CN110539463B - Temperature control device and temperature control method - Google Patents

Temperature control device and temperature control method Download PDF

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CN110539463B
CN110539463B CN201910449887.5A CN201910449887A CN110539463B CN 110539463 B CN110539463 B CN 110539463B CN 201910449887 A CN201910449887 A CN 201910449887A CN 110539463 B CN110539463 B CN 110539463B
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temperature
heating
medium
pipe
energization
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CN110539463A (en
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目次正明
荒木康也
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Matsui Universal Joint Manufacturing Co
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Matsui Universal Joint Manufacturing Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • B29C45/78—Measuring, controlling or regulating of temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76494—Controlled parameter
    • B29C2945/76531—Temperature

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

The invention provides a temperature control device (100) comprising: a medium temperature control unit (53) that controls the temperature of the medium by repeatedly turning on and off the heating pipes (815, 816, 817) that are provided on the outer periphery of the flow path pipes (811, 812, 813) through which the medium flows; and a heating pipe temperature control unit (52) that controls the temperature of the heating pipe (815, 816, 817) by adjusting the total time of the energization/shutdown time for each preset cycle or the energization/shutdown time for a period in which the preset cycle has elapsed a plurality of times. According to the present invention, it is possible to provide a temperature control device that suppresses the generation of scale stains and prevents overheating of a heater.

Description

Temperature control device and temperature control method
Technical Field
The present invention relates to a temperature control device and a temperature control method.
Background
In an injection molding machine for injection molding a product using a synthetic resin such as plastic, a mold is generally used. A mold for injection molding comprises: a cavity which is a space for filling the molten plastic, and a flow path pipe through which a medium for cooling and solidifying the molten plastic flows. In order to improve the precision of a molded product, a mold temperature adjusting device capable of accurately adjusting the temperature of a medium (mold) to a desired temperature is generally used.
Jp 2007-7950 a discloses a mold temperature control device including a heater in which a heating portion is immersed in a tank through which a medium flows, and the medium is heated by the heater during heating and cooled by cold water flowing from a water supply port through heat exchange during cooling, thereby controlling the temperature of the medium.
However, since the medium (usually water) usually contains inorganic salt compounds such as calcium, magnesium, and silica, when the heater is immersed in the medium, scale stains adhere to the surface of the heater.
The adhered scale stains are very stubborn and insoluble in water, and once adhered to the surface of the heater, the heat conductivity is reduced, and the heater is overheated, thereby causing failure. In addition, since the thermal conductivity is lowered, the heating of the medium is insufficient and the temperature of the medium is difficult to adjust.
The present invention has been made in view of the above problems, and an object thereof is to provide a temperature control device and a temperature control method for preventing overheating of a heater by suppressing generation of scale stains.
Disclosure of Invention
A temperature control device according to the present invention is a temperature control device for controlling a temperature of a medium circulated through an object via a pipeline, the temperature control device including: a medium temperature control unit that controls the temperature of the medium by repeatedly turning on and off a heating pipe provided on the outer periphery of a flow pipe through which the medium flows; and a heating pipe temperature control unit that controls the temperature of the heating pipe by adjusting the total time of the energization-off time for each preset cycle or the energization-off time for a period in which the preset cycle has elapsed a plurality of times.
A temperature control method according to the present invention is a temperature control method for controlling a temperature of a medium circulating through a pipe in an object, the temperature control method controlling the temperature of the medium by repeatedly turning on and off a heating pipe provided on an outer periphery of a flow path pipe through which the medium flows; and controlling the temperature of the heating pipe by adjusting the total time of the power-on closing time of each preset period or the power-on closing time of a period in which the preset period passes multiple times.
According to the present invention, it is possible to suppress the generation of scale stains and to prevent overheating of the heater.
Drawings
Fig. 1 is an explanatory view showing an example of the structure of a mold temperature adjusting machine of a temperature control device of the present embodiment;
fig. 2 is an external perspective view showing one example of the structure of the heating device of the present embodiment;
fig. 3 is an exploded perspective view showing an example of the structure of the heating device of the present embodiment;
fig. 4 is a front view showing an example of the structure of the heating device of the present embodiment;
fig. 5 is a model schematic view showing a main portion of a heating pipe wound around the outer periphery of a flow path pipe;
fig. 6 is a front view showing another example of the structure of the heating device of the present embodiment;
fig. 7 is an explanatory view showing an example of an operation mode of the heating apparatus;
FIG. 8 is a model diagram showing one example of the relationship between heater temperature and aggregate time of energization-off time;
fig. 9 is a model diagram showing an example of a change in heater temperature when the total time of the energization-off time is changed;
fig. 10 is a schematic model diagram showing a first example of a temperature control method by the mold temperature adjusting machine of the present embodiment;
FIG. 11 is a model diagram showing the relationship between the medium set temperature and the total time of the energization-off time;
FIG. 12 is a model diagram showing an example of a change in temperature of a medium;
fig. 13 is a schematic model diagram showing a second example of a temperature control method by the mold temperature regulator of the present embodiment;
FIG. 14 is a model diagram showing the relationship between the flow rate and the medium temperature difference between the inlet and the outlet of the heating device;
fig. 15 is a pattern diagram showing a relationship between a flow rate and a heater temperature;
FIG. 16 is a model diagram showing the relationship between the medium temperature difference between the inlet and the outlet of the heating device and the heater temperature;
FIG. 17 is a model diagram showing the relationship between the medium temperature difference between the inlet and the outlet of the heating device and the total time of the energization-off time;
fig. 18 is a flowchart showing an example of a processing procedure of the temperature control method of the mold temperature adjusting machine according to the present embodiment.
Detailed Description
The present invention will be described below with reference to the accompanying drawings showing specific embodiments of the present invention. Fig. 1 is an explanatory diagram showing an example of the structure of a mold temperature controller 100 of a temperature control device according to the present embodiment. In the present embodiment, the mold temperature controller 100 is described as an example of the temperature control device, but the temperature control device is not limited to the mold temperature controller. The mold temperature controller 100 is configured to control the temperature of the mold 200 (more specifically, the temperature of the medium supplied to the mold 200) as the target object.
As shown IN fig. 1, IN the mold temperature controller 100, a pipe line 11 (a feeding pipe line) is connected between an outlet side (OUT) of a pump 31 and an inlet side of a mold 200, a pipe line 12 (a returning pipe line) is connected between the outlet side of the mold 200 and an inlet side (IN) of the pump 31, and a medium (for example, water) is circulated IN the pipe lines 11 and 12 and a bypass pipe line 16 by the pump 31. That is, the pump 31 rotates the impeller at a high speed by the rotation of the motor in the casing, and circulates the medium through the pipes 11 and 12 and the bypass pipe 16 by the centrifugal force acting on the medium.
Near the outlet side of the pump 31 of the pipeline 11a pressure sensor 62 is arranged, which can measure the pressure of the medium near the outlet side of the pump 31. A heating device 80 is provided in the middle of the pipe 11 to heat the medium and raise the temperature of the medium. The thermostat 801 stops heating of the heating device 80 when a heating pipe (not shown) of the heating device 80 exceeds a preset temperature. Details of the heating device 80 will be described later.
A temperature sensor 71 is provided on the pipe line 11 on the upstream side of the heating device 80, and a temperature sensor 72 is provided on the pipe line 11 on the downstream side of the heating device 80. The temperature sensor 71 may detect the temperature of the medium on the upstream side of the heating device 80, and the temperature sensor 72 may detect the temperature of the medium on the downstream side of the heating device 80. The temperature sensor 73 can detect the surface temperature of the heating tube of the heating device 80. In this specification, the surface temperature of the heating pipe is also referred to as heater temperature.
The pipeline 11 is branched into 2 systems midway, and the branched pipelines 11 are connected to the inlet sides of the molds 200, respectively. The branched pipes 11 are provided with respective media supply valves 21 which can adjust the flow rates of the media in the branched pipes 11. Similarly, the line 12 is branched into 2 lines at the outlet side of the die 200, and the branched lines 12 are combined into 1 line 12 in the middle. The branched pipes 12 are respectively provided with a return valve 22 which can adjust the flow rate of the medium in each branched pipe 12.
A heat exchanger 40 is provided midway in the pipe line 12, and a cooling solenoid valve 23 is provided in the pipe line 12 on the outlet side of the heat exchanger 40. A bypass line 16 is provided between an appropriate position of the line 12 on the inlet side of the heat exchanger 40 (a position indicated by a reference symbol a in fig. 1, which is referred to as a branch point a) and an appropriate position of the line 12 on the outlet side of the cooling solenoid valve 23 (a position indicated by a reference symbol B in fig. 1, which is referred to as a branch point B).
