TWI735327B - Control method of electric injection-molding machine - Google Patents
Control method of electric injection-molding machine Download PDFInfo
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本案屬於塑膠射出成型機領域,尤指一種全電式塑膠射出成型機的控制方法。 This case belongs to the field of plastic injection molding machines, especially a control method for an all-electric plastic injection molding machine.
近年來,隨著環保意識逐漸受到重視,使得許多產業設備有很大的變遷,而射出成型產業的製程設備演進則成為一項明顯的例子,由過去普遍的液壓式設備轉換為較具環保概念的全電式設備。顧名思義,全電式塑膠射出成型機的動力系統全以電動馬達驅動,也就是以伺服馬達或感應馬達來取代原有之油壓缸或氣壓缸。全電式塑膠射出成型機具有快速、精準、穩定、安靜、省電、潔淨等特性,堪稱塑膠射出成型機革命性的里程碑。因此,全電式塑膠射出成型機的應用市場相當廣泛,舉凡從一般民生工業用品(例如,矽膠類產品、PET容器、汽機車零件、化妝品容器、家庭用容器、精密齒輪...等),進而以全電式塑膠射出成型機之快速、穩定、安靜的優勢應用於精密射出市場(例如,半導體元件、資訊電腦產品、光學鏡片、液晶導光板、IC卡、電子材料元件...等),似乎是無所不括。目前在全電式塑膠射出成型機的運作流程中,射膠保壓階段以及儲料計量階段都需應用到屬於壓力感測器之荷重元(load cell),即 全電式塑膠射出成型機會藉由荷重元感測料管將塑料推出時之壓力,並依據荷重元所回授的壓力感測值來對應調整控制策略。 In recent years, as the awareness of environmental protection has gradually received attention, many industrial equipment have undergone great changes, and the evolution of process equipment in the injection molding industry has become an obvious example. The general hydraulic equipment in the past has been converted to a more environmentally friendly concept. Of all-electric equipment. As the name suggests, the power system of the all-electric plastic injection molding machine is driven by electric motors, which means that the original hydraulic or pneumatic cylinders are replaced by servo motors or induction motors. The all-electric plastic injection molding machine has the characteristics of fast, accurate, stable, quiet, power saving, and clean, which can be called a revolutionary milestone for the plastic injection molding machine. Therefore, the application market of all-electric plastic injection molding machines is quite extensive, from general industrial products (for example, silicone products, PET containers, auto parts, cosmetic containers, household containers, precision gears, etc.), Furthermore, with the advantages of fast, stable and quiet all-electric plastic injection molding machine, it is applied to the precision injection market (for example, semiconductor components, information computer products, optical lenses, liquid crystal light guide plates, IC cards, electronic material components... etc.) , Seems to be all-encompassing. At present, in the operation process of the all-electric plastic injection molding machine, the pressure-holding phase of the plastic injection and the material storage metering phase need to be applied to the load cell belonging to the pressure sensor, namely The all-electric plastic injection molding machine uses the load cell to sense the pressure when the plastic is pushed out by the barrel, and adjust the control strategy accordingly based on the pressure sensing value returned by the load cell.
然而由於全電式塑膠射出成型機通常需要用到4台以上的大瓦特數的伺服驅動器及伺服馬達,故成本的壓力非常大,所以降低成本是全電式塑膠射出成型機非常重要的一環。目前部分業者考慮拿掉荷重元來達到節省成本之目的,然而如何使不具有荷重元之全電式塑膠射出成型機仍具有不錯的壓力控制,以維持射出效果則為目前的研發重點。 However, since the all-electric plastic injection molding machine usually requires more than 4 high-wattage servo drives and servo motors, the cost pressure is very high, so reducing the cost is a very important part of the all-electric plastic injection molding machine. At present, some companies are considering removing the load cell to achieve cost savings. However, how to make the all-electric plastic injection molding machine without the load cell still have good pressure control to maintain the injection effect is the current research and development focus.
