Injection mistake proofing method and system

Abstract

This application provides a method and system for preventing errors in material injection. The method includes: firstly, collecting mold markings on the mold; generating a labeling code based on the mold markings; then, obtaining material injection control information corresponding to the labeling code according to a first preset mapping relationship, wherein the first preset mapping relationship is a mapping relationship between the mold markings and the material injection control information; then, extracting a preset foaming material injection quantity from the material injection control information and obtaining the actual injection quantity; if the difference between the actual injection quantity and the preset foaming material injection quantity is greater than a floating threshold, controlling a sound alarm to sound. The sound alarm allows for timely notification that the actual injection quantity exceeds the floating threshold, enabling better control of the actual injection quantity and solving the problem of inaccurate injection quantity control.

Description

Technical Field

[0001] This application relates to the field of refrigerator manufacturing technology, and in particular to a method and system for preventing errors in material injection. Background Technology

[0002] The foaming of refrigerator cabinet doors is one of the steps in refrigerator production. The quality of the foaming directly affects the various performance aspects of the refrigerator. In particular, the speed and quality of foaming also directly affect the production efficiency of the production line.

[0003] Before entering the refrigerator door foaming process, the door has already undergone multiple processing and assembly steps. The purpose of door foaming is to evenly inject insulation material between the inner liner and the outer shell of the door, so that the door can maintain a low temperature and insulate against external heat. If the foaming effect is poor, the refrigerator's insulation effect will also be poor, which will not only affect the insulation effect, but also cause the refrigerator's refrigeration system to work for a longer period of time, increasing energy consumption.

[0004] If an error occurs during the foaming process when filling the foamed refrigerator with the wrong material, resulting in an incorrect amount of material, it will not only affect the refrigerator's performance and produce substandard doors, but may also render the doors unusable, impacting the production efficiency of subsequent stages. To minimize errors during filling, the foaming machine has a display showing the actual amount of material injected into the door, but this display cannot provide timely alerts, leading to inaccurate control of the filling amount. Summary of the Invention

[0005] This application provides a method and system for preventing errors in material injection, in order to solve the problem of inaccurate material injection control.

[0006] Firstly, this application provides a method for preventing errors in filling, including:

[0007] Collect the mold markings on the mold;

[0008] Generate a labeling code based on the mold identifier;

[0009] According to the first preset mapping relationship, the injection control information corresponding to the annotation code is obtained, and the first preset mapping relationship is the mapping relationship between the mold identifier and the injection control information;

[0010] The preset foaming material injection amount extracted from the injection control information;

[0011] Obtain the actual injection volume;

[0012] If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the sound alarm will be activated.

[0013] In some embodiments of this application, generating the annotation code based on the mold identifier includes:

[0014] The mold identifier is marked using the first identification information;

[0015] A labeling code is generated based on the mold identifier, and the labeling code carries the first identifier information.

[0016] In some embodiments of this application, obtaining the injection control information corresponding to the annotation code according to the first preset mapping relationship includes:

[0017] The injection control information is marked using the second identification information;

[0018] According to the second preset mapping relationship, the injection control information carrying the second identifier information is found through the first identifier information. The second preset mapping relationship is the correspondence between the first identifier information and the second identifier information.

[0019] In some embodiments of this application, obtaining the actual injection volume includes:

[0020] Locate the foaming machine that implements the aforementioned injection control information;

[0021] Calculate the output amount of foaming material from the foaming gun in the foaming machine, and the amount of foaming material received in the mold;

[0022] Obtain the actual injection volume, which is the average of the foaming material output volume and the foaming material received volume.

[0023] In some embodiments of this application, the method further includes:

[0024] If the difference between the actual injection amount and the preset foaming material injection amount is less than the floating threshold, calculate the error value between the difference between the actual injection amount and the preset foaming material injection amount and the floating threshold.

[0025] Adjust the foaming material output of the foaming gun according to the error value.

[0026] In some embodiments of this application, the method further includes:

[0027] Obtain the working status of the foam gun;

[0028] If the working state is the completed injection state, control the injection control information to generate feedback information;

[0029] The number of feedback messages is counted to obtain the number of times the foam gun can inject material.

[0030] In some embodiments of this application, the method further includes:

[0031] If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the display will be controlled to show the preset foaming material injection amount and the actual injection amount, and the indicator light of the preset color will be lit.

[0032] Secondly, this application provides a filling error prevention system applied to the filling error prevention method described in the first aspect. The system includes: a data acquisition module, a generation module, an acquisition module, and a control module.

