Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a control system of an injection molding machine with high weight repetition precision, which solves the problem that the high weight repetition precision of a product during injection molding cannot be ensured due to single pressure maintaining control method in the pressure maintaining process of the existing injection molding machine.
The aim of the invention can be achieved by the following technical scheme: the utility model provides an injection molding machine control system of high weight repetition precision, includes control module and with control module communication connection's injection molding machine, hydraulic pressure mechanism, viscosity detector and pressure sensor all install in injection molding machine and detect material viscosity and pressure in the mechanism of moulding plastics, viscosity detector and pressure sensor transmit the testing result to control module, control module calculates the die cavity pressure under this viscosity equivalent according to the viscosity equivalent to compare with the testing result of pressure sensor, control module controls hydraulic pressure mechanism and injection molding machine according to the comparison result and adjusts.
As a preferable technical scheme of the invention, the injection molding mechanism comprises an injection molding cylinder, a screw rod, a hopper and a driving assembly, wherein the screw rod is positioned at the tail part of the injection molding cylinder and is connected with the driving assembly, the driving assembly is connected with the hydraulic mechanism, an injection molding opening is formed in the top of the injection molding cylinder, the hopper is arranged on the injection molding opening, and the viscosity detector and the pressure sensor are both arranged in the injection molding cylinder.
As a preferred embodiment of the present invention, the drive assembly is composed of a hydraulic motor.
As a preferable technical scheme of the invention, the injection molding cylinder comprises an inner cylinder, a heating layer, a heat preservation and insulation layer and an outer cylinder which are sequentially connected from inside to outside, and a heater is arranged in the heating layer.
As a preferable embodiment of the present invention, the heater is an induction heater.
As a preferable embodiment of the present invention, the injection molding machine further comprises a position detector installed in the injection molding cylinder, the position detector detecting a moving distance of the screw.
As a preferable technical scheme of the invention, the front end of the injection molding mechanism is also provided with a mold clamping mechanism, the mold clamping mechanism comprises a film frame, a movable mold, a fixed film and a mold clamping hydraulic cylinder, the fixed film is arranged on the film frame, the movable mold is connected to the film frame in a sliding manner, the driving end of the mold clamping hydraulic cylinder is connected with the movable mold, and the fixed film is connected with the injection molding mechanism.
As a preferable technical scheme of the invention, a temperature and pressure integrated sensor is further arranged on the pouring gate of the mold clamping mechanism, the temperature and pressure integrated sensor is in communication connection with the control module, and the temperature and pressure integrated sensor detects the temperature and the pressure in the mold clamping mechanism.
The beneficial effects of the invention are as follows: the viscosity detector and the pressure detector are used for detecting the viscosity of materials in the injection molding mechanism and the pressure in the injection molding mechanism, the control module adjusts the cavity pressure in the pressure maintaining stage through the viscosity of the materials, so that the injection molding mechanism can adjust different cavity pressures according to different material viscosities to meet the requirement that the pressure of the injection molding machine is consistent in the pressure maintaining stage, the quality of produced products is consistent, and the problem that the high weight repetition precision of the products during injection molding cannot be guaranteed due to single pressure maintaining control method in the pressure maintaining process of the existing injection molding machine is solved.
Detailed Description
In order to further describe the technical means and effects adopted by the invention for achieving the preset aim, the following detailed description is given below of the specific implementation, structure, characteristics and effects according to the invention with reference to the attached drawings and the preferred embodiment.
Referring to fig. 1-4, the embodiment provides a control system of an injection molding machine with high weight repetition accuracy, which comprises a control module 1, an injection molding mechanism 2, a hydraulic mechanism, a viscosity detector 4 and a pressure sensor 5 which are in communication connection with the control module 1, wherein the viscosity detector 4 and the pressure sensor 5 are arranged in the injection molding mechanism 2 and detect the concentration of materials and the cavity pressure in the injection molding mechanism 2, the viscosity detector 4 and the pressure sensor 5 transmit detection results to the control module 1, the control module 1 calculates the cavity pressure under the viscosity equivalent according to the viscosity equivalent, the pressure sensor 5 detects the pressure provided by the hydraulic mechanism in the injection molding mechanism 2, and then compares the cavity pressure calculated by the control module 1 with the detection result of the pressure sensor 5, if the difference of the cavity pressure is caused by different materials, the control module 1 adjusts the hydraulic mechanism and the injection molding mechanism 2 according to the comparison result, when the injection molding machine performs injection molding, the viscosity detector 4 detects the molten materials in the injection molding mechanism 2, simultaneously detects the cavity pressure under the same pressure, the injection molding mechanism can perform pressure adjustment according to the detection result, the pressure can perform the adjustment of the injection molding mechanism under the same pressure, and the injection molding mechanism can perform pressure adjustment according to the pressure adjustment when the injection molding mechanism is different in pressure, thereby the weight of the product can reach high repetition accuracy in the process of carrying out the cyclic injection molding.
