CN115122602A

CN115122602A - Intelligent control method and system for injection molding machine

Info

Publication number: CN115122602A
Application number: CN202210563553.2A
Authority: CN
Inventors: 张龙军; 张春林
Original assignee: Ningbo Dongyang Technology Co ltd
Current assignee: Ningbo Dongyang Technology Co ltd
Priority date: 2022-05-23
Filing date: 2022-05-23
Publication date: 2022-09-30
Anticipated expiration: 2042-05-23
Also published as: CN115122602B

Abstract

The invention provides an intelligent control method of an injection molding machine, which comprises the following steps: determining the number of a plastic product injected by an injection molding machine, and searching a processing technology corresponding to the numbered plastic product and corresponding index data at a cloud end; performing injection molding production according to the processing technology obtained by searching, and collecting monitoring data in the injection molding production process; comparing the monitoring data with the index data, determining the data type with abnormity and finely adjusting the processing technology; and conveying the plastic product produced after the fine adjustment of the processing technology to a designated position for machine vision detection to obtain a detection result, determining whether the fine-adjusted processing technology has defects according to the detection result, and fine-adjusting the processing technology with the defects again until the defects disappear. The invention solves the problem that the existing injection molding machine can not automatically and intelligently adjust to carry out automatic production.

Description

Intelligent control method and system for injection molding machine

Technical Field

The invention relates to the technical field of automatic control, in particular to an intelligent control method and system for an injection molding machine.

Background

The injection molding machine is also called an injection molding machine or an injection machine, is a processing machine with the largest use amount in the plastic processing industry, not only can a large number of products be directly produced by the injection molding machine, but also is key equipment for forming an injection stretch blow molding process. It is a main forming equipment for making various shaped plastic products from thermoplastic plastics or thermosetting plastics by using plastic forming mould. The device is divided into a vertical type, a horizontal type and a full-electric type. The injection molding machine can heat the plastic, apply high pressure to the molten plastic, make it inject out and fill the cavity of the mould, take down and become the plastic products after cooling and shaping.

Old-fashioned injection molding machine often adopts the manual regulation processing parameter numerical value, makes the qualified volume production that carries on of product compliance, but general staff is not competent in this regulation work that has the technical, causes whenever the injection molding machine breaks down, when installing new injection molding machine and changing the mold processing and carrying out different product machining work, needs the staff to carry out constantly to adjust and comes from looking for suitable processing parameter, has wasted not a few manpowers and time.

Disclosure of Invention

The invention provides an intelligent control method and system for an injection molding machine, which are used for solving the problems that the existing injection molding machine cannot be independently and intelligently adjusted and can not be automatically produced.

An intelligent control method for an injection molding machine comprises the following steps:

determining the number of a plastic product injected by an injection molding machine, and searching a processing technology corresponding to the numbered plastic product and corresponding index data at the cloud;

performing injection molding production according to the processing technology obtained by searching, and collecting monitoring data in the injection molding production process;

comparing the monitoring data with the index data, determining the data type with abnormity and finely adjusting the processing technology;

and conveying the plastic product produced after the fine adjustment of the processing technology to an appointed position for machine vision detection to obtain a detection result, determining whether the fine-adjusted processing technology has defects according to the detection result, and fine-adjusting the processing technology with the defects again until the defects disappear.

Preferably, the determining the number of the plastic product injected by the injection molding machine, and searching the processing technology corresponding to the numbered plastic product and the corresponding index data at the cloud end include:

acquiring the number of the injection-molded plastic product input by a worker, and uploading the number of the plastic product to a cloud;

comparing and searching the plastic product number through a cloud server, and determining a processing technology correspondingly stored in the plastic product number and corresponding index data of each component in the processing process, wherein the index data comprises temperature, pressure, time, speed and travel;

and returning the processing technology and the corresponding index data which are correspondingly stored in the searched plastic product number through the cloud server.

Preferably, the injection molding production according to the processing technology obtained by searching, and the collecting of the monitoring data in the injection molding production process includes:

performing injection molding production according to the processing technology obtained by searching, wherein the production process mainly comprises four stages of filling, pressure maintaining, cooling and demolding;

the filling speed and the high-temperature area temperature in the filling process are automatically controlled according to the processing technology in the filling process, and the material temperature, the mold temperature, the oil temperature, the injection pressure, the injection time and the injection stroke in the filling process are collected;

in the pressure maintaining stage, the maintaining pressure and the pressure maintaining time are automatically controlled according to the processing technology, and the mold back pressure and the mold locking pressure in the pressure maintaining process are collected;

automatically controlling the pouring time and the pouring position of the cooling liquid in the cooling stage, and collecting the temperature of the mold surface during pouring, the temperature during drying and the drying duration time in the cooling process;

automatically controlling the demoulding action of the mould closing part in the demoulding stage, and acquiring demoulding pressure, demoulding speed and return stroke of the injection part in the demoulding process;

and packaging the collected material temperature, mold temperature, oil temperature, injection pressure, injection time, injection stroke, mold backpressure, mold locking pressure, mold surface wetting temperature, drying duration, demolding pressure, demolding speed and return stroke data of the injection part to form monitoring data.

