CN118219517A - Plastic injection molding process control method and system - Google Patents
Plastic injection molding process control method and system Download PDFInfo
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- CN118219517A CN118219517A CN202410402887.0A CN202410402887A CN118219517A CN 118219517 A CN118219517 A CN 118219517A CN 202410402887 A CN202410402887 A CN 202410402887A CN 118219517 A CN118219517 A CN 118219517A
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- 238000000034 method Methods 0.000 title claims abstract description 56
- 239000004033 plastic Substances 0.000 title claims abstract description 50
- 238000001746 injection moulding Methods 0.000 title claims abstract description 24
- 238000002347 injection Methods 0.000 claims abstract description 152
- 239000007924 injection Substances 0.000 claims abstract description 152
- 238000012544 monitoring process Methods 0.000 claims abstract description 74
- 238000001514 detection method Methods 0.000 claims abstract description 63
- 239000000463 material Substances 0.000 claims abstract description 20
- 238000001816 cooling Methods 0.000 claims abstract description 9
- 238000012512 characterization method Methods 0.000 claims description 59
- 238000004458 analytical method Methods 0.000 claims description 18
- 238000012545 processing Methods 0.000 claims description 10
- 238000004364 calculation method Methods 0.000 claims description 4
- 238000012360 testing method Methods 0.000 claims description 4
- 238000011156 evaluation Methods 0.000 claims description 3
- 238000004806 packaging method and process Methods 0.000 claims description 3
- 238000012797 qualification Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 12
- 239000000047 product Substances 0.000 description 15
- 238000010835 comparative analysis Methods 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 230000009286 beneficial effect Effects 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
- 239000000049 pigment Substances 0.000 description 2
- 239000004014 plasticizer Substances 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
- 230000002159 abnormal effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009434 installation 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
- 239000000155 melt Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006068 polycondensation reaction Methods 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
- 238000012216 screening Methods 0.000 description 1
- 230000011218 segmentation Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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
- B29C45/768—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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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The invention relates to the technical field of plastic injection molding, and particularly discloses a plastic injection molding process control method and system, comprising the following steps: preparing a mould, preparing a plastic material, injecting, cooling, solidifying and demoulding; and detecting and controlling the injection process: a: monitoring the injection machine in real time in the injection process, and judging whether the injection machine has fluctuation or not; b: detecting an injection result, and judging whether the injection result is qualified or not; c: analyzing whether the quality of an injection result is influenced when the injection machine fluctuates; according to the invention, key factors influencing the quality of the product can be found out by analyzing the monitoring data of the injection machine and the detection data of the injection result, the transparency of the production process can be realized, a manager can grasp the production progress and the quality condition more accurately, and the stability and the consistency of the quality of the product are improved.
Description
Technical Field
The invention relates to the technical field of plastic injection molding, in particular to a plastic injection molding process control method and a plastic injection molding process control system.
Background
The plastic is a high molecular compound which is composed of synthetic resin and additives such as filler, plasticizer, stabilizer, lubricant, pigment and the like, the main component is resin, the high molecular compound is polymerized by polyaddition or polycondensation reaction, the deformation resistance is medium, the high molecular compound is between fiber and rubber, the high molecular compound is composed of the synthetic resin and the additives such as filler, plasticizer, stabilizer, lubricant, pigment and the like, and the main characteristics of the plastic include light weight, excellent chemical stability, no rust, good impact resistance, better transparency and wear resistance, good insulativity, low thermal conductivity, general formability, good colorability, low processing cost and the like.
The Chinese patent publication No. CN113665079B discloses a control method and a system for plastic injection molding process, wherein the method comprises the following steps: at least collecting data of a machine, a die and related auxiliary machines; generating a set of standard process curves; obtaining a segmentation result; respectively analyzing the fluctuation range of each parameter point on each section of curve of each standard process curve; and judging the quality of the plastic injection molded product to obtain a judging result of the product quality.
However, in the prior art, only a single aspect of the injection machine or the injection result is often concerned, and it is difficult to accurately determine whether the fluctuation of the injection machine affects the quality of the injection result, and a comprehensive management system is lacking to integrate and analyze the data of each aspect.
