Implementing

Cavity Pressure Technology

© RJG, Inc.

Rev. 4.0 1
 Table of Contents

• Selecting the Right Sensor

• Sensor Installation
• Milling the Pocket
• Sensor Head Installation
• Cable Installation
• Case Mounting
• Lynx Sensor Tester
• Sample Installation

2
Selecting the Right Sensor

3
 Cavity Pressure Sensor Styles

 Button Style Sensors

(Also known as Indirect or Force Sensors)

 Flush Mount Style Sensors

(Also known as Direct or Pressure Sensors)

4
Cavity Pressure Technology

5
The size of the ejector pin
impacts the amount of force
applied. Therefore, the
sensors are rated in terms of
force (lb) rather than
pressure. For a full scale
pressure of 20000 psi in a
mold, the amount of force on
the sensor can be
determined as follows:

F = 20000 psi *  D²
4

(D is the diameter of the ejector

pin and  = 3.1416.)

Example: With a 1/8” pin (D), the force on the sensor equals
245 lb for a 20000 psi full scale pressure. This 245 lb is roughly
half of the full scale rated load of the Model T-412 sensor (500
lb) yielding a rugged application.
6
 Full Scale
Pin Size Sensor
Pressure
 Make sure that the 1/32" LS-B-127-50 65190 psi
sensor rating is 1/16" LS-B-127-50 16297 psi

appropriate for the pin 1/16" LS-B-127-125 40744 psi

3/32" LS-B-127-125 18108 psi
size and expected
3/32" LS-B-127-500 72433 psi
pressures 1/8" LS-B-127-500 40744 psi
5/32" LS-B-127-500 26076 psi
3/16" LS-B-127-500 18108 psi
3/16" LS-B-127-2000 72433 psi
1/4" LS-B-127-2000 40744 psi
5/16" LS-B-127-2000 26076 psi
3/8" LS-B-127-2000 18108 psi
3/8" LS-B-159-4000 36217 psi
7/16" LS-B-159-4000 26608 psi
1/2" LS-B-159-4000 20372 psi
9/16" LS-B-159-4000 16096 psi
5/8" LS-B-159-4000 13038 psi
This is an example of an 3/4" LS-B-159-4000 9054 psi
overloaded sensor

7
 Sensor Body Diameter Body Height Length*

LS-B-127-50
LS-B-127-125
0.500" 0.375"
LS-B-127-500
LS-B-127-2000 *Lengths over 48”
12", 24", 36", 48" are special order

LS-B-159-4000 0.625" 0.500"

Lynx™ Button Style Sensor Dimensions

Force Range (Overload Capacity)

LS-B-127-50........................................................................50 lb (75 lb)
LS-B-127-125...............................................................125 lb (187.5 lb)
LS-B-127-500..................................................................500 lb (750 lb)
LS-B-127-2000............................................................2000 lb (3000 lb)
LS-B-159-4000............................................................4000 lb (6000 lb)
Maximum Temperature - Sensor............................................250°F [121°C]
Maximum Temperature - Sensor (-H suffix)...........................425°F [218°C]
Maximum Temperature - Connector........................................140°F [60°C]
Temp. Comp.of Zero & Sensitivity Accuracy.............2% F.S./100°F [38°C]
Accuracy (LS-B-127)......................................................(50 lb.) .75% FS,
(125, 500, 2000 lb.) .5% FS, (4000 lb.) .75% FS
Repeatability........................................................................0.1% of Output
Std. Connector....................................................Microstyle DC Receptacle
Technical Specifications 8
Click here for a pdf version from our website. 9
 Select the Right Sensor for the
Temperature of the Application
 Sensors behind valve gates may need a higher rating to take the
impact of the valve opening

 Do not run sensors in molds heated by induction heating

 Contact RJG if mounting surface will be over 140° F

 Order high temperature sensors for applications over 250° F

10
Sensor Installation

11
Lynx Standard Button Dimensions

12
 Sensor placement should be behind a
moving ejector pin that is actually used
to eject the part.

A sensor located behind a moving

ejector pin will be able to sense and
measure the force required to eject the
part out of the mold.

The pin used must fully contact plastic

in the mold runner or cavity and not
contact or “kiss off” on mold steel in
such a way as to impart a pre-load and
cause false readings.

