CN111444619B - Online analysis method and equipment for injection mold cooling system - Google Patents
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Abstract
Description
技术领域technical field
本发明属于模具设计及评估领域,更具体地,涉及一种注塑模具冷却系统在线分析方法及设备。The invention belongs to the field of mold design and evaluation, and more specifically relates to an online analysis method and equipment for an injection mold cooling system.
背景技术Background technique
注塑成型因为生产效率高、产品质量好、材料消耗少、生产成本低而获得广泛应用,目前注塑模具的产量占整个塑料模具设计生产的三分之一以上。随着以塑代钢、以塑代木趋势的发展,塑料制品在日常生活和工业中得到了越来越多的应用,汽车、能源、机械、电子、信息、航空航天等行业对注塑成型技术的要求也在不断提高。Injection molding is widely used because of its high production efficiency, good product quality, low material consumption, and low production cost. At present, the output of injection molds accounts for more than one-third of the entire plastic mold design and production. With the development of the trend of substituting plastic for steel and plastic for wood, plastic products have been used more and more in daily life and industry, and industries such as automobiles, energy, machinery, electronics, information, aerospace, etc. requirements are also increasing.
注塑成型过程主要由锁模、塑化、注射、保压、冷却、开模、顶出等阶段组成,其中冷却时间约占成型周期的50%~80%。注塑模具冷却系统是决定塑件质量和生产效率的重要因素,它不但决定塑件的成型性能、尺寸精度和力学性能,避免塑件出现壁厚不均、翘曲变形、尺寸变化和残余应力等缺陷,而且通过决定冷却进程影响成型周期的长短。合理的冷却系统可以调节注塑模具内部的温度环境,实现塑件的均匀和快速冷却,从而保证塑件的质量并缩短注塑成型的周期,提高生产效率。因此,在模具设计阶段对冷却系统进行快速的分析,进而作为冷却系统调整优化的依据,对于缩短整个模具的设计周期和模具实际生产中的成型周期具有重大意义。The injection molding process is mainly composed of clamping, plasticizing, injection, pressure holding, cooling, mold opening, ejection and other stages, in which the cooling time accounts for about 50% to 80% of the molding cycle. Injection mold cooling system is an important factor to determine the quality and production efficiency of plastic parts. It not only determines the molding performance, dimensional accuracy and mechanical properties of plastic parts, but also avoids uneven wall thickness, warping deformation, dimensional changes and residual stress of plastic parts. Defects, and affect the length of the molding cycle by determining the cooling process. A reasonable cooling system can adjust the temperature environment inside the injection mold to achieve uniform and rapid cooling of the plastic parts, thereby ensuring the quality of the plastic parts and shortening the injection molding cycle and improving production efficiency. Therefore, it is of great significance to quickly analyze the cooling system in the mold design stage, and then use it as the basis for the adjustment and optimization of the cooling system, to shorten the design cycle of the entire mold and the molding cycle in the actual production of the mold.
传统的注塑模具冷却系统设计及分析主要依赖设计师的经验和直觉,这对设计师的水平提出了很高的要求,不利于初级设计师的工作。此外,依靠经验的设计缺乏理论依据和科学计算,需要通过不断的试模来判断设计是否合理,塑件出现缺陷时主要靠修模来解决,从而导致塑件的生产效率低,成本高且质量难以保证。随着计算机应用技术的发展,计算机辅助工程(CAE)在注塑模具领域的应用使得注塑模具冷却系统的设计效率和质量得到了大幅度提高。CAE主要采用有限元(FEM)、有限差分(FDM)和边界元(BEM)等数值分析方法,通过迭代法对冷却过程进行分析,分析结果中的冷却时间可以反映塑件的综合热影响效应。虽然CAE的结果比较准确,但是需要将CAD模型重构为相应格式的CAE模型,冷却系统修改之后还需要对模具重新划分网格,操作复杂,而且多次修改需要多次分析,计算量大,时间长,难以满足在线分析的要求。Traditional injection mold cooling system design and analysis mainly rely on the designer's experience and intuition, which puts forward high requirements on the designer's level, which is not conducive to the work of junior designers. In addition, design based on experience lacks theoretical basis and scientific calculations, and it is necessary to judge whether the design is reasonable through continuous mold testing. When there are defects in plastic parts, it is mainly solved by repairing molds, which leads to low production efficiency, high cost and high quality of plastic parts. Difficult to guarantee. With the development of computer application technology, the application of computer-aided engineering (CAE) in the field of injection molds has greatly improved the design efficiency and quality of injection mold cooling systems. CAE mainly uses numerical analysis methods such as finite element (FEM), finite difference (FDM) and boundary element (BEM), and analyzes the cooling process through iterative methods. The cooling time in the analysis results can reflect the comprehensive thermal influence effect of plastic parts. Although the results of CAE are relatively accurate, it is necessary to reconstruct the CAD model into a CAE model of the corresponding format. After the cooling system is modified, the mold needs to be re-meshed. It takes a long time and it is difficult to meet the requirements of online analysis.