Disclosure of Invention
The invention aims to provide a plastic injection molding process control method and a plastic injection molding process control system, which are used for solving the technical problems in the background.
The aim of the invention can be achieved by the following technical scheme:
a plastic injection molding process control method and system comprises the following steps: preparing a mould, preparing a plastic material, injecting, cooling, solidifying and demoulding;
And detecting and controlling the injection process:
a: monitoring the injection machine in real time in the injection process, and judging whether the injection machine has fluctuation or not;
b: detecting an injection result, and judging whether the injection result is qualified or not;
c: analyzing whether the quality of an injection result is influenced when the injection machine fluctuates;
c1: according to the history record, respectively acquiring monitoring data JC of an injection machine and a detection parameter M of an injection result in each injection process in the history record, and packaging the monitoring data JC and the detection parameter M in each injection process into a group of point location data (M, JC);
c2: according to all the point location data, constructing an influence analysis point bitmap based on a two-dimensional coordinate system established by taking the detection parameter as an X axis and the monitoring parameter as a Y axis;
And C3: according to all the points in the influence analysis point bitmap, a fitting straight line is obtained through a least square method, and the fitting straight line equation is as follows: y=kx+b, where k is represented as the slope of the fitting line, b is represented as the intercept of the fitting line, and k and b take values as constants;
and C4: analyzing the slope of the fitting straight line so as to judge whether the quality of an injection result is influenced when the injector fluctuates;
Presetting a slope threshold as KY, and comparing and analyzing an absolute value |k| of the slope with the slope threshold KY;
if the absolute value of the slope |k| is smaller than the slope threshold KY, judging that the quality of an injection result is not affected when the injector fluctuates;
If the absolute value |k| of the slope is not less than the slope threshold KY, the quality of the injection result is influenced when the fluctuation of the injection machine is judged.
As a further scheme of the invention: the method for judging whether the injector has fluctuation or not comprises the following steps:
A1: monitoring the injection machine in real time to obtain monitoring data in a target period of the injection machine;
wherein the monitoring data comprises: a voltage characterization value, a current characterization value, and a vibration characterization value;
A2: according to the detection data of the injection machine, calculating to obtain monitoring parameters;
a3: and comparing and analyzing the monitoring parameters so as to judge whether the injector has fluctuation.
As a further scheme of the invention: the method for acquiring the monitoring data comprises the following steps:
a11: acquiring real-time voltage of an injection machine in a target period, drawing a voltage fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and taking the real-time voltage as a Y axis, acquiring the area of an area surrounded by the voltage fluctuation curve in the target period and the average voltage in the target period according to the voltage fluctuation curve, wherein the ratio of the area to a voltage area threshold value is a voltage representation value, and marking the voltage representation value as DY;
A12: acquiring real-time current of an injector in a target period, drawing a current fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and taking real-time voltage as a Y axis, acquiring the area of an area surrounded by the current fluctuation curve in the target period and average current in the target period according to the current fluctuation curve, wherein the ratio of the area to a current area threshold value is a current characterization value, and marking the current characterization value as DL;
a13: the method comprises the steps of obtaining real-time vibration frequency of an injection machine in a target period, drawing a vibration fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and real-time voltage as a Y axis, obtaining the area of an area surrounded by the vibration frequency fluctuation curve in the target period and the average vibration frequency in the target period according to the vibration frequency fluctuation curve, wherein the ratio of the area to the vibration frequency area threshold is a vibration characterization value, and marking the vibration characterization value as ZD.
As a further scheme of the invention: data processing is carried out on the voltage representation value DY, the current representation value DL and the vibration representation value ZD, and the formula is adopted: And calculating to obtain a monitoring parameter JC, wherein a 1、a2、a3 is a preset scale factor and is larger than 0.
As a further scheme of the invention: the monitoring parameter threshold value is preset as JY, and the monitoring parameter JC and the monitoring parameter threshold value JY are compared and analyzed;
if the monitoring parameter JC is smaller than the monitoring parameter threshold JY, judging that the injector does not have severe or continuous fluctuation in the target period;
if the monitoring parameter JC is more than or equal to the monitoring parameter threshold JY, judging that the injector has severe or continuous fluctuation in the target period.