Preferably, comparing the monitoring data with the index data, determining the data type with the abnormality and finely adjusting the machining process comprises:

comparing the monitoring data with the index data, determining the data type with abnormality, and determining the work items needing fine adjustment according to the data type;

and determining the difference value between the data value corresponding to the abnormal data type and the standard data value in the index data, and adjusting the corresponding difference value of the work item.

Preferably, the step of conveying the plastic product produced after fine adjustment of the processing technology to a designated position for machine vision inspection and obtaining an inspection result includes:

conveying the produced plastic products to a specified detection place, and performing quality detection on the plastic products at a plurality of first-class fixed positions according to detection rules corresponding to the plastic products;

when the quality of the plastic product is detected, illuminating each first type of fixed position by utilizing lamplight with preset light intensity and collecting a surface image of the first type of fixed position;

binding the surface image with the first type of fixed position and uploading the surface image to a cloud server for quality analysis;

the cloud server determines a first type of image template of the first type of fixed position of the plastic product in a qualified state according to the serial number of the plastic product;

and comparing the surface image with the first type of image template to determine whether the plastic product has quality defects.

Preferably, the step of conveying the plastic product produced after fine adjustment of the processing technology to a designated position for machine vision inspection and obtaining an inspection result further includes:

determining the light transmittance of the type of the raw material of the plastic product under the unit thickness, and detecting the light transmittance of the plastic product when the light transmittance under the unit thickness is greater than a preset unit light transmittance threshold value;

when the light transmission detection is carried out, the plastic product is placed at a specified detection place and is subjected to light transmission irradiation; the position of the plastic product or the transmission light source is adjusted according to a preset adjustment rule in the light transmission irradiation process, so that the transmission light source can irradiate different second-type fixed positions on the plastic product;

collecting the light-transmitting image of the plastic product at the second type of fixed position by using a camera on the surface of the plastic product, which is back to the transmission light source;

sending the collected multiple light-transmitting images, the serial number of the plastic product and the type of the raw material of the plastic product to a cloud server for flaw quality analysis;

the cloud server determines a second type of image template of the plastic product in a qualified state at a second type of fixed position under the type of the raw material according to the serial number of the plastic product;

determining the average gray value of the light-transmitting image and the second type image template, and adjusting the integral gray value of the light-transmitting image according to the average gray value of the second type image template;

after the integral gray value of the light-transmitting image is adjusted, carrying out region division on the light-transmitting image according to a preset division rule, and determining the average gray value of pixels in each region on the light-transmitting image;

determining a first-class gray difference value between the average gray value of pixels in a certain area on the light-transmitting image and the average gray value of pixels in a corresponding area on a second-class image template, and determining that the plastic product has color difference in the area when the first-class gray difference value is greater than a preset first threshold value, so as to determine that the plastic product has first-class defects;

determining the gray value of each pixel point in a certain area on the light-transmitting image, comparing the gray value with the average gray value of the pixels in the area to determine a second gray difference value, comparing the second gray difference value with a preset second threshold value, and determining the pixel point as a flaw point when the gray difference value is greater than the second threshold value;

marking all the defective points on the light-transmitting image and judging whether a second type of defect formed by the defective points exists or not.

Preferably, after detecting that the produced plastic product has quality defects, judging whether the quality defects are caused by the failure of the processing materials;

if the processed material is not in compliance, a first type alarm is sent out;

if not, determining the position of the quality defect on the plastic product, and carrying out process monitoring aiming at the position;

when the process monitoring is carried out, firstly, a mold detection image of an area corresponding to the quality defect position of the plastic product on the mold closing device is obtained, the mold detection image is compared with a mold standard image preset in the area, whether the area corresponding to the quality defect position of the plastic product on the mold closing device has a defect or not is determined, and if the area has the defect, a second type of alarm is sent;

if the area corresponding to the quality defect position of the plastic product on the mold closing device has no defect, driving the injection molding machine to perform injection molding again according to the processing technology produced last time, and acquiring a thermal imaging image of the mold closing device at the product demolding stage;

analyzing the thermal imaging graph to determine whether the temperature of each position on the mold closing device meets the preset demolding temperature requirement, and if not, sending a third type alarm;

if the requirement of the preset demoulding temperature is met, determining the maximum temperature difference in a preset range around the area corresponding to the quality defect position of the plastic product on the mould closing device;

and when the maximum temperature difference is larger than a preset temperature difference threshold value, a fourth type alarm is sent out.

