阅读说明：本技术 射出成型机台状态监控系统及监控方法 (System and method for monitoring state of injection molding machine ) 是由 马光辉 林尚毅 陈力铭 薛凯薰 于 2020-06-09 设计创作，主要内容包括：一种射出成型机台状态监控系统及监控方法,该射出成型机台状态监控系统应用于一成型设备,成型设备包括成型机台、模具及模温机,所述射出成型机台监控系统包括数据采集器、控制器及报警器,数据采集器及报警器均与所述控制器通信连接；所述数据采集器与成型机台、模具及模温机通信连接,用于实时采集所述成型机台、所述模具及所述模温机的成型过程数据；所述控制器,用于接收所述成型过程数据,判断所述成型过程数据是否超出一数值管控范围；所述报警器用于当所述成型过程数据超出所述数值管控范围时进行报警。本发明的监控系统可提前预警,提前检修机台,避免机器老化造成良率下降,降低不必要的损失。(A state monitoring system and a monitoring method of an injection molding machine are provided, the state monitoring system of the injection molding machine is applied to a molding device, the molding device comprises a molding machine, a mold and a mold temperature controller, the monitoring system of the injection molding machine comprises a data collector, a controller and an alarm, and the data collector and the alarm are in communication connection with the controller; the data acquisition unit is in communication connection with the molding machine, the mold and the mold temperature controller and is used for acquiring molding process data of the molding machine, the mold and the mold temperature controller in real time; the controller is used for receiving the forming process data and judging whether the forming process data exceeds a numerical value control range; the alarm is used for giving an alarm when the forming process data exceeds the numerical value control range. The monitoring system can give an early warning in advance, overhaul the machine in advance, avoid yield reduction caused by machine aging and reduce unnecessary loss.)

1. The system for monitoring the state of the injection molding machine is applied to molding equipment, and the molding equipment comprises the molding machine, a mold and a mold temperature controller, and is characterized by comprising a data collector, a controller and an alarm, wherein the data collector and the alarm are in communication connection with the controller;

the data collector is in communication connection with the molding machine, the mold and the mold temperature controller and is used for collecting molding process data of the molding machine, the mold and the mold temperature controller in real time;

the controller is used for receiving the forming process data and judging whether the forming process data exceeds a numerical value control range;

the alarm is used for giving an alarm when the forming process data exceeds the numerical value control range.

2. An injection molding machine status monitoring system as claimed in claim 1, wherein the molding process data comprises molding machine molding process data, the molding machine molding process data comprising an injection start point position, an injection end point position, a switching time, a switching pressure, a sol end point, a sol time, a post-cooling time, a nozzle temperature.

3. An injection molding machine state monitoring system as claimed in claim 2, wherein said molding process data further comprises in-mold molding process data, said in-mold molding process data comprising plastic pressure, plastic temperature, male mold temperature and female mold temperature.

4. An injection molding machine status monitoring system as claimed in claim 3, wherein the molding process data further comprises mold temperature machine molding process data, the mold temperature machine molding process data comprising a water outlet hot water temperature and a water outlet cold water temperature.

5. An injection molding machine state monitoring system as claimed in claim 4, wherein the in-mold molding process data and the mold temperature machine molding process data are collected by means of high frequency data collection, and the frequency of the high frequency data collection is 20 Hz-50 Hz.

6. An injection molding machine state monitoring system as claimed in claim 1, wherein determining said numerical control range comprises the steps of:

acquiring the forming process data corresponding to good products in the formed products in real time; and

and establishing the numerical value control range according to the forming process data of all the good products.

7. An injection molding machine state monitoring system as claimed in claim 1, wherein said data collector further comprises a camera, said camera being in communication with said controller for collecting images of molded products in real time;

the controller is further used for receiving the image transmitted by the camera, comparing the image with a preset good product image, judging whether a formed product is a good product or not, and when the formed product is the good product, establishing and updating the numerical value control range according to the forming process data corresponding to the good product.

8. The system for monitoring the state of the injection molding machine as claimed in any one of claims 1 to 7, further comprising a memory, a display and a marker, wherein the memory, the display and the marker are all communicatively connected to the controller,

the memory is used for storing the molding process data and the numerical control range received by the controller;

the display is used for displaying the forming process data, the numerical control range and the alarm data in real time;

the marking device is used for printing numbers on the molded products.