[0033] The acquisition module acquires the mold markings on the mold;

[0034] The generation module is used to generate a labeling code based on the mold identifier;

[0035] The acquisition module is used to acquire the injection control information corresponding to the annotation code according to the first preset mapping relationship, wherein the first preset mapping relationship is the mapping relationship between the mold identifier and the injection control information; it is also used to extract the preset foaming material injection amount and the actual injection amount from the injection control information.

[0036] If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the control module is used to control the sound alarm to emit an alarm sound.

[0037] In some embodiments of this application, the system further includes: an audible alarm and a display. If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the control module is used to control the display to show the preset foaming material injection amount and the actual injection amount.

[0038] In some embodiments of this application, the system further includes an indicator light; if the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the control module is also used to control the indicator light of a preset color to light up.

[0039] As can be seen from the above technical solutions, this application provides a method and system for preventing errors in material injection. The method includes: firstly, collecting mold markings on the mold; generating a labeling code based on the mold markings; then, obtaining material injection control information corresponding to the labeling code based on a first preset mapping relationship, wherein the first preset mapping relationship is the mapping relationship between the mold markings and the material injection control information; then, extracting a preset foaming material injection quantity from the material injection control information and obtaining the actual injection quantity; if the difference between the actual injection quantity and the preset foaming material injection quantity is greater than a floating threshold, controlling a sound alarm to sound. The sound alarm allows for timely notification that the actual injection quantity exceeds the floating threshold, enabling better control of the actual injection quantity and solving the problem of inaccurate injection quantity control. Attached Figure Description

[0040] To more clearly illustrate the technical solution of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 This is a schematic diagram of the injection error prevention method shown in the embodiments of this application;

[0042] Figure 2 This is a schematic diagram of the injection error prevention system structure shown in an embodiment of this application. Detailed Implementation

[0043] The embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described below do not represent all embodiments consistent with this application. They are merely examples of systems and methods consistent with some aspects of this application as detailed in the claims.

[0044] The foaming process for refrigerator doors includes preparation, spraying, installation, foaming, and curing stages. During the foaming stage, foaming agent is injected into the foaming mold. The amount of foaming agent injected is monitored manually by checking the mold markings, codes, and injection volume. However, although the foaming machine displays the actual amount of foaming agent injected into the door, it cannot provide timely reminders, resulting in inaccurate control of the injection volume.

[0045] See Figure 1 This application provides a method for preventing errors in injection, comprising:

[0046] S101: Collect the mold markings on the mold.

[0047] In this embodiment, the mold identifier may include one or more combinations of text, symbols, marks, tags, numbers, and patterns. For example, the mold identifier may be in the form of text and numbers, and the mold identifier may be mold 001.

[0048] Specifically, when it is necessary to monitor the amount of material injected into the refrigerator door, the mold for foaming the refrigerator door can be obtained first, and then the mold identification can be obtained.

[0049] In some embodiments, different molds can be classified according to the amount of material injected into the refrigerator door; that is, the molds can be classified according to the amount of material injected. For example, if the amount of material injected is ab, the molds are identified as mold 001 and mold 005; if the amount of material injected is bc, the molds are identified as mold 005 and mold 009. In some embodiments, different amounts of material injected into different refrigerator doors can also be classified according to different molds. For example, molds identified as 005 and mold 009 can only be used to inject material into refrigerator doors with an amount of bc.

[0050] The mold identification also includes first mold information, which includes information that can provide a reference for injection, such as the amount of material the mold can provide, the historical amount of material the mold can provide, the working time of the mold, and the working duration of the mold.

[0051] S102: Generate annotation code based on mold identification.

[0052] After obtaining the mold identifier, a label code can be generated based on the mold identifier to identify a unique mold corresponding to the mold code.

[0053] To increase the accuracy of the correspondence between the annotation code and the mold, in some embodiments, the annotation code is generated based on the mold identifier, including: annotating the mold identifier with first identifier information, and then generating the annotation code based on the mold identifier, wherein the annotation code carries the first identifier information.

[0054] The first identification information may include one or more combinations of text, symbols, signs, marks, numbers, and patterns. For example, the first identification information may be a combination of numbers and symbols, and the first identification information is m-. Each mold identifier carries unique first identification information.

[0055] In some embodiments, a correspondence can also be generated between the mold identifier and the first identifier information. The mold identifier uses a combination of text and numbers, and the first identifier information uses a combination of numbers and symbols. There is a unique correspondence between the text of the mold identifier and the numbers of the first identifier information, and a unique correspondence between the data of the mold identifier and the symbols of the first identifier information.

