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Article

Open Access

Thermal Compensation and Fuzzy Control for Developing a High-Precision Optical Lens Mold

Author(s)

Chung-Ching Huang, Fu Zhang and Yi-Jen Yang

Full-Text PDF Download XML 544 Views

DOI:10.17265/2159-5275/2018.05.001

Affiliation(s)

Department of Mold and Die Engineering, National Kaohsiung University of Applied Sciences, Kaohsiung 807, Taiwan, ROC

ABSTRACT

Precision plastic lenses often exhibit dimensional deviations due to the thermal expansion of the mold during injection molding. Although this deviation is smaller in micron-sized (1–5 μm) lenses, it exceeds the tolerance requirement of such lenses. It is difficult to resolve this dimensional issue by using injection molding parameters (e.g., melt temperature, injection speed, and hold pressure). In this study, the thermal analysis of a mold was conducted, and it was confirmed that the deviation of lens dimension was caused by the thermal instability and thermal expansion of the mold. Due to the inconsistent heat distribution of the fixed and the movable side of the mold, the position of the location system was displaced approximately 1 to 5 μm. In this study, thermal compensation technology for this the mold was investigated. The temperature on both sides of the mold was measured, and mold temperature could be adjusted automatically using a control strategy based on fuzzy theory. During the mold preheating or mass production stage, the temperature on both sides of the mold could be easily adjusted to quickly obtain the required temperature range. The dilatation on both sides of the mold was revised to improve the alignment accuracy of the cavity, and the decenter error of these injection lenses was reduced to 1 μm. This technology can markedly improve the production yield and efficiency of plastic products requiring an extremely high dimensional accuracy.

KEYWORDS

Fuzzy control, temperature compensation, decenter error.

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