9. A method for monitoring the state of an injection molding machine is applied to a molding device, the molding device comprises the molding machine, a mold and a mold temperature controller, and the method for monitoring the state of the injection molding machine comprises the following steps:

collecting the forming process data of the forming machine table, the die and the die temperature controller in real time;

comparing the collected forming process data with a numerical control range, and judging whether the forming process data exceeds the numerical control range; and

and alarming when the forming process data exceeds the numerical value control range.

10. A method as claimed in claim 9, wherein said alarming comprises alarming according to a deviation of said molding process data from said numerical control range.

Technical Field

The invention relates to the technical field of injection molding equipment, in particular to a system and a method for monitoring the state of an injection molding machine.

Background

With the rapid development of electronic and information products, mold injection molding is widely used in the plastic industry, including 3C, automotive, household electrical appliances, and the like. The principle of the injection molding of the mold is that the plastic is dried to remove the water in the plastic, then the plastic is put into a material pipe, the temperature of the material pipe is set to heat the plastic to a molten state, the molten plastic is pushed into a mold cavity by a screw in a high-pressure mode, and after the plastic product is cooled and solidified, the mold is opened and the product is ejected.

In the process of molding plastic products, the molding process can be roughly divided into four stages, namely, a preparation stage (a mold heating stage and a material drying stage), a second injection stage (an injection stage and a pressure maintaining stage), a third cooling stage (a glue melting stage and a post cooling stage), and a fourth mold opening and ejection stage. If the molding parameters do not meet the standard in each stage of the injection molding, the molded product will have abnormal quality.

The traditional solution needs to monitor the molding parameters manually, the manual monitoring cannot achieve real-time monitoring, monitoring errors are caused, a lot of defective products are produced when problems are found, the yield of products is reduced, and unnecessary loss is caused.

Disclosure of Invention

In view of the above, a need exists for a system and a method for monitoring the status of an injection molding machine, which can meet the requirements of on-line monitoring of a molded product, early warning, timely finding of problems in molding equipment, and reduction of production loss.

The invention provides a state monitoring system of an injection molding machine, which is applied to molding equipment, wherein the molding equipment comprises a molding machine, a mold and a mold temperature controller, the monitoring system of the injection molding machine comprises a data collector, a controller and an alarm, and the data collector and the alarm are in communication connection with the controller.

The data collector is in communication connection with the molding machine, the mold and the mold temperature controller and is used for collecting molding process data of the molding machine, the mold and the mold temperature controller in real time.

The controller is used for receiving the forming process data and judging whether the forming process data exceeds a numerical value control range.

The alarm is used for giving an alarm when the forming process data exceeds the numerical value control range.

Further, the molding process data comprises molding machine molding process data, and the molding machine molding process data comprises an injection starting point position, an injection end point position, a switching position, switching time, switching pressure, a sol end point, sol time, post-cooling time and nozzle temperature.

Further, the molding process data further comprises in-mold molding process data, which comprises plastic pressure, plastic temperature, male mold temperature and female mold temperature.

Further, the molding process data further comprises molding temperature machine molding process data, and the molding temperature machine molding process data comprises water outlet hot water temperature and water outlet cold water temperature.

Further, the data of the molding process in the mold and the data of the molding process of the mold temperature controller are collected in a high-frequency data collection mode, and the frequency of the high-frequency data collection is 20 Hz-50 Hz.

Further, determining the numerical control range includes the following steps:

acquiring the forming process data corresponding to good products in the formed products in real time; and

and establishing the numerical value control range according to the forming process data of all the good products.

Furthermore, the data collector also comprises a camera which is in communication connection with the controller and used for collecting the image of the formed product in real time.

The controller is further used for receiving the image transmitted by the camera, comparing the image with a preset good product image, judging whether a formed product is a good product or not, and when the formed product is the good product, establishing and updating the numerical value control range according to the forming process data corresponding to the good product.

Further, the injection molding machine state monitoring system further comprises a memory, a display and a marker, wherein the memory, the display and the marker are in communication connection with the controller.

The memory is used for storing the molding process data and the numerical control range received by the controller.

The display is used for displaying the forming process data, the numerical value control range and the alarm data in real time.

The marking device is used for printing numbers on the molded products.

The invention also provides a method for monitoring the state of the injection molding machine, which is applied to a molding device, wherein the molding device comprises the molding machine, a mold and a mold temperature controller, and the method for monitoring the state of the injection molding machine comprises the following steps:

collecting the forming process data of the forming machine table, the die and the die temperature controller in real time;

comparing the collected forming process data with a numerical control range, and judging whether the forming process data exceeds the numerical control range; and

and alarming when the forming process data exceeds the numerical value control range.

Further, the alarming comprises alarming according to the deviation of the forming process data and the numerical value control range.

