Injection Molding Machine Control System and Method with Relay PLC Motion Control Module

Abstract

The present invention discloses an injection molding machine control system and method with a relay PLC motion control module, which includes 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 communicatively connected to the main controller PLC, and a relay PLC motion control module communicatively connected to the IO expansion module; the main controller PLC is responsible for overall logic control and data processing, the IO expansion module receives signals from the main controller PLC and outputs and collects signal feedback 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 control instructions, including a driver and a motor communicatively connected to the relay PLC motion control module; the sensor unit is used to monitor various parameters of the injection molding machine in real time, including a hub communicatively connected to the relay PLC motion control module, and a position ruler and a pressure sensor communicatively connected to the hub; the communication network is used to ensure information exchange between components.

Description

Technical Field

[0001] The present invention relates to the technical field of injection molding machine control, and particularly 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 feedbacks are directly received by the PLC main controller, which requires a large amount of memory and CPU speed for synchronous operation, and then the controller issues execution instructions. In the face of 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 leads to a significant increase in costs; poor scalability, for different types of machines, control programs need to be corresponding one by one; for large machines, all feedback signals need to be connected to the main controller, with a long wire length and easy to be interfered. In addition, traditional control systems often have problems of slow processing speed and high failure rate when dealing with a large amount of data and complex motions.

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

[0004] (I) Technical Problems to be Solved

[0005] The technical problems to be solved by the present invention are to provide an injection molding machine control system and method with a relay PLC motion control module, which improve the control accuracy, reliability, and automation degree of the injection molding machine, have 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.

[0006] (II) Technical Solutions

[0007] 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;

[0008] The control unit includes a main controller PLC, an IO expansion module communicatively connected to the main controller PLC, and a relay PLC motion control module communicatively connected to the IO expansion module; the main controller PLC is responsible for overall logic control and data processing, the IO expansion module is used to receive signals from the main controller PLC and output and collect signal feedback to the main controller PLC, and the relay PLC motion control module is responsible for processing complex motion control tasks;

[0009] The execution unit performs specific operations according to control instructions, and includes a driver communicatively connected to the relay PLC motion control module, and a motor connected to the driver;

[0010] The sensor unit is used to monitor various parameters of the injection molding machine in real time, and includes a hub communicatively connected to the relay PLC motion control module, a position ruler and a pressure sensor communicatively connected to the hub. The hub is used to collect the analog feedback signals of the position ruler and the pressure sensor and forward them to the relay PLC motion control module;

[0011] The communication network is used to ensure information exchange between components.

[0012] Specifically, the IO expansion module and the relay PLC motion control module can perform upstream transmission to send communication content to the previous device, or perform downstream transmission to send communication content to the next device.

[0013] 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 IO expansion modules is one or more, and the communication port of the main controller PLC is connected to the communication ports of all IO expansion modules.

[0014] 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.

[0015] 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 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 relay PLC motion control modules.

[0016] 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.

[0017] 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 the 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.

[0018] In some embodiments, the communication port of the relay PLC motion control module is connected to the IO interface, EtherCAT communication port or CANOpen communication port of the hub, and the relay PLC motion control module and the hub communicate using analog signals, EtherCAT or CANOpen protocol; 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.

[0019] In some embodiments, the input interface of the hub is connected to the position ruler, and the hub and the position ruler communicate using the 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 the EtherCAT or CANOpen protocol.

[0020] Specifically, the hub can also collect the analog feedback signals of the position ruler and the pressure sensor, convert them into communication signals, and forward them to the relay PLC motion control module through the EtherCAT or CANOpen protocol.

[0021] The solution adopted by the present invention to solve the above technical problems is the control method of an injection molding machine control system with a relay PLC motion control module. When the system runs, 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 running states of all components in real time, makes a safety shutdown judgment once an abnormality is found, and gives corresponding shutdown commands; the relay PLC motion control module receives the action instructions from the main controller PLC, controls the driver and the motor to execute the action commands through motion control algorithms, and feeds back the motion states in real time; and according to the data fed back by the sensor unit in real time, adjusts the parameters in real time according to the motion control algorithms to ensure the precise and reliable motion process of the injection molding machine; 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.

