Injection molding machine control system and method with relay PLC motion control module

Abstract

The invention discloses an injection molding machine control system and method with a relay PLC motion control module. The injection molding machine control system comprises a control unit, an execution unit, a sensor unit and a communication network. The control unit comprises a main controller PLC, an IO expansion module in communication connection with the main controller PLC, and a relay PLC motion control module in communication connection with the IO expansion module. The main controller PLC is responsible for overall logic control and data processing, the IO expansion module receives signals of the main controller PLC, outputs the signals, collects the signals and feeds the signals back to the main controller PLC, and the relay PLC motion control module is responsible for processing complex motion control tasks; the execution unit executes specific operation according to the control instruction and comprises a driver and a motor which are in communication connection with the relay PLC motion control module; the sensor unit is used for monitoring various parameters of the injection molding machine in real time, and comprises a concentrator in communication connection with the relay PLC motion control module, and a position ruler and a pressure sensor which are in communication connection with the concentrator; and the communication network is used for ensuring information exchange among the components.

Description

Technical Field

[0001] The invention relates to the technical field of injection molding machine control, and in particular to an injection molding machine control system and method with a relay PLC motion control module. Background Art

[0002] Traditional injection molding machine control systems mostly use a single PLC main controller for control. All signal feedback is directly received by the PLC main controller. The controller requires a large amount of memory and CPU speed to synchronize calculations, and then the controller issues execution instructions. Faced with increasingly complex injection molding processes and multi-axis motion control requirements, its computing power, control accuracy and response speed are increasingly difficult to meet the requirements of modern industrial production. Therefore, it is necessary to continuously upgrade the hardware configuration of the PLC main controller to meet production needs, which has led to a large increase in costs; poor scalability, for different types of machines, the control program needs to correspond one to one; for large machines, all feedback signals need to be connected to the main controller, the line length is long, and it is easy to be interfered. In addition, traditional control systems often have problems with slow processing speed and high failure rate when processing large amounts of data and complex movements.

[0003] Therefore, it is particularly important to develop an intelligent control system that can efficiently and accurately control the moving parts of the injection molding machine and has good scalability and maintainability. Summary of the invention

[0004] 1. Technical issues to be resolved The technical problem to be solved by the present invention is to provide an injection molding machine control system and method with a relay PLC motion control module, which improves the control accuracy, reliability and automation of the injection molding machine, has the advantages of high precision, high reliability, flexibility and easy maintainability, and can significantly improve the production efficiency and product quality of the injection molding machine.

[0005] (II) Technical solution The solution adopted by the present invention to solve the above technical problems is an injection molding machine control system with a relay PLC motion control module, including a control unit, an execution unit, a sensor unit and a communication network; The control unit includes a main controller PLC, an IO expansion module connected to the main controller PLC in communication, and a relay PLC motion control module connected to the IO expansion module in communication; the main controller PLC is responsible for overall logic control and data processing, the IO expansion module is used to receive the main controller PLC signal and output and collect signals to feed back to the main controller PLC, and the relay PLC motion control module is responsible for processing complex motion control tasks; The execution unit performs specific operations according to the control instructions, and includes a driver communicatively connected to the relay PLC motion control module, and a motor connected to the driver; The sensor unit is used to monitor various parameters of the injection molding machine in real time, and includes a hub connected to the relay PLC motion control module in communication, and a position scale and a pressure sensor connected to the hub in communication, and the hub is used to collect analog feedback signals of the position scale and the pressure sensor, and forward them to the relay PLC motion control module; The communication network is used to ensure information exchange between the various components.

[0006] Specifically, the IO expansion module and the relay PLC motion control module can perform uplink transmission to send the communication content to the previous device, and can also perform downlink transmission to send the communication content to the next device.

[0007] In some embodiments, the communication port of the main controller PLC is connected to the EtherCAT communication port of the IO expansion module, and the main controller PLC and the IO expansion module communicate using the EtherCAT protocol; and the number of the IO expansion modules is one or more, and the communication port of the main controller PLC is connected to the communication ports of all the IO expansion modules.

[0008] In some embodiments, the communication interfaces of two adjacent IO expansion modules are connected, and the two adjacent IO expansion modules communicate using the EtherCAT protocol.

