CN117183265A - Intelligent die terminal - Google Patents
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- CN117183265A CN117183265A CN202311043016.6A CN202311043016A CN117183265A CN 117183265 A CN117183265 A CN 117183265A CN 202311043016 A CN202311043016 A CN 202311043016A CN 117183265 A CN117183265 A CN 117183265A
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Abstract
The invention provides a mold intelligent terminal which is detachably arranged on an injection mold and comprises a sensor parameter acquisition module, an injection molding machine parameter interaction module and a processing unit. The sensor parameter acquisition module is configured to be in communication connection with a sensor system arranged on the injection mold and is used for acquiring sensor parameters perceived by the sensor system; the injection molding machine parameter interaction module is configured to be in communication connection with an injection molding machine and is used for carrying out interaction of production process parameters with the injection molding machine; when the processing unit determines that the sensor parameters are abnormal by comparing the sensor parameters acquired by the sensor parameter acquisition module with the preset standard parameter range, the processing unit adjusts the production process parameters received from the injection molding machine parameter interaction module according to the preset parameter adjustment rule, and feeds the adjusted production process parameters back to the injection molding machine through the injection molding machine parameter interaction module.
Description
Technical Field
The invention relates to the technical field of injection molds, in particular to an intelligent terminal of a mold.
Background
The mold is called an industrial master, plays an extremely important role in modern industrial production, and many parts are not separated from the mold in the household electrical appliance production process. Because of the important role of the mold in the production process, production management personnel are required to accurately grasp information such as the use times of each mold at any time.
The existing mold management terminals comprise mold management terminals realized based on RFID technology and also comprise mold management terminals realized through physical switch technology. But can not realize the functions of information reading and storage and data conversion of the injection molding process of the mold and can not play a technical guiding role in the production activity of the product.
In view of this, the present invention has been made.
Disclosure of Invention
The invention aims to solve the technical problems of at least overcoming the defects of the prior art, and providing the intelligent die terminal, wherein a sensor parameter acquisition module and an injection molding machine parameter interaction module are embedded into the intelligent die terminal, and when the sensor parameter acquired by the sensor parameter acquisition module is compared with a preset standard parameter range by utilizing a processing unit of the intelligent die terminal to determine that the sensor parameter is abnormal, the received production process parameter is adjusted according to a preset parameter adjustment rule, and the adjusted production process parameter is fed back to the injection molding machine, so that the integration level of the intelligent die terminal is improved.
In order to solve the technical problem, the invention provides a mold intelligent terminal detachably mounted on an injection mold, the mold intelligent terminal comprises:
the sensor parameter acquisition module is configured to be in communication connection with a sensor system arranged on the injection mold and is used for acquiring sensor parameters perceived by the sensor system;
The injection molding machine parameter interaction module is configured to be in communication connection with an injection molding machine and is used for carrying out interaction of production process parameters with the injection molding machine;
the processing unit is connected with the sensor parameter acquisition module and the injection molding machine parameter interaction module,
when the processing unit determines that the sensor parameters are abnormal by comparing the sensor parameters acquired by the sensor parameter acquisition module with a preset standard parameter range, the processing unit adjusts the production process parameters received from the injection molding machine parameter interaction module according to a preset parameter adjustment rule, and feeds the adjusted production process parameters back to the injection molding machine through the injection molding machine parameter interaction module.
In some embodiments, the processing unit sends out a reminding signal when determining that the sensor parameter is abnormal by comparing the sensor parameter collected by the sensor parameter collection module with a preset standard parameter range.
In some embodiments, the sensor system includes a pressure sensor and a temperature sensor disposed within the injection mold cavity for sensing a cavity pressure and a cavity temperature within the injection mold cavity.
In some embodiments, the sensor system includes a temperature and humidity sensor and a dew point sensor disposed on the injection mold housing for collecting the temperature, humidity and dew point of the environment in which the injection mold is located.
In some embodiments, the mold intelligent terminal further comprises:
the data communication module is used for being in communication connection with an external data terminal; and
the mould moving process parameter determining module is provided with a mould moving process parameter determining program in advance;
and the processing unit receives the data required by the mold shifting process parameter determining program through the data communication module, invokes the mold shifting process parameter determining program in the mold shifting process parameter determining module to process the received data to obtain mold shifting process parameters, and sends the mold shifting process parameters to the injection molding machine after mold shifting through the injection molding machine parameter interaction module.
In some embodiments, the mold intelligent terminal further comprises:
the debugging process parameter determining module is preset with a debugging process parameter determining program;
after the processing unit determines the moving mold process parameters, a debugging process parameter determining program in the debugging process parameter determining module is called to process the moving mold process parameters to obtain debugging process parameters, and the debugging process parameters are sent to the injection molding machine after moving mold through the injection molding machine parameter interaction module.
In some embodiments, the mold intelligent terminal further comprises:
the test process parameter determining module is preset with a test process parameter determining program;
and the processing unit receives input data which is transmitted by the external data terminal and is required by the test process parameter determining program through the data communication module, invokes the test process parameter determining program in the test process parameter determining module to process the input data to obtain test process parameters, and transmits the test process parameters to the external data terminal through the data communication module.
In some embodiments, the mold intelligent terminal further comprises:
the anti-falling sensing module is used for generating a falling signal when detecting that the intelligent terminal of the die is separated from the injection molding;
the processing unit is connected with the anti-falling sensing module and sends out a reminding signal when receiving the falling signal.
In some embodiments, the mold intelligent terminal further comprises:
the mold closing sensing module is used for generating a mold closing signal when detecting that the injection mold performs mold closing operation;
The processing unit is connected with the die closing sensing module, and counts the die closing period and the die closing times when the die closing signal is received.
In some embodiments, the mold intelligent terminal further comprises:
and the plan supervision module is connected with the processing unit and is configured to monitor the production cycle of the injection mold and the reject ratio of the injection mold production product through the mold closing cycle and the mold closing times counted by the processing unit, and send the production cycle and the reject ratio to the production informatization management system.
