CN107632196A - A kind of injection machine state recognition and abnormity early warning method - Google Patents
A kind of injection machine state recognition and abnormity early warning method Download PDFInfo
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- CN107632196A CN107632196A CN201710429900.1A CN201710429900A CN107632196A CN 107632196 A CN107632196 A CN 107632196A CN 201710429900 A CN201710429900 A CN 201710429900A CN 107632196 A CN107632196 A CN 107632196A
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- energy consumption
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- early warning
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Abstract
The invention discloses a kind of injection machine state recognition and abnormity early warning method, comprise the following steps：External acquisition processing device；Limited according to energy consumption and require input energy consumption threshold value of warning；Data and state characteristics tree are subjected to Characteristic Contrast analysis, judge whether Characteristics of Mutation, when feature presence, are then carried out in next step；When feature is not present, then the step is repeated；Judge whether this feature is off-note, if so, then carrying out abnormal alarm；If it is not, carry out in next step；Energy consumption warning index value is obtained, judges whether to need early warning, if so, then carrying out energy consumption early warning；If it is not, then updating repeat step three after injection machine state, the original state of the injection machine is shutdown.The present invention can realize state recognition and the abnormity early warning of injection machine.
Description
【Technical field】
The present invention relates to the technical field of injection machine, the skill of particularly a kind of injection machine state recognition and abnormity early warning method
Art field.
【Background technology】
Injection (mo(u)lding) machine (abbreviation injector or injection machine) is that thermoplastic or thermosetting material are utilized into plastic forming dies
The main former of variously-shaped plastic products is made in tool.Injection moulding is realized by injection machine and mould.Note
Molding machine is generally by injecting systems, Clamping System, hydraulic transmission system, electric control system, lubricating system, heating and cooling system
System, safety monitoring system etc. form.The safety device of injection machine is primarily used to protect people, the device of machine safety.Mainly by pacifying
Air cock, hydraulic valve, limit switch, optical detection device etc. form, and realize electrically --- machinery --- interlock protection of hydraulic pressure.Prison
Examining system is mainly monitored to the oil temperature, material temperature, system overcharge of injection machine, and technique and unit exception, and note abnormalities feelings
Condition is indicated or alarmed.The safety monitoring system security of existing lathe is low, is only conventional abnormal alarm, can not be to each
Kind state is identified；And only live security alarm, no remote alarms, also stateless monitoring；In addition, existing system
Only to abnormal alarm, and to energy consumption without monitoring, no early warning.
The existing scheme being acquired to injection machine energy consumption, if Tian Yu is in periodical《Chinese Plastics》On 5 monthly magazines in 2011
That delivers is entitled《Injection moulding process energy distribution experimental study based on LabVIEW》In propose a kind of energy consumption detection system, but
Not using energy consumption carry out state recognition, also without using energy consumption data progress early warning.
For this reason, it may be necessary to a kind of injection machine state recognition and abnormity early warning method, and need a kind of dress for coordinating this method
Put or system, for the state acquisition to injection machine, abnormity early warning, remotely check.
【The content of the invention】
The purpose of the present invention is exactly to solve the problems of the prior art, proposes a kind of injection machine state recognition and abnormity early warning
Method, state recognition and the abnormity early warning of injection machine can be realized.
To achieve the above object, the present invention proposes a kind of injection machine state recognition and abnormity early warning method, including following
Step：
Step 1：By the external acquisition processing device of injection machine of required detection early warning, acquisition processing device is gathered and located in advance
Each sensor signal is managed, each sensor signal includes position signalling Posi, pressure signal P res, tach signal Speed, flow letter
Number Flow and temperature signal Temp；Acquisition processing device gathers and pre-processes each sensor signal energy consumption signal, obtains power number
According to Power and energy consumption data Ener, the energy consumption signal includes current signal I=(I1, I2, I3), voltage signal U=(U1, U2,
U3)；
Step 2：Limited according to energy consumption and require input energy consumption threshold value of warning, the energy consumption threshold value of warning includes odd-numbered day total energy
Consume threshold value, single product energy consumption threshold value, batch products total energy consumption threshold value, idle energy consumption threshold value；
Step 3：Each sensor signal and the energy consumption signal that will be got in real time, Characteristic Contrast is carried out with state characteristics tree
Analysis, judges whether Characteristics of Mutation, when feature presence, then carries out in next step；When feature is not present, then repeat step three；
Step 4：Judge whether this feature is off-note, if so, then carrying out abnormal alarm；If it is not, carry out in next step；
Step 5：Energy consumption warning index value is obtained, judges whether to need early warning, if so, then carrying out energy consumption early warning；If it is not,
Then repeat step three after renewal injection machine state, the original state of the injection machine is shutdown.
