An intelligent micro-stress injection molding production control system

Abstract

The present invention provides an intelligent micro-stress injection molding production control system, belonging to the field of injection molding. The intelligent micro-stress injection molding production control system of the present invention includes an intelligent integrated control device, an injection mold, a heating device for heating the product cavity in the injection mold, a cooling device for cooling the product cavity of the injection mold, and a temperature measuring device arranged in the injection mold for detecting the temperature of the product cavity corresponding to the temperature zone. Among them, the intelligent integrated control device is respectively connected to 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 output energy in real time and quantitatively. The beneficial effects of the present invention are as follows: multi-unit collaborative operation, controlling the temperature of the product cavity, minimizing the residual stress of the injection molded product to the greatest extent, greatly reducing problems in aspects such as product appearance, flatness, size, and weight, and significantly reducing the defective rate of the product.

Description

Technical Field

[0001] The invention relates to the field of injection molding, and in particular to an intelligent micro-stress injection molding production control system. Background Art

[0002] As products become more and more complex, product tolerance requirements and surface appearance quality requirements are also getting higher and higher. The use of traditional injection molding technology has caused a variety of quality and cost problems that cannot be solved by existing domestic and foreign technologies, such as mold steel thermal expansion deformation, mold temperature imbalance, large internal stress in the product, and increasing manufacturing costs. It can be said that the field of plastic processing has encountered unprecedented challenges and urgently needs to seek a new set of systematic solutions to change the predicament.

[0003] Due to its intelligent system solution performance advantages and the "mutation" in the field of plastic processing, it provides a broad space for development in this field. In the current Chinese manufacturing industry, which faces high cost pressure and product specifications in the automotive, aviation, medical and electronic and electrical fields, there is an urgent need for innovative and diverse injection molding solutions. With the rise of the new energy vehicle market, the search for lighter and heavier vehicles with lower fuel consumption, as well as lighter automotive accessories and trims, and the production of these precision parts is also inseparable from new integrated solutions.

[0004] Based on more than ten years of experience in mold making and injection molding, the applicant found that it is difficult to solve the problems of stress elimination of injection molding products and mold temperature balance control during the injection molding process. These difficulties have not been overcome for a long time, resulting in the difficulty of systematically solving the quality problems of injection molding products and the difficulty of further improving the level of China's manufacturing industry. Although there are devices on the market that solve related problems, they can only solve certain problems in a targeted manner. They have defects and fail to provide a solution for the entire chain from mold design to injection molding production. For example: there is no sensor in the mold to detect the mold temperature, and the mold temperature auxiliary equipment can only simply heat and cannot accurately control the temperature; or there is no way to accurately control the mold temperature in different areas according to the product structure design; or there is no database established to use the central processor for intelligent analysis to provide the most appropriate production parameters, such as temperature, pressure, etc. Summary of the invention

[0005] In order to solve the problems in the prior art, the present invention provides an intelligent micro-stress injection molding production control system.

[0006] The present invention includes an intelligent integrated control device, an injection mold, a heating device for heating the product cavity in the injection mold, a cooling device for cooling the product cavity of the injection mold, and a temperature measuring device disposed in the injection mold for detecting the temperature of the product cavity corresponding to the temperature zone. Among them, the intelligent integrated control device is respectively connected to 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 output energy in real time and quantitatively.

[0007] The present invention is further improved. The intelligent integrated control device includes a host device and a slave device connected by a cable. Among them, the host device includes a host housing, a control board disposed in the host housing, an IO board and a power supply connected to the control board, and further includes a power control device connected to the control board and an intelligent output adjustment module for adjusting the power output. The slave device includes a slave housing and a coolant pipeline disposed in the slave housing. The slave housing is provided with an inlet and an outlet communicating with the coolant pipeline, and the outlet is connected to the cooling device.

[0008] The present invention is further improved. The coolant is water, the coolant pipeline is a water flow pipeline, and a control blowing device communicating with the water outlet is further disposed in the slave device. The control blowing device is connected to the control board by a cable. A water pump connected to the water inlet is further disposed in the slave device. A water flow regulator for adjusting the water flow size of the water outlet is further disposed on the water flow pipeline in the slave device. The water flow regulator is connected to the control board by a cable.

[0009] The present 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 includes a main control CPU, the main control CPU is connected to the IO module CPU, the control board 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 to the heating control module, the cooling control module, and the mold temperature detection module. The heating control module is used to control the heating tube to heat the mold, the cooling control module is used to control the cooling medium to cool the mold, the mold temperature detection module is used to detect the mold temperature, and the IO board is used to connect the main control CPU and the upper computer respectively.

[0010] The present invention is further improved. The injection mold includes a front mold core, a rear mold core, and a product cavity disposed between the front mold core and the rear mold core. Among them, the heating device and the temperature measuring device are disposed on the front mold core, and cooling devices are disposed on both the front mold core and the rear mold core.

[0011] The present invention is further improved. The front mold core includes a mold core body, which includes a mounting surface for mounting the mold core body, a cavity surface for setting the product mold cavity, and a side surface provided on the periphery of the mounting surface and the cavity surface. Among them, the mounting surface is provided with a strengthening structure, and the mounting surface is also provided with a mold core heating expansion positioning and guiding structure. Both the strengthening structure and the mold core heating expansion positioning and guiding structure are provided with heating expansion telescopic grooves. A mold core expansion gap is provided between the side surface and the mounting plate.

[0012] The present 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 cooling device, and a temperature measuring device for detecting the temperature of the product mold cavity corresponding to the temperature zone. The heating device and the cooling device in each temperature zone are separately controlled by an intelligent integrated control device. 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 separately controlled by an intelligent integrated control device.

