CN118219517A - A plastic injection molding process control method and system - Google Patents
A plastic injection molding process control method and system Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 53
- 238000001746 injection moulding Methods 0.000 title claims abstract description 47
- 239000004033 plastic Substances 0.000 title claims abstract description 43
- 229920003023 plastic Polymers 0.000 title claims abstract description 43
- 238000002347 injection Methods 0.000 claims abstract description 149
- 239000007924 injection Substances 0.000 claims abstract description 149
- 238000012544 monitoring process Methods 0.000 claims abstract description 65
- 238000001514 detection method Methods 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims abstract description 19
- 238000002360 preparation method Methods 0.000 claims abstract description 8
- 238000001816 cooling Methods 0.000 claims abstract description 6
- 238000012512 characterization method Methods 0.000 claims description 74
- 238000012360 testing method Methods 0.000 claims description 25
- 238000004458 analytical method Methods 0.000 claims description 18
- 238000011156 evaluation Methods 0.000 claims description 3
- 238000004364 calculation method Methods 0.000 claims description 2
- 238000001723 curing Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 12
- 238000007711 solidification Methods 0.000 abstract description 2
- 230000008023 solidification Effects 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 14
- 239000000243 solution Substances 0.000 description 10
- 238000012545 processing Methods 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 239000004014 plasticizer Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 229920000426 Microplastic Polymers 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000012644 addition polymerization Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000010835 comparative analysis Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000012643 polycondensation polymerization Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000003449 preventive effect Effects 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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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
- B29C45/768—Detecting defective moulding conditions
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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
- B29C2945/76003—Measured parameter
- B29C2945/76163—Errors, malfunctioning
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- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
本发明涉及塑料注塑成型技术领域，具体地公开了一种塑料注塑成型工艺控制方法及系统，包括以下步骤：模具准备、塑料材料准备、注射、冷却与固化、脱模；并对其中注射过程进行检测控制：A：对注射过程中注射机进行实时监测，判定注射机是否有波动；B：对注射结果进行检测，判定注射结果是否合格；C：分析注射机发生波动时是否对注射结果的质量产生影响；本发明通过分析注射机的监测数据和注射结果的检测数据，可以找出影响产品质量的关键因素，有助于实现生产过程的透明化，使得管理者能够更加准确地把握生产进度和质量状况，提高产品质量的稳定性和一致性。
The invention relates to the technical field of plastic injection molding, and specifically discloses a plastic injection molding process control method and system, comprising the following steps: mold preparation, plastic material preparation, injection, cooling and solidification, and demoulding; and detecting and controlling the injection process: A: real-time monitoring of an injection molding machine during the injection process to determine whether the injection molding machine has fluctuations; B: detecting the injection result to determine whether the injection result is qualified; C: analyzing whether the injection molding machine has an impact on the quality of the injection result when it fluctuates; the invention can find out the key factors affecting the product quality by analyzing the monitoring data of the injection molding machine and the detection data of the injection result, which is helpful to realize the transparency of the production process, so that managers can more accurately grasp the production progress and quality status, and improve the stability and consistency of product quality.
Description
技术领域Technical Field
本发明涉及塑料注塑成型技术领域，具体涉及一种塑料注塑成型工艺控制方法及系统。The invention relates to the technical field of plastic injection molding, and in particular to a plastic injection molding process control method and system.
背景技术Background technique
塑料是一种高分子化合物，由合成树脂及填料、增塑剂、稳定剂、润滑剂、色料等添加剂组成，主要成分是树脂，通过加聚或缩聚反应聚合而成的高分子化合物，其抗形变能力中等，介于纤维和橡胶之间，由合成树脂及填料、增塑剂、稳定剂、润滑剂、色料等添加剂组成，塑料的主要特性包括重量轻、优良的化学稳定性、不会锈蚀、耐冲击性好、具有较好的透明性和耐磨耗性、绝缘性好、导热性低以及一般成型性、着色性好、加工成本低等。Plastic is a polymer compound composed of synthetic resin and additives such as fillers, plasticizers, stabilizers, lubricants, and colorants. The main component is resin, a polymer compound polymerized by addition polymerization or condensation polymerization. Its deformation resistance is medium, between fiber and rubber. It is composed of synthetic resin and additives such as fillers, plasticizers, stabilizers, lubricants, and colorants. The main characteristics of plastics include light weight, excellent chemical stability, no rust, good impact resistance, good transparency and wear resistance, good insulation, low thermal conductivity, general formability, good colorability, and low processing cost.
公开号为CN113665079B的中国发明专利公开了一种塑料注塑成型工艺控制方法及系统，方法包括：至少采集机台、模具和相关辅机的数据；生成一组标准工艺曲线；得到分段结果；分别分析出每根标准工艺曲线每段曲线上每个参数点的波动范围；对塑料注塑成型的产品的质量进行判断，得到产品质量的判断结果。A Chinese invention patent with publication number CN113665079B discloses a plastic injection molding process control method and system, the method comprising: collecting data of at least a machine, a mold and related auxiliary machines; generating a set of standard process curves; obtaining segmented results; analyzing the fluctuation range of each parameter point on each segment of each standard process curve; judging the quality of the plastic injection molded product to obtain a judgment result of the product quality.
