CN117532838A - Intelligent hot runner and temperature control system and method thereof - Google Patents
Intelligent hot runner and temperature control system and method thereof Download PDFInfo
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- 238000002347 injection Methods 0.000 claims abstract description 16
- 239000007924 injection Substances 0.000 claims abstract description 16
- 238000004519 manufacturing process Methods 0.000 claims abstract description 12
- 230000033228 biological regulation Effects 0.000 claims abstract description 11
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- 239000011159 matrix material Substances 0.000 claims description 56
- 230000008859 change Effects 0.000 claims description 35
- 230000001105 regulatory effect Effects 0.000 claims description 26
- 238000004422 calculation algorithm Methods 0.000 claims description 22
- 238000004590 computer program Methods 0.000 claims description 15
- 238000001746 injection moulding Methods 0.000 claims description 15
- 230000008569 process Effects 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 12
- 238000003860 storage Methods 0.000 claims description 12
- 238000012423 maintenance Methods 0.000 claims description 10
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- 238000000465 moulding Methods 0.000 abstract description 5
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/78—Measuring, controlling or regulating of temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/2737—Heating or cooling means therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76531—Temperature
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- 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
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- Mechanical Engineering (AREA)
- Control Of Temperature (AREA)
Abstract
The invention is applicable to the technical field of hot runner control, and provides a temperature control system of an intelligent hot runner, which comprises a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulation module, an equipment control module, a wireless communication module, a memory, an alarm, a processing center and a smart phone, wherein the temperature balancing module, the temperature acquisition module, the heating control module, the voltage regulation module, the equipment control module, the wireless communication module, the memory and the alarm are respectively connected with the processing center; the intelligent mobile phone is respectively connected with the wireless communication module in the range of the Internet of things or the Internet. The invention can automatically and accurately control the temperature of the hot runner, not only stabilizes the molding production of the injection mold, prolongs the service life of the hot runner, reduces the injection production cost, improves the surface quality and mechanical property of the product, improves the degree of automation, ensures the consistent product quality of the multi-cavity mold, and effectively reduces the deformation of the thin-wall product.
Description
Technical Field
The invention belongs to the technical field of hot runner control, and particularly relates to an intelligent hot runner, a temperature control system and a temperature control method thereof.
Background
The hot runner (Hot Runner Systems) is a heating component system used in an injection mold, which injects melted plastic particles into a cavity of the mold, heats runners and runners of a traditional mold or a three-plate mold, and does not need to take out a brand-new structure of the runners and runners during each molding, thereby being an injection molding tool capable of improving the surface quality and mechanical properties of injection molding products, ensuring the consistent quality of molded products of the multi-cavity mold and effectively reducing the deformation of thin-wall injection molding products.
The hot runner ensures that the plastic in the runner and the gate keep a molten state by a heating method, and because a heating rod and a heating ring are arranged near or in the center of the runner, the whole runner from the nozzle outlet of the injection molding machine to the gate is in a high-temperature state, so that the plastic in the runner keeps molten, the runner is generally not required to be opened to take out the solidified material after shutdown, and the runner is only required to be heated to a required temperature when the injection molding machine is restarted, so that the hot runner process is sometimes called a hot manifold system or a runnerless molding.
At present, a hot runner system is easy to generate a process of controlling temperature to exceed a set value in the temperature regulation process, so that the hot runner system is greatly influenced.
Disclosure of Invention
In order to solve the defects in the prior art, the invention aims to provide an intelligent hot runner, a temperature control system and a temperature control method thereof, which can automatically and accurately control the temperature of the hot runner by arranging a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulating module and an equipment control module, thereby stabilizing the molding production of an injection mold, prolonging the service life of the hot runner, reducing the injection production cost, improving the injection molding efficiency, saving plastic raw materials, shortening the molding period, improving the surface quality and the mechanical property of products, improving the degree of automation, ensuring the consistent product quality of a multi-cavity mold and effectively reducing the deformation of thin-wall products.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
a temperature control method of an intelligent hot runner comprises the following steps:
s10, heating the hot runner by adopting a proportion term according to the difference between the actual temperature and the target temperature through a temperature balancing module to enable the temperature to reach a thermal balance state, and transmitting the temperature to a temperature acquisition module;
s20, the temperature acquisition module acquires the actual temperature of the hot runner through a temperature sensor arranged on the hot runner, converts the actual temperature into a thermoelectric signal and transmits the thermoelectric signal to the processing center;
S30, the processing center compares the real-time temperature of the hot runner with the target temperature stored in the memory: if the target temperature is reached, the temperature is transferred to the voltage regulating module for temperature maintenance operation, if the target temperature is smaller than the target temperature, the temperature is transferred to the alarm to inform the voltage regulating module to continue heating, and if the temperature is larger than 400 ℃, the temperature is transferred to the alarm to inform the shutdown maintenance;
s40, the heating control module continuously heats the hot runner by using disturbance power according to the difference between the actual temperature and the target temperature, and transmits the disturbance power to the temperature acquisition module;
s50, when the temperature of the hot runner is higher than 400 ℃, the equipment control module controls the switch button to close the hot runner and notifies the hot runner to be maintained;
s60, the voltage regulating module regulates voltage in a PID control mode on the hot runner so as to ensure that the temperature of the hot runner is unchanged and heat can be continuously supplied to the injection mold.
Further, before the step S10 of heating the hot runner with the proportional term, the method includes the following steps:
s11, selecting proper temperature between 100 ℃ and 400 ℃ according to the type, color and model of the plastic material, automatically setting the initial temperature according to the fluidity of the plastic material, the wall thickness of the injection molding piece and other parameters, and transmitting the initial temperature to the debugging and calibrating unit;
S12, the debugging and calibrating unit obtains whether the temperature of each part of the hot runner is uniform and accurate through a thermometer or a thermal imager, automatically adjusts the temperature until the temperature of each part is uniform, and transmits the temperature to the temperature memory unit;
s13, automatically and timely memorizing the temperature of the hot runner at the moment according to the fact that the real-time temperature of the hot runner is comprehensive and uniform, and transmitting the temperature to a target computing unit;
s14, the target calculating unit calculates a formula 'Td=Pt/Kp+T' according to the target temperature 1 ＝R(T 1 -T 0 )/Kp+T 1 Pt is heating power, R is thermal resistance, T 1 Is the temperature of a hot runner, T 0 For the ambient temperature, kp is a proportional term coefficient, td is a target temperature "the target temperature required for the hot runner is automatically calculated.
