阅读说明：本技术 一种智能化微应力注塑生产控制系统 (Intelligent micro-stress injection molding production control system ) 是由 李代伟 李周才 于 2020-06-16 设计创作，主要内容包括：本发明提供一种智能化微应力注塑生产控制系统,属于注塑领域。本发明智能化微应力注塑生产控制系统包括智能集成控制设备、注塑模具、用于对注塑模具中模腔加温的加热装置,用于对注塑模具模腔冷却的冷却装置、还包括设置在所述注塑模具中用于检测温区对应模腔的温度的测温装置,其中,所述智能集成控制设备分别与加热装置、冷却装置、测温装置和注塑模具相连,所述智能集成控制设备能够控制所述加热装置和冷却装置实时定量输出能源。本发明的有益效果为：多机组协同作业,控制模腔温度,最大程度减少注塑产品残余应力,极大减少了产品外观、平面度、尺寸、重量等方面的问题,产品不良率显著降低。(The invention provides an intelligent micro-stress injection molding production control system, and belongs to the field of injection molding. The intelligent micro-stress injection production control system comprises intelligent integrated control equipment, an injection mold, a heating device for heating a mold cavity in the injection mold, a cooling device for cooling the mold cavity of the injection mold, and a temperature measuring device arranged in the injection mold and used for detecting the temperature of the mold cavity corresponding to a temperature measuring area, wherein the intelligent integrated control equipment is respectively connected with the heating device, the cooling device, the temperature measuring device and the injection mold, and the intelligent integrated control equipment can control the heating device and the cooling device to quantitatively output energy in real time. The invention has the beneficial effects that: the multi-unit cooperative operation controls the temperature of the mold cavity, reduces the residual stress of the injection molding product to the maximum extent, greatly reduces the problems of the product in aspects of appearance, planeness, size, weight and the like, and obviously reduces the product reject ratio.)

1. The utility model provides an intelligent microstress injection moulding production control system which characterized in that: the intelligent integrated control device is respectively connected with the heating device, the cooling device, the temperature measuring device and the injection mold, and can control the heating device and the cooling device to quantitatively output energy in real time.

2. The intelligent microstress injection molding production control system of claim 1, wherein: the intelligent integrated control equipment comprises a host device and an auxiliary device which are connected through cables, wherein the host device comprises a host shell, a control panel arranged in the host shell, an IO panel and a power supply which are connected with the control panel, and the intelligent integrated control equipment further comprises an electric control device connected with the control panel and an intelligent output adjusting module used for adjusting electric power output, the auxiliary device comprises an auxiliary shell, a cooling liquid pipeline arranged in the auxiliary shell, an inlet and an outlet which are communicated with the cooling liquid pipeline are arranged on the auxiliary shell, and the outlet is connected with the cooling device.

3. The intelligent microstress injection molding production control system of claim 2, wherein: the cooling liquid is water, the cooling liquid pipeline is a water flow pipeline, a control blowing device communicated with the water outlet is further arranged in the auxiliary unit, the control blowing device is connected with the control panel through a cable, a water pump connected with the water inlet is further arranged in the auxiliary unit, a water flow regulator used for regulating the water flow of the water outlet is further arranged on the water flow pipeline in the auxiliary unit, and the water flow regulator is connected with the control panel through a cable.

4. The intelligent microstress injection molding production control system of claim 2, wherein: the heating system comprises an IO board, a control board, a heating control module, a cooling control module and a mould temperature detection module, wherein the IO board is provided with an IO module CPU, the control board is provided with a main control module, the main control module comprises a main control CPU, the main control CPU is connected with the IO module CPU, the main control CPU is further provided with a heating control module, a cooling control module and a mould temperature detection module, the main control CPU is respectively connected with the heating control module, the cooling control module and the mould temperature detection module, the heating control module is used for controlling a heating pipe to heat a mould, the cooling control module is used for controlling a cooling medium to cool the mould, the mould temperature detection module is used for detecting the mould temperature.

5. The intelligent microstress injection molding production control system of any one of claims 1-4, wherein: the injection mold comprises a front mold core, a rear mold core and a mold cavity arranged between the front mold core and the rear mold core, wherein the heating device and the temperature measuring device are arranged on the front mold core, and the front mold core and the rear mold core are respectively provided with a cooling device.

6. The intelligent microstress injection molding production control system of claim 5, wherein: the front mold core comprises a mold core body, the mold core body comprises a mounting surface for mounting the mold core body, a mold cavity surface for setting a product cavity, and side surfaces arranged on the periphery of the mounting surface and the periphery of the mold cavity surface, wherein the mounting surface is provided with a reinforcing structure, the mounting surface is also provided with a mold core heating expansion positioning guide structure, the reinforcing structure and the mold core heating expansion positioning guide structure are both provided with heating expansion telescopic grooves, and a mold core expansion gap is arranged between the side surfaces and the mounting plate.

7. The intelligent microstress injection molding production control system of claim 6, wherein: the front mold core is provided with more than 1 temperature zone, each temperature zone is provided with a set of heating device, a set of cooling device and a temperature measuring device for detecting the temperature of the temperature zone corresponding to the mold cavity, the heating device and the cooling device in each temperature zone are independently controlled by intelligent integrated control equipment, the rear mold core is provided with more than 1 cooling zone, each cooling zone is provided with a set of cooling device, and the cooling device in each cooling zone is independently controlled by the intelligent integrated control equipment.

8. The intelligent microstress injection molding production control system of claim 7, wherein: the heating device is a heating pipe, the cooling device is a cooling pipeline with cooling water arranged inside, a water inlet of the cooling pipeline is arranged on one side of the mold core body, and a water outlet of the cooling pipeline is arranged on the other side, opposite to the water inlet, of the mold core body.