By adopting the technical scheme, compared with the prior art, the invention has the following beneficial effects.
(1) According to the invention, the intelligent terminal of the mold is provided with the sensor parameter acquisition module for acquiring the sensor parameters of the injection mold and the injection molding machine parameter interaction module for interacting production process parameters with the injection molding machine, the processing unit is used for comparing the sensor parameters with the preset standard parameter range, when the sensor parameters are determined to be abnormal, the production process parameters received from the injection molding machine parameter interaction module are adjusted according to the preset parameter adjustment rule, and the adjusted production process parameters are sent to the injection molding machine through the injection molding machine parameter interaction module to be used for guiding the production activities of products.
(2) According to the invention, the mold testing process parameter determining module is embedded into the mold intelligent terminal, and the processing unit of the mold intelligent terminal is utilized to execute the mold testing process parameter determining program in the mold testing process parameter determining module, so that the mold testing process parameter is obtained, the integration level of the mold intelligent terminal is improved, and the equipment cost required by the mold testing process parameter determining program is reduced.
(3) According to the invention, the mold shifting process parameter determining module and the debugging process parameter determining module are embedded into the mold intelligent terminal, so that an external device is not required to execute a mold shifting process parameter determining program and a debugging process parameter determining program, and the equipment cost is reduced.
(4) The invention is used for providing data support for the production informatization management system by configuring the planning supervision module for the intelligent terminal of the die, so that the production informatization management system is convenient for preparing materials for the next activity of producing products.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention. It is evident that the drawings in the following description are only examples, from which other drawings can be obtained by a person skilled in the art without the inventive effort. In the drawings:
Fig. 1 is a schematic view of a mold intelligent terminal provided according to a first exemplary embodiment of the present invention;
FIG. 2 is a flow chart of a method of deriving a tuning process parameter according to an exemplary embodiment of the invention;
FIG. 3 is a flow chart of a method of obtaining a standard parameter range;
fig. 4 is a flowchart of step S310 according to an exemplary embodiment of the present invention;
fig. 5 is a flowchart of step S330 according to an exemplary embodiment of the present invention;
fig. 6 is a flowchart of step S220 according to an exemplary embodiment of the present invention;
fig. 7 is a schematic diagram of a mold intelligent terminal provided according to a second exemplary embodiment of the present invention;
in the figure: 100. a die intelligent terminal; 101. a processing unit; 102. a test mold process parameter determining module; 103. a data communication module; 104. A sensor parameter acquisition module; 105. The injection molding machine parameter interaction module; 106. a mould moving process parameter determining module; 107. A debugging process parameter determining module; 108. An anti-falling sensing module; 109. the die assembly sensing module; 110. a planning supervision module;
20. an external data terminal; 30. a sensor system; 40. an injection molding machine; 50. and a production informatization management system.
It should be noted that these drawings and the written description are not intended to limit the scope of the inventive concept in any way, but to illustrate the inventive concept to those skilled in the art by referring to the specific embodiments.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions in the embodiments will be clearly and completely described with reference to the accompanying drawings in the embodiments of the present invention, and the following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.
In the description of the present invention, it should be noted that the directions or positional relationships indicated by the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention.
Fig. 1 illustrates a structure of a mold intelligent terminal 100 provided according to a first exemplary embodiment of the present invention. The mold intelligent terminal 100 is detachably installed on the injection mold. The injection mold may be selected to be used for manufacturing an integrally formed housing or component, such as an injection mold for manufacturing a cell phone case, or an injection mold for manufacturing an automobile component, and it should be understood that the injection mold is any mold structure for manufacturing an integrally formed component, which is not limited in this regard.
As shown in fig. 1, the mold intelligent terminal 100 includes a processing unit 101, a data communication module 103, a sensor parameter acquisition module 104, and an injection molding machine parameter interaction module 105.
Wherein the sensor parameter acquisition module 104 is configured to be in communication with the sensor system 30 disposed on the injection mold for acquiring sensor parameters sensed by the sensor system 30. Optionally, the sensor system 30 includes a pressure sensor and a temperature sensor disposed in the injection mold cavity for sensing a cavity pressure and a cavity temperature in the injection mold cavity.
The sensor system 30 further comprises a temperature and humidity sensor and a dew point sensor arranged on the injection mold shell and used for collecting the temperature, humidity and dew point of the environment where the injection mold is located. This is because, when precision injection molding is performed, there is a strict requirement on whether the surrounding environment can meet a production standard, so that it is necessary to debug the injection molding process parameters of the injection molding machine based on the temperature, humidity and dew point of the environment in which the injection mold is located. For example, when the temperature of cooling water on an injection mold is extremely low, the situation of water condensation occurs in an environment with high temperature and high humidity, and the preset product produced under the situation can have the problems of air marks, water marks and the like.
Still optionally, the sensor system 30 further includes a flow sensor, a barometric pressure sensor, and a temperature sensor probe disposed on the injection mold. The flow sensor, the air pressure sensor and the temperature sensing detector are respectively used for collecting cooling water flow, hot runner air pressure and hot runner temperature in the injection mold.
The processing unit 101 sends out a reminding signal when determining that the sensor parameter is abnormal by comparing the sensor parameter acquired by the sensor parameter acquisition module 104 with a preset standard parameter range.
The standard parameter range here refers to a parameter range corresponding to the sensor parameter. For example, corresponding to the cavity pressure and cavity temperature are a standard cavity pressure range and a standard cavity temperature range. Corresponding to the temperature, humidity and dew point of the environment in which the injection mold is located is a standard ambient temperature range, a standard ambient humidity range, and a standard ambient dew point range. Corresponding to the cooling water flow rate, hot runner pressure, and hot runner temperature are a standard cooling water flow rate range, a standard hot runner pressure range, and a standard hot runner temperature range.