The heat exchanger 40 has a cooling passage pipe 13a through which cooling water flows on one side and a medium passage pipe 12a through which a medium flows on the other side. Both ends of the cooling passage pipe 13a communicate with a cooling passage 13 through which cooling water is supplied. Both ends of the medium flow path pipe 12a communicate with the pipe 12. The heat exchanger 40 exchanges heat between the cooling water flowing through the cooling flow path pipe 13a and the medium flowing through the medium flow path pipe 12a, and cools the medium flowing through the medium flow path pipe 12a to adjust the temperature. In fig. 1, the mold temperature controller 100 is configured to include the heat exchanger 40, but the mold temperature controller 100 is not limited to the configuration of the example shown in fig. 1, and may be configured to directly supply water from the water supply port to the pipes 11 and 12 without including the heat exchanger 40 to cool the medium.
A pressure sensor 63 and an open spill valve are provided in the vicinity of the inlet side of the pump 31 in the pipe 12. The pressure sensor 63 is used to measure the pressure of the medium near the inlet side of the pump 31. A filter is provided in the pipe line 12 on the inlet side of the heat exchanger 40 (on the upstream side of the branch point a). The filter is used for removing solid components contained in the medium.
A pipe 14 is provided between the water supply port and a branch point B of the pipe 12. The water supply port side of the pipe 14 is provided with a filter and pressure sensor 61. The pressure sensor 61 is used to measure the feed water pressure. A check valve 26 is provided midway in the pipe line 14, and branch pipes 14a provided with a pressurizing pump 32 are connected to both sides of the check valve 26.
The booster pump 32 pressurizes the pressure of the medium in the lines 11, 12 and the bypass line 16 to a pressure higher than the saturated vapor pressure.
Further, a cooling pipe line 13 for branching the cooling water and flowing the cooling water to the heat exchanger 40 is connected to an upstream side of the pipe line 14 to which the branch pipe 14a is connected. The cooling line 13 is connected to one end of the cooling line pipe 13a on the inlet side of the heat exchanger 40. The cooling pipe 13 connected to the other end of the cooling pipe 13a on the outlet side of the heat exchanger 40 is connected to a drain port. A cooling water electromagnetic valve 25 is provided midway in the cooling line 13 connected to the drain port.
A drain line 15 connected to a drain port is connected to the line 12 between the heat exchanger 40 and the cooling solenoid valve 23. A drain solenoid valve 24 is provided midway in the drain line 15.
The mold temperature controller 100 includes a control unit 50. The control unit 50 includes: a valve opening/closing control section 51, a heating tube temperature control section 52, and a medium temperature control section 53. In the example of fig. 1, the heating-pipe temperature control unit 52 and the medium temperature control unit 53 are configured to be independent of each other, but the present invention is not limited to this configuration, and the heating-pipe temperature control unit 52 and the medium temperature control unit 53 may be configured to be combined into one temperature control unit. The heating tube temperature control unit 52 and the medium temperature control unit 53 can acquire temperature data detected by the temperature sensors 71, 72, and 73.
The valve opening/closing control unit 51 controls the opening and closing of the cooling solenoid valve 23, the drain solenoid valve 24, and the cooling water solenoid valve 25. The medium temperature control unit 53 controls the temperature of the medium to be increased in the heating step and to be decreased in the cooling step.
Hereinafter, an outline of the operation of the mold temperature controller 100 will be described. After the drain solenoid valve 24, the cooling solenoid valve 23, the medium feed valve 21, and the medium return valve 22 are opened, water as a medium is supplied from the water supply port, and air in the circulation flow path pipes such as the pipes 11 and 12 and the bypass pipe 16 is completely removed. Thereafter, the drain solenoid valve 24 is closed, and the medium is filled in the circulation flow path pipes such as the pipes 11 and 12 and the bypass pipe 16. The pressure pump 32 maintains the pressure of the medium in the circulation passage pipes such as the pipes 11 and 12 and the bypass pipe 16 at a saturated vapor pressure or higher corresponding to the temperature of the medium. In the heating control, the medium in the circulation passage such as the pipes 11 and 12 and the bypass pipe 16 is heated to a desired set temperature by the heating device 80. In the cooling control, the temperature of the medium in the circulation passage such as the bypass passage 16 is cooled to a desired set temperature by the heat exchanger 40 or by directly supplying water from a water supply port into the circulation passage. The temperature of the medium in the circulation flow path pipes such as the pipes 11 and 12 and the bypass pipe 16 (that is, the temperature of the medium in the mold 200) can be adjusted (controlled) to a desired set temperature (at the time of stabilization) by the heating operation and the cooling operation of the heating device 80.
The heating device 80 will be described in detail below. The heating device 80 may be composed of 1 or more heating units.
Fig. 2 is an external perspective view showing an example of the structure of the heating device 80 of the present embodiment, fig. 3 is an exploded perspective view showing an example of the structure of the heating device 80 of the present embodiment, and fig. 4 is a front view showing an example of the structure of the heating device 80 of the present embodiment. In addition, the heating device 80 shown in the examples of fig. 2, 3, and 4 is constituted by 1 heating unit. In addition, for convenience of explanation, fig. 4 shows an internal structure of the heating device.
The heating device 80 (heating means) forms a medium flow path by a flow path pipe 811 (1 st flow path pipe), a flow path pipe 812 (2 nd flow path pipe), a flow path pipe 813 (3 rd flow path pipe) which are arranged in parallel with a predetermined gap therebetween, and manifolds 84 and 85 provided at both ends of the flow path pipes 811, 812, and 813. 2 heating pipes 815, 815 are wound around the outer periphery of the flow pipe 811 at appropriate intervals along the flow direction of the flow pipe 811. 2 heating pipes 816 and 816 are wound around the outer periphery of the flow pipe 812 at appropriate intervals in the flow direction of the flow pipe 812. 2 heating pipes 817, 817 are wound around the outer periphery of the flow path pipe 813 at appropriate intervals in the flow direction of the flow path pipe 813.
The heating pipes 815, 816, 817 may be configured such that a heating element such as a nichrome wire is covered with a metal pipe through an insulator, and are also called as a heating wire heater (Sheath heater).
The manifold 84 has formed therein: an inlet/outlet pipe 841 for allowing the medium to flow into/out of the inlet of the heating unit; and a communication pipe 842 for communicating the ends of the 2 flow path pipes. In addition, the manifold 85 has formed therein: an inlet/outlet pipe 851 serving as an inlet port through which the medium flows to the heating unit or an outlet port through which the medium flows out of the heating unit; and a communication pipe 852 communicating the ends of the 2 flow path pipes.
That is, an inlet port (inlet/outlet pipe 851) is provided at one end 811a of the flow pipe 811, the other end 811b of the flow pipe 811 is communicated with one end 812b of the flow pipe 812 via the communication pipe 842 (first communication pipe), the other end 812a of the flow pipe 812 is communicated with one end 813a of the flow pipe 813 via the communication pipe 852 (second communication pipe), and an outlet port (inlet/outlet pipe 841) is provided at the other end 813b of the flow pipe 813. The medium flows in from the inlet (inlet/outlet pipe 851), flows in the passage pipes 811, 812, and 813, and then flows out from the outlet (inlet/outlet pipe 841). The medium flowing through the flow pipes 811, 812, 813 is heated by the heating pipes 815, 516, 817.
2 leads are led out from both ends of the heating tube 815, and the 2 leads can be connected to, for example, a U terminal and a V terminal of three-phase alternating current. 2 leads are led out from both ends of the heater tube 816, and the 2 leads can be connected to, for example, a V terminal and a W terminal of three-phase alternating current. 2 leads are led out from two ends of the heating tube 817, and the 2 leads can be connected with a W terminal and a U terminal of three-way alternating current, for example. With this configuration, each set of phase currents of the three-phase ac power can be applied to any one of the heating pipes 815, 816, 817 according to the current applied thereto, so that the configuration can be applied to the three-phase ac power.
The covers 81 are attached to the rear surface side and the covers 82 and 83 are attached to the front surface side so as to cover the flow pipes 811, 812, and 813 around which the heating pipes 815, 516, and 817 are wound, respectively. Gaps through which the lead wires of the heating pipes 815, 516, 817 can be led out are formed between the cover 82 and the cover 83, between the cover 82 and the manifold 84, and between the cover 83 and the manifold 85, respectively. Heat insulating materials (not shown) are provided between the heating pipes 815, 516, 817 and the inner surfaces of the covers 81, 82, 83. This heat insulating material can suppress heat release from the heating pipes 815, 516, 817 to the outside, and can transfer the heat to the flow pipe 811, 812, 813 side.
Further, 3 flow path pipes 811, 812, 813 are arranged in parallel in the flow direction, and the effective lengths of the heating pipes 815, 516, 817 in the flow direction can be increased without increasing the outer diameter of the heating unit by forming a flow path for the medium by the manifolds 84, 85 arranged at both ends of each of the flow path pipes 811, 812, 813, thereby achieving a reduction in the size of the heating unit.
Fig. 5 is a schematic diagram showing a model showing a main part of the heating pipe 817 wound around the outer periphery of the flow path pipe 813. Since the other heating pipes 815 and 816 have the same structure, the description thereof is omitted. As shown in fig. 5, the heating tubes 817 have an outer diameter Φ that is smaller than the pitch p between adjacent heating tubes 817 (Φ < p). That is, the heating pipes 817 are not densely arranged, and the heating pipes 817 adjacent to each other on the outer periphery of the flow path pipe 813 are wound around the outer periphery of the flow path pipe 813 with a certain gap therebetween. By providing the gap, the heating pipe 817 can be prevented from being overheated.