Further, the step S10 of "bringing the temperature thereof to a thermal equilibrium state" includes the steps of:
s101, when the hot runner reaches heat balance, the integral heating unit performs heating control on the hot runner by adding an integral item and transmits the heated control to the heating limiting unit;
s102, when the temperature of the hot runner reaches the temperature close to the target temperature, accumulating integral items of the temperature limitation of the hot runner by a heating limiting unit, ensuring that the heating power and the heat conduction of the runner plate reach heat balance, and transmitting the heat balance to a temperature acquisition module;
S103, the temperature acquisition module acquires real-time temperature information of the hot runner in any two time periods and transmits the real-time temperature information to the processing center;
s104, the processing center compares the obtained difference of the real-time temperatures of the hot runners in any two time periods with a threshold value of the temperature difference stored in the memory: if the temperature of the hot runner is not exceeded, the temperature of the hot runner reaches balance, if the temperature of the hot runner is exceeded, the hot runner is unbalanced and is transmitted to an alarm to inform the alarm to continue heating to balance.
Further, the step S20 of "the temperature sensor obtaining the actual temperature of the hot runner" includes the following steps:
s21, a matrix calculation unit calculates a covariance matrix according to a covariance matrix calculation formula 'Pk|k-1=Pk-1|k-1+Qk, wherein Pk-1|k-1 is the covariance matrix of the previous moment k-1, and Qk is the covariance matrix of process noise', and the covariance matrix is transmitted to a gain calculation unit;
s22, the gain calculation unit calculates a covariance matrix according to a Kalman gain calculation formula 'Kk=Pk|k-1/(Pk|k-1+Rk), wherein Kk is Kalman gain, pk|k-1 is a covariance matrix, rk is measurement noise', and the covariance matrix is transmitted to the temperature calculation unit;
s23, the temperature calculating unit calculates the temperature value of the hot runner according to a calculation formula of Tk|k=Tk-1|k-1+Kk (Tm-H.Tk|k-1) of a temperature value of the hot runner by a Kalman filtering algorithm, wherein Tk|k is a temperature estimated value obtained by correcting a temperature estimated value of a previous time k-1 and a measured value of a current time k at time k, tk-1|k-1 is a temperature estimated value obtained by correcting the previous time k-1, kk is Kalman gain, tm is a temperature value of the hot runner obtained at time k, H is an observation matrix, tk|k-1 is a temperature estimated value of the previous time k-1.
Further, in the step S40, "continuously heating the hot runner with the disturbance power", the method includes the following steps:
s41, the temperature difference determining unit calculates a temperature change value delta T of the internal hot runner in the last period by detecting the change of the temperature of the hot runner in real time, calculates a temperature change average value in the last period, and transmits the temperature change average value to the power calculating unit;
s42, the power calculation unit calculates real-time disturbance power according to a disturbance power calculation formula Pd=m.C.delta.T, pd is disturbance power, m is the mass of the hot runner, C is the specific heat capacity of the hot runner, delta T is a temperature change value of the hot runner monitored in real time, and the real-time disturbance power is transmitted to the power addition unit;
s43, the power adding unit heats the heating device of the hot runner through preset disturbance power, the existing heat balance state is broken, the temperature rise is realized, and the temperature of the hot runner reaches the target temperature quickly.
The invention also provides a temperature control system of the intelligent hot runner, which comprises a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulation module, an equipment control module, a wireless communication module, a memory, an alarm, a processing center and a smart phone, wherein the temperature balancing module, the temperature acquisition module, the heating control module, the voltage regulation module, the equipment control module, the wireless communication module, the memory and the alarm are respectively connected with the processing center; the intelligent mobile phone is respectively connected with the wireless communication module in the range of the Internet of things or the Internet;
The wireless communication module is provided with an Internet of things unit which is responsible for receiving and transmitting wireless signals and is automatically connected with other same-network equipment in an effective network range;
the processing center is responsible for information transmission of a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulating module, an equipment control module, a wireless communication module, a memory and an alarm, is a hub center of the system, and compares the real-time temperature of the hot runner with the target temperature stored in the memory: if the target temperature is reached, the temperature is transferred to the voltage regulating module for temperature maintenance operation, if the target temperature is smaller than the target temperature, the temperature is transferred to the alarm for notification to continue heating, and if the temperature is larger than 400 ℃, the temperature is transferred to the alarm for notification to be closed and maintained; comparing the obtained difference between the real-time temperatures of the hot runners in any two time periods with a threshold value of the real-time temperature difference stored in the memory: if the temperature of the hot runner is not exceeded, the temperature of the hot runner reaches balance, if the temperature of the hot runner is exceeded, the hot runner is unbalanced and is transmitted to an alarm to inform the alarm to continue heating to balance;
when the real-time temperature of the hot runner is smaller than the target temperature stored in the memory, the alarm automatically alarms and transmits the alarm to inform the heating control module to continue heating; when the real-time temperature of the hot runner is higher than 400 ℃, automatically alarming and informing to close for maintenance; when the obtained difference of the real-time temperatures of the hot runners in any two time periods exceeds the threshold value of the real-time temperature difference stored in the memory, automatically alarming and informing to continue heating so as to balance the heat;
The memory is responsible for information storage of a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulating module, an equipment control module, a wireless communication module and an alarm, and storage of target temperature of a hot runner and thresholds of real-time temperature differences in different time periods;
the temperature acquisition module comprises a matrix calculation unit, a gain calculation unit and a temperature calculation unit, acquires the actual temperature of the hot runner through a temperature sensor arranged on the hot runner, converts the actual temperature into a thermoelectric signal and transmits the thermoelectric signal to the processing center;
and the equipment control module controls the switch button to close the hot runner when the temperature of the hot runner is higher than 400 ℃ and notifies the hot runner to be maintained.
Further, the temperature balance module comprises an initial temperature setting unit, a debugging and calibrating unit, a temperature memory unit, a target calculating unit, an integral heating unit and a heating limiting unit, and the heating unit is used for continuously heating the hot runner by adopting a proportion term according to the difference between the actual temperature and the target temperature and transmitting the heated hot runner to the temperature acquisition module;
the heating control module comprises a temperature difference determining unit, a power calculating unit and a power adding unit, and continuously heats the hot runner by using disturbance power through the heating unit according to the difference between the actual temperature and the target temperature and transmits the disturbance power to the temperature obtaining module;
The voltage regulating module carries out PID control mode regulation on the voltage in the hot runner so as to ensure that the temperature of the hot runner is unchanged and can continuously provide heat for the injection mold so as to ensure normal injection production.