The standard parameter ranges may form a standard curve. For example, a standard mold cavity pressure range and a standard mold cavity temperature range may form a standard pressure curve and a standard temperature curve. The standard ambient temperature range, the standard ambient humidity range, and the standard ambient dew point range may form a standard ambient temperature curve, a standard ambient humidity curve, and a standard ambient dew point curve.
Because the data collected by the pressure sensor, the temperature and humidity sensor, the dew point sensor, the flow sensor, the air pressure sensor and the temperature sensor in the die cavity are directly collected from the injection die of the produced preset product, no kinetic energy loss exists, and therefore, the die parameter range of the qualified product can be used as an index for representing whether the preset product produced by the injection molding machine is the qualified product. In other words, the standard curve is a sample directly contacted with the product, and has uniqueness, so long as the curve for confirming the mold parameters is the standard curve corresponding to the qualified product, the produced product is necessarily a qualified product.
When the processing unit 101 determines that the sensor parameters acquired by the sensor parameter acquisition module 104 exceed the preset standard parameter range, which means that the working condition of the injection mold at the moment cannot produce qualified products, the processing unit 101 sends out a reminding signal to remind a technician to adjust the parameters of the injection molding machine and the injection mold.
As an example, when it is determined from the data sensed by the flow sensor that the reynolds number of the cooling water path is lower than the turbulence level, this means that the heat carrying capacity of the cooling water path is insufficient, and it is necessary to remind the technician to increase the water pressure or check the water path.
When the air pressure sensor detects that the air pressure is insufficient, the air pressure sensor sends out an air pressure shortage reminding, so that the problem that the valve needle cannot be completely opened or closed due to insufficient air pressure of the hot runner air valve is prevented.
And when the temperature of the hot runner is found to be abnormal by using the temperature sensing detector, a reminding signal is sent out. For example, when the temperature does not reach the standard, the feedback is to wait for heating, and when the temperature exceeds the standard, whether the problem of material decomposition and the like can be caused is sent, and a reminding signal of the problem of the hot runner is checked in time.
The injection molding machine parameter interaction module 105 is configured to be communicatively coupled to the injection molding machine 40 for interaction of production process parameters with the injection molding machine 40. When the processing unit 101 determines that the sensor parameter is abnormal by comparing the sensor parameter acquired by the sensor parameter acquisition module 104 with a preset standard parameter range, the processing unit adjusts the production process parameter received from the injection molding machine parameter interaction module 105 according to a preset parameter adjustment rule, and feeds back the adjusted production process parameter to the injection molding machine 40 through the injection molding machine parameter interaction module 105.
Specifically, the preset parameter adjustment rule may be stored in advance in the database of the processing unit 101, or may be stored in advance in a cloud communicatively connected to the processing unit 101. When the processing unit 101 determines that the sensor parameter acquired by the sensor parameter acquisition module 104 exceeds the preset standard parameter range, which means that the working condition of the injection mold at the moment cannot produce a qualified product, the processing unit 101 invokes the preset parameter adjustment rule and adjusts the production process parameter of the injection molding machine 40 according to the preset parameter adjustment rule, and then the adjusted production process parameter is fed back to the injection molding machine 40 through the injection molding machine parameter interaction module 105, so that the injection molding machine 40 adopts the adjusted production process parameter to produce the qualified product, and the qualification rate of the product is ensured.
In some embodiments, the mold intelligent terminal 100 further includes a mold shifting process parameter determining module 106, and referring to fig. 1, a mold shifting process parameter determining program is preset in the mold shifting process parameter determining module 106. After receiving the data required by the mold shifting process parameter determining program through the data communication module 103, the processing unit 101 invokes the mold shifting process parameter determining program in the mold shifting process parameter determining module 106 to process the received data to obtain mold shifting process parameters, and sends the mold shifting process parameters to the injection molding machine 40 after mold shifting through the injection molding machine parameter interaction module 105.
The moving of the mold comprises the conditions of changing the injection molding machine, changing the injection mold, manufacturing a new injection mold, leaving a factory and the like.
It will be appreciated that in either case, if the injection molding machine is still performing production activities using the injection molding process parameters prior to mold transfer, the quality of the injection molded product will necessarily be affected. Therefore, after the mold is moved, the injection molding process parameters of the injection molding machine are required to be debugged so as to determine the debugging process parameters required by the injection molding machine when the preset product is produced after the mold is moved, and thus the qualified preset product is produced.
In some embodiments, the data required by the transfer molding process parameter determination program includes historical production process parameters of the historical injection molding machine producing the pre-set product, first device parameters of the historical injection molding machine, and second device parameters of the post-transfer injection molding machine.
The processing unit 101 invokes a process parameter determining program of the process parameter determining module 106, and adjusts the historical production process parameter according to the proportional relationship between the first equipment parameter and the second equipment parameter, so as to obtain the process parameter of the die.
Specifically, the historical production process parameters may, for example, select injection process parameters that were used the last time the historical injection molding machine was used to produce the preset product. The historical production process parameters include historical location parameters and historical injection parameters. The historical location parameter and the historical injection parameter correspond to the initial location parameter and the initial injection parameter. The equipment parameters include, but are not limited to, screw diameter, screw aspect ratio, maximum injection pressure, maximum injection speed, maximum metering, etc.
The historical position parameters may be adjusted according to the ratio of the screw diameter or the ratio of the screw length to the ratio of the screw length in the first device parameter to the ratio of the screw length in the second device parameter to obtain the initial position parameters. The historical injection pressure, the historical injection speed, the historical measurement and the like can be respectively adjusted according to the proportion of the maximum injection pressure, the proportion of the maximum injection speed and the proportion of the maximum measurement in the first equipment parameter and the second equipment parameter so as to obtain the initial injection parameter.