The outer diameter φ of the heating pipes 815, 816, 817 may be set to 5mm or less. As a result, when the heating pipes 815, 816, 817 are wound around the outer peripheries of the flow path pipes 811, 812, 813 having a specific length, the number of windings can be increased, and the areas of the outer peripheries of the flow path pipes 811, 812, 813, which are in contact with the heating pipes 815, 816, 817 can be increased, so that the heat of the heating pipes 815, 816, 817 can be efficiently transferred to the medium through the flow path pipes 811, 812, 813.
The heating pipes 815, 816, 817 are wound in a coil form with an inner diameter smaller than the outer diameter of the flow pipe 811, 812, 813, and the flow pipe 811 is inserted into the inner surface of the coil-wound heating pipe 815. The heating pipe 815 inserted into the flow pipe 811 has elasticity, and therefore, applies a force that decreases toward the inner center in the radial direction, and the heating pipe 815 is brought into close contact with the flow pipe 811, thereby transferring the heat of the heating pipe 815 to the flow pipes 811, 812, and 813. The other heating pipes 816 and 817 are formed in the same structure.
In addition, the heating pipes 815, 816, 817 may be welded to the flow path pipes 811, 812, 813. In this manner, the heat of the heating pipes 815, 816, 817 can be further transferred to the flow path pipes 811, 812, 813.
The power density of the heating unit may be set to 10W/cm 2 The following. The power density here refers to the electrical load (W) per unit area (1 cm square) of the heating pipes 815, 816, 817. For example, when the outer diameter of the heating pipes 815, 816, 817 is Φ, the effective length of the wound heating pipes 815, 816, 817 in the flow direction is L, and the electric power is W, the power density is represented by W/(Φ × pi × L). By setting the power density to 10W/cm 2 Hereinafter, overheating of the heating pipes 815, 816, 817 can be prevented.
Fig. 6 is a front view showing another example of the structure of the heating device 80 of the present embodiment. In the example of fig. 6, the heating unit 80 is constituted by 2 heating units. As shown in fig. 6, the manifold 84 of the heating unit on one side and the manifold 85 of the heating unit on the other side are connected by a connecting pipe 86.
The heating unit may be connected in plurality. With this configuration, the medium temperature can be adjusted to a set temperature by connecting only a required number of heating units according to the size of the heating capacity of the heating apparatus 80, and at the same time, since the heating units having the same configuration are used, it is not necessary to increase the kinds of parts due to the need of the heating capacity, so that the cost can be reduced.
Further, as shown in fig. 6, the configuration in which 2 heating units are connected is not provided in the long flow direction, but 2 heating units are arranged in the direction perpendicular to the flow direction, so that the outer diameter of the heating device 80 can be suppressed from increasing, and the device can be miniaturized. In addition, the number of connectable heating units is not limited to 2. For example, 3 or more may be used. When 3 or 4 heating units are connected, they may be disposed on the back side of 2 heating units, for example. In this case, a U-shaped connection pipe may be used.
The operation of the heating device 80 will be described below. Specifically, the operation of the heating device 80 is controlled by the heating-tube temperature control unit 52 and the medium temperature control unit 53.
The medium temperature control unit 53 controls the temperature of the medium by repeatedly turning on or off the energization of the heating pipes 815, 516, 817 provided on the outer peripheries of the flow path pipes 811, 812, 813 (for example, at a predetermined cycle). Since the heating pipes 815, 516, 817 are disposed on the outer peripheries of the flow path pipes 811, 812, 813, the medium does not contact the heating pipes 815, 516, 817, and thus scale stains do not adhere to the surfaces of the heating pipes 815, 516, 817. This prevents the heat transfer rate of the heating device 80 from decreasing.
The above-mentioned preset period may also be referred to as a proportional period. In the following description, the term proportional period is used. The proportional period may be set to 1 second, 2 seconds, or the like, for example. When the temperature of the medium is higher than the set temperature, the medium temperature control unit 53 adjusts the cooling medium energization on-time, which is the cooling medium on-time in the proportional cycle of the cooling step, to be longer (for example, from 5 seconds to 8 seconds) and controls the temperature of the medium to be lowered. When the temperature of the medium is lower than the set temperature, the medium temperature control unit 53 adjusts the energization-off time in the proportional cycle of the heating step to be shorter (for example, from 0.1 second to 0.05 second) and controls the temperature of the medium to be increased. The adjustment of the power-on off time is performed every proportional period. The desired temperature range including the set temperature of the medium may be referred to as a proportional band, and the proportional band may be, for example, ± 10 ℃ of the set temperature or ± 5 ℃ of the set temperature.
When the temperature of the medium is higher than the set temperature, the cooling operation is performed by the heat exchanger 40. For example, by performing the opening and closing operation of the cooling solenoid valve 23, the medium maintained in a relatively low temperature state in the medium flow path pipe 12a of the heat exchanger 40 is made to flow through the pipes 12 and 11 and the bypass pipe 16 while the cooling solenoid valve 23 is opened only for a required time, whereby the temperature of the medium can be lowered. Further, by opening the cooling water electromagnetic valve 25 only for a required time at a required time point, the cooling water from the water supply port is made to flow to the cooling flow path pipe 13a of the heat exchanger 40, so that the temperature of the medium flow path pipe 12a of the heat exchanger 40 can be maintained at a predetermined temperature (for example, 80 ℃).
The heating pipe temperature control unit 52 may also control the temperature (surface temperature) of the heating pipes 815, 516, 817 of the heating device 80. Specifically, the heating pipe temperature control unit 52 controls the temperatures of the heating pipes 815, 516, 817 by adjusting the energization/shutdown time of each proportional cycle or adjusting the total energization/shutdown time of a period in which the proportional cycle has elapsed a plurality of times. The period during which the proportional period passes through a plurality of times is also referred to as a control period.
More specifically, the heating pipe temperature control unit 51 controls the temperatures of the heating pipes 815, 516, 817 by adjusting the total time of the energization/shutdown time for a period in which the Proportional cycle of the PID control (Proportional-Integral-Differential Controller) has elapsed a plurality of times. The PID control is to control the energization/shutdown time as a linear function of the deviation between the actual temperature of the medium and the target temperature by the medium temperature control of the medium temperature control unit 53. In this way, the temperature of the heating pipes 815, 516, 817 can be prevented from exceeding the upper limit temperature, and overheating of the heating pipes 815, 516, 817 can be prevented.
Fig. 7 is an explanatory diagram showing one example of the operation mode of the heating device 80. Here, when the proportional period is T and the number of proportional periods (also referred to as the number of cycles) is n, the control period can be represented as n × T. The number of cycles n may be, for example, 15 cycles, but is not limited thereto, and may be 10 cycles, 20 cycles, or 30 cycles. In the following description, the proportional period T is 1 second, and the number of cycles n is 15. So that the control period is 15 seconds.
As shown in fig. 7, the total time Dn of the energization-off times in the control cycle is represented by the following general formula (1) when the energization-off times are d1, d2, … and Dn respectively for the cycle numbers 1, 2, … and n.
Figure 927334DEST_PATH_IMAGE001
The total time Dn of the energization-off time in the control cycle may be represented by the general formula (2) instead of the general formula (1). Here, di means the energization-off time satisfying the general formula (3). In the general formula (3), dmin means the minimum energization-off time. That is, the total time Dn of the energization-off times in the control cycle may be set to a total time of energization-off times equal to or longer than the minimum energization-off time dmin among energization-off times in the proportional cycles. In other words, the energization-off time smaller than the minimum energization-off time dmin is excluded from the extraneous calculation to find the total time.
The heating pipe temperature control unit 52 may adjust the total time Dn to be longer when the temperatures of the heating pipes 815, 516, 817 become higher, so that the temperatures of the heating pipes 815, 516, 817 approach the target temperatures. In this way, the temperature of the heating pipes 815, 516, 817 can be prevented from exceeding the upper limit temperature, and overheating of the heating pipes 815, 516, 817 can be prevented.
As shown in fig. 7, the medium temperature control unit 53 may operate the heating device 80 in the continuous energization mode (1 st control mode) and the on/off energization mode (2 nd control mode). The continuous energization mode is a mode in which the heating pipes 815, 516, 817 are continuously energized in a state in which the energization off time of each proportional cycle is 0. The on/off energization mode is a mode in which energization to the heating pipes 815, 516, 817 is repeatedly switched on or off at a proportional cycle. In the present specification, the case where the energization time is 0 is also included in the on/off energization mode in the proportional period of 1 or more control periods.
When the medium temperature is heated from the heating start temperature (for example, 20 ℃ or the like) to the set temperature (for example, 180 ℃ or the like), the medium temperature control section 53 may adopt the continuous energization mode. In addition, the medium temperature control unit 53 may adopt an on/off energization mode when the medium temperature is maintained at the set temperature. In addition, the medium temperature control unit 53 may adopt an on/off energization mode when the medium temperature is heated from the heating start temperature to the set temperature.