本案之目的在於提供一種全電式塑膠射出成型機的控制方法,俾使全電式塑膠射出成型機無需荷重元而節省生產成本,同時保持不錯的射出效果。 The purpose of this case is to provide a control method for an all-electric plastic injection molding machine, so that the all-electric plastic injection molding machine does not require a load element and saves production costs while maintaining a good injection effect.
為達上述目的,本案之一較廣實施態樣為提供一種控制方法,應用於全電式塑膠射出成型機,全電式塑膠射出成型機包含射膠馬達、減速機構、射膠螺桿、料管及射嘴,減速機構利用減速比而提高射膠馬達之扭力,射膠螺桿由射膠馬達經由減速機構所輸出之扭力帶動而旋轉及移動,進而推動料管將於料管內之塑料轉為熔膠,並自射嘴射出,控制方法包含:S1於全電式塑膠射出成型機運作時,採樣射膠馬達所接收之驅動電流,以得到第一電流值;S2計算操作電流值,其中操作電流值至少包含射膠馬達進行轉速控制時所需的電流;S3將第一電流值減去操作電流值,以得到第二電流值;以及S4將第二電流值換算成射膠螺桿給予料管的推力,並根據料管的截面積將推力換算成反映射嘴之前端壓力之推估值。 In order to achieve the above purpose, one of the broader implementation aspects of this case is to provide a control method which is applied to an all-electric plastic injection molding machine. The all-electric plastic injection molding machine includes an injection motor, a reduction mechanism, an injection screw, and a barrel. And the nozzle, the reduction mechanism uses the reduction ratio to increase the torque of the injection motor. The injection screw is driven by the torque output from the injection motor through the reduction mechanism to rotate and move, thereby pushing the barrel to turn the plastic in the barrel into The glue is melted and ejected from the nozzle. The control method includes: S1 samples the drive current received by the plastic injection motor when the all-electric plastic injection molding machine is operating to obtain the first current value; S2 calculates the operating current value, where the operation The current value includes at least the current required for the speed control of the rubber injection motor; S3 subtracts the operating current value from the first current value to obtain the second current value; and S4 converts the second current value into the injection screw to feed the barrel According to the cross-sectional area of the material pipe, the thrust is converted into an estimated value of the pressure at the front end of the reverse mapping nozzle.
1:全電式塑膠射出成型機 1: All-electric plastic injection molding machine
10:馬達驅動器 10: Motor driver
11:射膠馬達 11: Injection motor
12:減速機構 12: Deceleration mechanism
13:射膠螺桿 13: Injection screw
14:料管 14: Material pipe
15:射嘴 15: Shooting mouth
i:驅動電流 i: drive current
S1~S4:控制方法的步驟 S1~S4: Steps of the control method
第1圖為本案第一較佳實施例之全電式塑膠射出成型機的控制方法的步驟流程示意圖;第2圖為第1圖所述之控制方法所應用之全電式塑膠射出成型機的簡易元件結構示意圖;第3圖係為傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力,與本案之全電式塑膠射出成型機利用第1圖所示之控制方法所估測出的射嘴的前端壓力兩者之間的比較示意圖;第4圖係為本案第二較佳實施例之全電式塑膠射出成型機的控制方法的步驟流程示意圖;第5圖係為傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力,與本案之全電式塑膠射出成型機利用第4圖所示之控制方法所估測出的射嘴的前端壓力兩者之間的比較示意圖;第6圖為本案之全電式塑膠射出成型機之射膠馬達運轉時所被施加之阻尼力與射膠馬達之轉動速度的關係示意圖;第7圖為本案之全電式塑膠射出成型機之射膠馬達運轉時所被施加之動摩擦力與射膠馬達之轉動速度的關係示意圖;第8圖為具荷重元之傳統全電式塑膠射出成型機進行200模的射出成型實驗時,模次與重量的關係示意圖; 第9圖為第2圖所示之全電式塑膠射出成型機在使用第4圖所示之控制方法下,且進行200模的射出成型實驗時,模次與重量的關係示意圖。 