9. The intelligent microstress injection molding production control system of claim 8, wherein: the quantity of the heating pipes and the number of the cooling pipelines are multiple, the heating pipes and the cooling pipelines are arranged at intervals, every two distances among the temperature measuring devices, the cooling pipelines and the heating pipes are equal, the vertical distance between the temperature measuring devices and a product cavity, the distance between the temperature measuring devices and the cooling pipelines and the distance between the temperature measuring devices and the heating pipes are equal, and the distances between the heating pipes and a mold core body mounting surface and the distances between the heating pipes and the mold core body product cavity are equal.

10. The intelligent microstress injection molding production control system of claim 6, wherein: injection mold is still including thermal-insulated backup pad and mounting panel, wherein, one side of thermal-insulated backup pad is equipped with the mounting groove that corresponds with mold core thermal expansion location guide structure, intelligent microstress injection molding production control system's mold core thermal expansion location guide structure fixes in the mounting groove, the mounting panel is equipped with and holds the holding tank of mold core body and thermal-insulated backup pad, the mounting panel outside is equipped with pipeline entry and the pipeline export that is linked together with cooling duct.

Technical Field

The invention relates to the field of injection molding, in particular to an intelligent micro-stress injection molding production control system.

Background

Along with the increasing complexity of products, the tolerance requirement and the appearance quality requirement of the products are also increased, and various quality and cost problems caused by the adoption of the traditional injection molding technology cannot be solved by the existing domestic and foreign prior art, such as thermal expansion deformation of die steel, unbalanced die temperature, larger internal stress of a workpiece, continuous improvement of manufacturing cost and the like. It can be said that the plastic processing field has encountered unprecedented challenges, and a new set of systematic solutions is urgently needed to change the dilemma.

Because the intelligent system solves the performance advantage and provides wide development space for the field due to 'mutation' in the field of plastic processing. The innovative multiple injection molding solutions are urgently needed in the fields of automobiles, aviation, medical treatment and electronic and electrical appliances with high requirements on the cost pressure and the product specification of the manufacturing industry in China at present. With the outburst of the new energy market of automobiles, lightweight automobiles with lower oil consumption and lighter automobile parts and ornaments are searched, and the production of the precision parts is also not away from a new unified solution scheme.

Based on more than ten years of die manufacturing and injection molding production experience, the applicant finds that the problems of stress relief of injection molding products and mold temperature balance control in the injection molding process are difficult to solve, and the difficulties are not overcome for a long time, so that the quality problems of the injection molding products are difficult to solve systematically, and the level of the Chinese manufacturing industry is difficult to further improve. Although there are devices available on the market that solve the related problems, they can only solve one aspect of the problem, which is not only flawed, but also fail to provide a solution from mold design to injection molding to produce a full chain, such as: an inductor is not arranged in the die to detect the die temperature, and the die temperature auxiliary equipment can only be simply heated, so that the temperature cannot be accurately controlled; or the mold temperature can not be accurately controlled in different areas according to the structural design of the product; or a database is not established, and a central processing unit is used for intelligently analyzing to give the most appropriate production parameters, such as temperature, pressure and the like.

Disclosure of Invention

In order to solve the problems in the prior art, the invention provides an intelligent micro-stress injection molding production control system.

The intelligent integrated control device is respectively connected with the heating device, the cooling device, the temperature measuring device and the injection mold, and can control the heating device and the cooling device to quantitatively output energy in real time.

The invention is further improved, the intelligent integrated control equipment comprises a host machine device and an auxiliary machine device which are connected through a cable, wherein the host machine device comprises a host machine shell, a control panel arranged in the host machine shell, an IO panel connected with the control panel and a power supply, the intelligent integrated control equipment also comprises electric control equipment connected with the control panel and an intelligent output adjusting module used for adjusting electric output, the auxiliary machine device comprises an auxiliary machine shell, a cooling liquid pipeline arranged in the auxiliary machine shell, the auxiliary machine shell is provided with an inlet and an outlet which are communicated with the cooling liquid pipeline, and the outlet is connected with a cooling device.

The invention is further improved, the cooling liquid is water, the cooling liquid pipeline is a water flow pipeline, a control blowing device communicated with a water outlet is further arranged in the auxiliary machine device, the control blowing device is connected with the control panel through a cable, a water pump connected with a water inlet is further arranged in the auxiliary machine device, a water flow regulator used for regulating the water flow of the water outlet is further arranged on the water flow pipeline in the auxiliary machine device, and the water flow regulator is connected with the control panel through a cable.

The invention is further improved, the IO board is provided with an IO module CPU, the control board is provided with a main control module, the main control module comprises a main control CPU, the main control CPU is connected with the IO module CPU, the main control board is further provided with a heating control module, a cooling control module and a mould temperature detection module, the main control CPU is respectively connected with the heating control module, the cooling control module and the mould temperature detection module, the heating control module is used for controlling a heating pipe to heat a mould, the cooling control module is used for controlling a cooling medium to cool the mould, the mould temperature detection module is used for detecting the mould temperature, and the IO board is respectively connected with the main control CPU and an upper computer.

The invention is further improved, the injection mold comprises a front mold core, a rear mold core and a mold cavity arranged between the front mold core and the rear mold core, wherein the heating device and the temperature measuring device are arranged on the front mold core, and the front mold core and the rear mold core are respectively provided with a cooling device.

The invention is further improved, the front mold core comprises a mold core body, the mold core body comprises a mounting surface for mounting the mold core body, a mold cavity surface for arranging a product cavity, and side surfaces arranged at the periphery of the mounting surface and the mold cavity surface, wherein the mounting surface is provided with a reinforcing structure, the mounting surface is also provided with a mold core heating expansion positioning guide structure, the reinforcing structure and the mold core heating expansion positioning guide structure are both provided with heating expansion telescopic grooves, and a mold core expansion gap is arranged between the side surfaces and the mounting plate.