发明内容Contents of the invention
针对现有技术的以上缺陷或改进需求,本发明提供了注塑模具冷却系统在线分析方法,其目的在于将影响塑料制品冷却的因素分为内部因素和外部因素两类,分别根据两类因素计算得到内部因子和外部因子,结合二者计算得到反映制品实际冷却情况的综合热影响效应,从而实现冷却系统的在线分析,由此解决当前冷却系统分析时间长、效率低的技术问题。Aiming at the above defects or improvement needs of the prior art, the present invention provides an online analysis method for the cooling system of injection molds, the purpose of which is to divide the factors affecting the cooling of plastic products into two types: internal factors and external factors, which are calculated according to the two types of factors respectively The internal factor and external factor are combined to calculate the comprehensive thermal influence effect reflecting the actual cooling condition of the product, so as to realize the online analysis of the cooling system, thereby solving the technical problems of long analysis time and low efficiency of the current cooling system.
为实现上述目的,按照本发明的一个方面,提供了一种注塑模具冷却系统在线分析方法,包括以下步骤:In order to achieve the above object, according to one aspect of the present invention, an online analysis method for an injection mold cooling system is provided, comprising the following steps:
离线训练阶段:Offline training phase:
步骤1:不考虑冷却系统的影响,将模具和塑件的模型离散为三角单元;其中,包含同一个节点的三角单元互为邻接单元,选取任意三角单元作为中心单元,将该中心单元及其邻接单元的冷却时间共同作为表征内部因素对塑件冷却效果影响的内部因子,此时内部因子是一个矩阵,记为:Step 1: Regardless of the influence of the cooling system, the model of the mold and the plastic part is discretized into triangular units; among them, the triangular units containing the same node are adjacent to each other, and any triangular unit is selected as the central unit, and the central unit and its The cooling time of adjacent units is jointly used as an internal factor that characterizes the influence of internal factors on the cooling effect of plastic parts. At this time, the internal factor is a matrix, which is recorded as:
其中,θin表示内部因子,t表示当前选定的三角单元的冷却时间,分别表示第1圈第1~n1个三角单元的冷却时间,分别表示第2圈第1~n2个三角单元的冷却时间,和分别表示第3圈第1~n3个三角单元的冷却时间,和分别表示第m圈第1~nm个三角单元的冷却时间;Among them, θ in represents the internal factor, t represents the cooling time of the currently selected triangular unit, Respectively represent the cooling time of the 1st to n1 triangular units in the first cycle, Respectively represent the cooling time of the 1st to n 2 triangular units in the second cycle, with Respectively represent the cooling time of the 1st to n 3 triangular units in the third circle, with Respectively represent the cooling time of the 1st to n m triangular units in the mth circle;
步骤2:在步骤1的模型中引入恒温边界的有限长持续线热源模型对步骤1的模型进行冷却,从而计算表征外部因素对塑件冷却效果影响的外部因子,公式如下:Step 2: Introduce a finite-length continuous line heat source model with a constant temperature boundary into the model of step 1 to cool the model of step 1, so as to calculate the external factors that represent the influence of external factors on the cooling effect of plastic parts. The formula is as follows:
其中,θex表示外部因子,i=1…q表示模具不同边界面,q为模具边界面数量,Among them, θ ex represents the external factor, i=1...q represents the different boundary surfaces of the mold, q is the number of the boundary surfaces of the mold,
和分别表示中心单元质心相对于源线热源轴线方向的坐标和源线热源关于边界面i的镜像线热源轴线方向的坐标, and represent the coordinates of the centroid of the central unit relative to the axis direction of the source-line heat source and the coordinates of the source-line heat source with respect to the axis direction of the mirror image line of the boundary surface i, respectively,
和分别表示源线热源的两个端点在轴线方向的坐标, and respectively represent the coordinates of the two end points of the source line heat source in the axis direction,
和分别表示源线热源关于边界面i的镜像线热源的两个端点在轴线方向的坐标, with Respectively represent the coordinates of the two end points of the source line heat source on the mirror line heat source of the boundary surface i in the axial direction,
