CN114750382B - Injection molding pressure control system and control method - Google Patents
Injection molding pressure control system and control method Download PDFInfo
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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
- 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
- B29C2945/76498—Pressure
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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
- B29C2945/76929—Controlling method
- B29C2945/76956—Proportional
- B29C2945/76966—Proportional and integral, i.e. Pl regulation
- B29C2945/76969—Proportional and integral, i.e. Pl regulation derivative and integral, i.e. PID regulation
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Abstract
Description
技术领域Technical field
本发明涉及注塑机控制技术领域,特别涉及一种注塑压力控制系统和控制方法。The invention relates to the technical field of injection molding machine control, and in particular to an injection molding pressure control system and a control method.
背景技术Background technique
目前,塑料制品在现代社会中被广泛使用,从生活用品到工业配件、医疗器械,到处都离不开塑料制品,人们对于塑料制品的质量要求也在逐步提升,但是传统的注塑成型的方法所制得的塑料制品因为在注塑过程的注射压力而产生一些变形,或者是由于保压过程中的保压压力不足产生收缩或者翘曲变形,因此如何有效地对注塑过程和成形过程进行精确有效的压力控制成为注塑生产中必须要考虑的问题。At present, plastic products are widely used in modern society. From daily necessities to industrial accessories and medical equipment, plastic products are inseparable from everywhere. People's quality requirements for plastic products are also gradually increasing. However, traditional injection molding methods The plastic products produced may undergo some deformation due to the injection pressure during the injection molding process, or may shrink or warp due to insufficient holding pressure during the holding process. Therefore, how to effectively and accurately control the injection molding and forming processes? Pressure control has become an issue that must be considered in injection molding production.
专利号为CN 103481479 B的发明专利公开了一种注塑成型机的压力控制装置,该专利设置了保压部、计量部和预备注射部,其中,保压部基于利用检测螺杆沿轴心方向受到的力的力检测部检测出的力进行压力控制,此外,预备注射部基于利用树脂压力检测部检测的树脂压力进行压力控制。能够更加准确地检测出注塑成型机中的压力而进行压力控制。但是该专利无法对压力的变化速度进行精确的控制以及压力控制滞后,控制方法存在局限性。The invention patent with patent number CN 103481479 B discloses a pressure control device for an injection molding machine. The patent is provided with a pressure maintaining part, a metering part and a preparatory injection part. The pressure maintaining part is based on the detection of the screw along the axis direction. The force detected by the force detection unit performs pressure control, and the preliminary injection unit performs pressure control based on the resin pressure detected by the resin pressure detection unit. It can more accurately detect the pressure in the injection molding machine and perform pressure control. However, this patent cannot accurately control the speed of pressure change and the pressure control lags behind. The control method has limitations.
发明内容Contents of the invention
针对上述注塑压力控制滞后,对压力变化速率无法精确控制的问题,本发明提供了一种注塑压力控制系统和控制方法,通过PID控制模块对注塑时的压力变化速率以及注塑压力进行控制方法,达到了对注塑压力和压力变化速率及时、精确控制的目的。In view of the above-mentioned injection pressure control lag and the inability to accurately control the pressure change rate, the present invention provides an injection molding pressure control system and a control method, which uses a PID control module to control the pressure change rate and injection pressure during injection molding to achieve In order to achieve the purpose of timely and precise control of injection molding pressure and pressure change rate.
本发明的上述技术问题主要是通过下述技术方案得以解决的:本发明的一种注塑压力控制系统包括模具压力感应模块、喷嘴压力感应模块、比较模块、驱动控制模块、测速模块、PID控制模块和主控模块,所述模具压力感应模块和主控模块连接,所述主控模块和喷嘴压力感应模块连接,所述喷嘴压力感应模块和PID控制模块连接,所述驱动控制模块和测速模块以及PID控制模块连接,所述测速模块和比较模块连接,所述比较模块和PID控制模块连接,所述模具压力感应模块和PID控制模块连接,所述主控模块和PID控制模块连接。其中,所述测速模块用于获取螺杆的转动速度,所述比较模块用于输入待注射材料的注射时理想压力变换曲线。The above technical problems of the present invention are mainly solved through the following technical solutions: an injection molding pressure control system of the present invention includes a mold pressure sensing module, a nozzle pressure sensing module, a comparison module, a drive control module, a speed measurement module, and a PID control module and the main control module, the mold pressure sensing module is connected to the main control module, the main control module is connected to the nozzle pressure sensing module, the nozzle pressure sensing module is connected to the PID control module, the drive control module is connected to the speed measurement module and The PID control module is connected, the speed measurement module is connected to the comparison module, the comparison module is connected to the PID control module, the mold pressure sensing module is connected to the PID control module, and the main control module is connected to the PID control module. Among them, the speed measurement module is used to obtain the rotation speed of the screw, and the comparison module is used to input the ideal pressure transformation curve during injection of the material to be injected.