The invention is further improved, the front mold core is provided with more than 1 temperature zone, each temperature zone is provided with a set of heating device, a set of cooling device and a temperature measuring device for detecting the temperature of the mold cavity corresponding to the temperature zone, the heating device and the cooling device in each temperature zone are independently controlled by intelligent integrated control equipment, the rear mold core is provided with more than 1 cooling zone, each cooling zone is provided with a set of cooling device, and the cooling device in each cooling zone is independently controlled by the intelligent integrated control equipment.

The invention is further improved, the heating device is a heating pipe, the cooling device is a cooling pipeline with cooling water arranged inside, a water inlet of the cooling pipeline is arranged on one side of the mold core body, and a water outlet of the cooling pipeline is arranged on the other side of the mold core body opposite to the water inlet.

The invention is further improved, the number of the heating pipes and the number of the cooling pipes are multiple, the heating pipes and the cooling pipes are arranged at intervals, the distances between the temperature measuring devices, the cooling pipes and the heating pipes are equal, the vertical distance between the temperature measuring devices and a product cavity, the distance between the temperature measuring devices and the cooling pipes and the distance between the temperature measuring devices and the heating pipes are equal, and the distances between the heating pipes and a mold core body mounting surface and the distances between the heating pipes and the mold core body product cavity are equal.

The invention is further improved, the injection mold also comprises a heat insulation support plate and a mounting plate, wherein one side of the heat insulation support plate is provided with a mounting groove corresponding to the mold core heating expansion positioning guide structure, the mold core heating expansion positioning guide structure of the intelligent micro-stress injection production control system is fixed in the mounting groove, the mounting plate is provided with a holding groove for holding the mold core body and the heat insulation support plate, and the outer side of the mounting plate is provided with a pipeline inlet and a pipeline outlet which are communicated with a cooling pipeline.

Compared with the prior art, the invention has the beneficial effects that: the multi-unit cooperative operation controls the temperature of the mold cavity, reduces the residual stress of the injection molding product to the maximum extent, greatly reduces the problems of the product in aspects of appearance, planeness, size, weight and the like, obviously reduces the reject ratio of the product, greatly improves the production efficiency, and can greatly reduce the production cost of the molding manufacturing industry.

Drawings

FIG. 1 is a schematic diagram of a host device according to the present invention;

FIG. 2 is a schematic view of an opened internal structure of a front door panel of the host device according to the present invention;

FIG. 3 is a schematic view of an opened interior structure of a rear door panel of the host device;

FIG. 4 is a schematic structural view of the auxiliary machinery device;

FIG. 5 is a schematic view of the internal structure of the auxiliary machinery apparatus;

FIG. 6 is a schematic circuit diagram of a main control board, which includes a schematic circuit diagram of a main control module, a mold temperature detection module, and a heating driving unit;

fig. 7-11 are enlarged partial views of fig. 6, wherein,

FIG. 7 is a master CPU circuit schematic;

FIG. 8 is a schematic circuit diagram of an interface unit of the flow control panel;

FIG. 9 is a schematic circuit diagram of a temperature sensing module;

FIG. 10 is a schematic circuit diagram of a heating driving unit;

FIG. 11 is a schematic circuit diagram of an interface unit connected to a heating output unit;

FIG. 12 is a schematic circuit diagram of a heating output unit;

FIG. 13 is a schematic diagram of a patching module circuit;

FIG. 14 is a schematic diagram of a master CPU circuit of the IO module;

FIG. 15 is a schematic diagram of a communication interface circuit of the IO module;

FIG. 16 is a schematic circuit diagram of a signal input unit and a signal output unit;

FIG. 17 is a schematic circuit diagram of an alarm signal driving unit;

FIG. 18 is a schematic circuit diagram of a booster pump drive unit;

FIG. 19 is a schematic circuit diagram of a check valve driving unit;

FIG. 20 is a schematic circuit diagram of the AC phase-dislocation protection unit and the water temperature detection unit;

FIG. 21 is a schematic view of an injection mold configuration;

FIG. 22 is a schematic view of a front core cavity face configuration;

FIG. 23 is a cross-sectional view of FIG. 22B-B;

FIG. 24 is an enlarged view of a portion C of FIG. 23;

FIGS. 25 and 26 are sectional views of FIGS. 22A-A;

fig. 27 and 28 are schematic front core mounting surfaces;

FIG. 29 is a sectional view of another embodiment of the front core;

FIG. 30 is a block diagram of the system of the present invention.

Detailed Description

The present invention will be described in further detail with reference to the accompanying drawings and examples.

As shown in fig. 30, the injection molding device comprises an intelligent integrated control device, an injection mold, a heating device for heating a mold cavity in the injection mold, a cooling device for cooling the mold cavity of the injection mold, and a temperature measuring device arranged in the injection mold for detecting the temperature of the mold cavity corresponding to a temperature measuring area, wherein the intelligent integrated control device is respectively connected with the heating device, the cooling device, the temperature measuring device and the injection mold, and the intelligent integrated control device can control the heating device and the cooling device to quantitatively output energy in real time.

The invention has the advantages that the innovative design scheme of the mold capable of detecting and feeding back the mold condition in the injection molding process is matched with the intelligent analysis of the central processing unit of the intelligent integrated control equipment, the automatic digital control and the multi-unit cooperative operation of the injection mold, the cooling device, the heating device and the like are realized, the temperature of the mold cavity is controlled, the residual stress of the injection molding product is reduced to the maximum extent, the problems in aspects of the appearance, the planeness, the size, the weight and the like of the product are greatly reduced, the reject ratio of the product is obviously reduced, the production efficiency is greatly improved, and the production cost of the molding manufacturing industry can be.