[0013] The present invention is further improved. The heating device is a heating pipe, and the cooling device is a cooling pipe with cooling water inside. The water inlet of the cooling pipe is arranged on one side of the mold core body, and the water outlet is arranged on the other side of the mold core body opposite to the water inlet.

[0014] The present invention is further improved. The number of the heating pipes and the cooling pipes is both multiple. The heating pipes and the cooling pipes are arranged at intervals. The distances between the temperature measuring device, the cooling pipe, and the heating pipe are equal to each other. The vertical distance from the temperature measuring device to the product mold cavity, the distance between the temperature measuring device and the cooling pipe, and the distance between the temperature measuring device and the heating pipe are equal. The distances from the heating pipe to the mounting surface of the mold core body and from the heating pipe to the product mold cavity of the mold core body are equal.

[0015] The present invention is further improved. The injection mold further includes a heat insulation support plate and a mounting plate. Among them, an installation groove corresponding to the mold core heating expansion positioning and guiding structure is provided on one side of the heat insulation support plate. The mold core heating expansion positioning and guiding structure of the intelligent micro-stress injection production control system is fixed in the installation groove. The mounting plate is provided with a receiving groove for receiving the mold core body and the heat insulation support plate. A pipe inlet and a pipe outlet communicated with the cooling pipe are provided on the outside of the mounting plate.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: Multiple units cooperate to control the temperature of the product mold cavity, minimize the residual stress of the injection molded product to the greatest extent, greatly reduce the problems in aspects such as the appearance, flatness, size, and weight of the product, significantly reduce the defective rate of the product, greatly improve the production efficiency, and can greatly reduce the production cost of the molding manufacturing industry. Description of the Drawings

[0017] Figure 1Schematic diagram of the main device structure of the present invention;

[0018] Figure 2 Schematic diagram of the internal structure of the main device of the present invention with the front door panel opened;

[0019] Figure 3 Schematic diagram of the internal structure of the main device with the rear door panel opened;

[0020] Figure 4 Schematic diagram of the auxiliary device structure;

[0021] Figure 5 Schematic diagram of the internal structure of the auxiliary device;

[0022] Figure 6 Schematic diagram of the control board circuit principle, including the main control module, mold temperature detection module, and heating drive unit circuit principle diagram;

[0023] Figures 7 - 11 For Figure 6 Partial enlarged view, where,

[0024] Figure 7 Schematic diagram of the main control CPU circuit principle;

[0025] Figure 8 Schematic diagram of the flow control board interface unit circuit principle;

[0026] Figure 9 Schematic diagram of the temperature detection module circuit principle;

[0027] Figure 10 Schematic diagram of the heating drive unit circuit principle;

[0028] Figure 11 Schematic diagram of the interface unit circuit principle connected to the heating output unit;

[0029] Figure 12 Schematic diagram of the heating output unit circuit principle;

[0030] Figure 13 Schematic diagram of the transfer module circuit principle;

[0031] Figure 14 Schematic diagram of the IO module main control CPU circuit principle;

[0032] Figure 15 Schematic diagram of the communication interface circuit principle of the IO module;

[0033] Figure 16 Schematic diagram of the signal input unit and signal output unit circuit principle;

[0034] Figure 17 Schematic diagram of the alarm signal drive unit circuit principle;

[0035] Figure 18 It is the schematic circuit diagram of the booster pump drive unit;

[0036] Figure 19 It is the schematic circuit diagram of the check valve drive unit;

[0037] Figure 20 It is the schematic circuit diagram of the AC phase error protection unit and the water temperature detection unit;

[0038] Figure 21 It is the schematic diagram of the injection mold structure;

[0039] Figure 22 It is the schematic diagram of the cavity surface structure of the front mold core;

[0040] Figure 23 It is Figure 22 Sectional view B - B;

[0041] Figure 24 It is Figure 23 Enlarged view of part C;

[0042] Figure 25 and Figure 26 It is Figure 22 Sectional view A - A;

[0043] Figure 27 and Figure 28 It is the schematic diagram of the installation surface of the front mold core;

[0044] Figure 29 It is the schematic diagram of the partition of another embodiment of the front mold core;

[0045] Figure 30 It is the system block diagram of the present invention. Detailed implementation manners

[0046] The present invention will be further described in detail below with reference to the drawings and embodiments.

[0047] As Figure 30 shown, the present invention includes an intelligent integrated control device, an injection mold, a heating device for heating the product cavity in the injection mold, a cooling device for cooling the product cavity of the injection mold, and a temperature measuring device disposed in the injection mold for detecting the temperature of the corresponding product cavity in the temperature zone. Among them, the intelligent integrated control device is respectively connected to 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 output energy in real time and quantitatively.

[0048] The innovative mold design solution of the present invention can detect and feedback the mold condition during the injection molding process. With the intelligent analysis of the central processor of the intelligent integrated control device, it collaborates with multiple units such as the injection mold, cooling device, heating device, etc. for automated digital control, controls the temperature of the product cavity, minimizes the residual stress of the injection molded product to the greatest extent, significantly reduces the problems in aspects such as the appearance, flatness, size, and weight of the product, significantly reduces the defective rate of the product, greatly improves the production efficiency, and can significantly reduce the production cost of the molding manufacturing industry if promoted.

