Hot runner temperature control system capable of identifying thermocouple and heater

Abstract

The invention relates to the technical field of hot runner temperature control, and discloses a hot runner temperature control system capable of identifying a thermocouple and a heater, which comprises a load, a relay control circuit, an operational amplifier circuit and an MCU (Microprogrammed Control Unit) control circuit. During operation, the load first generates a first power generation force. The first starting power signal is compared with standard data pre-stored in the MCU control circuit to obtain a first comparison result. The MCU control circuit controls the relay to achieve load positive and negative end conversion, so that the load generates second starting power again, and the second starting power is processed by the operational amplifier circuit to form a second starting power signal. The signal is also compared with the standard data to obtain a second comparison result; and finally, whether the load is a thermocouple or a heater is judged based on two comparison results. The operational amplifier circuit adaptively adjusts the gain of the operational amplifier circuit based on the signal characteristic of the first starting power so as to ensure that the signal is not saturated due to too high gain and is not lost due to insufficient gain.

Description

Technical Field

[0001] The present application relates to the technical field of hot runner temperature control, and more specifically, to a hot runner temperature control system capable of identifying thermocouples and heaters. Background Art

[0002] In the field of hot runner temperature control, accurate identification of thermocouples and heaters is essential to ensure the safety and efficiency of the system. Existing technologies such as patent CN114721449A have provided a solution that can avoid load damage caused by incorrect wiring and effectively distinguish between thermocouples and heaters. However, with the increasing demand for industrial automation and precision manufacturing, the requirements for hot runner temperature control systems have become more stringent. Especially in terms of high precision and high reliability, the existing technology still has room for improvement.

[0003] Traditional hot runner temperature control systems usually rely on preset parameters or fixed algorithms to process signals from thermocouples or heaters. Although this method can meet basic needs to a certain extent, it may cause misjudgment due to changes in signal strength when facing different types of loads. Especially in industrial environments, due to the influence of environmental factors, the stability of the signal is difficult to guarantee, which increases the probability of system errors. In addition, when encountering thermocouples and heaters with similar electrical characteristics, traditional methods may not be able to make accurate judgments, which may cause abnormal operation of the equipment or even damage.

[0004] Therefore, an optimized hot runner temperature control system that can identify thermocouples and heaters is desired. Summary of the invention

[0005] In order to solve the above technical problems, the present application is proposed. The embodiment of the present application provides a hot runner temperature control system that can identify thermocouples and heaters, which uses an operational amplifier circuit to adaptively adjust its gain based on the signal characteristics of the first power to ensure that the signal is neither saturated due to excessive gain nor caused by insufficient gain.

[0006] According to one aspect of the present application, a hot runner temperature control system capable of identifying a thermocouple and a heater is provided, comprising: a load, a relay control circuit, an operational amplifier circuit and an MCU control circuit, wherein the load is bidirectionally connected to the relay control circuit, the other output end of the relay control circuit is connected to the operational amplifier circuit, the output end of the operational amplifier circuit is connected to the MCU control circuit, and the output end of the MCU control circuit is further connected to the other input end of the relay control circuit, wherein the operation process of the hot runner temperature control system comprises: the load generates a first electric power; the first electric power passes through the operational amplifier circuit to obtain a first electric power signal; the operational amplifier circuit The circuit adaptively adjusts its gain based on the signal characteristics of the first power; compares the first power signal with the standard data pre-stored in the MCU control circuit to obtain a first comparison result; the MCU control circuit controls the relay control circuit to realize the positive and negative terminal conversion of the load; the load generates a second power; the second power passes through the operational amplifier circuit to obtain a second power signal; the second power signal is compared with the standard data pre-stored in the MCU control circuit to obtain a second comparison result; based on the first comparison result and the second comparison result, the load type of the load is judged, and the load type is a thermocouple or a heater.

[0007] In the above hot runner temperature control system capable of identifying thermocouples and heaters, the first electromotive force is an initial electromotive force generated after the load is powered on at room temperature.

[0008] In the above-mentioned hot runner temperature control system that can identify thermocouples and heaters, the load type of the load is judged based on the first comparison result and the second comparison result, and the load type is a thermocouple or a heater, including: judging whether the first comparison result and the second comparison result are both within the data range of the heater; if so, determining that the load type is a heater; if not, judging that the load type is a thermocouple.