作为优选,所述模具压力感应模块包括模具型腔压力传感器,所述模具型腔压力传感器和主控模块连接。所述模具压力感应模块还包括警示模块,当压力超过材料成型所需压力阈值时发出警报。Preferably, the mold pressure sensing module includes a mold cavity pressure sensor, and the mold cavity pressure sensor is connected to the main control module. The mold pressure sensing module also includes a warning module that issues an alarm when the pressure exceeds a pressure threshold required for material molding.
作为优选,所述主控模块包括取样模块、处理模块和参数配置模块,所述参数配置模块和喷嘴压力感应模块连接,所述处理模块和PID控制模块连接。所述取样模块用于获取待加工材料的注塑时各阶段的压力阈值以及注塑各阶段的时间阈值,所述处理模块用于获取压力信号,并将其传输至PID控制模块。所述喷嘴压力感应模块包括高温熔体压力传感器。Preferably, the main control module includes a sampling module, a processing module and a parameter configuration module, the parameter configuration module is connected to the nozzle pressure sensing module, and the processing module is connected to the PID control module. The sampling module is used to obtain the pressure thresholds at each stage of injection molding of the material to be processed and the time thresholds at each stage of injection molding. The processing module is used to obtain pressure signals and transmit them to the PID control module. The nozzle pressure sensing module includes a high temperature melt pressure sensor.
作为优选,所述驱动控制模块包括转速信号整形模块,所述信号转换模块和PID控制模块连接。所述信号转换模块将转速信号转换为控制信号,同时将PID控制模块形成的反馈信号转换为速度控制信号。Preferably, the drive control module includes a rotational speed signal shaping module, and the signal conversion module is connected to the PID control module. The signal conversion module converts the rotational speed signal into a control signal, and at the same time converts the feedback signal formed by the PID control module into a speed control signal.
一种注塑压力控制方法,包括步骤:An injection molding pressure control method includes the steps:
S1通过参数配置模块对喷嘴压力感应模块设置第一压力阈值、第二压力阈值和第三压力阈值;S1 sets the first pressure threshold, the second pressure threshold and the third pressure threshold to the nozzle pressure sensing module through the parameter configuration module;
S2向比较模块中输入待注射材料的注射时理想压力变换曲线;S2 inputs the ideal pressure transformation curve during injection of the material to be injected into the comparison module;
S3通过测速模块测得螺杆的转速,将其传入驱动控制模块;S3 measures the speed of the screw through the speed measurement module and transmits it to the drive control module;
S4所述驱动控制模块将转速信号转换为控制信号传入PID控制模块;The drive control module in S4 converts the rotational speed signal into a control signal and transmits it to the PID control module;
S5使用模具压力感应模块和喷嘴压力感应模块测得压力,将压力信号传入PID控制模块;S5 uses the mold pressure sensing module and the nozzle pressure sensing module to measure the pressure, and transmits the pressure signal to the PID control module;
S6所述PID控制模块根据比较模块输入的理想压力变换曲线进行压力控制。The PID control module in S6 performs pressure control according to the ideal pressure transformation curve input by the comparison module.
其中所述注塑时理想压力变换曲线包括注射过程的压力曲线,保压过程的压力曲线和成型过程的总曲线,所述参数配置模块还可以对注塑过程各阶段的时间阈值进行配置。The ideal pressure transformation curve during injection molding includes the pressure curve of the injection process, the pressure curve of the pressure holding process and the overall curve of the molding process. The parameter configuration module can also configure the time thresholds of each stage of the injection molding process.