但是，现有技术中，往往只关注注射机或注射结果的单一方面，很难准确判断注射机的波动是否对注射结果的质量产生了影响，缺乏一个综合管理系统来整合和分析各方面的数据。However, the existing technology often only focuses on a single aspect of the injection machine or the injection result. It is difficult to accurately determine whether the fluctuation of the injection machine has an impact on the quality of the injection result. There is a lack of a comprehensive management system to integrate and analyze data from all aspects.
发明内容Summary of the invention
本发明的目的在于提供一种塑料注塑成型工艺控制方法及系统，以解决上述背景中技术问题。The object of the present invention is to provide a plastic injection molding process control method and system to solve the technical problems in the above background.
本发明的目的可以通过以下技术方案实现：The purpose of the present invention can be achieved through the following technical solutions:
一种塑料注塑成型工艺控制方法及系统，包括以下步骤：模具准备、塑料材料准备、注射、冷却与固化、脱模；A plastic injection molding process control method and system, comprising the following steps: mold preparation, plastic material preparation, injection, cooling and curing, and demoulding;
并对其中注射过程进行检测控制：And the injection process is detected and controlled:
A：对注射过程中注射机进行实时监测，判定注射机是否有波动；A: Monitor the injection machine in real time during the injection process to determine whether the injection machine has fluctuations;
B：对注射结果进行检测，判定注射结果是否合格；B: Test the injection results to determine whether they are qualified;
C：分析注射机发生波动时是否对注射结果的质量产生影响；C: Analyze whether the fluctuation of the injection machine affects the quality of the injection result;
C1：根据历史记录，分别获取历史记录中每次注射过程中注射机的监测数据JC以及注射结果的检测参数M，并将每次注射过程中的监测数据JC和检测参数M打包成一组点位数据(M，JC)；C1: According to the historical records, the monitoring data JC of the injection machine and the detection parameters M of the injection results in each injection process in the historical records are obtained respectively, and the monitoring data JC and the detection parameters M in each injection process are packaged into a set of point data (M, JC);
C2：根据所有的点位数据，基于以检测参数为X轴，监测参数为Y轴建立的二维坐标系中构建影响分析点位图；C2: Based on all the point data, an impact analysis point map is constructed in a two-dimensional coordinate system with the detection parameter as the X-axis and the monitoring parameter as the Y-axis;
C3：根据影响分析点位图中的所有点位，通过最小二乘法得到一条拟合直线，以及该拟合直线方程为：Y＝k×X+b，其中，k表示为拟合直线的斜率，b表示为拟合直线的截距，且k和b取值为常数；C3: According to all the points in the impact analysis point map, a fitting straight line is obtained by the least square method, and the equation of the fitting straight line is: Y = k × X + b, where k represents the slope of the fitting straight line, b represents the intercept of the fitting straight line, and k and b are constants;
C4：对拟合直线的斜率进行分析，从而判定注射机发生波动时是否对注射结果的质量产生影响；C4: Analyze the slope of the fitted straight line to determine whether the injection machine fluctuations affect the quality of the injection results;
预设斜率阈值为KY，将斜率的绝对值|k|与斜率阈值KY进行对比分析；The slope threshold is preset as KY, and the absolute value of the slope |k| is compared and analyzed with the slope threshold KY;
若斜率的绝对值|k|＜斜率阈值KY，则判定注射机发生波动时不会对注射结果的质量产生影响；If the absolute value of the slope |k| is less than the slope threshold KY, it is determined that the injection machine fluctuation will not affect the quality of the injection result;
若斜率的绝对值|k|≥斜率阈值KY，则判定注射机发生波动时会对注射结果的质量产生影响。If the absolute value of the slope |k| ≥ the slope threshold KY, it is determined that the injection machine fluctuation will affect the quality of the injection result.
作为本发明进一步的方案：所述判定注射机是否有波动的方法为：As a further solution of the present invention: the method for determining whether the injection molding machine has fluctuations is:
A1：对注射机进行实时监测，获取注射机目标周期内的监测数据；A1: Monitor the injection machine in real time and obtain monitoring data within the target cycle of the injection machine;
其中，监测数据包括：电压表征值、电流表征值、振动表征值；Among them, the monitoring data include: voltage characterization value, current characterization value, vibration characterization value;
A2：根据注射机的检测数据，计算获得监测参数；A2: Calculate and obtain monitoring parameters based on the test data of the injection molding machine;
A3：对监测参数进行对比分析，从而判定注射机是否有波动。A3: Compare and analyze the monitoring parameters to determine whether the injection molding machine has fluctuations.