[0009] In the above-mentioned hot runner temperature control system that can identify thermocouples and heaters, the operational amplifier circuit adaptively adjusts its gain based on the signal characteristics of the first electric force, including: sampling the first electric force by the operational amplifier circuit to obtain a continuous data set of discrete potential sampling points; analyzing the continuous data set of discrete potential sampling points based on a predefined rule set to obtain a gain adjustment strategy.

[0010] In the above-mentioned hot runner temperature control system that can identify thermocouples and heaters, the continuous data set of the potential discrete sampling points is analyzed based on a predefined rule set to obtain a gain adjustment strategy, including: in response to the maximum value of 5 consecutive potential discrete sampling points in the continuous data set of the potential discrete sampling points exceeding 80% of the output range, reducing the gain with a first predetermined step size.

[0011] In the above hot runner temperature control system capable of identifying thermocouples and heaters, the first predetermined step size is reduced by 1 dB each time.

[0012] In the above-mentioned hot runner temperature control system that can identify thermocouples and heaters, the continuous data set of the potential discrete sampling points is analyzed based on a predefined rule set to obtain a gain adjustment strategy, including: in response to the minimum value of 5 consecutive potential discrete sampling points in the continuous data set of the potential discrete sampling points exceeding 20% ​​of the output range, increasing the gain with a second predetermined step size, wherein the second predetermined step size is greater than the first predetermined step size.

[0013] In the above hot runner temperature control system capable of identifying thermocouples and heaters, the second predetermined step size is increased by 1.2 dB each time.

[0014] Compared with the prior art, the hot runner temperature control system provided by the present application can identify thermocouples and heaters, and uses an operational amplifier circuit to adaptively adjust its gain based on the signal characteristics of the first power to ensure that the signal is neither saturated due to excessive gain nor caused signal loss due to insufficient gain. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] By describing the embodiments of the present application in more detail in conjunction with the accompanying drawings, the above and other purposes, features and advantages of the present application will become more apparent. The accompanying drawings are used to provide a further understanding of the embodiments of the present application and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain the present application and do not constitute a limitation of the present application. In the accompanying drawings, the same reference numerals generally represent the same components or steps.

[0016] Figure 1 The figure shows a functional module schematic diagram of a hot runner temperature control system according to an embodiment of the present application.

[0017] Figure 2 The figure shows a flow chart of the operation process of the hot runner temperature control system according to an embodiment of the present application.

[0018] Figure 3 The diagram illustrates a logic schematic diagram of determining the load type of the load based on the first comparison result and the second comparison result according to an embodiment of the present application, where the load type is a thermocouple or a heater.

[0019] Figure 4 The figure shows a flow chart of the operational amplifier circuit adaptively adjusting its gain based on the signal characteristics of the first power according to an embodiment of the present application.

[0020] Among them, 1. MCU control circuit; 2. operational amplifier circuit; 3. relay control circuit; 4. load; 41. thermocouple; 42. heater; 5. display end. DETAILED DESCRIPTION

[0021] Below, the exemplary embodiments according to the present application will be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application, and it should be understood that the present application is not limited to the exemplary embodiments described here.

[0022] Figure 1 The figure shows a functional module schematic diagram of a hot runner temperature control system according to an embodiment of the present application. Figure 1 As shown, the present application provides a hot runner temperature control system that can identify thermocouples and heaters, including: a load 4, a relay control circuit 3, an operational amplifier circuit 2, and an MCU control circuit 1, wherein the load 4 is bidirectionally connected to the relay control circuit 3, the other output end of the relay control circuit 3 is connected to the operational amplifier circuit 2, the output end of the operational amplifier circuit 2 is connected to the MCU control circuit 1, and the output end of the MCU control circuit 1 is connected to the other input end of the relay control circuit 3, wherein the load type of the load 4 includes a thermocouple 41 and a heater 42, and further, the hot runner temperature control system may also include a display end 5 connected to the MCU control circuit 1, and the display end 5 may be used to display the judgment result. Thus, it is convenient to intuitively see the judgment result on the display end 5.

[0023] Figure 2 FIG. 1 is a flow chart showing the operation process of the hot runner temperature control system according to an embodiment of the present application. Figure 2As shown, the operation process of the hot runner temperature control system includes: S1, the load generates a first power; S2, the first power passes through the operational amplifier circuit to obtain a first power signal, and the operational amplifier circuit adaptively adjusts its gain based on the signal characteristics of the first power; S3, the first power signal is compared with the standard data pre-stored in the MCU control circuit to obtain a first comparison result; S4, the MCU control circuit controls the relay control circuit to realize the positive and negative terminal conversion of the load; S5, the load generates a second power; S6, the second power passes through the operational amplifier circuit to obtain a second power signal; S7, the second power signal is compared with the standard data pre-stored in the MCU control circuit to obtain a second comparison result; S8, based on the first comparison result and the second comparison result, the load type of the load is judged, and the load type is a thermocouple or a heater.