Hereinafter, a method of setting the total time Dn of the energization-off time in the control cycle (n × T) will be described in detail. For convenience of description, the temperatures of the heating pipes 815, 516, 817 are referred to as heater temperatures.
Fig. 8 is a model diagram showing an example of the relationship between the heater temperature and the total time of the energization-off time Dn. In fig. 8, the vertical axis represents temperature, and the horizontal axis represents time. The minimum flow rate of the medium in the mold temperature adjusting machine 100 was 10L/min, and the maximum flow rate was 65L/min. When the flow rate of the medium is the minimum flow rate, the heat transfer amount from the heating pipes 815, 516, 817 to the medium is small, and therefore the heater temperature is the highest, and the total time Dn of the control cycle or the energization off time is likely to be affected. Thus, in the example of FIG. 8, the flow rate is a minimum flow rate of 10L/min. The set temperature of the medium was 180 ℃. The proportional period T is 1 second, the number of cycles is 15, and the control period is 15 seconds. Fig. 8 is a graph showing changes in the heater temperature when the heater temperature is set to the initial temperature (for example, 290 ℃ as the target temperature), the power supply to the heater is set to the continuous power supply (power supply off time = 0), and the total time Dn of the power supply off time in the control cycle is set to 0.25 second, 0.5 second, and 1.0 second, respectively. In fig. 8, for convenience of explanation, the heater temperature when the energization-off time is set to the highest temperature.
When the current is continuously applied, the heater temperature rises from the initial temperature, and the temperature continues to rise to a very high temperature. When the total time Dn =0.25 seconds, the heater temperature gradually increases from the initial temperature, and after increasing to a higher temperature, the heater temperature becomes stable. When the total time Dn =0.5 seconds, the heater temperature is substantially maintained at the initial temperature and stabilized. When the total time Dn =1.0 second, the heater temperature gradually decreases from the initial temperature to a slightly lower temperature, and then the heater temperature becomes stable.
Fig. 9 is a model diagram showing an example of the change in the heater temperature when the total time Dn of the energization-off time is changed. In fig. 9, the vertical axis represents temperature, and the horizontal axis represents time. Fig. 9A shows a state of change in the heater temperature in the case where the total time Dn =0.5 seconds. When the total time Dn =0.5 seconds, the total time of the on-time is 14.5 seconds and the total time of the off-time is 0.5 seconds in the control cycle. It is seen that when the total time Dn =0.5 seconds, the heater temperature at the first (starting point) of the control cycle is approximately the same as the heater temperature at the last (ending point), and the heater temperature stably changes in a state in which no rising tendency or falling tendency is exhibited.
Fig. 9B shows a state of change in the heater temperature in the case where the total time Dn =0.25 seconds. When the total time Dn =0.25 seconds, the total time of the on time is 14.75 seconds and the total time of the off time is 0.25 seconds in the control cycle. It is seen that when the total time Dn =0.25 seconds, the heater temperature at the final (end) becomes higher than the heater temperature at the first (start) of the control cycle, and the heater temperature gradually rises and then becomes stable.
Fig. 9C shows a state of change in the heater temperature in the case where the total time Dn =1.0 second. When the total time Dn =1.0 second, the total time of the on-time is 14.0 seconds and the total time of the off-time is 1.0 second in the control cycle. It can be seen that when the total time Dn =1.0 second, the heater temperature at the final (end) of the control cycle becomes lower than the heater temperature at the first (start) of the control cycle, and the heater temperature gradually decreases and then becomes stable.
In order to prevent overheating of the heating pipes 815, 516, 817, the heater temperature needs to be maintained at the target temperature in the on/off energization mode, and it is generally desirable that the heater temperature steadily shifts or shifts with a decreasing tendency. Further, if the heater temperature can be maintained at the target temperature when the heater temperature is required to be the maximum temperature (for example, the medium flow rate is the minimum flow rate), the heater temperature does not rise above the target temperature even if the medium flow rate varies. Therefore, the total time Dn of the energization-off times in the control cycle is preferably 0.5 seconds or more in general.
In addition, the same results were obtained even if the comparative example period T and the number of cycles n were changed.
The heating tube temperature control unit 52 may set the total time of the energization/shutdown times of the control cycle in which the proportional cycle passes a predetermined number of times (cycle number) to be one-half or more of the proportional cycle. When the proportional period is T and the number of cycles is n, the total time Dn of the energization/shutdown time of the control period (n × T) may satisfy the following general formula (4).
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For example, as described above, when the proportional period T is 1 second and the number of cycles is 15, the total time Dn of the energization-off time may be set to 0.5 seconds or more. Similarly, when the number of cycles is 10 or 20, for example, the total time Dn of the energization-off time may be set to 0.5 seconds or more. When the proportional period T is, for example, 2 seconds, the total time Dn of the energization-off time may be set to be slightly longer than 0.5 seconds, for example, 1 second or more.
With the above configuration, when the temperature of the medium is maintained at the set temperature, the temperature of the heating pipes 815, 516, 817 can be maintained at the target temperature higher than or close to the set temperature of the medium, and the temperature of the heating pipes 815, 516, 817 can be set to the optimum temperature.
The heating pipe temperature control unit 52 may set the total time Dn during which the energization-off time of the control cycle is 10% or more of the proportional cycle to one-half or more of the proportional cycle. For example, when the proportional period T is 1 second and the energization-off time is less than 10% of the proportional period T, that is, the energization-off time is less than 0.1 second, the temperature of the heating pipes 815, 516, 817 is controlled to be too short, and thus the effect of reducing the temperature of the heating pipes 815, 516, 817 cannot be obtained. The energization-off time corresponding to 10% of the proportional period T is the minimum energization-off time dmin in the general formula (3).
At this time, by setting the total time Dn of the energization shut-off times to 10% or more of the proportional cycle to one-half or more of the proportional cycle, the temperature of the heating pipes 815, 516, 817 can be accurately maintained at the target temperature or a temperature close to the target temperature.
The heating tube temperature control unit 52 has a function as an output unit, and can output a warning when the total time Dn of the energization-off times of the control cycle, which is equal to or longer than 10% of the proportional cycle, is less than half of the proportional cycle. The output of the warning reminder can be sound, can be characters or figures, and can also be the lightening or flashing of a display lamp.
When the total time Dn of the energization-off times equal to or longer than 10% of the proportional cycle is less than one-half of the proportional cycle, the tube temperature control unit 52 may adjust the energization-off times to an extremely short time or continuously energize the heating tubes 815, 516, 817 so that the temperatures of the heating tubes approach the target temperatures. This state is a state in which the heating pipes 815, 516, 817 are insufficiently heated, and there is a risk that stable temperature control cannot be performed. Thus, by outputting a warning alert, the user may be notified that there is a failure in the heating control of the heating pipes 815, 516, 817.
As described above, by setting the total time Dn of the energization-off time of the control cycle to be equal to or more than one-half of the proportional cycle, the heater temperature changes with the temperature of the medium, regardless of whether the temperature of the medium is raised to the set temperature (heating control) or the temperature of the medium is maintained at the set temperature (at the time of stabilization).
That is, the heating pipe temperature control unit 52 can control the temperature of the heating pipes 815, 516, 817 based on the set temperature of the medium. The total time Dn of the energization/shutdown time of the control cycle is adjusted by utilizing a characteristic that the temperature of the heating pipes 815, 516, 817 changes at a temperature higher than the temperature of the medium, for example, such that the temperature of the heating pipes 815, 516, 817 is higher than the set temperature of the medium by a required temperature. Thus, the temperature of the heating pipes 815, 516, 817 can be set to the optimum temperature according to the set temperature of the medium.
Fig. 10 is a schematic model diagram showing a first example of a method for controlling temperature by the mold temperature controller 100 of the present embodiment. In fig. 10, the vertical axis represents temperature, and the horizontal axis represents time. The heating control is performed from time 0 to time ts (during temperature rise), and the time ts and thereafter is indicated as a stationary period. In the heating control, the medium temperature control unit 53 starts heating the medium from the initial heating temperature (for example, 20 ℃) to the set temperature (for example, 180 ℃) in the continuous energization mode. At this time, the heater temperature rises together with the temperature of the medium.
After the temperature of the medium reaches the set temperature at time ts, the medium temperature control unit 53 adjusts the on/off time of each proportional cycle in the on/off energization mode to maintain the temperature of the medium at the set temperature. In addition, after the time ts, the cooling solenoid valve 23 and the cooling water solenoid valve 25 are opened for only a preset time at a desired point of time to perform a cooling operation of the medium.
The heating tube temperature control unit 52 can control the heater temperature based on the set temperature of the medium by setting the total time Dn of the energization/shutdown time of the control cycle to be equal to or more than one half of the proportional cycle. For example, in the example of fig. 10, the heater temperature at which the flow rate of the medium is 30L/min is shown. The heater temperature gradually increases toward the upper limit of the heater temperature when the flow rate of the medium becomes the minimum flow rate, and gradually decreases toward the lower limit of the heater temperature when the flow rate of the medium becomes the maximum flow rate.