Preferably, acquisition processing device in the step 1 include acquisition processing device main body, display screen, button,
Data-interface, power interface, lathe external switch, energy consumption detection circuit, master controller, alarm, control button, memory cell,
Wireless communication line and each sensor, each sensor include position sensor, pressure sensor, speed probe, flow sensing
Device and temperature sensor；The acquisition processing device body front end is embedded with display screen and button, and button includes lathe external switch
And control button, acquisition processing device body front end are provided with data-interface, power interface；The master controller and display screen, position
Put sensor, pressure sensor, speed probe, flow sensor, temperature sensor, energy consumption detection circuit, alarm, control
Button, memory cell, wireless communication line are electrically connected with, and memory cell is electrically connected with data-interface；The lathe external-open
Close, energy consumption detection circuit is spaced apart electric connection with injection machine.
Preferably, the state characteristics tree in the step 3 includes injection machine state, Characteristics of Mutation and corresponding biography
Sensor state and energy consumption characters.
Preferably, the acquisition methods of the state characteristics tree in the step 3 comprise the following steps：
Step 1：By the external acquisition processing device of injection machine of required detection early warning, acquisition processing device is gathered and located in advance
Manage each sensor signal；
Step 2：Completion is molded data acquisition and the injection machine state recording of experiment several times；
Step 3：Data analysis is carried out, excavates the Characteristics of Mutation between injection machine state；
Step 4：Injection machine Characteristics of Mutation is corresponding with sensor states and energy consumption characters, establish state characteristics tree；
Step 5：Optimal State characteristics tree：First carry out injection experiment, data acquisition, state recording；Corresponding state feature again
Tree, calculation error；Then whether error threshold is more than to judge whether to need to correct characteristics tree according to error, if so, amendment shape
Re-optimization after state characteristics tree, if it is not, terminating optimization, obtain final state characteristics tree.
Preferably, the method for judging whether Characteristics of Mutation in the step 3 is：By calculating continuous ten
Slope, power consumption values between the averages of data, amplitude, extreme value, and above-mentioned data and existing Characteristics of Mutation are contrasted；It is described to be mutated
The sensor states and energy consumption characters being characterized as between injection machine state.
Preferably, the energy consumption warning index in the step 5 includes odd-numbered day total energy consumption warning index, single product energy
Consume warning index, batch products total energy consumption warning index, idle energy consumption warning index.
Beneficial effects of the present invention：The present invention can realize state recognition and the abnormity early warning of injection machine.
The feature and advantage of the present invention will be described in detail by embodiment combination accompanying drawing.
【Brief description of the drawings】
Fig. 1 is the front view of the acquisition processing device of a kind of injection machine state recognition of the present invention and abnormity early warning method；
Fig. 2 is the injection machine line schematic diagram of a kind of injection machine state recognition of the present invention and abnormity early warning method；
Fig. 3 is the schematic diagram of a kind of injection machine state recognition of the present invention and abnormity early warning method；
Fig. 4 is the method flow diagram of a kind of injection machine state recognition of the present invention and abnormity early warning method；
Fig. 5 is the state characteristics tree method for building up flow of a kind of injection machine state recognition of the present invention and abnormity early warning method
Figure；
Fig. 6 is the state characteristics tree structural representation of a kind of injection machine state recognition of the present invention and abnormity early warning method.
