CN112824090A - Control method of all-electric plastic injection molding machine - Google Patents
Control method of all-electric plastic injection molding machine Download PDFInfo
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- CN112824090A CN112824090A CN201911147895.0A CN201911147895A CN112824090A CN 112824090 A CN112824090 A CN 112824090A CN 201911147895 A CN201911147895 A CN 201911147895A CN 112824090 A CN112824090 A CN 112824090A
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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
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
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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
- B29C45/03—Injection moulding apparatus
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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
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- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The present disclosure relates to a control method for an all-electric plastic injection molding machine, the control method comprising: (S1) sampling the driving current received by the glue injection motor to obtain a first current value; (S2) calculating an operation current value, wherein the operation current value at least includes a current required by the injection motor for controlling the rotation speed; (S3) subtracting the operation current value from the first current value to obtain a second current value; and (S4) converting the second current value into a thrust force given to the material pipe by the glue injection screw, and converting the thrust force into an estimated value reflecting the pressure of the front end of the nozzle according to the sectional area of the material pipe.
Description
Technical Field
The present disclosure relates to plastic injection molding machines, and more particularly to a method for controlling an all-electric plastic injection molding machine.
Background
In recent years, as environmental awareness is gradually paid attention, many industrial equipments have been changed greatly, and the process equipment of the injection molding industry is evolving into an obvious example, and the process equipment is changed from the hydraulic equipment which is common in the past into all-electric equipment with a more environmental concept. As the name suggests, the power system of the all-electric plastic injection molding machine is driven by an electric motor, i.e. a servo motor or an induction motor is used to replace the original hydraulic cylinder or pneumatic cylinder. The all-electric plastic injection molding machine has the characteristics of rapidness, accuracy, stability, quietness, power saving, cleanness and the like, and can be called as a revolutionary milestone of the plastic injection molding machine. Therefore, the application market of the all-electric plastic injection molding machine is quite extensive, and it seems to be indiscriminate that the all-electric plastic injection molding machine is applied to the precision injection market (for example, semiconductor devices, information computer products, optical lenses, liquid crystal light guide plates, IC cards, electronic material devices … …, etc.) from general household industrial products (for example, silicone rubber products, PET containers, automobile parts, cosmetic containers, household containers, precision gears … …, etc.) and further with the advantages of rapidness, stability and quietness of the all-electric plastic injection molding machine. At present, in the operation flow of an all-electric plastic injection molding machine, a loading cell belonging to a pressure sensor is required to be applied in a glue injection pressure maintaining stage and a material storage metering stage, that is, the all-electric plastic injection molding machine senses the pressure when plastic is pushed out from a material pipe through the loading cell, and correspondingly adjusts a control strategy according to a pressure sensing value fed back by the loading cell.
However, since the all-electric plastic injection molding machine usually needs more than 4 servo drivers and servo motors with large wattage, the pressure of cost is very high, so that the cost reduction is an important part of the all-electric plastic injection molding machine. At present, some manufacturers consider to remove the load cell to achieve the purpose of saving cost, however, how to make the all-electric plastic injection molding machine without the load cell have good pressure control to maintain the injection effect is the focus of research and development.
Disclosure of Invention
The present disclosure is directed to a control method for an all-electric plastic injection molding machine, so that the all-electric plastic injection molding machine does not need a load cell, thereby saving the production cost and maintaining good injection effect.
To achieve the above object, a broader aspect of the present disclosure provides a control method for an all-electric plastic injection molding machine, the all-electric plastic injection molding machine including a glue injection motor, a speed reduction mechanism, a glue injection screw, a material tube, and a nozzle, the speed reduction mechanism increasing a torque of the glue injection motor by using a reduction ratio, the glue injection screw being driven by the glue injection motor via the torque output by the speed reduction mechanism to rotate and move, thereby pushing the material tube to convert plastic in the material tube into molten glue and inject the molten glue from the nozzle, the control method including: s1, when the all-electric plastic injection molding machine is running, sampling the driving current received by the injection motor to obtain a first current value; s2, calculating an operation current value, wherein the operation current value at least comprises the current required by the glue injection motor for controlling the rotating speed; s3 subtracting the operation current value from the first current value to obtain a second current value; and S4, converting the second current value into the thrust force given to the material pipe by the rubber injection screw, and converting the thrust force into an estimated value reflecting the pressure of the front end of the injection nozzle according to the sectional area of the material pipe.