The heating tube temperature control unit 52 adjusts the total time Dn of the energization-off times of the control cycle so that the heater temperature is equal to or higher than the heater temperature lower limit value (lower limit temperature) and equal to or lower than the heater temperature upper limit value (upper limit temperature). The lower limit temperature is a temperature higher than the set temperature of the medium by a first temperature T1, and the upper limit temperature is a temperature higher than the set temperature of the medium by a second temperature T2.
In this way, the heater temperature can be set to a temperature between the lower heater temperature limit and the upper heater temperature limit. For example, by setting the upper limit of the heater temperature to a temperature that does not reach a temperature (for example, 400 ℃) that affects the service life of the heating pipes 815, 516, 817, it is possible to prevent the expected service life of the heating pipes 815, 516, 817 from becoming short. Further, the lower limit of the heater temperature is set to a temperature higher than a temperature that affects a temperature rise time for raising the temperature of the medium to the set temperature, thereby preventing the temperature rise time of the medium from being longer than an expected time.
For example, the first temperature T1 may be set to 50 ℃, and the second temperature T2 may be set to 120 ℃. When the first temperature T1 is less than 50 c, the temperature rise time of the medium may be longer than expected. In addition, when the second temperature T2 is higher than 120 ℃, the life expectancy of the heating pipes 815, 516, 817 is shortened. With the above configuration, regardless of the set temperature of the medium, it is possible to prevent the reduction in the expected life of the heater pipes 815, 816, 817 and the increase in the temperature of the medium from becoming longer than expected.
Fig. 11 is a model diagram showing a relationship between the medium set temperature and the total time Dn of the energization-off time. In fig. 11, the vertical axis represents temperature, and the horizontal axis represents time. As shown in fig. 11, when the total time Dn of the energization/shutdown time of the control cycle is set to 0.5 second when the set temperature of the medium is 18 ℃, the temperature of the heating pipes 815, 516, 817 similarly rises and may exceed the heater temperature upper limit value when the set temperature of the medium rises as high as 200 ℃ and 250 ℃, and therefore, the temperature of the heating pipes 815, 516, 817 can be set to be equal to or lower than the heater temperature upper limit value by adjusting the total time Dn of the energization/shutdown time to be slightly longer than 0.5 second (for example, 0.6 second, 0.7 second, 1.0 second, and the like).
As described above, the heating pipe temperature control unit 52 may set the total time Dn of the energization/shutdown time of the control cycle to be equal to or more than one-half of the proportional cycle T in accordance with the set temperature of the medium. Specifically, as the set temperature of the medium becomes higher, the total time Dn of the energization-off time can be adjusted to be longer correspondingly.
With the above configuration, the temperatures of the heating pipes 815, 516, 817 can be maintained at the target temperatures higher than or close to the set temperatures of the medium in accordance with the set temperatures of the medium, and the temperatures of the heating pipes 815, 516, 817 can be set to the optimum temperatures.
The operation mode of the heating device 80 during heating (during temperature rise) will be described below.
Fig. 12 is a model diagram showing an example of a change in temperature of a medium. In fig. 12, the vertical axis represents temperature, and the horizontal axis represents time. In fig. 12, a line (broken line) denoted by reference character a indicates a case where the continuous energization mode is adopted during the temperature rise of the medium from the temperature before the start of heating (for example, 20 ℃) to the set temperature (180 ℃ in the example of fig. 12), and the on-off energization mode is adopted after the temperature of the medium reaches the set temperature. On the other hand, a line denoted by reference numeral B (a solid line indicates a case where the continuous energization mode is adopted in a process in which the medium is heated from the temperature before the start of heating (for example, 20 ℃) to the preset temperature (120 ℃ in the example of fig. 12), and then the on-off energization mode is adopted.
As shown in fig. 12, in the graph denoted by reference numeral B, the time at which the temperature of the medium reaches the set temperature is ts1, in the graph denoted by reference numeral a, the time at which the temperature of the medium reaches the set temperature is ts2, and ts1= ts2+ Δ ts. The time difference Δ ts varies with the preset temperature, and is, for example, about 5 seconds to 10 seconds. That is, the time difference Δ ts is small when the preset temperature is high, and the time difference Δ ts is large when the preset temperature is low.
If it is desired that the temperature rise time required for raising the temperature of the medium to the set temperature is as short as possible (for example, if the time difference Δ ts can be allowed), the continuous energization mode may be adopted while the medium is being raised from the temperature before the start of heating to the set temperature, and the on/off energization mode may be adopted after the temperature of the medium reaches the set temperature, as shown by reference character a. In addition, if the temperature rise time during the temperature rise of the medium to the set temperature is sufficiently long, not only the mode shown by reference numeral a but also the continuous energization mode during the temperature rise of the medium from the temperature before the start of heating to the set temperature and thereafter the on/off energization mode may be adopted as shown by reference numeral B.
Fig. 13 is a schematic model diagram showing a second example of the temperature control method performed by the mold temperature controller 100 of the present embodiment. In fig. 13, the vertical axis represents temperature, and the horizontal axis represents time. In the heating control (during temperature rise) in which the temperature of the medium is raised to the set temperature from time 0 to time ts, a stationary period follows time ts. The set temperature of the medium shown in the example of fig. 13 is higher (e.g., 250 deg.c, etc.) as compared to the example of fig. 10.
The medium temperature control unit 53 may switch to the on/off power mode when the heater temperature is raised to a preset temperature in the continuous power mode. In the example of fig. 13, at time t1 when the heater temperature reaches the preset temperature (time shorter than the temperature rise time ts to reach the set temperature of the medium), the medium temperature control section 53 switches from the continuous energization mode to the on/off energization mode.
As shown in fig. 13, since the heater temperature changes at a higher level than the temperature of the medium, when the set temperature of the medium is high (for example, 250 degrees celsius or the like), the heater temperature also becomes higher, and if the continuous energization mode is continued even after time t1, the heater temperature may exceed the allowable heater temperature (upper limit heater temperature).
Therefore, by setting a preset temperature (for example, the target temperature of the heating pipes 815, 516, 817 may be set, or the lower limit temperature may be set), when the temperature of the heating pipes 815, 516, 817 is raised to the preset temperature, by switching from the continuous energization mode to the on/off energization mode, the time for the medium to be raised to the set temperature can be shortened, and overheating of the heating pipes 815, 516, 817 can be prevented. In addition, the preset temperature may be appropriately set according to factors such as the set temperature of the medium and the allowable temperature of the heater.
Hereinafter, a method of estimating the flow rate of the medium based on the medium temperatures on the upstream side of the heating pipes 815, 516, 817 and the medium temperatures on the downstream side of the heating pipes 815, 516, 817 and controlling the temperatures of the heating pipes 815, 516, 817 based on the estimated flow rate will be described.
Fig. 14 is a model diagram showing the relationship between the flow rate and the medium temperature difference between the inlet and the outlet of the heating device 80. In fig. 14, the vertical axis represents temperature, and the horizontal axis represents flow rate. Fig. 14 is a graph showing a state where the temperature of the medium is 180 ℃ and the total time Dn of the energization/shutdown time in the control cycle is 0.5 seconds.
In the medium circulation line including the flow path in the mold 200, a temperature gradient is conspicuously located between the inlet and the outlet of the mold 200 and between the upstream side and the downstream side of the heating pipes 815, 516, 817, and therefore, the medium temperature on the upstream side of the heating pipes 815, 516, 817 corresponds to the outlet temperature (the return side) of the mold 200, and the medium temperature on the downstream side of the heating pipes 815, 516, 817 corresponds to the inlet temperature (the feed side) of the mold 200. As shown in fig. 14, when the flow rate of the medium is small, the temperature of the medium after heat exchange in the mold 200 is high, and therefore, the temperature gradient between the inlet and the outlet of the mold 200 is large, and the temperature difference detected by the temperature sensors 71 and 72 is also large. Further, when the flow rate of the medium is large, the temperature of the medium after heat exchange in the mold 200 is low, so that the temperature gradient between the inlet and the outlet of the mold 200 is small, and the temperature difference detected by the temperature sensors 71 and 72 is also small.
Fig. 15 is a schematic diagram showing a relationship between the flow rate and the heater temperature. In fig. 15, the vertical axis represents temperature, and the horizontal axis represents flow rate. Fig. 15 is a graph showing a state where the set temperature of the medium is 180 ℃ and the total time Dn of the energization/shutdown time of the control cycle is 0.5 second.
As shown in fig. 15, when the flow rate of the medium is small, the heat amount for heating the medium requires only a small amount of heat, and thus the heat exchange is poor and the heater temperature is high. When the flow rate of the medium is large, the heat quantity for heating the medium needs to be large, and the rise of the heater temperature with good heat exchange is suppressed.
Fig. 16 is a model diagram showing a relationship between a medium temperature difference between an inlet and an outlet of the heating device 80 and a heater temperature. In fig. 16, the vertical axis represents temperature, and the horizontal axis represents flow rate. Fig. 16 is a graph showing a state where the set temperature of the medium is 180 ℃ and the total time Dn of the energization/shutdown time in the control cycle is 0.5 second. The graph shown in fig. 16 is a graph obtained by overwriting the graphs shown in fig. 14 and 15.