[0022] Specifically, the relay PLC motion control module receives the action instructions of the main controller PLC, controls the driver and the motor to execute the action commands through the built-in PID control algorithm, and feeds back the motion state in real time; and adjusts the parameters in real time according to the data fed back by the sensor unit in real time according to the adaptive control algorithm to ensure the accuracy and reliability of the injection molding machine during the motion process.

[0023] In some embodiments, the motion control algorithms include PID control algorithm, adaptive control algorithm, and interpolation algorithm.

[0024] Specifically, the control method includes:

[0025] 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 are achieved. The motion control algorithm, such as the PID control algorithm, is used to ensure the stability and accuracy of the injection process;

[0026] Intelligent parameter adjustment: According to the data fed back by the sensor in real time, such as temperature, pressure, position, etc., the main controller PLC and the relay PLC motion control module work together to automatically adjust the injection parameters, such as injection time, injection speed, injection pressure, holding pressure, holding time, action slope, etc., to achieve the best injection molding effect;

[0027] Fault diagnosis and warning: The system of the main controller PLC 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 give an early warning immediately and issue corresponding instructions to improve the reliability and maintenance efficiency of the equipment;

[0028] Remote monitoring and upgrade: Through the communication network, remote monitoring and fault diagnosis of the injection molding machine are realized, and at the same time, remote upgrade of the control system is supported, which is convenient for users to expand and optimize functions according to actual needs.

[0029] (III) Beneficial effects

[0030] Compared with the prior art, the present invention designs an injection molding machine control system and method with a relay PLC motion control module.

[0031] (1) The present invention realizes high-precision position, speed, and acceleration control of each axis of the injection molding machine through the relay PLC motion control module, and uses a motion control algorithm, such as the PID control algorithm, to ensure the stability and accuracy of the injection process;

[0032] (2) The present invention, according to the data fed back by the sensor in real time, such as temperature, pressure, position, etc., the main controller PLC and the relay PLC motion control module work together to automatically adjust the injection parameters, such as injection time, injection speed, injection pressure, holding pressure, holding time, action slope, etc., to achieve the best injection molding effect;

[0033] (3) The system of 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. Once an abnormality is found, it immediately gives an early warning and issues corresponding instructions, improving the reliability and maintenance efficiency of the equipment;

[0034] (4) The present invention realizes remote monitoring and fault diagnosis of the injection molding machine through a communication network, and at the same time supports remote upgrading of the control system, facilitating users to expand and optimize functions according to actual needs. Description of the Drawings

[0035] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0036] Figure 1 It is a schematic structural diagram of the injection molding machine control system with a relay PLC motion control module of the present invention.

[0037] The corresponding component names for the reference numerals in the drawings are: 100, main controller PLC; 101, IO expansion module; 102, relay PLC motion control module; 200, driver; 201, motor; 300, hub; 301, position ruler; 302, pressure sensor. Detailed Embodiments

[0038] The following will further describe in detail the specific embodiments of the present invention in conjunction with the drawings and embodiments. The following embodiments are used to illustrate the present invention, but cannot be used to limit the scope of the present invention.

[0039] In the description of the present invention, it should be noted that unless otherwise clearly defined and limited, the terms "installation", "connection", and "connection" 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 directly connected, or indirectly connected through an intermediate medium, and it can be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0040] The following describes the implementation manners of the present application through specific specific examples. Those skilled in the art can easily understand other advantages and effects of the present application from the content 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 manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, without 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 those of ordinary skill in the art without making creative efforts belong to the scope protected by the present application.

[0041] It should be noted that the following describes various aspects of the embodiments within the scope of the appended claims. 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 illustrative only. Based on the present application, those skilled in the art should understand that one 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 aspects described herein can be used to implement the device and / or practice the method. Additionally, this device and / or this method can be implemented using other structures and / or functionality in addition to one or more of the aspects described herein.

[0042] It should also be noted that the diagrams provided in the following embodiments only illustrate the basic concept of the present application schematically. The diagrams only show the components related to the present application and are not drawn according to the number, shape, and size of the components in actual implementation. The type, quantity, and proportion of each component in its actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0043] In addition, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the examples can be practiced without these specific details.

