TW202031456A - Injection quality control method of injection molding machine and system thereof comprising an injection molding machine and a quality calculation module for monitoring injection quality and providing instant alarms - Google Patents

Abstract

The present invention provides an injection quality control method of an injection molding machine and its system. The method comprises: inputting injection molding data, and calculating through a quality calculation module to obtain a PVT simulation curve and a specific volume simulation parameter (vt); calculating through a quality calculation module to obtain a PVT actual curve and a specific volume actual parameter (vr); and comparing the specific volume simulation parameter (vt) with the specific volume actual parameter (vr), if two of which match, the injection quality is good; if the two do not match, the injection quality is defective, and the process parameters of the injection molding machine in the injection process are adjusted to make the subsequent injection ratio of the specific volume actual parameter (vr) with the specific volume simulation parameter (vt) consistent.

Description

Injection quality control method and system of injection molding machine

The present invention relates to a control method and system of an injection molding machine, in particular to an injection quality control method and system of an injection molding machine.

The parameters related to the quality of the products produced by the plastic injection molding machine are quite numerous and complex, so how to effectively control the product quality stability has always been a very difficult but important issue. Traditionally, in order to control the quality of plastic injection molding, it is only possible to adjust the machine through a try and error method through an experienced master. However, when it comes to different injection machines, different ambient temperatures or For different molds, the control parameters must be adjusted accordingly. Such back and forth will often lead to the increase of machine adjustment time, the reduction of machine utilization, and the lack of improvement in the ratio of defective products. Therefore, there is still room for improvement in how to effectively monitor the injection quality of the injection molding machine and provide warnings to the operators in real time.

In view of this, the object of the present invention is to provide an injection quality control method and system for an injection molding machine, which can efficiently monitor the injection quality of the injection machine and provide immediate warning to the operator.

To achieve the above object, the present invention provides an injection quality control method for an injection molding machine. The method includes the following steps: inputting an injection molding data, and calculating through a quality calculation module to obtain a PVT simulation curve, and The PVT simulation curve obtains a specific volume simulation parameter (vt); through the quality calculation module, a PVT actual curve when an injection molding machine is actually injected is obtained, and a specific volume actual parameter (vr) is obtained from the PVT actual curve. ); compare the specific volume simulation parameter (vt) with the actual specific volume parameter (vr), if the two are consistent, the injection system is good; if the two do not match, the injection system It is a defective product, and the process parameters of the injection molding machine in the injection process are adjusted so that the actual specific volume parameters (vr) of subsequent injections are consistent with the specific volume simulation parameters (vt).

In addition, the present invention also provides an injection quality control system for an injection molding machine, which includes: an injection molding machine and a quality calculation module. The quality calculation module is electrically connected to the injection molding machine. The quality calculation module includes a PVT curve model unit and a quality judgment model unit. The PVT curve model unit performs calculations based on inputted injection molding data to obtain A PVT simulation curve and a specific volume simulation parameter (vt) are output. The quality judgment model unit calculates a PVT actual curve according to the actual injection situation of the injection molding machine, and obtains a specific volume actual from the PVT actual curve. Parameter (vr), and the quality judgment model unit performs a comparison operation between the actual specific volume parameter (vr) and the specific volume simulation parameter (vt).

In this way, the present invention uses the aforementioned technical features, and the user only needs to input the injection molding data into the quality calculation module before the actual production of the injection molding machine, and obtain the good product through the calculation of the quality calculation module. PVT simulation curve and specific volume simulation parameters (vt), and then each time the injection machine actually produces production, the quality calculation module is used to calculate the production situation to obtain the actual PVT curve and The actual specific volume parameters (vr), and the specific volume simulation parameters (vt) and the specific volume actual parameters (vr) are compared. If the two match, the injection is a good product and production can continue; if If the two do not match, the injection system is defective. At this time, the operator of the injection machine can immediately adjust the various process parameters of the injection machine so that the actual volumetric parameters (vr) of the subsequent injection can be compared with this The specific volume simulation parameters (vt) are consistent.

The detailed features or steps of an injection quality control method and system for an injection molding machine provided by the present invention will be described in the following description. However, those with ordinary knowledge in the field of the present invention should be able to understand that these detailed descriptions and specific examples for implementing the present invention are only used to illustrate the present invention, and are not intended to limit the scope of the patent application of the present invention.

First of all, it should be noted that the technical features provided by the present invention are not limited to the specific structures, uses, and applications described in the embodiments. The terms used in the description are all exemplary description terms that can be understood by those with ordinary knowledge in the technical field. The content of this manual refers to "front", "upper", "lower", "rear", and "left". Directional adjectives such as, "right", "top", "bottom", "inner", and "outer" are just exemplary descriptions based on the normal direction of use, and are not intended to limit the scope of claims.