As shown in fig. 1 to 5, the present invention includes a host device 1 and a slave device 2 connected by a cable, wherein 10 24-core sockets 117 are provided in the host device 1, 2 24-core sockets 202 are provided on the slave device 2, 24-core plugs capable of being plugged into the 24-core sockets are respectively provided at both ends of the cable so as to be plugged into the 24-core sockets on the host device 1 and the slave device 2, and the host device 1 and the slave device 2 communicate and supply power through the cable. The main machine device is internally provided with electrical equipment and a circuit board, the auxiliary machine device is internally provided with waterway equipment, and water and electricity are separately arranged, so that potential safety hazards are eliminated, and the safety is greatly improved. In addition, all modules in the main machine device 1 and all modules in the auxiliary machine device 2 are controlled by the control panel in a unified mode, and real-time performance and convenience of control are guaranteed.

As shown in fig. 1 to 3, the host device 1 includes a host housing 101, the host housing 101 includes a front door panel 1011 disposed on the front side of the host housing 101 and a rear door panel 1013 disposed on the back side of the host housing 101, the front door panel 1011 is provided with a cabinet lock 1012 for opening or locking the front door panel 1011, and further provided with a system control panel 102 for operating the device and an indicator lamp 105 for indicating the working state of the device, the number of the indicator lamps is 3, and the indicator lamps are respectively a power indicator lamp, an operation indicator lamp and an alarm indicator lamp, and further include an emergency stop switch 103 disposed below the indicator lamp 105. A carrying hanging ring 106 is further provided on the top surface of the main body case 101, and a carrying roller 107 is provided on the bottom of the main body case 101 for carrying and moving.

As shown in fig. 2, the IO board 113 and the power supply 114 are further disposed on the inner side of the front door panel, four rows of 12 main control boards 108 are disposed on the side close to the front door panel 1011 inside the main housing 101 in this embodiment, and a power control area is disposed below the main control boards 108, and the ac contactor 109, the ac circuit breaker 111, and the phase detector 110 for detecting the phase and performing the phase-dislocation protection are disposed therein. A terminal block 112 is also provided.

As shown in fig. 3, a cabinet lock is also disposed on the back door 1013, and in this embodiment, two upper half areas and two lower half areas are disposed at a side of the main machine housing 101 near the back door 1012, and correspondingly, the number of the back door 1013 is two, the two upper half areas and the two lower half areas are respectively an upper door and a lower door, 4 heat dissipation fans 115 are disposed on the inner side of the upper door, and heat dissipation holes are disposed at positions of the upper door corresponding to the heat dissipation fans 115. The upper half area is provided with 8 groups of intelligent output adjusting modules 116 for adjusting power output, and 10 24-core sockets 117 are arranged in the lower half area and used for connecting the host device 1 with equipment such as an upper computer and an auxiliary machine device 2.

As shown in fig. 4 and 5, the sub-unit 2 of this embodiment has no circuit therein, and is connected to the main unit 1 via 2 24-core sockets 202, thereby controlling the components in the sub-unit 2 by the main unit 1. Specifically, the auxiliary unit device 2 of this embodiment includes an auxiliary unit casing 201, a water outlet pipe and a water inlet pipe which are arranged in the auxiliary unit casing 201, the auxiliary unit casing 201 is provided with a water inlet 208 which is communicated with the water inlet pipe, and 8 water outlets 207 which are communicated with the water outlet pipe, the other end of the water inlet pipe of this embodiment is connected with a high pressure water pump 205, and the high pressure water pump 205 is driven by a water pump motor 204. The water flow regulator 203 is arranged on the water outlet pipeline and can regulate the water flow of the water outlet, and the water flow regulator 203 is controlled by the control board through a cable. Of course, the auxiliary machinery unit 2 of this embodiment may not be provided with a high pressure water pump, but may be externally connected to a water pump device through the water inlet 208. The water inlet pipeline and the water outlet pipeline are changed into a water flow pipeline. The number of the cooling devices is 8, so that 8 water outlets are arranged to control the work of the 8 cooling devices respectively. The high pressure water pump 205 can rapidly adjust and pressurize the water flow in the cooling device, thereby adjusting the output of the cooling water according to the temperature feedback and shortening the cooling time and the cycle period.

The auxiliary unit device 2 of the embodiment is also internally provided with a control air blowing device 206 communicated with the water outlet 207, the auxiliary unit device of the embodiment is connected with an external blowing device through the air blowing port, and the control air blowing device 206 is controlled by the control panel through a cable. The blowing control device of the embodiment is 8 electromagnetic valves, and respectively controls the communication between the blowing port and the 8 water outlet pipelines, so as to blow out residual water in the 8 water outlet pipelines, reduce the heat absorption of the water and further facilitate the temperature control of the injection mold.

The number of the water outlets 207, the solenoid valves, the water flow regulators 203, the intelligent output regulating modules 116, and the like in this example can be set to other numbers according to requirements.

Preferably, the IO board 113 of this embodiment is provided with an IO module CPU, and the control board 108 is provided with a main control module, where the main control module includes a main control CPU, and the main control CPU is connected with the IO module CPU.

The main control board 108 of this example is further provided with a heating control module, a cooling control module and a mold temperature detection module, the main control CPU is respectively connected with the heating control module, the cooling control module and the mold temperature detection module, the heating control module is used for controlling a heating pipe to heat a mold, the cooling control module is used for controlling a cooling medium in a cooling pipe to cool the mold, the mold temperature detection module is used for detecting the mold temperature, and the IO board 113 is used for respectively connecting the main control CPU and an upper computer.

The invention can detect the mold temperature constantly through the full-automatic control of the main control CPU, and quantitatively output energy according to the mold temperature control to carry out heating or cooling control, so that the temperature difference between the cavity and the core is less than 2 ℃, thereby greatly improving the appearance quality of the product. The invention can work with injection machine, cooling machine, heating machine. The mold temperature and the pressure of the mold in the injection molding process can be monitored constantly through the embedded sensor connected with the mold, and data are fed back to the main control CPU for intelligent control.