作为优选,所述步骤S1具体包括:Preferably, step S1 specifically includes:
S11员工向采样模块中输入注塑所用材料注塑成型时最大注射压力以及保压压力;S11 employees input the maximum injection pressure and holding pressure of the materials used for injection molding into the sampling module;
S12将最大注射压力的50%设为第一压力阈值,90%设为第二压力阈值,将保压压力设为第三压力阈值。S12 sets 50% of the maximum injection pressure as the first pressure threshold, 90% as the second pressure threshold, and sets the holding pressure as the third pressure threshold.
根据需求,若保压过程分为更多阶段还可以根据各阶段设置更多的压力阈值。According to needs, if the pressure holding process is divided into more stages, more pressure thresholds can be set according to each stage.
作为优选,所述步骤S6具体包括:Preferably, step S6 specifically includes:
S61所述PID控制模块根据理想压力变换曲线生成注射增长速率变化率下限阈值K1和上限阈值K2;The PID control module in S61 generates the lower limit threshold K1 and the upper limit threshold K2 of the injection growth rate change rate based on the ideal pressure transformation curve;
S62当注射增长速率处于[K1,K2]区间外时,PID控制模块向驱动控制模块生成反馈信号,控制螺杆转速增加/减少,直至注射增长速率变化率处于[K1,K2]区间内;S62 When the injection growth rate is outside the [K1, K2] interval, the PID control module generates a feedback signal to the drive control module to control the screw speed to increase/decrease until the injection growth rate change rate is within the [K1, K2] interval;
S63当喷嘴处压力达到第一压力阈值时,处理模块向PID控制模块传输转换提醒信号,所述PID控制模块生成注射速率变化率阈值K3,将所述注射速率变化率变换控制于[K2,K3];S63 When the pressure at the nozzle reaches the first pressure threshold, the processing module transmits a conversion reminder signal to the PID control module. The PID control module generates the injection rate change rate threshold K3 and controls the injection rate change rate transformation to [K2, K3 ];
S64当注射压力达到第二压力阈值时,处理模块判断是否进入保压过程,若是,PID控制模块,块生成注射下降速率变化率阈值K4,并控制螺杆转速将注射下降速率变化率控制在[0.9K4,1.1K4],直至喷嘴处压力为第三压力阈值。S64 When the injection pressure reaches the second pressure threshold, the processing module determines whether to enter the pressure maintaining process. If so, the PID control module generates the injection drop rate change rate threshold K4, and controls the screw speed to control the injection drop rate change rate at [0.9 K4,1.1K4], until the pressure at the nozzle reaches the third pressure threshold.
其中处于保压过程时若分为多个阶段,PID控制模块还可以在后续的保压阶段生成更多的注射下降速率变化率。If the pressure holding process is divided into multiple stages, the PID control module can also generate more injection drop rate changes in subsequent pressure holding stages.
本发明的有益效果:Beneficial effects of the present invention:
1.可以根据所要注塑的材料进行设备的参数设置,提高了注塑效率;1. The equipment parameters can be set according to the material to be injected, which improves the injection molding efficiency;
2.提高了对注塑压力的控制精度和控制速度;2. Improved the control accuracy and speed of injection molding pressure;
3.可以对注塑时注射压力的增长速度以及转换为保压过程时的压力转换速度进行精确控制,使得生产出来的产品质量更高。3. It can accurately control the growth rate of injection pressure during injection molding and the pressure conversion speed when converting to pressure holding process, making the products produced with higher quality.
附图说明Description of the drawings
图1是本发明的一种结构示意图。Figure 1 is a schematic structural diagram of the present invention.
图2是本发明的一种方法流程图。Figure 2 is a flow chart of a method of the present invention.
图中1. 模具型腔压力传感器,2. 高温熔体压力传感器,3. 模具,4.喷嘴,5.驱动电机。In the picture, 1. Mold cavity pressure sensor, 2. High temperature melt pressure sensor, 3. Mold, 4. Nozzle, 5. Drive motor.