[0056] The text and numbers of the mold markings can be set in the first marking library and the second marking library respectively, and the numbers and symbols of the first marking information can be set in the third marking library and the fourth marking library respectively. There is a unique correspondence between the first marking library and the third marking library, and a unique correspondence between the second marking library and the fourth marking library. To ensure the unique correspondence, it can be understood that the number of texts in the first marking library is the same as the number of numbers in the third marking library, and the number of numbers in the second marking library is the same as the number of symbols in the fourth marking library.

[0057] S103: Obtain the injection control information corresponding to the annotation code according to the first preset mapping relationship.

[0058] After generating the annotation code, the injection control information corresponding to the mold can be determined according to the preset mapping relationship. The first preset mapping relationship is the mapping relationship between the mold identifier and the injection control information. This first preset mapping relationship indicates that in the mold corresponding to the mold identifier, the information corresponding to the annotation code is the injection control information that controls the injection quantity. In other words, the mold corresponding to the injection control information that needs to perform injection is the mold that includes the mold code.

[0059] The first preset mapping relationship can be a pre-established correspondence used to indicate the correspondence between mold identification information and injection control information. Based on the first preset mapping relationship, it can be determined which mold in the injection machine matches a given injection control information. In this way, by establishing the correspondence, injection control information can be associated with mold identification on the injection machine, so that the corresponding mold can be found through the injection control program.

[0060] In some embodiments, the first preset mapping relationship may be generated after the mold identifier is marked with the first identification information. That is, in order to verify the first identification information and make the search process more accurate, and to make the first preset mapping relationship more accurate, in some embodiments, according to the first preset mapping relationship, the injection control information corresponding to the marking code is obtained, including: marking the injection control information with the second identification information; and searching for the injection control information carrying the second identification information through the first identification information according to the second preset mapping relationship, wherein the second preset mapping relationship is the correspondence between the first identification information and the second identification information.

[0061] The second preset mapping relationship is generated after the injection control information is annotated with the second identification information. That is, firstly, the mold identification is marked with the first identification information, then the first preset mapping relationship is generated, then the injection control information is marked with the second identification information, and then the second preset mapping relationship is generated.

[0062] Based on the second preset mapping relationship, the corresponding injection control information can be directly determined through the first identification information. Thus, not only can the mold be found through the injection control program via the first preset mapping relationship, or the injection control information be found through the mold, but it can also be found through the second preset mapping relationship.

[0063] In this embodiment, the injection control information includes injection quantity, injection name, injection type, injection properties, injection material, injection manufacturing process, injection quality control, injection packaging and transportation, and other relevant information. The injection type includes, for example, chemical foaming materials, physical foaming materials, and surfactants. Injection properties include the physical and chemical properties of the foaming agent. The injection manufacturing process includes the manufacturing process and flow of the injection. Injection quality control includes control standards and requirements, such as appearance quality and performance testing. Injection packaging and transportation requirements include, for example, moisture protection, shock protection, and dust protection. Other relevant information includes safety warnings, environmental protection requirements, and other information related to the injection process.

[0064] Each label code corresponds to a material injection control information. Based on the material injection control information, you can find the foaming material used in the mold, as well as other information included in the material injection control information, such as the injection quantity.

[0065] S104: Preset foaming material injection amount extracted from the injection control information.

[0066] The preset foam material injection amount is the injection amount in the injection control information. Here, the preset foam material injection amount is a range; for example, if the preset foam material injection amount is ab, then preset foam material injection amount a is the minimum injection amount, and preset foam material injection amount b is the maximum injection amount. To make the foam material injection amount more precise, the preset foam material injection amount can also be a single value, for example, preset foam material injection amount a.

[0067] S105: Obtain the actual injection volume.

[0068] During the injection molding process of the refrigerator door, the foaming material is dispensed using a foaming gun. A high-pressure foaming machine forces the foaming material into the gun under high pressure. The high-pressure jet within the gun ensures thorough mixing and reaction of the foaming material before it is filled into the pre-installed inner liner, outer shell, and other door components. Over a period of time, the foaming material solidifies, forming a hard foam to complete the door injection. However, during this process, if residual foaming material remains in the gun after the previous injection, or if the gun malfunctions or fails to dispense all the foaming material into the door, the preset injection volume may differ from the actual injection volume.