Injection molding is one of the most important polymer molding modes, and the high molecular weight processed each year accounts for more than one third of the total weight. The injection molding machine is a machine for realizing injection molding and comprises a mold and an injection molding machine, and the injection molding machine can be divided into a mold clamping mechanism 7, an injection mechanism, a hydraulic system 3 and a control system. A typical injection molding process includes several steps of mold closing, injection, dwell, pre-molding and cooling, mold opening and ejection. The injection molding firstly heats the polymer raw material to a molten state by using a material cylinder and a screw 22, then the polymer raw material is injected into a closed mold cavity by the injection screw 22, and a required product is formed by a pressure maintaining process and a cooling process, wherein the process which most directly influences the quality of the product is the injection pressure maintaining process, and the quality of the final product is directly related, so that the precise control is required. The unreasonable setting of the pressure maintaining parameters and the low control precision of the pressure maintaining process can directly lead to the injection molding defects such as edge overflow, warping and the like, and the injection molding precision can not be ensured.
Because the injection molding process is very complicated, the precision of injection molded products is generally divided into appearance quality including dimensional precision, smoothness, etc., and internal quality including strength, toughness, internal stress distribution, molecular orientation force, etc. The appearance shape, the size, the polymer raw materials of different products are different, and the like, so that appearance quality indexes such as appearance size and the like are difficult to be suitable for all injection molding products, and therefore, the injection molding industry currently generally adopts injection molding repetition precision to describe the quality of injection molding products, namely, repeated injection molding products are repeated for a plurality of times in weight to describe the injection molding quality, and therefore, how to realize high repetition precision control of injection molding is a key problem of injection molding control.
The key process of injection molding is injection and pressure maintaining, so that high-precision injection repetition precision can be realized only by precisely controlling the injection and pressure maintaining processes. In order to realize the injection repeated precision control, the injection repeated precision control is realized from the control precision of process parameters, such as the speed, pressure and position control precision of injection and pressure maintaining processes are high, the pressure maintaining process is realized by cooling and molding polymer raw materials under certain pressure and temperature, and cooling and feeding are realized to ensure the consistency of products, so that the quality influence of the pressure maintaining process on the injection molding process is more direct, the control of the current pressure maintaining process basically adopts a time control mode, the pressure maintaining process is divided into a plurality of pressure maintaining stages according to pressure change, the conversion of each stage adopts a time control mode, the next pressure maintaining stage is changed when the time reaches, the final pressure maintaining process is finished by adopting a time control mode, and the pressure maintaining control method is an approximate control method essentially for simulating the molding pressure and temperature change process of the polymer raw materials in a die cavity. However, this control method cannot essentially ensure high repeatable control accuracy of the injection molding process, because the injection molding process is affected by many external interference factors per cycle, and the melt temperature and the injection amount may be inaccurate, so that it is difficult to ensure high repeatable accuracy with fixed pressure maintaining control.
In order to ensure high repeatable control precision of the cyclic injection molding process, the repeated precision of injection molding is precisely controlled by controlling the pressure maintaining pressure of the pressure maintaining stage in the injection molding process, and the pressure maintaining is finished by controlling the quantity of the cavity pressure when the pressure maintaining stage is carried out on materials with different viscosities and different resistances generated during injection molding due to inconsistent molten states when the materials are molten, so that the pressure of the cavity is changed when the materials with higher viscosity are subjected to the same parameters of an injection molding machine, and the repeated precision of injection molding is reduced.
In order to better detect the cavity pressure and the material viscosity, and to better control the cavity pressure in the pressure maintaining stage, in this embodiment, the injection molding mechanism 2 includes an injection molding cylinder 21, a screw 22, a hopper 23 and a driving component 24, the screw 22 is located in the injection molding cylinder 21 and the tail is connected with the driving component 24, the driving component 24 is connected with a hydraulic mechanism, an injection molding port is formed in the top of the injection molding cylinder 21, the hopper 23 is mounted on the injection molding port, the viscosity detector 4 and the pressure sensor 5 are both mounted in the injection molding cylinder 21, when injection molding is performed, the material enters the injection molding cylinder 21 from the hopper 23 to melt, the driving component 24 drives the screw 22 to perform injection molding on the melted material, and the viscosity detector 4 located in the injection molding cylinder 21 detects the viscosity of the material, meanwhile, the pressure sensor 5 detects the pressure in the injection molding cylinder 21, the pressure provided by the hydraulic system 3 is obtained, and in order to keep the injection molding, the hydraulic mechanism adjusts the provided pressure value through the detection result of the pressure sensor 5, and simultaneously, the cavity pressure work and the solution viscosity are balanced, and the solution viscosity are subjected to work and the solution viscosity are performed, and the solution is subjected to work and the working is balanced by the cavity viscosity and the solution viscosity. P (P) C L=MμL C The method comprises the steps of carrying out a first treatment on the surface of the Wherein P is C Since L is the cavity pressure, μ is the viscosity equivalent, M is the product mass, lc is the distance traveled by the solution, in order to achieve high repetition accuracy of the injection molding machine, M is the quantification, and the distance traveled by the screw 22 and the solution is fixed at each injection, the cavity pressure value can be obtained by measuring the viscosity equivalent, the difference can be obtained by comparing the value with a predetermined value, and finally the cavity pressure value in the pressure maintaining stage can be adjusted to a predetermined value, so that the repetition accuracy of the injection molding machine can be improved.