By way of example, the screw diameter of the history injection molding machine is D1, the screw diameter of the injection molding machine after the mold is moved is D2, and it can be determined that the ratio between the cross-sectional area of the screw of the injection molding machine after the mold is moved and the cross-sectional area of the screw of the history injection molding machine is m, m= (D2/D1) 2 . Based on this, the initial position parameter can be obtained by multiplying m on the basis of the history position parameter. For example, the storage position of the history injection molding machine is 90, the storage position of the injection molding machine is adjusted to 90×m after the mold is moved, the advancing speed of the history injection molding machine is 32, and the advancing speed of the injection molding machine is adjusted to 32×m after the mold is moved.
The maximum injection pressure of the history injection molding machine is P1, the maximum injection pressure of the injection molding machine after the mold is moved is P2, and the ratio between the maximum injection pressure of the injection molding machine after the mold is moved and the maximum injection pressure of the history injection molding machine can be determined to be n, wherein n=P2/P1. Based on this, the initial injection pressure can be obtained by multiplying n on the basis of the historical injection pressure. For example, the injection pressure of the historical injection molding machine is 100, and the injection pressure of the injection molding machine is adjusted to 100 x n after the mold is moved.
The maximum injection speed of the history injection molding machine is S1, the maximum injection speed of the injection molding machine after moving the mold is S2, and the ratio between the maximum injection speed of the injection molding machine after moving the mold and the maximum injection speed of the history injection molding machine can be determined to be l, l=S2/S1. Based on this, the initial injection speed can be obtained by multiplying l on the basis of the historical injection speed.
It will be understood that the units of the respective parameters are not limited herein, and that the units of the parameters may be common units in the art. In addition, the foregoing examples are merely illustrative of the present invention and are not to be construed as limiting the scope of the present invention.
It should be noted that, in the case of mold shifting such as the injection mold replacement manufacturer and the shipment of a new injection mold, the history injection molding machine has the same equipment parameters as the injection molding machine after mold shifting. In this case, the historical production process parameters may be used as the transfer process parameters.
In some embodiments, the accuracy of the mold transfer process parameters obtained by calling the mold transfer process parameter determining program in the mold transfer process parameter determining module 106 to process the received data may be low. Based on this, the mold intelligent terminal 100 further includes a debugging process parameter determining module 107, and referring to fig. 1, a debugging process parameter determining program is preset in the debugging process parameter determining module 107. After determining the mold shifting process parameters, the processing unit 101 invokes a debugging process parameter determining program in the debugging process parameter determining module 107 to process the mold shifting process parameters to obtain debugging process parameters, and sends the debugging process parameters to the injection molding machine 40 after mold shifting through the injection molding machine parameter interaction module 105.
The steps of processing the shift model process parameters to obtain the debugging process parameters by the processing unit 101 calling the debugging process parameter determining program in the debugging process parameter determining module 107 are described in detail below.
The invention is first explained with respect to terms referred to herein.
Process parameters: the process parameters refer to parameters set on the injection molding machine.
The historical production process parameters refer to injection process parameters when a qualified preset product is produced by using a historical injection molding machine before moving a mold. From the foregoing explanation of the mold transfer, it will be appreciated herein that "history injection molding machine" does not mean that the injection molding machine must not be employed after the mold transfer. As an example, in the case of mold shifting such as injection mold replacement manufacturers and new injection mold shipment, the previously used injection molding machine is also referred to herein as a history injection molding machine.
The mold shifting process parameters refer to injection process parameters of the injection molding machine 40 when the predetermined product is produced after mold shifting determined before debugging. The debugging process parameters refer to injection molding process parameters of the injection molding machine when the preset product is produced after the mold is moved after the debugging. It can be seen that the production process parameters of the injection molding machine are for the injection molding machine, while the direct contact with the produced preset product is the injection mold. Therefore, the production process parameters cannot be used as an indicator of whether the preset product produced by the injection molding machine is a good product. In other words, the injection process parameters of the injection molding machine are set values instead of actual values, and different pressure losses are caused by wear of the injection molding machine, lubricating oil temperature, weather reasons, which lead to a change in the pressure, speed, acting on the plastic part.
Mold parameters: as previously described herein, the mold parameters refer to sensor parameters acquired using the sensor system 30 provided on the injection mold, and the present invention is not described herein.
Standard parameter range: the standard parameter range refers to a parameter range corresponding to the mold parameter.
Corresponding to the cavity pressure and cavity temperature are a standard cavity pressure range and a standard cavity temperature range. Corresponding to the temperature, humidity and dew point of the environment in which the injection mold is located is a standard ambient temperature range, a standard ambient humidity range, and a standard ambient dew point range.
The standard parameter ranges may form a standard curve. For example, a standard mold cavity pressure range and a standard mold cavity temperature range may form a standard pressure curve and a standard temperature curve. The standard ambient temperature range, the standard ambient humidity range, and the standard ambient dew point range may form a standard ambient temperature curve, a standard ambient humidity curve, and a standard ambient dew point curve.
Because the data collected by the pressure sensor, the temperature and humidity sensor and the dew point sensor in the die cavity and the shell are directly collected from the injection die of the produced preset product, no kinetic energy loss exists, the die parameter range of the qualified product can be used as an index for representing whether the preset product produced by the injection molding machine is the qualified product or not. In other words, the standard curve is a sample directly contacted with the product, and has uniqueness, so long as the curve for confirming the mold parameters is the standard curve corresponding to the qualified product, the produced product is necessarily a qualified product.
Fig. 2 shows a flow of a method 200 for processing the shift model process parameters to obtain the debug process parameters by the processing unit 101 invoking the debug process parameter determination program in the debug process parameter determination module 107. It should be noted that the method 200 is performed before the actual production activity of producing the preset product by using the post-mold injection machine.
As shown in fig. 2, the execution of the method 200 includes the steps of:
s210, collecting mold parameters of an injection mold in the process that the injection molding machine operates based on the mold shifting process parameters;
s220, responding to the fact that the mold parameters exceed the standard parameter range corresponding to the preset product, and debugging the mold shifting process parameters based on preset parameter debugging rules until the mold parameters of the injection mold do not exceed the standard parameter range; and
s230, taking the debugged mold shifting technological parameters as the debugged technological parameters of the injection molding machine when the preset product is produced after mold shifting.