The invention provides a temperature control system of an intelligent hot runner, which also comprises a computer readable storage medium containing a memory; the memory stores a computer program, and each functional module realizes the steps of the temperature control method of the intelligent hot runner when executing the computer program; the computer readable storage medium stores a computer program, and the computer program when executed by each functional module realizes the steps of the temperature control method of the intelligent hot runner.
The invention also provides an intelligent hot runner, which is realized by the temperature control system of the intelligent hot runner and the temperature control method of the intelligent hot runner.
Compared with the prior art, the invention has the beneficial effects that:
through setting up temperature balance module, temperature acquisition module, control module that heats, voltage regulation module, equipment control module, can carry out automatic accurate control to the temperature of hot runner, both stabilized injection mold's shaping production, prolonged hot runner's life, reduced injection molding manufacturing cost, improved injection molding's efficiency, practiced thrift the plastic raw and other materials, shortened the shaping cycle, improved product surface quality and mechanical properties, improved degree of automation, guaranteed the product quality of multi-cavity mould unanimously, effectively reduced thin wall product and warp.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings that are required for the description of the embodiments or exemplary techniques will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present application, and other drawings may be obtained according to these drawings without inventive effort for a person of ordinary skill in the art.
FIG. 1 is a schematic diagram of a process control procedure according to the present invention;
FIG. 2 is a schematic diagram of the process before step S10 in the method of the present invention;
FIG. 3 is a schematic diagram of a step S10 decomposition process in the method flow of the present invention;
FIG. 4 is a schematic diagram of a step S20 decomposition process in the method flow of the present invention;
FIG. 5 is a schematic diagram of a step S40 decomposition process in the method flow of the present invention;
FIG. 6 is a schematic diagram of a system module application of the present invention;
FIG. 7 is a schematic diagram of a temperature balancing module according to the present invention;
FIG. 8 is a schematic diagram of a temperature acquisition module according to the present invention;
fig. 9 is a schematic diagram of the heating control module according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
The following describes in detail the implementation of the present invention in connection with specific embodiments:
in order to make the technical problems, technical schemes and beneficial effects to be solved by the present application more clear, the present application is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the present application.
It should be noted that when a module is referred to as being "disposed on" another module, it can be directly on the other module or be indirectly on the other module. When a module is referred to as being "connected to" another module, it can be directly connected to the other module or be indirectly connected to the other module.
In the description of the present application, the meaning of "a plurality" is two or more, unless explicitly defined otherwise. The meaning of "a number" is one or more than one unless specifically defined otherwise.
In the description of the present application, it should be noted that, unless explicitly specified and limited otherwise, the terms "connected," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the terms in this application will be understood by those of ordinary skill in the art as the case may be. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless expressly specified otherwise.
Referring to fig. 1, the invention further provides a temperature control method of an intelligent hot runner, comprising the following steps:
s10, heating the hot runner by adopting a proportion term according to the difference between the actual temperature and the target temperature through a temperature balancing module to enable the temperature to reach a thermal balance state, and transmitting the temperature to a temperature acquisition module;
further, the proportional term is a control mode for adjusting the output power according to the magnitude of the current error (i.e., the difference between the target temperature and the actual temperature), the output power is calculated by multiplying the error by a proportional coefficient, so that the temperature rise or fall is controlled by increasing or decreasing the magnitude of the output power, and the proportional term is used for heating control by using the PID algorithm, regardless of the integral term and the differential term.
Further, the PID algorithm is a control algorithm combining three links of Proportional, integral and Differential, is a control algorithm with the most mature technology and the most extensive application in a continuous system, is suitable for the situation that the controlled object model is not known clearly, and is operated according to the input deviation value and the function relation of Proportional, integral and Differential, and the operation result is used for controlling output, including a Proportional algorithm, an Integral algorithm and a Differential algorithm.
Further, the proportional algorithm refers to that only the current error of the control object is considered, the control signal is output only when the current error exists, and the control signal is not output when the current error exists, that is, the control signal is not output when the deviation generates the proportional algorithm, that is, measures are taken to adjust the control signal, so that the state value of the control object cannot be controlled on a set value by the independent proportional algorithm, and the control signal always fluctuates up and down on the set value; but the proportional control is sensitive and reacts to the output immediately with errors.
Further, the integration algorithm considers the historical error condition of the controlled object, and the past error condition participates in the current output control, but during the period that the system does not reach the target, the current control is often disturbed (i.e. the trailing leg) due to the historical error, and the current output is disturbed due to improper use. However, after the system enters a stable state, particularly when the current value and the set value have no deviation, the integration algorithm can output a relatively stable control signal according to the past deviation value so as to prevent the deviation from the target and play a role in playing a role in preventing the needle from being shot.
Further, the differential algorithm simply considers the recent change rate, when the deviation of the system approaches to a certain fixed value (the change rate is 0), the differential algorithm does not output a signal to adjust the deviation, so the differential algorithm cannot be used alone, only the change speed of the deviation is concerned, whether the deviation exists or not (the deviation is not necessarily 0 when the change rate of the deviation is 0) is not considered, but the differential algorithm can obtain the recent change trend of the control object, and can assist the output signal to restrain the change of the control object as early as possible. It can be understood that the output signal is greatly adjusted to be suppressed when there is a drastic change, so that a large change of the control object is avoided.
S20, the temperature acquisition module acquires the actual temperature of the hot runner through a temperature sensor arranged on the hot runner, converts the actual temperature into a thermoelectric signal and transmits the thermoelectric signal to the processing center;
s30, the processing center compares the real-time temperature of the hot runner with the target temperature stored in the memory: if the target temperature is reached, the temperature is transferred to the voltage regulating module for temperature maintenance operation, if the target temperature is smaller than the target temperature, the temperature is transferred to the alarm to inform the voltage regulating module to continue heating, and if the temperature is larger than 400 ℃, the temperature is transferred to the alarm to inform the alarm to close and maintain;
further, when the difference between the real-time temperature of the hot runner and the target temperature is smaller than the preset switching threshold, it means that the real-time temperature of the hot runner has reached the target temperature, otherwise, the standard of the target temperature is not reached, and the related technician can set the switching threshold according to the actual situation.