[0024] In step S1, the load generates the first starting power. It should be understood that, under normal temperature, an initial electromotive force, i.e., the first starting power, will be generated after the load is powered on. This starting power is a voltage signal naturally generated by the load without external interference, which reflects the electrical characteristics of the load under static conditions. That is, in one example, the first starting power is the initial starting power generated after the load is powered on under normal temperature. Under normal temperature, it means that the load starts working without being affected by the external temperature. This is because the electrical characteristics of thermocouples and heaters at different temperatures will be very different, while at normal temperature, the difference between the two is relatively small, which is more suitable for preliminary judgment. In addition, selecting a normal temperature state also helps to reduce the impact of external factors on the measurement results and improve the accuracy of the measurement. For example, if the measurement is performed under high temperature, it may cause signal distortion and affect subsequent judgments. Therefore, selecting normal temperature as the starting condition can not only ensure the stability of the measurement, but also reflect the basic characteristics of the load.

[0025] In step S2, the first electric power passes through the operational amplifier circuit to obtain a first electric power signal, and the operational amplifier circuit adaptively adjusts its gain based on the signal characteristics of the first electric power. It should be understood that due to the differences in physical structure and working principle between thermocouples and heaters, the electric power they generate under the same conditions will also be different. In order to capture these subtle differences, the operational amplifier circuit is used to amplify the first electric power to form a first electric power signal. The operational amplifier circuit plays a vital role here, because it not only needs to be sensitive enough to amplify weak signals, but also needs to have the ability to adaptively adjust the gain to ensure that the output signal is neither saturated due to excessive gain nor caused by insufficient gain. Signal loss.

[0026] In step S3, the first power signal is compared with the standard data pre-stored in the MCU control circuit to obtain a first comparison result. It should be understood that at this stage, the MCU will compare the received first power signal with the internally stored standard data. Here, the standard data is pre-stored inside the MCU and represents the typical signal characteristics that the thermocouple and the heater should generate under normal working conditions. For example, for a specific model of thermocouple, its initial power at room temperature may be a weak but stable voltage value; while the heater may exhibit a higher resistance characteristic. These characteristics are used to establish a standard data set for comparison. Through this comparison, the MCU can obtain the first comparison result, which helps to initially understand what type the load may belong to. However, the identity of the load cannot be fully confirmed by a single measurement, so further operations are required to verify the accuracy of the results.

[0027] In step S4, the MCU control circuit controls the relay control circuit to achieve the conversion of the positive and negative terminals of the load. It should be understood that in order to obtain more information for the final judgment, the MCU control circuit will then send an instruction to the relay control circuit, requiring it to change the positive and negative terminal connections of the load. This conversion is to simulate the behavior of the load in a different but related electrical environment. For example, thermocouples and heaters may show different resistance changes or other electrical characteristics when the positive and negative polarity are reversed.

[0028] In step S5, the load generates a second starting force. It should be understood that after the positive and negative terminals are converted, the load generates a new starting force again, which is called the second starting force. During this process, the current flow direction inside the load changes, which may cause changes in the electrical characteristics of certain types of loads, especially for those components that are sensitive to polarity. For example, a heater is usually symmetrical, and its resistance characteristics will not change significantly when the positive and negative polarities are reversed, while a thermocouple may show different resistance values ​​or other electrical characteristics after the polarity is reversed due to its internal structure.

[0029] In step S6 and step S7, the second power is passed through the operational amplifier circuit to obtain a second power signal, and the second power signal is compared with the standard data pre-stored in the MCU control circuit to obtain a second comparison result. It should be understood that the second power is also processed by the operational amplifier circuit to become a second power signal, and is sent back to the MCU control circuit for a second comparison. At this time, the MCU uses the previously saved standard data to evaluate the newly obtained signal again to obtain a second comparison result.

[0030] In step S8, the load type of the load is determined based on the first comparison result and the second comparison result, and the load type is a thermocouple or a heater. It should be understood that the results of the two comparisons are combined together to form a basis for determining the load type. Figure 3 The figure shows a logic diagram of determining the load type of the load based on the first comparison result and the second comparison result according to an embodiment of the present application, wherein the load type is a thermocouple or a heater. Figure 3 As shown, judging the load type of the load based on the first comparison result and the second comparison result, the load type is a thermocouple or a heater, including: judging whether the first comparison result and the second comparison result are both within the data range of the heater; if so, determining that the load type is a heater; if not, judging that the load type is a thermocouple.