It should be understood that the steps illustrated in method 200 are not exclusive and that method 200 may also include additional steps not illustrated and/or may omit illustrated steps, as the scope of the present invention is not limited in this respect. It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. In addition, unless explicitly defined or contradicted by context, the particular steps included in the methods described herein need not be limited to the order described, but may be performed in any order or in parallel. Step S210 to step S230 are described in detail below with reference to fig. 1 to 7.
S210
After determining the mold-moving process parameters of the injection molding machine at the time of producing the preset product after the mold-moving, in step S210, the mold parameters of the injection molding machine are collected by using the sensor system 30 provided on the injection mold during the operation of the injection molding machine 40 based on the mold-moving process parameters.
The sensor system 30 includes pressure, temperature and flow sensors disposed within the injection mold cavity for sensing the cavity pressure and cavity temperature within the injection mold cavity. The mold cavity pressure and mold cavity temperature may form a pressure curve versus temperature curve.
Optionally, the sensor system 30 further includes a temperature and humidity sensor and a dew point sensor disposed on the injection mold housing, and is configured to collect the temperature, humidity and dew point of the environment where the injection mold is located, so as to determine whether the temperature and humidity and dew point of the environment where the injection mold is located can reach the conditions for producing a qualified preset product.
S220
In step S220, when the processing unit 101 determines that the mold parameter exceeds the standard parameter range corresponding to the preset product, the mold shifting process parameter is debugged based on the preset parameter debugging rule until the mold parameter of the injection mold does not exceed the standard parameter range.
The method 300 of obtaining the standard parameter ranges is described in detail below.
As shown in fig. 3, the method 300 includes the steps of:
s310, determining preset technological parameters required by producing the preset product based on the product parameters of the preset product;
s320, performing a DOE test based on the preset process parameters, and collecting sensor parameters by using a sensor system 30 arranged on a test die in the DOE test process; and
s330, forming the standard parameter range based on the collected sensor parameters in response to determining that the preset product produced by the DOE test meets the preset requirement.
Specifically, the preset process parameters include injection parameters and position injection parameters. As shown in fig. 4, step S310 includes:
s311, calling the injection parameters from a preset historical process library based on the product parameters of the preset product; and
s312, carrying out die flow analysis based on the product parameters of the preset product to determine the position injection molding parameters.
Specifically, a large database composed of actual data during injection molding production and debugging is recorded after the adjustment of the same type of products in a mode of accumulating and calculating the mean value through accumulation of the database, and the large database is stored as a replicable historical process library. The historical process library may be pre-stored in the database of the processing unit 101, or may be pre-stored in a cloud communicatively connected to the processing unit 101, so that the processing unit 101 may call in step S311.
In step S311, the processing unit 101 invokes the product parameters in the history process library to confirm the related parameters of the injection pressure and the injection speed, and calculates an opening/closing time and an ejection time according to the basic performance of the apparatus.
In step S312, the average wall thickness of the ejection face is confirmed by the die flow analysis and the front end of the product, and an average value is made according to whether the preset product has a deformed position, so that the weight of the preset product can be calculated, and the initial calculation of the shortest cooling time is performed. Injection position, cooling time, storage position and other position injection parameters can be obtained through the die flow analysis. Meanwhile, the pressure maintaining pressure and time of the equipment can be preset through pressure maintaining presetting of die flow analysis. The mode flow analysis is performed by software commonly used in the art, and the invention is not described herein.
In some embodiments, the positional injection molding parameters include cooling time. The above-mentioned step S312 performs the die flow analysis based on the product parameters of the preset product, and performs the preliminary calculation of the shortest cooling time in combination with the weight of the preset product, to obtain the original cooling time.
In the invention, the compensation cooling time is also determined based on the material property of the preset product, and then the cooling time is determined according to the original cooling time and the compensation cooling time.
Specifically, the cooling time of the preset product is confirmed through various temperatures of a physical property table of the material, namely, compensation calculation is carried out through the heat capacity index, the heat dissipation rate, the wall thickness and the ejection temperature in the physical property table, meanwhile, calculation is carried out according to the performance in the physical property table of the material, whether the material with the working temperature needs to be dried or not is always calculated at the same time, and the die temperature is absolutely matched according to the actual glass transition temperature (Tg temperature) of the material, so that the compensation cooling time is obtained. In addition, an optimal back pressure can be given to the material to melt the material better.
In step S320, a DOE test is performed based on the preset process parameters determined in step S310, and sensor parameters are collected using the sensor system 30 provided on the test mold during the DOE test. The process of collecting the sensor parameters by using the sensor system 30 provided on the test die may refer to the description of step S210, and the present invention will not be described herein.
In some embodiments, as shown in fig. 5, step S330 includes:
s331, responding to the fact that the preset product produced by the DOE test meets the preset requirement, and recording a first sensor parameter;
S332, continuously adjusting the value of the preset process parameter upwards/downwards until the preset product produced by the DOE test is determined to not meet the preset requirement, and recording a second sensor parameter; and
s333, taking a parameter range included in the second sensor parameter as the standard parameter range.
Specifically, in step S331, when the processing unit 101 determines that the preset product produced by the DOE test meets the preset requirement based on the pre-trained image processing model, the sensor parameter collected at the current time is recorded as the first sensor parameter. As an example, an image acquisition unit may be used to acquire an image of a preset product produced by the DOE test, and based on a deep learning network training, an image processing model for determining that the preset product produced by the DOE test meets a preset requirement.
In step S332, the values of the preset process parameters are continuously adjusted upwards/downwards until it is determined that the preset product produced by the DOE test DOEs not meet the preset requirement, and the second sensor parameters are recorded.
It should be noted that the second sensor parameter includes an upper value limit when the preset product produced by the DOE test DOEs not meet the preset requirement after the preset process parameter is adjusted upwards, and a lower value limit when the preset product produced by the DOE test DOEs not meet the preset requirement after the preset process parameter is adjusted downwards.
