CN101462348B - Electromagnetic heating system of injection mould machine - Google Patents

Electromagnetic heating system of injection mould machine Download PDF

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CN101462348B
CN101462348B CN2008101220234A CN200810122023A CN101462348B CN 101462348 B CN101462348 B CN 101462348B CN 2008101220234 A CN2008101220234 A CN 2008101220234A CN 200810122023 A CN200810122023 A CN 200810122023A CN 101462348 B CN101462348 B CN 101462348B
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electromagnetic
voltage
output
temperature
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CN101462348A (en
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黄旭峰
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Abstract

The invention relates to an injector electromagnetic heating system, which comprises a material barrel and an electrical control cabinet. The system also comprises electromagnetic induction coils which are sectionally fired outside the material barrel, heat sensitive elements arranged on each temperature measuring point and an electromagnetic controller, wherein the electromagnetic induction coil generates an alternating magnetic field after being galvanized with high frequency and high voltage electricity; the temperature measuring points are arranged close to each section of the electromagnetic induction coils; the electromagnetic controller comprises a microprocessor and a peripheral circuit so as to convert power frequency current into high frequency and high voltage current, output the high frequency and high voltage current to the electromagnetic induction coil, monitor the temperature of the material barrel in a real-time mode and adjust the heating power of each section in time. The controller is integrated on a control board so as to realize control over a plurality of coils of one heating host machine, simplify the heating system, reduce the manufacturing cost and save 15 percent of electricity compared with the prior electromagnetic heating system.

Description

A kind of electromagnetic heating system of injection mould machine
Technical field
The present invention relates to the method and system of injection machine heating, relate in particular to the method and system of electromagnetic heating technique.
Background technology
At present, use the injection machine heater to be mostly to adopt the resistance-type heating, this heating means, the caloric requirement that is produced by resistance wire is delivered on the heater block by heat, in heat transfer process, will cause heat most of lost, as be lost in the air, make thermal conversion efficiency lower, thereby cause waste of electric energy.Because of high temperature ageing blows, service life is shorter easily for resistance wire in addition, and preheating time is longer.Deficiency at this heating means, someone has proposed electromagnetic heating method, its method is that electromagnetic induction coil is passed to high-frequency high-voltage current, produce the alternating magnetic field that changes at a high speed, when passing through the metal barrel, the magnetic line of force in the magnetic field in barrel, produces powerful eddy current, itself is in short-circuit condition barrel, and eddy current is heating at a high speed under the effect of barrel self-resistance, thereby reaches the thing in the heating of metal barrel.Electromagnetic heating technique Preliminary Applications in injection machine, heat than resistance wire, electromagnetic heating method is because by metal barrel self-heating, there are not the thermal energy loss of heat transfer process and the electric energy loss of heating self, energy savings significantly, the thermal efficiency is higher than 96%, and power saving rate reaches more than 60%.Because electromagnetic induction coil itself do not generate heat, thus long service life, and this method also to have a heating rate fast, need not advantages such as maintenance.
The patent No. is 200720031342.5 a kind of plastic extruder, plastic machine electric heater unit, comprise that being installed in plastic extruder, injection machine puts spiral and walk to expect temperature sensor on the pipe, one can show sample temperature and the temperature controller and the electromagnetic oven motherboard circuit that compare with setting value, the relay control terminal of temperature controller is responsible for the conducting and the disconnection of electromagnetic oven motherboard circuit drive(r) stage control interface, is installed in spiral and walks to expect that the electromagnetic induction coil on the pipe is connected electrically in the output of electromagnetic oven motherboard circuit.This installs each coil needs a heating main frame to go control, has not only wasted resource, also makes cost higher.
Summary of the invention
The present invention solves the technical problem that electromagnetic induction coil of prior art needs an independent heating main frame, a kind of a plurality of electromagnetic induction coils of heating host computer control are provided, the heating that circulates improves the injection machine electromagnetic heating method and the system of system saving electricity rate greatly.