作为本发明进一步的方案：所述监测数据的获取方法为：As a further solution of the present invention: the method for obtaining the monitoring data is:
A11：获取目标周期内注射机的实时电压，并基于以时间为X轴，实时电压为Y轴建立的二维坐标系，绘制电压波动曲线，根据电压波动曲线，获得目标周期内的电压波动曲线与目标周期内的平均电压之间围成区域的面积，该面积与电压面积阈值之比即为电压表征值，并将电压表征值标记为DY；A11: Obtain the real-time voltage of the injection machine within the target cycle, and draw a voltage fluctuation curve based on a two-dimensional coordinate system with time as the X-axis and the real-time voltage as the Y-axis. According to the voltage fluctuation curve, obtain the area of the region enclosed by the voltage fluctuation curve within the target cycle and the average voltage within the target cycle. The ratio of the area to the voltage area threshold is the voltage characterization value, and the voltage characterization value is marked as DY.
A12：获取目标周期内注射机的实时电流，并基于以时间为X轴，实时电压为Y轴建立的二维坐标系，绘制成电流波动曲线，根据电流波动曲线，获得目标周期内的电流波动曲线与目标周期内的平均电流之间围成区域的面积，该面积与电流面积阈值之比即为电流表征值，并将电流表征值标记为DL；A12: The real-time current of the injection machine in the target cycle is obtained, and a current fluctuation curve is drawn based on a two-dimensional coordinate system with time as the X-axis and the real-time voltage as the Y-axis. According to the current fluctuation curve, the area of the region enclosed by the current fluctuation curve in the target cycle and the average current in the target cycle is obtained. The ratio of the area to the current area threshold is the current characterization value, and the current characterization value is marked as DL.
A13：获取目标周期内注射机的实时振动频率，并基于以时间为X轴，实时电压为Y轴建立的二维坐标系，绘制成振动波动曲线，根据振动频率波动曲线，获得目标周期内的振动频率波动曲线与目标周期内的平均振动频率之间围成区域的面积，该面积与振动频率面积阈值之比即为振动表征值，并将振动表征值标记为ZD。A13: Obtain the real-time vibration frequency of the injection molding machine within the target cycle, and draw a vibration fluctuation curve based on a two-dimensional coordinate system with time as the X-axis and real-time voltage as the Y-axis. According to the vibration frequency fluctuation curve, obtain the area of the region enclosed by the vibration frequency fluctuation curve within the target cycle and the average vibration frequency within the target cycle. The ratio of this area to the vibration frequency area threshold is the vibration characterization value, and the vibration characterization value is marked as ZD.
作为本发明进一步的方案：将电压表征值DY、电流表征值DL、振动表征值ZD进行数据处理，通过公式：计算获得监测参数JC，其中，a1、a2、a3为预设比例因子，且均大于0。As a further solution of the present invention: the voltage characterization value DY, the current characterization value DL, and the vibration characterization value ZD are processed by the formula: The monitoring parameter JC is obtained by calculation, wherein a 1 , a 2 , and a 3 are preset proportional factors, and are all greater than zero.
作为本发明进一步的方案：预设监测参数阈值为JY，将监测参数JC与监测参数阈值JY进行对比分析；As a further solution of the present invention: the monitoring parameter threshold is preset as JY, and the monitoring parameter JC is compared and analyzed with the monitoring parameter threshold JY;
若监测参数JC＜监测参数阈值JY，则判定注射机在目标周期内没有发生剧烈或者持续性的波动；If the monitoring parameter JC is less than the monitoring parameter threshold JY, it is determined that the injection molding machine has no drastic or continuous fluctuations within the target cycle;
若监测参数JC≥监测参数阈值JY，则判定注射机在目标周期内有发生剧烈或者持续性的波动。If the monitoring parameter JC ≥ the monitoring parameter threshold JY, it is determined that the injection molding machine has experienced drastic or continuous fluctuations within the target cycle.
作为本发明进一步的方案：所述判定注射结果是否合格的方法为：As a further solution of the present invention: the method for determining whether the injection result is qualified is:
B1：对注射结果进行检测，获取注射结果的检测数据；B1: Test the injection result and obtain test data of the injection result;
其中，检测数据包括：气泡表征值、流动性表征值；Among them, the detection data include: bubble characterization value, fluidity characterization value;
B2：根据注射结果的检测数据，计算获得注射结果的检测参数；B2: Calculate and obtain the detection parameters of the injection results according to the detection data of the injection results;
B3：对获得的检测参数进行对比分析，从而判定注射结果是否合格。B3: Compare and analyze the obtained test parameters to determine whether the injection result is qualified.