[0049] As Figures 1 - 5 As shown in the figure, the present invention includes a main machine device 1 and a secondary machine device 2 connected by a cable. There are 10 24-core sockets 117 in the main machine device 1, and 2 24-core sockets 202 on the secondary machine device 2. Both ends of the cable are respectively provided with 24-core plugs that can be inserted into the 24-core sockets, and are respectively inserted into the 24-core sockets on the main machine device 1 and the secondary machine device 2. The main machine device 1 and the secondary machine device 2 communicate and supply power through the cable. The main machine device is equipped with electrical equipment and circuit boards, and the secondary machine device is equipped with waterway equipment. The separation of water and electricity eliminates potential safety hazards and greatly improves safety. In addition, each module in the main machine device 1 and each module in the secondary machine device 2 are uniformly controlled by a control board, ensuring the real-time and convenience of control.

[0050] As Figures 1 - 3 As shown in the figure, the main machine device 1 includes a main machine housing 101. The main machine housing 101 includes a front door panel 1011 provided on the front of the main machine housing 101 and a rear door panel 1013 provided on the back of the main machine housing 101. A cabinet lock 1012 for opening or locking the front door panel 1011 is provided on the front door panel 1011. There is also a system control screen 102 for operating the equipment and an indicator light 105 for indicating the working state of the equipment. The number of indicator lights is 3, namely a power indicator light, an operation indicator light, and an alarm indicator light. There is also an emergency stop switch 103 provided below the indicator light 105. A handling lifting ring 106 is also provided on the top surface of the main machine housing 101, and load-carrying rollers 107 are provided at the bottom of the main machine housing 101, facilitating handling and movement.

[0051] As Figure 2 As shown in the figure, an IO board 113 and a power supply 114 are also provided on the inner side of the front door panel. Inside the main machine housing 101 of this example, there are four rows near the front door panel 1011, with 12 interconnected control boards 108 in each row. Below the control boards 108 is a power control area, which is equipped with an AC contactor 109, an AC circuit breaker 111, and a phase detector 110 for detecting the phase and performing phase error protection. There is also a terminal block 112.

[0052] As Figure 3As shown, a cabinet lock is also provided on the rear door panel 1013. Inside the mainframe housing 101 of this example, there are two spaced upper and lower regions near the rear door panel 1013. Correspondingly, the number of rear door panels 1013 is two, namely the upper door panel and the lower door panel. There are 4 cooling fans 115 on the inner side of the upper door panel, and cooling holes are provided at the positions corresponding to the cooling fans 115 on the upper door panel. There are 8 groups of intelligent output adjustment modules 116 for adjusting power output in the upper region, and 10 24-core sockets 117 are arranged in the lower region for connecting devices such as the mainframe device 1 to the host computer and the slave device 2.

[0053] As Figure 4 and Figure 5 shown, there is no circuit in the slave device 2 of this example. It is connected to the mainframe device 1 through 2 24-core sockets 202 to realize the control of the internal components of the slave device 2 by the mainframe device 1. Specifically, the slave device 2 of this example includes a slave housing 201, a water outlet pipe and a water inlet pipe arranged in the slave housing 201. An inlet port 208 communicating with the water inlet pipe and 8 outlet ports 207 communicating with the water outlet pipe are provided on the slave housing 201. The other end of the water inlet pipe of this example is connected to a high-pressure water pump 205, and the high-pressure water pump 205 is driven by a water pump motor 204. This example also includes a water flow regulator 203 provided on the water outlet pipe for adjusting the water flow rate of the outlet port. The water flow regulator 203 is controlled by a control board through a cable. Of course, a high-pressure water pump may not be provided in the slave device 2 of this example, but a water pump device is externally connected through the inlet port 208. The water inlet pipe and the water outlet pipe are changed to be provided with a single water flow pipe. There are 8 cooling devices in this example. Therefore, 8 outlet ports are provided to respectively control the operation of the 8 cooling devices. The high-pressure water pump 205 can quickly adjust and increase the water pressure in the cooling device, so as to adjust the output of the cooling water according to the temperature feedback, shortening the cooling time and the circulation period.

[0054] A control blowing device 206 communicating with the outlet port 207 is also provided in the slave device 2 of this example. The slave device of this example is connected to an external blowing device through a blowing port. The control blowing device 206 is controlled by a control board through a cable. The control blowing device of this example is 8 solenoid valves, which respectively control the communication between the blowing port and the 8 water outlet pipes, and are used to blow out the residual water in the 8 water outlet pipes, reducing the heat absorption of the water, so that the temperature of the injection mold is easier to control.

[0055] The quantities of the outlet ports 207, solenoid valves, water flow regulators 203, intelligent output adjustment modules 116, etc. in this example can be set to other quantities according to requirements.

[0056] Preferably, the IO board 113 of this example is provided with an IO module CPU, the control board 108 is provided with a main control module, and the main control module includes a main control CPU, and the main control CPU is connected to the IO module CPU.

[0057] The control board 108 of this example is also provided with a heating control module, a cooling control module, and a mold temperature detection module. The main control CPU is respectively connected to the heating control module, the cooling control module, and the mold temperature detection module. The heating control module is used to control the heating tube to heat the mold. The cooling control module is used to control the cooling medium in the cooling tube to cool the mold. The mold temperature detection module is used to detect the mold temperature. The IO board 113 is used to connect the main control CPU and the host computer respectively.

[0058] Through the full-automatic control of the main control CPU, the present invention can always detect the mold temperature, and control the quantitative output of energy according to the mold temperature for heating or cooling control, so that the temperature difference between the cavity and the core can be less than 2°C, thereby greatly improving the appearance quality of the product. The present invention cooperates with multiple units such as an injection molding machine, a cooling unit, and a heating unit. Through the embedded sensor connected thereto, the mold temperature and pressure can be monitored at all times during the injection molding process, and the data is fed back to the main control CPU for intelligent control.