Figure 1 is a step flow diagram of the control method of the all-electric plastic injection molding machine according to the first preferred embodiment of the present invention; Figure 2 is the all-electric plastic injection molding machine used in the control method described in Figure 1 Schematic diagram of simple component structure; Figure 3 is the traditional all-electric plastic injection molding machine using the load cell to sense the tip pressure of the nozzle, and the all-electric plastic injection molding machine in this case uses the control method shown in Figure 1 A schematic diagram of the comparison between the estimated front end pressure of the nozzle; Figure 4 is a schematic diagram of the step flow diagram of the control method of the all-electric plastic injection molding machine according to the second preferred embodiment of this project; Figure 5 is This is the front end pressure of the nozzle sensed by the traditional all-electric plastic injection molding machine using the load cell, and the front end of the nozzle estimated by the all-electric plastic injection molding machine in this case using the control method shown in Figure 4 Comparison diagram between the two pressures; Figure 6 is a schematic diagram of the relationship between the damping force applied to the injection motor of the all-electric plastic injection molding machine in operation and the rotation speed of the injection motor; Figure 7 is the case Schematic diagram of the relationship between the dynamic friction applied by the injection motor of the all-electric plastic injection molding machine and the rotation speed of the injection motor; Figure 8 is a traditional all-electric plastic injection molding machine with a load cell for 200 molds Schematic diagram of the relationship between mold number and weight during the injection molding experiment; Figure 9 is a schematic diagram of the relationship between the number of molds and the weight of the all-electric plastic injection molding machine shown in Figure 2 when the control method shown in Figure 4 is used and the 200-mold injection molding experiment is performed.
體現本案特徵與優點的一些典型實施例將在後段的說明中詳細敘述。應理解的是本案能夠在不同的態樣上具有各種的變化,其皆不脫離本案的範圍,且其中的說明及圖示在本質上當作說明之用,而非架構於限制本案。 Some typical embodiments embodying the features and advantages of this case will be described in detail in the following description. It should be understood that the case can have various changes in different aspects, which do not depart from the scope of the case, and the descriptions and diagrams therein are essentially for illustrative purposes, rather than being constructed to limit the case.