In figure：1- acquisition processing devices main body, 2- display screens, 3- buttons, 4- data-interfaces, 5- power interfaces, 6- positions
Sensor, 7- pressure sensors, 8- injection machines are spaced apart, 9- speed probes, 10- flow sensors, 11- temperature sensors, 12-
Lathe external switch, 13- energy consumptions detection circuit, 14- master controllers, 15- alarms, 16- control buttons, 17- memory cell, 18-
Wireless communication line, 19- computers, 20- mobile phones.
【Embodiment】
Refering to Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5 and Fig. 6, the present invention, comprise the following steps：
Step 1：By the external acquisition processing device of injection machine of required detection early warning, acquisition processing device is gathered and located in advance
Each sensor signal is managed, each sensor signal includes position signalling Posi, pressure signal P res, tach signal Speed, flow letter
Number Flow and temperature signal Temp；Acquisition processing device gathers and pre-processes each sensor signal energy consumption signal, obtains power number
According to Power and energy consumption data Ener, the energy consumption signal includes current signal I=(I1, I2, I3), voltage signal U=(U1, U2,
U3)；
Step 2：Limited according to energy consumption and require input energy consumption threshold value of warning, the energy consumption threshold value of warning includes odd-numbered day total energy
Consume threshold value, single product energy consumption threshold value, batch products total energy consumption threshold value, idle energy consumption threshold value；
Step 3：Each sensor signal and the energy consumption signal that will be got in real time, Characteristic Contrast is carried out with state characteristics tree
Analysis, judges whether Characteristics of Mutation, when feature presence, then carries out in next step；When feature is not present, then repeat step three；
Step 4：Judge whether this feature is off-note, if so, then carrying out abnormal alarm；If it is not, carry out in next step；
Step 5：Energy consumption warning index value is obtained, judges whether to need early warning, if so, then carrying out energy consumption early warning；If it is not,
Then repeat step three after renewal injection machine state, the original state of the injection machine is shutdown.
Specifically, the acquisition processing device in the step 1 includes acquisition processing device main body (1), display screen (2), pressed
Key (3), data-interface (4), power interface (5), lathe external switch (12), energy consumption detection circuit (13), master controller (14), report
Alert device (15), control button (16), memory cell (17), wireless communication line (18) and each sensor, each sensor include position
Put sensor (6), pressure sensor (7), speed probe (9), flow sensor (10) and temperature sensor (11)；It is described to adopt
Collection processing unit main body (1) front end is embedded with display screen (2) and button (3), and button (3) includes lathe external switch (12) and control
Button (16), acquisition processing device main body (1) front end are provided with data-interface (4), power interface (5)；The master controller (14)
With display screen (2), position sensor (6), pressure sensor (7), speed probe (9), flow sensor (10), TEMP
Device (11), energy consumption detection circuit (13), alarm (15), control button (16), memory cell (17), wireless communication line (18)
It is electrically connected with, memory cell (17) is electrically connected with data-interface (4)；The lathe external switch (12), energy consumption detection circuit
(13) it is spaced apart (8) electric connection with injection machine.
Specifically, the state characteristics tree stated in step 3 includes injection machine state, Characteristics of Mutation and corresponding sensor
State and energy consumption characters.
Specifically, the acquisition methods of the state characteristics tree in the step 3 comprise the following steps：
Step 1：By the external acquisition processing device of injection machine of required detection early warning, acquisition processing device is gathered and located in advance
Manage each sensor signal；
Step 2：Completion is molded data acquisition and the injection machine state recording of experiment several times；
Step 3：Data analysis is carried out, excavates the Characteristics of Mutation between injection machine state；
Step 4：Injection machine Characteristics of Mutation is corresponding with sensor states and energy consumption characters, establish state characteristics tree；
Step 5：Optimal State characteristics tree：First carry out injection experiment, data acquisition, state recording；Corresponding state feature again
Tree, calculation error；Then whether error threshold is more than to judge whether to need to correct characteristics tree according to error, if so, amendment shape
Re-optimization after state characteristics tree, if it is not, terminating optimization, obtain final state characteristics tree.