S40, the heating control module continuously heats the hot runner by using disturbance power according to the difference between the actual temperature and the target temperature, and transmits the disturbance power to the temperature acquisition module;
further, the disturbance power refers to a fluctuation of the system power due to a fluctuation of the voltage load, the power, and a disturbance of the pulse or an incoming fluctuation of the system power due to a sudden change of the system parameter.
Further, step S20 is repeatedly performed until the target temperature is not reached in the process of heating the hot runner; when the real-time temperature of the hot runner reaches the target temperature, the normal PID control mode is switched to and the disturbance power output is closed.
S50, when the temperature of the hot runner is higher than 400 ℃, the equipment control module controls the switch button to close the hot runner and notifies the hot runner to be maintained;
s60, the voltage regulating module regulates voltage in a PID control mode on the hot runner so as to ensure that the temperature of the hot runner is unchanged and heat can be continuously supplied to the injection mold.
Further, the PID control mode refers to a control method for adjusting temperature by utilizing proportion, integration and differentiation, wherein the proportion term coefficient, the integral term coefficient and the differential term coefficient can be adjusted according to actual conditions, and at the moment, the temperature controller controls heating power by means of the proportion, the integration and the differentiation, so that accurate control of the temperature of the hot runner is realized, the hot runner is maintained near the target temperature, and deviation is not too large.
Further, the steps S40, S50, and S60 do not occur simultaneously or in any order, but only one of them, and the step numbers are merely a matter of convenience and are not confused.
Referring to fig. 2, before "heating the hot runner with the proportional term" in step S10, the method includes the following steps:
s11, selecting proper temperature between 100 ℃ and 400 ℃ according to the type, color and model of the plastic material, automatically setting the initial temperature according to the fluidity of the plastic material, the wall thickness of the injection molding piece and other parameters, and transmitting the initial temperature to the debugging and calibrating unit;
s12, the debugging and calibrating unit obtains whether the temperature of each part of the hot runner is uniform and accurate through a thermometer or a thermal imager, automatically adjusts the temperature until the temperature of each part is uniform, and transmits the temperature to the temperature memory unit;
s13, automatically and timely memorizing the temperature of the hot runner at the moment according to the fact that the real-time temperature of the hot runner is comprehensive and uniform, and transmitting the temperature to a target computing unit;
s14, the target calculating unit calculates the target temperature according to the target temperature calculation formula "td=pt/kp+t1=r (T1-T 0 )/Kp+T 1 Pt is heating power, R is thermal resistance, T 1 Is the temperature of a hot runner, T 0 For the ambient temperature, kp is a proportional term coefficient, td is a target temperature, "the setting required by the hot runner is automatically calculatedCan ensure the stability of injection molding quality and reject ratio, improve production efficiency and reduce production cost.
Further, the target temperature calculation formula is calculated by a heat balance principle, and due to external heat conduction of the hot runner, a stable state is finally reached, and the heating power is equal to the heat dissipation power. That is, in this steady state, a balance is achieved between the heating power and the heat dissipation power, the temperature of the system will remain steady and will no longer rise or fall, when the heating power is equal to the heat dissipation power, then the temperature is increased according to pt=r (T1-T 0 )＝Kp(Td-T 1 ) Can be converted into Td=Pt/Kp+T 1 ＝R(T 1 -T 0 ) Kp+T1 is the calculation formula of the target temperature.
Referring to fig. 3, the step S10 of "bringing the temperature to a thermal equilibrium state" includes the following steps:
s101, when the hot runner reaches heat balance, the integral heating unit performs heating control on the hot runner by adding an integral item and transmits the heated control to the heating limiting unit;
further, the integral term is a control method for calculating the output power according to the historical accumulated value of the current error.
S102, when the temperature of the hot runner reaches the temperature close to the target temperature, accumulating integral items of the temperature limitation of the hot runner by a heating limiting unit so as to ensure that the heating power in the hot runner and the heat conduction of the runner plate reach heat balance, and transmitting the heat balance to a temperature acquisition module;
S103, the temperature acquisition module acquires real-time temperature information of the hot runner in any two time periods and transmits the real-time temperature information to the processing center;
s104, the processing center compares the obtained difference of the real-time temperatures of the hot runners in any two time periods with a threshold value of the temperature difference stored in the memory: if the temperature of the hot runner is not exceeded, the temperature of the hot runner reaches balance, if the temperature of the hot runner is exceeded, the hot runner is unbalanced and is transmitted to an alarm to inform the alarm to continue heating to balance the hot runner, and therefore whether the hot runner reaches a thermal balance state is judged.
Further, the two arbitrary time periods are divided into a plurality of intervals at the same time, the real-time temperature of the hot runner at the end of each interval is obtained in time, and then the difference between the temperatures of the hot runners in any two adjacent time intervals is calculated and compared with a preset temperature difference threshold; the magnitude of the threshold value of the real-time temperature difference in different time periods is not particularly limited in this embodiment, and is set by an operator.
Referring to fig. 4, in the step S20, the "the temperature sensor obtains the actual temperature of the hot runner" includes the following steps:
s21, a matrix calculation unit calculates a covariance matrix according to a covariance matrix calculation formula 'Pk|k-1=Pk-1|k-1+Qk, wherein Pk-1|k-1 is the covariance matrix of the previous moment k-1, and Qk is the covariance matrix of process noise', and the covariance matrix is transmitted to a gain calculation unit;
S22, the gain calculation unit calculates a covariance matrix according to a Kalman gain calculation formula 'Kk=Pk|k-1/(Pk|k-1+Rk), wherein Kk is Kalman gain, pk|k-1 is a covariance matrix, rk is measurement noise', and the covariance matrix is transmitted to the temperature calculation unit;
further, the measured noise Rk needs to take a proper value according to the actual situation, if the value of Rk is smaller, the predicted value converges faster, and if the value of Rk is too small, the filter is too sensitive to noise, so that the filtering result is unstable.
S23, the temperature calculating unit calculates the temperature value of the hot runner according to a calculation formula of Tk|k=Tk-1|k-1+Kk (Tm-H.Tk|k-1) of a temperature value of the hot runner by a Kalman filtering algorithm, wherein Tk|k is a temperature estimated value obtained by correcting a temperature estimated value of a previous time k-1 and a measured value of a current time k at time k, tk-1|k-1 is a temperature estimated value obtained by correcting the previous time k-1, kk is Kalman gain, tm is a temperature value of the hot runner obtained at time k, H is an observation matrix, tk|k-1 is a temperature estimated value of the previous time k-1.