Preferably, the method also comprises the steps of acquiring the temperature of the mold closing device of the injection molding machine in real time and judging whether the current temperature of the mold closing device meets the injection molding conditions;

starting injection molding after the injection molding conditions are met, and acquiring the temperature of the cooling liquid of the mold closing device in real time;

determining first cooling time according to the temperature of cooling liquid of the mold closing device and the current temperature of the mold closing device and according to the temperature of the cooling liquid of the mold closing device preset in the cloud server and a corresponding table of the current temperature of the mold closing device and the cooling time;

spraying cooling liquid to the mold closing device according to the first cooling time, opening the mold after cooling spraying and standing, and obtaining the temperature distribution condition of the inner surface of the mold closing device after opening the mold;

correcting the first cooling time according to the temperature distribution condition of the inner surface of the mold closing device to obtain second cooling time, and spraying cooling liquid to the mold closing device according to the second cooling time;

and judging whether the plastic product produced by spraying the cooling liquid on the mold closing device according to the second cooling time is qualified, and if so, recording the second cooling time, the ambient temperature and humidity around the mold closing device, the current temperature of the cooling liquid and the current temperature of the mold closing device and then storing the recorded data in a cloud server.

In order to achieve the above object, an embodiment of the present invention further provides an intelligent control system for an injection molding machine, including:

the data searching module is used for determining the number of the plastic product injected by the injection molding machine and searching the processing technology corresponding to the numbered plastic product and the corresponding index data at the cloud end;

the production monitoring module is used for carrying out injection molding production according to the processing technology obtained by searching and collecting monitoring data in the injection molding production process;

the process adjusting module is used for comparing the monitoring data with the index data, determining the data type with abnormity and finely adjusting the processing process;

and the rechecking and adjusting module is used for detecting the plastic product produced after the fine adjustment of the processing technology, determining whether the defect exists in the fine-adjusted processing technology according to the detection result, and fine-adjusting the processing technology with the defect again until the defect disappears.

Preferably, the data searching module includes:

the serial number determining unit is used for inputting the serial number of the injection-molded plastic product by a worker and uploading the serial number of the plastic product to the cloud end;

the processing index acquisition unit is used for comparing and searching the serial number of the plastic product through the cloud server, and determining the processing technology correspondingly stored by the serial number of the plastic product and the index data of each part in the corresponding processing process, wherein the index data comprises temperature, pressure, time, speed and travel;

and the data returning unit is used for returning the processing technology and the corresponding index data which are correspondingly stored in the searched plastic product number through the cloud server.

The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:

FIG. 1 is a flow chart of the steps of an intelligent control method for an injection molding machine according to an embodiment of the present invention;

FIG. 2 is a flowchart illustrating the steps of searching data by the cloud in the embodiment of the present invention;

fig. 3 is a schematic structural diagram of an intelligent control system of an injection molding machine according to an embodiment of the present invention.

Detailed Description

The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, and it will be understood that they are described herein for the purpose of illustration and explanation and not limitation.

The invention provides an intelligent control method of an injection molding machine, as shown in figure 1, comprising the following steps:

step S1, determining the number of the plastic product injected by the injection molding machine, and searching the processing technology and the index data corresponding to the numbered plastic product in the cloud;

s2, performing injection molding production according to the searched processing technology, and collecting monitoring data in the injection molding production process;

step S3, comparing the monitoring data with the index data, determining the data type with abnormality and finely adjusting the processing technology;

and step S4, conveying the plastic product produced after the fine adjustment of the processing technology to a designated position for machine vision detection to obtain a detection result, determining whether the fine-adjusted processing technology has defects according to the detection result, and fine-adjusting the processing technology with the defects again until the defects disappear.