[0044] The following describes the technical solutions provided by each embodiment of the present application in conjunction with the accompanying drawings.

[0045] Such as Figure 1As shown in the figure, the present invention provides an injection molding machine control system with a relay PLC motion control module, which includes 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 communicatively connected to the main controller PLC100, and a relay PLC motion control module 102 communicatively connected to the IO expansion module 101; 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 them, as well as collect signal feedback and send it 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 control instructions, and includes 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 includes a hub 300 communicatively connected to the relay PLC motion control module 102, a position ruler 301 and a pressure sensor 302 communicatively connected to the hub 300, and the hub 300 is used to collect analog feedback signals from the position ruler 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 components. Specifically, the IO expansion module 101 and the relay PLC motion control module 102 can perform upstream transmission to send communication content to the previous device, or perform downstream transmission to send communication content to the next device.

[0046] 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.

[0047] 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 module 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.

[0048] 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.

[0049] In some embodiments, the communication port of the relay PLC motion control module 102 is connected to the IO interface, 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, EtherCAT, or CANOpen protocol; and, the number of the hubs 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 ruler 301, and the hub 300 and the position ruler 301 communicate using the 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 the EtherCAT or CANOpen protocol. Specifically, the hub 300 can also collect the analog feedback signals of the position ruler 301 and the pressure sensor 302, convert them into communication signals, and forward them to the relay PLC motion control module 102 through the EtherCAT or CANOpen protocol.

[0050] The present invention provides a control method for an injection molding machine control system with a relay PLC motion control module 102. During system operation, the main controller PLC 100 is responsible for overall logic control and data processing, and issues action commands; at the same time, the main controller PLC 100 monitors the operating status of each component in real time, makes a safety shutdown judgment once an abnormality is detected, and gives a corresponding shutdown command; the relay PLC motion control module 102 receives the action commands from the main controller PLC 100, controls the driver 200 and the motor 201 to execute the action commands through the built-in PID control algorithm, and feeds back the motion status in real time; and according to the data fed back by the sensor unit in real time, adjusts the parameters in real time according to the adaptive control algorithm to ensure the accuracy and reliability of the injection molding machine during the motion process; 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. 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 achieved, and motion control algorithms such as the PID control algorithm are used to ensure the stability and accuracy of the injection molding process; intelligent parameter adjustment: according to the data fed back by the sensors in real time, such as temperature, pressure, position, etc., the main controller PLC 100 and the relay PLC motion control module 102 work together to automatically adjust 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 system of the main controller PLC 100 has a built-in fault diagnosis system, monitors the operating status of each component in real time, gives an early warning immediately once an abnormality is detected, and issues corresponding instructions to improve the reliability and maintenance efficiency of the equipment; remote monitoring and upgrade: through the communication network, remote monitoring and fault diagnosis of the injection molding machine are achieved, and at the same time, remote upgrade of the control system is supported, which is convenient for users to expand and optimize functions according to actual needs.

[0051] For the same or similar parts among the various embodiments in this specification, reference can be made to each other. Each embodiment focuses on the differences from other embodiments.

[0052] As described above, the above is only the specific implementation manner 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 those skilled in the art within the technical scope disclosed by the present application should be covered by the protection scope of the present application. Therefore, the protection scope of the present application should be subject to 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 various components; 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); 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).

2. The injection molding machine control system with relay PLC motion control module according to claim 1 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.

3. The injection molding machine control system with relay PLC motion control module according to claim 1 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.

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 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).

5. 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 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).

6. 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.

7. 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 6, characterized in that: When the system is running, the main controller PLC (100) is responsible for overall logic control and data processing, and issues action 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 action instruction of the main controller PLC (100), controls the driver (200) and the motor (201) to execute the action command through a motion control algorithm, and feeds back the motion status in real time; and adjusts parameters in real time according to the motion control algorithm based on the data fed back in real time by the sensor unit, 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; the motion control algorithm includes a PID control algorithm, an adaptive control algorithm, and an interpolation algorithm.

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