Furthermore, the singular forms of "a", "an" and "the" as used in the scope of the patent application of the present invention all include plural meanings. Therefore, for example, the description of "an element" refers to one or more elements, and includes equivalent replacements known to those having ordinary knowledge in the art. All conjunctions used in similar situations should also be understood as the broadest meaning. The specific shapes and structural features or technical terms described in the content should also be understood as including the functions that can be achieved by specific structures or technical terms. Equivalent to replace structural or technical terms.

Please refer to the drawings first. An injection quality control method and system for an injection molding machine according to an embodiment of the present invention. The control system includes an injection molding machine 10 and a quality calculation module 20.

Please refer to Figure 1, the injection molding machine 10 includes a signal measurement module 12, the signal measurement module 12 includes at least one pressure sensor (not shown) and at least one temperature sensor (Figure Not shown), the pressure sensing system can be set on the ejector pin, the front end of the barrel, the glue inlet, the gate, the near gate, the end position of the filling in the mold and the flow direction of the melt through the filling of the injection molding machine. At any position or multiple positions, the temperature sensing system can be set at the ejector pin, the front end of the barrel, the injection port, the gate, the near gate, the end position of the filling in the mold, and the melting and filling in the mold of the injection molding machine Any position or multiple positions such as flow direction. In addition, the remaining structures and components of the injection molding machine 10 are widely known to those with ordinary knowledge in the relevant technical field, so they will not be described further.

The quality calculation module 20 is electrically connected to the injection molding machine 10. The quality calculation module 20 includes a PVT curve model unit 40 and a quality judgment model unit 50. The PVT curve model unit 40 emits according to an input The forming data is calculated to obtain a PVT simulation curve and a specific volume simulation parameter (vt). The quality judgment model unit 50 calculates a PVT actual curve according to the actual injection situation of the injection molding machine 10, and then The actual PVT curve obtains a specific volume actual parameter (vr), and the quality judgment model unit 50 performs a comparison operation between the specific volume actual parameter (vr) and the specific volume simulation parameter (vt).

In this embodiment, the injection molding information includes, but is not limited to, a flow length, projected area, product volume, gate thickness/diameter, product thickness, the proportion of the volume occupied by the runner, the average distance between the water pipe and the film surface, materials and injection Information about the model of the forming machine. Furthermore, the quality calculation module 20 can be assembled in the injection molding machine 10, or can be located remotely or in the cloud and connected to the injection molding machine 10 through a method such as wired or wireless communication. The quality computing module 20 can be, but is not limited to, a desktop computer, a notebook computer, or a smart handheld electronic device.

In addition, in this embodiment, the quality calculation module 20 also includes a material database 22, a pressure forming database 24, a temperature forming database 26, a mold feature database 28, and a quality related feature database 30 The database 22, 24, 26, 28, 30 are electrically connected to the PVT curve model unit 40 and the quality judgment model unit 50.

The material database 22 may include, but is not limited to, data on a molten state material property parameter, a solid state material property parameter, a glass transition temperature data, a glass transition temperature relative pressure data, and a material shrinkage rate.的信息。 Information.

The pressure forming database 24 may include, but is not limited to, data on injection pressure, data on holding pressure, data on V/P switching parameters, data on injection time, data on holding time, and Data of pressing time, data of injection speed and data of injection time.

The temperature forming database 26 may include, but is not limited to, data on a barrel temperature, a mold temperature, a chiller temperature, a hot glue channel temperature, and a barrel feed speed data. And a piece of data on the shear rate of the melted glue in the barrel.

The mold feature database 28 may include, but is not limited to, data of a mold surface, data of a mold plane, data of a first-rate aspect ratio (thin parts), and data of general parts. The quality-related characteristic database 30 may include, but is not limited to, a product short shot data and a product weight data.