As shown in fig. 6, 10 and 12, the heating control module includes a heating driving unit and a heating output unit respectively connected to the main control CPU, the number of the heating output units is more than one, and the heating driving unit is provided with driving interfaces whose number is consistent with that of the output ends of the heating output units. The heating output units of the embodiment are 5 groups, each group controls the two heating modules to heat, of course, other numbers of heating output units can be arranged according to requirements, and the switching module is additionally arranged between the main control board and the heating output units because more heating output units are arranged.

As shown in fig. 6 and 11-13, the main control module is connected to the interface J19 of the adaptor module through an interface J20, and the interface J19 is respectively connected to 5 interfaces J14-J18 connected to the heating output modules, wherein the interface J14 is connected to the interface J1 of the first group of heating output modules.

The first group of heating output units of the embodiment comprises a interface J1 connected with the main control module and two identical output units respectively connected with an interface J1, wherein one output unit comprises a relay RLY1, a current detection early coil T101, a thyristor U101 for adjusting the current, a switch tube Q101 and a switch tube Q102,

pin 1 of the relay RLY1 is respectively connected with pins 8, 40 and 72 of an interface J1, pin 2 of the relay RLY1 outputs a set voltage and is connected with the cathode of a diode D103, pin 1 is respectively connected with the anode of the diode and the drain of a switch tube Q102, the source of the switch tube Q102 is grounded, the grid is connected with the relay interface of a heating driving unit, and pin 3 of the relay RLY1 is respectively connected with pins 1 and 3 of a current detection early current coil T101 and pin 4 of a thyristor U101;

pin 2 of the current detection early coil T101 is connected with pin 35 of the interface J1, pin 4 of the current detection early coil T101 is connected with pin 3 of the interface J1,

pin 6 of silicon controlled rectifier U101 links to each other with the live wire terminal L of interface J1, pin 1 of silicon controlled rectifier U101 passes through resistance connection 24V power, pin 2 of silicon controlled rectifier U101 links to each other with the drain electrode of switch tube Q101, and the source ground of switch tube Q101, the grid links to each other with the silicon controlled rectifier drive interface of heating drive unit.

As shown in fig. 10, the heating driving unit of this embodiment includes 10 relay interfaces and 10 thyristor driving interfaces, which respectively control the switches and the output energy of the 10 output units.

As shown in fig. 6, 8, 18 and 19, the cooling control module of this example includes a flow control unit and an air blowing unit, wherein the main control module includes a flow control panel interface unit connected to the flow control unit and an air blowing driving interface unit connected to the air blowing unit, the cooling control module further includes a booster pump driving unit for driving a booster pump for making water enter a cooling pipe, the main control CPU is connected to the flow control panel interface unit and the air blowing driving interface unit, respectively, and the booster pump driving unit is connected to the IO module. Of course, the booster pump driving unit of the embodiment can also be directly controlled by the main control CPU, but the air channel and the circuit of the embodiment are directly controlled by the main control CPU, and the water channel is controlled by the IO module main control CPU unit, so that the water channel and the circuit are separately controlled, the safety is higher, the output control of the water pump is increased, and the water flow can be well controlled. In order to prevent water from flowing backwards, the cooling control module of the embodiment further comprises a one-way valve driving unit for controlling the one-way valve on the cooling pipe, and the one-way valve driving unit is connected with the IO module.

As shown in fig. 6 and 9, the mold temperature detecting module of this embodiment includes a detecting chip U1, an amplifier U7B, and an optical coupler U8, wherein pins 6 and 7 of the detecting chip U1 are respectively connected to a first output terminal of a current loop T3, pins 8 and 11 of the detecting chip U1 are respectively connected to a second output terminal of the current loop T3, a first input terminal of the current loop T3 is connected to a Temp _ SEN + terminal of a temperature sensor, a second input terminal of the current loop T3 is connected to a Temp _ SEN-terminal of the temperature sensor, pins 12 and 13 of the detecting chip are respectively connected to pins 1 and 2 of a main control CPU through a voltage stabilizing chip U4, pins 14 and 1 of the detecting chip are respectively connected to pins 3 and 4 of the main control CPU through a voltage stabilizing chip U5,

the positive direction input end of the comparator U7B is connected with one end of a resistor R12 and one end of a resistor R13 respectively, the other end of the resistor R13 is grounded, the other end of the resistor R12 is connected with a reference voltage output pin 9 of a detection chip U1 and is connected with a 5V power supply through a resistor R11, the output pin of the comparator U7B is connected with a pin 2 of an optical coupler U8 through an electron R19, a pin 1 of the optical coupler U8 is connected with the 5V power supply, a pin 3 of the optical coupler U8 is grounded, a pin 4 is connected with a pin 5 of a main control CPU, and is connected with the 3.3V power supply through a resistor R17. The temperature sensor can acquire the temperatures of the die cavity and the die core in real time, so that the die temperature can be adjusted and controlled in real time. The temperature sensor of this example is located in the mold near the mold cavity.

As shown in fig. 14 to 16, the IO module includes an IO module main control CPU unit, a communication interface respectively connected to the main control module and the computer, and a signal input unit and a signal output unit connected to the injection molding machine, wherein the IO module main control CPU unit is respectively connected to the communication interface, the signal input unit, and the signal output unit. The invention has high compatibility and can be compatible with injection molding machines of all brands.

As shown in fig. 17, the IO module of this embodiment further includes an alarm signal driving unit, so as to start an alarm indicator lamp to alarm when a device fails or is in an abnormal condition, but other alarm devices may also be used in this embodiment.