[0031] In practical applications, suppose that a load of unknown type is connected to the system. When the system starts, the load will generate the first power at room temperature, and will be amplified by the op amp circuit to form the first power signal. This signal is then sent to the MCU for the first comparison. If the characteristics of the first power signal are closer to the standard data of the heater, then it is preliminarily judged that the load may be a heater. However, in order to further confirm this preliminary conclusion, the system will continue to perform the positive and negative terminal conversion operation, so that the load will generate a new power (i.e., the second power) again, and amplify it through the op amp circuit to become the second power signal. Then, the MCU will compare the second power signal with the standard data for the second time. At this time, if the second power signal also meets the standard data characteristics of the heater, such as its resistance characteristics do not change significantly, or it remains relatively stable after the polarity is reversed, then the system can more confidently conclude that the load is indeed a heater. Conversely, if the second power signal exhibits characteristics similar to a thermocouple, such as showing a different resistance value or other electrical characteristics after the polarity is reversed, then even if the first comparison result shows that the load is like a heater, it will eventually be judged that the load is a thermocouple.

[0032] By adopting the above method, the true identity of the load can be identified as accurately as possible without damaging the load. Traditional methods often rely on simple resistance measurement or other single parameter detection. Although this method is simple and direct, it is prone to misjudgment in complex industrial application scenarios. By introducing the collection and comparison of two power signals, not only can the characteristics of the load be examined from multiple angles, but also the reliability and accuracy of the judgment can be increased.

[0033] Further, consider that the gain determines how the op amp amplifies the input signal. For the hot runner temperature control system, the appropriate gain should be able to amplify the weak voltage signal generated by the thermocouple or heater to a level suitable for subsequent processing. However, too high a gain may lead to saturation problems, that is, when the input signal slightly exceeds a certain range, the output will reach the limit value and cannot correctly reflect the change of the input; on the contrary, if the gain is too low, it may not be enough to significantly improve the signal strength. Specifically, thermocouples and heaters usually produce very small voltage changes, which need to be significantly amplified for effective measurement and control. For example, the thermoelectric electromotive force generated by some types of thermocouples may be only a few microvolts (μV) to tens of millivolts (mV). In order to make these signals suitable for subsequent processing (such as analog-to-digital conversion, comparison, etc.), they must be properly amplified by the op amp. The amplified signal should be in a range suitable for processing by the back-end circuit. For example, if the analog signal is to be converted to a digital signal next, this range should match the input range of the A / D converter to avoid information loss or distortion. But when the gain of the op amp is set too high, even a slight input change may cause the output to quickly reach the power supply voltage rail (i.e., the maximum or minimum value), a situation known as saturation. Once saturation occurs, the output signal no longer follows the input change linearly, thus losing its true reflection of the original signal. In addition, there may be a delay in recovering from the saturation state, which affects the response speed and accuracy of the system. Too high a gain will not only amplify the useful signal, but also disproportionately amplify any background noise that exists. This may cause the signal-to-noise ratio to drop, causing the useful signal to be submerged in the noise, affecting the quality of the final measurement result. If the gain is set too low, although the problem of saturation and noise amplification can be avoided, the input signal may not be amplified enough to trigger the action of the subsequent circuit or provide enough resolution for accurate measurement. Especially when using a high-resolution A / D converter, the insufficiently amplified signal may cause the quantization error to increase, affecting the performance of the overall system. Lower gain means that the maximum signal amplitude that the system can handle is smaller, which is a limitation for applications that need to monitor a large temperature range or rapid temperature changes.

[0034] Therefore, the present application adds an adaptive gain adjustment mechanism, that is, the operational amplifier circuit adaptively adjusts its gain based on the signal characteristics of the first power. The application of the adaptive gain adjustment mechanism enables the operational amplifier circuit to better adapt to the signal strength changes generated by different loads, ensuring stable and reliable signal input even in harsh environments.

[0035] Figure 4 The figure shows a flow chart of the operational amplifier circuit adaptively adjusting its gain based on the signal characteristics of the first power according to an embodiment of the present application. Figure 4As shown, the operational amplifier circuit adaptively adjusts its gain based on the signal characteristics of the first electric power, including: S21, sampling the first electric power by the operational amplifier circuit to obtain a continuous data set of discrete potential sampling points; S22, analyzing the continuous data set of discrete potential sampling points based on a predefined rule set to obtain a gain adjustment strategy.