As a further scheme of the invention: the method for judging whether the injection result is qualified comprises the following steps:
b1: detecting an injection result to obtain detection data of the injection result;
wherein the detection data includes: bubble characterization values, flowability characterization values;
B2: according to the detection data of the injection result, calculating detection parameters for obtaining the injection result;
b3: and comparing and analyzing the obtained detection parameters so as to judge whether the injection result is qualified or not.
As a further scheme of the invention: the detection data acquisition method comprises the following steps:
B11: arranging an acoustic wave emitting device on one side of the mold, arranging an acoustic wave receiving device on the other side of the mold, emitting an acoustic wave with fixed intensity to the plastic material injected into the mold through the acoustic wave emitting device, enabling the acoustic wave to pass through the mold and the plastic material in the mold, receiving the acoustic wave through the acoustic wave receiving device, obtaining the residual intensity of the acoustic wave, calculating the difference between the obtained residual intensity of the acoustic wave and the predicted acoustic wave intensity, taking an absolute value, wherein the obtained absolute difference is a bubble characterization value, and marking the bubble characterization value as QP;
B12: and (3) carrying out flowability test on the plastic material by a flowability tester, thereby evaluating the flowability uniformity of the injection result, recording the evaluation result as a flowability characterization value, wherein the larger the flowability characterization value is, the better the flowability uniformity of the injection result is, and marking the flowability characterization value as LD.
As a further scheme of the invention: and carrying out data processing on the bubble characterization value QP and the fluidity characterization value LD, carrying out ratio calculation on the bubble characterization value QP and the fluidity characterization value LD, obtaining the ratio of the ratio to the ratio threshold value as a detection parameter, and marking the detection parameter as M.
As a further scheme of the invention: presetting a detection parameter threshold value as MY, and comparing and analyzing the detection parameter M with the detection parameter threshold value MY;
If the detection parameter M is less than the detection parameter threshold MY, judging that the injection result is qualified;
If the detection parameter M is more than or equal to the detection parameter threshold MY, judging that the injection result is unqualified.
A plastic injection molding process control system, comprising:
The fluctuation analysis module is used for monitoring the injection machine in real time in the injection process and judging whether the injection machine has fluctuation or not;
the qualification judging module is used for detecting the injection result and judging whether the injection result is qualified or not;
The influence analysis module is used for analyzing whether the quality of the injection result is influenced when the injection machine fluctuates.
The invention has the beneficial effects that:
(1) According to the invention, through monitoring the running state of the injection machine in real time and timely finding out abnormal fluctuation of parameters such as voltage, current and vibration, mechanical faults are prevented, the risk of production interruption is reduced, and the preventive maintenance measure is helpful for ensuring continuous and stable running of the injection machine, so that the production efficiency is improved;
(2) The quality of the product can be evaluated through the detection of the injection result, so that the product is beneficial to ensuring that the product meets the preset quality standard, reducing the defective rate and improving the customer satisfaction;
(3) According to the invention, key factors influencing the quality of the product can be found out by analyzing the monitoring data of the injection machine and the detection data of the injection result, the transparency of the production process can be realized, a manager can grasp the production progress and the quality condition more accurately, and the stability and the consistency of the quality of the product are improved.
Drawings
The invention is further described below with reference to the accompanying drawings.