Specifically, the method for judging whether Characteristics of Mutation in the step 3 is：By calculating continuous ten numbers
According to average, amplitude, slope, power consumption values between extreme value, and above-mentioned data and existing Characteristics of Mutation are contrasted；It is described to be mutated spy
Levy the sensor states and energy consumption characters between injection machine state.
Specifically, the energy consumption warning index in the step 5 includes odd-numbered day total energy consumption warning index, single product energy consumption
Warning index, batch products total energy consumption warning index, idle energy consumption warning index.
The course of work of the present invention：
A kind of injection machine state recognition of the present invention and abnormity early warning method in the course of the work, have position, pressure, turned
Speed, flow, temperature, the acquisition processing device of energy consumption access injection machine to be measured, carry out the foundation of state characteristics tree, special using state
Sign tree, carries out real time contrast's analysis, obtains the real-time status of injection machine, and carry out abnormity early warning.Energy consumption warning index includes single
Day total energy consumption warning index, single product energy consumption warning index, batch products total energy consumption warning index, idle energy consumption early warning refer to
Mark.Odd-numbered day total energy consumption warning index is one day energy at most consumed of current injection machine to be limited according to the requirement of energy consumption control
Consumption；Single product energy consumption warning index is that the total energy consumption of a complete injection molding process is limited；Batch products total energy consumption
Warning index is that injection machine start is limited to the total energy consumption between shutdown；Idle energy consumption warning index is that stand-by time is produced
Energy consumption limit, main Machine-Tool Control of saving wastes.
Energy consumption detection circuit 13 in the present invention is using three voltage sensors, three current sensor compositions, difference
Obtain voltage, the electric current of each single item electricity.
The present invention, state recognition and the abnormity early warning of injection machine can be realized.
Above-described embodiment is the description of the invention, is not limitation of the invention, it is any to simple transformation of the present invention after
Scheme belong to protection scope of the present invention.
Claims (6)
1. a kind of injection machine state recognition and abnormity early warning method, it is characterised in that：Comprise the following steps：
Step 1：By the external acquisition processing device of injection machine of required detection early warning, acquisition processing device is gathered and pre-processed each
Sensor signal, each sensor signal include position signalling Posi, pressure signal P res, tach signal Speed, flow signal
Flow and temperature signal Temp；Acquisition processing device gathers and pre-processes each sensor signal energy consumption signal, obtains power data
Power and energy consumption data Ener, the energy consumption signal include current signal I=(I1, I2, I3), voltage signal U=(U1, U2,
U3)；
Step 2：Limited according to energy consumption and require input energy consumption threshold value of warning, the energy consumption threshold value of warning includes odd-numbered day total energy consumption threshold
Value, single product energy consumption threshold value, batch products total energy consumption threshold value, idle energy consumption threshold value；
Step 3：Each sensor signal and the energy consumption signal that will be got in real time, Characteristic Contrast analysis is carried out with state characteristics tree,
Characteristics of Mutation is judged whether, when feature presence, is then carried out in next step；When feature is not present, then repeat step three；
Step 4：Judge whether this feature is off-note, if so, then carrying out abnormal alarm；If it is not, carry out in next step；
Step 5：Energy consumption warning index value is obtained, judges whether to need early warning, if so, then carrying out energy consumption early warning；If it is not, then more
Repeat step three after new injection machine state, the original state of the injection machine is shutdown.
2. a kind of injection machine state recognition as claimed in claim 1 and abnormity early warning method, it is characterised in that：The step 1
In acquisition processing device include acquisition processing device main body (1), display screen (2), button (3), data-interface (4), power supply connect
Mouthful (5), lathe external switch (12), energy consumption detection circuit (13), master controller (14), alarm (15), control button (16), deposit
Storage unit (17), wireless communication line (18) and each sensor, each sensor include position sensor (6), pressure sensor
(7), speed probe (9), flow sensor (10) and temperature sensor (11)；Acquisition processing device main body (1) front end
Embedded with display screen (2) and button (3), button (3) includes lathe external switch (12) and control button (16), acquisition processing device
Main body (1) front end is provided with data-interface (4), power interface (5)；The master controller (14) and display screen (2), position sensor
(6), pressure sensor (7), speed probe (9), flow sensor (10), temperature sensor (11), energy consumption detection circuit
(13), alarm (15), control button (16), memory cell (17), wireless communication line (18) are electrically connected with, memory cell
(17) it is electrically connected with data-interface (4)；The lathe external switch (12), energy consumption detection circuit (13) are spaced apart with injection machine
(8) it is electrically connected with.
