{"id":7788,"date":"2025-06-10T10:51:53","date_gmt":"2025-06-10T08:51:53","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/"},"modified":"2025-09-22T15:44:57","modified_gmt":"2025-09-22T13:44:57","slug":"cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/","title":{"rendered":"Cross-phase process control concepts in injection moulding using modern control strategies"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_3a4bff43a9243838866fa4098697da6b .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_3a4bff43a9243838866fa4098697da6b .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_3a4bff43a9243838866fa4098697da6b\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                                    <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n\n<p class=\"wp-block-paragraph\">The underlying phase-combining process control strategy solves the switching problems of conventional injection molding processes for the first time by means of continuous cavity pressure control in the injection and holding pressure phases. Using model predictive control (MPR), a high degree of reproducibility of the process and component quality was demonstrated. This process control concept has now been further developed for the processing of recycled plastic granulate.<\/p>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte.jpg\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte-748x499.jpg 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte-1536x1024.jpg 1536w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte-768x512.jpg 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1536\" height=\"1024\" alt=\"Phasen\u00fcbergreifende Regelungskonzepte\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; IKV<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Figure: Adjusting the cavity pressure level based on the Bayesian optimisation can compensate for material fluctuations<\/figcaption><\/figure>\n\n\n<p class=\"wp-block-paragraph\">First, batch differences were recorded in the test laboratory and in injection molding tests and the interactions between material, process variables and component quality were mapped. No clear correlation was found between the material parameters of the recyclates and the component quality, nor between the process parameters of the recyclate processing and the component quality, as there are interactions with the material composition. However, the key figures of the screw pressure and cavity pressure curve can be monitored in order to detect changes in the injection molding process and thus take batch fluctuations into account in the process control concept.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The alternative approach of direct quality tracking was therefore pursued as part of the project. Bayesian optimisation (BO) was used for this purpose, which does not require explicit modeling of the correlations between cavity pressure reference and component quality. Instead, the interdependencies are mapped indirectly using a data-driven surrogate model. Based on an extended model-predictive cavity pressure control and a superimposed reference optimisation, a tracking of the component quality over different PCR batches and components was successfully demonstrated using Bayesian optimisation. The reproducibility of the process and component quality achieved surpasses conventional plastic injection molding processes.<\/p>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the DFG for funding the project (funding code HO 4776\/44-2) and the project partners for their cooperation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Project duration: 05.2022 &#8211; 04.2024<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Promotion:<\/p>\n\n\n<section id=\"logo-bar-block_071a814a003093ae5b458678cc4b2ae6\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG-748x591.png 748w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"748\" height=\"591\" alt=\"Logo-DFG\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.<\/p>\n","protected":false},"featured_media":7787,"parent":0,"template":"","tags":[921,860,1168,1158],"research_fields":[813],"class_list":["post-7788","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","tag-injection-moulding","tag-process-control","tag-process-parameters","tag-recyclate-en","research_fields-injection-moulding"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Cross-phase process control concepts in injection moulding using modern control strategies | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Cross-phase process control concepts in injection moulding using modern control strategies | IKV-Aachen\" \/>\n<meta property=\"og:description\" content=\"When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/\" \/>\n<meta property=\"og:site_name\" content=\"IKV-Aachen\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/profile.php?id=523026911193540&amp;_rdr\" \/>\n<meta property=\"article:modified_time\" content=\"2025-09-22T13:44:57+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"1800\" \/>\n\t<meta property=\"og:image:height\" content=\"1200\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Estimated reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"2 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/\",\"name\":\"Cross-phase process control concepts in injection moulding using modern control strategies | IKV-Aachen\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2025\\\/06\\\/Phasenuebergreifende-Regelungskonzepte.jpg\",\"datePublished\":\"2025-06-10T08:51:53+00:00\",\"dateModified\":\"2025-09-22T13:44:57+00:00\",\"description\":\"When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.\",\"breadcrumb\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/#breadcrumb\"},\"inLanguage\":\"en-GB\",\"potentialAction\":[{\"@type\":\"ReadAction\",\"target\":[\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/\"]}]},{\"@type\":\"ImageObject\",\"inLanguage\":\"en-GB\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/#primaryimage\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2025\\\/06\\\/Phasenuebergreifende-Regelungskonzepte.jpg\",\"contentUrl\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2025\\\/06\\\/Phasenuebergreifende-Regelungskonzepte.jpg\",\"width\":1800,\"height\":1200,\"caption\":\"Figure: Adjusting the cavity pressure level based on the Bayesian optimisation can compensate for material fluctuations\"},{\"@type\":\"BreadcrumbList\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\\\/#breadcrumb\",\"itemListElement\":[{\"@type\":\"ListItem\",\"position\":1,\"name\":\"Home\",\"item\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/\"},{\"@type\":\"ListItem\",\"position\":2,\"name\":\"Cross-phase