CN112008951A - Intelligent energy-saving control system for injection molding drying temperature - Google Patents
Intelligent energy-saving control system for injection molding drying temperature Download PDFInfo
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- CN112008951A CN112008951A CN202010651592.9A CN202010651592A CN112008951A CN 112008951 A CN112008951 A CN 112008951A CN 202010651592 A CN202010651592 A CN 202010651592A CN 112008951 A CN112008951 A CN 112008951A
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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
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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
- B29C2045/0096—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor drying the moulding material before injection, e.g. by heating
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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
- 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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- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The invention aims to provide an intelligent energy-saving control system for injection molding drying temperature, which is wide in application range. The invention comprises a processor, a PID controller, a PD controller and the following steps: A. setting a wind speed command, a target temperature and a temperature difference value, periodically scanning the wind speed command by a processor and controlling the rotating speed of a fan by a frequency converter; B. a temperature sensor in the charging barrel collects a plurality of temperature data in a fixed period and sorts the data according to the magnitude of the values; C. taking partial data positioned in the middle sequence in the sorted temperature data combination, summing and averaging the partial data, and further obtaining the current temperature; D. the target temperature is different from the current temperature, a temperature rise stage is carried out when the difference value is greater than the temperature difference value, and the difference value obtained at present is input into a PID controller to control the temperature of the heating rod; E. and when the difference is smaller than or equal to the temperature difference, the heat preservation stage is carried out, and the currently obtained difference is input into the PD controller to control the temperature of the heating rod. The invention is applied to the technical field of intelligent energy-saving control of injection molding drying temperature.
Description
Technical Field
The invention is applied to the technical field of injection molding drying temperature control, and particularly relates to an intelligent energy-saving control system for injection molding drying temperature.
Background
The injection molding equipment needs to dry the raw materials in the charging barrel before injection molding, and the raw materials are processed after drying and then enter the equipment for injection molding operation. The traditional drying temperature control system for the charging barrel of the injection molding machine detects the temperature in the charging barrel through a temperature sensing probe, compares the temperature with a set temperature, and controls the on-off of a heating rod to control whether the temperature is compensated. The heating rod is controlled to heat by controlling the opening and closing of the pneumatic switch or the contactor, and then the heat of the heating rod is taken away by the air supplied by the fan running at full power, so that the effect of the constant temperature fan is realized. However, the power consumption is high, and when the blower is operated at full speed, the heat of the heating rod is rapidly taken away, so that the heating rod needs to be heated frequently. Meanwhile, the heating mode has large temperature fluctuation which is about +/-5 ℃, and is not suitable for materials with small drying temperature range such as polyformaldehyde.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides an intelligent energy-saving control system for injection molding drying temperature, which is wide in application range.
The technical scheme adopted by the invention is that the injection molding drying temperature control system comprises a processor, a PID controller and a PD controller, and the injection molding drying temperature control system controls the injection molding drying temperature according to the following steps:
A. the processor reads a fan speed command preset by a user in a first fixed period T1, the processor outputs the fan speed command to the frequency converter through an internal digital-to-analog conversion module, and the frequency converter adjusts the output frequency according to the input voltage so as to control the fan speed;
B. setting a target temperature value D _ TEMP and a temperature difference value, circularly acquiring temperature information in a charging barrel of the injection molding machine by a temperature sensor in the charging barrel in a second fixed period T2 by the processor, setting the acquisition number of temperature data in the second fixed period T2 as N1, sequencing N1 acquired temperature data from small to large by the processor, and sequentially allocating serial numbers 1 to N1 to the sequenced N1 temperature data;
C. the processor extracts the N2 temperature data in the middle of the N1 temperature data after sorting, namely the temperature data with the serial numbers of [ ((N1-N2)/2) +1] to (N1+ N2)/2, sums the N2 temperature data and divides the sum by N2 to obtain an average value, and the average value is used as the current temperature TEMP of the charging barrel in the second fixed period T2;
D. when the difference value between the target temperature D _ TEMP and the current temperature TEMP is larger than the temperature difference value, the charging barrel is in a heating state, the processor inputs the calculated difference value delta TEMP into the PID controller, the PID controller calculates and outputs a pulse width modulation signal to a pressure regulating module of a heating rod on the injection molding machine according to the target temperature D _ TEMP, and the pressure regulating module controls the heating power of the heating rod;
E. when the difference value between the target temperature D _ TEMP and the current temperature TEMP is smaller than or equal to the temperature difference value, the charging barrel enters a heat preservation state, the processor inputs the calculated difference value delta TEMP into the PD controller, the PD controller outputs a pulse width modulation signal to a pressure regulating module of a heating rod on the injection molding machine, and the pressure regulating module controls the heating power of the heating rod.