[0059] As Figure 6 、 Figure 10 and Figure 12 As shown in, the heating control module includes a heating drive unit and a heating output unit respectively connected to the main control CPU. The number of heating output units is more than one. The heating drive unit is provided with drive interfaces with the same number as the output ends of the heating output units. The heating output unit of this example is 5 groups, and each group controls two heating modules to heat. Of course, other numbers of heating output units can also be set according to requirements. Because there are many heating output units, a transfer module is added between the control board and the heating output unit in this example.

[0060] As Figure 6 、 Figures 11 - 13 As shown in, the main control module is connected to the interface J19 of the transfer module through the interface J20. The interface J19 is respectively connected to 5 interfaces J14 - J18 connected to the heating output module. Among them, the interface J14 is connected to the interface J1 of the first group of heating output modules.

[0061] The first group of heating output units of this example includes an interface J1 connected to the main control module and two identical output units respectively connected to the interface J1. One of the output units includes a relay RLY1, a current detection choke coil T101, a thyristor U101 for adjusting the current magnitude, a switching tube Q101, and a switching tube Q102. Among them,

[0062] Pin 1 of the relay RLY1 is respectively connected to pins 8, 40, and 72 of the interface J1. Pin 2 of the relay RLY1 outputs a set voltage and is connected to the negative electrode of the diode D103. Pin 1 is respectively connected to the positive electrode of the diode and the drain of the switching transistor Q102. The source of the switching transistor Q102 is grounded, and the gate is connected to the relay interface of the heating drive unit. Pin 3 of the relay RLY1 is respectively connected to pins 1 and 3 of the current detection choke coil T101 and pin 4 of the thyristor U101;

[0063] Pin 2 of the current detection choke coil T101 is connected to pin 35 of the interface J1, and pin 4 of the current detection choke coil T101 is connected to pin 3 of the interface J1.

[0064] Pin 6 of the thyristor U101 is connected to the live wire terminal L of the interface J1. Pin 1 of the thyristor U101 is connected to the 24V power supply through a resistor. Pin 2 of the thyristor U101 is connected to the drain of the switching transistor Q101. The source of the switching transistor Q101 is grounded, and the gate is connected to the thyristor drive interface of the heating drive unit.

[0065] As Figure 10 shown, the heating drive unit in this example includes 10 relay interfaces and 10 thyristor drive interfaces, which respectively control the switches and output energy magnitudes of 10 output units.

[0066] As Figure 6 、 Figure 8 、 Figure 18 and Figure 19 shown, the cooling control module in this example includes a flow control unit and a blowing unit. Among them, the main control module includes a flow control board interface unit connected to the flow control unit and a blowing drive interface unit connected to the blowing unit. The cooling control module also includes a booster pump drive unit for driving the booster pump that makes water enter the cooling pipeline. The main control CPU is respectively connected to the flow control board interface unit and the blowing drive interface unit. The booster pump drive unit is connected to the IO module. Of course, the booster pump drive unit in this example can also be directly controlled by the main control CPU. However, the gas path and circuit in this example are directly controlled by the main control CPU, while the water path is controlled by the IO module main control CPU unit. Separating the control of the water path and the circuit is safer and increases the control of the pump output, enabling good control of the water flow. To prevent water backflow, the cooling control module in this example also includes a check valve drive unit for controlling the check valve on the cooling pipe, and the check valve drive unit is connected to the IO module.

[0067] As Figure 6 and Figure 9As shown, the mold temperature detection module in this example includes a detection chip U1, an amplifier U7B, and an optocoupler U8. Among them, pin 6 and pin 7 of the detection chip U1 are respectively connected to the first output terminal of the choke coil T3. Pin 8 and pin 11 of the detection chip U1 are respectively connected to the second output terminal of the choke coil T3. The first input terminal of the choke coil T3 is connected to the Temp_SEN+ terminal of the temperature sensor, and the second input terminal of the choke coil T3 is connected to the Temp_SEN- terminal of the temperature sensor. Pin 12 and pin 13 of the detection chip are respectively connected to pin 1 and pin 2 of the main control CPU through a voltage regulator chip U4. Pin 14 and pin 1 of the detection chip are respectively connected to pin 3 and pin 4 of the main control CPU through a voltage regulator chip U5.

[0068] The positive input terminal of the comparator U7B is respectively connected to one end of a resistor R12 and a resistor R13. The other end of the resistor R13 is grounded. The other end of R12 is connected to the reference voltage output pin 9 of the detection chip U1 and is connected to the 5V power supply through a resistor R11. The output pin of the comparator U7B is connected to pin 2 of the optocoupler U8 through an electronic R19. Pin 1 of the optocoupler U8 is connected to the 5V power supply. Pin 3 of the optocoupler U8 is grounded. Pin 4 is connected to pin 5 of the main control CPU and is connected to the 3.3V power supply through a resistor R17. Through the temperature sensor, the temperature of the product cavity and the mold core can be obtained in real time, facilitating real-time adjustment and control of the mold temperature. The temperature sensor in this example is arranged near the product cavity of the mold.

[0069] As Figures 14 - 16 shown, the IO module includes an IO module main control CPU unit, a communication interface respectively connected to the main control module and the computer, a signal input unit and a signal output unit connected to the injection molding machine. Among them, the IO module main control CPU unit is respectively connected to the communication interface, the signal input unit, and the signal output unit. The present invention has high compatibility and can be compatible with all brands of injection molding machines.