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a flow chart of a method of determining whether an injector has a surge in the present invention;
FIG. 3 is a flow chart of a method for determining whether an injection result is acceptable in the present invention;
FIG. 4 is a flow chart of a method for analyzing whether the quality of an injection result is affected when the fluctuation of the injection machine occurs in the invention;
fig. 5 is a schematic diagram of the system of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Embodiment one:
Referring to fig. 1 to 4, the control method for plastic injection molding process according to the embodiment of the invention includes the following steps:
step one: preparing a die: preparing a mould for manufacturing a required plastic product in advance, wherein the mould comprises design, manufacture and installation;
The design of the mould is carried out according to the shape, the size and the material characteristics of the required product, and the factors such as the material, the processing precision and the like of the mould are required to be considered during manufacturing;
step two: preparing a plastic material: heating plastic particles or powder to a molten state so that the plastic particles or powder become viscous and flow, and pushing the plastic particles or powder into a die by an injection machine;
Step three: injection: injecting molten plastic material into the mold under the action of high pressure of an injection machine to fill the whole mold cavity;
During injection, the molten plastic material needs to be precisely filled into each cavity of the mold under high pressure, and if the parameters of the injection machine are controlled improperly, defects of plastic products can be caused, so that the quality of the final product can be directly influenced;
A: the method has the advantages that the real-time monitoring is carried out on the injection machine in the injection process, whether the injection machine has fluctuation is judged, potential mechanical faults can be predicted and prevented through the real-time monitoring, the risk of production interruption is reduced, the problems can be timely found and solved, the continuous and stable operation of the injection machine is ensured, and therefore the production efficiency is improved;
A1: monitoring the injection machine in real time to obtain monitoring data in a target period of the injection machine;
wherein the monitoring data comprises: a voltage characterization value, a current characterization value, and a vibration characterization value;
The target period includes: 1 minute, 3 minutes;
The data of key parameters such as voltage, current and vibration are collected, a basis is provided for subsequent analysis, and the running state of the injection machine can be more comprehensively known by setting a target period
A11: acquiring real-time voltage of an injection machine in a target period, drawing a voltage fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and taking the real-time voltage as a Y axis, acquiring the area of an area surrounded by the voltage fluctuation curve in the target period and the average voltage in the target period according to the voltage fluctuation curve, wherein the ratio of the area to a voltage area threshold value is a voltage representation value, and marking the voltage representation value as DY;
A12: acquiring real-time current of an injector in a target period, drawing a current fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and taking real-time voltage as a Y axis, acquiring the area of an area surrounded by the current fluctuation curve in the target period and average current in the target period according to the current fluctuation curve, wherein the ratio of the area to a current area threshold value is a current characterization value, and marking the current characterization value as DL;
A13: acquiring real-time vibration frequency of an injection machine in a target period, drawing a vibration fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and taking real-time voltage as a Y axis, acquiring area of an area surrounded by the vibration frequency fluctuation curve in the target period and average vibration frequency in the target period according to the vibration frequency fluctuation curve, wherein the ratio of the area to a vibration frequency area threshold value is a vibration characterization value, and marking the vibration characterization value as ZD;
a2: according to the detection data of the injection machine, calculating to obtain monitoring parameters, and comprehensively processing a plurality of monitoring data to obtain a comprehensive monitoring parameter, so that the subsequent analysis is facilitated;
data processing is carried out on the voltage representation value DY, the current representation value DL and the vibration representation value ZD, and the formula is adopted: Calculating to obtain a monitoring parameter JC, wherein a 1、a2、a3 is a preset scale factor, and the monitoring parameters are all larger than 0, and through the preset scale factor, different monitoring data can be subjected to standardized processing, so that the comparability between different parameters is realized;
a3: the monitoring parameters are compared and analyzed to judge whether the injector has fluctuation, so that the fluctuation of the injector can be timely found and processed, the stability of the injection process is ensured, and the product quality is improved;
The preset monitoring parameter threshold is JY, the monitoring parameter JC and the monitoring parameter threshold JY are subjected to comparative analysis, and the fluctuation condition of the injection machine can be found in time through comparative analysis of the monitoring parameter and the preset threshold;
if the monitoring parameter JC is smaller than the monitoring parameter threshold JY, judging that the injector does not have severe or continuous fluctuation in the target period;
If the monitoring parameter JC is more than or equal to the monitoring parameter threshold JY, judging that the injector has severe or continuous fluctuation in the target period;
B: detecting the injection result, judging whether the injection result is qualified or not, and evaluating the quality of the product by detecting the injection result, so that potential quality problems such as excessive bubbles or uneven fluidity can be found;