It is obvious by above-mentioned scheme, keep the heat energy of heating rod output stable through the speed of artifical settlement fan, avoid the cooling too fast make the heating rod frequently heat increase the power consumption. The fan rotating speed is more stable through the periodic scanning wind speed instruction, and the fan can respond in time after the wind speed instruction is modified. And filtering interference data in the temperature data samples by taking the data in the middle of the sequence and summing the partial data to obtain an average value. And the PID controller consists of a proportional unit P, an integral unit I and a differential unit D, and can stably and reliably control the temperature rise stage through PID control. When the temperature TEMP in the charging barrel is close to the set target temperature D _ TEMP, the influence of an integral unit I in a PID controller on the temperature can be avoided by adopting the PD controller to carry out temperature control, so that the stability of a heat preservation state is improved, the temperature fluctuation is controlled to +/-1.6 ℃, and the requirement of the drying temperature of most accommodation raw materials is met. When the collection number N1 and the reservation number N2 are both odd numbers or even numbers, the data are accurate. The temperature difference value is +/-1 ℃ to +/-3 ℃. The intelligent energy-saving injection molding drying temperature control system can also be applied to other scenes in which drying temperature control is needed, such as temperature control during barn drying or during other raw material drying. The temperature sensor is positioned in the air inlet pipe of the charging barrel and used for detecting the temperature output by the heating rod. Different target temperatures D _ TEMP are set according to different raw materials so as to meet the drying requirement.
Preferably, the processor is a microcontroller of type STC98C 52.
Preferably, the model formula of the PID controller is as followsWhereinIs the output of the PID, and,is a coefficient of proportionality that is,is the difference between the current temperature and the target temperature,is the coefficient of the integral of the signal,is the accumulation of the error(s),is a coefficient of the differential to be,is the difference between the last temperature and the target temperature; the model formula of the PD controller isWhereinIs the output of the PID, and,is a coefficient of proportionality that is,is the difference between the current temperature TEMP and the target temperature D _ TEMP,is a coefficient of the differential to be,is the difference between the last temperature and the target temperature D _ TEMP.
Preferably, the step a further comprises the following steps: the initial fan speed command is fan minimum rotating speed S0 set by a user, the input voltage of a frequency converter corresponding to the wind speed is V0, the maximum rotating speed of the fan controlled by the frequency converter is Smax, the input voltage of the frequency converter corresponding to the maximum wind speed is Vmax, a set target temperature D _ TEMP and the current temperature TEMP are differenced to obtain delta TEMP, the temperature difference delta TEMP is input into a PI controller, the output voltage V of the PI controller is converted to the frequency converter to control the rotating speed of the fan, and the model formula of the PI controller is V0And simultaneously performing amplitude limiting processing on the output of the PI controller, namely when the value of V is smaller than V0, the output of the PI controller is V0, and when the value of V is larger than Vmax, the output of the PI controller is equal to Vmax, whereinIs a coefficient of proportionality that is,is the difference between the current temperature TEMP and the target temperature D _ TEMP,is the coefficient of the integral of the signal,is an error accumulation.
According to the scheme, the initial fan speed command is the minimum rotating speed of the fan set by a user, the PI controller calculates through a model formula, then obtains the required fan speed command according to the difference value of the target temperature and the current temperature, outputs voltage to the frequency converter to adjust the rotating speed of the fan, automatically controls the rotating speed of the fan, and achieves the effect of automatic energy saving.