As shown in fig. 20, the IO module of this embodiment further includes an AC phase-error protection unit connected to the phase detector 110, where the AC phase-error protection unit includes a resistor R304, a resistor R303, a polar capacitor C304, a polar capacitor C305, and a thermistor RT2, where the pin 10 of the IO module main control CPU is connected to one end of the resistor R303 and the positive electrode of the polar capacitor C305, the other end of the resistor R303 is connected to one end of the resistor R304 and the negative electrode of the thermistor RT2, the positive electrode of the thermistor RT2 is connected to the 3.3V power supply and the positive electrode of the polar capacitor C304, and the negative electrode of the polar capacitor C304, the negative electrode of the polar capacitor C305, and the other end of the resistor R304 are grounded, respectively. The phase loss detection and protection of the three-phase power are realized through real-time detection of the thermistor RT2 in the AC phase-dislocation protection unit.

The IO module of this example still includes the water temperature detecting element that is used for in the cooling tube, water temperature detecting element includes resistance R312, resistance R311, polarity electric capacity C308, polarity electric capacity C309, thermistor RT1, wherein, IO module master control CPU's pin 11 links to each other with resistance R311's one end and polarity electric capacity C309's anodal respectively, resistance R311's the other end links to each other with resistance R312's one end and thermistor RT 1's negative pole respectively, and thermistor RT 1's positive pole links to each other with 3.3V power and polarity electric capacity C308's positive pole respectively, polarity electric capacity C308's negative pole, polarity electric capacity C309's negative pole and resistance R312's the other end ground connection respectively. The cooling degree of the temperature of the mold core and the temperature of the mold cavity can be well evaluated by detecting the water temperature of the cooling water.

As shown in fig. 21 to 26, as an embodiment of the present invention, the mold of the present invention includes a front mold core 3, a rear mold core 4, and a mold cavity 5 disposed between the front mold core 3 and the rear mold core 4, in this example, the front mold core 3 is provided with a heating device 16, a cooling device 15, and a temperature sensor 17 for detecting the temperature of the temperature zone corresponding to the mold cavity, in this example, the front mold core is provided for 1 st 2, that is, one mold is provided with two front mold cores 3.

As shown in fig. 23-25 and 27, the mold core 3 of the present invention includes a mold core body 301, the mold core body 301 includes a mounting surface 3012 for mounting the mold core body 301, a cavity surface 3011 for setting a product cavity for injection molding a product 19, and a side surface 3013 disposed at the periphery of the mounting surface 3012 and the cavity surface 3011, wherein the mounting surface 3012 is provided with a reinforcing structure, the mounting surface 3012 is further provided with a mold core heating and expanding positioning guide structure, the reinforcing structure and the mold core heating and expanding positioning guide structure are both provided with a heating and expanding telescopic slot 305, and a mold core expansion gap d is provided between the side surface 3012 and a mounting plate (in this example, a front mold core, the mounting plate is an a plate 7). The width of the mold core expansion gap d of the embodiment is 0.01mm, the width of the mold core expansion gap d is calculated according to the expansion coefficient of the front mold core 3 material and the required mold temperature, and the expansion gaps of different mold core materials are different. The core of this embodiment is preferably made of steel with fast heat conduction, high corrosion resistance, high toughness and stretchability, so as to minimize the warpage of the die steel.

If the thermal expansion groove 305 and the core expansion gap d are not provided, the installation is limited, and when the front core 3 expands due to heat, the front core 3 is arched toward the product cavity, thereby affecting the appearance of the product 19 in the product cavity 5. The intelligent micro-stress injection molding production control system can well avoid the micro-strain phenomenon of the front mold core 3.

As shown in fig. 27, the reinforcing structure of this embodiment includes reinforcing ribs 304 integrally formed with the side surface and provided around the mounting surface, and reinforcing ribs 302 provided inside the reinforcing ribs 304, the reinforcing ribs 302 being provided in a criss-cross manner to connect the reinforcing ribs 304 at both ends, so that the rigidity of the steel material can be improved, and the core body 301 can be made as thin as possible, thereby reducing absorption and conduction of energy of the core body 301, making the rate of heating the core faster, making the temperature easier to control, and avoiding a situation where the cavity temperature is greatly increased by energy accumulated in the core after the heating is stopped. The mold core body 301 of the embodiment realizes a lightweight design on the premise that the rigidity is not affected. The raw material is saved. And the residual stress of the product can be greatly reduced, the deformation is reduced, and the dimensional stability is improved.

The mold core heating expansion positioning guide structure comprises positioning ribs 303 arranged at the transverse center and the longitudinal center of the mounting surface 3012, so that the central position of the whole front mold core 3 is fixed, the phenomenon that the center is deviated due to shrinkage of the mold core body 301 is avoided, and the positioning ribs 303 protrude out of the surface of the reinforcing structure. The front mold core 3 is fixed as a fixing structure.

The mould core heating expansion location guide structure of this example still includes and sets up 4 reference columns 306 on the strengthening rib 304, reference column 306 sets up on four angles of mould core body 301, combines location muscle 303 to it is spacing to middle part and four angles of mould core body 301, preferred, location bone 306, location muscle 304 and the flexible groove 305 of heating expansion use location muscle 303 sets up for center pin axial symmetry, more does benefit to shrink after the thermal energy of mould core body 301 balanced. The phenomenon that the surface of the product 19 is deformed due to the micro deformation of the mold core caused by the unbalanced shrinkage after the heating and the thermal expansion is avoided.

As shown in fig. 22, 27 and 28, since the higher the temperature of the core body 301, the greater the shrinkage, therefore, the unbalanced heating of the core body 301 also causes a micro strain of the core body 301, therefore, in order to keep the temperature balance between the mold core body 301 and the mold cavity of this embodiment, each front mold core 3 of this embodiment is provided with 2 temperature zones, 4 temperature zones are provided for 2 front mold cores 3, each temperature zone is provided with a set of heating device 1601 and cooling device 15 and a temperature sensor 17, the heating device 16 and the cooling device 15 in each temperature zone are controlled by the controller, the number of the rear mold cores 4 of this embodiment is also 2, each rear mold core 4 is provided with 2 cooling zones (not shown in the figure, the installation manner of the cooling device is the same as that of the front mold core 3), each cooling zone is provided with a set of cooling device 15, and the cooling device in each cooling zone 15 is controlled by the controller.