Drawings
FIG. 1 is a schematic flow chart illustrating the steps of a control method for an all-electric plastic injection molding machine according to a first preferred embodiment of the present disclosure;
FIG. 2 is a schematic diagram of a simplified component structure of an all-electric plastic injection molding machine to which the control method of FIG. 1 is applied;
FIG. 3 is a schematic diagram illustrating the comparison between the front pressure of the nozzle sensed by the load cell of the conventional all-electric plastic injection molding machine and the front pressure of the nozzle estimated by the control method of FIG. 1 of the all-electric plastic injection molding machine according to the present disclosure;
FIG. 4 is a flowchart illustrating the steps of a control method for an all-electric plastic injection molding machine according to a second preferred embodiment of the present disclosure;
FIG. 5 is a schematic diagram illustrating the comparison between the front pressure of the nozzle sensed by the load cell of the conventional all-electric plastic injection molding machine and the front pressure of the nozzle estimated by the control method shown in FIG. 4 of the all-electric plastic injection molding machine according to the present disclosure;
FIG. 6 is a schematic diagram illustrating the relationship between the damping force applied to the injection motor of the all-electric plastic injection molding machine and the rotation speed of the injection motor according to the present disclosure;
FIG. 7 is a schematic diagram illustrating the relationship between the dynamic friction applied to the injection motor of the all-electric plastic injection molding machine and the rotation speed of the injection motor according to the present disclosure;
FIG. 8 is a schematic diagram showing the relationship between the number of molds and the weight of a 200-mold injection molding experiment performed by a conventional all-electric plastic injection molding machine with a load cell;
fig. 9 is a schematic diagram showing the relationship between the number of molds and the weight of the all-electric plastic injection molding machine shown in fig. 2 when the control method shown in fig. 4 is used to perform a 200-mold injection molding experiment.
Description of reference numerals:
1: all-electric plastic injection molding machine
10: motor driver
11: glue injection motor
12: speed reducing mechanism
13: injection screw
14: material pipe
15: nozzle
i: drive current
S1-S4: steps of the control method
Detailed Description
Some exemplary embodiments that incorporate the features and advantages of the present disclosure will be described in detail in the specification which follows. It is to be understood that the disclosure is capable of various modifications in various embodiments without departing from the scope of the disclosure, and that the description and drawings are to be regarded as illustrative in nature, and not as restrictive.
Referring to fig. 1 and 2, fig. 1 is a schematic flow chart illustrating a control method of an all-electric plastic injection molding machine according to a first preferred embodiment of the disclosure, and fig. 2 is a schematic structural diagram illustrating a simple component of the all-electric plastic injection molding machine to which the control method of fig. 1 is applied. As shown in fig. 1 and fig. 2, the control method of the present embodiment can be applied to an all-electric plastic injection molding machine 1, and can be performed when the all-electric plastic injection molding machine 1 is operated in an injection stage and a material storage metering stage, wherein the structure and operation of the all-electric plastic injection molding machine 1 are similar to those of the all-electric plastic injection molding machine 1 which is widely used, and only the difference is that the all-electric plastic injection molding machine 1 to which the control method of the present embodiment is applied does not need to have a load cell, so in fig. 2, only the part of the component structure of the all-electric plastic injection molding machine 1 which is related to the control method of the present embodiment is labeled, and the detailed structure and the overall operation of the all-electric plastic injection molding machine 1 are not described.
In the present embodiment, the all-electric plastic injection molding machine 1 mainly includes a motor driver 10, a plastic injection motor 11, a speed reduction mechanism 12, a plastic injection screw 13, a material pipe 14 and a nozzle 15. The motor driver 10 is used for providing a driving current i to drive the injection motor 11 to operate, and correspondingly adjusting the driving current i according to an operation parameter, such as the driving current i, of the all-electric plastic injection molding machine 1, which is fed back by a detection element (not shown) inside the all-electric plastic injection molding machine 1. The speed reducing mechanism 12 is connected to the glue injecting motor 11 and has a speed reducing ratio, and the speed reducing mechanism 12 can use the speed reducing ratio to achieve the purpose of reducing the rotation speed of the glue injecting motor 11 but increasing the torque. The pipe 14 is connected to a nozzle 15 and can be filled with plastic. The injection screw 13 is connected to the speed reduction mechanism 12 and the material pipe 14, and the injection screw 13 can be moved forward and backward by the injection motor 11 driven by the torque force output from the speed reduction mechanism 12, so as to push the plastic to be melted and transformed into molten plastic in the material pipe 14, and then the molten plastic is injected to a mold (not shown) from an injection nozzle 15 connected to the material pipe 14 in a moving manner.