[0009] In some embodiments, the communication port of the IO expansion module is connected to the communication port of the relay PLC motion control module, and the IO expansion module and the relay PLC motion control module communicate using the EtherCAT protocol; and the number of the relay PLC motion control modules is one or more, and the communication port of the IO expansion module is connected to the communication ports of all the relay PLC motion control modules.

[0010] In some embodiments, the communication interfaces of two adjacent relay PLC motion control modules are connected, and the two adjacent relay PLC motion control modules communicate using the EtherCAT protocol.

[0011] In some embodiments, the communication port of the relay PLC motion control module is connected to the communication port of the driver, and the relay PLC motion control module and the driver communicate using EtherCAT or CANOpen protocol; and the number of the drivers is one or more, and the communication port of the relay PLC motion control module is connected to the communication ports of all the drivers.

[0012] In some embodiments, the communication port of the relay PLC motion control module is connected to the IO interface or EtherCAT communication port or CANOpen communication port of the hub, and the relay PLC motion control module and the hub communicate using analog signals or EtherCAT or CANOpen protocols; and, the number of the hubs is one or more, and the communication port of the relay PLC motion control module is connected to the communication ports of all the hubs.

[0013] In some embodiments, the input interface of the hub is connected to the position scale, and the hub and the position scale communicate using EtherCAT or CANOpen protocol; the input interface of the hub is connected to the pressure sensor, and the hub and the pressure sensor communicate using EtherCAT or CANOpen protocol.

[0014] Specifically, the hub can also collect analog feedback signals from the position scale and pressure sensor, convert them into communication signals, and forward them to the relay PLC motion control module via the EtherCAT or CANOpen protocol.

[0015] The solution adopted by the present invention to solve the above technical problems is a control method of an injection molding machine control system with a relay PLC motion control module. When the system is running, the main controller PLC is responsible for overall logic control and data processing, and issues action instructions; at the same time, the main controller PLC monitors the operating status of each component in real time, makes a safe shutdown judgment once an abnormality is found, and gives a corresponding shutdown command; the relay PLC motion control module receives the action instructions of the main controller PLC, controls the driver and motor to execute the action commands through the motion control algorithm, and feeds back the motion status in real time; and according to the data fed back in real time by the sensor unit, the parameters are adjusted in real time according to the motion control algorithm to ensure that the injection molding machine movement process is accurate and reliable; at the same time, the relay PLC motion control module uploads the collected data to the main controller PLC in real time for safety status monitoring.

[0016] Specifically, the relay PLC motion control module receives the main controller PLC action instructions, controls the driver and motor to execute the action commands through the built-in PID control algorithm, and provides real-time feedback on the motion status; and according to the real-time feedback data from the sensor unit, adjusts the parameters in real time according to the adaptive control algorithm to ensure that the injection molding machine motion process is accurate and reliable.

[0017] In some embodiments, the motion control algorithm includes a PID control algorithm, an adaptive control algorithm, and an interpolation algorithm.

[0018] Specifically, the control method includes: High-precision motion control: Through the relay PLC motion control module, high-precision position, speed and acceleration control of each axis of the injection molding machine can be achieved. Motion control algorithms, such as PID control algorithm, are used to ensure the stability and accuracy of the injection molding process. Intelligent parameter adjustment: According to the real-time feedback data from the sensor, such as temperature, pressure, position, etc., the main controller PLC and the relay PLC motion control module work together to automatically adjust the injection molding parameters, such as injection time, injection speed, injection pressure, holding pressure, holding time, action slope, etc., to achieve the best injection molding effect; Fault diagnosis and early warning: The main controller PLC has a built-in fault diagnosis system that monitors the operating status of each component in real time. Once an abnormality is found, it will immediately issue an early warning and corresponding instructions to improve the reliability and maintenance efficiency of the equipment. Remote monitoring and upgrading: Through the communication network, the remote monitoring and fault diagnosis of the injection molding machine can be realized. At the same time, the remote upgrading of the control system is supported, which is convenient for users to expand and optimize functions according to actual needs.