As shown in fig. 16, when the temperature difference between the medium temperature on the downstream side and the medium temperature on the upstream side of the heating pipes 815, 516, 817 is large, the flow rate of the medium is small, and the heater temperature is increased. When the temperature difference between the medium temperature on the downstream side and the medium temperature on the upstream side of the heating pipes 815, 516, 817 is small, it can be seen that the flow rate of the medium is large and the heater temperature is low.
Fig. 17 is a model diagram showing a relationship between a medium temperature difference between an inlet and an outlet of the heating device 80 and a total time of the energization-off time. In fig. 17, the vertical axis represents temperature, and the horizontal axis represents time. As shown in fig. 17, when the temperature difference between the downstream medium temperature and the upstream medium temperature of the heating pipes 815, 516, 817 is large, the flow rate of the medium is small, and the temperatures of the heating pipes 815, 516, 817 rise, so that the total time of the energization off time can be made long. On the other hand, when the temperature difference between the downstream medium temperature and the upstream medium temperature of the heating pipes 815, 516, 817 is small, the flow rate of the medium is large, and the temperatures of the heating pipes 815, 516, 817 are low, so that the total time of the energization-off time can be made short. In this way, the flow rate of the medium can be estimated based on the medium temperature difference, and the temperature of the heating pipes 815, 516, 817 can be accurately maintained at the target temperature or a temperature close to the target temperature.
Fig. 18 is a flowchart showing an example of a processing procedure of the temperature control method of the mold temperature adjusting machine 100 according to the present embodiment. For convenience of explanation, the following description will be made by combining the heating-tube temperature control unit 52 and the medium temperature control unit 53 as a single temperature control unit. The temperature control unit starts heating the medium in a continuous energization mode (S11), and determines whether or not the heater temperature reaches a preset temperature (S12). If the heater temperature does not reach the preset temperature (NO in S12), the temperature control part judges whether the temperature of the medium reaches the set temperature (S13).
If the temperature of the medium does not reach the set temperature (NO in S13), the temperature control unit continues the processing of step S12 and thereafter, and if the temperature of the medium reaches the set temperature (YES in S13), the processing of step S14 described below is performed. When the heater temperature reaches the preset temperature (YES in S12), the temperature control section sets the total time of the energization OFF time of the control cycle to the preset value (S14). For example, when the proportional period T is 1 second, the number of cycles is 15, the set temperature of the medium is 180 ℃, and the flow rate of the medium is the minimum flow rate, the total time Dn of the energization-off time may be set to 0.5 second.
The temperature control unit switches from a continuous power-on mode to an on/off power-on mode (S15), and determines whether or not a temperature difference between the heater temperature and the temperature of the medium is within a preset range (S16). The preset range may be, for example, a first temperature T1 or higher and a second temperature T2 or lower. When the temperature difference is not within the preset range (NO in S16), the temperature control unit adjusts the total time of the energization-off time (S17), and executes the processing in step S18 described below. For example, when the temperature difference exceeds the second temperature T2, the total energization-off time may be increased.
If the temperature difference between the heater temperature and the medium temperature is within the preset range (YES in S16), the temperature control unit determines whether the medium temperature reaches the set temperature (S18). If the temperature of the medium does not reach the set temperature (NO in S18), the temperature control unit continues the processing of and after step S16, and if the temperature of the medium reaches the set temperature (YES in S18), it is determined whether the control is finished (S19). If the control has not been completed (NO in S19), the temperature control unit continues the processing in and after step S16, and if the control has been completed (YES in S19), the processing is terminated.
According to the above embodiment, it is possible to prevent a malfunction due to scale stains adhering to the surface of the heater. Further, even when an interlock device for protecting the heater is not provided (for example, during empty incineration, in a closed state where no medium convection is present, or the like), the temperature of the heater surface does not exceed the upper limit temperature, and therefore, damage to the heater or reduction in the service life of the heater can be prevented.
In the above embodiment, water may be used as the medium, but oil may be used instead of water.
In the above embodiment, the mold temperature controller is described as an example of the temperature control device, but the temperature control device is not limited to the mold temperature controller, and the present embodiment can be applied to any device provided with a heater device.
A temperature control device according to the present embodiment is a temperature control device that controls a temperature of a medium that circulates through a conduit to an object, the temperature control device including: a medium temperature control unit that controls the temperature of the medium by repeatedly turning on and off a heating pipe provided on the outer periphery of a flow path pipe through which the medium flows; and a heating pipe temperature control unit that controls the temperature of the heating pipe by adjusting the total time of the energization-off time for each preset cycle or the energization-off time for a period in which the preset cycle has elapsed a plurality of times.
A temperature control method according to the present embodiment is a temperature control method for controlling a temperature of a medium circulated through an object through a pipe, the temperature control method being characterized by controlling the temperature of the medium by repeatedly turning on and off a heating pipe provided on an outer periphery of a flow pipe through which the medium flows; and controlling the temperature of the heating pipe by adjusting the total time of the power-on closing time of each preset period or the power-on closing time of a period in which the preset period passes multiple times.
And a medium temperature control unit that controls the medium temperature by repeatedly switching (for example, repeatedly switching at a predetermined cycle) the on/off operation of the power supply to the heating pipe provided on the outer periphery of the flow pipe through which the medium flows. The heating tube may be a structure in which a heating element such as a nichrome wire is covered with a metal tube through an insulator, and is also called a heating wire heater (Sheath heater). The heating pipe is arranged on the periphery of the flow path pipe, so that the medium cannot be contacted with the heating pipe, and scale and dirt cannot be adhered to the surface of the heating pipe. So that the heat transfer rate of the heating pipe can be prevented from being lowered.
The predetermined period may also be referred to as a proportional period. The proportional period may be 1 second, 2 seconds, etc. The medium temperature control unit adjusts a cooling medium energization on time (i.e., a time during which the cooling medium is on) in a preset cycle of the cooling process to be longer (for example, from 5 seconds to 8 seconds) so as to lower the temperature of the medium when the temperature of the medium is higher than a set temperature. When the temperature of the medium is lower than the set temperature, the medium temperature control unit adjusts the energization-off time in the preset cycle of the heating process to be short (for example, from 5 seconds to 8 seconds) to increase the temperature of the medium. The adjustment of the power-on off time is performed according to each preset period.
The heating pipe temperature control unit controls the temperature of the heating pipe by adjusting the total time of the energization-off time for each preset period or the energization-off time for a period in which the preset period has elapsed a plurality of times. The period during which the preset period passes through a plurality of times may also be referred to as a control period. That is, when the preset period is T and the number of times is n, the control period is n × T. The number may also be referred to as the number of cycles. The number of cycles may be 15, but is not limited thereto, and may be 10, 20, or 30.
When the energization-off times of the cycles 1, 2, …, n are set to d1, d2, …, dn, respectively, the total energization-off time Dn can be represented as Dn = d1+ d2+ … + Dn. The temperature control unit can adjust the total time Dn to be longer when the temperature of the heating pipe is too high, thereby making the temperature of the heating pipe approach the target temperature. Thus, the temperature of the heating pipe can be prevented from exceeding the upper limit temperature, and overheating of the heating pipe can be prevented.
In the temperature control device according to the present embodiment, the heating pipe temperature control unit controls the temperature of the heating pipe by adjusting the total time of the energization and shutdown times during which the proportional cycle of the PID control has elapsed a plurality of times.
The heating pipe temperature control unit controls the temperature of the heating pipe by adjusting the total time of the energization/shutdown time during which the Proportional cycle of the PID control (Proportional-Integral-Differential Controller) has elapsed a plurality of times. The PID control is a control in which the energization-off time is controlled as a linear function of the deviation between the actual temperature of the medium and the target temperature by the medium temperature control of the medium temperature control unit. This prevents the temperature of the heating pipe from exceeding the upper limit temperature, and thus prevents the heating pipe from overheating.
In the temperature control device according to the present embodiment, the medium temperature control unit includes: a first control mode in which the heating pipe is continuously energized by setting the energization-off time of each of the preset periods to 0; and a second control mode in which the turning on or off of the energization to the heating pipe is repeated at a preset cycle.
The first control mode is a mode in which the heating pipe is continuously energized in a state in which the energization-off time of each of the preset cycles is 0. The second control mode is an on/off energization mode in which energization to the heating pipe is turned on or off repeatedly at a predetermined cycle. In the present specification, the on/off power-on mode may be set for a proportional period of 1 or more of the control periods when the power-on time is 0. The medium temperature control unit may adopt the first control mode when raising the medium temperature from the heating start temperature (e.g., 20 ℃) to a set temperature (e.g., 180 ℃). The medium temperature control unit may adopt the second control mode when the temperature of the medium is maintained at the set temperature. The medium temperature control unit may adopt the second control mode when raising the temperature of the medium from the heating start temperature to the set temperature.
In the temperature control device according to the present embodiment, the medium temperature control unit switches to the second control mode when the temperature of the heating pipe is raised to a preset temperature in the first control mode.