b1: detecting the injection result, acquiring detection data of the injection result, collecting data such as a bubble characterization value, a fluidity characterization value and the like, providing a basis for subsequent analysis, and more objectively evaluating the quality of the injection result through a quantitative index;
wherein the detection data includes: bubble characterization values, flowability characterization values;
B11: arranging an acoustic wave emitting device on one side of the mold, arranging an acoustic wave receiving device on the other side of the mold, emitting an acoustic wave with fixed intensity to the plastic material injected into the mold through the acoustic wave emitting device, enabling the acoustic wave to pass through the mold and the plastic material in the mold, receiving the acoustic wave through the acoustic wave receiving device, obtaining the residual intensity of the acoustic wave, calculating the difference between the obtained residual intensity of the acoustic wave and the predicted acoustic wave intensity, taking an absolute value, wherein the obtained absolute difference is a bubble characterization value, and marking the bubble characterization value as QP;
B12: carrying out flowability test on the plastic material by a flowability tester, thereby evaluating the flowability uniformity of the injection result, recording the evaluation result as a flowability characterization value, wherein the larger the flowability characterization value is, the better the flowability uniformity of the injection result is, and marking the flowability characterization value as LD;
Wherein, the flow property test instrument includes: a melt flow rate meter, a spiral flow meter;
b2: according to the detection data of the injection result, the detection parameters of the injection result are obtained through calculation, the bubble characterization value and the fluidity characterization value are comprehensively processed to obtain a comprehensive detection parameter, the subsequent analysis is convenient, and the quality of the injection result in different batches or under different conditions can be conveniently compared through the detection parameters;
Performing data processing on the bubble characterization value QP and the fluidity characterization value LD, performing ratio calculation on the bubble characterization value QP and the fluidity characterization value LD, obtaining the ratio of the ratio to the ratio threshold value as a detection parameter, and marking the detection parameter as M;
b3: comparing and analyzing the obtained detection parameters so as to judge whether the injection result is qualified, and further tracing the reasons for the unqualified injection result and adopting corresponding measures to improve the unqualified injection result;
The preset detection parameter threshold value is MY, the detection parameter M and the detection parameter threshold value MY are subjected to comparative analysis, and whether an injection result is qualified or not can be judged through comparative analysis of the detection parameter and the preset threshold value, so that the product quality is ensured;
if the detection parameter M is smaller than the detection parameter threshold MY, judging that the injection result is qualified, wherein the smaller the detection parameter M is, the better the quality of the injection result is;
If the detection parameter M is more than or equal to the detection parameter threshold MY, judging that the injection result is unqualified;
C: whether the quality of the injection result is influenced when the injection machine fluctuates is analyzed, and according to the analysis result, the operation parameters or maintenance measures of the injection machine can be optimized in a targeted manner so as to improve the product quality and the production efficiency;
c1: according to the history record, respectively acquiring monitoring data JC of an injection machine and a detection parameter M of an injection result in each injection process in the history record, and packaging the monitoring data JC and the detection parameter M in each injection process into a group of point location data (M, JC);
C2: according to all the point location data, an influence analysis point bitmap is constructed on the basis of a two-dimensional coordinate system established by taking the detection parameter as an X axis and the monitoring parameter as a Y axis, and the relation between the fluctuation of the injection machine and the quality of the injection result can be intuitively known by constructing the influence analysis point bitmap;
And C3: according to all the points in the influence analysis point bitmap, a fitting straight line is obtained through a least square method, and the fitting straight line equation is as follows: y=kx+b, where k is represented as the slope of the fitting line, b is represented as the intercept of the fitting line, and k and b take values as constants;
and C4: analyzing the slope of the fitting straight line so as to judge whether the quality of an injection result is influenced when the injector fluctuates;
Presetting a slope threshold as KY, and comparing and analyzing an absolute value |k| of the slope with the slope threshold KY;
if the absolute value of the slope |k| is smaller than the slope threshold KY, judging that the quality of an injection result is not affected when the injector fluctuates;
If the absolute value |k| of the slope is not less than the slope threshold KY, judging that the quality of an injection result is influenced when the injector fluctuates;
step four: cooling and solidifying: cooling the plastic material in the mould to solidify and shape the plastic material;
it should be noted that: the cooling time and the cooling temperature depend on factors such as the type and the thickness of materials, and the specific design of the die can influence the cooling time and the cooling quality;
Step five: demolding: after the plastic product is cooled and solidified, opening the mould and taking out the formed part;
It should be noted that: the mold typically has some release agent to assist in the easy removal of the molded part from the mold.