Drawings
FIG. 1 is a flowchart illustrating a first embodiment of the present invention;
FIG. 2 is a temperature change diagram of a traditional injection molding machine charging barrel drying temperature control system in a heat preservation state;
FIG. 3 is a graph showing temperature changes in the heat-retaining state of the present invention;
fig. 4 is a flowchart of the operation of the second embodiment of the present invention.
Detailed Description
The first embodiment is as follows:
as shown in fig. 1, in this embodiment, the present invention includes a processor, a PID controller, and a PD controller, and the control system controls the injection molding drying temperature according to the following steps:
A. the processor reads a fan speed command preset by a user in a first fixed period T1, the processor outputs the fan speed command to the frequency converter through an internal digital-to-analog conversion module, and the frequency converter adjusts the output frequency according to the input voltage so as to control the fan speed;
B. setting a target temperature value D _ TEMP and a temperature difference value, circularly acquiring temperature information in a charging barrel of the injection molding machine by a temperature sensor in the charging barrel in a second fixed period T2 by the processor, setting the acquisition number of temperature data in the second fixed period T2 as N1, sequencing N1 acquired temperature data from small to large by the processor, and sequentially allocating serial numbers 1 to N1 to the sequenced N1 temperature data;
C. the processor extracts the N2 temperature data in the middle of the N1 temperature data after sorting, namely the temperature data with the serial numbers of [ ((N1-N2)/2) +1] to (N1+ N2)/2, sums the N2 temperature data and divides the sum by N2 to obtain an average value, and the average value is used as the current temperature TEMP of the charging barrel in the second fixed period T2;
D. when the difference value between the target temperature D _ TEMP and the current temperature TEMP is larger than the temperature difference value, the charging barrel is in a heating state, the processor inputs the calculated difference value delta TEMP into the PID controller, the PID controller calculates and outputs a pulse width modulation signal to a pressure regulating module of a heating rod on the injection molding machine according to the target temperature D _ TEMP, and the pressure regulating module controls the heating power of the heating rod;
E. when the difference value between the target temperature D _ TEMP and the current temperature TEMP is smaller than or equal to the temperature difference value, the charging barrel enters a heat preservation state, the processor inputs the calculated difference value delta TEMP into the PD controller, the PD controller outputs a pulse width modulation signal to a pressure regulating module of a heating rod on the injection molding machine, and the pressure regulating module controls the heating power of the heating rod.
In this embodiment, the processor is a microcontroller of type STC98C 52.
In this embodiment, the fan is the three-phase fan, and the converter is the three-phase converter, and then realizes providing more powerful air supply effect.
In this embodiment, the model formula of the PID controller isWhereinIs the output of the PID, and,is a coefficient of proportionality that is,is the difference between the current temperature and the target temperature,is the coefficient of the integral of the signal,is the accumulation of the error(s),is a coefficient of the differential to be,is the difference between the last temperature and the target temperatureA value; the model formula of the PD controller isWhereinIs the output of the PID, and,is a coefficient of proportionality that is,is the difference between the current temperature TEMP and the target temperature D _ TEMP,is a coefficient of the differential to be,is the difference between the last temperature and the target temperature D _ TEMP.
In this embodiment, the voltage regulation module includes a silicon controlled rectifier power circuit, an output power control circuit, a phase detection circuit, an over-temperature detection circuit, and a cooling fan. The silicon controlled power circuit is used for connecting the input of a three-phase power supply and the output of the voltage regulating module; the output power control circuit is used for controlling the conduction phase angle of the silicon controlled power circuit; the phase detection circuit is used for detecting the phase angle of the alternating current; the temperature detection circuit is used for testing the temperature of the voltage regulation module and performing over-temperature protection; the heat radiation fan is used for radiating heat for the pressure regulating module.