具体实施方式Detailed ways
本文中所描述的具体实施例仅仅是对本发明精神作举例说明。The specific embodiments described herein are merely illustrative of the spirit of the invention.
实施例:本实施例的一种注塑压力控制系统,如图1所示,包括模具压力感应模块,所述模具压力感应模块包括模具型腔压力传感器1,所述模具型腔压力传感器1设于模具3内,所述模具压力感应模块和主控模块连接,所述主控模块包括取样模块、处理模块和参数配置模块,所述取样模块用于获取待加工材料的注塑时各阶段的压力阈值以及注塑各阶段的时间阈值,所述处理模块用于获取压力信号,所述处理模块和PID控制模块连接,所述处理模块将获取的压力信号传输至PID控制模块,所述参数配置模块用于设置喷嘴压力感应模块的压力阈值,所述喷嘴压力感应模块包括高温熔体压力传感器2,所述高温熔体压力传感器2设于喷嘴4上。Embodiment: An injection molding pressure control system of this embodiment, as shown in Figure 1, includes a mold pressure sensing module. The mold pressure sensing module includes a mold cavity pressure sensor 1. The mold cavity pressure sensor 1 is located on In the mold 3, the mold pressure sensing module is connected to the main control module. The main control module includes a sampling module, a processing module and a parameter configuration module. The sampling module is used to obtain the pressure thresholds at each stage during injection molding of the material to be processed. And the time threshold of each stage of injection molding, the processing module is used to obtain the pressure signal, the processing module is connected to the PID control module, the processing module transmits the obtained pressure signal to the PID control module, and the parameter configuration module is used to Set the pressure threshold of the nozzle pressure sensing module. The nozzle pressure sensing module includes a high-temperature melt pressure sensor 2 . The high-temperature melt pressure sensor 2 is provided on the nozzle 4 .
所述控制系统还包括测速模块,所述测速模块与驱动电机5连接,所述测速模块用于获取螺杆的转速,所述测速模块将转速信号传输至驱动控制模块,所述驱动控制模块包括信号转换模块,所述信号转换模块用于将转速信号转换为控制信号,同时将PID控制模块形成的反馈信号转换为速度控制信号。所述驱动电机5还和比较模块连接,所述比较模块用于输入待注射材料的注射时理想压力变换曲线。所述PID控制模块还和驱动控制模块连接,用于根据比较模块输入的理想压力变换曲线进行压力控制。The control system also includes a speed measurement module. The speed measurement module is connected to the drive motor 5. The speed measurement module is used to obtain the rotation speed of the screw. The speed measurement module transmits the rotation speed signal to the drive control module. The drive control module includes a signal. Conversion module, the signal conversion module is used to convert the rotation speed signal into a control signal, and at the same time convert the feedback signal formed by the PID control module into a speed control signal. The drive motor 5 is also connected to a comparison module, which is used to input the ideal pressure transformation curve during injection of the material to be injected. The PID control module is also connected to the drive control module for performing pressure control based on the ideal pressure transformation curve input by the comparison module.
本实施例的一种注塑压力控制方法,如图2所示,包括步骤:An injection molding pressure control method in this embodiment, as shown in Figure 2, includes the steps:
S1通过参数配置模块对喷嘴压力感应模块设置第一压力阈值、第二压力阈值和第三压力阈值;S1 sets the first pressure threshold, the second pressure threshold and the third pressure threshold to the nozzle pressure sensing module through the parameter configuration module;
具体包括:Specifically include:
S11员工向采样模块中输入注塑所用材料注塑成型时最大注射压力以及保压压力;S11 employees input the maximum injection pressure and holding pressure of the materials used for injection molding into the sampling module;
S12将最大注射压力的50%设为第一压力阈值,90%设为第二压力阈值,将保压压力设为第三压力阈值。S12 sets 50% of the maximum injection pressure as the first pressure threshold, 90% as the second pressure threshold, and sets the holding pressure as the third pressure threshold.
根据需求,若保压过程分为更多阶段还可以根据各阶段设置更多的压力阈值,所述50%和90%还可以根据设备的模具变化,注塑的材料变化进行调整。According to needs, if the pressure holding process is divided into more stages, more pressure thresholds can be set according to each stage. The 50% and 90% can also be adjusted according to changes in the mold of the equipment and changes in injection molding materials.