The working principle and the beneficial effects of the technical scheme are as follows: the serial number of the plastic product injected by the injection molding machine is determined, the serial number is uploaded to the cloud for searching, the processing technology corresponding to the plastic product corresponding to the serial number and the corresponding index data are obtained, production is controlled according to the obtained processing technology, and the feeding amount, the heating temperature, the material melting temperature and melting time, the injection molding stroke, the injection molding pressure, the pressure maintaining time, the cooling time and the like are controlled. And monitoring data in the production process are collected in the control process, wherein the monitoring data comprise material temperature, mold temperature, oil temperature, injection pressure, injection time length, injection stroke, mold backpressure, mold locking pressure, mold surface wetting temperature, drying temperature and drying duration, demolding pressure, demolding speed, return stroke data of the injection part and the like. And comparing the monitoring data with the index data, determining the data type with abnormality, and finely adjusting the processing technology, for example, if the temperature of the mold is too low, heating the mold for assistance, and if the injection pressure is too low, increasing the injection pressure, and the like. And finally, detecting the plastic product produced after the fine adjustment of the processing technology, determining whether the fine-adjusted processing technology has defects according to the detection result, and fine-adjusting the processing technology with the defects again until the defects disappear. Thereby realized intelligent regulation and the automated production of the parameter of injection molding machine, improved injection molding production's work efficiency when having reduced the input of manual regulation.

In a preferred embodiment, as shown in fig. 2, determining a serial number of a plastic product injection-molded by an injection molding machine, and searching a cloud for a processing technology and corresponding index data corresponding to the serial number of the plastic product includes:

s11, acquiring the injection molding plastic product number input by a worker, and uploading the plastic product number to a cloud end;

step S12, the serial number of the plastic product is compared and searched through a cloud server, and the processing technology which is correspondingly stored by the serial number of the plastic product and the index data of each component in the corresponding processing process are determined, wherein the index data comprise temperature, pressure, time, speed and travel;

and step S13, returning the processing technology and the corresponding index data which are correspondingly stored in the searched plastic product number through the cloud server.

The working principle and the beneficial effects of the technical scheme are as follows: the plastic product number of moulding plastics through the manual input of staff, upload this number to the high in the clouds, contrast the searching through high in the clouds server to this plastic product number, confirm the processing technology that this plastic product number corresponds the storage and the index data of each part in the corresponding course of working, wherein, index data includes temperature, pressure, time, speed, stroke etc., the processing technology that corresponds the storage and the index data that correspond with this plastic product number that will seek at last return, realize utilizing the high in the clouds to store the standard big data in the course of producing, can carry out data extraction when needing to use, and can confirm the data difference that appears in the course of producing fast through the computing power of high in the clouds, and confirm corresponding adjustment scheme, thereby realize the intelligent adjustment to injection molding machine production technology.

In a preferred embodiment, performing injection molding according to the found processing technology, and collecting monitoring data during the injection molding process includes:

performing injection molding production according to the found processing technology, wherein the production process mainly comprises four stages of filling, pressure maintaining, cooling and demolding;

the method comprises the following steps of automatically controlling the filling speed and the temperature of a high-temperature area in the filling process according to a processing technology in the filling process, and collecting the material temperature, the mold temperature, the oil temperature, the injection pressure, the injection time and the injection stroke in the filling process;

The working principle and the beneficial effects of the technical scheme are as follows: when monitoring data in the injection molding production process are collected, injection molding production is carried out according to the found processing technology, and the production process mainly comprises four stages of filling, pressure maintaining, cooling and demolding; the method comprises the following steps of automatically controlling the filling speed and the temperature of a high-temperature area in the filling process according to a processing technology, wherein the filling speed depends on the volume filled by a plastic material in unit time, and collecting the material temperature, the mold temperature, the oil temperature, the injection pressure, the injection molding duration and the injection molding stroke in the filling process by using a temperature sensor, a distance measuring sensor and a pressure sensor; in the pressure maintaining stage, the maintaining pressure and the pressure maintaining time are automatically controlled according to the processing technology, and a pressure sensor is used for collecting the mold back pressure and the mold locking pressure in the pressure maintaining process; automatically controlling the pouring time and the pouring position of the cooling liquid in the cooling stage, and acquiring the temperature of the mold surface during pouring, the temperature during drying and the drying duration time in the cooling process by using a temperature sensor; automatically controlling the demoulding action of the mould closing part in the demoulding stage, and acquiring demoulding pressure, demoulding speed and return stroke of the injection part in the demoulding process by using a pressure sensor and an acceleration sensor; and finally, packing the acquired material temperature, mold temperature, oil temperature, injection pressure, injection time, injection stroke, mold backpressure, mold locking pressure, mold surface wetting temperature, drying duration, demolding pressure, demolding speed and return stroke data of the injection part to form monitoring data. The monitoring data acquired by the sensor is used for acquiring information of different parts of the injection molding machine in different production stages, so that abnormal conditions occurring in the production process can be comprehensively and quickly perceived conveniently, the data is comprehensive, detailed scene restoration can be performed on the machining process according to the monitoring data, the scene can be restored after a working accident occurs to determine the accident reason and record and study, and corresponding data warning can be performed in the later working process conveniently to prevent the accident from happening again.