Compared with the prior art, the injection molding machine state monitoring system provided by the invention has the following beneficial effects:

1. through injection molding machine state monitoring system, early warning can be in advance, the maintenance of former is carried out, avoided the machine ageing, still produce the product, cause the yield to descend scheduling problem.

2. Through repeated comparison and verification with manual inspection in the actual production process, the injection molding machine state monitoring system provided by the invention can find problems in advance compared with manual inspection, can give early warning and carry out maintenance on molding equipment in advance, effectively reduces the production of defective products and reduces unnecessary loss in the production process.

Drawings

Fig. 1 is a schematic diagram of a system for monitoring a status of an injection molding machine according to an embodiment of the present invention.

Fig. 2 is a flowchart of a method for monitoring a status of an injection molding machine according to an embodiment of the present invention.

Fig. 3 is a flowchart of a method for determining a numerical control range in a system for monitoring a state of an injection molding machine according to an embodiment of the present invention.

Fig. 4 is a schematic diagram of a system for monitoring the status of an injection molding machine according to another embodiment of the present invention.

Description of the main elements

System 100 for monitoring the status of an injection molding machine

Data acquisition units 1, 8

Displacement sensor 11

Temperature sensor 12

Pressure sensor 13

Time relay 14

Controller 2

Alarm 3

Memory 4

Display 5

Marking device 6

Camera 7

The following detailed description will further illustrate the invention in conjunction with the above-described figures.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Example one

Fig. 1 is a schematic diagram of a system 100 for monitoring the status of an injection molding machine according to an embodiment of the present invention.

In this embodiment, the system 100 for monitoring the status of the injection molding machine can be applied to a molding apparatus, which is an injection molding apparatus including a molding machine, a mold and a mold temperature controller.

As shown in fig. 1, the system 100 for monitoring the status of an injection molding machine specifically includes: data collection station 1, controller 2 and alarm 3, data collection station 1 with alarm 3 all with controller 2 communication connection.

The data collector 1 is arranged at the position where the forming machine table, the die and the die temperature controller need to collect data, is in communication connection with the forming machine table, the die and the die temperature controller, and is used for collecting data of the forming process of the forming machine table, the die and the die temperature controller. Under the condition that the equipment can bear load, aiming at the data acquisition of the die and the die temperature controller, the data acquisition unit 1 can acquire data in a high-frequency mode, and the acquisition frequency can be 20Hz to 50Hz, preferably 20Hz, further preferably 30Hz, further preferably 40Hz, and further preferably 50 Hz.

In four stages of the plastic product molding process, in a preparation stage, whether plastic particles entering a charging barrel in the molding machine are dried or not and the internal temperature of the mold need to be monitored; in the injection stage, the displacement condition of a screw in the molding machine table, the change of the temperature and the pressure in the mold, the corresponding molding time and the like need to be monitored; in the cooling stage, the cooling condition of the mold needs to be monitored; the surface temperature of the molded product needs to be monitored in the mold opening and ejection stages. Therefore, different collectors need to be set corresponding to different data collection points. According to the characteristics of the data needing to be collected, the data collector 1 comprises but is not limited to a displacement sensor 11, a temperature sensor 12, a pressure sensor 13 and a time relay 14.

The molding process data includes, but is not limited to, molding process data of a molding machine, molding process data in a mold, and molding process data of a mold temperature machine.

As shown in table 1, different data collectors are provided for the three molding devices according to the parameters of the four molding processes to be collected.

TABLE 1

As shown in Table 1, different data collectors 1 are arranged in the plastic product molding process to collect corresponding molding process data at different positions, only parameters to be controlled in part of the molding process are given in Table 1, and the corresponding data collectors 1 can be increased or decreased according to actual needs.

For the molding machine, each molded product generally has only one set of data in one production cycle. For the mold and the mold temperature controller, according to the setting of the acquisition frequency of the data acquisition unit 1, each molded product has a plurality of sets of data in one production cycle, that is, each molded product has a series of data for a certain detected molding process data, for example, the plastic temperature in the mold, and each molded product has a series of data according to the setting of the acquisition frequency.

And the controller 2 is used for receiving the molding process data acquired by the data acquisition unit 1 and judging whether the molding process data exceeds a numerical control range.

And the alarm 3 is used for giving an alarm when the forming process data exceeds the numerical value control range. If the real-time collected forming process data exceed the numerical control range, the alarm 3 gives an alarm.