It is worth noting that, in this embodiment and other possible embodiments, the number of pressure sensors and temperature sensors of the signal measurement module 12 may be plural, and they are respectively arranged in the injection molding machine. Different positions, preferably, multiple pressure sensors and multiple temperature sensors can be installed at different positions in the mold of the injection molding machine, through multiple pressure sensors and multiple temperature sensors at different positions inside the mold The detector can obtain the actual PVT curve corresponding to different positions and the actual specific volume parameters (vr) corresponding to each actual PVT curve in each injection cycle. The actual specific volume parameters (vr) are compared with the specific volume simulation parameters (vt), so as to more accurately grasp the plastic molding situation of the injection process, and the actual PVT curve and the actual specific volume parameters (vr) obtained from this calculation It will also be more conducive to evaluating the quality of injection. For example, if the actual specific volume parameters (vr) of only part of the injection cycle match the specific volume simulation parameters (vt), then through analyzing the actual specific volume The points in the mold where the parameter (vr) does not match the specific volume simulation parameter (vt) correspond to the position in the mold, and it can be known that the injection at these positions is abnormal, and then the process parameters can be adjusted according to the position. In addition, multiple actual specific volume parameters (vr) at different positions in this injection cycle can be compared with each other to evaluate the consistency of plastic molding at various positions in this cycle.

The above describes the injection quality control system of the injection molding machine 10 of the embodiment of the present invention, and then the control method of the present invention (please refer to FIGS. 1 to 3 together), which includes:

Input the injection molding data, and calculate the PVT simulation curve through the quality calculation module 20, and obtain the specific volume simulation parameter (vt) from the PVT simulation curve.

Wherein, the quality calculation module 20 uses its PVT curve model unit 40 and the material database 22, the pressure forming database 24, the temperature forming database 26, the mold feature database 28, and the quality related feature database The combination of 30 can calculate the PVT simulation curve and the specific volume simulation parameter (vt).

In addition, the control method uses the quality calculation module 20 to calculate the actual PVT curve of the injection molding machine 10 during actual injection, and obtains the actual specific volume parameter (vr) from the PVT actual curve.

Wherein, the actual PVT curve and the actual specific volume parameter (vr) are obtained when the injection molding machine 10 is in the actual injection process, through the signal measurement module 12 to simultaneously measure the real-time pressure and real-time temperature, and The real-time pressure and the real-time temperature are transmitted to the quality calculation module 20, and then obtained by the quality calculation module 20. In this embodiment, the quality calculation module 20 uses its quality judgment model unit 50 to calculate the actual PVT curve and the ratio based on the real-time pressure and real-time temperature information during the actual injection process of the injection molding machine 10 The actual parameters (vr).

Finally, this method compares the specific volume simulation parameter (vt) with the specific volume actual parameter (vr). If the two are consistent, the injection system is a good product; if the two are not consistent, the The secondary injection system is a defective product, and the process parameters of the injection molding machine 10 in the injection process are adjusted so that the actual specific volume parameters (vr) of subsequent injections are consistent with the specific volume simulation parameters (vt).

The specific volume simulation parameter (vt) and the specific volume actual parameter (vr) are compared through the quality judgment model unit 50 of the quality calculation module 20.

Since the injected product can be considered good as long as it meets certain conditions, the specific volume simulation parameter (vt) can be set as an interval range, and the injected products within this interval meet the quality requirements of good products. Therefore, when When the actual specific volume (vr) is within the range, the injection system is a good product.

Furthermore, please also refer to Figure 3. In order to speed up the comparison between the specific volume simulation parameter (vt) and the specific volume actual parameter (vr), the user can only perform the specific volume value at the end point of the PVT curve Comparison, that is, in an injection cycle, only the specific volume simulation parameter (vt) and the specific volume actual parameter (vr) need to be compared once, which can speed up the comparison. Because the end point of the PVT curve and The overall quality consistency of plastic molding is obviously related, so just compare the specific volume values at the end points of the PVT curve to grasp the quality of the shot. In addition to the aforementioned method only for the end point of the PVT curve, the user can also compare the specific volume values of the end point of the PVT curve and the v/P point at the same time, because the v/P point is the plastic entering the mold. Therefore, by increasing the comparison of v/P points, the accuracy of the comparison can be improved, and the chance of misjudgment can be avoided. It is obviously helpful for products with special shapes or products with large differences in thickness. .

However, when the specific volume simulation parameter (vt) does not match the specific volume actual parameter (vr), the quality calculation module 20 will calculate the specific volume simulation parameter (vt) and the specific volume actual parameter (vr) Calculate the process parameters that need to be adjusted through the percentage of difference. The process parameters can include but are not limited to a pressure forming parameter and a temperature forming parameter. The pressure forming parameter can include but is not limited to injection pressure Parameters, holding pressure parameters, V/P switching parameters, injection time parameters, holding pressure time parameters, holding pressure time parameters, or injection speed parameters and injection time parameters, etc.; the temperature forming parameters can include but are not limited to the barrel Temperature parameters, mold temperature parameters, ice water machine temperature parameters, hot glue channel temperature parameters, material pipe feeding speed parameters, or shear rate parameters of melted glue in the material pipe, etc.