In a preferred embodiment, comparing the monitored data with the target data, determining the type of data for which the anomaly exists, and fine-tuning the process includes:

The working principle and the beneficial effects of the technical scheme are as follows: when the process is adjusted, the monitoring data and the index data need to be compared, so as to determine the data type with the abnormality and perform fine adjustment on the processing process, wherein when the monitoring data and the index data are compared, whether the monitoring data are abnormal or not is determined according to the specific requirements of the index data, because the data accuracy required by each index data may be different, for example, if the index data of the material temperature is set to be 200 degrees centigrade, the set abnormal judgment temperature of the material temperature is 190 degrees centigrade to 210 degrees centigrade, and when the temperature acquired at a predetermined time point (for example, the time point after the heating stage is completed) is not in the range, it can be judged that the material temperature is abnormal. Determining the data type with abnormality, determining the work items needing fine adjustment according to the data type, determining the difference value between the data value corresponding to the data type with abnormality and the standard data value in the index data, and adjusting the corresponding difference value of the work items, for example, the material temperature is 180 ℃, if the temperature is too low, the material temperature is compared with the material temperature in the monitoring data, determining the temperature difference to be 20 ℃, determining that the heating firepower needs to be increased or the heating time needs to be prolonged according to the temperature difference, if the temperature is too high, the heating firepower needs to be decreased or the heating time needs to be shortened, and specifically, the required heating power needs to be increased or decreased, and the prolonged or shortened time can be determined according to a preset corresponding table. Therefore, the automatic adjustment of the production and processing technology is realized, the investment of manual adjustment is reduced, and the work efficiency of injection molding production is improved.

In a preferred embodiment, the step of conveying the plastic product produced after fine adjustment of the processing technology to a designated position for machine vision inspection and obtaining the inspection result comprises:

The working principle and the beneficial effects of the technical scheme are as follows: when a plastic product is detected, the produced plastic product needs to be conveyed to a specified detection place, and quality detection of a plurality of first-class fixed positions is performed on the plastic product according to a detection rule corresponding to the plastic product, wherein each first-class fixed position can be preset, so that comprehensive detection of the plastic product or local detection of key parts is realized; when the quality of the plastic product is detected, the light with specific light intensity is used for irradiating each first type of fixed position and collecting the surface image of the first type of fixed position, wherein the light environment in the working chamber needs to be ensured to be in a preset standard environment before the light with preset light intensity is used for irradiating, and the abnormal detection result caused by the change of the ambient light is prevented; binding the surface image with the first type of fixed position and uploading the surface image to a cloud server for quality analysis, so that the image is rapidly and comprehensively analyzed by using the computing power of a cloud; the cloud server determines a first type of image template of the first type of fixed position of the plastic product in a qualified state according to the serial number of the plastic product, the first type of image template is stored in the cloud server in advance, and the determination is a template calling process; comparing the surface image with the first type of image template, and when comparing, improving the characteristics of each part in the image by calculating the similarity by using a blocking method, and preventing the calculated similarity from being too high due to the similarity of the image colors, wherein the calculation formula is as follows:

where Sim (T, M) represents the similarity between the surface image and the first type of image template, K is the number of color space samples, T _i Representing the number of pixels, m, of samples belonging to the i-th class of color space in the surface image _i Representing the number of pixels belonging to the i-th class of color space samples in the first class of image templates. And determining whether the plastic product has quality defects according to the similarity. Therefore, whether each part of the plastic product meets the production requirement is determined through comparison and analysis with the standard image, and the plastic product is automatically checked.

In a preferred embodiment, the step of conveying the plastic product produced after fine adjustment of the processing technology to a designated position for machine vision inspection and obtaining the inspection result further comprises:

collecting a light-transmitting image of the plastic product at the second type of fixed position by using a camera on one surface of the plastic product, which is opposite to the transmission light source;

determining a first-class gray difference value between the average gray value of pixels in a certain area on the light-transmitting image and the average gray value of pixels in a corresponding area on the second-class image template, and determining that the plastic product has color difference in the area when the first-class gray difference value is greater than a preset first threshold value, so as to determine that the plastic product has first-class defects;

determining the gray value of each pixel point in a certain area on the light-transmitting image, comparing the gray value with the average gray value of the pixels in the area to determine a second gray difference value, comparing the second gray difference value with a preset second threshold value, and determining the pixel point as a defect point when the gray difference value is greater than the second threshold value;

and marking all the defective points on the light-transmitting image and judging whether a second type of defect formed by the defective points exists or not.

