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DOE · Plastic Injection Simulator v4 · RESTRICTED ACCESS
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KeepLean

Plastic Injection Molding Process Simulator

DOE · PID Control · Cycle Animation — KEEPLEAN v2

120×80×30mm
NOx Sensor Housing
120×80×30 mm · 2.5mm wall
PA6-GF25
350×250×80mm
Intake Manifold Cover
350×250×80 mm · 3–4mm wall
PA6-GF30
100×80×60mm
EGR Valve Housing
100×80×60 mm · 3mm wall
PA6-HT
Ø90×25mm
Fuel Pump Flange
Ø90 × 25 mm · 2–3mm wall
PA6-GF30
🔲 NOx Sensor Housing — Technical Specifications
Dimensions
120 × 80 × 30 mm
Wall Thickness
2.5 mm
Material Grade
PA6-GF25
Max Temperature
180°C
⚖️ Weight Target
48 ± 1 g
Range: 47.0 – 49.0 g
📐 Flatness Target
< 0.20 mm
Critical surface quality
Annual Volume
800K / year
Key Challenge
Injection speed control
PA6-GF25
Polyamide 6 · Automotive Housing
g ± g
Target: 48.0 g · Range: 47–49 g
< mm
Max: 0.20 mm
🎛️ PID Controllers — Process Regulation
🌡 Barrel Temperature
Setpoint 250 °C
250°C 270°C
SP (Setpoint)
250 °C
PV (Process Value)
— °C
Kp 5.0
Ki 2.00
Kd 0.00
Process Variable oscillograph
💧 Injection Pressure
Setpoint 1000 bar
1000 1400 bar
SP (Setpoint)
1000 bar
PV (Process Value)
— bar
Kp 5.0
Ki 2.00
Kd 0.00
Process Variable oscillograph
❄️ Mold Temperature
Setpoint 50 °C
50°C 80°C
SP (Setpoint)
50 °C
PV (Process Value)
— °C
Kp 5.0
Ki 2.00
Kd 0.00
Process Variable oscillograph
💨 Injection Speed — 3 Stages
S1
Initial Fill 0 → 80% volume
80 mm/s
80 100 mm/s
Fill zone: 0–80%
S2
Mid-Fill Transition 80 → 95% volume
60 mm/s
40 60 mm/s
Transition: 80–95%
S3
Pack / Hold 95–100% + densification
5 mm/s
5 30 mm/s
Pack + Hold: 95–100%
Effective Speed
(weighted avg)
46 mm/s
🎬 Injection Cycle Animation
0 run(s)  |  Conformity: —
🔒 Mold Close
1.5s
💉 Injection
1.0s
⏸ Hold Press.
2.0s
❄️ Cooling
2.5s
🔓 Mold Open
1.0s
⬇️ Ejection
0.5s
Z1 Z2 Z3 Z4 Z5 48.1g ✓ INJECTION UNIT MOLD ⏸ STANDBY Cycle: 8.5s | CT: —
En attente du premier run…
Cycle total : 8.5 s
🎮 Interactive Simulator — Parameter Settings
📊 Defect Tracker — Cumulative Run History S1 Fill S2 Transition S3 Pack/Hold
S1
◼
Short Shot
—
S1
∿
Silver Streak
—
S1
⤳
Jetting
—
S2
〰
Weld Line
—
S2
⚡
Flash
—
S2
○
Bubble / Void
—
S3
⌣
Sink Mark
—
S3
⌇
Warpage
—
S3
⊡
Sticking
—
📋 Run Results
Run Barrel °C
(PV actual)		 Press. bar
(PV actual)		 S1 mm/s
Fill		 S2 mm/s
Transit.		 S3 mm/s
Pack		 Mold °C
(PV actual)		 Weight (g) Flatness (mm)