3. a kind of injection machine state recognition as claimed in claim 1 and abnormity early warning method, it is characterised in that：The step 3
In state characteristics tree include injection machine state, Characteristics of Mutation and corresponding sensor states and energy consumption characters.
4. a kind of injection machine state recognition as claimed in claim 1 and abnormity early warning method, it is characterised in that：The step 3
In the acquisition methods of state characteristics tree comprise the following steps：
Step 1：By the external acquisition processing device of injection machine of required detection early warning, acquisition processing device is gathered and pre-processed each
Sensor signal；
Step 2：Completion is molded data acquisition and the injection machine state recording of experiment several times；
Step 3：Data analysis is carried out, excavates the Characteristics of Mutation between injection machine state；
Step 4：Injection machine Characteristics of Mutation is corresponding with sensor states and energy consumption characters, establish state characteristics tree；
Step 5：Optimal State characteristics tree：First carry out injection experiment, data acquisition, state recording；Corresponding state characteristics tree again,
Calculation error；Then whether error threshold is more than to judge whether to need to correct characteristics tree according to error, if so, amendment state is special
Re-optimization after sign tree, if it is not, terminating optimization, obtains final state characteristics tree.
5. a kind of injection machine state recognition as claimed in claim 1 and abnormity early warning method, it is characterised in that：The step 3
In the method for judging whether Characteristics of Mutation be：Slope between average, amplitude, extreme value by calculating continuous ten data,
Power consumption values, and above-mentioned data and existing Characteristics of Mutation are contrasted；The existing sensing of the Characteristics of Mutation between injection machine state
Device state and energy consumption characters.
6. a kind of injection machine state recognition as claimed in claim 1 and abnormity early warning method, it is characterised in that：The step 5
In energy consumption warning index to include odd-numbered day total energy consumption warning index, single product energy consumption warning index, batch products total energy consumption pre-
Alert index, idle energy consumption warning index.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| TWI785498B (en) * | 2020-07-31 | 2022-12-01 | 日商三菱重工業股份有限公司 | Diagnosis device, diagnosis method and diagnosis program of rotating machine |
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| CN200998906Y (en) * | 2007-01-08 | 2008-01-02 | 深圳市奥宇控制系统有限公司 | Energy-saving intelligent control system of injection machine |
| CN101362376A (en) * | 2008-09-11 | 2009-02-11 | 深圳市赛为智能股份有限公司 | Power-saving device of injection moulding machine |
| CN203141798U (en) * | 2012-12-30 | 2013-08-21 | 宁波弘讯科技股份有限公司 | Fault early warning system of injection molding machine |
| CN105334833A (en) * | 2015-11-26 | 2016-02-17 | 上海辰竹仪表有限公司 | Remote monitoring system for injection molding machine |
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2017
- 2017-06-08 CN CN201710429900.1A patent/CN107632196A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN200998906Y (en) * | 2007-01-08 | 2008-01-02 | 深圳市奥宇控制系统有限公司 | Energy-saving intelligent control system of injection machine |
| CN101362376A (en) * | 2008-09-11 | 2009-02-11 | 深圳市赛为智能股份有限公司 | Power-saving device of injection moulding machine |
| CN203141798U (en) * | 2012-12-30 | 2013-08-21 | 宁波弘讯科技股份有限公司 | Fault early warning system of injection molding machine |
| CN105334833A (en) * | 2015-11-26 | 2016-02-17 | 上海辰竹仪表有限公司 | Remote monitoring system for injection molding machine |
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| TWI785498B (en) * | 2020-07-31 | 2022-12-01 | 日商三菱重工業股份有限公司 | Diagnosis device, diagnosis method and diagnosis program of rotating machine |
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Application publication date: 20180126 |