In step S333, a parameter range included in the lower value limit and the upper value limit included in the second sensor parameter is set as the standard parameter range.
For example, in step S331, when it is determined that the preset product produced by the DOE test meets the preset requirement, the cavity pressure collected by the pressure sensor is 80. In other words, the pre-set product produced at a cavity pressure of 80 is standard, which requires a commissioning search. In step S332, the values of the preset process parameters are adjusted downward until the pressure sensor collects the cavity pressure 60 when it is determined that other problems occur in the preset product, and the cavity pressure 60 is recorded as the lower limit of the values of the cavity pressure. In step S332, the values of the preset process parameters are adjusted upwards until the pressure sensor collects the die cavity pressure 100 when it is determined that other problems occur in the preset product, and the die cavity pressure 100 is recorded as the upper limit of the die cavity pressure. In step S333, the range of the cavity pressures 60 to 100 is determined as the standard cavity pressure range.
The standard mold cavity temperature range, standard ambient humidity range, and standard ambient dew point range may be determined based on methods similar to those described above, and are not described in detail herein.
In some embodiments, as shown in fig. 6, in step S220, the step of debugging the parameters of the mold shifting process based on preset parameter debugging rules includes:
s221, increasing the injection speed in response to determining that the slope of a pressure curve formed by the mold cavity pressure is lower than the slope of a standard pressure curve in the standard mold cavity pressure range;
s222, increasing the injection pressure in response to determining that the slope of a pressure curve formed by the cavity pressure is still lower than the slope of the standard pressure curve after the injection speed is increased;
s223, adjusting the dwell time in response to determining that the integral area of a pressure curve formed by the die cavity pressure is lower than the integral area of the standard pressure curve;
and S224, increasing the pressure maintaining pressure in response to determining that the highest point of the pressure curve formed by the mold cavity pressure is lower than the highest point of the standard pressure curve, or in response to determining that the highest point of the temperature curve formed by the mold cavity temperature is lower than the highest point of the standard temperature curve in the standard mold cavity temperature range.
Specifically, the processing unit 101 compares the pressure curve formed by the cavity pressure with the standard pressure curve within the standard cavity pressure range, and when determining that the slope of the pressure curve formed by the cavity pressure is lower than the slope of the standard pressure curve within the standard cavity pressure range, the injection speed is insufficient, and the injection speed should be increased to perform slope adjustment. When the injection speed is adjusted, the slope of the pressure curve formed by the mold cavity pressure is still lower than the slope of the standard pressure curve, and the injection pressure is increased to ensure that the slope of the pressure curve formed by the mold cavity pressure is matched with the slope of the standard pressure curve.
In addition, when it is determined that the integral area of the pressure curve formed by the cavity pressure is lower than the integral area of the standard pressure curve, the pressure maintaining time is adjusted to adjust the integral area so as to ensure that the area of the pressure curve is enough.
And increasing the holding pressure to perform the peak pressure/temperature elevation when it is determined that the peak of the pressure curve formed by the cavity pressure is lower than the peak of the standard pressure curve, or in response to it being determined that the peak of the temperature curve formed by the cavity temperature is lower than the peak of the standard temperature curve in the standard cavity temperature range, meaning that the pressure value/temperature value of the peak cannot reach the standard curve range. Meanwhile, according to the peripheral sensors, an external factor is inserted, and the difference of the working environments is found.
In addition, when the pressure curve or the temperature curve is determined to move backwards, the injection speed is adjusted, the speed is increased, the curve moves forwards integrally, if the forward movement peak value is increased, the injection quantity can be adjusted and reduced according to the previous factor, the injection speed is required to be reduced when the curve moves forwards integrally, the pressure curve moves backwards, and if the peak value is reduced, the injection quantity is increased again for debugging.
It should be noted that the preset parameter tuning rule may be stored in the database of the processing unit 101 in advance, or may be stored in the cloud end communicatively connected to the processing unit 101 in advance, so that the processing unit 101 may call in step S220.
S230
In step S230, the debugged mold-moving process parameter is used as a debug process parameter of the injection molding machine 40 when the preset product is produced after mold-moving, and is sent to the injection molding machine 40.
The injection molding machine 40 is operated based on the adjusted mold shift process parameters to produce a predetermined product meeting the predetermined requirements.
Through the scheme, the mold shifting process parameters of the injection molding machine 40 when the preset product is produced after mold shifting are debugged based on the relation between the mold parameters of the injection molding mold and the standard parameter ranges corresponding to the preset product, so that the debugging process parameters of the injection molding machine 40 when the preset product is produced after mold shifting are determined, the purpose of automatically debugging the mold shifting injection process parameters is achieved, and the problems of low debugging efficiency and low precision caused by debugging depending on the artificial practice experience after mold shifting in the prior art are solved.
In addition, the injection molding machine 40 operates based on the debugged mold shifting process parameters, so that the times and time for adjusting the injection molding process parameters in the operation process of the injection molding machine 40 can be reduced, and the production efficiency can be improved.
In some embodiments, as shown in fig. 1, the mold intelligent terminal 100 further includes a mold test process parameter determination module 102. A test process parameter determining program is preset in the test process parameter determining module 102; the data communication module 103 is used for being in communication connection with the external data terminal 20; the processing unit 101 is connected with the data communication module 103 and the test model process parameter determining module 102. After receiving the input data required by the test process parameter determining program sent by the external data terminal 20 through the data communication module 103, the processing unit 101 invokes the test process parameter determining program in the test process parameter determining module 102 to process the input data to obtain test process parameters, and sends the test process parameters to the external data terminal 20 through the data communication module 103.
The external data terminal 20 is an electronic device such as a smart phone, a personal computer, or a server. The data communication module 103 performs data communication with the external data terminal 20 by using a wireless transmission method or a wired transmission method. As an example, the data communication module 103 may be WIFI or bluetooth; the data communication module 103 may also be type_c and a serial port.