[0069] To make the obtained injection volume closer to the actual injection volume, in some embodiments, obtaining the actual injection volume includes: locating the foaming machine that implements injection control information; calculating the foaming material output of the foaming gun in the foaming machine and the foaming material received in the mold; and obtaining the actual injection volume, which is the average of the foaming material output and the foaming material received.

[0070] After extracting the preset foaming material injection amount, the high-pressure foaming machine obtains the preset foaming material injection amount and processes the foaming material according to the preset foaming material injection amount. The processing process includes extracting and mixing the foaming material, and then extruding the processed foaming amount into the foaming gun head. The foaming gun head fills the foaming material into the various door parts such as the pre-installed inner liner and shell of the refrigerator.

[0071] To calculate the amount of foaming material received within the mold, in some embodiments, a grating ruler can be used. For example, a grating ruler can be installed between the foaming nozzle and the mold to measure the change in distance between the foaming nozzle and the mold, thereby calculating the amount of foaming material received within the mold. Optionally, during the injection process, a pressure sensor can be used to monitor changes in injection pressure, and combined with parameters such as injection flow rate, the amount of foaming material received within the mold can be calculated. It is understood that different methods for calculating the amount of foaming material received can be selected depending on the specific foaming material. Similarly, the amount of foaming material received can also be calculated using the two methods described above.

[0072] After calculating the foaming material receiving amount, the average of the foaming material receiving amount and the foaming material output amount is used as the actual injection amount. Alternatively, the average of the foaming material receiving amount, the foaming material output amount, and the preset foaming material injection amount can be used as the actual injection amount.

[0073] S106: If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the sound alarm will be activated.

[0074] Based on the calculated actual injection volume, compared with the preset foaming material injection volume, it can be determined whether the current injection is qualified. The qualified standard is less than or equal to the floating threshold. In this embodiment, the floating threshold can be 5%. When the difference between the actual injection volume and the preset foaming material injection volume is greater than 5%, the monitoring personnel are alerted to achieve the effect of error prevention monitoring. The sound alarm is controlled to sound an alarm. The alarm sound can be a continuous prompt sound within a specified time, or it can be a warning voice, such as: "Injection volume exceeded, please handle as soon as possible," etc.

[0075] Because the sound of injection or other noise in the injection workshop makes it impossible for monitoring personnel to hear or clearly hear the alarm, in some embodiments, if the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the display will be controlled to show the preset foaming material injection amount and the actual injection amount, and the indicator light of the preset color will be lit.

[0076] When the difference between the actual injection volume and the preset foaming material injection volume exceeds 5%, an alarm will sound, and the preset and actual injection volumes will be displayed on the monitor. If the monitoring personnel are observing the monitor at this time, they can see that the floating threshold has been exceeded. In addition to the display screen, indicator lights can also be controlled to illuminate. In some embodiments, the color of the preset indicator light can be used to indicate to the monitoring personnel whether the injection volume is normal. For example, if the indicator light is red, it indicates that the floating threshold has been exceeded; if the indicator light is green, it indicates that the floating threshold has not been exceeded.

[0077] After calculating the actual injection volume, in some embodiments, if the difference between the actual injection volume and the preset foaming material injection volume is less than a floating threshold, the error value between the difference between the actual injection volume and the preset foaming material injection volume and the floating threshold is calculated; the foaming material output volume of the foaming gun is adjusted according to the error value. In some embodiments, the difference between the actual injection volume and the preset foaming material injection volume can also be monitored in real time. If the difference between the actual injection volume and the preset foaming material injection volume is 1 / 2 of the floating threshold, a preset color indicator light is controlled to illuminate, for example, a yellow indicator light is illuminated.

[0078] After the foaming process is completed, in some embodiments, the working status of the foaming gun can also be obtained; if the working status is "completed foaming", the foaming control information is used to generate feedback information; the number of feedback information is counted to obtain the number of times the foaming gun has been used. In other words, the number of times the foaming gun has been used can be obtained based on the working status of the foaming gun.

[0079] Based on the above-described filling error prevention method, some embodiments of this application also provide a filling error prevention system, see [link to relevant documentation]. Figure 2 The system includes: a data acquisition module 210, a data generation module 220, an acquisition module 230, and a control module 240;

[0080] The acquisition module 210 is used to acquire mold markings on the mold;

[0081] The generation module 220 is used to generate annotation codes based on mold markings;

[0082] The acquisition module 230 is used to acquire the injection control information corresponding to the label code according to the first preset mapping relationship, wherein the first preset mapping relationship is the mapping relationship between the mold identifier and the injection control information; it is also used to extract the preset foaming material injection amount from the injection control information and acquire the actual injection amount;

[0083] If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the control module 240 controls the sound alarm to sound.