The heating device 16 in this example is a heating pipe, and the cooling device 15 is a cooling pipe with a cooling medium therein. The cooling medium in this example may be water or another liquid medium that absorbs heat.

As shown in fig. 21-26, the heating device 16 of this embodiment is disposed on the front mold core, so that the mold is further provided with a heat insulation support plate 5 on the top surface of the front mold core 3 to prevent heat loss. One side of thermal-insulated backup pad 5 is equipped with the mounting groove that corresponds with mold core thermal expansion location guide structure, the mold core thermal expansion location guide structure of intelligent micro-stress injection molding production control system is fixed in the mounting groove, A board 7 is equipped with and holds mold core body 301 and thermal-insulated backup pad 5's holding tank, thermal-insulated backup pad 5 is fixed in A board 7 bottom surface, cooling duct 15's water inlet 1501 sets up the one side at the mould, cooling duct 15's delivery port 1502 sets up the opposite side at the mould. The water inlet 1501 and the water outlet are both arranged on the A plate 7 and are communicated with a cooling pipeline in the front mold core 3. The cooling water enters from one side of the die and flows out from the other side, so that the time of the cooling water staying in the cooling pipeline is greatly shortened, more cooling water passes through the cooling pipeline in unit time, and the cooling efficiency is better. All the cooling pipelines are arranged in parallel in the mold core, and the water flow reaching the vicinity of the mold cavity is basically consistent, so that the mold temperature balance is favorably kept.

The top surface of the A plate 7 is provided with a runner plate 9, and the top surface of the runner plate 9 is a panel 10. The rear mould core 4 of the embodiment is fixed on a B plate 8, two square irons 11 are arranged on two sides between a bottom plate 14 and the B plate 8, an ejector pin bottom plate 13 is fixed on the bottom plate between the two square irons, an ejector pin panel 12 is arranged on the ejector pin bottom plate 13, and two ejector pins penetrate through the B plate 8 and are connected with a mould cavity.

Of course, the temperature zone of this embodiment may be set on the rear mold core 4 to realize the heating and cooling functions of the front mold core 3 and the rear mold core 4, or the temperature zone may be set on the rear mold core 4 and the cooling zone may be set on the front mold core 3, so that the heating device on the rear mold core 4 heats the mold cavity 5 and the cooling device on the front and rear mold cores cools the product. In this case, the heat insulating support plate is disposed on the side where the heating means is provided.

A plurality of temperature areas are adopted for respectively heating or cooling, each temperature area and each cooling area are independently controlled, and an independent temperature sensor 17 is arranged, so that the temperature of the die cavity can be accurately controlled, the temperature difference can be controlled within 2 ℃, the micro-stress of the die core body 301 is ensured, the thermal expansion deformation is prevented, the die temperature balance of the die cavity is favorably kept, and the warping deformation of the product 19 caused by unbalanced heating and cooling is prevented.

As shown in fig. 29, the intelligent micro-stress injection molding production control system of the present embodiment is particularly suitable for processing high-precision products, and as an embodiment, if the products are flat arc-shaped, the present embodiment can equally divide the front mold core 3 and the rear mold core into 8 regions (the vertical line is the boundary of each region) according to the shape of the mold cavity, so as to independently control the temperature of each temperature region, thereby avoiding the problems that the cooling pipeline and the heating pipe are horizontally arranged, the distance from the mold cavity 5 is too large, the mold temperature difference of the products is too large, the mold cavity temperatures are different, the molten state liquid fluidity is different during injection molding, the shear rate is different, and the quality of the products cannot be guaranteed in the prior art; the cooling is asynchronous, which causes the warping deformation of the product. The invention is especially suitable for the die cavity with a three-dimensional complex shape, and the subareas are set according to the shape of the product, thereby ensuring the temperature difference of each area of the product. The scheme of the invention is not limited by the size, shape, structure and wall thickness of the product. The processing method can process thin-wall products with the thickness of more than or equal to 0.5mm, and can not cause the warping deformation of the products.

The mounting surface 3012 of the front core 3 of this embodiment can also be processed into a non-planar structure according to the shape of the product, as long as the surface of the reinforcing structure is ensured to be horizontally contacted with the surface of the heat insulation support plate 6. Of course, the surface of the heat insulation support plate 6 in this embodiment can also be matched with the surface of the front mold core 3012, so that the heat insulation effect is better.

As shown in fig. 25 to 28, in this example, the number of heating pipes and cooling pipes in each temperature zone is plural, and the heating pipes and the cooling pipes are arranged at intervals. Thereby facilitating control of the balance of temperature differences.

The distances between the temperature sensor 17, the cooling pipeline 15 and the heating pipe 16 are equal, and preferably form an equilateral triangle. The distance between the temperature sensor 17 and the mold cavity, the distance between the temperature sensor 17 and the cooling pipeline 15, and the distance between the temperature sensor 17 and the heating pipe are equal. Thereby making the mold temperature measured by the temperature sensor 17 more accurate. The design reason for the multipoint distance equality is that: the front mold core 3 is heated or cooled in the heating or cooling process (steel) and has energy gathering and heat conducting time, so that the sensor 17 is arranged at the average value of the distances between the cooling pipeline 15 and the heating pipe 16 and the surface of the mold cavity, and the heating, cooling and mold cavity surface (namely the surface temperature of a product) test results are more accurate.