Through the scheme, the processing unit 101 of the intelligent die terminal 100 is utilized to execute the test die process parameter determining program in the test die process parameter determining module 102 so as to obtain the test die process parameter, improve the integration level of the intelligent die terminal 100 and simultaneously reduce the equipment cost required by the test die process parameter determining program.
Specifically, upon receiving the query command, the external data terminal 20 analyzes the query element included in the query command, and the query element includes, for example, mold information, injection molding machine information, and material information. The mold information may be identification information of the mold, and the identification information of the mold may include a name, a model number, a kind, a number, etc. of the mold; the injection molding machine information can be identification information of the injection molding machine, and the identification information of the injection molding machine can comprise names, models, types, numbers and the like of the injection molding machine; the material information may be attribute information of the material, and the attribute information of the material may include a name, a type, a number, a grammage, and the like of the material.
The external data terminal 20 extracts matching data from the production process history data based on the query element to obtain a basic process parameter. As an example, the production process history data may include production process history data of various molds, for example, production process history data of various molds for producing injection molded products using various materials on respective injection molding machines adapted thereto.
In addition, the external data terminal 20 can simulate the injection process of the injection mold by using simulation software, so as to obtain simulation process parameters of the injection mold, and the simulation software can be software commonly used in the field.
After acquiring the basic process parameters and the simulation process parameters, the external data terminal 20 transmits the basic process parameters and the simulation process parameters to the processing unit 101 of the mold intelligent terminal 100 through the data communication module 103. The processing unit 101 invokes the test process parameter determining program to process the basic process parameter and the simulation process parameter, thereby determining the test process parameter of the injection mold.
In some embodiments, the base process parameters may include an intermediate process parameter and a first target process parameter, wherein the intermediate process parameter refers to a process parameter that needs to be calculated to direct actual production, and the target process parameter refers to a process parameter that may direct actual production. Specifically, after the basic process parameters are obtained, the intermediate process parameters may be calculated to obtain second target process parameters, and then the target process parameters are determined according to the first target process parameters and the second target process parameters.
In other words, the second target process parameter may be calculated according to the intermediate process parameter, and a parameter set formed by the first target process parameter and the second target process parameter is used as the target process parameter. For example, the target process parameters may include at least one of injection parameters, dwell parameters, stock parameters, molding parameters, and rotary dwell positions. Wherein, the injection parameters may include injection pressure, speed, position, time, etc. of each injection stage, the pressure maintaining parameters may include pressure, time, speed, etc. of each injection stage, the storage parameters may include storage pressure, speed, position, barrel temperature, hot runner temperature, etc. of each injection stage, and the molding parameters may include mold opening and closing time, ejection time, cooling time, molding time, etc. The number of injection stages will vary depending on the injection product that the injection mold is used to produce. For example, some injection molded products may include three to four injection molding stages and some injection molded products may include five to six injection molding stages. Finally, the mold testing process parameters of the injection mold can be determined according to the target process parameters and the simulation process parameters.
Specifically, the types of the target process parameter and the simulation process parameter may be different, the target process parameter and the simulation process parameter may be unified into a unified type, and then the mold test process parameter of the injection mold is determined according to the target process parameter and the simulation process parameter after the unified type. For example, the target process parameter may be a specific pressure value of two stages, and the simulation process parameter is a pressure ratio of two stages, the specific pressure value of two stages in the target process parameter may be converted into the pressure ratio of two stages, so as to determine the trial process parameter according to the converted target process parameter and the simulation process parameter.
When determining the test process parameters, the average value of corresponding values in the target process parameters and the simulation process parameters can be taken, and corresponding weights can be set for the target process parameters and the simulation process parameters, so that the test process parameters can be determined according to the target process parameters, the simulation process parameters and the corresponding weights.
Fig. 7 illustrates a structure of a mold intelligent terminal 100 provided according to a second exemplary embodiment of the present invention.
As shown in fig. 7, the mold intelligent terminal 100 further includes a falling-off prevention sensing module 108, where the falling-off prevention sensing module 108 is configured to generate a falling-off signal when the mold intelligent terminal 100 is detected to be separated from the injection molding. The processing unit 101 is connected with the anti-falling sensing module 108, and sends out a reminding signal when receiving the falling signal.
It is understood that the anti-drop sensing module 108 can convert a drop mechanical signal into an electrical signal. For example, the anti-falling sensing module 108 includes a mechanical falling structure and a push button switch, when the mold intelligent terminal 100 is separated from the mold assembly, the mechanical falling structure is ejected from the mold intelligent terminal 100 and separated from the push button switch, the push button switch is in a conductive state, when the mold intelligent terminal 100 is mounted on the mold assembly, the mechanical falling structure is compressed into the mold intelligent terminal 100 and presses the push button switch, and the push button switch is in a disconnection state; the on signal of the button switch indicates that the intelligent die terminal 100 is separated from the die assembly, and the off signal of the button switch indicates that the intelligent die terminal 100 is arranged on the die assembly; the anti-drop sensing module 108 generates a drop signal when a turn-on signal of the push button switch is detected. The specific configurations of the mechanical release structure and the push button switch are not particularly limited in the embodiments of the present invention.
Optionally, the mold intelligent terminal 100 further includes an alarm module, and when receiving the drop signal, the processing unit 101 may send a control instruction to the alarm module, so that the alarm module alerts in an alarm manner such as an indicator light or a buzzer, so that a worker can find that the mold drops in time. Or, the processing unit 101 can also transmit the falling alarm signal to the cloud platform through the information reporting module, so that the staff can monitor the falling state remotely.
In some embodiments, the mold intelligent terminal 100 further includes a mold clamping sensing module 109, wherein the mold clamping sensing module 109 is configured to generate a mold clamping signal when the injection mold is detected to perform a mold clamping operation. The processing unit 101 is connected to the mold closing sensing module 109, and counts a mold closing cycle and a mold closing number when the mold closing signal is received.