[0084] In some embodiments, the system further includes: an audible alarm, a display, and indicator lights. If the difference between the actual injection amount and the preset foaming material injection amount is greater than a floating threshold, the control module 240 is used to control the display to show the preset foaming material injection amount and the actual injection amount. The control module 240 is also used to control the indicator lights of a preset color to light up.

[0085] As can be seen from the above technical solutions, the embodiments of this application provide a method and system for preventing errors in material injection. The method includes: firstly, collecting mold markings on the mold; generating a labeling code based on the mold markings; then, obtaining material injection control information corresponding to the labeling code based on a first preset mapping relationship, wherein the first preset mapping relationship is the mapping relationship between the mold markings and the material injection control information; then, extracting a preset foaming material injection quantity from the material injection control information and obtaining the actual injection quantity; if the difference between the actual injection quantity and the preset foaming material injection quantity is greater than a floating threshold, controlling an audible alarm to sound an alarm. The alarm sound allows for timely notification that the actual injection quantity exceeds the floating threshold, enabling better control of the actual injection quantity and solving the problem of inaccurate injection quantity control.

[0086] Similar parts between the embodiments provided in this application can be referred to mutually. The specific implementation methods provided above are only a few examples under the overall concept of this application and do not constitute a limitation on the scope of protection of this application. For those skilled in the art, any other implementation methods extended from the solution of this application without creative effort shall fall within the scope of protection of this application.

Claims

1. A method of preventing a mistake in a material injection, characterized by, include: Collect the mold markings on the mold; Generate a labeling code based on the mold identifier; According to the first preset mapping relationship, the injection control information corresponding to the annotation code is obtained, and the first preset mapping relationship is the mapping relationship between the mold identifier and the injection control information; The preset foaming material injection amount extracted from the injection control information; Obtain the actual injection volume; If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the sound alarm will be activated. The step of generating a label code based on the mold identifier includes: The mold identifier is marked using the first identification information; A labeling code is generated based on the mold identifier, and the labeling code carries the first identifier information; The step of obtaining the injection control information corresponding to the annotation code according to the first preset mapping relationship includes: The injection control information is marked using the second identification information; According to the second preset mapping relationship, the injection control information carrying the second identifier information is found through the first identifier information. The second preset mapping relationship is the correspondence between the first identifier information and the second identifier information. The process of obtaining the actual injection volume includes: Locate the foaming machine that implements the aforementioned injection control information; Calculate the output amount of foaming material from the foaming gun in the foaming machine, and the amount of foaming material received in the mold; The actual injection volume is obtained, which is the average of the foaming material output volume and the foaming material received volume. The method further includes: Obtain the working status of the foam gun; If the working state is the completed injection state, control the injection control information to generate feedback information; The number of feedback messages is counted to obtain the number of times the foam gun can inject material.

2. The method of claim 1, wherein, The method further includes: If the difference between the actual injection amount and the preset foaming material injection amount is less than the floating threshold, calculate the error value between the difference between the actual injection amount and the preset foaming material injection amount and the floating threshold. Adjust the foaming material output of the foaming gun according to the error value.

3. The injection error prevention method according to claim 1, characterized in that, The method further includes: If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the display will be controlled to show the preset foaming material injection amount and the actual injection amount, and the indicator light of the preset color will be lit.

4. A filling error prevention system, characterized in that, The system, applied to the injection error prevention method according to any one of claims 1-3, comprises: The acquisition module acquires the mold markings on the mold. A generation module is used to generate a labeling code based on the mold identifier; The acquisition module is used to acquire the injection control information corresponding to the annotation code according to a first preset mapping relationship, wherein the first preset mapping relationship is the mapping relationship between the mold identifier and the injection control information; it is also used to extract the preset foaming material injection amount and the actual injection amount from the injection control information. If the difference between the actual injection amount and the preset foaming material injection amount is greater than a floating threshold, the control module controls the sound alarm to emit an alarm sound.

5. The filling error prevention system according to claim 4, characterized in that, The system also includes an audible alarm and a display. If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the control module is used to control the display to show the preset foaming material injection amount and the actual injection amount.

6. The filling error prevention system according to claim 5, characterized in that, The system also includes an indicator light. If the difference between the actual injection amount and the preset foaming material injection amount is greater than the floating threshold, the control module is also used to control the indicator light of a preset color to light up.

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