13
 Tool Shop / Machining

 Ejector pin heads should not be etched

(e.g. with cavity number). This can
wear out the sensor nub. Etching can
be done on the side of the pin head

14
 Designing Installation

 Do not place sensor behind an ejector pin if the

mold surface angle is greater than 30°

15
Milling the Pocket

16
Pocket Radius

 Design sensor pocket to the

specifications in the manual.
Specify no radius on the bottom
to prevent side-loading

17
Pocket Surface Finish

 The metal that transmits

pressure to the sensor from a
ejector pin must be a smooth
surface. The mold surface
must also have a surface
finish of 32 or better

18
Counterbore

 If the ejector pin head is

larger than the sensor
head, additional clearance
room must be provided

19
20
Sensor Head Installation

21
Tool Shop / Machining

 Ejector pin
head must be
perpendicular
to the pin
shaft

22
Tool Shop / Machining

 Sensor pocket must

be perpendicular to
the force applied from
the ejector pin

23
Sensor Installation

 Pin should be
centered and rest
only on sensor nub

24
Sensor Installation

 Nub must touch the

ejector pin (do not
install upside down)

25
Cable Installation

26
 Self Locking Cable Guide Installation

 Put the sensor’s cable through the cable guide, then insert the
guide & cable into the channel.
 Install as many cable guides as necessary in order to secure the
cable in the channel.
 Guide can be removed by gently pulling up on the sensor’s cable.

27
 Cable Retention Guides

Cable Guides

Place
any excess
cable under
the cable guides.

Note: This is not for blue piezoelectric cables 28

 Suggestions and Common Errors
related to Cavity Pressure Sensors

 Be sure not to order too

short of cable.
 Up to 6” of cable can be
coiled. This also allows
the sensor to be moved
between molds.

29
Designing Installation
 Try to bury the sensor
wire. It should go straight
into the mold from the
bottom of the Lynx case
(on RJG Standard
sensors). This will prevent
sensor cable damage. Do
not allow the sensor cable
to fall outside the mold.

30
Designing Installation

 Make sure there is

room in the slot for
extra sensor wire

31
 Sensor Installation

 Do not pinch sensor wires

during mold assembly

32
 Sensor Installation

 Do not run sensor wire from one

sensor under the button stem of
another causing bending or twisting

33
 Cable Retention Putty
 Use Cable Retention Putty to
Cable Guide retain sensor wires when the
Cable
Retention use of the cable guides
Putty supplied with our sensors will
not work for your application.
Example: Multiple wires per
channel.

Sensor Channel .5” x .38” DP

Sensor Cable For Multiple Sensors

34
 Cable Retention Putty

Cable Retention Putty

 Cable Retention Putty should

also be used to retain extra
coiled sensor wire.

Sensor Cable

Note: If more Cable Retention Putty or cable guides are needed,

please contact RJG’s customer support at 231-947-3111.
35
Case Mounting

36
 Suggestions and Common Errors related to
Cavity Pressure Sensors

 Use cushioning stop pins if the Lynx case is going

to be mounted on an ejector plate that slams hard
on each cycle

37
 Tool Shop / Machining

 Do not drill or cut the Lynx case

 Observe all clearances so as not

to pre-load a sensor when the
mold is assembled

 Do not store or install where

solvents, acids, or other
corrosives could come into
contact with the sensor

38
 Designing Installation

 If Lynx case or connector is not

recessed, design protective end
block or cover

39
 Designing Installation

 Allow room at the end of Lynx housings

for the attachment and removal of cables

40
Lynx Sensor Tester

41
Lynx Sensor Tester Operating Instructions

42
 Lynx Sensor Tester: Testing Strategies

 During assembly of the mold, check the sensors at each step that might apply
pre-loading or side loads to the sensor; e.g. just after the clamp plate is
assembled.

 After assembling the mold, press on each sensor or ejector pin to ensure that
the force can be applied to the sensor. While the force is applied, the green or
yellow LED will flash. When the force reaches 10% (2% for piezo) the red LED
will stay on. If no lights flash, the lack of clearance is preventing movement.

 Piezo sensors will start with the green LED on. If you see a change to yellow or
red without pressing on the sensor then the sensor wire is damaged or the
connections are dirty. If the green light does not flash when you apply force to
the piezo sensor then the sensor wire is probably broken or disconnected.

 If a sensor is “suspect” (yellow LED is On) it may have side loading which can
cause it to fail in operation. If it passes when removed from the mold check the
pocket for improper radius or bending of the sensor stem. If it remains suspect
when removed from the mold then it should be returned for re-calibration.

 If a sensor is “failed” (red LED is On) remove it from the mold assembly and
check it again. If it passes (green) out of the mold then it is being preloaded or
side loaded when installed. If it does not pass then it is permanently damaged
and must be returned for repair.
43
Sample Installation

44
 Correctly Milled Pocket
< 0.05” radius

Counterbore
(Spot Face)

45
Correctly Installed Sensor

46
Correctly Installed Sensors

47
Alternative Case Mounting Example

48
Incorrectly Milled Pocket

49
Incorrectly Installed Sensor

50
 Resources Available

RJG Main Phone Number – 1-231-947-3111

RJG Customer Support – 1-800-472-0566

RJG Website – http://rjginc.com/

Technical resources: http://rjginc.com/resourcecenter.html

Solid Models: http://rjginc.com/resource_models.html

Product Manuals: http://rjginc.com/resource_product.html

Cavity Pressure Overview: http://rjginc.com/cavitymain.html

51