作为本发明进一步的方案：所述检测数据的获取方法为：As a further solution of the present invention: the method for acquiring the detection data is:
B11：在模具的一侧设置声波发射装置，并在模具的另一侧设置声波接收装置，通过声波发射装置向模具中注射完成的塑料材料发射固定强度的声波，使声波穿过模具以及模具中的塑料材料，并通过声波接收装置接收声波，获得声波的剩余强度，并将获得的声波的剩余强度与预计声波强度进行差值计算并取绝对值，获得的绝对差值即为气泡表征值，并将气泡表征值标记为QP；B11: A sound wave transmitting device is arranged on one side of the mold, and a sound wave receiving device is arranged on the other side of the mold. The sound wave transmitting device transmits a sound wave of fixed intensity to the plastic material injected into the mold, so that the sound wave passes through the mold and the plastic material in the mold, and the sound wave is received by the sound wave receiving device to obtain the residual intensity of the sound wave. The difference between the obtained residual intensity of the sound wave and the expected intensity of the sound wave is calculated and the absolute value is taken. The obtained absolute difference is the bubble characterization value, and the bubble characterization value is marked as QP;
B12：通过流动性能测试仪器对塑料材料进行流动性测试，从而评估注射结果流动性的均匀性，并将评估结果记录为流动性表征值，流动性表征值数值越大表示注射结果流动性的均匀性越好，并将流动性表征值标记为LD。B12: Perform fluidity test on plastic materials by using a fluidity testing instrument to evaluate the fluidity uniformity of the injection result, and record the evaluation result as a fluidity characterization value. The larger the fluidity characterization value, the better the fluidity uniformity of the injection result, and the fluidity characterization value is marked as LD.
作为本发明进一步的方案：将气泡表征值QP、流动性表征值LD进行数据处理，将气泡表征值QP与流动性表征值LD进行比值计算，获得的比值与比值阈值之比即为检测参数，并将检测参数标记为M。As a further solution of the present invention: the bubble characterization value QP and the fluidity characterization value LD are subjected to data processing, and the ratio of the bubble characterization value QP to the fluidity characterization value LD is calculated. The ratio of the obtained ratio to the ratio threshold is the detection parameter, and the detection parameter is marked as M.
作为本发明进一步的方案：预设检测参数阈值为MY，将检测参数M与检测参数阈值MY进行对比分析；As a further solution of the present invention: the detection parameter threshold is preset as MY, and the detection parameter M is compared and analyzed with the detection parameter threshold MY;
若检测参数M＜检测参数阈值MY，则判定注射结果为合格；If the detection parameter M is less than the detection parameter threshold MY, the injection result is determined to be qualified;
若检测参数M≥检测参数阈值MY，则判定注射结果为不合格。If the detection parameter M≥the detection parameter threshold MY, the injection result is determined to be unqualified.
一种塑料注塑成型工艺控制系统，包括：A plastic injection molding process control system, comprising:
波动分析模块，所述波动分析模块用于对注射过程中注射机进行实时监测，判定注射机是否有波动；A fluctuation analysis module, which is used to monitor the injection machine in real time during the injection process and determine whether the injection machine has fluctuations;
合格判定模块，所述合格判定模块用于对注射结果进行检测，判定注射结果是否合格；A qualified determination module, which is used to detect the injection result and determine whether the injection result is qualified;
影响分析模块，所述影响分析模块用于分析注射机发生波动时是否对注射结果的质量产生影响。The impact analysis module is used to analyze whether fluctuations in the injection machine have an impact on the quality of the injection result.
本发明的有益效果：Beneficial effects of the present invention:
(1)本发明通过实时监测注射机的运行状态，及时发现电压、电流和振动等参数的异常波动，从而预防机械故障，减少生产中断的风险，这种预防性的维护措施有助于确保注射机持续稳定运行，进而提高生产效率；(1) The present invention monitors the operating status of the injection molding machine in real time and promptly detects abnormal fluctuations in parameters such as voltage, current and vibration, thereby preventing mechanical failures and reducing the risk of production interruption. This preventive maintenance measure helps ensure the continuous and stable operation of the injection molding machine, thereby improving production efficiency;
(2)本发明通过对注射结果的检测，可以评估产品的质量，有助于确保产品符合预设的质量标准，减少次品率，提高客户满意度；(2) The present invention can evaluate the quality of the product by detecting the injection results, which helps to ensure that the product meets the preset quality standards, reduce the defective rate, and improve customer satisfaction;
(3)本发明通过分析注射机的监测数据和注射结果的检测数据，可以找出影响产品质量的关键因素，有助于实现生产过程的透明化，使得管理者能够更加准确地把握生产进度和质量状况，提高产品质量的稳定性和一致性。(3) The present invention can identify key factors affecting product quality by analyzing the monitoring data of the injection machine and the detection data of the injection results, which helps to achieve transparency in the production process, allowing managers to more accurately grasp the production progress and quality status, and improve the stability and consistency of product quality.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
下面结合附图对本发明作进一步的说明。The present invention will be further described below in conjunction with the accompanying drawings.
