Injection molding apparatus and method of detecting misalignment in the injection molding apparatus

A method of detecting misalignment using a misalignment sensing system in a molding structure for producing molded articles, the molding structure including a first component and a second component, at least one of the first component and the second component being selectively repositionable between a closed configuration of the mold structure and an open configuration of the mold structure, the misalignment sensing system including:

• a straight lock alignment member including:
• a male portion coupled to and extending from the first component of the molding structure, and
• a female portion coupled to the second component of the molding structure, the female portion being configured for a complimentary fit with the male portion so as to engage the male portion when the molding structure enters a closed configuration;
• at least one sensor connected to one of the male portion and the female portion, the at least one sensor being configured to detect a deformation of any one of the male portion and the female portion, the deformation being induced by a misalignment between the first component of the molding structure and the second component of the molding structure;
• and
• a control unit communicatively coupled to the at least one sensor, the control unit configured to receive a sensed misalignment condition from the at least one sensor for processing thereof;
• the method being executed by the control unit, the method comprising:
• causing the at least one sensor to sense, during a given molding cycle when the molding structure is actuated toward the closed configuration, strain on the one of the female portion and the male portion;
• receiving, by the control unit, at least one strain measurement from the at least one sensor;
• and
• determining, by the control unit, a misalignment of the first component of the mold structure and the second component of the mold structure based on the at least one strain measurement.