S2向比较模块中输入待注射材料的注射时理想压力变换曲线;S2 inputs the ideal pressure transformation curve during injection of the material to be injected into the comparison module;
S3通过测速模块测得螺杆的转速,将其传入驱动控制模块;S3 measures the speed of the screw through the speed measurement module and transmits it to the drive control module;
S4所述驱动控制模块将转速信号转换为控制信号传入PID控制模块;The drive control module in S4 converts the rotational speed signal into a control signal and transmits it to the PID control module;
S5使用模具压力感应模块和喷嘴压力感应模块测得压力,将压力信号传入PID控制模块;S5 uses the mold pressure sensing module and the nozzle pressure sensing module to measure the pressure, and transmits the pressure signal to the PID control module;
S6所述PID控制模块根据比较模块输入的理想压力变换曲线进行压力控制。The PID control module in S6 performs pressure control according to the ideal pressure transformation curve input by the comparison module.
具体包括:Specifically include:
S61所述PID控制模块根据理想压力变换曲线生成注射增长速率变化率下限阈值K1和上限阈值K2;The PID control module in S61 generates the lower limit threshold K1 and the upper limit threshold K2 of the injection growth rate change rate based on the ideal pressure transformation curve;
S62当注射增长速率处于[K1,K2]区间外时,PID控制模块向驱动控制模块生成反馈信号,控制螺杆转速增加/减少,直至注射增长速率变化率处于[K1,K2]区间内;S62 When the injection growth rate is outside the [K1, K2] interval, the PID control module generates a feedback signal to the drive control module to control the screw speed to increase/decrease until the injection growth rate change rate is within the [K1, K2] interval;
S63当喷嘴处压力达到第一压力阈值时,处理模块向PID控制模块传输转换提醒信号,所述PID控制模块生成注射速率变化率阈值K3,将所述注射速率变化率变换控制于[K2,K3];S63 When the pressure at the nozzle reaches the first pressure threshold, the processing module transmits a conversion reminder signal to the PID control module. The PID control module generates the injection rate change rate threshold K3 and controls the injection rate change rate transformation to [K2, K3 ];
S64当注射压力达到第二压力阈值时,处理模块判断是否进入保压过程,若是,PID控制模块,块生成注射下降速率变化率阈值K4,并控制螺杆转速将注射下降速率变化率控制在[0.9K4,1.1K4],直至喷嘴处压力为第三压力阈值。其中0.9和1.1还可以根据不同的保压需求进行适应性调整。S64 When the injection pressure reaches the second pressure threshold, the processing module determines whether to enter the pressure maintaining process. If so, the PID control module generates the injection drop rate change rate threshold K4, and controls the screw speed to control the injection drop rate change rate at [0.9 K4,1.1K4], until the pressure at the nozzle reaches the third pressure threshold. Among them, 0.9 and 1.1 can also be adaptively adjusted according to different pressure holding requirements.
其中处于保压过程时若分为多个阶段,PID控制模块还可以在后续的保压阶段生成更多的注射下降速率变化率。If the pressure holding process is divided into multiple stages, the PID control module can also generate more injection drop rate changes in subsequent pressure holding stages.
本发明所属技术领域的技术人员可以对所描述的具体实施例做各种各样的修改或补充或采用类似的方式替代,但并不会偏离本发明的精神或者超越所附权利要求书所定义的范围。Those skilled in the art to which the present invention belongs can make various modifications or additions to the described specific embodiments or substitute them in similar ways, but this will not deviate from the spirit of the present invention or exceed the definition of the appended claims. range.
尽管本文较多地使用了主控模块、处理模块、模具压力感应模块、PID控制模块等术语,但并不排除使用其它术语的可能性。使用这些术语仅仅是为了更方便地描述和解释本发明的本质;把它们解释成任何一种附加的限制都是与本发明精神相违背的。Although this article uses terms such as main control module, processing module, mold pressure sensing module, and PID control module more often, it does not rule out the possibility of using other terms. These terms are used only to more conveniently describe and explain the essence of the present invention; interpreting them as any additional limitations is contrary to the spirit of the present invention.
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