[0070] As Figure 17 shown, the IO module in this example further includes an alarm signal driving unit. When a fault or an abnormal situation occurs in the equipment, the alarm indicator is started to give an alarm. Of course, other alarm devices can also be used in this example.

[0071] As Figure 20As shown, the IO module in this example further includes an AC phase error protection unit connected to the phase detector 110. 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. Among them, pin 10 of the main control CPU of the IO module is respectively 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 respectively connected to one end of the resistor R304 and the negative electrode of the thermistor RT2. The positive electrode of the thermistor RT2 is respectively connected to the 3.3V power supply and the positive electrode of the polar capacitor C304. The negative electrodes of the polar capacitor C304, the polar capacitor C305, and the other end of the resistor R304 are respectively grounded. Through the real-time detection of the thermistor RT2 in the AC phase error protection unit, the detection and protection of the three-phase power supply phase loss are realized.

[0072] The IO module in this example further includes a water temperature detection unit for the cooling pipeline. The water temperature detection unit includes a resistor R312, a resistor R311, a polar capacitor C308, a polar capacitor C309, and a thermistor RT1. Among them, pin 11 of the main control CPU of the IO module is respectively connected to one end of the resistor R311 and the positive electrode of the polar capacitor C309. The other end of the resistor R311 is respectively connected to one end of the resistor R312 and the negative electrode of the thermistor RT1. The positive electrode of the thermistor RT1 is respectively connected to the 3.3V power supply and the positive electrode of the polar capacitor C308. The negative electrodes of the polar capacitor C308, the polar capacitor C309, and the other end of the resistor R312 are respectively grounded. Through the detection of the water temperature of the cooling water, the cooling degree of the mold core and the product mold cavity can be well evaluated.

[0073] As Figures 21 - 26 shown, 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 product mold cavity 5 provided between the front mold core 3 and the rear mold core 4. In this example, a heating device 16, a cooling device 15, and a temperature sensor 17 for detecting the temperature of the product mold cavity corresponding to the temperature zone are provided on the front mold core 3. The front mold core in this example is set as 1 to 2, that is, two front mold cores 3 are provided in one mold.

[0074] As Figures 23 - 25 、 Figure 27As shown in the figure, the front 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 the product mold cavity for injecting the product 19, and a side surface 3013 provided on the periphery of the mounting surface 3012 and the cavity surface 3011. Among them, the mounting surface 3012 is provided with a strengthening structure, and the mounting surface 3012 is also provided with a mold core heating expansion positioning and guiding structure. Both the strengthening structure and the mold core heating expansion positioning and guiding structure are provided with heating expansion and contraction grooves 305. There is a mold core expansion gap d between the side surface 3013 and the mounting plate (in this example, the front mold core, so the mounting plate is the A plate 7). The width of the mold core expansion gap d in this example is 0.01 mm. The width of the mold core expansion gap d is calculated according to the expansion coefficient of the material of the front mold core 3 and the required mold temperature. Different mold core materials have different expansion gaps. Preferably, the mold core material in this example is steel with rapid heat conduction, high corrosion resistance, high toughness and stretchability, so as to minimize the warping of the mold steel to the greatest extent.

[0075] If the heating expansion and contraction groove 305 and the mold core expansion gap d are not provided, due to installation limitations, when the front mold core 3 expands due to heat, the front mold core 3 will arch towards the product mold cavity, thus affecting the appearance of the injection-molded product 19 in the product mold cavity 5. The intelligent micro-stress injection production control system in this example can well avoid such micro-strain phenomena of the front mold core 3.

[0076] As Figure 27 As shown in the figure, the strengthening structure in this example includes reinforcing ribs 304 provided on the periphery of the mounting surface and integrally formed with the side surface, and strengthening bones 302 provided inside the reinforcing ribs 304. The strengthening bones 302 are arranged vertically and horizontally, connecting the two ends of the reinforcing ribs 304, which can improve the stiffness of the steel and enable the mold core body 301 to be set as thin as possible, thereby reducing the absorption and conduction of energy by the mold core body 301, making the mold temperature heating speed faster and the temperature easier to control, and avoiding the situation where the energy accumulated in the mold core causes a large increase in the product mold cavity temperature after the heating is stopped. Under the premise that the rigidity of the mold core body 301 is not affected in this example, a lightweight design is realized, saving raw materials. And it can greatly reduce the residual stress of the product, reduce deformation, and improve dimensional stability.

[0077] The mold core heating expansion positioning and guiding structure in this example includes positioning ribs 303 provided at the horizontal center and the vertical center of the mounting surface 3012, so as to fix the overall center position of the front mold core 3 and avoid the phenomenon of deviation from the center due to the shrinkage of the mold core body 301. The positioning ribs 303 protrude from the surface of the strengthening structure to fix the front mold core 3 as a fixing structure.

[0078] The core heating expansion positioning and guiding structure of this example further includes 4 positioning posts 306 arranged on the reinforcing rib 304. The positioning posts 306 are arranged at the four corners of the core body 301. Combining with the positioning rib 303, the middle part and the four corners of the core body 301 are limited. Preferably, the positioning posts 306, the positioning rib 303 and the heating expansion and contraction groove 305 are symmetrically arranged with the positioning rib 303 as the central axis, which is more conducive to the contraction balance of the core body 301 after thermal expansion. It avoids the micro-deformation of the core caused by unbalanced contraction after heating thermal expansion, and further causes the surface deformation of the injection molded product 19.