As shown in fig. 2, when the target temperature was set to 70 ℃, the temperature change of the conventional injection molding machine charging barrel drying temperature control system was monitored by a temperature recorder through a double thermocouple as shown in the following graph. In the heat preservation stage, the temperature fluctuation range tested by the temperature recorder is 69.4-80.3 ℃, and the temperature fluctuation is about +/-5 ℃. The average value of the temperatures is 75.07 ℃ which is 5.07 ℃ higher than the set temperature of 70 ℃.
As shown in fig. 3, when the target temperature is set to 70 ℃, the temperature recorder is used to monitor the temperature change of the intelligent energy-saving injection molding drying temperature control method through the two thermocouples, as shown in the following chart. In the heat preservation stage, the temperature fluctuation range tested by the temperature recorder is 68.38-71.6 ℃, and the temperature fluctuation is about +/-1.6 ℃. The average value of the temperature of 69.99 ℃ is 0.01 ℃ lower than the set temperature of 70 ℃.
The target temperature is set to be 70 ℃, the average electricity consumption per hour is tested by an electricity consumption meter, and the test results are as follows:
in manual control, the frequency converter is mainly adjusted to be 20 Hz-30 Hz in output frequency.
Different target temperatures are set according to different raw materials to meet the drying requirement. For example, the drying temperature of ABS plastic is more than 80 ℃, and the drying time is more than two hours; the drying temperature of the PS plastic is 70-80 ℃, and the drying time is one to two hours; the drying temperature of the PE plastic is 60-80 ℃, and the drying time is one to two hours; the drying temperature of the PP plastic is 60-80 ℃, and the drying time is one to two hours; the drying temperature of the PVC plastic is 60-70 ℃, and the drying time is one to two hours; the drying temperature of the PMMA plastic is 80-90 ℃, and the drying time is more than three hours; the drying temperature of the PA plastic is more than 80 ℃, and the drying time is four to six hours; the drying temperature of the PC plastic is more than 120 ℃, and the drying time is two to four hours; the drying temperature of the POM plastic is more than 80 ℃, and the drying time is more than two hours; drying the MPPO plastic at the temperature of 80-100 ℃ for two to four hours; the drying temperature of the PBT plastic is above 130 ℃, and the drying time is three to forty-two hours; the drying temperature of the R-PET plastic is above 130 ℃, and the drying time is four to five hours; the drying temperature of the PPS plastic is 130-180 ℃, and the drying time is one to three hours; the drying temperature of the PES plastic is about 180 ℃, and the drying time is more than three hours; the PEEK plastic is dried at the temperature of about 150 ℃ for more than three hours.
Example two:
as shown in FIG. 4, this embodimentThe difference from the first embodiment is that the step a further includes the following steps: the initial fan speed command is fan minimum rotating speed S0 set by a user, the input voltage of a frequency converter corresponding to the wind speed is V0, the maximum rotating speed of the fan controlled by the frequency converter is Smax, the input voltage of the frequency converter corresponding to the maximum wind speed is Vmax, a set target temperature D _ TEMP and the current temperature TEMP are differenced to obtain delta TEMP, the temperature difference delta TEMP is input into a PI controller, the output voltage V of the PI controller is converted to the frequency converter to control the rotating speed of the fan, and the model formula of the PI controller is V0And simultaneously performing amplitude limiting processing on the output of the PI controller, namely when the value of V is smaller than V0, the output of the PI controller is V0, and when the value of V is larger than Vmax, the output of the PI controller is equal to Vmax, whereinIs a coefficient of proportionality that is,is the difference between the current temperature TEMP and the target temperature D _ TEMP,is the coefficient of the integral of the signal,is an error accumulation.
In this embodiment, the first fixed period T1 and the second fixed period T2 have the same size and start at the same time, so that the fan adjustment and the temperature control are performed synchronously.