Embodiment two:
On the basis of the first embodiment, referring to fig. 5, a plastic injection molding process control system according to an embodiment of the present invention includes:
The fluctuation analysis module is used for monitoring the injection machine in real time in the injection process and judging whether the injection machine has fluctuation or not;
The qualification judging module is used for detecting the injection result and judging whether the injection result is qualified or not;
the influence analysis module is used for analyzing whether the quality of the injection result is influenced when the injector fluctuates.
The size of the threshold is set for convenience of comparison, and the size of the threshold depends on the number of sample data and the number of cardinalities set for each group of sample data by a person skilled in the art;
The formulas are all formulas obtained by collecting a large amount of data for software simulation and selecting a formula close to a true value, and factors in the formulas are set by a person skilled in the art according to actual conditions; such as: formula (VI) Collecting multiple groups of monitoring data by a person skilled in the art and setting corresponding monitoring parameters for each group of monitoring data; substituting the set monitoring parameters and the collected monitoring data into a formula, forming a ternary once equation set by any three formulas, screening the calculated factors, and taking an average value to obtain values of a 1、a2、a3 of 2.37, 1.65 and 2.43 respectively;
The size of the factor is a specific numerical value obtained by quantizing each parameter, so that the subsequent comparison is convenient, and the size of the factor depends on the number of the monitoring data and the corresponding monitoring parameters are preliminarily set for each group of the monitoring data by a person skilled in the art; as long as the proportional relation between the parameter and the quantized value is not affected, for example, the monitored parameter is in direct proportion to the value of the voltage characterization value.
The foregoing describes one embodiment of the present invention in detail, but the description is only a preferred embodiment of the present invention and should not be construed as limiting the scope of the invention. All equivalent changes and modifications within the scope of the present invention are intended to be covered by the present invention.
Claims (10)
1. The plastic injection molding process control method is characterized by comprising the following steps of: preparing a mould, preparing a plastic material, injecting, cooling, solidifying and demoulding;
And detecting and controlling the injection process:
a: monitoring the injection machine in real time in the injection process, and judging whether the injection machine has fluctuation or not;
b: detecting an injection result, and judging whether the injection result is qualified or not;
c: analyzing whether the quality of an injection result is influenced when the injection machine fluctuates;
c1: according to the history record, respectively acquiring monitoring data JC of an injection machine and a detection parameter M of an injection result in each injection process in the history record, and packaging the monitoring data JC and the detection parameter M in each injection process into a group of point location data (M, JC);
c2: according to all the point location data, constructing an influence analysis point bitmap based on a two-dimensional coordinate system established by taking the detection parameter as an X axis and the monitoring parameter as a Y axis;
And C3: according to all the points in the influence analysis point bitmap, a fitting straight line is obtained through a least square method, and the fitting straight line equation is as follows: y=kx+b, where k is represented as the slope of the fitting line, b is represented as the intercept of the fitting line, and k and b take values as constants;
and C4: analyzing the slope of the fitting straight line so as to judge whether the quality of an injection result is influenced when the injector fluctuates;
Presetting a slope threshold as KY, and comparing and analyzing an absolute value |k| of the slope with the slope threshold KY;
if the absolute value of the slope |k| is smaller than the slope threshold KY, judging that the quality of an injection result is not affected when the injector fluctuates;
If the absolute value |k| of the slope is not less than the slope threshold KY, the quality of the injection result is influenced when the fluctuation of the injection machine is judged.
2. The method for controlling a plastic injection molding process according to claim 1, wherein the method for determining whether the injector has a fluctuation comprises the steps of:
A1: monitoring the injection machine in real time to obtain monitoring data in a target period of the injection machine;
wherein the monitoring data comprises: a voltage characterization value, a current characterization value, and a vibration characterization value;
A2: according to the detection data of the injection machine, calculating to obtain monitoring parameters;
a3: and comparing and analyzing the monitoring parameters so as to judge whether the injector has fluctuation.