ri 1和ri 2分别表示中心单元质心相对于源线热源距离和中心单元质心到源线热源关于边界面i的镜像线热源的距离;r i 1 and r i 2 represent the distance from the centroid of the central unit to the heat source on the source line and the distance from the centroid of the central unit to the heat source on the image line of the heat source on the boundary surface i;
步骤3:将步骤1的模具和塑件的模型及步骤2的初始冷却系统模型作为一个整体,通过仿真得到塑件冷却时间,即塑件的综合热影响效应;Step 3: Take the model of the mold and plastic part in step 1 and the initial cooling system model in step 2 as a whole, and obtain the cooling time of the plastic part through simulation, that is, the comprehensive thermal influence effect of the plastic part;
步骤4:建立神经网络模型,将步骤1的内部因子θin、步骤2的外部因子θex作为输入特征,步骤3的综合热影响效应作为期望输出,对该神经网络模型进行训练,获得综合热影响效应预测模型;Step 4: Establish a neural network model, take the internal factor θ in of step 1 and the external factor θ ex of step 2 as input features, and the comprehensive thermal impact effect of step 3 as the expected output, train the neural network model, and obtain the comprehensive heat Impact effect prediction model;
在线分析阶段:Online analysis stage:
步骤5:在注塑模具冷却系统的调整优化过程中,根据调整后冷却管道的尺寸及位置数据,按照步骤2的方法重新计算外部因子,内部因子则直接沿用步骤1的结果,然后采用步骤4中训练得到的综合热影响效应预测模型来预测综合热影响效应。Step 5: During the adjustment and optimization process of the injection mold cooling system, according to the size and position data of the adjusted cooling pipe, recalculate the external factors according to the method of step 2, and the internal factors directly follow the results of step 1, and then use the results of step 4 The integrated thermal impact effect prediction model obtained by training is used to predict the integrated thermal impact effect.
进一步地,步骤1中m的值为1~5。Further, the value of m in step 1 is 1-5.
进一步地,步骤4中的神经网络模型为BP神经网络模型,BP神经网络模型包含四层:输入层,隐含层1,隐藏层2和输出层;所述输入层节点数量m入在1~60之间,该数量与所选取的中心单元和邻接单元的总数量相等;所述隐藏层1的节点数量h1≥2m入+1,所述隐藏层2的节点数量在2~20之间,输出层的节点数量为1,节点传递函数选取Sigmoid函数。Further, the neural network model in step 4 is a BP neural network model, and the BP neural network model includes four layers: an input layer, a hidden layer 1, a hidden layer 2 and an output layer; the number of nodes in the input layer m is between 1 and between 60, the number is equal to the total number of selected central units and adjacent units; the number of nodes in the hidden layer 1 h 1 ≥ 2m into +1, the number of nodes in the hidden layer 2 is between 2 and 20 , the number of nodes in the output layer is 1, and the node transfer function selects the Sigmoid function.
进一步地,步骤四中的BP神经网络模型采用变步长调整和批处理的方法进行迭代优化。Further, the BP neural network model in step 4 is iteratively optimized by means of variable step size adjustment and batch processing.
进一步地,步骤4中,在训练之前,将内部因子和外部因子分别作为原始数据,按照如下公式分别进行最大最小归一化处理:Further, in step 4, before training, internal factors and external factors are respectively used as original data, and the maximum and minimum normalization processes are performed according to the following formulas:
其中,x0、xmin、xmax和xnorm分别表示原始数据、原始数据序列中的最小值、原始数据序列中的最大值和最大最小归一化后的数据。Among them, x 0 , x min , x max and x norm represent the original data, the minimum value in the original data sequence, the maximum value in the original data sequence, and the maximum and minimum normalized data, respectively.
为实现上述目的,按照本发明的另一个方面,提供了一种计算机可读存储介质,该计算机可读存储介质上存储有计算机程序,该计算机程序被处理器执行时实现如前任一项所述的方法。In order to achieve the above object, according to another aspect of the present invention, a computer-readable storage medium is provided, and a computer program is stored on the computer-readable storage medium, and when the computer program is executed by a processor, the above-mentioned Methods.
为实现上述目的,按照本发明的另一个方面,提供了一种注塑模具冷却系统在线分析设备,其特征在于,包括如前所述的计算机可读存储介质以及处理器,处理器用于调用和处理计算机可读存储介质中存储的计算机程序。In order to achieve the above object, according to another aspect of the present invention, an online analysis device for the cooling system of an injection mold is provided, which is characterized in that it includes the computer-readable storage medium and a processor as described above, and the processor is used to call and process A computer program stored on a computer readable storage medium.