The control method of the present embodiment can be executed by the motor driver 10, and the principle of the control method is mainly that the feedback value of the driving current i received by the glue injection motor 11 contains a lot of information, one of which is the front end pressure of the nozzle 15, and the pressure value is conventionally detected by the load cell, and in order to achieve the purpose of removing the load cell to save the cost of the all-electric plastic injection molding machine 1, the control method of the present embodiment is configured to separate the front end pressure of the nozzle 15 from the driving current i received by the glue injection motor 11, so that the operation of the all-electric plastic injection molding machine 1 can be correspondingly adjusted according to the separated front end pressure of the nozzle 15.
Therefore, the control method of the present embodiment is to firstly perform step S1, and sample the driving current i received by the glue injection motor 11 in a feedback manner when the all-electric plastic injection molding machine 1 is running, so as to obtain the first current value.
Next, step S2 is executed to calculate an operation current value, wherein the operation current value at least includes a current required for controlling the rotation speed of the glue injection motor 11. Since the current component having the largest proportion of the driving current i received by the glue motor 11 is the current required for accelerating or decelerating the glue motor 11, and the current required for accelerating or decelerating the glue motor 11 must be preferentially excluded from the driving current i in order to accurately estimate the tip pressure of the nozzle 15, the current required for accelerating or decelerating the glue motor 11 is calculated from the rotational speed of the glue motor 11 in step S2. The rotational speed of the glue injection motor 11 is given in rad/sec. Next, step S3 is executed to subtract the operation current value from the first current value to obtain a second current value.
As can be seen from the above, the component of the second current value actually excludes the current required by the glue injection motor 11 during acceleration or deceleration, so the second current value can more accurately reflect the front end pressure of the nozzle 15, and the control method of the embodiment in the step S3 is how to estimate the front end pressure of the nozzle 15 from the second current value. Therefore, when the step S3 is completed, that is, the step S4 is executed, the second current value is converted into a thrust force given to the material pipe 14 by the glue injection screw 13, and the thrust force is converted into an estimated value reflecting the pressure at the front end of the nozzle 15 according to the cross-sectional area of the material pipe 14.
In the above embodiment, in step S2, the rotation speed of the glue injection motor 11 may be sampled by an encoder (not shown) or the like to generate a sampling signal. After sampling the rotation speed of the glue injection motor 11, the sampling signal may be subjected to a first low-pass filtering to filter out high-frequency components in the sampling signal, wherein the first low-pass filtering sets a cut-off frequency of 800 hz. Then, under the sampling condition of 1m/sec, the rotational speed of the glue injection motor 11 reflected in the sampling signal after the first low-pass filtering is converted into an acceleration, and finally, the acceleration is converted into a current required for controlling the rotational speed of the glue injection motor 11 by using the following formula (1):
wherein I is a current required for controlling the rotation speed of the injection motor 11, J is an integral inertia of the injection screw driven by the injection motor 11, and Kt is a torque constant of the injection motor 11.
In step S4, the second current value is converted into the thrust force applied to the material pipe 14 by the injection screw 13 using the following equation (2):
wherein F is the thrust given to the material pipe 14 by the injection screw 13, and the unit is Kg, R is the reduction ratio of the reduction mechanism 12, and P is the lead of the injection screw 13, and the unit is mm.
In step S4, the thrust force F is converted into an estimated value reflecting the tip pressure of the nozzle 15 by the following equation (3):
wherein P0 is the estimated value of the pressure at the front end of the nozzle 15, and r is the radius of the sectional area of the material pipe 14.
In addition, in some embodiments, in step S4, after the thrust force F is converted into an estimated value reflecting the front pressure of the nozzle 15, a second low-pass filtering may be performed, wherein the second low-pass filtering is performed to set the cutoff frequency to be 5 to 20hz, and the second low-pass filtering is performed to simulate the delay time from the output of the glue-injecting motor 11 to the generation of the front pressure by the nozzle 15.