請參閱第1圖及第2圖,其中第1圖為本案第一較佳實施例之全電式塑膠射出成型機的控制方法的步驟流程示意圖,第2圖為第1圖所述之控制方法所應用之全電式塑膠射出成型機的簡易元件結構示意圖。如第1圖及第2圖所示,本實施例之控制方法可應用於全電式塑膠射出成型機1中,且可分別於全電式塑膠射出成型機1運作於射出階段以及儲料計量階段時執行,其中全電式塑膠射出成型機1的結構與運作皆與一般廣泛運用的全電式塑膠射出成型機1的結構相仿,僅差異在應用本實施例之控制方法之全電式塑膠射出成型機1無須具有荷重元,故於第2圖中,僅對與本實施例之控制方法具有相關性的全電式塑膠射出成型機1的部分元件結構進行標示,並不對全電式塑膠射出成型機1的細部結構及整體運作進行描述。
Please refer to Figure 1 and Figure 2. Figure 1 is a schematic diagram of the step flow diagram of the control method of the all-electric plastic injection molding machine according to the first preferred embodiment of the present invention. Figure 2 is the control method described in Figure 1 A schematic diagram of the simple component structure of the all-electric plastic injection molding machine used. As shown in Figures 1 and 2, the control method of this embodiment can be applied to the all-electric plastic
於本實施例中,全電式塑膠射出成型機1主要包含馬達驅動器10、射膠馬達11、減速機構12、射膠螺桿13、料管14及射嘴15。馬達驅動器10用以提供驅動電流i驅動射膠馬達11運作,並依據全電式塑膠射出成型機1之內部的檢測元件(未圖示)以回授方式傳來之關於全電式塑膠射出成型機1的運作參數,例如驅動電流i等等,而對應調整驅動電流i。減速機構12與射膠馬達11連接,且具有
一減速比,減速機構12可利用減速比而達到使射膠馬達11降轉速但提高扭力之目的。料管14與射嘴15連接,且可填充塑料。射膠螺桿13與減速機構12及料管14連接,射膠螺桿13可由射膠馬達11經由減速機構12所輸出之扭力帶動而進行前後移動,進而推動塑料於料管14中經熔融轉為熔膠後,再以移動之方式使該熔膠自與料管14連接的射嘴15射出至模具(未圖示)。
In this embodiment, the all-electric plastic
本實施例之控制方法可由馬達驅動器10來執行,而該控制方法的原理主要為由於射膠馬達11所接收之驅動電流i的回授值包含了相當多的資訊,其中之一資訊即為射嘴15之前端壓力,而此壓力數值傳統是由荷重元進行檢測,而為了達到拿掉荷重元以節省全電式塑膠射出成型機1之成本之目的,本實施例之控制方法即架構於從射膠馬達11所接收之驅動電流i中將射嘴15之前端壓力分離出來,如此一來,即可根據所分離出射嘴15之前端壓力而對應調整全電式塑膠射出成型機1之運作。
The control method of this embodiment can be executed by the
因此本實施例之控制方法即為先實施步驟S1,於全電式塑膠射出成型機1運作時,經由回授方式採樣射膠馬達11所接收之驅動電流i,以得到第一電流值。
Therefore, in the control method of this embodiment, step S1 is implemented first. When the all-electric plastic
接著,執行步驟S2,計算並取得一操作電流值,其中操作電流值至少包含對射膠馬達11進行轉速控制時所需的電流。由於在射膠馬達11所接收之驅動電流i中,佔比例最大的電流成分為讓射膠馬達11進行加速或減速時所需的電流,而為了準確地估測出射嘴15之前端壓力,必須優先從驅動電流i中剔除讓射膠馬達11進行加速或減速時所需的電流,因此在步驟S2中,是透過射膠馬達11的轉動速度,例如加速度,而計算出射膠馬達11在進行加速或減速所需要的電
流,其中。射膠馬達11的轉動速度的單位為rad/sec。接著,執行步驟S3,將第一電流值減去操作電流值而得到第二電流值。
Then, step S2 is executed to calculate and obtain an operating current value, where the operating current value at least includes the current required for controlling the rotational speed of the
由上述可知,第二電流值的成分實際上已排除了射膠馬達11在進行加速或減速所需要的電流,故第二電流值可較為準確地反映出射嘴15之前端壓力,而本實施例的控制方法在步驟S3的後續步驟即為如何由第二電流值中推估射嘴15之前端壓力。因此當步驟S3執行完後,即執行步驟S4,將第二電流值換算成射膠螺桿13給予料管14的一推力,並根據料管14的截面積將該推力換算成反映射嘴15之前端壓力之推估值。由於料管14與射嘴15連接,又射膠螺桿13可推動塑料於料管14中經熔融轉為熔膠後而由射嘴15射出至模具,故在步驟S4中,依據射膠螺桿13給予料管14的推力及料管14的截面積即可得知射嘴15之前端壓力之推估值。
It can be seen from the above that the component of the second current value actually excludes the current required by the
於上述實施例中,在步驟S2中,可藉由編碼器(未圖示)等來採樣射膠馬達11的位置,並依位置運算出射膠馬達11的加減速α。另外,將射膠馬達11的加減速α乘上射膠馬達11帶動射膠螺桿13的整體慣量J可以得到射膠馬達11加減速所需要的扭力T acc ,即如下述方程式(1)所示:T acc =J*α...(1)。
In the above embodiment, in step S2, the position of the
而方程式(1)中提及之射膠馬達11加減速所需要的扭力T acc ,更可以透過射膠馬達11的扭力常數Kt,去反推算出射膠馬達11進行加減速所需要的電流I acc ,即如下述方程式(2)所示:
另外,在步驟S4中,乃是利用方程式(1)及下述方程式(4)-(6)來推得方程式(7),以利用方程式(7)將第二電流值,即I f ,換算成射膠螺桿13給予料管14的推力,其中方程式(4)-(7)如下所示:I f =I m -I acc ...(4)
In addition, in step S4, equation (1) and the following equations (4)-(6) are used to derive equation (7), so as to use equation (7) to convert the second current value, I f , to The
F=α 1×I f ×Kt...(5) F = α 1 × I f × Kt ... (5)
又在步驟S4中,係利用下述方程式(8)將推力F換算成反映射嘴15之前端壓力之推估值:
另外,於一些實施例中,在步驟S4中,當將推力F換算成反映射嘴15之前端壓力之推估值後,更可進行低通濾波,其中該低通濾波設定截止頻率為5~20hz,而進行低通濾波主要目的在於模擬由射膠馬達11出力至射嘴15產生前端壓力這段的延遲時間。
In addition, in some embodiments, in step S4, after converting the thrust F into an estimated value of the pressure at the front end of the
請參閱第3圖,其係為傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力,與本案之全電式塑膠射出成型機利用第1圖所示之控制方法所估測出的射嘴的前端壓力兩者之間的比較示意圖。如圖所示,線條顏色相對較深的代表傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力,於圖中標示為a,線條顏色相對較淺的代表本案之全電式塑膠射出成型機利用第1圖所示之控制方法所估測出的射嘴15的前端壓力之推估值,即步驟S4中所得到之射嘴的前端壓力之推估值,於圖中標示為b,而虛框I表示為全電式塑膠射出成型機運作於射膠保壓階段,虛框II表示為全電式塑膠射出成型機運作於儲料計量階段。由第3圖可知,因虛框I及虛框II中之線條b的波型實際上已接近線條a的波型,故代表本案第一較佳實施例之控制方法所估測出的射嘴15的前端壓力之推估值確實已可反映傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力,因此使用本案第一較佳實施例之控制方法之全電式塑膠射出成型機1
便可無須使用荷重元而節省成本,同時可利用射嘴15的前端壓力之推估值而進行對應的控制,以保持不錯的射出效果。
Please refer to Figure 3, which is the traditional all-electric plastic injection molding machine using the load cell to sense the tip pressure of the nozzle, and the all-electric plastic injection molding machine in this case uses the control method shown in Figure 1. A schematic diagram of the comparison between the estimated tip pressure of the nozzle. As shown in the figure, the line with a relatively dark color represents the front end pressure of the nozzle sensed by the traditional all-electric plastic injection molding machine using a load cell, which is marked as a in the figure, and the line with a relatively light color represents the whole of the case. The estimated value of the tip pressure of the
然而由於第3圖之虛框II中的線條a與線條b兩者間仍存在較大偏移值(offset),因此為了可更準確地估測出的射嘴15的前端壓力,本案之第二較佳實施例之控制方法將進一步從驅動電流i中剔除射膠馬達11運轉時所被施加的阻尼力與動摩擦力的影響(為了簡化第二實施例之控制方法的運算式,本案第二實施例之控制方法忽略靜摩擦力,將動摩擦力視為固定的力,且將阻尼力視為線性且與射膠馬達11之轉速有關的力),以下將進行說明。
However, because there is still a large offset between the line a and the line b in the virtual box II in Figure 3, in order to more accurately estimate the tip pressure of the
請參閱第4圖及第5圖,其中第4圖係為本案第二較佳實施例之全電式塑膠射出成型機的控制方法的步驟流程示意圖,第5圖係為傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力,與本案之全電式塑膠射出成型機利用第4圖所示之控制方法所估測出的射嘴的前端壓力兩者之間的比較示意圖。如圖所示,本施實施例之控制方法與第1圖所示之控制方法相仿,惟本實施例之控制方法在步驟S2中,操作電流值除了包含射膠馬達11進行轉速控制時所需的電流外,更包含射膠馬達11運轉時所被施加之阻尼力所對應的電流,以及馬達10運轉時所被施加之動摩擦力所對應的電流。因此當執行步驟S3將第一電流值減去操作電流值而得到第二電流值時,第二電流值已排除了射膠馬達11在進行加速或減速所需要的電流、射膠馬達11運轉時所被施加之阻尼力所對應的電流以及馬達10運轉時所被施加之動摩擦力所對應的電流。