Further illustratively, the observation matrix H is used to describe a linear relationship between the state vector and the observed value; the method comprises the steps of obtaining the real-time temperature of a hot runner, predicting and correcting a temperature value acquired by a temperature sensor by adopting a Kalman filtering algorithm, processing and filtering signals by combining a covariance matrix, measurement noise and other parameters and a state vector and an observation matrix, so that measurement errors are reduced, and temperature acquisition accuracy is improved.
Referring to fig. 5, in the step S40, "continuously heating the hot runner with the disturbance power", the method includes the following steps:
s41, the temperature difference determining unit calculates a temperature change value delta T of the internal hot runner in the last period by detecting the change of the temperature of the hot runner in real time, calculates a temperature change average value in the last period, and transmits the temperature change average value to the power calculating unit;
s42, the power calculation unit calculates a formula P through disturbance power d ＝m·C·ΔT,P d For disturbance power, m is the mass of the hot runner, C is the specific heat capacity of the hot runner, deltaT is the real-time disturbance power calculated by monitoring the temperature change value of the hot runner in real time, and the disturbance power is transmitted to a power adding unit;
s43, the power adding unit heats the heating device of the hot runner through preset disturbance power, the heat balance state is broken, the temperature rising is realized, the temperature of the hot runner reaches the target temperature quickly, the long-time heat balance of the system before the target temperature is reached is avoided, the continuous rising of the temperature is ensured, the temperature change speed can be quickened under the stable state of the system, the overshoot phenomenon caused by integral saturation when the temperature value is changed greatly is avoided, and the stable operation of the hot runner system is ensured.
Referring to fig. 6, the invention further provides a temperature control system of an intelligent hot runner, which comprises a temperature balancing module, a temperature obtaining module, a heating control module, a voltage regulating module, an equipment control module, a wireless communication module, a memory, an alarm, a processing center and a smart phone, wherein the temperature balancing module, the temperature obtaining module, the heating control module, the voltage regulating module, the equipment control module, the wireless communication module, the memory and the alarm are respectively connected with the processing center; the intelligent mobile phone is respectively connected with the wireless communication module in the range of the Internet of things or the Internet.
The wireless communication module is provided with an Internet of things unit which is responsible for receiving and transmitting wireless signals and is automatically connected with other same-network equipment in an effective network range.
The processing center is responsible for information transmission of a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulating module, an equipment control module, a wireless communication module, a memory and an alarm, is a hub center of the system, and compares the real-time temperature of the hot runner with the target temperature stored in the memory: if the target temperature is reached, the temperature is transferred to the voltage regulating module for temperature maintenance operation, if the target temperature is smaller than the target temperature, the temperature is transferred to the alarm for notification to continue heating, and if the temperature is larger than 400 ℃, the temperature is transferred to the alarm for notification to be closed and maintained; comparing the obtained difference between the real-time temperatures of the hot runners in any two time periods with a threshold value of the real-time temperature difference stored in the memory: if the temperature of the hot runner is not exceeded, the temperature of the hot runner reaches balance, if the temperature of the hot runner is exceeded, the hot runner is unbalanced and is transmitted to an alarm to inform the alarm to continue heating to balance.
When the real-time temperature of the hot runner is smaller than the target temperature stored in the memory, the alarm automatically alarms and transmits the alarm to inform the heating control module to continue heating; and automatically alarming and informing to continue heating to balance the heat when the acquired difference of the real-time temperatures of the hot runners in any two time periods exceeds the threshold value of the real-time temperature difference stored in the memory.
The memory is responsible for information storage of a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulating module, an equipment control module, a wireless communication module and an alarm, and storage of target temperature of a hot runner and thresholds of real-time temperature differences in different time periods.
Referring to fig. 7, the temperature balancing module includes an initial temperature setting unit, a debugging and calibrating unit, a temperature memory unit, a target calculating unit, an integral heating unit, and a heating limiting unit, and continuously heats the hot runner by a proportional term through the heating unit according to the difference between the actual temperature and the target temperature until the hot runner reaches thermal balance, and transmits the thermal balance to the temperature obtaining module.
Further, the initial temperature setting unit selects proper temperature between 100 ℃ and 400 ℃ according to the type, color and model of the plastic material, automatically sets the initial temperature according to the fluidity of the plastic material, the wall thickness of the injection molding piece and other parameters, and transmits the initial temperature to the debugging and calibrating unit.
Furthermore, the debugging and calibrating unit obtains whether the temperature of each part of the hot runner is uniform and accurate through a thermometer or a thermal imager, automatically adjusts the temperature until the temperature of each part is uniform, and transmits the temperature to the temperature memory unit.
Further, the temperature memory unit automatically and timely memorizes the temperature of the hot runner at the moment when the temperature of the hot runner reaches the overall uniformity, and transmits the temperature to the target calculation unit.
Further, the target calculating unit automatically calculates a target temperature required to be set for the hot runner according to a target temperature calculating formula of "td=pt/kp+t1=r (T1-T0)/kp+t1, pt is heating power, R is thermal resistance, T1 is hot runner temperature, T0 is ambient temperature, kp is a proportional term coefficient, and Td is a target temperature".
Further, the integral heating unit performs heating control on the hot runner by increasing an integral item when the hot runner reaches heat balance, and transmits the heating control to the heating limiting unit.
Further, when the temperature of the hot runner reaches the target temperature, the heating limiting unit ensures that the heating power and the heat conduction of the runner plate reach heat balance through accumulating integral items of the temperature limitation of the hot runner, and transmits the heat balance to the temperature acquisition module.
Further, the temperature acquisition module acquires real-time temperature information of the hot runner in any two time periods through the temperature sensor and transmits the real-time temperature information to the processing center.
Referring to fig. 8, the temperature acquisition module includes a matrix calculation unit, a gain calculation unit, and a temperature calculation unit, and acquires an actual temperature of the hot runner through a temperature sensor disposed on the hot runner, converts the actual temperature into a thermoelectric signal, and transmits the thermoelectric signal to the processing center.
Further, the matrix calculation unit calculates a covariance matrix according to a covariance matrix calculation formula "pk|k-1=pk-1|k-1+qk, pk-1|k-1 is a covariance matrix of the previous time k-1, qk is a covariance matrix of process noise", and transmits the covariance matrix to the gain calculation unit.
Further, the gain calculation unit calculates a covariance matrix according to a Kalman gain formula "Kk=Pk|k-1/(Pk|k-1+Rk), kk being Kalman gain, pk|k-1 being a covariance matrix, rk being measurement noise", and transmits the covariance matrix to the temperature calculation unit.