The medium temperature control part can switch to a second control mode when the temperature of the heating pipe is raised to a preset temperature through the first control mode. When raising the temperature of the medium from the heating start temperature, the medium temperature control unit may increase the temperature raising rate of the medium faster than in the second control mode by using the first control mode, and may shorten the time until the temperature reaches the set temperature, for example. On the other hand, since the temperature of the heating pipe changes at a higher temperature than the temperature of the medium, the temperature of the heating pipe also becomes higher when the set temperature of the medium is relatively high (e.g., 250 ℃).
Therefore, it is possible to switch from the first control mode to the second control mode after the temperature of the heating pipe is raised to the preset temperature by setting the preset temperature (for example, it may be a target temperature of the heating pipe or a lower limit temperature), so that it is possible to prevent overheating of the heating pipe while shortening the temperature raising time for raising the temperature of the medium to the preset temperature.
In the temperature control device according to the present embodiment, the temperature control unit for the heating pipe controls the temperature of the heating pipe based on the set temperature of the medium.
The heating pipe temperature control unit may control the temperature of the heating pipe based on the set temperature of the medium. By using the feature that the temperature of the heating pipe changes at a higher temperature than the temperature of the medium, for example, the total time of the energization-off time may be adjusted so that the temperature of the heating pipe is higher than the set temperature of the medium by a preset temperature. Thus, the temperature of the heating pipe can be set to the optimum temperature according to the set temperature of the medium.
In the temperature control device according to the present embodiment, the heating pipe temperature control unit adjusts the energization-off time in each of the preset cycles or adjusts the total time of the energization-off times so that the temperature of the heating pipe is equal to or higher than the lower limit temperature and equal to or lower than the upper limit temperature; wherein the lower limit temperature is a temperature higher than the set temperature of the medium by a first temperature; the upper limit temperature is a temperature higher than the set temperature of the medium by a second temperature.
The temperature control unit for heating the pipe adjusts the energization-off time or the total time of the energization-off times for each preset cycle so that the temperature of the heating pipe is within a range of a lower limit temperature higher than the set temperature of the medium by a first temperature and a lower limit temperature higher than the set temperature by a second temperature. In this way, the temperature of the heating pipe can be set to a temperature between the lower limit temperature and the upper limit temperature. For example, by setting the upper limit of the heater temperature to a temperature that does not affect the service life of the heating pipe, it is possible to prevent the expected service life of the heating pipe from becoming short. In addition, the lower limit value of the heater temperature is set to a temperature higher than a temperature that affects a temperature rise time for raising the temperature of the medium to the set temperature, thereby preventing the temperature rise time of the medium from being longer than an expected time.
In the temperature control device according to the present embodiment, the first temperature is 50 ℃; the second temperature is 120 ℃.
The first temperature was 50 ℃ and the second temperature was 120 ℃. When the first temperature is less than 50 ℃, the temperature rise time of the medium becomes longer than the expected time. In addition, when the second temperature is higher than 120 ℃, the expected life of the heating tube may be shortened. With the above configuration, it is possible to prevent the expected life of the heating pipe from being shortened and the temperature rise time of the medium from being longer than the expected time, depending on the set temperature of the medium.
In the temperature control device according to the present embodiment, the heating tube temperature control unit sets the total time of the energization-off times during which the preset cycle has passed a preset number of times to be equal to or more than one-half of the preset cycle.
The heating tube temperature control unit may set a total time of the energization/shutdown times during which the preset cycle has passed the preset number of times to one-half or more of the preset cycle. When the preset period (proportional period) is T and the preset number of times (cycle number) is n, the total time Dn of the energization/shutdown time of the control period (n × T) may be set to Dn ≧ T/2. For example, when the proportional period T is 1 second and the number of cycles is 15, the total time Dn of the energization-off time may be set to 0.5 seconds or more. Similarly, when the number of cycles is 10 or 20, for example, the total time Dn of the energization-off time may be set to 0.5 seconds or more. When the proportional period T is, for example, 2 seconds, the total time Dn of the energization/shutdown time may be set to be slightly longer than 0.5 seconds, for example, 1 second or more.
With the above configuration, when the temperature of the medium is maintained at the set temperature, the temperature of the heating pipe can be maintained at the target temperature higher than or close to the set temperature of the medium, and the temperature of the heating pipe can be set to the optimum temperature.
In the temperature control device according to the present embodiment, the heating tube temperature control unit sets the total time of the energization-off times when the energization-off time is 10% or more of the preset period after the preset period elapses, to one-half or more of the preset period.
The heating pipe temperature control unit may set a total time of the energization off time when the energization off time during which the preset cycle has passed a preset number of times to be 10% or more of the preset cycle to one-half or more of the preset cycle. For example, when the preset period (proportional period) T is set to 1 second and the energization-off time is less than 10% of the preset period, that is, when the energization-off time is less than 0.1 second, the temperature control of the heater tube is too short, and the effect of lowering the temperature of the heater tube cannot be obtained.
Therefore, by setting the total time of the energization-off times for which the energization-off time is 10% or more of the preset cycle to be one-half or more of the preset cycle, the temperature of the heating pipe can be accurately maintained at the target temperature or a temperature close to the target temperature.
In the temperature control device according to the present embodiment, the temperature control unit for a heating pipe includes an output unit that outputs a warning message when a total time of the on/off times during which the preset cycle has elapsed for a preset number of times is less than one-half of the preset cycle, the total time being the on/off time that is 10% or more of the preset cycle.
And an output unit that outputs warning information when the total time of the energization-off times during which the preset cycle has elapsed for a preset number of times is less than one-half of the preset cycle, the total time being an energization-off time that is 10% or more of the preset cycle. When the total time of the energization-off times, which is 10% or more of the preset cycle, is less than half of the preset cycle, the heating-tube temperature control unit may adjust the energization-off time to a very short time or continuously energize the heating tube so that the temperature of the heating tube approaches the target temperature. This state is a state in which heating by the heating pipe is insufficient, and there is a risk that stable temperature control cannot be performed. Therefore, by outputting the warning alert, it is possible to notify the user that there is a failure in the heating control of the heating pipe.
The temperature control device according to the present embodiment includes a temperature sensor that detects a medium temperature on an upstream side of the heating pipe and a medium temperature on a downstream side of the heating pipe, and the temperature control unit for the heating pipe adjusts the energization-off time for each of the predetermined cycles or adjusts the total time of the energization-off times based on a temperature difference between the medium temperature on the downstream side and the medium temperature on the upstream side.
And a temperature sensor for detecting the medium temperature at the upstream side of the heating pipe and the medium temperature at the downstream side of the heating pipe. And a temperature control unit that adjusts the energization-off time for each preset cycle or adjusts the total time of the energization-off times based on a temperature difference between the downstream-side medium temperature and the upstream-side medium temperature.
In the medium circulation line including the flow path in the die, the temperature gradient is significant between the inlet and the outlet of the die and between the upstream side and the downstream side of the heating pipe, and therefore, the temperature of the medium on the upstream side of the heating pipe corresponds to the outlet temperature (return medium side) of the die, and the temperature of the medium on the downstream side of the heating pipe corresponds to the inlet temperature (feed medium side) of the die. When the flow rate of the medium is small, the temperature of the medium after heat exchange in the mold is high, and therefore, the temperature gradient between the inlet and the outlet of the mold is large, and the temperature difference detected by the temperature sensor is also large. In addition, when the flow rate of the medium is large, the temperature of the medium after heat exchange in the mold is low, so that the temperature gradient between the inlet and the outlet of the mold is small, and the temperature difference detected by the temperature sensor is also small. On the other hand, when the flow rate of the medium is small, the amount of heat required for heating the medium is small, and therefore the heater temperature is high. When the flow rate of the medium is large, the heat quantity for heating the medium needs to be large, and the rise of the heater temperature is suppressed.
Therefore, when the temperature difference between the medium temperature on the downstream side of the heating pipe and the medium temperature on the upstream side is large, the flow rate of the medium decreases, and the temperature of the heating pipe rises, so that the energization-off time of each preset cycle or the total time of the energization-off times can be made long. In addition, when the temperature difference between the medium temperature on the downstream side of the heating pipe and the medium temperature on the upstream side is small, the temperature of the heating pipe is low when the flow rate of the medium is large, and therefore the energization-off time or the total time of the energization-off times of the respective predetermined cycles can be made short. Thus, the temperature of the heating pipe can be accurately maintained at the target temperature or a temperature close to the target temperature depending on the amount of the medium flow.
The temperature control device according to the present embodiment includes a heating unit having a passage pipe through which the medium flows and a plurality of heating pipes wound around an outer periphery of the passage pipe, and an outer diameter of each of the heating pipes is smaller than a distance between adjacent heating pipes on the outer periphery of the passage pipe.