Above-mentioned technical problem of the present invention is mainly solved by following technical proposals:
A kind of electromagnetic heating system of injection mould machine comprises barrel, and electrical control cabinet also comprises: segmentation is wound on the outer electromagnetic induction coil of barrel, produces alternating magnetic field after passing to high-frequency high-voltage; Be located at the temperature-sensitive element on each point for measuring temperature, described point for measuring temperature be arranged on every section electromagnetic induction coil near; Electromagnetic controller comprises microprocessor and peripheral circuit, power current is converted into high-frequency high-voltage current and outputs to electromagnetic induction coil, and monitor barrel temperature in real time, in time adjusts the heating power of each section; Wherein, the output of described electrical control cabinet connects the power input of electromagnetic controller, the be connected in parallel signal input part of electromagnetic controller of temperature-sensitive element, the input of the electromagnetic induction coil output with electromagnetic controller that is connected in parallel.
Electromagnetic controller is gathered near the temperature of the point for measuring temperature of each electromagnetic induction coil, compare with the preset temperature of each section, judging whether need be to the logical high-frequency high-voltage of electromagnetic induction coil, if the temperature that records is less than default temperature, increase heating power, reach preset temperature up to the point for measuring temperature temperature,, then reduce heating power if the temperature that records is too high.The present invention adopts an electromagnetic controller to control a plurality of coils, be provided with programmable logic controller (PLC) in the electromagnetic controller, as long as by programmable logic controller (PLC) is programmed, realize circulating and in an orderly manner electromagnetic induction coil is heated, compare traditional coil of a heater control, simplified mechanism, reduced cost, and, therefore also improved the power saving rate of electromagnetic heating system because electromagnetic controller itself is also wanted consumed power.The temperature survey available heat galvanic couple of point for measuring temperature or thermal resistance method are measured in the electromagnetic heating system of injection mould machine.Whole system only needs to install the temperature-sensitive element of electromagnetic induction coil and point for measuring temperature on injecting machine material tube, other work is finished by the electromagnetic controller unification, microprocessor and peripheral circuit in the electromagnetic controller are integrated on the mainboard, and be comparatively cheer and bright, and reduced volume, optimized structure, and traditional electromagnetic heating system is more owing to the heating main frame, and circuit is various, and is relatively more chaotic, make the mistake easily, and volume is bigger.
Peripheral circuit comprises major loop, barrel temperature observation circuit, PWM pulsewidth circuit for regulating and controlling, synchronous circuit, oscillating circuit and exciting circuit.The barrel temperature observation circuit, its output connects the pin of microprocessor, sends microprocessor to after being arranged at the signal value processing that temperature-sensitive element records on the point for measuring temperature, adjusts the variation of heating power according to the variations in temperature of barrel.Major loop mainly is made up of rectifier bridge, choke coil, heat coil, resonant capacitance and main switch IGBT.Rectification circuit becomes the alternating voltage of AC220V50/60HZ into DC voltage, convert DC voltage to high frequency voltage that frequency is 20-40KHZ through control circuit again, the electric current that changes can produce the magnetic field that changes at a high speed through heat coil at a high speed, the magnetic line of force in magnetic field is through the metal device, produce countless little eddy current, make metal device heating at a high speed voluntarily itself, reach heating function.PWM pulsewidth circuit for regulating and controlling, microprocessor CPU is provided with the PWM output, and the input of PWM pulsewidth circuit for regulating and controlling connects the PWM output of microprocessor CPU, and PWM pulsewidth circuit for regulating and controlling is converted into pwm pulse signal and pulse width correspondent voltage signal; Synchronous circuit, an end connects major loop, and the other end connects oscillating circuit, is used for making the switching pulse forward position of high-frequency and high-voltage and IGBT to go up the VCE pulse back edge synchronised that produces; Oscillating circuit, the input of oscillating circuit connects the output of PWM pulsewidth circuit for regulating and controlling, its output connects major loop, and the signal that will feed back through the control signal PWM and the major loop of PWM pulsewidth