Further, the temperature calculating unit calculates the temperature value of the hot runner according to a calculation formula of a Kalman filtering algorithm for the temperature value of the hot runner, wherein Tk|k=Tk-1|k-1+Kk (Tm-H. Tk|k-1), tk|k is a temperature estimated value obtained by correcting the temperature estimated value of the previous time k-1 and the measured value of the current time k at the time k, tk-1|k-1 is a temperature estimated value obtained by correcting the previous time k-1, kk is Kalman gain, tm is the temperature value of the hot runner obtained at the time k, H is an observation matrix, tk|k-1 is the temperature estimated value of the previous time k-1.
Referring to fig. 9, the heating control module includes a temperature difference determining unit, a power calculating unit, and a power adding unit, and continuously heats the hot runner with disturbance power by the heating unit according to the difference between the actual temperature and the target temperature, and transmits the disturbance power to the temperature obtaining module.
Further, the temperature difference determining unit calculates a temperature change value delta T of the hot runner in the last period of time by detecting the change of the temperature of the hot runner in real time, calculates a temperature change average value in the last period of time, and transmits the temperature change average value to the power calculating unit.
Further, the power calculation unit calculates real-time disturbance power by a disturbance power calculation formula of "pd=m·c·Δt, pd is disturbance power, m is mass of the hot runner, C is specific heat capacity of the hot runner, Δt is a temperature change value of the hot runner monitored in real time", and transmits the calculated disturbance power to the power addition unit.
Further, the power adding unit heats the heating device of the hot runner through preset disturbance power, the existing heat balance state is broken, the temperature rise is realized, and the temperature of the hot runner reaches the target temperature quickly.
The voltage regulating module carries out PID control mode regulation on the voltage in the hot runner so as to ensure that the temperature of the hot runner is unchanged and can continuously provide heat for the injection mold so as to ensure normal injection production.
And the equipment control module controls the switch button to close the hot runner when the temperature of the hot runner is higher than 400 ℃ and notifies the hot runner to be maintained.
The invention provides a temperature control system of an intelligent hot runner, which also comprises a computer readable storage medium containing a memory; the memory stores a computer program, and each functional module realizes the steps of the temperature control method of the intelligent hot runner when executing the computer program; the computer readable storage medium stores a computer program, and the computer program when executed by each functional module realizes the steps of the temperature control method of the intelligent hot runner.
Further, the computer program is divided into a plurality of modules/units which are stored in the memory and executed by the respective modules/units to complete the present invention; the modules/units may be a series of computer program instructions capable of performing a specified function, for describing the execution of the computer program in each of the modules/units.
The working principle of the system operation:
After the hot runner is opened to set the target temperature, the hot runner is heated by adopting a proportion term according to the difference between the actual temperature and the target temperature through the temperature balancing module, so that the temperature reaches a thermal balance state, and the temperature reaches a temperature acquisition module:
also included before this is: selecting proper temperature between 100 ℃ and 400 ℃ according to the type, color and model of the plastic material through an initial temperature setting unit, automatically setting the initial temperature according to parameters such as the fluidity of the plastic material and the wall thickness of an injection molding part, and transmitting the initial temperature to a debugging and calibrating unit; then the debugging and calibrating unit obtains whether the temperature of each part of the die is uniform and accurate through a thermometer or a thermal imager, automatically adjusts the temperature until the temperature of each part of the die is uniform, and transmits the temperature to the temperature memory unit; then the temperature memory unit automatically and timely memorizes the temperature of the die at the moment when the temperature of the die reaches the overall uniformity, and transmits the temperature to the target calculation listA meta-element; then the target calculation unit calculates a target temperature according to a target temperature calculation formula (td=pt/kp+t1=r (T 1 -T 0 )/Kp+T 1 Pt is heating power, R is thermal resistance, T 1 For the hot runner temperature, T0 is the ambient temperature, kp is the proportional term coefficient, td is the target temperature), the target temperature required to be set by the hot runner is automatically calculated;
The process also comprises the following steps: when the hot runner reaches heat balance, the integral heating unit performs heating control on the hot runner by adding an integral item and transmits the heated control to the heating limiting unit; when the temperature of the hot runner reaches the temperature close to the target temperature, the heating power and the heat conduction of the runner plate are ensured to reach heat balance through accumulation of the integral items of the temperature limitation of the hot runner by the heating limiting unit, and the heat balance is transmitted to the temperature acquisition module; acquiring real-time temperature information of the hot runners in any two time periods through a temperature acquisition module, and transmitting the real-time temperature information to a processing center; then the processing center compares the obtained difference between the real-time temperatures of the hot runners in any two time periods with the threshold value of the real-time temperature difference stored in the memory: if the temperature of the hot runner is not exceeded, the temperature of the hot runner reaches balance, if the temperature of the hot runner is exceeded, the hot runner is unbalanced and is transmitted to an alarm to inform the alarm to continue heating to balance;
the temperature acquisition module acquires the actual temperature of the hot runner through a temperature sensor, converts the actual temperature into a thermoelectric signal and transmits the thermoelectric signal to a processing center, wherein the temperature acquisition module comprises: the covariance matrix is calculated by a matrix calculation unit according to a covariance matrix calculation formula 'Pk|k-1=Pk-1|k-1+Qk, pk-1|k-1 is the covariance matrix of the previous moment k-1, qk is the covariance matrix of process noise', and the covariance matrix is transmitted to a gain calculation unit; the control gain calculation unit calculates a covariance matrix according to a Kalman gain calculation formula 'Kk=Pk|k-1/(Pk|k-1+Rk), wherein Kk is Kalman gain, pk|k-1 is a covariance matrix, rk is measurement noise', and the covariance matrix is transmitted to the temperature calculation unit; calculating a formula of Tk|k=Tk-1|k-1+Kk (Tm-H.Tk|k-1) for the temperature of the hot runner by a temperature calculation unit according to a Kalman filtering algorithm, wherein Tk|k is a temperature estimated value obtained by correcting a temperature estimated value of a previous time k-1 and a measured value of a current time k at time k, tk-1|k-1 is a temperature estimated value obtained by correcting the previous time k-1, kk is Kalman gain, tm is a temperature value obtained by obtaining the hot runner at time k, H is an observation matrix, tk|k-1 is a temperature estimated value of the previous time k-1, and calculating the temperature value of the hot runner;
Then the processing center compares the real-time temperature of the hot runner with the target temperature stored in the memory: if the target temperature is reached, informing the equipment control module to keep the temperature running, and if the target temperature is smaller than the target temperature, transmitting the temperature to the alarm to inform the voltage regulating module to continue heating; and then the heating control module continuously heats the hot runner by using disturbance power according to the difference between the actual temperature and the target temperature and transmits the disturbance power to the temperature acquisition module, wherein the heating control module comprises: calculating a temperature change value delta T of the internal hot runner in the last period of time by detecting the change of the temperature of the hot runner in real time through the temperature difference determining unit, calculating a temperature change average value in the last period of time, and transmitting the temperature change average value to the power calculating unit; the power calculation unit then calculates the formula "P" by the disturbance power d ＝m·C·ΔT,P d For disturbance power, m is the mass of the hot runner, C is the specific heat capacity of the hot runner, deltaT is the real-time disturbance power calculated by monitoring the temperature change value of the hot runner in real time, and the disturbance power is transmitted to a power adding unit; then the power adding unit heats the heating device of the hot runner through preset disturbance power, the heat balance state is broken, the temperature rise is realized, and the temperature of the hot runner reaches the target temperature quickly; then, the voltage regulating module regulates the voltage of the hot runner in a PID control mode so as to ensure that the temperature of the hot runner is unchanged and the hot runner can continuously provide heat for the injection mold; and then the equipment control module opens or closes the hot runner through the switch button so as to ensure the normal use of the hot runner.