Meanwhile, different alarm levels can be set through the controller 2, and different alarms can be given when the forming process data exceeds the deviation of the numerical control range. In this embodiment, alarm 3 is bee calling organ, works as the shaping process data surpass when the deviation of numerical value management and control scope is less, bee calling organ's sound is less, along with the shaping process data surpass the increase of the deviation of numerical value management and control scope, bee calling organ's sound also can constantly increase. Or, the alarm 3 can also be alarm lamps of different colors, and the alarm lamps of different colors can be flickered according to the deviation of the forming process data exceeding the numerical control range.

The production process parameters of the mold temperature machine, the mold and the molding machine are not accidental if the abnormality occurs, most of the parameters are caused by the aging phenomenon after the machine operates for a period of time, and an operator can know whether the molding equipment has the aging problem in advance according to alarm prompts of different levels and timely overhaul the molding equipment, so that the problem that the yield of products is reduced because the molding equipment is not discovered due to aging is avoided, and the production loss is reduced.

Obviously, in the present embodiment, means for eliminating errors are also designed for the accidental fluctuation of the molding process data. For example, the alarm may be given only when the number of times that a certain molding process data exceeds the numerical control range exceeds 2 or 3. Or the deviation of the certain forming process data exceeding the numerical control range is small, and the alarm is given after 3 or 4 times. Therefore, false alarm caused by error fluctuation can be avoided, and the production efficiency is influenced. Of course, the above time limit is limited to the means for explaining the exclusion error.

In this embodiment, the injection molding machine state monitoring system further includes a memory 4, the memory 4 is used for storing the molding process data and the numerical value control range, the later stage can be conveniently obtained after data storage, and comparison is performed on the controller 2.

In this embodiment, the system 100 for monitoring the state of the injection molding machine further includes a display 5, where the display 5 is configured to display the molding process data, the numerical control range and the alarm data in real time, so as to facilitate the checking of operators.

In this embodiment, the system 100 for monitoring the state of the injection molding machine further includes a marker 6, and the marker 6 is used for printing a production number on a molded product, so as to facilitate subsequent identification.

Fig. 2 is a flowchart of a method for monitoring the status of an injection molding machine according to the present invention, which is applied to the system 100 for monitoring the status of an injection molding machine.

In this embodiment, the method for monitoring the state of the injection molding machine can be applied to a molding apparatus, and more particularly, to an injection molding apparatus. As shown in fig. 2, the method for monitoring the state of the injection molding machine specifically includes the following steps:

and step S1, collecting the forming process data of the forming machine, the mould and the mould temperature controller in real time.

Firstly, the corresponding data collector 1 is installed at the position corresponding to the mold temperature controller in the molding machine and the mold, and the production process data is collected as shown in table 1 (only the positions and collected data of a part of the data collector 1 in the molding process are emitted in table 1). Subsequently, the molding process data acquired by the corresponding data acquisition unit 1 represents the production data collected by the molding machine, the mold and the mold temperature controller in the production process. Under the same plastic product molding process production conditions, in the production process, the molding process data acquired by the data acquisition unit 1 at each time point in four stages of the plastic product molding process of each molded product is recorded. In the case where the facility can be loaded, data is collected at a high frequency, for example, 20Hz to 50Hz, preferably 20Hz, more preferably 30Hz, still more preferably 40Hz, and still more preferably 50Hz with respect to the inside of the mold and the mold temperature controller.

Step S2, comparing the collected forming process data with a numerical control range, and determining whether the forming process data exceeds the numerical control range.

Because of cost reason, every can not every the shaping product all carries out quality testing, according to the aforesaid establish numerical value management and control scope, alright in order to will gather in real time the shaping process data with the numerical value management and control scope is compared, in the scope, then judges as the yields, is not in the scope, then judges as the rejects, simultaneously to the rejects correspond the shaping process data corresponds concrete parameter in the production process, detects whether ageing appears in the former equipment, early warning in advance, discovers in advance, avoids causing too much defective products' production because of equipment ageing or trouble.

And step S3, alarming when the forming process data exceeds the numerical control range.

And if the forming process data acquired in real time exceed the numerical control range, alarming at different levels is carried out according to the exceeding deviation. For example, the average hot water temperature value corresponding to the extracted good product in the injection stage is between 60 ℃ and 70 ℃, if the hot water temperature corresponding to the undetected molded product in the subsequent production is not in the interval, different levels of alarms are given according to the deviation degree, and meanwhile, the molding equipment needs to be overhauled in time, so that batch badness caused by equipment problems is avoided.