图1是本发明方法流程图；Fig. 1 is a flow chart of the method of the present invention;
图2是本发明中判定注射机是否有波动方法流程图；2 is a flow chart of a method for determining whether an injection molding machine has fluctuations in the present invention;
图3是本发明中判定注射结果是否合格方法流程图；3 is a flow chart of a method for determining whether an injection result is qualified in the present invention;
图4是本发明中分析注射机发生波动时是否对注射结果的质量产生影响方法流程图；4 is a flow chart of a method for analyzing whether fluctuations in an injection machine affect the quality of injection results in the present invention;
图5是本发明系统示意图。FIG. 5 is a schematic diagram of the system of the present invention.
具体实施方式Detailed ways
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
实施例一：Embodiment 1:
请参阅图1－图4所示，本发明实施例所述的一种塑料注塑成型工艺控制方法，包括以下步骤：Referring to FIG. 1 to FIG. 4 , a plastic injection molding process control method according to an embodiment of the present invention comprises the following steps:
步骤一：模具准备：事先准备制造所需塑料制品的模具，包括设计、制造和安装；Step 1: Mold preparation: Prepare the mold for manufacturing the required plastic products in advance, including design, manufacturing and installation;
其中，模具的设计要根据所需制品的形状、尺寸和材料特性进行，制造时需要考虑模具的材料、加工精度等因素；Among them, the design of the mold should be based on the shape, size and material properties of the required product, and factors such as the mold material and processing accuracy should be considered during manufacturing;
步骤二：塑料材料准备：将塑料颗粒或粉末加热至熔融状态，使其变得黏稠流动，可以被注射机推进模具中；Step 2: Plastic material preparation: Heat the plastic granules or powder to a molten state, making it viscous and fluid, and can be pushed into the mold by the injection machine;
步骤三：注射：将熔融的塑料材料通过注射机的高压作用，注入模具中，填充整个模具腔室；Step 3: Injection: The molten plastic material is injected into the mold through the high pressure of the injection machine to fill the entire mold cavity;
注射过程中，熔融的塑料材料需要在高压作用下精确地填充到模具的每一个腔室中，如果注射机的参数控制不当，可能会导致塑料制品的缺陷，从而将直接影响到最终产品的质量；During the injection process, the molten plastic material needs to be accurately filled into each cavity of the mold under high pressure. If the parameters of the injection molding machine are not properly controlled, defects in the plastic product may occur, which will directly affect the quality of the final product.
A：对注射过程中注射机进行实时监测，判定注射机是否有波动，通过实时监测，可以预测并预防潜在的机械故障，减少生产中断的风险，并且可以及时发现并解决问题，确保注射机持续稳定运行，从而提高生产效率；A: Real-time monitoring of the injection machine during the injection process can be used to determine whether the injection machine has fluctuations. Through real-time monitoring, potential mechanical failures can be predicted and prevented, reducing the risk of production interruptions. Problems can also be discovered and resolved in a timely manner to ensure the continuous and stable operation of the injection machine, thereby improving production efficiency.
A1：对注射机进行实时监测，获取注射机目标周期内的监测数据；A1: Monitor the injection machine in real time and obtain monitoring data within the target cycle of the injection machine;
其中，监测数据包括：电压表征值、电流表征值、振动表征值；Among them, the monitoring data include: voltage characterization value, current characterization value, vibration characterization value;
目标周期包括：1分钟，3分钟；Target cycles include: 1 minute, 3 minutes;
收集电压、电流和振动等关键参数的数据，为后续分析提供基础，通过设定目标周期，可以更加全面地了解注射机的运行状态Collect data on key parameters such as voltage, current and vibration to provide a basis for subsequent analysis. By setting the target cycle, you can have a more comprehensive understanding of the operating status of the injection molding machine.
A11：获取目标周期内注射机的实时电压，并基于以时间为X轴，实时电压为Y轴建立的二维坐标系，绘制电压波动曲线，根据电压波动曲线，获得目标周期内的电压波动曲线与目标周期内的平均电压之间围成区域的面积，该面积与电压面积阈值之比即为电压表征值，并将电压表征值标记为DY；A11: Obtain the real-time voltage of the injection machine within the target cycle, and draw a voltage fluctuation curve based on a two-dimensional coordinate system with time as the X-axis and the real-time voltage as the Y-axis. According to the voltage fluctuation curve, obtain the area of the region enclosed by the voltage fluctuation curve within the target cycle and the average voltage within the target cycle. The ratio of the area to the voltage area threshold is the voltage characterization value, and the voltage characterization value is marked as DY.
A12：获取目标周期内注射机的实时电流，并基于以时间为X轴，实时电压为Y轴建立的二维坐标系，绘制成电流波动曲线，根据电流波动曲线，获得目标周期内的电流波动曲线与目标周期内的平均电流之间围成区域的面积，该面积与电流面积阈值之比即为电流表征值，并将电流表征值标记为DL；A12: The real-time current of the injection machine in the target cycle is obtained, and a current fluctuation curve is drawn based on a two-dimensional coordinate system with time as the X-axis and the real-time voltage as the Y-axis. According to the current fluctuation curve, the area of the region enclosed by the current fluctuation curve in the target cycle and the average current in the target cycle is obtained. The ratio of the area to the current area threshold is the current characterization value, and the current characterization value is marked as DL.