Claims (4)
1. The utility model provides an intelligent energy-saving control system of stoving temperature of moulding plastics, its characterized in that, it includes treater, PID controller and PD controller, and this control system controls the stoving temperature of moulding plastics according to following step:
A. the processor reads a fan speed command preset by a user in a first fixed period T1, the processor outputs the fan speed command to the frequency converter through an internal digital-to-analog conversion module, and the frequency converter adjusts the output frequency according to the input voltage so as to control the fan speed;
B. setting a target temperature value D _ TEMP and a temperature difference value, circularly acquiring temperature information in a charging barrel of the injection molding machine by a temperature sensor in the charging barrel in a second fixed period T2 by the processor, setting the acquisition number of temperature data in the second fixed period T2 as N1, sequencing N1 acquired temperature data from small to large by the processor, and sequentially allocating serial numbers 1 to N1 to the sequenced N1 temperature data;
C. the processor extracts the N2 temperature data in the middle of the N1 temperature data after sorting, namely the temperature data with the serial numbers of [ ((N1-N2)/2) +1] to (N1+ N2)/2, sums the N2 temperature data and divides the sum by N2 to obtain an average value, and the average value is used as the current temperature TEMP of the charging barrel in the second fixed period T2;
D. when the difference value between the target temperature D _ TEMP and the current temperature TEMP is larger than the temperature difference value, the charging barrel is in a heating state, the processor inputs the calculated difference value delta TEMP into the PID controller, the PID controller calculates and outputs a pulse width modulation signal to a pressure regulating module of a heating rod on the injection molding machine according to the target temperature D _ TEMP, and the pressure regulating module controls the heating power of the heating rod;
E. when the difference value between the target temperature D _ TEMP and the current temperature TEMP is smaller than or equal to the temperature difference value, the charging barrel enters a heat preservation state, the processor inputs the calculated difference value delta TEMP into the PD controller, the PD controller outputs a pulse width modulation signal to a pressure regulating module of a heating rod on the injection molding machine, and the pressure regulating module controls the heating power of the heating rod.
2. The intelligent energy-saving injection molding drying temperature control system according to claim 1, characterized in that: the processor is a microcontroller of type STC98C 52.
3. The intelligent energy-saving injection molding drying temperature control system according to claim 1, characterized in that: the model formula of the PID controller isWhereinIs the output of the PID, and,is a coefficient of proportionality that is,is the difference between the current temperature and the target temperature,is the coefficient of the integral of the signal,is the accumulation of the error(s),is a coefficient of the differential to be,is the difference between the last temperature and the target temperature; the model formula of the PD controller isWhereinIs the output of the PID, and,is a coefficient of proportionality that is,is the difference between the current temperature TEMP and the target temperature D _ TEMP,is a coefficient of the differential to be,is the difference between the last temperature and the target temperature.
4. The intelligent energy-saving injection molding drying temperature control system according to claim 1, wherein the step A further comprises the following steps: the initial fan speed command is fan minimum rotating speed S0 set by a user, the input voltage of a frequency converter corresponding to the wind speed is V0, the maximum rotating speed of the fan controlled by the frequency converter is Smax, the input voltage of the frequency converter corresponding to the maximum wind speed is Vmax, a set target temperature D _ TEMP and the current temperature TEMP are differenced to obtain delta TEMP, the temperature difference delta TEMP is input into a PI controller, the output voltage V of the PI controller is converted to the frequency converter to control the rotating speed of the fan, and the model formula of the PI controller is V0And simultaneously performing amplitude limiting processing on the output of the PI controller, namely when the value of V is smaller than V0, the output of the PI controller is V0, and when the value of V is larger than Vmax, the output of the PI controller is equal to Vmax, whereinIs a coefficient of proportionality that is,is the difference between the current temperature TEMP and the target temperature D _ TEMP,is the coefficient of the integral of the signal,is an error accumulation.
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CN115214101A (en) * | 2022-07-18 | 2022-10-21 | 深圳市谷德科技有限公司 | Temperature control method and system for mold injection |
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CN115214101A (en) * | 2022-07-18 | 2022-10-21 | 深圳市谷德科技有限公司 | Temperature control method and system for mold injection |
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CN117283750A (en) * | 2023-11-27 | 2023-12-26 | 国网甘肃省电力公司电力科学研究院 | New material masterbatch environment-friendly drying equipment and drying method |
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