circuit for regulating and controlling processing is made comparisons, and produces a pulse signal that offers the work of IGBT exciting circuit; The IGBT exciting circuit, its input connects the output of oscillating circuit, and with the pulse signal amplification of oscillating circuit output, amplified pulse signal connects the G utmost point of IGBT; Switch control is used for the control heating and opens or stop, and the high-frequency high-voltage of selecting inverter circuit is produced is in which road output, and its output is the electromagnetic induction coil that is connected in parallel.Oscillating circuit is to compare at the signal that control signal PWM of master chip microprocessor CPU output and major loop feed back, make it to produce a pulse signal of supplying with the exciting circuit work of IGBT, the pulsewidth of adjusting PWM just can make the heating power of electromagnetic controller change, the wide more power of pulsewidth is just big more, otherwise more little.Because the pulse amplitude of oscillating circuit output is about 4.1V, this voltage can not directly be controlled the saturation conduction of IGBT and end, so must signal be amplified by exciting circuit.Microprocessor CPU is wide and narrow by the control pwm pulse, and the heating power control voltage of oscillating circuit is delivered in control, has controlled the length of IGBT ON time, and the result has controlled the size of heating power.The effect of synchronous circuit mainly is to have guaranteed to be added to switching pulse forward position and the IGBT that the G of IGBT extremely goes up to go up the VCE pulse back edge synchronised that produces.Because in the one-period of high frequency electric, the resonant capacitance of main circuit resonant tank is the state of charging and discharge.When electric capacity in the charging output of the time not vibrating, just do not have switching pulse to add to the G utmost point of IGBT yet, guaranteed that IGBT can conducting in this time, when capacitor discharge, just having vibrates output, has switching pulse to add to the G utmost point of IGBT.So reach synchronous effect.ON-OFF control circuit is the heating unlatching of control electromagnetic controller or stops.When not heating, microprocessor CPU has a pin output low level (also stopping PWM output simultaneously), makes the IGBT exciting circuit stop output, and IGBT ends, and then heating stops.When beginning to heat, a pin output of microprocessor CPU high level, the PWM output pin begins to export at interval the PWM probe signal simultaneously, microprocessor CPU is by analyzing the voltage waveform situation of change of current detection circuit and VCE testing circuit feedback simultaneously, judge whether to put into metal device to be heated, if, the PWM output pin of microprocessor CPU transfers the normal pwm signal of output to, electromagnetic controller enters normal heated condition, otherwise, then continue output PWM probe signal, send the information of reporting simultaneously, as still ineligible in one minute, then close.
Peripheral circuit also comprises current detection circuit, Vce supervisory circuit and circuit and square-wave, wherein: current detection circuit, its input connects power supply, and output connects the pin of microprocessor CPU, supply voltage is converted into DC voltage is sent to microprocessor CPU; The Vce supervisory circuit connects major loop, and the Vce voltage change information of obtaining IGBT is sent to microprocessor CPU; Circuit and square-wave connects main power source, is used to monitor supply frequency information.Power circuit has individual current transformer, the AC voltage that its secondary records, through the bridge rectifier rectification, electric capacity is level and smooth, the DC voltage that is obtained is delivered to microprocessor CPU, and this voltage is high more, and the electric current of expression power supply input is big more, microprocessor CPU is made the exercises instruction automatically according to the variation of this voltage of monitoring.The VCE testing circuit passes through some control circuits with the pulse voltage on the IGBT colelctor electrode, on emitter stage, obtain its sampling voltage, this VCE voltage change information of having reacted IGBT is sent into microprocessor CPU, and microprocessor CPU is made the exercises instruction automatically according to the variation of this voltage of monitoring.Current detection circuit cooperates VCE circuit feedack, differentiates whether put into metal device to be heated, and instruction acts accordingly.Current detection circuit cooperates the supply frequency information of VCE circuit feedack and circuit and square-wave monitoring, and the pulsewidth of regulation and control PWM makes power output keep stable.According to the VCE sampling voltage value, adjust the PWM pulsewidth automatically, control VCE impulse amplitude is not higher than 1100V (this value is the withstand voltage of IGBT).When recording other reasons and cause the VCE pulse to be higher than 1150V, microprocessor CPU sends immediately and stops the heating instruction.