[0079] As Figure 22 , Figure 27 and Figure 28 shown, the higher the temperature of the core body 301, the greater the shrinkage. Therefore, the uneven heating of the core body 301 will also cause the micro-strain of the core body 301. Therefore, in order to keep the temperatures of the core body 301 and the product mold cavity of this example balanced, 2 temperature zones are arranged on each front core 3 in this example. A total of 4 temperature zones are arranged for the 2 front cores 3. A set of heating device 16 (the first heating device 1601, the second heating device 1602, the third heating device 1603, and the fourth heating device 1604 respectively), a cooling device 15 and a temperature sensor 17 are arranged in each temperature zone. The heating device 16 and the cooling device 15 in each temperature zone are controlled separately by a controller. The number of rear cores 4 in this example is also 2. 2 cooling zones are arranged on each rear core 4 (not shown in the figure, the installation method of the cooling device is the same as that of the front core 3). A set of cooling device 15 is arranged in each cooling zone. The cooling device in each cooling zone is controlled separately by a controller.

[0080] The heating device 16 of this example is a heating pipe, and the cooling device 15 is a cooling pipe provided with a cooling medium. The cooling medium of this example can be water or other liquid media that absorb heat.

[0081] As Figures 21 - 26As shown in the figure, the heating device 16 of this example is arranged on the front mold core. Therefore, a heat insulation support plate 6 is also arranged on the top surface of the front mold core 3 of this mold to prevent heat dissipation. One side of the heat insulation support plate 6 is provided with an installation groove corresponding to the mold core heating expansion positioning and guiding structure, and the mold core heating expansion positioning and guiding structure of the intelligent micro-stress injection molding production control system is fixed in the installation groove. The A plate 7 is provided with a receiving groove for receiving the mold core body 301 and the heat insulation support plate 6. The heat insulation support plate 6 is fixed on the bottom surface of the A plate 7. The water inlet 1501 of the cooling pipeline is arranged on one side of the mold, and the water outlet 1502 of the cooling pipeline is arranged on the other side of the mold. The water inlet 1501 and the water outlet are both arranged on the A plate 7 and are communicated with the cooling pipeline in the front mold core 3. The cooling water enters from one side of the mold and flows out from the other side, greatly shortening the residence time of the cooling water in the cooling pipeline. Therefore, more cooling water passes through per unit time, and the cooling efficiency is better. Each cooling pipeline is arranged in parallel in the mold core, and the water flow reaching near the product cavity is basically the same, which is beneficial to maintaining the mold temperature balance.

[0082] A runner plate 9 is arranged on the top surface of the A plate 7, and the top surface of the runner plate 9 is the panel 10. The rear mold core 4 of this example is fixed on the B plate 8. Two square irons 11 are arranged on both sides between the bottom plate 14 and the B plate 8. A thimble bottom plate 13 is fixed on the bottom plate between the two square irons, and a thimble panel 12 is arranged on the thimble bottom plate 13. Two thimbles pass through the B plate 8 and are connected to the product cavity.

[0083] Of course, the temperature zone of this example can also be arranged on the rear mold core 4 to enable the front mold core 3 and the rear mold core 4 to realize the heating and cooling functions simultaneously. It can also be arranged on the rear mold core 4, while the cooling zone is arranged on the front mold core 3. Thus, the heating device on the rear mold core 4 heats the product cavity 5, and the cooling devices of the front and rear mold cores cool the product. At this time, the heat insulation support plate is arranged on the side with the heating device.

[0084] Multiple temperature zones are used for heating or cooling respectively. Each temperature zone and cooling zone are controlled separately, and a separate temperature sensor 17 is set, which can accurately control the temperature of the product cavity so that the temperature difference can be controlled within 2 degrees Celsius, thereby ensuring the micro-stress of the mold core body 301, preventing its thermal expansion and deformation, being beneficial to maintaining the mold temperature balance of the product cavity, and preventing the warping and deformation of the injection molded product 19 caused by uneven heating and cooling.

[0085] Such as Figure 29As shown, the intelligent micro-stress injection molding production control system in this example is particularly suitable for the processing of high-precision products. As an embodiment, if the product is in a flat arc shape, in this example, the front mold core 3 and the rear mold core can be evenly divided into 8 zones according to the shape of the product cavity (the vertical lines are the dividing lines of each zone), so as to separately control the temperature of each temperature zone, avoiding the situation in the prior art where the cooling pipes and heating pipes are horizontally arranged, with a large difference in the distance from the product cavity 5, resulting in a large difference in the mold temperature of the product, different temperatures in the product cavity, different fluidities of the molten liquid during injection molding, different shear rates, and unable to guarantee the quality of the product; asynchronous cooling causes warping and deformation of the product. The present invention is particularly suitable for product cavities with three-dimensional complex shapes, and partitions are set according to the shape of the product, so as to ensure the temperature difference in each area of the product. The solution of the present invention is not limited by the size, shape, structure, and wall thickness of the product. It can process thin-walled products with a wall thickness greater than or equal to 0.5 mm without causing warping and deformation of the product.

[0086] The installation surface 3012 of the front mold core 3 in this example 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 in horizontal contact with the surface of the heat insulation support plate 6. Of course, the surface of the heat insulation support plate 6 in this example can also be adapted to the surface of the installation surface 3012 of the front mold core, with better heat insulation effect.

[0087] As Figures 25 - 28 As shown, the number of heating pipes and cooling pipes in each temperature zone in this example is multiple, and the heating pipes and cooling pipes are arranged at intervals. This is beneficial to controlling the balance of the temperature difference.