The working principle and the beneficial effects of the technical scheme are as follows: when the product is subjected to quality detection, deeper quality detection is further performed on the transparent plastic, the light transmittance of the type of the raw material of the plastic product under the unit thickness is determined, when the light transmittance under the unit thickness is greater than a preset unit light transmittance threshold value, the plastic product is subjected to light transmittance detection, the process is a material judgment process, whether the light transmittance of the material meets the condition of the light transmittance detection or not is judged, the light transmittance detection is started after the condition of the light transmittance detection is met, and the light transmittance is the ratio of the light intensity received by the transmission surface to the light intensity of the irradiation surface under the unit thickness (set to be one centimeter in thickness). When the light transmission detection is carried out, the plastic product is placed at a specified detection place and is subjected to light transmission irradiation; the position of the plastic product or the transmission light source is adjusted according to a preset adjustment rule in the process of light transmission irradiation, so that the transmission light source can irradiate different second-type fixed positions on the plastic product, and key parts can be detected; collecting the light-transmitting image of the plastic product at the second type of fixed position by using a camera on the surface of the plastic product, which is back to the transmission light source; sending the collected multiple light-transmitting images, the serial number of the plastic product and the type of the raw material of the plastic product to a cloud server for flaw quality analysis; the cloud server determines a second type of image template of the plastic product in a qualified state at a second type of fixed position under the type of the raw material according to the serial number of the plastic product; determining the average gray values of the light-transmitting image and the second type image template, and adjusting the overall gray value of the light-transmitting image according to the average gray value of the second type image template, thereby correcting system errors caused by equipment or environmental problems; after the integral gray value of the light-transmitting image is adjusted, carrying out region division on the light-transmitting image according to a preset division rule, and determining the average gray value of pixels in each region on the light-transmitting image; determining a first-class gray difference value between the average gray value of pixels in a certain area on the light-transmitting image and the average gray value of pixels in a corresponding area on the second-class image template, and when the first-class gray difference value is greater than a preset first threshold value, determining that the plastic product has color difference in the area, thereby determining that the plastic product has a first-class defect, wherein the first-class defect is a thickness defect, and when no other area of the plastic product has the defect, the defect judgment result is not caused by system errors, but the judgment result is caused by different thickness degrees of the area or different camera parameters corresponding to the area and other camera parameters, so that an alarm is sent to realize the corresponding detection of each area of the plastic product; determining the gray value of each pixel point in a certain area on the light-transmitting image, comparing the gray value with the average gray value of the pixels in the area to determine a second gray difference value, comparing the second gray difference value with a preset second threshold, and determining the pixel point as a defective point when the gray difference value is greater than the second threshold, so as to realize the detection of the defective point; marking all the defective points on the light-transmitting image and judging whether a second type of defect formed by the defective points exists or not, wherein the second type of defect is plastic moire caused by insufficient mixing. Therefore, the thickness degree and the internal texture of the transparent plastic product are analyzed by using a light transmission detection method to determine whether defects exist, and the detection result is more comprehensive and careful.

In a preferred embodiment, after detecting that the produced plastic product has quality defects, judging whether the quality defects are caused by the non-compliance of the processing materials;

if the machining materials are not in compliance, a first type alarm is sent out;

when the process monitoring is carried out, firstly, a mold detection image of an area corresponding to the quality defect position of the plastic product on the mold closing device is obtained, the mold detection image is compared with a mold standard image preset in the area, whether the area corresponding to the quality defect position of the plastic product on the mold closing device has a defect or not is determined, and if the area has the defect, a second type alarm is sent;

analyzing the thermal imaging graph to determine whether the temperature of each position on the mold closing device meets the preset mold release temperature requirement, and if not, sending a third type alarm;

The working principle and the beneficial effects of the technical scheme are as follows: after detecting that the produced plastic product has quality defects, judging whether the quality defects are caused by the failure of the processing materials; if the machined material is not in compliance, a first class alarm is sent to remind a worker to replace the machined material and clean the injection molding machine; if not, determining the position of the quality defect on the plastic product, and carrying out process monitoring aiming at the position; when the process monitoring is carried out, firstly, a mold detection image of an area corresponding to the plastic product quality defect position on the mold closing device is obtained, the mold detection image is compared with a mold standard image preset in the area, whether the area corresponding to the plastic product quality defect position on the mold closing device has a defect or not is determined, and if the area has the defect, a second type of alarm is sent to remind a worker to maintain and replace the mold closing device; if the area corresponding to the quality defect position of the plastic product on the mold closing device has no defect, driving the injection molding machine to perform injection molding again according to the processing technology produced last time, and acquiring a thermal imaging graph of the mold closing device at the product demolding stage; analyzing the thermal imaging graph to determine whether the temperature of each position on the mold closing device meets the preset mold release temperature requirement, and if not, sending a third type alarm to remind a worker to adjust the processing technology; if the requirement of the preset demoulding temperature is met, determining the maximum temperature difference in a preset range around the area corresponding to the quality defect position of the plastic product on the mould closing device; when the maximum temperature difference is larger than a preset temperature difference threshold value, a fourth type alarm is sent to remind a worker to adjust the internal structure of the mold.