[0019] (III) Beneficial effects Compared with the prior art, the present invention designs an injection molding machine control system and method with a relay PLC motion control module. (1) The present invention realizes high-precision position, speed and acceleration control of each axis of the injection molding machine by relaying the PLC motion control module, and adopts motion control algorithms, such as PID control algorithms, to ensure the stability and accuracy of the injection molding process; (2) The present invention automatically adjusts injection molding parameters, such as injection time, injection speed, injection pressure, holding pressure, holding time, action slope, etc., based on real-time feedback data from sensors, such as temperature, pressure, position, etc., and the coordinated work of the main controller PLC and the relay PLC motion control module to achieve the best injection molding effect; (3) The main controller PLC of the present invention has a built-in fault diagnosis system, which monitors the operating status of each component in real time, and immediately issues an early warning and corresponding instructions once an abnormality is found, thereby improving the reliability and maintenance efficiency of the equipment; (4) The present invention realizes remote monitoring and fault diagnosis of the injection molding machine through the communication network, and supports remote upgrading of the control system, so that users can expand and optimize the functions according to actual needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0021] Figure 1 It is a structural schematic diagram of the injection molding machine control system with a relay PLC motion control module of the present invention.

[0022] The corresponding component names of the various figure marks in the figure are: 100, main controller PLC; 101, IO expansion module; 102, relay PLC motion control module; 200, driver; 201, motor; 300, hub; 301, position scale; 302, pressure sensor. DETAILED DESCRIPTION

[0023] The specific implementation of the present invention is further described in detail below in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0024] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0025] The following describes the implementation methods of the present application through specific examples, and those skilled in the art can easily understand other advantages and effects of the present application from the contents disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The present application can also be implemented or applied through other different specific implementation methods, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, in the absence of conflict, the following embodiments and the features in the embodiments can be combined with each other. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in the field without making creative work belong to the scope of protection of the present application.

[0026] It should be noted that various aspects of the embodiments within the scope of the appended claims are described below. It should be apparent that the aspects described herein can be embodied in a wide variety of forms, and any specific structure and / or function described herein is merely illustrative. Based on the present application, it should be understood by those skilled in the art that an aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number and aspect described herein can be used to implement the device and / or practice the method. In addition, other structures and / or functionalities other than one or more of the aspects described herein can be used to implement this device and / or practice this method.

[0027] It should also be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present application. The drawings only show components related to the present application rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0028] Additionally, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, it will be understood by those skilled in the art that the examples can be practiced without these specific details.

[0029] The technical solutions provided by various embodiments of the present application are described below in conjunction with the accompanying drawings.

[0030] like Figure 1As shown, the present invention provides an injection molding machine control system with a relay PLC motion control module, including a control unit, an execution unit, a sensor unit and a communication network; the control unit includes a main controller PLC100, an IO expansion module 101 connected to the main controller PLC100 for communication, and a relay PLC motion control module 102 connected to the IO expansion module 101 for communication; the main controller PLC100 is responsible for overall logic control and data processing, the IO expansion module 101 is used to receive signals from the main controller PLC100 and output and collect signals to feed back to the main controller PLC100, and the relay PLC motion control module 102 is responsible for processing complex motion control tasks ; The execution unit performs specific operations according to the control instructions, and includes a driver 200 that is communicatively connected to the relay PLC motion control module 102, and a motor 201 that is connected to the driver 200; The sensor unit is used to monitor various parameters of the injection molding machine in real time, and includes a hub 300 that is communicatively connected to the relay PLC motion control module 102, and a position scale 301 and a pressure sensor 302 that are communicatively connected to the hub 300, and the hub 300 is used to collect analog feedback signals of the position scale 301 and the pressure sensor 302, and forward them to the relay PLC motion control module 102; The communication network is used to ensure information exchange between various components. Specifically, the IO expansion module 101 and the relay PLC motion control module 102 can perform uplink transmission to send the communication content to the previous device, and can also perform downlink transmission to send the communication content to the next device.

[0031] In some embodiments, the communication port of the main controller PLC100 is connected to the EtherCAT communication port of the IO expansion module 101, and the main controller PLC100 and the IO expansion module 101 communicate using the EtherCAT protocol; and, the number of the IO expansion module 101 is one, and the communication port of the main controller PLC100 is connected to the communication port of the IO expansion module 101.

[0032] In some embodiments, the communication port of the IO expansion module 101 is connected to the communication port of the relay PLC motion control module 102, and the IO expansion module 101 and the relay PLC motion control module 102 communicate using the EtherCAT protocol; and the number of the relay PLC motion control modules 102 is three, and the communication port of the IO expansion module 101 is connected to the communication ports of all the relay PLC motion control modules 102. In some embodiments, the communication interfaces of two adjacent relay PLC motion control modules 102 are connected, and the two adjacent relay PLC motion control modules 102 communicate using the EtherCAT protocol.