[0088] The distances between the temperature sensor 17, the cooling pipe, and the heating pipe are equal to each other, preferably in an equilateral triangle. The distance between the temperature sensor 17 and the product cavity, the distance between the temperature sensor 17 and the cooling pipe, and the distance between the temperature sensor 17 and the heating pipe are equal. This makes the mold temperature measured by the temperature sensor 17 more accurate. The reason for the design with equal distances at multiple points is that during the heating or cooling thermal process (for steel), the front mold core 3 will have energy accumulation and heat conduction time during heating or cooling. Therefore, the temperature sensor 17 is set at the mean value of the distances between the cooling pipe, the heating pipe, and the surface of the product cavity, making the test results of heating, cooling, and the surface of the product cavity (i.e., the surface temperature of the workpiece) more accurate.

[0089] In this example, 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. Similarly, the distance between the cooling pipe in the front mold core and the top surface and the cavity surface of the front mold core is equal.

[0090] By partitioning the mold and embedding a temperature measuring device, the mold temperature of each zone is controlled separately, effectively ensuring the balance of the mold temperature, which is not restricted by the product size, shape, structure, and wall thickness. It can process products of various shapes and ensure their quality and appearance quality.

[0091] As Figure 23 and Figure 24 shown, when designing the A plate in this example, the thermal expansion phenomenon of the steel of the front mold core 3 is fully considered. Therefore, there is a mold core expansion gap d of 0.01 mm between the outer periphery of the front mold core and the A plate. However, the front mold core 3 in this example is set as one for two, and the runner is arranged between the two front mold cores 3. Therefore, in order to avoid the branch runner between the runner and the gate interfering with the micro-strain of the front mold core 3, in this example, a bridging insert 18 is provided on the A plate 7. The bridging insert 18 straddles the mold core expansion gap d between the A plate 7 and the front mold core 3. The branch runner between the runner and the gate is arranged above the bridging insert 18. The bridging insert 18 is in clearance fit with the front mold core 3, so as not to interfere with the thermal expansion and contraction of the front mold core 3. And it can also effectively prevent the molten liquid from flowing into the mold core expansion gap d and blocking the mold core expansion gap d.

[0092] The injection molding steps of this example based on the intelligent micro-stress injection molding production control system are as follows:

[0093] I. Initial setting at equipment startup (mold opening of the injection molding machine): Set the injection molding parameters of the injection molding machine, including heating temperature, cooling temperature, etc.

[0094] II. Heating: Each selected temperature zone is automatically simulated and analyzed through 3 cycles. The simulation analysis is caused by the energy accumulation and heat conduction time of the mold steel. The temperature sensor detects that the final actual temperature is higher than the set value, and then the CPU analyzes, calculates, and adjusts the energy output. During the heating process, the cooling system stops working, and the flow valve and air flow valve are in the closed state. (While heating, the injection molding machine works synchronously, such as ejecting the product and then closing the mold) The temperature sensor outputs a shutdown when the heating temperature of each temperature zone reaches the set value.

[0095] III. After n seconds (n is a natural number, and the adjustable value in this example is 0 - 99S) of the thermal conduction temperature balance time, the system issues an instruction to the injection molding machine to inject (shoot the glue).

[0096] IV. Cooling: After the set time (adjustable value of 0 - 99S) at the start of injection (shooting the glue), the high-pressure water pump 205 of the cooling liquid starts, and at the same time, the cooling variable valve starts to cool. (The high-pressure water pump 205 makes the liquid reach a turbulent state. The water flow regulator 203 reduces the flow rate according to the area with fast cooling, and on the contrary, increases the flow rate in the area with slow cooling, so that all areas of the entire mold reach the same cooling speed.

[0097] V. Blowing: When the cooling of all areas reaches the set value, the water flow regulator 203 closes and the high-pressure water pump 205 stops working. The blowing valve starts to blow air, and the blowing time can be adjusted within 0 - 99S. Blowing means blowing out the cooling liquid in the cooling channels. Purpose:

[0098] 1. Reduce the energy output during heating due to the increase in the cooling liquid level in the cooling channels;

[0099] 2. During heating, the steam generated after heating the liquid in the cooling pipes causes the surface temperature of the mold cavity to be unbalanced.

[0100] VI. Mold opening / Ejection and production: After completing the above steps, the control board 108 issues commands for mold opening, ejection and production, and at the same time starts the next cycle. And through data acquisition, analysis, adjustment and output of the previous cycle.

[0101] In the injection mold of the present invention, a temperature measuring device is embedded to monitor the mold temperature and pressure at all times during the injection process, and the data is fed back to the main control CPU for intelligent analysis and control, including: engineering simulation and comprehensive analysis (a database has been accumulated from past R & D experiments, and the most suitable production technical parameters can be intelligently matched according to product requirements), intelligent and extremely fast adjustment.

[0102] The heating and cooling devices adopt intelligent numerical control analysis to quantitatively output energy. The temperature difference at any position between the cavity and the core can be less than 2°C. This device adopts a full-automatic mode and has high compatibility, and can be compatible with all brands of injection molding machines. It can be widely used in various injection product manufacturing enterprises. It is suitable for a variety of injection molding schemes, such as chemical microcellular foaming molding, high-gloss paint-free molding, high-fiber gloss molding, thin-wall molding, wood fiber material gloss molding, gas-assisted molding, etc., which can avoid secondary processing and save a large amount of time, labor and raw material costs for manufacturing enterprises.