In a preferred embodiment, the method further comprises the steps of acquiring the temperature of the mold closing device of the injection molding machine in real time, and judging whether the current temperature of the mold closing device meets the injection molding conditions;

The working principle and the beneficial effects of the technical scheme are as follows: detecting the temperature in the injection molding working process, acquiring the temperature of a mold closing device of the injection molding machine in real time, and judging whether the current temperature of the mold closing device meets the injection molding conditions; starting injection molding after the injection molding conditions are met, preventing the product defects and mold clamping caused by the fact that hot standby work is not carried out before work, and acquiring the temperature of cooling liquid of a mold closing device in real time; determining first cooling time according to the temperature of the cooling liquid of the mold closing device and the current temperature of the mold closing device and according to the temperature of the cooling liquid of the mold closing device preset in the cloud server and a corresponding table of the current temperature of the mold closing device and the cooling time; spraying cooling liquid to the mold closing device according to the first cooling time, opening the mold after cooling spraying and standing, and obtaining the temperature distribution condition of the inner surface of the mold closing device after opening the mold; correcting the first cooling time according to the temperature distribution condition of the inner surface of the mold closing device to obtain second cooling time, and spraying cooling liquid to the mold closing device according to the second cooling time; and judging whether the plastic product produced by spraying the cooling liquid on the mold closing device according to the second cooling time is qualified, and if so, recording the second cooling time, the ambient temperature and humidity around the mold closing device, the current temperature of the cooling liquid and the current temperature of the mold closing device and then storing the recorded data in a cloud server. The cooling time is determined according to the temperature of the cooling liquid of the mold closing device and the current temperature of the mold closing device, so that the spraying time length of the cooling liquid is controlled. And after the mold is opened, the spraying time is revised according to the temperature distribution condition of the inner surface of the mold device, finally, the temperature, the spraying time, the ambient temperature and the ambient humidity of the cooling liquid which meet the requirements are recorded and stored, corresponding parameters are strictly controlled to produce when corresponding production work is carried out next time, the adjustment is not needed, and the work production efficiency is improved.

In order to achieve the above object, an embodiment of the present invention further provides an intelligent control system for an injection molding machine, as shown in fig. 3, including:

the data searching module 1 is used for determining the number of a plastic product injected by the injection molding machine and searching the processing technology corresponding to the numbered plastic product and the corresponding index data at the cloud end;

the production monitoring module 2 is used for carrying out injection molding production according to the searched processing technology and collecting monitoring data in the injection molding production process;

the process adjusting module 3 is used for comparing the monitoring data with the index data, determining the data type with abnormity and finely adjusting the processing process;

and the rechecking and adjusting module 4 is used for detecting the plastic product produced after the fine adjustment of the processing technology, determining whether the fine-adjusted processing technology has defects according to the detection result, and fine-adjusting the processing technology with the defects again until the defects disappear.

The working principle and the beneficial effects of the technical scheme are as follows: the number of the plastic product injected by the injection molding machine is determined through the data searching module 1, the number is uploaded to the cloud for searching, the processing technology corresponding to the plastic product corresponding to the number and the corresponding index data are obtained, production is controlled through the production monitoring module 2 according to the obtained processing technology, and the feeding amount, the heating temperature, the material melting temperature and melting time, the injection molding stroke, the injection molding pressure, the pressure maintaining time length, the cooling time length and the like are controlled. And monitoring data in the production process are collected in the control process, wherein the monitoring data comprise material temperature, mold temperature, oil temperature, injection pressure, injection time length, injection stroke, mold backpressure, mold locking pressure, mold surface wetting temperature, drying temperature and drying duration, demolding pressure, demolding speed, return stroke data of the injection part and the like. The process adjusting module 3 compares the monitoring data with the index data, determines the data type with abnormality and finely adjusts the processing process, for example, if the temperature of the mold is too low, the mold is heated for assistance, and if the injection pressure is too low, the injection pressure is increased, and the like. And finally, detecting the plastic product produced after the fine adjustment of the processing technology through a rechecking adjustment module 4, determining whether the defect exists in the fine-adjusted processing technology according to the detection result, and fine-adjusting the processing technology with the defect again until the defect disappears. Thereby realized intelligent regulation and the automated production of the parameter of injection molding machine, improved injection molding production's work efficiency when having reduced the input of manual regulation.