A13：获取目标周期内注射机的实时振动频率，并基于以时间为X轴，实时电压为Y轴建立的二维坐标系，绘制成振动波动曲线，根据振动频率波动曲线，获得目标周期内的振动频率波动曲线与目标周期内的平均振动频率之间围成区域的面积，该面积与振动频率面积阈值之比即为振动表征值，并将振动表征值标记为ZD；A13: The real-time vibration frequency of the injection molding machine within the target cycle is obtained, and a vibration fluctuation curve is drawn based on a two-dimensional coordinate system with time as the X-axis and real-time voltage as the Y-axis. According to the vibration frequency fluctuation curve, the area enclosed by the vibration frequency fluctuation curve within the target cycle and the average vibration frequency within the target cycle is obtained. The ratio of the area to the vibration frequency area threshold is the vibration characterization value, and the vibration characterization value is marked as ZD.
A2：根据注射机的检测数据，计算获得监测参数，将多个监测数据综合处理，得到一个综合的监测参数，便于后续分析；A2: Based on the detection data of the injection molding machine, the monitoring parameters are calculated and multiple monitoring data are processed comprehensively to obtain a comprehensive monitoring parameter for subsequent analysis;
将电压表征值DY、电流表征值DL、振动表征值ZD进行数据处理，通过公式：计算获得监测参数JC，其中，a1、a2、a3为预设比例因子，且均大于0，通过预设比例因子，可以对不同监测数据进行标准化处理，使得不同参数之间具有可比性；The voltage characterization value DY, the current characterization value DL, and the vibration characterization value ZD are processed by the formula: The monitoring parameter JC is calculated, wherein a 1 , a 2 , and a 3 are preset proportional factors, and are all greater than 0. By using the preset proportional factors, different monitoring data can be standardized so that different parameters are comparable.
A3：对监测参数进行对比分析，从而判定注射机是否有波动，可以及时发现并处理注射机的波动，有助于确保注射过程的稳定性，从而提高产品质量；A3: Comparative analysis of monitoring parameters can be conducted to determine whether the injection machine has fluctuations. Fluctuations of the injection machine can be discovered and handled in a timely manner, which helps to ensure the stability of the injection process and thus improve product quality.
预设监测参数阈值为JY，将监测参数JC与监测参数阈值JY进行对比分析，通过对比分析监测参数与预设阈值，可以及时发现注射机的波动情况；The preset monitoring parameter threshold is JY, and the monitoring parameter JC is compared and analyzed with the monitoring parameter threshold JY. By comparing and analyzing the monitoring parameter with the preset threshold, the fluctuation of the injection machine can be discovered in time;
若监测参数JC＜监测参数阈值JY，则判定注射机在目标周期内没有发生剧烈或者持续性的波动；If the monitoring parameter JC is less than the monitoring parameter threshold JY, it is determined that the injection molding machine has no drastic or continuous fluctuations within the target cycle;
若监测参数JC≥监测参数阈值JY，则判定注射机在目标周期内有发生剧烈或者持续性的波动；If the monitoring parameter JC ≥ the monitoring parameter threshold JY, it is determined that the injection molding machine has experienced drastic or continuous fluctuations within the target cycle;
B：对注射结果进行检测，判定注射结果是否合格，通过对注射结果的检测，可以评估产品的质量，可以发现潜在的质量问题，如气泡过多或流动性不均匀；B: Test the injection results to determine whether they are qualified. By testing the injection results, the quality of the product can be evaluated and potential quality problems can be found, such as excessive bubbles or uneven fluidity;
B1：对注射结果进行检测，获取注射结果的检测数据，收集气泡表征值和流动性表征值等数据，为后续分析提供基础，通过量化指标，可以更加客观地评估注射结果的质量；B1: Test the injection results, obtain the test data of the injection results, collect data such as bubble characterization values and fluidity characterization values, and provide a basis for subsequent analysis. Through quantitative indicators, the quality of the injection results can be evaluated more objectively;
其中，检测数据包括：气泡表征值、流动性表征值；Among them, the detection data include: bubble characterization value, fluidity characterization value;