[0103] In summary, the present invention has the following outstanding advantages:

[0104] 1. Whether it is traditional resin raw materials or resin raw materials added with inorganic or organic fillers, high-quality product surfaces can be injection molded in one step, eliminating shrinkage marks, flow marks, water traps, gate marks, etc., eliminating secondary processes such as product painting and appearance polishing, saving raw material and time costs, reducing environmental pollution, and at the same time facilitating the recycling of resin;

[0105] 2. It can greatly reduce the residual stress of the product, reduce the warping and deformation of the product, significantly improve the dimensional stability of the product, and release productivity;

[0106] 3. By increasing the coolant pressure, even if ordinary water is used as the coolant, the production molding cycle can be shortened by 10 - 20%;

[0107] 4. By using the microcellular foaming molding technology in combination, problems in aspects such as product appearance, flatness, size, and weight are greatly reduced, the defective rate of the product is significantly decreased, and while achieving product lightweighting, 5 - 20% of raw materials can be saved;

[0108] 5. The product has a thin wall, and the thinnest can reach 0.5 mm.

[0109] The specific embodiments described above are the preferred embodiments of the present invention, and do not limit the specific implementation scope of the present invention thereby. The scope of the present invention includes but is not limited to this specific embodiment. All equivalent changes made in accordance with the present invention are within the protection scope of the present invention.

Claims

1. An intelligent micro-stress injection molding production control system, Characterized in that: It includes an intelligent integrated control device, an injection mold, a heating device for heating the product cavity in the injection mold, a cooling device for cooling the product cavity of the injection mold, and a temperature measuring device provided in the injection mold for detecting the temperature of the product cavity corresponding to the temperature zone. Among them, the intelligent integrated control device is respectively connected to 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 output energy in real time and quantitatively. The injection mold includes a front mold core, a rear mold core and a product cavity provided between the front mold core and the rear mold core. Among them, the heating device and the temperature measuring device are provided on the front mold core, and cooling devices are provided on both the front mold core and the rear mold core. The front mold core includes a mold core body, and the mold core body includes an installation surface for installing the mold core body, a cavity surface for setting the product cavity, and a side surface provided on the periphery of the installation surface and the cavity surface. Among them, the installation surface is provided with a strengthening structure, and the installation surface is also provided with a mold core heating expansion positioning and guiding structure. Both the strengthening structure and the mold core heating expansion positioning and guiding structure are provided with heating expansion and contraction grooves, and a mold core expansion gap is provided between the side surface and the mounting plate.

2. The intelligent micro-stress injection molding production control system according to claim 1, Characterized in that: The intelligent integrated control device includes a host device and a slave device connected by a cable. Among them, the host device includes a host housing, a control board provided in the host housing, an IO board and a power supply connected to the control board, and also includes a power control device connected to the control board and an intelligent output adjustment module for adjusting the power output. The slave device includes a slave housing and a coolant pipeline provided in the slave housing. The slave housing is provided with an inlet and an outlet communicated with the coolant pipeline, and the outlet is connected to the cooling device.

3. The intelligent micro-stress injection molding production control system according to claim 2, Characterized in that: The coolant is water, the coolant pipeline is a water flow pipeline, and a control blowing device communicated with the water outlet is further provided in the slave device. The control blowing device is connected to the control board by a cable. A water pump connected to the water inlet is further provided in the slave device, and a water flow regulator for adjusting the water flow size of the water outlet is further provided on the water flow pipeline in the slave device. The water flow regulator is connected to the control board by a cable.

4. The intelligent micro-stress injection molding production control system according to claim 2, Characterized in that: The IO board is provided with an IO module CPU, the control board is provided with a main control module, the main control module includes a main control CPU, the main control CPU is connected to the IO module CPU, the control board 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 to the heating control module, the cooling control module, and the mold temperature detection module, the heating control module is used to control the heating pipe to heat the mold, the cooling control module is used to control the cooling medium to cool the mold, the mold temperature detection module is used to detect the mold temperature, and the IO board is used to connect to the main control CPU and the upper computer respectively.

5. The intelligent micro-stress injection molding production control system according to any one of claims 1-4, characterized in that: The front mold core is provided with more than 1 temperature zone, each temperature zone is provided with a set of heating device, a cooling device, and a temperature measuring device for detecting the temperature of the product cavity corresponding to the temperature zone, the heating device and the cooling device in each temperature zone are independently controlled by an intelligent integrated control device, 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 an intelligent integrated control device.

6. The intelligent micro-stress injection molding production control system according to claim 5, characterized in that: The heating device is a heating pipe, the cooling device is a cooling pipe with cooling water inside, the water inlet of the cooling pipe is arranged on one side of the mold core body, and the water outlet is arranged on the other side of the mold core body opposite to the water inlet.

7. The intelligent micro-stress injection molding production control system according to claim 6, characterized in that: The number of the heating pipes and the cooling pipes is multiple, the heating pipes and the cooling pipes are arranged at intervals, the distances between the temperature measuring device, the cooling pipe, and the heating pipe are equal to each other, the vertical distance from the temperature measuring device to the product cavity, the distance between the temperature measuring device and the cooling pipe, and the distance between the temperature measuring device and the heating pipe are equal, and the distance from the heating pipe to the mounting surface of the mold core body and the distance from the heating pipe to the product cavity of the mold core body are equal.

8. The intelligent micro-stress injection molding production control system according to any one of claims 1-4, characterized in that: The injection mold further includes a heat insulation support plate and a mounting plate. Among them, one side of the heat insulation support plate is provided with a mounting groove corresponding to the mold core heating expansion positioning and guiding structure, and the mold core heating expansion positioning and guiding structure of the intelligent micro-stress injection molding production control system is fixed in the mounting groove. The mounting plate is provided with a receiving groove for receiving the mold core body and the heat insulation support plate, and the outside of the mounting plate is provided with a pipe inlet and a pipe outlet connected to the cooling pipe.

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