Specific alarm levels can be set according to actual conditions aiming at different levels of deviation for alarm. In this embodiment, alarm 3 can adopt bee calling organ, works as shaping process data surpass when the deviation of numerical value management and control scope is less, bee calling organ's sound is less, along with shaping process data surpass the increase of the deviation of numerical value management and control scope, bee calling organ's sound also can constantly increase. Or, the alarm 3 can also be alarm lamps of different colors, and the alarm lamps of different colors can be flickered according to the deviation of the forming process data exceeding the numerical control range. Obviously, in the present embodiment, means for eliminating errors are also designed for the accidental fluctuation of the molding process data. For example, the alarm may be given only when the number of times that a certain molding process data exceeds the numerical control range exceeds 2 or 3. Or the deviation of the certain forming process data exceeding the numerical control range is small, and the alarm is given after 3 or 4 times. Therefore, false alarm caused by error fluctuation can be avoided, and the production efficiency is influenced.

As shown in fig. 3, in the present embodiment, the method for establishing the numerical control range specifically includes the following steps:

and step Q1, sampling and obtaining good products in the molded products. In the production process, the molded product is sampled and checked, the sampled molded product is compared with a standard good product (specific comparison items comprise product appearance, size and the like), a good product is determined, all numbers of the good product obtained by sampling and checking are matched with corresponding molding process data, namely, each good product corresponds to a series of molding process data in the whole molding process.

In the embodiment, the molded product is randomly inspected in the early stage of production with the same parameter setting value, and several products can be continuously inspected in a random manner or randomly inspected, for example, more than 20 products are initially inspected or 1 product is extracted every 10 products. And (3) judging the quality of the formed product subjected to the selective inspection according to a standard sample, observing whether the appearance of the formed product subjected to the selective inspection has defects or whether each dimension has an over-specification phenomenon, inspecting the good product, and recording the product number of each good product.

And Q2, establishing the numerical control range after the forming process data of all the good products are acquired. Since each molded product has a series of data in one production cycle and the number of good products is also multiple, the controller 2 needs to calculate according to the series of data to obtain the numerical control range corresponding to each control parameter. For the molding process data of the mold and the mold temperature controller, since the data collector 1 is a high-frequency data collector, each molded product has multiple sets of data in one production cycle, that is, each molded product has a series of data for a certain detected molding process data, and the average value, median, maximum value, minimum value, sum and the like of a certain molding process data corresponding to four stages of the molding process of a plastic product of each molded product can be calculated through calculation; and each formed product only has one data according to the forming process data of the forming machine, but a corresponding range needs to be calculated according to the process data of all good products, and the obtained forming process data is arranged to establish a corresponding numerical control range.

In this embodiment, the numerical control range is updated in real time. The numerical control range is a dynamic range, and the range can be continuously adjusted according to the production promotion. After the numerical control range is established, the data collector 1 collects the molding process data of the molded product, the molding process data of the good product is transmitted to the controller 2 through sampling inspection, and the controller 2 automatically updates the molding process data.

Example two

Referring to fig. 4, a second embodiment of the present invention is an injection molding machine state monitoring system, and the difference between the second embodiment and the first embodiment is that the data collector 8 further includes a camera 7, the camera 7 is used for collecting an image of a molded product, and the controller 2 is further used for receiving the image transmitted by the camera 7, comparing the image with a preset good product image, and determining whether the molded product is a good product, where the specific determined parameters include whether the appearance has a defect, whether the size meets the standard, and the like. It should be noted that, within the scope of the spirit or the basic features of the present invention, each specific solution applicable to the first embodiment may also be correspondingly applicable to the second embodiment, and for the sake of brevity and avoidance of repetition, the detailed description thereof is omitted here. In this embodiment, the camera 7 and the controller 2 are adopted to cooperate with each other, so that online automatic sampling can be realized, good product quality parameters can be extracted, and the problem that the numerical value control range is established by further manually sampling and corresponding obtained good products to the forming process data is avoided.

Compared with the prior art, the injection molding machine state monitoring system provided by the invention has the following beneficial effects:

1. through injection molding machine state monitoring system, can advance the early warning, carry out the maintenance of mould temperature machine or shaping machine, avoid the machine ageing, still produce the product, cause the yield to descend the scheduling problem.

2. Through comparison and verification of offline repetition with manual inspection in actual production, the injection molding machine state monitoring system provided by the invention can find problems in advance compared with manual inspection, can give early warning and maintain the machine, effectively reduces production of defective products and reduces unnecessary loss.

In addition, it is obvious to those skilled in the art that other various corresponding changes and modifications can be made according to the technical idea of the present invention, and all such changes and modifications should fall within the scope of the claims of the present invention.