[0033] In some embodiments, the communication port of the relay PLC motion control module 102 is connected to the communication port of the driver 200, and the relay PLC motion control module 102 and the driver 200 communicate using the EtherCAT or CANOpen protocol; and the number of the drivers 200 is three, and the communication port of the relay PLC motion control module 102 is connected to the communication ports of all the drivers 200. In some embodiments, the communication interfaces of two adjacent drivers 200 are connected, and the two adjacent drivers 200 communicate using the EtherCAT or CANOpen protocol.

[0034] In some embodiments, the communication port of the relay PLC motion control module 102 is connected to the IO interface or EtherCAT communication port or CANOpen communication port of the hub 300, and the relay PLC motion control module 102 and the hub 300 communicate using analog signals or EtherCAT or CANOpen protocols; and the number of the hub 300 is one, and the communication port of the relay PLC motion control module 102 is connected to the communication port of the hub 300. In some embodiments, the input interface of the hub 300 is connected to the position scale 301, and the hub 300 and the position scale 301 communicate using EtherCAT or CANOpen protocols; the input interface of the hub 300 is connected to the pressure sensor 302, and the hub 300 and the pressure sensor 302 communicate using EtherCAT or CANOpen protocols. Specifically, the hub 300 may also collect analog feedback signals from the position scale 301 and the pressure sensor 302 , convert them into communication signals, and forward them to the relay PLC motion control module 102 via the EtherCAT or CANOpen protocol.

[0035] The present invention provides a control method for an injection molding machine control system with a relay PLC motion control module 102. When the system is running, the main controller PLC100 is responsible for overall logic control and data processing, and issues action instructions; at the same time, the main controller PLC100 monitors the operating status of each component in real time, makes a safe shutdown judgment once an abnormality is found, and gives a corresponding shutdown command; the relay PLC motion control module 102 receives the action instruction of the main controller PLC100, controls the driver 200 and the motor 201 to execute the action command through the built-in PID control algorithm, and feeds back the motion status in real time; and according to the data fed back in real time by the sensor unit, the parameters are adjusted in real time according to the adaptive control algorithm to ensure that the motion process of the injection molding machine is accurate and reliable; at the same time, the relay PLC motion control module 102 uploads the collected data to the main controller PLC100 in real time for safety status monitoring. Specifically, the control method includes: high-precision motion control: through the relay PLC motion control module 102, high-precision position, speed and acceleration control of each axis of the injection molding machine is realized, and motion control algorithms, such as PID control algorithms, are used to ensure the stability and accuracy of the injection molding process; intelligent parameter adjustment: according to the real-time feedback data from the sensor, such as temperature, pressure, position, etc., the main controller PLC100 and the relay PLC motion control module 102 work together to automatically adjust the injection molding parameters, such as injection time, injection speed, injection pressure, holding pressure, holding time, action slope, etc., to achieve the best injection molding effect; fault diagnosis and early warning: the main controller PLC100 has a built-in fault diagnosis system to monitor the operating status of each component in real time. Once an abnormality is found, it will immediately warn and issue corresponding instructions to improve the reliability and maintenance efficiency of the equipment; remote monitoring and upgrading: through the communication network, remote monitoring and fault diagnosis of the injection molding machine are realized, and remote upgrading of the control system is supported, so that users can expand and optimize functions according to actual needs.

[0036] The same and similar parts between the various embodiments in this specification can be referenced to each other, and each embodiment focuses on the differences from other embodiments.

[0037] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application shall be based on the protection scope of the claims.

Claims

1. Injection molding machine control system with relay PLC motion control module, characterized by: It includes a control unit, an execution unit, a sensor unit and a communication network; The control unit comprises a main controller PLC (100), an IO expansion module (101) communicatively connected to the main controller PLC (100), and a relay PLC motion control module (102) communicatively connected to the IO expansion module (101); the main controller PLC (100) is responsible for overall logic control and data processing, the IO expansion module (101) is used to receive signals from the main controller PLC (100) and output and collect signals to feed back to the main controller PLC (100), and the relay PLC motion control module (102) is responsible for processing complex motion control tasks; The execution unit executes a specific operation according to the control instruction, and comprises a driver (200) communicatively connected to the relay PLC motion control module (102), and a motor (201) connected to the driver (200); The sensor unit is used to monitor various parameters of the injection molding machine in real time, and comprises a hub (300) communicatively connected to the relay PLC motion control module (102), and a position ruler (301) and a pressure sensor (302) communicatively connected to the hub (300); the hub (300) is used to collect analog feedback signals of the position ruler (301) and the pressure sensor (302), and forward the analog feedback signals to the relay PLC motion control module (102); The communication network is used to ensure information exchange between the various components.