3. The method for controlling a plastic injection molding process according to claim 2, wherein the method for acquiring the monitoring data comprises the steps of:
a11: acquiring real-time voltage of an injection machine in a target period, drawing a voltage fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and taking the real-time voltage as a Y axis, acquiring the area of an area surrounded by the voltage fluctuation curve in the target period and the average voltage in the target period according to the voltage fluctuation curve, wherein the ratio of the area to a voltage area threshold value is a voltage representation value, and marking the voltage representation value as DY;
A12: acquiring real-time current of an injector in a target period, drawing a current fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and taking real-time voltage as a Y axis, acquiring the area of an area surrounded by the current fluctuation curve in the target period and average current in the target period according to the current fluctuation curve, wherein the ratio of the area to a current area threshold value is a current characterization value, and marking the current characterization value as DL;
a13: the method comprises the steps of obtaining real-time vibration frequency of an injection machine in a target period, drawing a vibration fluctuation curve based on a two-dimensional coordinate system established by taking time as an X axis and real-time voltage as a Y axis, obtaining the area of an area surrounded by the vibration frequency fluctuation curve in the target period and the average vibration frequency in the target period according to the vibration frequency fluctuation curve, wherein the ratio of the area to the vibration frequency area threshold is a vibration characterization value, and marking the vibration characterization value as ZD.
4. A method of controlling a plastic injection molding process according to claim 3, wherein:
data processing is carried out on the voltage representation value DY, the current representation value DL and the vibration representation value ZD, and the formula is adopted: And calculating to obtain a monitoring parameter JC, wherein a 1、a2、a3 is a preset scale factor and is larger than 0.
5. The method for controlling a plastic injection molding process according to claim 4, wherein:
The monitoring parameter threshold value is preset as JY, and the monitoring parameter JC and the monitoring parameter threshold value JY are compared and analyzed;
if the monitoring parameter JC is smaller than the monitoring parameter threshold JY, judging that the injector does not have severe or continuous fluctuation in the target period;
if the monitoring parameter JC is more than or equal to the monitoring parameter threshold JY, judging that the injector has severe or continuous fluctuation in the target period.
6. The method for controlling a plastic injection molding process according to claim 1, wherein the method for determining whether the injection result is acceptable is:
b1: detecting an injection result to obtain detection data of the injection result;
wherein the detection data includes: bubble characterization values, flowability characterization values;
B2: according to the detection data of the injection result, calculating detection parameters for obtaining the injection result;
b3: and comparing and analyzing the obtained detection parameters so as to judge whether the injection result is qualified or not.
7. The method for controlling a plastic injection molding process according to claim 6, wherein the detection data acquisition method comprises:
B11: arranging an acoustic wave emitting device on one side of the mold, arranging an acoustic wave receiving device on the other side of the mold, emitting an acoustic wave with fixed intensity to the plastic material injected into the mold through the acoustic wave emitting device, enabling the acoustic wave to pass through the mold and the plastic material in the mold, receiving the acoustic wave through the acoustic wave receiving device, obtaining the residual intensity of the acoustic wave, calculating the difference between the obtained residual intensity of the acoustic wave and the predicted acoustic wave intensity, taking an absolute value, wherein the obtained absolute difference is a bubble characterization value, and marking the bubble characterization value as QP;
B12: and (3) carrying out flowability test on the plastic material by a flowability tester, thereby evaluating the flowability uniformity of the injection result, recording the evaluation result as a flowability characterization value, wherein the larger the flowability characterization value is, the better the flowability uniformity of the injection result is, and marking the flowability characterization value as LD.
8. The method for controlling a plastic injection molding process according to claim 7, wherein:
And carrying out data processing on the bubble characterization value QP and the fluidity characterization value LD, carrying out ratio calculation on the bubble characterization value QP and the fluidity characterization value LD, obtaining the ratio of the ratio to the ratio threshold value as a detection parameter, and marking the detection parameter as M.
9. The method for controlling a plastic injection molding process according to claim 8, wherein:
presetting a detection parameter threshold value as MY, and comparing and analyzing the detection parameter M with the detection parameter threshold value MY;
If the detection parameter M is less than the detection parameter threshold MY, judging that the injection result is qualified;
If the detection parameter M is more than or equal to the detection parameter threshold MY, judging that the injection result is unqualified.
10. A plastic injection molding process control system implementing the method of any one of claims 1-9, comprising:
The fluctuation analysis module is used for monitoring the injection machine in real time in the injection process and judging whether the injection machine has fluctuation or not;
the qualification judging module is used for detecting the injection result and judging whether the injection result is qualified or not;
The influence analysis module is used for analyzing whether the quality of the injection result is influenced when the injection machine fluctuates.
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