Peripheral circuit also comprises the surge voltage observation circuit, and its input connects main power source, and output connects oscillating circuit and microprocessor CPU respectively, is used for making electromagnetic controller suspend heating when power supply has the surge voltage input suddenly.Supply voltage just often, oscillating circuit can be exported oscillation pulse signal, when power supply has surge voltage when input suddenly, this voltage through the electric resistance partial pressure sampling, changes sampling voltage and passes through comparator again by Capacitance Coupled, the oscillating impulse voltage of oscillating circuit output is dragged down, electromagnetic controller suspends heating, and simultaneously, microprocessor CPU monitors Stop message, send immediately and suspend the heating instruction, treat after the surge voltage that when transferring ON to by OFF, microprocessor CPU sends the heating instruction more again.
Peripheral circuit also comprises the IGBT temperature observation circuit, and its output connects microprocessor CPU, is used to monitor the variations in temperature of IGBT.The temperature that IGBT produces sees through fin and reaches the negative tempperature coefficient thermistor TH that is close on it, the variations in temperature of IGBT that the variation of this resistance is anti-indirectly, the voltage change of thermistor has been reacted the variation of thermistor resistance in fact, it is the variations in temperature of IGBT, microprocessor CPU is by the variation of this voltage of monitoring, make corresponding action instruction: when the IGBT junction temperature is higher than 85 ℃, adjust the output of PWM, make IGBT junction temperature≤85 ℃; When the IGBT junction temperature owing to certain reason (as the cooling system fault) when being higher than 95 ℃, heating stops immediately, and reports information; When thermistor TH open circuit or short circuit, send not enabled instruction, and report relevant information.
Also be provided with cooling system in the electromagnetic controller.IGBT and rectifier DB are close on the fin, and the hot type that produces when utilizing air-flow that fan running forms by the electromagnetic controller inlet and outlet with part time jobs such as heat on the fin and drums goes out outside the controller.
The barrel lateral wall is provided with insulation material, and electromagnetic induction coil is wound on the insulation material outside.Insulation material can prevent heat leakage, and prevents that heat is delivered to electromagnetic induction coil, reduces the electromagnetic induction coil influence in service life.Insulation material is selected ceramic fibre for use.
Barrel is provided with guard shield outward, and guard shield is located at outside the electromagnetic induction coil.Because electromagnetic induction coil passes to high-frequency high-voltage, guard shield can guarantee staff's safety, and can prevent that dust steam etc. from entering.Guard shield based on aluminium alloy, mainly is to play the double beauty function of protection in the selection of material.
The beneficial effect that the present invention brings is: the present invention monitors in real time to the pairing point for measuring temperature of electromagnetic induction coil, and the heating power of adjusting this electromagnetic induction coil is in real time controlled barrel temperature.Control circuit of the present invention is integrated on the control panel, has realized a plurality of coils of heating host computer control, has simplified heating system, has reduced cost of manufacture, and higher by 15% than traditional electromagnetic heating system power saving rate.
Description of drawings
Accompanying drawing 1 is a kind of structural representation of the present invention;
Accompanying drawing 2 is circuit structure block diagrams of the present invention.
The specific embodiment
Below by embodiment, and in conjunction with the accompanying drawings, the technical scheme of inventing is described in further detail.