The heating unit has a flow path pipe through which a medium flows, and a heating pipe wound around the outer circumference of the flow path pipe by a plurality of turns. The outer diameter of the heating pipe is smaller than the distance between the adjacent heating pipes on the periphery of the flow path pipe. Namely, a flow path pipe for flowing the medium, and a heating pipe wound several times around the outer circumference of the flow path pipe. And the outer diameter of the heating pipe is smaller than the distance between the adjacent heating pipes on the periphery of the flow path pipe. That is, the heating pipes are not densely arranged, and the heating pipes adjacent to each other on the outer periphery of the flow path pipe are wound around the outer periphery of the flow path pipe with a certain gap therebetween. By providing the gap, the heating pipe can be prevented from being overheated.
In the temperature control device according to the present embodiment, the outer diameter of the heating pipe is 5mm or less.
The outer diameter of the heating pipe is less than 5 mm. In this way, when the heating pipe is wound around the outer periphery of the passage pipe having a specific length, the number of windings can be increased, so that the area of the outer periphery of the passage pipe, which is in contact with the heating pipe, can be increased, and the heat of the heating pipe can be efficiently transferred to the medium through the passage pipe.
In the temperature control device according to the present embodiment, the power density of the heating means is 10W/cm 2 The following.
The power density of the heating unit is 10W/cm 2 The following. The power density is the electrical load (W) per unit area (1 cm square) of the heating tube. For example, when the outer diameter of the heating tube is φ, the effective length of the wound heating tube is L, and the electric power is W, the power density is represented as W/(φ × π × L). Thus, overheating of the heating pipe can be prevented.
In the temperature control device according to the present embodiment, the heating unit includes: a first flow path pipe, a second flow path pipe and a third flow path pipe through which the medium flows; an inflow port provided at one end of the first flow path pipe; a first communication pipe communicating the other end of the first flow path pipe with one end of the second flow path pipe; a second communicating pipe which communicates the other end of the second flow path pipe with one end of the third flow path pipe; an outlet port provided at the other end of the third flow path pipe; one or more first heating pipes wound around the outer periphery of the first flow path pipe; one or more second heating pipes wound around the outer periphery of the second flow path pipe; and one or more third heating pipes wound around the outer periphery of the third flow path pipe, wherein the first heating pipe, the second heating pipe, and the third heating pipe are each added with a different one-phase of three-phase alternating current.
A heating unit provided with: a first flow path pipe, a second flow path pipe and a third flow path pipe through which a medium flows; an inflow port provided at one end of the first flow path pipe; a first communicating pipe for communicating the other end of the first flow path pipe with one end of the second flow path pipe; a second communicating pipe for communicating the other end of the second flow path pipe with one end of the third flow path pipe; an outlet provided at the other end of the third flow path pipe; one or more first heating pipes wound around the outer periphery of the first flow path pipe; one or more second heating pipes wound around the outer periphery of the second flow path pipe; and one or more third heating pipes wound around the outer periphery of the third flow path pipe, wherein the first heating pipe, the second heating pipe and the third heating pipe are respectively added with a different phase of the three-phase alternating current. The medium is heated while flowing through the first flow path pipe, the second flow path pipe, and the third flow path pipe.
In this way, each phase of the three-phase ac power can be applied to any one of the 3 groups of heating pipes, and can be applied to the three-phase ac power.
In the temperature control device according to the present embodiment, the heating means may be connected in plurality.
The heating unit may be connected in plurality. In this way, the medium temperature can be adjusted to the set temperature only by connecting a specific number of heating units according to the size of the heating capacity, and since the heating units are identical, there is no case where the number of types of components is increased according to the heating capacity, thereby reducing the cost.
At least some of the above embodiments may be combined arbitrarily.
Description of the reference numerals
11. 12, 14 pipelines;
13. a cooling pipeline;
15. a drain line;
16. a bypass line;
21. a media delivery valve;
22. a medium returning valve;
23. cooling the electromagnetic valve;
24. a water discharge electromagnetic valve;
25. a cooling water electromagnetic valve;
31. a pump;
40. a heat exchanger;
50. a control unit;
51. a valve opening/closing control unit;
52. a temperature control unit for heating the tube;
53. a medium temperature control unit;
71. 72, 73 temperature sensors;
80. a heating device;
811. 812, 813 flow conduit;
815. 816, 817 heating pipes;
851. an inflow port;
841. an outflow port;
842. 852 communicating pipe;
100. a mold temperature adjuster (temperature control device);
200. a mold (object).

Claims (17)

1. A mold temperature control device for controlling the temperature of a medium circulating through a mold through a pipe, comprising:
a medium temperature control unit that controls the temperature of a medium circulating in the mold by repeatedly opening and closing a heating pipe that is provided on the outer periphery of a flow path pipe through which the medium flows; and
and a heating pipe temperature control unit that controls the temperature of the heating pipe by adjusting the energization/shutdown time for each preset cycle or the total time of energization/shutdown times for a period of time over which a plurality of times have elapsed in the preset cycle.
2. The mold temperature control apparatus according to claim 1,
and a heating pipe temperature control unit that controls the temperature of the heating pipe by adjusting the total time of energization/shutdown times during a plurality of passes of the proportional cycle of the PID control.
3. The mold temperature control apparatus according to claim 1,
the medium temperature control unit includes:
setting the energization off time of each of the preset periods to 0 to perform a first control mode of continuously energizing the heating pipe; and
and repeatedly performing a second control mode of turning on or off the energization of the heating pipe at a preset period.
4. The mold temperature control apparatus according to claim 3,
the medium temperature control part is switched to the second control mode when the temperature of the heating pipe is increased to a preset temperature in the first control mode.
5. The mold temperature control apparatus according to any one of claims 1 to 4,
the heating pipe temperature control unit controls the temperature of the heating pipe based on a set temperature of a medium circulating through the die.
6. The mold temperature control apparatus according to any one of claims 1 to 4,
the heating pipe temperature control part is used for adjusting the power-on closing time in each preset period or adjusting the total time of the power-on closing time to enable the temperature of the heating pipe to be more than or equal to the lower limit temperature and less than or equal to the upper limit temperature; wherein the lower limit temperature is a temperature higher than a set temperature of a medium circulating in the mold by only a first temperature; the upper limit temperature is a temperature higher than the set temperature of the medium by a second temperature.
7. The mold temperature control apparatus according to claim 6,
the first temperature is 50 ℃; the second temperature is 120 ℃.
8. The mold temperature control apparatus according to any one of claims 1 to 4,
the heating tube temperature control unit sets a total time of the energization-off times during a period in which a preset number of times has elapsed in the preset cycle to one-half or more of the preset cycle.
9. The mold temperature control apparatus according to any one of claims 1 to 4,
the heating tube temperature control unit sets a total time of the energization shutdown time when the energization shutdown time in a period in which a preset number of times has elapsed in the preset cycle is 10% or more of the preset cycle to one-half or more of the preset cycle.
10. The mold temperature control apparatus according to any one of claims 1 to 4,
the temperature control unit for a heating tube includes:
and an output unit that outputs a warning alert when a total time of the energization-off times during a period in which a preset number of times of elapse of the preset period is equal to or longer than 10% of the preset period is less than one-half of the preset period.
11. The mold temperature control device according to any one of claims 1 to 4, comprising:
a temperature sensor for detecting a medium temperature on an upstream side of the heating pipe and a medium temperature on a downstream side of the heating pipe,
the heating pipe temperature control unit adjusts the energization-off time for each of the preset cycles or adjusts the total time of the energization-off times based on a temperature difference between the downstream medium temperature and the upstream medium temperature.
12. The mold temperature control device according to any one of claims 1 to 4, comprising:
a heating unit having a passage pipe through which a medium circulating in the mold flows, and a heating pipe wound around the passage pipe a plurality of times,
the outer diameter of the heating pipe is smaller than the distance between adjacent heating pipes on the periphery of the flow path pipe.
13. The mold temperature control apparatus of claim 12,
the outer diameter of the heating pipe is less than 5 mm.
14. The mold temperature control apparatus according to claim 12,
the power density of the heating unit is 10W/cm 2 The following.
15. The mold temperature control apparatus of claim 12,
the heating unit includes:
a first flow path pipe, a second flow path pipe and a third flow path pipe through which a medium circulating in the mold flows;
an inflow port provided at one end of the first flow path pipe;
a first communication pipe communicating the other end of the first flow path pipe with one end of the second flow path pipe;
a second communicating pipe which communicates the other end of the second flow path pipe with one end of the third flow path pipe;
an outlet port provided at the other end of the third flow path pipe;
one or more first heating pipes wound around the outer periphery of the first flow path pipe;
one or more second heating pipes wound around the outer periphery of the second flow path pipe;
one or more third heating pipes wound around the outer periphery of the third flow path pipe,
the first heating pipe, the second heating pipe and the third heating pipe are respectively added with a different phase in the three-phase alternating current.
16. The mold temperature control apparatus according to claim 12,
the heating unit may be connected in plurality.
17. A method for controlling the temperature of a mold, which is a method for controlling the temperature of a medium circulating through a mold through a pipe,
controlling the temperature of a medium circulating in the mold by repeatedly turning on or off a heating pipe that is provided at the outer periphery of a flow path pipe through which the medium flows; and
the temperature of the heating pipe is controlled by adjusting the energization-off time of each preset period or the total time of the energization-off times during a plurality of elapsed periods of the preset period.
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