When an operator or manager goes outdoors or goes on business, the intelligent mobile phone can be utilized to automatically network with the system in an effective network, and the operation condition of the hot runner is wirelessly or remotely controlled, so that the injection molding production condition of the hot runner matched with the die is controlled in a networking and intelligent mode.
Further, the present invention is described in terms of implementation of a software program for a hot runner temperature control system, and the method implemented for each temperature control system is divided into a plurality of modules or units, to implement software program instructions generated by each step, where the software program instructions include the temperature control system for an intelligent hot runner and the temperature control method for an intelligent hot runner described above.
The invention also provides an intelligent hot runner, which is realized by the temperature control system of the intelligent hot runner and the temperature control method of the intelligent hot runner.
It will be evident to those skilled in the art that the present application is not limited to the details of the foregoing illustrative embodiments, and that the present application may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the application being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Finally, it should be noted that the foregoing embodiments are merely for illustrating the technical solution of the present application and not for limiting the same, and although the present application has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications and equivalents may be made to the technical solution of the present application, and are included in the protection scope of the present application.
Claims (9)
1. A temperature control method of an intelligent hot runner is characterized by comprising the following steps: the method comprises the following steps:
s10, heating the hot runner by adopting a proportion term according to the difference between the actual temperature and the target temperature through a temperature balancing module to enable the temperature to reach a thermal balance state, and transmitting the temperature to a temperature acquisition module;
s20, the temperature acquisition module acquires the actual temperature of the hot runner through a temperature sensor arranged on the hot runner, converts the actual temperature into a thermoelectric signal and transmits the thermoelectric signal to the processing center;
s30, the processing center compares the real-time temperature of the hot runner with the target temperature stored in the memory: if the target temperature is reached, the temperature is transferred to the voltage regulating module for temperature maintenance operation, if the target temperature is smaller than the target temperature, the temperature is transferred to the alarm to inform the voltage regulating module to continue heating, and if the temperature is larger than 400 ℃, the temperature is transferred to the alarm to inform the shutdown maintenance;
S40, the heating control module continuously heats the hot runner by using disturbance power according to the difference between the actual temperature and the target temperature, and transmits the disturbance power to the temperature acquisition module;
s50, when the temperature of the hot runner is higher than 400 ℃, the equipment control module controls the switch button to close the hot runner and notifies the hot runner to be maintained;
s60, the voltage regulating module regulates voltage in a PID control mode on the hot runner so as to ensure that the temperature of the hot runner is unchanged and heat can be continuously supplied to the injection mold.
2. The method for controlling the temperature of an intelligent hot runner according to claim 1, wherein: before the step S10 of heating the hot runner by the proportional term, the method includes the following steps:
s11, selecting proper temperature between 100 ℃ and 400 ℃ according to the type, color and model of the plastic material, automatically setting the initial temperature according to the fluidity of the plastic material, the wall thickness of the injection molding piece and other parameters, and transmitting the initial temperature to the debugging and calibrating unit;
s12, the debugging and calibrating unit obtains whether the temperature of each part of the hot runner is uniform and accurate through a thermometer or a thermal imager, automatically adjusts the temperature until the temperature of each part is uniform, and transmits the temperature to the temperature memory unit;
S13, automatically and timely memorizing the temperature of the hot runner at the moment according to the fact that the real-time temperature of the hot runner is comprehensive and uniform, and transmitting the temperature to a target computing unit;
s14, the target calculating unit calculates a formula T according to the target temperature d ＝P t /K p +T 1 ＝R(T 1 -T 0 )/K p +T 1 ，P t For heating power, R is thermal resistance, T 1 Is the temperature of a hot runner, T 0 At ambient temperature, K p As proportional term coefficient, T d And automatically calculating the target temperature required to be set for the hot runner for the target temperature.
3. The method for controlling the temperature of an intelligent hot runner according to claim 1, wherein: in the step S10, "bringing the temperature thereof to a thermal equilibrium state", the method comprises the steps of:
s101, when the hot runner reaches heat balance, the integral heating unit performs heating control on the hot runner by adding an integral item and transmits the heated control to the heating limiting unit;
s102, when the temperature of the hot runner reaches the temperature close to the target temperature, accumulating integral items of the temperature limitation of the hot runner by a heating limiting unit, ensuring that the heating power and the heat conduction of the runner plate reach heat balance, and transmitting the heat balance to a temperature acquisition module;
s103, the temperature acquisition module acquires real-time temperature information of the hot runner in any two time periods and transmits the real-time temperature information to the processing center;
s104, the processing center compares the obtained difference of the real-time temperatures of the hot runners in any two time periods with a threshold value of the temperature difference stored in the memory: if the temperature of the hot runner is not exceeded, the temperature of the hot runner reaches balance, if the temperature of the hot runner is exceeded, the hot runner is unbalanced and is transmitted to an alarm to inform the alarm to continue heating to balance.