In a preferred embodiment, the data lookup module comprises:

the serial number determining unit is used for uploading the serial number of the injection-molded plastic product input by a worker to the cloud;

the processing index acquisition unit is used for comparing and searching the plastic product number through the cloud server, and determining the processing technology correspondingly stored by the plastic product number and the index data of each component in the corresponding processing process, wherein the index data comprises temperature, pressure, time, speed and travel;

The working principle and the beneficial effects of the technical scheme are as follows: the serial number of the injection molding plastic product manually input by a worker is uploaded to the cloud end through the serial number determining unit, the process index acquisition unit utilizes the cloud server to compare and search the serial number of the plastic product, determines the processing process correspondingly stored by the serial number of the plastic product and the index data of each part in the corresponding processing process, wherein the index data comprises temperature, pressure, time, speed, travel and the like, and finally the processing technology which is correspondingly stored by the searched plastic product number and the corresponding index data are returned by the data return unit, so that the standard big data in the production process can be stored by utilizing a cloud, when the method is needed, data extraction can be carried out, and data differences occurring in the production process can be rapidly determined through the computing power of the cloud, and determining a corresponding adjusting scheme, thereby realizing intelligent adjustment of the production process of the injection molding machine.

It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.

Claims

1. An intelligent control method for an injection molding machine is characterized by comprising the following steps:

determining the number of a plastic product injected by an injection molding machine, and searching a processing technology corresponding to the numbered plastic product and corresponding index data at a cloud end;

and conveying the plastic product produced after the fine adjustment of the processing technology to a designated position for machine vision detection to obtain a detection result, determining whether the fine-adjusted processing technology has defects according to the detection result, and fine-adjusting the processing technology with the defects again until the defects disappear.

2. The intelligent control method of the injection molding machine according to claim 1, wherein the determining the serial number of the plastic product injected by the injection molding machine, and searching the processing technology and the corresponding index data corresponding to the serial number of the plastic product at the cloud end comprises:

the method comprises the steps that the serial number of the plastic product is compared and searched through a cloud server, and the processing technology which is correspondingly stored in the serial number of the plastic product and the index data of each component in the corresponding processing process are determined, wherein the index data comprise temperature, pressure, time, speed and travel;

3. The intelligent control method of an injection molding machine according to claim 1, wherein the performing injection molding production according to the processing technology obtained by searching, and the collecting monitoring data in the injection molding production process comprises:

and packaging the acquired material temperature, mold temperature, oil temperature, injection pressure, injection time, injection stroke, mold backpressure, mold locking pressure, mold surface wetting temperature, drying duration, demolding pressure, demolding speed and return stroke data of the injection part to form monitoring data.

4. The intelligent control method of an injection molding machine according to claim 1, wherein comparing the monitored data with the index data, determining the type of data for which there is an anomaly, and performing fine tuning on the machining process comprises:

5. The intelligent control method of the injection molding machine according to claim 1, wherein the step of conveying the plastic products produced after fine adjustment of the processing technology to a designated position for machine vision inspection comprises the steps of:

when the quality of the plastic product is detected, illuminating each first type of fixed position by utilizing preset light intensity and collecting a surface image of the first type of fixed position;

6. The intelligent control method of an injection molding machine according to claim 5, wherein the step of conveying the plastic products produced after the fine adjustment of the processing technology to a designated position for machine vision inspection further comprises the steps of:

7. The intelligent control method of the injection molding machine according to claim 1, wherein after detecting that the produced plastic product has quality defects, judging whether the quality defects are caused by the failure of the processing materials;

if the processed material is not in compliance, a first type alarm is sent out;

8. The intelligent control method of the injection molding machine according to claim 1, further comprising the steps of acquiring the temperature of a mold closing device of the injection molding machine in real time, and judging whether the current temperature of the mold closing device meets injection molding conditions;

9. An injection molding machine intelligence control system, comprising:

the process adjusting module is used for comparing the monitoring data with the index data, determining the data type with abnormality and finely adjusting the processing process;

10. The intelligent control system of an injection molding machine of claim 9, wherein the data lookup module comprises:

the processing system comprises a process index acquisition unit, a processing unit and a processing unit, wherein the process index acquisition unit is used for comparing and searching the serial number of the plastic product through a cloud server, and determining the processing process correspondingly stored by the serial number of the plastic product and the index data of each component in the corresponding processing process, and the index data comprises temperature, pressure, time, speed and travel;