总体而言,本发明所构思的以上技术方案与现有技术相比,能够取得下列有益效果:Generally speaking, compared with the prior art, the above technical solutions conceived by the present invention can achieve the following beneficial effects:
1、本发明的分析方法可以直接在CAE系统中运行,其中离线训练阶段最多只需要两次CAE分析,即内部因子和综合热影响效应的分析;而在线分析阶段可以直接沿用离线训练阶段的内部因子,并且外部因子可以直接重新计算而无需重新划分有限元网格。因此,采用本发明的方法,迭代计算次数大大减少,过程简单,计算量小,节省时间,能够实现冷却系统的在线分析,能够在保证冷却分析结果满足使用精度的条件下,实现快速甚至实时的计算。1. The analysis method of the present invention can be run directly in the CAE system, wherein the offline training stage only needs CAE analysis twice at most, that is, the analysis of internal factors and comprehensive thermal influence effects; and the online analysis stage can directly follow the internal analysis of the offline training stage. factors, and the external factors can be directly recalculated without remeshing the finite element mesh. Therefore, by adopting the method of the present invention, the number of iterative calculations is greatly reduced, the process is simple, the amount of calculation is small, and time is saved. The online analysis of the cooling system can be realized, and fast or even real-time analysis can be realized under the condition that the cooling analysis results meet the accuracy of use. calculate.
2、步骤1中所选取的邻接单元的数量优选以计算单元为中心向外扩展1~5圈所包含的网格单元数量,能够在保证计算精度的前提下进一步减少计算量和计算时间。2. The number of adjacent cells selected in step 1 is preferably the number of grid cells included in 1 to 5 circles from the center of the calculation unit, which can further reduce the calculation amount and calculation time under the premise of ensuring calculation accuracy.
3、通过选用BP神经网络模型,以及对BP神经网络模型的具体结构和节点数量进行设计,能够保证准确度并提高训练效率。3. By selecting the BP neural network model and designing the specific structure and number of nodes of the BP neural network model, the accuracy can be guaranteed and the training efficiency can be improved.
4、BP神经网络模型采用变步长调整和批处理的方法进行算法改进,能够克服传统算法训练时间长和收敛慢的缺点。4. The BP neural network model adopts the method of variable step size adjustment and batch processing to improve the algorithm, which can overcome the disadvantages of long training time and slow convergence of traditional algorithms.
5、训练前先对内部因子和外部因子进行最大最小归一化,可以进一步提升模型的精度及收敛速度。5. Before training, perform maximum and minimum normalization on internal factors and external factors, which can further improve the accuracy and convergence speed of the model.
附图说明Description of drawings
图1是本发明的算法流程示意图;Fig. 1 is a schematic diagram of an algorithm flow chart of the present invention;
图2是网格单元传热示意图;Fig. 2 is a schematic diagram of grid unit heat transfer;
图3是恒温边界的有限长持续线热源示意图;Fig. 3 is a schematic diagram of a finite-length continuous line heat source at a constant temperature boundary;
图4是本发明的BP神经网络示意图;Fig. 4 is the BP neural network schematic diagram of the present invention;
图5的(a)(b)是实施案例的预测结果与实际结果对比示意图。(a) (b) of Fig. 5 is a schematic diagram of the comparison between the predicted result and the actual result of the implementation case.
具体实施方式Detailed ways
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。此外,下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not constitute a conflict with each other.
本发明的基本原理为:以未设计冷却系统时CAE分析的单元冷却时间作为表征影响塑件冷却的内部因子,以简化的恒温边界的有限长持续线热源模型计算表征影响塑件冷却的外部因子,通过内部因子和外部因子得出对塑件的综合热影响效应。The basic principle of the present invention is: take the unit cooling time analyzed by CAE when the cooling system is not designed as the internal factor affecting the cooling of the plastic part, and use the simplified constant temperature boundary finite-length continuous line heat source model to calculate and characterize the external factor affecting the cooling of the plastic part , through the internal factors and external factors to obtain the comprehensive thermal influence effect on plastic parts.