As an example, the clamp sensing module 109 performs clamp counting using a magnetic induction technique. The optional mold closing sensing module 109 comprises a reed switch, a corresponding magnet is arranged on the mold assembly, the reed switch is combined with magnet sensing, a coil or a permanent magnet in the reed switch is utilized for sensing, when a magnetic field signal exists, an N pole and an S pole in the reed switch are closed to achieve loop conduction, and when the magnetic field signal disappears, an elastic sheet in the reed switch has elasticity, and the elastic sheet is restored to an open state to achieve loop disconnection. Thus, the time counting function of the die is achieved by closing the reed switch. The reed switch is used as the die closing sensing module 109, which is more sensitive, faster, longer in service life and lower in cost.
In some embodiments, the mold intelligent terminal 100 further includes a planning and monitoring module 110, where the planning and monitoring module 110 is connected to the processing unit 101, and configured to monitor, through the mold closing period and the mold closing frequency counted by the processing unit 101, a production period of the injection mold and a reject ratio of a product produced by the injection mold, and send the production period and the reject ratio to the production informatization management system 50.
In the above-mentioned scheme, through interconnection with the factory production informatization management system 50 (Manufacturing Execution System, abbreviated as MES), the time required for production and the recommendation of whether the later work needs to dry the material, the drying time length, etc. can be calculated through the monitored cycle value and the reject ratio.
For example, the number of production orders is 100, the later production material is ABS material, and drying is required. The period of the product in production is 60s, the reject ratio is 1%, 1H10Min is estimated to be produced by an automatic measuring and calculating place when 40 products are produced, and attention is paid to the following production, mold replacement and material drying.
It should be noted that, the intelligent terminal 100 provided by the present invention may further include other parts for implementing related functions, such as a housing, a battery, etc., which are not described herein.
The foregoing description is only illustrative of the preferred embodiment of the present invention, and is not to be construed as limiting the invention, but is to be construed as limiting the invention to any and all simple modifications, equivalent variations and adaptations of the embodiments described above, which are within the scope of the invention, may be made by those skilled in the art without departing from the scope of the invention.
Claims (10)
1. A mold intelligent terminal, characterized in that, detachably installs on injection mold, the mold intelligent terminal includes:
the sensor parameter acquisition module is configured to be in communication connection with a sensor system arranged on the injection mold and is used for acquiring sensor parameters perceived by the sensor system;
the injection molding machine parameter interaction module is configured to be in communication connection with an injection molding machine and is used for carrying out interaction of production process parameters with the injection molding machine;
the processing unit is connected with the sensor parameter acquisition module and the injection molding machine parameter interaction module,
when the processing unit determines that the sensor parameters are abnormal by comparing the sensor parameters acquired by the sensor parameter acquisition module with a preset standard parameter range, the processing unit adjusts the production process parameters received from the injection molding machine parameter interaction module according to a preset parameter adjustment rule, and feeds the adjusted production process parameters back to the injection molding machine through the injection molding machine parameter interaction module.
2. The intelligent terminal of claim 1, wherein the intelligent terminal comprises a plurality of terminals,
and the processing unit sends out a reminding signal when determining that the sensor parameter is abnormal by comparing the sensor parameter acquired by the sensor parameter acquisition module with a preset standard parameter range.
3. The intelligent terminal of claim 1, wherein the intelligent terminal comprises a plurality of terminals,
the sensor system comprises a pressure sensor and a temperature sensor which are arranged in the injection mold cavity and are used for collecting the mold cavity pressure and the mold cavity temperature in the injection mold cavity.
4. The intelligent terminal of claim 1, wherein the intelligent terminal comprises a plurality of terminals,
the sensor system comprises a temperature and humidity sensor and a dew point sensor which are arranged on the injection mold shell and used for collecting the temperature, humidity and dew point of the environment where the injection mold is located.
5. The mold intelligent terminal of any one of claims 1 to 4, further comprising:
the data communication module is used for being in communication connection with an external data terminal; and
the mould moving process parameter determining module is provided with a mould moving process parameter determining program in advance;
and the processing unit receives the data required by the mold shifting process parameter determining program through the data communication module, invokes the mold shifting process parameter determining program in the mold shifting process parameter determining module to process the received data to obtain mold shifting process parameters, and sends the mold shifting process parameters to the injection molding machine after mold shifting through the injection molding machine parameter interaction module.
6. The mold intelligent terminal of claim 5, further comprising:
the debugging process parameter determining module is preset with a debugging process parameter determining program;
after the processing unit determines the moving mold process parameters, a debugging process parameter determining program in the debugging process parameter determining module is called to process the moving mold process parameters to obtain debugging process parameters, and the debugging process parameters are sent to the injection molding machine after moving mold through the injection molding machine parameter interaction module.
7. The mold intelligent terminal of claim 5, further comprising:
the test process parameter determining module is preset with a test process parameter determining program;
and the processing unit receives input data which is transmitted by the external data terminal and is required by the test process parameter determining program through the data communication module, invokes the test process parameter determining program in the test process parameter determining module to process the input data to obtain test process parameters, and transmits the test process parameters to the external data terminal through the data communication module.
8. The mold intelligent terminal of any one of claims 1 to 4, further comprising:
the anti-falling sensing module is used for generating a falling signal when detecting that the intelligent terminal of the die is separated from the injection molding;
the processing unit is connected with the anti-falling sensing module and sends out a reminding signal when receiving the falling signal.
9. The mold intelligent terminal of any one of claims 1 to 4, further comprising:
the mold closing sensing module is used for generating a mold closing signal when detecting that the injection mold performs mold closing operation;
the processing unit is connected with the die closing sensing module, and counts the die closing period and the die closing times when the die closing signal is received.
10. The mold intelligent terminal of claim 9, further comprising:
and the plan supervision module is connected with the processing unit and is configured to monitor the production cycle of the injection mold and the reject ratio of the injection mold production product through the mold closing cycle and the mold closing times counted by the processing unit, and send the production cycle and the reject ratio to the production informatization management system.
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