Embodiment: as shown in Figure 1, electromagnetic heating system of injection mould machine comprises, injecting machine material tube 1, hopper, covering insulation material 4 on barrel 1, insulation material is selected ceramic fibre for use, insulation material 4 can prevent that barrel is heated the back heat and scatters and disappears, insulation material outside segmentation coiling electromagnetic induction coil 3, the electromagnetic induction coil 3 outer guard shields 5 that are provided with, guard shield 5 is based on aluminium alloy, be provided with point for measuring temperature near every section electromagnetic induction coil, thermistor 2 places on this point for measuring temperature, and electromagnetic induction coil 3 parallel connections are electrically connected on same electromagnetic controller 6, and power supply is provided by electrical control cabinet 7.Electromagnetic controller comprises microprocessor and peripheral circuit, peripheral circuit comprises major loop, barrel temperature observation circuit, PWM pulsewidth circuit for regulating and controlling, synchronous circuit, oscillating circuit and exciting circuit, also comprises current detection circuit, Vce supervisory circuit, circuit and square-wave, surge voltage observation circuit, IGBT temperature observation circuit and cooling system.Wherein, major loop mainly is made up of rectifier bridge, choke coil, heat coil, resonant capacitance and main switch IGBT, microprocessor is provided with the PWM output, this PWM output connects PWM pulsewidth circuit for regulating and controlling, the pulsewidth circuit for regulating and controlling converts pwm signal to the voltage signal corresponding with pulsewidth, oscillating circuit connects the output of pulsewidth circuit for regulating and controlling, and oscillating circuit also connects major loop by synchronous circuit, control the high-frequency high-voltage that major loop produces with pwm signal, control the frequency of high-frequency high-voltage by the pulsewidth of control PWM, and then control heating power.The exciting circuit that the pulse signal that oscillating circuit produces is input to IGBT amplifies signal, just can be input to the G end of IGBT.The Vce supervisory circuit connects major loop, and the input of current detection circuit, circuit and square-wave, surge voltage observation circuit and MCU/PLC supervisory circuit is connected main power source respectively, and their output connects microprocessor respectively.The output of barrel temperature observation circuit and IGBT temperature observation circuit also is connected microprocessor.
On electromagnetic controller, preset temperature value earlier, the temperature requirement of each section is different.Start the after-current testing circuit and cooperate the Vce supervisory circuit, detect and whether put into metal material, confirm to put into the back, make the metal material self-heating the logical high-frequency high-voltage current of electromagnetic induction coil.Thermistor is arranged on the point for measuring temperature of each section, along with its resistance value of variation of temperature changes, temperature transition has been become the corresponding signal of telecommunication, after processing circuit processes separately, send microprocessor to, microprocessor compares temperature value that records and the temperature value of presetting, if the temperature value that records is less than default temperature, then widen the pulsewidth of PWM by microprocessor, improve heating power, if the temperature that records is higher than in the default temperature, then reduce the pulsewidth of PWM, reduce heating power.
Power supply is input as 220V, the alternating current of 50/60HZ is in major loop, through behind the rectification circuit, change the direct current of pulsation into, be converted to direct current stably through choke coil again, because the electromagnetic induction coil input needs high-frequency high-voltage could produce eddy current, so direct current changes high-frequency high-voltage into through an inverter circuit, the frequency of high-frequency high-voltage is to be controlled by microprocessor, its frequency is 20-40KHZ, after switch control, outputs to the electromagnetic induction coil that needs energising.
Current detection circuit cooperates VCE circuit feedack, differentiates whether put into metal device to be heated, and instruction acts accordingly.Current detection circuit cooperates the supply frequency information of VCE circuit feedack and circuit and square-wave monitoring, and the pulsewidth of regulation and control PWM makes power output keep stable.The surge voltage observation circuit is used for making electromagnetic controller suspend heating when power supply has the surge voltage input suddenly, prevents to burn out device.The IGBT temperature observation circuit prevents the too high device that burns out of IGBT junction temperature.

