Compact integrated sensor module for in-line viscosity monitoring
A compact, integrated sensor module for real-time, in-line viscosity monitoring of polymer melts using pressure and ultrasonic transducers. It enables precise, non-invasive measurement and data acquisition, optimizing industrial injection molding processes.
Overview
The proposed compact, integrated sensor module is a cutting-edge solution for real-time, in-line viscosity monitoring of polymer melts. Designed to fit seamlessly within the existing nozzle of injection molding machinery, this module employs a combination of pressure and ultrasonic transducers to provide highly sensitive and accurate data on the apparent viscosity of polymer melts. The system's non-invasive nature and real-time monitoring capabilities allow for improved process control and optimization in industrial settings.
Technical specifications
- Pressure Transducers: Strategically placed along a precisely engineered flow channel to measure pressure drop, offering sensitive viscosity data.
- Ultrasonic Transducers: Flush-mounted within the nozzle wall to emit and receive high-frequency sound waves, ensuring robust, non-invasive material characterization.
- Data Acquisition System: High-speed system captures synchronous readings from sensors, correlating with off-line lab data.
- Temperature Monitoring: Miniature, fast-response thermocouples provide precise local temperature readings of the polymer melt.
- Materials: Constructed from advanced, high-temperature resistant materials, including specialized stainless steel alloys.
Technology readiness level
The technology is currently at TRL 2, with feasibility and design stages underway. The project includes a comprehensive plan for fabrication, calibration, validation, and pilot implementation, aiming to move towards higher TRL stages through structured development phases.
About Kettering University
Kettering University is a STEM‑focused private university in Flint, Michigan known for immersive, industry‑aligned education. Its signature year‑round cooperative education model places students in paid roles across multiple terms, creating a dependable pipeline of talent and applied research for employers. On campus, the GM Mobility Research Center provides a configurable proving ground for mobility testing, complemented by a Crash Safety Center for occupant protection work and a 9,000‑square‑foot Innovation Center that supports startup and corporate labs. Research activity is backed by competitive federal support, including recent awards from the National Science Foundation. Dedicated corporate engagement and customized training programs streamline sponsored projects, upskilling, and workforce partnerships.
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