Please refer to fig. 3, which is a schematic diagram illustrating a comparison between the front pressure of the nozzle sensed by the load cell of the conventional all-electric plastic injection molding machine and the front pressure of the nozzle estimated by the control method shown in fig. 1 of the all-electric plastic injection molding machine according to the present disclosure. As shown in the figure, the line with a relatively dark color represents the front end pressure of the nozzle sensed by the conventional all-electric plastic injection molding machine using the load cell, and is denoted by a in the figure, the line with a relatively light color represents the estimated value of the front end pressure of the nozzle 15 estimated by the all-electric plastic injection molding machine according to the present disclosure using the control method shown in fig. 1, that is, the estimated value of the front end pressure of the nozzle obtained in step S4, and is denoted by b in the figure, the dotted frame i indicates that the all-electric plastic injection molding machine operates in the injection pressure maintaining stage, and the dotted frame ii indicates that the all-electric plastic injection molding machine operates in the stock material metering stage. As can be seen from fig. 3, since the wave pattern of the line b in the dashed box i and the dashed box ii is actually close to the wave pattern of the line a, the estimated value of the front end pressure of the nozzle 15 estimated by the control method according to the first preferred embodiment of the present disclosure can actually reflect the front end pressure of the nozzle sensed by the load cell of the conventional all-electric plastic injection molding machine, so that the all-electric plastic injection molding machine 1 using the control method according to the first preferred embodiment of the present disclosure can save cost without using the load cell, and can perform corresponding control using the estimated value of the front end pressure of the nozzle 15 to maintain good injection effect.
However, since a large offset (offset) still exists between the lines a and b in the dashed box ii of fig. 3, in order to more accurately estimate the pressure at the front end of the nozzle 15, the control method of the second preferred embodiment of the present disclosure further eliminates the influence of the damping force and the dynamic friction force applied when the glue injection motor 11 is operated from the driving current i (in order to simplify the calculation formula of the control method of the second embodiment, the control method of the second embodiment of the present disclosure ignores the static friction force), which will be described below.
Referring to fig. 4 and 5, fig. 4 is a flowchart illustrating a control method of an all-electric plastic injection molding machine according to a second preferred embodiment of the present disclosure, and fig. 5 is a schematic diagram illustrating a comparison between a front end pressure of a nozzle sensed by a load cell of a conventional all-electric plastic injection molding machine and a front end pressure of the nozzle estimated by the all-electric plastic injection molding machine according to the present disclosure using the control method illustrated in fig. 4. As shown in the figure, the control method of the present embodiment is similar to the control method shown in fig. 1, and in step S2, the operation current values of the control method of the present embodiment include a current corresponding to the damping force applied when the glue injection motor 11 is operated and a current corresponding to the dynamic friction force applied when the motor 10 is operated, in addition to the current required when the glue injection motor 11 performs the rotation speed control. Therefore, when the second current value is obtained by subtracting the operation current value from the first current value in step S3, the second current value excludes the current required for acceleration or deceleration of the glue injection motor 11, the current corresponding to the damping force applied when the glue injection motor 11 is operated, and the current corresponding to the dynamic friction force applied when the motor 10 is operated.
Referring to fig. 5, a relatively darker line color represents the front pressure of the nozzle sensed by the load cell of the conventional all-electric plastic injection molding machine, which is denoted by a in the drawing, a relatively lighter line color represents the front pressure of the nozzle 15 estimated by the all-electric plastic injection molding machine of the present disclosure using the control method shown in fig. 4, i.e., the estimated value of the front pressure of the nozzle 15 obtained in step S4, which is denoted by b in the drawing, and a dashed box i indicates that the all-electric plastic injection molding machine operates in the injection pressure maintaining stage, and a dashed box ii indicates that the all-electric plastic injection molding machine operates in the stock material metering stage. As can be seen from fig. 5, in both the dotted frame i and the dotted frame ii, the waveform of the line b is actually close to the waveform of the line a, and the offset (offset) between the line a and the line b is very small, so that the estimated value of the front pressure of the nozzle 15 estimated by the control method according to the second preferred embodiment of the present disclosure can more accurately reflect the front pressure of the nozzle sensed by the load cell of the conventional all-electric plastic injection molding machine compared to the control method according to the first preferred embodiment.