Claims (5)

1. an electromagnetic heating system of injection mould machine comprises barrel (1), and electrical control cabinet (7) is characterized in that also comprising:
Segmentation is wound on the outer electromagnetic induction coil (3) of barrel (1), produces alternating magnetic field after passing to high-frequency high-voltage;
Be located at the temperature-sensitive element (2) on each point for measuring temperature, described point for measuring temperature be arranged on every section electromagnetic induction coil (3) near;
Electromagnetic controller (6) comprises microprocessor and peripheral circuit, power current is converted into high-frequency high-voltage current and outputs to electromagnetic induction coil, and monitor barrel temperature in real time, in time adjusts the heating power of each section;
Wherein, the output of described electrical control cabinet connects the power input of electromagnetic controller, the be connected in parallel signal input part of electromagnetic controller of temperature-sensitive element, and the input of electromagnetic induction coil is connected in parallel in the output of electromagnetic controller;
Described peripheral circuit comprises major loop, barrel temperature observation circuit, PWM pulsewidth circuit for regulating and controlling, synchronous circuit, oscillating circuit, IGBT exciting circuit, current detection circuit, VCE supervisory circuit, circuit and square-wave, surge voltage observation circuit and IGBT temperature observation circuit, wherein:
The barrel temperature observation circuit, its output connects the pin of microprocessor CPU, sends microprocessor to after being arranged at the treated processing of circuit of signal that temperature-sensitive element records on the point for measuring temperature, monitors barrel temperature in real time;
Major loop, major loop mainly is made up of rectifier bridge, choke coil, heat coil, resonant capacitance and main switch IGBT, major loop mainly is the direct current that power frequency AC is changed into pulsation, convert DC voltage to high-frequency high-voltage again, the high-frequency high-voltage current that changes flows through and is wound on the outer electromagnetic induction coil of barrel at a high speed, and the metal material in the barrel is understood self and generated heat at a high speed;
PWM pulsewidth circuit for regulating and controlling, microprocessor CPU is provided with the PWM output, and the input of PWM pulsewidth circuit for regulating and controlling connects the PWM output of microprocessor CPU, and PWM pulsewidth circuit for regulating and controlling is converted into pwm pulse signal and pulse width correspondent voltage signal;
Synchronous circuit, an end connects major loop, and the other end connects oscillating circuit, is used for making the switching pulse forward position of high-frequency and high-voltage and IGBT to go up the VCE pulse back edge synchronised that produces;
Oscillating circuit, the input of oscillating circuit connects the output of PWM pulsewidth circuit for regulating and controlling, its output connects major loop, and the signal that will feed back through the control signal PWM and the major loop of PWM pulsewidth circuit for regulating and controlling processing is made comparisons, and produces a pulse signal that offers the work of IGBT exciting circuit;
The IGBT exciting circuit, its input connects the output of oscillating circuit, and with the pulse signal amplification of oscillating circuit output, amplified pulse signal connects the G utmost point of IGBT;
Switch control is used for the control heating and opens or stop, and the high-frequency high-voltage of selecting inverter circuit is produced is in which road output, and its output is the electromagnetic induction coil that is connected in parallel.
Current detection circuit, its input connects power supply, and output connects the pin of microprocessor CPU, supply voltage is converted into DC voltage is sent to microprocessor CPU;
The VCE supervisory circuit connects major loop, and the VCE voltage change information of obtaining IGBT is sent to microprocessor CPU;
Circuit and square-wave connects main power source, is used to monitor supply frequency information;
The surge voltage observation circuit, its input connects main power source, and output connects oscillating circuit and microprocessor CPU respectively, is used for making electromagnetic controller suspend heating when power supply has the surge voltage input suddenly;
The IGBT temperature observation circuit, its output connects microprocessor CPU, is used to monitor the variations in temperature of IGBT.
2. electromagnetic heating system of injection mould machine according to claim 1 is characterized in that also being provided with in the described electromagnetic controller cooling system.
3. electromagnetic heating system of injection mould machine according to claim 1 is characterized in that described barrel (1) lateral wall is provided with insulation material (4), and electromagnetic induction coil (3) is wound on insulation material (4) outside.
4. according to claim 1 or 3 described electromagnetic heating system of injection mould machine, it is characterized in that being provided with guard shield (5) outside the described barrel (1), and guard shield (5) is located at outside the electromagnetic induction coil.
5. electromagnetic heating system of injection mould machine according to claim 4 is characterized in that described guard shield is based on aluminum alloy materials.
CN2008101220234A 2008-10-27 2008-10-27 Electromagnetic heating system of injection mould machine Expired - Fee Related CN101462348B (en)

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Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
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CN101462348B true CN101462348B (en) 2010-12-29

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