Please refer to Figures 4 and 5. Figure 4 is a schematic diagram of the step flow diagram of the control method of the all-electric plastic injection molding machine according to the second preferred embodiment of the present invention. Figure 5 is the traditional all-electric plastic injection Comparison between the nozzle tip pressure sensed by the molding machine using the load cell and the nozzle tip pressure estimated by the all-electric plastic injection molding machine in this case using the control method shown in Figure 4 Schematic. As shown in the figure, the control method of this embodiment is similar to the control method shown in Figure 1. However, in the control method of this embodiment, in step S2, the operating current value except for the
請再參閱第5圖,其中線條顏色相對較深的代表傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力,於圖中標示為a,線條顏色相對較淺的代表本案之全電式塑膠射出成型機利用第4圖所示之控制方法所估測出的射嘴15的前端壓力,即步驟S4中所得到之射嘴15的前端壓力之推估值,於圖中標示為b,而虛框I表示為全電式塑膠射出成型機運作於射膠保壓階段,虛框II
表示為全電式塑膠射出成型機運作於儲料計量階段。由第5圖可知,無論是在虛框I或虛框II中,線條b的波型實際上已接近線條a的波型,且線條a與線條b兩者間的偏移值(offset)已非常小,故代表本案第二較佳實施例之控制方法所估測出的射嘴15的前端壓力之推估值相較於第一較佳實施例之控制方法可更準確地反映傳統全電式塑膠射出成型機利用荷重元感測到之射嘴的前端壓力。
Please refer to Figure 5 again, where the relatively darker line represents the pressure at the front end of the nozzle sensed by the traditional all-electric plastic injection molding machine using the load cell, which is marked as a in the figure, and the relatively lighter line represents The all-electric plastic injection molding machine in this case uses the control method shown in Figure 4 to estimate the tip pressure of the
請參閱第6圖及第7圖,其中第6圖為本案之全電式塑膠射出成型機之射膠馬達運轉時所被施加之阻尼力與射膠馬達之轉動速度的關係示意圖,第7圖為本案之全電式塑膠射出成型機之射膠馬達運轉時所被施加之動摩擦力與射膠馬達之轉動速度的關係示意圖。如圖所示,於第二實施例之控制方法之步驟S2中,由於射膠馬達11運轉時所被施加之阻尼力實際上與射膠馬達11的轉動速度成正比,故當藉由編碼器等採樣到射膠馬達11的轉動速度,即可推得射膠馬達11運轉時所被施加之阻尼力,進而可依據阻尼力換算對應的電流值。同樣地,射膠馬達11運轉時所被施加之動摩擦力實際上亦與射膠馬達11的轉動速度存在關係性,因此藉由編碼器等採樣到射膠馬達11的轉動速度,即可推得射膠馬達11運轉時所被施加之動摩擦力,進而可依據動摩擦力換算對應的電流值。更進一步說明,為了依據阻尼力換算對應的電流值,以及依據動摩擦力換算對應的電流值,可以透過讓射膠馬達11在料管14內無任何塑料的情形下,運行兩種不同的轉速,來得到射膠馬達11在克服阻尼力及動摩擦力所需的電流,而得到克服阻尼力及動摩擦力所需的電流可採用如下所示之方程式(9)-(11):
綜上所述,本案提供一種全電式塑膠射出成型機的控制方法,其係可利用全電式塑膠射出成型機現有的運作參數而準確地估測射嘴之前端壓力,使得使用該控制方法之全電式塑膠射出成型機不但無需設置荷重元而節省成本,同時可保持不錯的射出效果。 In summary, this case provides a control method for an all-electric plastic injection molding machine, which can use the existing operating parameters of the all-electric plastic injection molding machine to accurately estimate the pressure at the front end of the nozzle, so that the control method can be used The all-electric plastic injection molding machine not only saves costs without having to install load cells, but also maintains a good injection effect.
S1~S4:控制方法的步驟 S1~S4: Steps of the control method
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TW548148B (en) * | 2000-01-12 | 2003-08-21 | Mitsubishi Electric Corp | Thrust converter, and method and device for controlling the thrust converter |
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