In this embodiment, the quality calculation module 20 uses its quality judgment model unit 50 and the material database 22, the pressure forming database 24, the temperature forming database 26, the mold feature database 28, and the quality The relevant feature database 30 is matched to calculate the process parameters that need to be adjusted. At this time, the operator can adjust the process parameters of the injection machine according to the calculation results.

In summary, the operator of the present invention only needs to input the injection molding data into the quality calculation module 20 before the injection molding machine is produced, and obtain the PVT simulation of the good product through the calculation of the quality calculation module 20 The curve and its specific volume simulation parameters (vt), which are the simulated curves and parameters of good products calculated by the quality calculation module 20, and then each time the injection machine is actually produced, the quality calculation module 20 will Calculate the actual PVT curve and its specific volume actual parameter (vr) during the second production, and compare the specific volume simulation parameter (vt) and the specific volume actual parameter (vr). If If the two match, the injection is good, and production can be continued; if the two do not match, the injection is defective. At this time, the operator of the injection machine can immediately check the parameters of the injection machine. Adjust so that the actual specific volume (vr) of subsequent injection is consistent with the specific volume simulation parameter (vt).

In other words, the present invention can effectively monitor the injection quality of the injection molding machine by comparing the actual specific volume parameters (vr) with the specific volume simulation parameters (vt) during each actual injection, and prompt the operation immediately Personnel perform observation or shutdown adjustments. Furthermore, when the specific volume simulation parameter (vt) does not match the specific volume actual parameter (vr), the present invention further performs calculations through the quality calculation module 20, and uses its quality Determine the combination of the model unit 50 and the material database 22, the pressure forming database 24, the temperature forming database 26, the mold feature database 28, and the quality-related feature database 30 to calculate the process to be adjusted Parameters, at this time, the operator can adjust the process parameters of the injection machine according to the calculation result, which improves the accuracy and speed of the operator's adjustment.

Finally, it must be explained again that the control method and system components of the present invention disclosed in the foregoing embodiments are only examples, and are not intended to limit the patent scope of the present invention. Anything that does not deviate from the spirit of the present invention is simple. Structural modification or change, or replacement with other equivalent components should still fall within the scope of the patent application of the present invention.

10: Injection molding machine 12: Signal measurement module 20: Quality calculation module 22: Material database 24: Pressure forming database 26: Temperature forming database 28: Mold feature database 30: Quality-related characteristics database 40P: VT curve model unit 50: Quality judgment model unit

The following examples are used in conjunction with the drawings to further illustrate the present invention, in which: Figure 1 is a system architecture diagram of an embodiment of the present invention; Figure 2 is a flowchart of an embodiment of the present invention; FIG. 3 is a schematic diagram of the comparison points of specific volume values in the PVT curve according to an embodiment of the present invention, and mainly shows the positions of the end points and v/P points of the PVT curve.

10: Injection molding machine

12: Signal measurement module

20: Quality calculation module

22: Material database

24: Pressure forming database

26: Temperature forming database

28: Mold feature database

30: Quality-related characteristics database

40: PVT curve model unit

50: Quality judgment model unit

Claims (21)