本方法将决定冷却结果的因素分为两种:内部因素和外部因素,内部因素包括塑件和模具的材料、形状、尺寸以及模具温度,外部因素包括冷却管道的尺寸、位置和冷却介质的温度、流速等。对于同一副模具,内部因素是恒定的,这里以不设计冷却系统时CAE分析所得的冷却时间大小表征内部因素对冷却过程的影响,也称作内部因子。对冷却系统进行修改优化,改变的是冷却管道的尺寸及位置,一般而言冷却管道的长度比直径大1~2个数量级,因此可以把冷却管道近似为线热源,通过求解傅里叶导热微分方程得到冷却管道影响效应,也称作外部因子。本方法只需要进行两次CAE分析,通过BP神经网络构建预测模型,以不设计冷却系统时CAE分析所得塑件各网格单元的冷却时间(内部因子)和计算所得的外部因子作为训练模型的输入,以包含初始冷却系统CAE分析所得塑件各网格单元的冷却时间作为训练模型的输出。在冷却系统调整优化阶段,只需要对外部因子重新计算,再利用BP神经网络预测模型得到综合热影响效应,实现冷却系统在线分析。This method divides the factors that determine the cooling result into two types: internal factors and external factors. Internal factors include the material, shape, size, and mold temperature of plastic parts and molds. External factors include the size and location of cooling pipes and the temperature of cooling medium. , flow rate, etc. For the same pair of molds, the internal factors are constant. Here, the cooling time obtained from CAE analysis when the cooling system is not designed is used to characterize the influence of internal factors on the cooling process, also known as internal factors. To modify and optimize the cooling system, what changes is the size and position of the cooling pipe. Generally speaking, the length of the cooling pipe is 1 to 2 orders of magnitude larger than the diameter, so the cooling pipe can be approximated as a line heat source. By solving the Fourier heat conduction differential Equations for cooling channel influence effects, also known as external factors. This method only needs two CAE analyzes to build a prediction model through the BP neural network, and use the cooling time (internal factor) of each grid unit of the plastic part obtained from the CAE analysis and the calculated external factor when the cooling system is not designed as the training model. Input, including the cooling time of each grid unit of the plastic part obtained from the CAE analysis of the initial cooling system as the output of the training model. In the cooling system adjustment and optimization stage, it is only necessary to recalculate the external factors, and then use the BP neural network prediction model to obtain the comprehensive thermal impact effect, and realize the online analysis of the cooling system.
本发明采用如下技术方案:The present invention adopts following technical scheme:
步骤1:利用CAE软件对只包括模具和塑件的模型进行冷却分析,得到塑件每个网格单元的冷却时间。由于塑件各单元温度不同,存在着因温差而导致的热量传递,进而影响该单元的冷却过程。塑件表面被离散为三角单元后,单元之间存在几何上的拓扑关系,包含同一个节点的三角形单元互为邻接单元,因此选取该单元及邻接单元的冷却时间共同作为该单元的内部因子,此时内部因子是一个矩阵。Step 1: Use CAE software to conduct cooling analysis on the model including only the mold and plastic parts, and obtain the cooling time of each grid unit of the plastic parts. Since the temperature of each unit of the plastic part is different, there is heat transfer caused by the temperature difference, which in turn affects the cooling process of the unit. After the surface of the plastic part is discretized into triangular units, there is a geometric topological relationship between the units. The triangular units containing the same node are adjacent to each other. Therefore, the cooling time of this unit and the adjacent units is selected as the internal factor of the unit. At this point the internal factor is a matrix.
优选地,步骤1中每个单元的冷却过程受所有其他单元的影响,增加邻接单元的数量可以更好地表征内部因子,进而提高综合热影响效应的精度,但是增大计算成本和时间,一般选取1~5圈临接单元即可。Preferably, the cooling process of each unit in step 1 is affected by all other units, increasing the number of adjacent units can better characterize the internal factors, thereby improving the accuracy of the comprehensive thermal influence effect, but increasing the calculation cost and time, generally Select 1 to 5 circles of adjacent units.
步骤2:设计初始冷却系统,计算所有网格单元的质心坐标和冷却管道的端点坐标,通过恒温边界的有限长持续线热源模型计算外部因子,所使用的公式为:Step 2: Design the initial cooling system, calculate the coordinates of the centroid of all grid cells and the coordinates of the end points of the cooling pipe, and calculate the external factor through the finite-length continuous line heat source model of the constant temperature boundary. The formula used is:
所述θex表示外部因子,i=1…6表示模具的六个边界面,和分别表示单元质心相对于源线热源轴线方向的坐标和源线热源关于边界面i的镜像线热源轴线方向的坐标,和表示源线热源的两个端点在轴线方向的坐标,和表示源线热源关于边界面i的镜像线热源的两个端点在轴线方向的坐标,ri 1和ri 2分别表示单元质心相对于源线热源距离和单元质心到源线热源关于边界面i的镜像线热源的距离。The θ ex represents the external factor, i=1...6 represents the six boundary surfaces of the mould, with represent the coordinates of the unit centroid relative to the axis direction of the source line heat source and the coordinates of the source line heat source with respect to the axis direction of the mirror line heat source of the boundary surface i, respectively, with Indicates the coordinates of the two end points of the source line heat source in the axial direction, and Indicates the coordinates of the two end points of the source line heat source on the boundary surface i of the mirror line heat source in the axis direction, r i 1 and r i 2 represent the distance between the unit centroid and the source line heat source and the unit centroid to the source line heat source on the boundary surface i The distance of the mirror line to the heat source.