Referring to fig. 6 and 7, fig. 6 is a schematic diagram illustrating a relationship between a damping force applied to the injection motor of the all-electric plastic injection molding machine according to the present disclosure and a rotation speed of the injection motor, and fig. 7 is a schematic diagram illustrating a relationship between a dynamic friction force applied to the injection motor of the all-electric plastic injection molding machine according to the present disclosure and a rotation speed of the injection motor. As shown in the figure, in step S2 of the control method of the second embodiment, since the damping force applied when the glue injection motor 11 is running is substantially proportional to the rotation speed of the glue injection motor 11, when the rotation speed of the glue injection motor 11 is sampled by an encoder, the damping force applied when the glue injection motor 11 is running can be derived, and the corresponding current value can be converted according to the damping force. Similarly, the dynamic friction force applied when the glue injection motor 11 is operated is actually related to the rotation speed of the glue injection motor 11, so that the dynamic friction force applied when the glue injection motor 11 is operated can be estimated by sampling the rotation speed of the glue injection motor 11 by an encoder or the like, and the corresponding current value can be converted according to the dynamic friction force.
Referring to fig. 8 and 9, and the following table i and table ii, wherein fig. 8 is a schematic diagram showing a relationship between a mold number and a weight when a conventional all-electric plastic injection molding machine with a load cell performs a 200-mold injection molding experiment, fig. 9 is a schematic diagram showing a relationship between a mold number and a weight when the all-electric plastic injection molding machine shown in fig. 2 performs a 200-mold injection molding experiment by using the control method shown in fig. 4, table i is an experiment data table corresponding to fig. 8, and table ii is an experiment data table corresponding to fig. 9. As can be seen from fig. 8, 9, and the first and second tables, when the conventional all-electric plastic injection molding machine with load cell performs the injection molding operation of the 200 mold, the CV value (coefficient of variation value) is about nine per thousand at each mold sub-stage, and when the all-electric plastic injection molding machine using the control method shown in fig. 4 performs the injection molding operation of the 200 mold, the CV value (coefficient of variation value) is also about nine per thousand at each mold sub-stage end, which is not much different from that of the conventional all-electric plastic injection molding machine with load cell.
Watch two
In summary, the present disclosure provides a control method for an all-electric plastic injection molding machine, which can accurately estimate the front pressure of a nozzle by using the existing operating parameters of the all-electric plastic injection molding machine, so that the all-electric plastic injection molding machine using the control method does not need to provide a load cell to save the cost, and can maintain good injection effect.
Claims (7)
1. A control method is applied to an all-electric plastic injection molding machine, the all-electric plastic injection molding machine comprises an injection motor, a speed reducing mechanism, an injection screw, a material pipe and an injection nozzle, the speed reducing mechanism is used for improving the torque force of the injection motor, the injection screw is driven by the torque force output by the injection motor through the speed reducing mechanism to move, and further the plastic of the material pipe in the material pipe is pushed to be converted into molten plastic and injected from the injection nozzle, the control method comprises the following steps:
s1, when the all-electric plastic injection molding machine is running, sampling a driving current received by the injection motor to obtain a first current value;
s2, calculating an operation current value, wherein the operation current value at least includes the current required by the injection motor for controlling the rotation speed;
s3 subtracting the operation current value from the first current value to obtain a second current value; and
s4, converting the second current value into a thrust force given to the material pipe by the rubber injection screw, and converting the thrust force into an estimated value reflecting the front end pressure of the nozzle according to the section area of the material pipe.
2. The control method of claim 1, wherein in the step S2, the rotational speed of the shooting motor is sampled to generate a sampling signal, the sampling signal is subjected to a first low-pass filtering, the rotational speed of the shooting motor reflected in the filtered sampling signal is converted into an acceleration, and the acceleration is converted into a current required by the shooting motor for controlling the rotational speed.
3. The control method according to claim 2, wherein the first low-pass filtering in step S2 sets the cutoff frequency to 800 hz.
4. The control method according to claim 1, wherein in the step S4, after converting the thrust into the estimated value reflecting the front end pressure of the nozzle, the estimated value is further subjected to a second low-pass filtering.
5. The control method according to claim 4, wherein the second low pass filtering sets the cutoff frequency to be 5 to 20 hz.
6. The control method according to claim 1, wherein in the step S2, the operation current further includes a current corresponding to a damping force applied when the glue injection motor is operated and a current corresponding to a dynamic friction force applied when the motor is operated.
7. The control method according to claim 1, wherein the control method is performed when the all-electric plastic injection molding machine is operating in a glue injection pressure maintaining stage and a stock metering stage, respectively.
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