In order to better complete the injection molding process, in one embodiment, the driving assembly 24 is composed of a hydraulic motor, the response speed of the hydraulic motor is very fast, and a large torque can be generated in a short time, so that the hydraulic motor is adjusted according to the control of the control module 1 more quickly, and when the hydraulic motor works, the friction coefficient of the driving part of the hydraulic motor is small, and the output and transmission force are stable, so that the hydraulic motor works stably and reliably, meanwhile, the hydraulic motor can conveniently control the working state through a hydraulic control system, and the output torque and the rotating speed of the motor are finely adjusted, so that the output force can be more accurate.
In order to improve the utilization rate of heat when materials are melted, avoid the waste of energy sources, save energy and protect environment, in an embodiment, the injection molding cylinder 21 comprises an inner cylinder 211, a heating layer 212, a heat preservation and insulation layer 213 and an outer cylinder 214 which are sequentially connected from inside to outside, and a heater is arranged in the heating layer 212, so that heat can be directly transferred to the materials through the inner cylinder 211 and the heating layer 212, and the utilization rate of heat is improved. The heater can make the temperature in the heating layer 212 reach the required melting temperature, so that the materials are melted rapidly, and the heat preservation and insulation layer 213 can effectively prevent heat dissipation and reduce energy waste. The heat is concentrated in the heating layer 212 by reducing heat conduction and radiation loss, so that the energy consumption of the heater is effectively reduced, the temperature in the injection molding barrel 21 can be accurately controlled by controlling the heating layer 212 through the heater, the material is ensured to reach the required melting temperature, the stability is maintained, the viscosity of the solution of the material during melting can be kept consistent as much as possible, and the quality of injection molding products is improved.
For better heating, in one embodiment, the heater is an induction heater 215, and the induction heater 215 uses the induction heating principle to generate electromagnetic induction in the heating layer 212 through alternating current, so as to convert energy into heat energy. The heating mode has the characteristics of high heat efficiency and rapid heating, can provide rapid and efficient heating effect, and the induction heater 215 realizes accurate control on the heating process by adjusting parameters such as current, frequency, size of a heating block and the like. The heating device can be flexibly adjusted according to the heating requirement of the material, the stable and accurate heating process is ensured, and the design of the induction heater 215 can uniformly distribute the heat in the heating block, so that the heating uniformity is realized. The temperature control and the product quality in the injection molding process are ensured, and the production efficiency is improved.
In order to reduce the deviation of the position of each screw 22 when injection molding is performed due to the installation error or other errors during injection molding, in an embodiment, the injection molding machine further comprises a position detector 6, wherein the position detector 6 is installed in the injection molding cylinder 21, and the position detector 6 detects the moving distance of the screw 22, and the position of the screw 22 is easily deviated due to the influence of various factors, such as friction force, thermal expansion and the like. These deviations can be detected in time through the position detector 6 and adjusted in time, so that the poor quality of the injection molding process is avoided, and the injection molding quantity and the injection molding speed can be adjusted in time due to the fact that the deviation can be found in time by the position detector 6, thereby greatly reducing the defects and the rejection rate of products and improving the working efficiency.
In order to better complete the pressure maintaining stage to improve the repeated precision of injection molding, in an embodiment, the front end of the injection molding mechanism 2 is further provided with a mold clamping mechanism 7, the mold clamping mechanism 7 comprises a film frame 71, a movable mold 72, a fixed film 73 and a mold clamping hydraulic cylinder 74, the fixed film 73 is arranged on the film frame 71, the movable mold 72 is connected to the film frame 71 in a sliding manner, the driving end of the mold clamping hydraulic cylinder 74 is connected with the movable mold 72, the fixed film 73 is connected with the injection molding mechanism 2, when injection molding is performed, materials flow out from the front end of the injection molding cylinder 21 into a mold cavity between the fixed film 73 and the movable mold 72 from a gate of the mold to complete the mold clamping process, and meanwhile, after the injection stage is completed into the pressure maintaining stage, in order to reduce the cavity pressure of the pressure maintaining stage, a temperature and pressure integral sensor 8 is further arranged on the gate of the mold clamping mechanism 7 to be in communication connection with the control module 1, the temperature and pressure integral sensor 8 detects the temperature and pressure in the mold clamping mechanism 7, the temperature and the pressure of the pressure integral sensor 8 detect the temperature and the pressure in the pressure maintaining stage, when the pressure maintaining stage is mainly controlled by the pressure maintaining stage, the pressure maintaining is performed, the pressure maintaining is reduced, the pressure maintaining stage is detected by the pressure maintaining sensor is very heavy, the temperature and the product is reduced, and the defect rate is reduced, and the defect is caused by the detection that the temperature and the defect is detected when the pressure is detected.
The present invention is not limited to the above embodiments, but is capable of modification and variation in detail, and other modifications and variations can be made by those skilled in the art without departing from the scope of the present invention.