步骤3:利用CAE软件分析包含初始冷却系统设计的方案,得到网格单元的冷却时间,即综合热影响效应。Step 3: Use CAE software to analyze the scheme including the initial cooling system design, and obtain the cooling time of the grid unit, that is, the comprehensive thermal influence effect.
步骤4:根据步骤1、步骤2和步骤3所获得的数据,建立内部因子、外部因子和综合热影响效应的神经网络模型,内部因子和外部因子作为输入特征,综合热影响效应作为期望输出。Step 4: Based on the data obtained in Step 1, Step 2 and Step 3, establish a neural network model of internal factors, external factors and comprehensive thermal impact effects, internal factors and external factors as input features, and comprehensive thermal impact effects as expected output.
优选地,步骤4中的神经网络模型采用BP神经网络,模型包含四层:输入层,隐含层1,隐藏层2和输出层。所述输入层节点数量m入在1~60之间,其数量视所选取的邻接单元数量而定;所述隐藏层1的节点数量h1≥2m入+1,隐藏层2的节点数量在2~20之间,输出层的节点数量为1。节点传递函数选取Sigmoid函数,公式为:Preferably, the neural network model in step 4 adopts BP neural network, and the model includes four layers: input layer, hidden layer 1, hidden layer 2 and output layer. The number of nodes in the input layer m is between 1 and 60, and its number depends on the number of adjacent units selected; the number of nodes in the hidden layer 1 is h1≥2m in +1, and the number of nodes in the hidden layer 2 is 2 ~20, the number of nodes in the output layer is 1. The node transfer function selects the Sigmoid function, and the formula is:
训练方法选取Levenberg-Marquardt算法,对于中等规模的网络训练速度最快。所述神经网络的训练,根据步骤一所取得的数据量的大小选择合适的最大训练次数、精度要求、学习率和最小梯度要求。The training method selects the Levenberg-Marquardt algorithm, which is the fastest for medium-scale network training. For the training of the neural network, an appropriate maximum number of training times, accuracy requirements, learning rate and minimum gradient requirements are selected according to the amount of data obtained in step one.
优选地,对步骤1和步骤2中所获得的的数据进行最大最小归一化处理,需要对内部因子矩阵的每一行和外部因子分别归一化。Preferably, the maximum-minimum normalization processing is performed on the data obtained in step 1 and step 2, and each row of the internal factor matrix and the external factors need to be normalized separately.
最大最小归一化方法为:The max-min normalization method is:
所述x0、xmin、xmax和xnorm分别表示原始数据、原始数据序列中的最小值、原始数据序列中的最大值和归一化后的数据。The x 0 , x min , x max and x norm represent the original data, the minimum value in the original data sequence, the maximum value in the original data sequence and the normalized data, respectively.
优选地,所述BP神经网络模型采用变步长调整和批处理的方法进行算法改进,以克服传统算法训练时间长和收敛慢的缺点。Preferably, the BP neural network model adopts variable step size adjustment and batch processing methods for algorithm improvement, so as to overcome the shortcomings of traditional algorithms such as long training time and slow convergence.
步骤5:在注塑模具冷却系统的调整优化过程中,根据修改后冷却管道的尺寸及位置数据重新计算外部因子,内部因子不用重新计算,采用步骤4中训练的BP神经网络模型预测综合热影响效应。Step 5: During the adjustment and optimization process of the injection mold cooling system, the external factors are recalculated according to the size and position data of the modified cooling pipe, and the internal factors do not need to be recalculated. The BP neural network model trained in step 4 is used to predict the comprehensive thermal impact effect .
下面以塑料制品为例,对上述方法进行更为具体地说明:The following takes plastic products as an example to describe the above method in more detail:
步骤1:图2所示为本案例中塑料制品划分网格的局部,具有共同节点的单元互为邻接单元,图中单元1(即图2中心标有“①”的单元)由近及远两种不同底纹的单元分别表示第一圈邻接单元和第二圈邻接单元。由于单元1(即图2中心标有“①”的单元)与邻接单元存在温差,所以存在着热量传递(如图2中的箭头所示),因此在考虑内部因子时不能将各个单元孤立计算。Step 1: Figure 2 shows the part of the mesh of the plastic product in this case. The units with common nodes are adjacent to each other. Unit 1 in the figure (that is, the unit marked with "①" in the center of Figure 2) is from near to far The cells with two different shadings represent the adjacent cells of the first ring and the adjacent cells of the second ring respectively. Since there is a temperature difference between unit 1 (that is, the unit marked with "①" in the center of Figure 2) and adjacent units, there is heat transfer (as shown by the arrow in Figure 2), so each unit cannot be calculated in isolation when considering internal factors .