process control concepts in injection moulding using modern control strategies\"}]},{\"@type\":\"WebSite\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#website\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/\",\"name\":\"IKV-Aachen\",\"description\":\"Forschung f\u00fcr die Praxis\",\"publisher\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#organization\"},\"alternateName\":\"Institut f\u00fcr Kunststoffverarbeitung\",\"potentialAction\":[{\"@type\":\"SearchAction\",\"target\":{\"@type\":\"EntryPoint\",\"urlTemplate\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/?s={search_term_string}\"},\"query-input\":{\"@type\":\"PropertyValueSpecification\",\"valueRequired\":true,\"valueName\":\"search_term_string\"}}],\"inLanguage\":\"en-GB\"},{\"@type\":\"Organization\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#organization\",\"name\":\"IKV-Aachen\",\"alternateName\":\"Institut f\u00fcr Kunststoffverarbeitung (IKV)\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/\",\"logo\":{\"@type\":\"ImageObject\",\"inLanguage\":\"en-GB\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#\\\/schema\\\/logo\\\/image\\\/\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2025\\\/02\\\/ikv-ikv-1.png\",\"contentUrl\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2025\\\/02\\\/ikv-ikv-1.png\",\"width\":512,\"height\":512,\"caption\":\"IKV-Aachen\"},\"image\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#\\\/schema\\\/logo\\\/image\\\/\"},\"sameAs\":[\"https:\\\/\\\/www.facebook.com\\\/profile.php?id=523026911193540&_rdr\",\"https:\\\/\\\/www.instagram.com\\\/ikvaachen\\\/\"]}]}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Cross-phase process control concepts in injection moulding using modern control strategies | IKV-Aachen","description":"When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/","og_locale":"en_GB","og_type":"article","og_title":"Cross-phase process control concepts in injection moulding using modern control strategies | IKV-Aachen","og_description":"When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.","og_url":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/","og_site_name":"IKV-Aachen","article_publisher":"https:\/\/www.facebook.com\/profile.php?id=523026911193540&_rdr","article_modified_time":"2025-09-22T13:44:57+00:00","og_image":[{"width":1800,"height":1200,"url":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte.jpg","type":"image\/jpeg"}],"twitter_card":"summary_large_image","twitter_misc":{"Estimated reading time":"2 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"WebPage","@id":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/","url":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/","name":"Cross-phase process control concepts in injection moulding using modern control strategies | IKV-Aachen","isPartOf":{"@id":"https:\/\/ikv-aachen.de\/en\/#website"},"primaryImageOfPage":{"@id":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/#primaryimage"},"image":{"@id":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/#primaryimage"},"thumbnailUrl":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte.jpg","datePublished":"2025-06-10T08:51:53+00:00","dateModified":"2025-09-22T13:44:57+00:00","description":"When processing post-consumer recyclates (PCR) considerable differences between the properties of different material batches have to be accounted for. In order to be able to achieve consistently high component quality in injection moulding processes even with such batch fluctuations, the cross-phase process control concepts for injection moulding using modern control strategies developed in the first phase of the project were further developed for the use of recycled plastic granulate.","breadcrumb":{"@id":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/#breadcrumb"},"inLanguage":"en-GB","potentialAction":[{"@type":"ReadAction","target":["https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/"]}]},{"@type":"ImageObject","inLanguage":"en-GB","@id":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/#primaryimage","url":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte.jpg","contentUrl":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/06\/Phasenuebergreifende-Regelungskonzepte.jpg","width":1800,"height":1200,"caption":"Figure: Adjusting the cavity pressure level based on the Bayesian optimisation can compensate for material fluctuations"},{"@type":"BreadcrumbList","@id":"https:\/\/ikv-aachen.de\/en\/rp\/cross-phase-process-control-concepts-in-injection-moulding-using-modern-control-strategies\/#breadcrumb","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https:\/\/ikv-aachen.de\/en\/"},{"@type":"ListItem","position":2,"name":"Cross-phase process control concepts in injection moulding using modern control strategies"}]},{"@type":"WebSite","@id":"https:\/\/ikv-aachen.de\/en\/#website","url":"https:\/\/ikv-aachen.de\/en\/","name":"IKV-Aachen","description":"Forschung f\u00fcr die Praxis","publisher":{"@id":"https:\/\/ikv-aachen.de\/en\/#organization"},"alternateName":"Institut f\u00fcr Kunststoffverarbeitung","potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/ikv-aachen.de\/en\/?s={search_term_string}"},"query-input":{"@type":"PropertyValueSpecification","valueRequired":true,"valueName":"search_term_string"}}],"inLanguage":"en-GB"},{"@type":"Organization","@id":"https:\/\/ikv-aachen.de\/en\/#organization","name":"IKV-Aachen","alternateName":"Institut f\u00fcr Kunststoffverarbeitung (IKV)","url":"https:\/\/ikv-aachen.de\/en\/","logo":{"@type":"ImageObject","inLanguage":"en-GB","@id":"https:\/\/ikv-aachen.de\/en\/#\/schema\/logo\/image\/","url":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/02\/ikv-ikv-1.png","contentUrl":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/02\/ikv-ikv-1.png","width":512,"height":512,"caption":"IKV-Aachen"},"image":{"@id":"https:\/\/ikv-aachen.de\/en\/#\/schema\/logo\/image\/"},"sameAs":["https:\/\/www.facebook.com\/profile.php?id=523026911193540&_rdr","https:\/\/www.instagram.com\/ikvaachen\/"]}]}},"_links":{"self":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/rp\/7788","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/rp"}],"about":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/types\/cpt_ikv_rp"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/media\/7787"}],"wp:attachment":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/media?parent=7788"}],"wp:term":[{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/tags?post=7788"},{"taxonomy":"research_fields","embeddable":true,"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/research_fields?post=7788"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}