An injection quality control method for an injection molding machine, which includes: Input an injection molding data, and calculate through a quality calculation module to obtain a PVT simulation curve, and obtain a specific volume simulation parameter (vt) from the PVT simulation curve; Calculate through the quality calculation module to obtain a PVT actual curve when an injection molding machine is actually injected, and obtain a specific volume actual parameter (vr) from the PVT actual curve; and Compare the specific volume simulation parameter (vt) with the actual specific volume parameter (vr). If the two match, the injection system is good; if the two do not match, the injection system is not. Good product, and adjust the process parameters of the injection molding machine during the injection process to make the actual specific volume parameters (vr) of subsequent injection consistent with the specific volume simulation parameters (vt). For example, the method described in item 1 of the scope of patent application, wherein the specific volume simulation parameter (vt) is an interval range, and when the specific volume actual parameter (vr) is within the interval range, the injection system is Good product. Such as the method described in item 2 of the scope of patent application, wherein, if the specific volume simulation parameter (vt) does not match the specific volume actual parameter (vr), the quality calculation module will calculate the specific volume simulation parameter ( vt) and the actual parameter (vr) of the specific volume difference percentage, and then through the difference percentage calculation process parameters to be adjusted. The method described in item 3 of the scope of patent application, wherein the specific volume simulation parameter (vt) and the specific volume actual parameter (vr) are compared with the specific volume value at the end point of the PVT curve. . The method described in item 3 of the scope of the patent application, wherein the specific volume simulation parameter (vt) is compared with the specific volume actual parameter (vr) for the end point of the PVT curve and the v/P point Compare the specific volume values. For example, the method described in item 4 or item 5 of the scope of patent application, wherein the quality calculation module includes a PVT curve model unit, and the PVT curve model unit is used to obtain the PVT simulation curve and the specific volume simulation parameter ( vt). The method described in item 6 of the scope of patent application, wherein the actual PVT curve and the actual specific volume parameter (vr) are obtained by synchronously measuring the real-time pressure and real-time temperature during the actual injection process of the injection molding machine , And the real-time pressure and the real-time temperature are transmitted to the quality calculation module, and then calculated by the quality calculation module. For the method described in item 7 of the scope of patent application, wherein the quality calculation module includes a quality judgment model unit, and the quality calculation module obtains the actual PVT curve and the ratio through the calculation of the quality judgment model unit The actual parameters (vr). The method described in item 8 of the scope of patent application, wherein the injection molding machine includes a signal measurement module, the signal measurement module measures the real-time pressure through a pressure sensor, and the pressure sensor is set in Any position of the injection molding machine, such as the ejector pin, the front end of the material tube, the glue inlet, the gate, the near gate, the end position of the filling in the mold, and the flow direction of the melt through the filling in the mold. The method described in item 8 of the scope of patent application, wherein the injection molding machine includes a signal measurement module, the signal sensor module measures the real-time temperature through a temperature sensor, and the temperature sensor is set Fill any position such as the end position, thimble or material tube in the mold. The method described in item 8 of the scope of patent application, wherein the specific volume simulation parameter (vt) and the specific volume actual parameter (vr) are compared through the quality judgment model unit of the quality calculation module. For the method described in item 8 of the scope of patent application, wherein the quality calculation module includes a material database, a pressure forming database and a temperature forming database, and the quality judgment model unit is based on the difference percentage and the The material database, the pressure forming database and the temperature forming database are calculated to obtain the injection parameters that need to be adjusted. An injection quality control system for an injection molding machine, which includes: An injection molding machine; and A quality calculation module is electrically connected to the injection molding machine. The quality calculation module includes a PVT curve model unit and a quality judgment model unit. The PVT curve model unit performs calculations based on inputted injection molding data. A PVT simulation curve and a specific volume simulation parameter (vt) are obtained. The quality judgment model unit calculates according to the actual injection situation of the injection molding machine to obtain a PVT actual curve, and obtains a specific volume actual from the PVT actual curve Parameter (vr), and the quality judgment model unit performs a comparison operation between the actual specific volume parameter (vr) and the specific volume simulation parameter (vt). For example, the system described in item 13 of the scope of patent application, wherein the quality calculation module is assembled in the injection molding machine, or is installed in the remote or cloud and communicates with the injection molding machine through wired or wireless communication. connection. For example, in the system described in item 14 of the scope of patent application, the quality computing module is one of a desktop computer, a notebook computer, or a smart handheld electronic device. For example, the system described in item 14 of the scope of patent application, wherein the quality calculation module further includes a material database, a pressure forming database and a temperature forming database, and the databases are electrically connected to the PVT curve The model unit and the quality judgment model unit. The system described in item 16 of the scope of patent application, wherein the material database includes data of a molten state material property parameter, a solid material property parameter data, a glass transition temperature data, a glass transition temperature relative pressure The data and the data of a material shrinkage rate. For example, the system described in item 16 of the scope of patent application, wherein the pressure forming database contains data on injection pressure, data on holding pressure, data on V/P switching parameters, data on injection time, and Data on pressing time, data on holding time, data on injection speed, and data on injection time. For example, the system described in item 16 of the scope of patent application, wherein the temperature forming database contains data of a barrel temperature, a mold temperature, a chiller, a hot glue channel temperature, and a material The data of the pipe feeding speed and the data of the shear rate of the melted glue in the material pipe. The system described in item 14 of the scope of patent application, wherein the injection molding machine includes a signal measurement module, the signal measurement module includes a pressure sensor, and the pressure sensor is provided in the injection molding machine The ejector pin, the front end of the material pipe, the glue inlet, the gate, near the gate, the end position of the filling in the mold, and the flow direction of the melt through the filling in the mold. The system described in item 14 of the scope of patent application, wherein the injection molding machine includes a signal measurement module, the signal measurement module includes a temperature sensor, and the temperature sensor is provided in the injection molding machine The ejector pin, the front end of the material pipe, the glue inlet, the gate, near the gate, the end position of the filling in the mold, and the flow direction of the melt through the filling in the mold.

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