塑料制品的冷却与其形状和尺寸关系密切,具体地,每一个单元都受到其他所有单元的影响,但是在计算内部因子时包含所有单元会出现大量冗余,大幅度增加计算量和计算时间,因此,本实施优选1~5层邻接单元即可。内部因子的表达式如下:The cooling of plastic products is closely related to its shape and size. Specifically, each unit is affected by all other units, but including all units in the calculation of internal factors will cause a lot of redundancy, which will greatly increase the amount of calculation and calculation time. Therefore In this embodiment, preferably 1 to 5 layers of adjacent units are sufficient. The expression of the internal factor is as follows:
所述θin表示内部因子,t表示当前单元(即当前选定的中心单元)的冷却时间,和分别表示第1圈第1个邻接单元和第n1个单元的冷却时间,和分别表示第2圈第1个邻接单元和第n2个单元的冷却时间,和分别表示第3圈第1个邻接单元和第n3个单元的冷却时间,和分别表示第m圈第1个邻接单元和第nm个单元的冷却时间,以上冷却时间均是在未设计冷却系统时计算所得。未设计冷却系统的本质其实是不考虑冷却系统的影响,反映在实际的仿真模拟计算过程中,先不进行冷却系统的建模,处理起来会更为简单。在其他实施例中,也可以在仿真过程中设计冷却系统后将其对单元冷却的影响调为0,但是模型调试过程会稍微复杂一些。The θ in represents an internal factor, and t represents the cooling time of the current unit (i.e. the currently selected center unit), and Respectively represent the cooling time of the 1st adjacent unit and the n1th unit in the 1st circle, and Respectively represent the cooling time of the first adjacent unit and the n2th unit in the second circle, and Respectively represent the cooling time of the first adjacent unit and the nth 3rd unit in the third circle, with Respectively represent the cooling time of the first adjacent unit of the mth circle and the n mth unit, and the above cooling times are calculated when the cooling system is not designed. The essence of not designing the cooling system is that it does not consider the influence of the cooling system. It is reflected in the actual simulation calculation process that it will be easier to deal with without modeling the cooling system first. In other embodiments, after the cooling system is designed during the simulation, its influence on the cooling of the unit can be adjusted to 0, but the model debugging process will be slightly more complicated.
步骤2:图3所示为恒温边界的有限长持续线热源的示意图,根据傅里叶导热微分方程可以求得瞬时点热源传热的解析解,在时间和空间上积分即可得有限长持续线热源的解析解。Step 2: Figure 3 shows a schematic diagram of a finite-length continuous line heat source with a constant temperature boundary. According to the Fourier heat conduction differential equation, the analytical solution of the heat transfer of an instantaneous point heat source can be obtained, and the finite-length continuous line can be obtained by integrating in time and space Analytical solution for a linear heat source.
由于边界恒温,因此在源热源与边界对称的位置添加一镜像热源,二者相减为外部因子,在本实施例中模具有上、下、左、右、前、后共6个面,需要设置6个镜像热源。因此,外部因子的计算公式如下:Due to the constant temperature of the boundary, a mirror image heat source is added at the position where the source heat source is symmetrical to the boundary, and the subtraction of the two is an external factor. In this embodiment, the mold has 6 surfaces, namely upper, lower, left, right, front and rear. Set up 6 mirrored heat sources. Therefore, the calculation formula of the external factor is as follows:
所述θex表示外部因子,i=1…6表示模具的六个边界面,和分别表示中心单元质心相对于源线热源轴线方向的坐标和源线热源关于边界面i的镜像线热源轴线方向的坐标,和表示源线热源的两个端点在轴线方向的坐标,和表示源线热源关于边界面i的镜像线热源的两个端点在轴线方向的坐标,ri 1和ri 2分别表示中心单元质心相对于源线热源距离和单元质心到源线热源关于边界面i的镜像线热源的距离。上述公式适用于具有不同数量边界面的模具。The θ ex represents the external factor, i=1...6 represents the six boundary surfaces of the mould, and represent the coordinates of the centroid of the central unit relative to the axis direction of the source-line heat source and the coordinates of the source-line heat source with respect to the axis direction of the mirror image line of the boundary surface i, respectively, with Indicates the coordinates of the two end points of the source line heat source in the axial direction, with Indicates the coordinates of the two end points of the source line heat source on the boundary surface i of the mirror image line heat source in the axis direction, r i 1 and r i 2 represent the distance from the center unit centroid to the source line heat source and the unit centroid to the source line heat source on the boundary surface The distance of the heat source to the image line of i. The above formula is valid for dies with different numbers of boundary surfaces.