B11：在模具的一侧设置声波发射装置，并在模具的另一侧设置声波接收装置，通过声波发射装置向模具中注射完成的塑料材料发射固定强度的声波，使声波穿过模具以及模具中的塑料材料，并通过声波接收装置接收声波，获得声波的剩余强度，并将获得的声波的剩余强度与预计声波强度进行差值计算并取绝对值，获得的绝对差值即为气泡表征值，并将气泡表征值标记为QP；B11: A sound wave transmitting device is arranged on one side of the mold, and a sound wave receiving device is arranged on the other side of the mold. The sound wave transmitting device transmits a sound wave of fixed intensity to the plastic material injected into the mold, so that the sound wave passes through the mold and the plastic material in the mold, and the sound wave is received by the sound wave receiving device to obtain the residual intensity of the sound wave. The difference between the obtained residual intensity of the sound wave and the expected intensity of the sound wave is calculated and the absolute value is taken. The obtained absolute difference is the bubble characterization value, and the bubble characterization value is marked as QP;
B12：通过流动性能测试仪器对塑料材料进行流动性测试，从而评估注射结果流动性的均匀性，并将评估结果记录为流动性表征值，流动性表征值数值越大表示注射结果流动性的均匀性越好，并将流动性表征值标记为LD；B12: Perform fluidity test on plastic materials by using a fluidity performance tester to evaluate the fluidity uniformity of the injection result, and record the evaluation result as a fluidity characterization value. The larger the fluidity characterization value, the better the fluidity uniformity of the injection result, and the fluidity characterization value is marked as LD;
其中，流动性能测试仪器包括：熔体流动速率测定仪，螺旋流动仪；Among them, flow performance testing instruments include: melt flow rate tester, spiral flow meter;
B2：根据注射结果的检测数据，计算获得注射结果的检测参数，将气泡表征值和流动性表征值进行综合处理，得到一个综合的检测参数，便于后续分析，且通过检测参数，可以方便地对比不同批次或不同条件下的注射结果质量；B2: According to the test data of the injection results, the test parameters of the injection results are calculated, and the bubble characterization value and the fluidity characterization value are comprehensively processed to obtain a comprehensive test parameter, which is convenient for subsequent analysis. Through the test parameters, the quality of injection results under different batches or different conditions can be easily compared;
将气泡表征值QP、流动性表征值LD进行数据处理，将气泡表征值QP与流动性表征值LD进行比值计算，获得的比值与比值阈值之比即为检测参数，并将检测参数标记为M；The bubble characterization value QP and the fluidity characterization value LD are subjected to data processing, and a ratio of the bubble characterization value QP to the fluidity characterization value LD is calculated. The ratio of the obtained ratio to the ratio threshold is the detection parameter, and the detection parameter is marked as M;
B3：对获得的检测参数进行对比分析，从而判定注射结果是否合格，对于不合格的注射结果，可以进一步追溯原因，并采取相应措施进行改进；B3: Compare and analyze the obtained test parameters to determine whether the injection results are qualified. For unqualified injection results, the causes can be further traced and corresponding measures can be taken to improve them;
预设检测参数阈值为MY，将检测参数M与检测参数阈值MY进行对比分析，通过对比分析检测参数与预设阈值，可以判定注射结果是否合格，从而确保产品质量；The detection parameter threshold is preset as MY, and the detection parameter M is compared and analyzed with the detection parameter threshold MY. By comparing and analyzing the detection parameter with the preset threshold, it can be determined whether the injection result is qualified, thereby ensuring the product quality;
若检测参数M＜检测参数阈值MY，则判定注射结果为合格，且检测参数M越小，注射结果的质量越好；If the detection parameter M is less than the detection parameter threshold MY, the injection result is determined to be qualified, and the smaller the detection parameter M is, the better the quality of the injection result is;
若检测参数M≥检测参数阈值MY，则判定注射结果为不合格；If the detection parameter M ≥ the detection parameter threshold MY, the injection result is judged to be unqualified;
C：分析注射机发生波动时是否对注射结果的质量产生影响，而且根据分析结果，可以针对性地优化注射机的运行参数或维护措施，以提高产品质量和生产效率；C: Analyze whether the fluctuation of the injection machine affects the quality of the injection result. According to the analysis results, the operating parameters or maintenance measures of the injection machine can be optimized to improve product quality and production efficiency.