4. The method for controlling the temperature of an intelligent hot runner according to claim 1, wherein: in the step S20, the step of "the temperature sensor obtains the actual temperature of the hot runner" includes the following steps:
s21, a matrix calculation unit calculates a covariance matrix according to a covariance matrix calculation formula 'Pk|k-1=Pk-1|k-1+Qk, wherein Pk-1|k-1 is the covariance matrix of the previous moment k-1, and Qk is the covariance matrix of process noise', and the covariance matrix is transmitted to a gain calculation unit;
s22, the gain calculation unit calculates a covariance matrix according to a Kalman gain calculation formula 'Kk=Pk|k-1/(Pk|k-1+Rk), wherein Kk is Kalman gain, pk|k-1 is a covariance matrix, rk is measurement noise', and the covariance matrix is transmitted to the temperature calculation unit;
s23, the temperature calculating unit calculates the temperature value of the hot runner according to a calculation formula of Tk|k=Tk-1|k-1+Kk (Tm-H.Tk|k-1) of a temperature value of the hot runner by a Kalman filtering algorithm, wherein Tk|k is a temperature estimated value obtained by correcting a temperature estimated value of a previous time k-1 and a measured value of a current time k at time k, tk-1|k-1 is a temperature estimated value obtained by correcting the previous time k-1, kk is Kalman gain, tm is a temperature value of the hot runner obtained at time k, H is an observation matrix, tk|k-1 is a temperature estimated value of the previous time k-1.
5. The method for controlling the temperature of an intelligent hot runner according to claim 1, wherein: in the step S40, "continuously heating the hot runner with the disturbance power", the method includes the following steps:
s41, the temperature difference determining unit calculates a temperature change value delta T of the internal hot runner in the last period by detecting the change of the temperature of the hot runner in real time, calculates a temperature change average value in the last period, and transmits the temperature change average value to the power calculating unit;
s42, the power calculation unit calculates real-time disturbance power according to a disturbance power calculation formula Pd=m.C.delta.T, pd is disturbance power, m is the mass of the hot runner, C is the specific heat capacity of the hot runner, delta T is a temperature change value of the hot runner monitored in real time, and the real-time disturbance power is transmitted to the power addition unit;
s43, the power adding unit heats the heating device of the hot runner through preset disturbance power, the existing heat balance state is broken, the temperature rise is realized, and the temperature of the hot runner reaches the target temperature quickly.
6. A temperature control system of intelligent hot runner, its characterized in that: the intelligent temperature control system comprises a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulation module, an equipment control module, a wireless communication module, a memory, an alarm, a processing center and a smart phone, wherein the temperature balancing module, the temperature acquisition module, the heating control module, the voltage regulation module, the equipment control module, the wireless communication module, the memory and the alarm are respectively connected with the processing center; the intelligent mobile phone is respectively connected with the wireless communication module in the range of the Internet of things or the Internet;
The wireless communication module is provided with an Internet of things unit which is responsible for receiving and transmitting wireless signals and is automatically connected with other same-network equipment in an effective network range;
the processing center is responsible for information transmission of a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulating module, an equipment control module, a wireless communication module, a memory and an alarm, is a hub center of the system, and compares the real-time temperature of the hot runner with the target temperature stored in the memory: if the target temperature is reached, the temperature is transferred to the voltage regulating module for temperature maintenance operation, if the target temperature is smaller than the target temperature, the temperature is transferred to the alarm for notification to continue heating, and if the temperature is larger than 400 ℃, the temperature is transferred to the alarm for notification to be closed and maintained; comparing the obtained difference between the real-time temperatures of the hot runners in any two time periods with a threshold value of the real-time temperature difference stored in the memory: if the temperature of the hot runner is not exceeded, the temperature of the hot runner reaches balance, if the temperature of the hot runner is exceeded, the hot runner is unbalanced and is transmitted to an alarm to inform the alarm to continue heating to balance;
when the real-time temperature of the hot runner is smaller than the target temperature stored in the memory, the alarm automatically alarms and transmits the alarm to inform the heating control module to continue heating; when the real-time temperature of the hot runner is higher than 400 ℃, automatically alarming and informing to close for maintenance; when the obtained difference of the real-time temperatures of the hot runners in any two time periods exceeds the threshold value of the real-time temperature difference stored in the memory, automatically alarming and informing to continue heating so as to balance the heat;
The memory is responsible for information storage of a temperature balancing module, a temperature acquisition module, a heating control module, a voltage regulating module, an equipment control module, a wireless communication module and an alarm, and storage of target temperature of a hot runner and thresholds of real-time temperature differences in different time periods;
the temperature acquisition module comprises a matrix calculation unit, a gain calculation unit and a temperature calculation unit, acquires the actual temperature of the hot runner through a temperature sensor arranged on the hot runner, converts the actual temperature into a thermoelectric signal and transmits the thermoelectric signal to the processing center;
and the equipment control module controls the switch button to close the hot runner when the temperature of the hot runner is higher than 400 ℃ and notifies the hot runner to be maintained.
7. The intelligent hot runner temperature control system according to claim 6, wherein: the temperature balance module comprises an initial temperature setting unit, a debugging and calibrating unit, a temperature memory unit, a target calculation unit, an integral heating unit and a heating limiting unit, and the heating unit is used for continuously heating the hot runner by adopting a proportion term according to the difference between the actual temperature and the target temperature and transmitting the heated hot runner to the temperature acquisition module;
the heating control module comprises a temperature difference determining unit, a power calculating unit and a power adding unit, and continuously heats the hot runner by using disturbance power through the heating unit according to the difference between the actual temperature and the target temperature and transmits the disturbance power to the temperature obtaining module;
The voltage regulating module carries out PID control mode regulation on the voltage in the hot runner so as to ensure that the temperature of the hot runner is unchanged and can continuously provide heat for the injection mold so as to ensure normal injection production.
8. The intelligent hot runner temperature control system according to claim 6, wherein: also included is a computer-readable storage medium comprising a memory; the memory stores a computer program, and each functional module realizes the steps of the temperature control method of the intelligent hot runner when executing the computer program; the computer readable storage medium stores a computer program, and the computer program when executed by each functional module realizes the steps of the temperature control method of the intelligent hot runner.
9. An intelligent hot runner, its characterized in that: the method is realized by the temperature control method of the intelligent hot runner according to any one of the claims 1 to 5 and the temperature control system of the intelligent hot runner according to any one of the claims 6 to 8.
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| CN202311557181.3A CN117532838A (en) | 2023-11-21 | 2023-11-21 | Intelligent hot runner and temperature control system and method thereof |
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