步骤3:在获得内部因子和外部因子后,将包含初始设计的冷却系统方案进行CAE分析,得到综合热影响效应;Step 3: After obtaining the internal factors and external factors, conduct CAE analysis on the cooling system scheme including the initial design to obtain the comprehensive thermal impact effect;
步骤4:然后建立内部因子、外部因子和综合热影响效应的神经网络模型,将内部因子和外部因子作为神经网络模型的输入特征,综合热影响效应作为神经网络模型的期望输出。Step 4: Then establish a neural network model of internal factors, external factors and comprehensive thermal impact effects, use internal factors and external factors as the input features of the neural network model, and comprehensive thermal impact effects as the expected output of the neural network model.
优选地,本案例中采用BP神经网络模型,模型训练的最大迭代步数为1000,学习率为0.1,允许迭代误差0.0001。作为一个简单的示例性展示,本案例设计的BP神经网络模型包含四层:输入层、隐含层1、隐含层2与输出层;输入层表示内部因子和外部因子,包含57个节点;隐藏层1和隐藏层2分别包含120和10个节点;输出层表示综合热影响效应,包含1个节点。节点传递函数选取Sigmoid函数,公式为:Preferably, the BP neural network model is used in this case, the maximum number of iteration steps for model training is 1000, the learning rate is 0.1, and the iteration error is allowed to be 0.0001. As a simple example, the BP neural network model designed in this case contains four layers: input layer, hidden layer 1, hidden layer 2, and output layer; the input layer represents internal factors and external factors, and contains 57 nodes; Hidden layer 1 and hidden layer 2 contain 120 and 10 nodes, respectively; the output layer represents the comprehensive thermal effect and contains 1 node. The node transfer function selects the Sigmoid function, and the formula is:
其中,x表示节点的输入数据,S(x)表示节点的输出数据;Among them, x represents the input data of the node, and S(x) represents the output data of the node;
优选地,训练方法选取Levenberg-Marquardt算法,训练过程采用变步长调整和批处理的方法进行算法改进,以克服传统算法训练时间长和收敛慢的缺点。Preferably, the Levenberg-Marquardt algorithm is selected as the training method, and the training process adopts the method of variable step size adjustment and batch processing to improve the algorithm, so as to overcome the shortcomings of traditional algorithms such as long training time and slow convergence.
优选地,在训练之前,对内部因子和外部因子进行最大最小归一化处理。归一化方法为:Preferably, before training, the internal factors and external factors are subjected to maximum and minimum normalization processing. The normalization method is:
所述x0、xmin、xmax和xnorm分别表示原始数据、原始数据序列中的最小值、原始数据序列中的最大值和最大最小归一化后的数据。The x 0 , x min , x max and x norm represent the original data, the minimum value in the original data sequence, the maximum value in the original data sequence, and the maximum and minimum normalized data, respectively.
对于训练后的BP模型,利用其进行在线检测的方法如下:For the trained BP model, the method of using it for online detection is as follows:
步骤5:在注塑模具冷却系统的调整优化过程中,根据修改后冷却管道的尺寸及位置数据,按照步骤2的方法重新计算外部因子,内部因子则不用重新计算,直接沿用步骤1的结果,然后采用步骤4中训练得到的BP神经网络模型预测综合热影响效应。本案例的预测结果及实测结果如图5所示,由图5可知预测结果和实际结果的变化规律高度一致,能够准确反映塑料制品各部位因位置和结构不同而受到冷却系统的真实影响的差异,可以精确预测制品的过热点等缺陷。Step 5: During the adjustment and optimization process of the injection mold cooling system, according to the size and position data of the modified cooling pipe, recalculate the external factors according to the method of step 2, and the internal factors do not need to be recalculated, and the results of step 1 are directly used, and then Use the BP neural network model trained in step 4 to predict the comprehensive thermal impact effect. The prediction results and actual measurement results of this case are shown in Figure 5. From Figure 5, it can be seen that the variation rules of the prediction results and the actual results are highly consistent, which can accurately reflect the differences in the real influence of the cooling system on various parts of plastic products due to their different positions and structures. , can accurately predict defects such as hot spots of products.
本领域的技术人员容易理解,以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。It is easy for those skilled in the art to understand that the above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention, All should be included within the protection scope of the present invention.
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