2. The injection molding machine control system with relay PLC motion control module according to claim 1 is characterized in that: The communication port of the main controller PLC (100) is connected to the EtherCAT communication port of the IO expansion module (101), and the main controller PLC (100) and the IO expansion module (101) communicate using the EtherCAT protocol; and the number of the IO expansion modules (101) is one or more, and the communication port of the main controller PLC (100) is connected to the communication ports of all the IO expansion modules (101).

3. The injection molding machine control system with relay PLC motion control module according to claim 2 is characterized in that: The communication interfaces of two adjacent IO expansion modules (101) are connected, and the two adjacent IO expansion modules (101) communicate using the EtherCAT protocol.

4. The injection molding machine control system with relay PLC motion control module according to claim 1 is characterized in that: The communication port of the IO expansion module (101) is connected to the communication port of the relay PLC motion control module (102), and the IO expansion module (101) and the relay PLC motion control module (102) communicate using the EtherCAT protocol; and the number of the relay PLC motion control modules (102) is one or more, and the communication port of the IO expansion module (101) is connected to the communication ports of all the relay PLC motion control modules (102).

5. The injection molding machine control system with relay PLC motion control module according to claim 4 is characterized in that: The communication interfaces of two adjacent relay PLC motion control modules (102) are connected, and the two adjacent relay PLC motion control modules (102) communicate using the EtherCAT protocol.

6. The injection molding machine control system with relay PLC motion control module according to claim 1, characterized in that: The communication port of the relay PLC motion control module (102) is connected to the communication port of the driver (200), and the relay PLC motion control module (102) and the driver (200) communicate using an EtherCAT or CANOpen protocol; and the number of the drivers (200) is one or more, and the communication port of the relay PLC motion control module (102) is connected to the communication ports of all the drivers (200).

7. The injection molding machine control system with relay PLC motion control module according to claim 1, characterized in that: The communication port of the relay PLC motion control module (102) is connected to the IO interface or the EtherCAT communication port or the CANOpen communication port of the hub (300), and the relay PLC motion control module (102) and the hub (300) communicate using analog signals or the EtherCAT or CANOpen protocol; and the number of the hubs (300) is one or more, and the communication port of the relay PLC motion control module (102) is connected to the communication ports of all the hubs (300).

8. The injection molding machine control system with relay PLC motion control module according to claim 1, characterized in that: The input interface of the hub (300) is connected to the position scale (301), and the hub (300) and the position scale (301) communicate using an EtherCAT or CANOpen protocol; the input interface of the hub (300) is connected to the pressure sensor (302), and the hub (300) and the pressure sensor (302) communicate using an EtherCAT or CANOpen protocol.

9. The control method of the injection molding machine control system with a relay PLC motion control module according to any one of claims 1 to 8, characterized in that: When the system is running, the main controller PLC (100) is responsible for overall logic control and data processing, and issues motion instructions; at the same time, the main controller PLC (100) monitors the operating status of each component in real time, makes a safe shutdown judgment once an abnormality is found, and issues a corresponding shutdown command; the relay PLC motion control module (102) receives the motion instruction of the main controller PLC (100), controls the driver (200) and the motor (201) to execute the motion command through the motion control algorithm, and feeds back the motion status in real time; and adjusts the parameters in real time according to the data fed back in real time by the sensor unit according to the motion control algorithm, so as to ensure that the motion process of the injection molding machine is accurate and reliable; at the same time, the relay PLC motion control module (102) uploads the collected data to the main controller PLC (100) in real time for safety status monitoring.

10. The control method of the injection molding machine control system with relay PLC motion control module according to claim 9, characterized in that: The motion control algorithm includes a PID control algorithm, an adaptive control algorithm, and an interpolation algorithm.

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