment due to human observation errors. For example, by comparing different brightness, color and other details, it is more accurate to determine whether the mold has abnormalities.

Data recording and analysis: The LCD screen can also record relevant data during the inspection process, such as inspection time, inspection results, etc. These data can be used for subsequent analysis and statistics to help companies better understand the use of molds and problems in the production process, so as to take corresponding improvement measures to improve production efficiency and product quality.

五、Parameter characteristics of the mold protector screen

1. 10.4-inch LCD screen：the screen can be selected in a variety of sizes, such as 10.4 inches, 12.1 inches or other customized sizes, which can be configured according to actual needs.
2. Simple operation: Touch screen control, setting inspection parameters is completed in one cycle, generally less than 2 minutes, and operators can learn to operate in 10 minutes.
3. High speed and high precision: High-speed and high-resolution digital camera, precise detection, position detection accurate to 0.05 mm, judgment processing time at least 0.02 seconds.
4. Reliable components and standards: The selected components are industrial products, and the product design strictly follows industrial standards to ensure the stability and reliability of the equipment.
5. Strong anti-interference ability: Using non-luminous near-infrared light source, it is not affected by external light and produces false alarms; near-infrared light combined with optimized algorithm software technology can solve the problems of changes in ambient light around the factory, movement of robots, movement of personnel, etc. that affect production detection.

六、Choose the appropriate model according to the characteristics of the mold protector screen

Clarify the requirements for LCD screens: indoor industrial scenes, 10.4 inches with touch, clear resolution, fast response time, anti-interference, and stable supply.

Brand	Resolution	Model	Brightness	Contrast	Active Area	Work Temp
BOE	800*600	BA104S01-200(ET104S0M-N15)	300	800:1	211.2*158.4	-20/70
BOE	800*600	BA104S01-300(ET104S0M-N16)	350	800:1	211.2*158.4	-20/70
BOE	1024*768	GV104X0M-N10	450	1100:1	210.4*157.8	-30/85
BOE	800*600	BA104S01-100	500	800:1	211.2*158.4	-20/70
IVO	1024*768	M104GNX1 R1	350	900:1	211.2*158.4	-20/70
Tianma	1024*768	TM104TDGP10	450	1200:1	210.432*157.824	-20/70
AUO	800*600	G104STN01.0	400	700:1	211.2*158.4	-30/80
AUO	800*600	G104STN01.3	450	700:1	211.2*158.4	-30/80
Innolux	800*600	G104ACE-LH1	400	1000:1	211.2*158.4	-30/85
Innolux	1024*768	G104XCE-L01	500	1000:1	210.432*157.824	-30/85
AUO	1024*768	G104XVN01.0	470	3000:1	210.4*157.8	-30/80
AUO	640*480	G104VAN01.0	450	700:1	211.2*158.4	-30/85
KYOCERA	800*600	TCG104SVLPAANN-AN20-S	450	900:1	211.2*158.4	-20/70

七、Why choose the model BA104S01-300

• In terms of price：There are four options （BA104S01-200；BA104S01-300；GV104X0M-N10;BA104S01-100）
• In terms of resolution：Support 800*600，There are three options (BA104S01-200；BA104S01-300；BA104S01-100)
• In terms of brightness, contrast, viewing angle, viewing area, and operating temperature:

BA104S01-100>BA104S01-300>BA104S01-300

The better the parameter performance, the higher the price.

From the perspective of stability:BA104S01-300，Currently in production, supply is stable.

八、LEEHON Advantages（Why choose LEEHON?）

Choose us and unlock a new experience of industrial display!

Authenticity guarantee: Officially authorized agent of core brands (BOE, AUO, Kyocera), authentic supply, worry-free quality.And we have a large amount of spot inventory.

Service upgrade: Not only sell screens! Capacitive/resistive touch screen + driver board, one-stop to get a complete set of display driver solutions for you, saving worry and effort!

Focusing on industrial display and providing professional solutions. Choosing Hangzhou LEEHON Technology Co., Ltd. means choosing professionalism, reliability and convenience!