The distance x between the heating pipe and the top surface of the front mold core is equal to the distance y between the heating pipe and the cavity surface of the front mold core. The measurement is more accurate, and the distance between the cooling pipeline in the front mold core of the embodiment and the top surface of the front mold core is equal to the distance between the cooling pipeline in the front mold core and the cavity surface of the front mold core.

Through the subregion to the mould and embedding temperature measuring device, the control mold temperature is alone controlled in every district, effectively guarantees the mould temperature balance, does not receive the restriction of product size, shape, structure, wall thickness. Can process products with various shapes and can ensure the quality and the appearance quality of the products.

As shown in fig. 23 and 24, in the plate a design of the present example, the thermal expansion phenomenon of the steel material of the front core 3 is sufficiently considered, and therefore, a core expansion gap d of 0.01mm exists between the outer periphery of the front core and the plate a, but since the front core 3 of the present example is provided in two by one, and the runner is provided between the two front cores 3, in order to avoid the branch runner between the runner and the gate 3 from interfering with the micro strain of the front core 3, the plate a 7 of the present example is provided with the bridging insert 18, the bridging insert 18 rides over the core expansion gap d of the plate a 7 and the front core 3, the runner and the branch runner of the gate 3 are provided over the bridging insert 18, and the bridging insert 18 is in clearance fit with the front core 3, so that the thermal expansion and contraction of the front core 3 are not interfered. In addition, the phenomenon that the molten liquid flows into the mold core expansion gap d to block the mold core expansion gap d can be effectively avoided.

The injection molding steps of the intelligent micro-stress injection molding production control system are as follows:

firstly, initial setting of equipment starting (mold opening of an injection molding machine): and setting parameters of injection molding of the injection molding machine, including heating temperature, cooling temperature and the like.

Heating, wherein each selected temperature zone is automatically simulated and analyzed through 3 cycles, and the simulation analysis is as follows: the final actual temperature detected by the temperature sensor is higher than the set value due to the energy accumulation and heat conduction time of the die steel, and then the energy output is analyzed, calculated and adjusted through the CPU. And in the heating process, the cooling system stops working, and the flow valve and the airflow valve are in a closed state. (the injection molding machine synchronously works while heating, such as ejecting a product and then closing the mold) the temperature sensor outputs and closes when the heating temperature of each temperature zone reaches a set value.

And thirdly, after the heat conduction temperature is balanced for n seconds (n is a natural number, and the adjustable value of the example is 0-99S), the system sends an instruction to an injection molding machine for injection (glue injection).

Fourthly, cooling: after the injection (injection) starts for a set time (0-99S adjustable value), the cooling liquid high-pressure water pump 205 is started and the cooling variable valve is started to start cooling. (the high-pressure water pump 205 makes the liquid reach the turbulent flow state, the flow regulator 203 reduces the flow according to the area with fast cooling, on the contrary, the flow is increased in the area with slow cooling, all areas of the whole set of die reach the same step-like cooling.

Fifthly, air blowing: when all the areas are cooled to reach the set value, the water flow regulator 203 is closed, and the high-pressure water pump 205 stops working. The air blowing valve starts to blow air, the air blowing time is adjustable within 0-99S, and the air blowing is as follows: the cooling liquid in the cooling channel is blown out, and the purpose is as follows:

1. the energy output when the heating is increased due to the cooling liquid surface in the cooling channel is reduced;

2. when heating, the liquid in the cooling pipeline passes through the heated steam to ensure that the surface temperature of the cavity of the mould cannot be balanced.

Sixthly, mold opening/ejection is carried out: after the above steps are completed, the main control board 108 sends out instructions to open the mold and eject out, and simultaneously starts the next cycle. And the data is acquired, analyzed, adjusted and output and the like in the previous cycle.

The invention embeds a temperature measuring device in an injection mold, monitors mold temperature and pressure constantly in the injection molding process, and feeds data back to a main control CPU for intelligent analysis and control, comprising: engineering simulation and comprehensive analysis (a database is accumulated from experiments developed in the past, and the most suitable production technical parameters can be intelligently matched according to product requirements), and intelligent and extremely rapid adjustment is realized.

The heating and cooling device adopts intelligent numerical control analysis to quantitatively output energy. The temperature difference between the cavity and the core at any position can be less than 2 ℃. The equipment adopts a full-automatic mode, has high compatibility, can be compatible with injection molding machines of all brands, and can be widely applied to injection molding product manufacturing enterprises. The method is suitable for various injection molding schemes, such as chemical micropore foaming molding, highlight paint-free molding, high fiber gloss molding, thin wall molding, wood fiber material gloss molding, gas-assisted molding and the like, can avoid secondary processing, and saves a large amount of time, labor and raw material cost for manufacturing enterprises.

In conclusion, the invention has the following outstanding advantages:

1. the surface of a high-quality product can be formed by one-step injection molding no matter the traditional resin raw material or the resin raw material added with inorganic or organic fillers, shrinkage marks, flow marks, water clamping lines, glue mouth marks and the like are eliminated, secondary procedures of spraying paint, polishing appearance and the like on the product are eliminated, the raw material and time cost are saved, the environmental pollution is reduced, and meanwhile, the recycling of the resin is facilitated;

2. the residual stress of the product can be reduced to the maximum extent, the warping and deformation of the product are reduced, the dimensional stability of the product is obviously improved, and the productivity is released;

3. by increasing the pressure of the cooling liquid, the production molding period can be shortened by 10-20% even if common water is used as the cooling liquid;

4. the micropore foaming forming technology is matched, so that the problems of the product in aspects of appearance, flatness, size, weight and the like are greatly reduced, the reject ratio of the product is obviously reduced, and 5-20% of raw materials can be saved while the product is lightened;

5. the product is thinned, and the thinnest can be 0.5 mm.

The above-described embodiments are intended to be illustrative, and not restrictive, of the invention, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.