C1：根据历史记录，分别获取历史记录中每次注射过程中注射机的监测数据JC以及注射结果的检测参数M，并将每次注射过程中的监测数据JC和检测参数M打包成一组点位数据(M，JC)；C1: According to the historical records, the monitoring data JC of the injection machine and the detection parameters M of the injection results in each injection process in the historical records are obtained respectively, and the monitoring data JC and the detection parameters M in each injection process are packaged into a set of point data (M, JC);
C2：根据所有的点位数据，基于以检测参数为X轴，监测参数为Y轴建立的二维坐标系中构建影响分析点位图，通过构建影响分析点位图，可以直观地了解注射机波动与注射结果质量之间的关系；C2: Based on all the point data, an impact analysis point diagram is constructed in a two-dimensional coordinate system with the detection parameter as the X-axis and the monitoring parameter as the Y-axis. By constructing the impact analysis point diagram, the relationship between the injection machine fluctuation and the injection result quality can be intuitively understood;
C3：根据影响分析点位图中的所有点位，通过最小二乘法得到一条拟合直线，以及该拟合直线方程为：Y＝k×X+b，其中，k表示为拟合直线的斜率，b表示为拟合直线的截距，且k和b取值为常数；C3: According to all the points in the impact analysis point map, a fitting straight line is obtained by the least square method, and the equation of the fitting straight line is: Y = k × X + b, where k represents the slope of the fitting straight line, b represents the intercept of the fitting straight line, and k and b are constants;
C4：对拟合直线的斜率进行分析，从而判定注射机发生波动时是否对注射结果的质量产生影响；C4: Analyze the slope of the fitted straight line to determine whether the injection machine fluctuations affect the quality of the injection results;
预设斜率阈值为KY，将斜率的绝对值|k|与斜率阈值KY进行对比分析；The slope threshold is preset as KY, and the absolute value of the slope |k| is compared and analyzed with the slope threshold KY;
若斜率的绝对值|k|＜斜率阈值KY，则判定注射机发生波动时不会对注射结果的质量产生影响；If the absolute value of the slope |k| is less than the slope threshold KY, it is determined that the injection machine fluctuation will not affect the quality of the injection result;
若斜率的绝对值|k|≥斜率阈值KY，则判定注射机发生波动时会对注射结果的质量产生影响；If the absolute value of the slope |k| ≥ the slope threshold KY, it is determined that the injection machine fluctuation will affect the quality of the injection result;
步骤四：冷却与固化：在模具中的塑料材料进行冷却，使其固化成型；Step 4: Cooling and solidification: The plastic material in the mold is cooled to solidify and form;
需要说明的是：冷却时间和温度取决于材料的种类和厚度等因素，模具的具体设计也会影响冷却时间和质量；It should be noted that cooling time and temperature depend on factors such as the type and thickness of the material. The specific design of the mold will also affect the cooling time and quality.
步骤五：脱模：待塑料制品冷却固化后，打开模具并取出成型件；Step 5: Demolding: After the plastic product cools and solidifies, open the mold and take out the molded part;
需要说明的是：模具上通常会有一些释放剂，以帮助成型件轻松脱离模具。It should be noted that there is usually some release agent on the mold to help the molded part easily release from the mold.
实施例二：Embodiment 2:
在实施例一的基础上，请参阅图5所示，本发明实施例所述的一种塑料注塑成型工艺控制系统，包括：Based on the first embodiment, please refer to FIG. 5 , a plastic injection molding process control system according to the embodiment of the present invention includes:
波动分析模块用于对注射过程中注射机进行实时监测，判定注射机是否有波动；The fluctuation analysis module is used to monitor the injection machine in real time during the injection process to determine whether the injection machine has fluctuations;
合格判定模块用于对注射结果进行检测，判定注射结果是否合格；The qualified judgment module is used to detect the injection result and determine whether the injection result is qualified;
影响分析模块用于分析注射机发生波动时是否对注射结果的质量产生影响。The impact analysis module is used to analyze whether fluctuations in the injection molding machine will affect the quality of the injection results.
上述阈值的大小的设定是为了便于比较，关于阈值的大小，取决于样本数据的多少及本领域技术人员对每一组样本数据设定基数数量；The above thresholds are set for the convenience of comparison. The thresholds depend on the amount of sample data and the number of bases set by technicians in this field for each set of sample data.
上述公式均是采集大量数据进行软件模拟得出且选取与真实值接近的一个公式，公式中的因子是由本领域技术人员根据实际情况进行设置；如：公式由本领域技术人员采集多组监测数据并对每一组监测数据设定对应的监测参数；将设定的监测参数和采集的监测数据代入公式，任意三个公式构成三元一次方程组，将计算得到的因子进行筛选并取均值，得到a1、a2、a3的取值分别为2.37、1.65和2.43；The above formulas are obtained by collecting a large amount of data and performing software simulation to select a formula close to the actual value. The factors in the formula are set by technicians in this field according to actual conditions; for example: Formula A technician in this field collects multiple groups of monitoring data and sets corresponding monitoring parameters for each group of monitoring data; substitutes the set monitoring parameters and the collected monitoring data into the formula, any three formulas constitute a three-variable linear equation system, and the calculated factors are screened and averaged to obtain the values of a 1 , a 2 , and a 3 , which are 2.37, 1.65, and 2.43, respectively;
因子的大小是为了将各个参数进行量化得到的一个具体的数值，便于后续比较，关于因子的大小，取决于监测数据的多少及本领域技术人员对每一组监测数据初步设定对应的监测参数；只要不影响参数与量化后数值的比例关系即可，如监测参数与电压表征值的数值成正比。The size of the factor is to quantify each parameter to obtain a specific value for subsequent comparison. The size of the factor depends on the amount of monitoring data and the initial setting of corresponding monitoring parameters for each set of monitoring data by technical personnel in this field; as long as it does not affect the proportional relationship between the parameter and the quantized value, such as the monitoring parameter is proportional to the value of the voltage characterization value.
以上对本发明的一个实施例进行了详细说明，但所述内容仅为本发明的较佳实施例，不能被认为用于限定本发明的实施范围。凡依本发明申请范围所作的均等变化与改进等，均应仍归属于本发明的专利涵盖范围之内。The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.
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