[0036] Specifically, in step S21, the operational amplifier circuit samples the first electric power through a high-speed A / D converter to obtain a series of discrete potential data points. These data points constitute a continuous data set, which provides a basis for subsequent analysis. After each sampling, the newly acquired data point will be added to a queue of fixed length, and the earliest sample will be removed, so that the latest data points can always be kept for instant analysis. In one example, a queue containing the latest 5 samples is used, which helps to capture the trend changes of the signal without being affected by transient noise.

[0037] Specifically, in step S22, the system will conduct an in-depth analysis of this continuous data set based on a predefined rule set, so as to develop a reasonable gain adjustment strategy. Specifically, when it is found that the maximum value of 5 consecutive potential discrete sampling points exceeds 80% of the output range of the op amp, the system will take measures to reduce the gain with a first predetermined step size (reduced by 1dB each time). This setting is to leave enough buffer space for the op amp to avoid approaching saturation while preventing misjudgment due to occasional peaks. On the contrary, if the minimum value of 5 consecutive potential discrete sampling points is lower than 20% of the output range, the gain is increased with a second predetermined step size (increased by 1.2dB each time). Here, the reason why the second predetermined step size is greater than the first predetermined step size is that a smaller gain increase may not significantly improve the signal quality due to the presence of background noise, and a larger step size can restore the signal strength to an appropriate level more quickly.

[0038] That is, in one example, analyzing the continuous data set of the potential discrete sampling points based on the predefined rule set to obtain a gain adjustment strategy includes: in response to the maximum value of five consecutive potential discrete sampling points in the continuous data set of the potential discrete sampling points exceeding 80% of the output range, reducing the gain with a first predetermined step size. In one example, the first predetermined step size is reduced by 1 dB each time.

[0039] In one example, analyzing the continuous data set of the potential discrete sampling points based on a predefined rule set to obtain a gain adjustment strategy includes: in response to the minimum value of five consecutive potential discrete sampling points in the continuous data set of the potential discrete sampling points exceeding 20% ​​of the output range, increasing the gain with a second predetermined step size, wherein the second predetermined step size is greater than the first predetermined step size. In one example, the second predetermined step size is increased by 1.2 dB each time.

[0040] Through the above method, it is possible to maximize performance while maintaining high accuracy. First, by sampling the first power at high frequency and constructing a continuous data set, the true waveform of the signal can be effectively captured, providing a solid data foundation for accurately evaluating its strength. The gain adjustment strategy based on a predefined rule set can fully consider the actual application scenario. For example, the selection of the two thresholds of 80% and 20% can prevent saturation and ensure sufficient signal strength. More importantly, the use of different gain adjustment steps (reducing 1dB vs. increasing 1.2dB) reflects the principle of differentiated treatment of different situations: for situations close to saturation, you should act cautiously and gradually reduce the gain; for situations where the signal is too weak, you can be more bold to increase the gain so that normal operation can be quickly restored.

[0041] It is worth noting that each gain adjustment is gradual rather than a one-time drastic change. This ensures a smooth transition of the system and prevents the destabilizing effects of sudden changes. After each adjustment, the system waits for a period of time to return to a steady state before continuing to monitor the signal characteristics to ensure that the adjustment effect is as expected. In addition, to further improve the reliability and robustness of the system, upper and lower limit protection mechanisms are set up to prevent the safety range from being exceeded even in extreme cases. It should be understood that the application of the gradual adjustment method is also based on stability considerations. Although a quick response may seem beneficial, it may actually cause unnecessary oscillations, which is not conducive to long-term stable operation. By gradually adjusting in small steps, smooth gain changes can be achieved without affecting the overall performance of the system. At the same time, giving the system enough time to enter a new steady state before making the next decision helps to ensure that each adjustment is based on the most accurate information, thereby improving the reliability of the entire process.

[0042] Finally, considering various unexpected situations that may occur in actual applications, such as power supply fluctuations, sensor failures, etc., the system also adds additional safety protection measures. For example, setting upper and lower limits for gain adjustment can avoid the risk of loss of control under extreme conditions; and redundant verification mechanisms such as dual-channel monitoring further enhance the system's fault tolerance, ensuring that basic functions can be maintained even when some components fail.

[0043] In a specific example of the present application, since there is a disconnection triggering effect on the temperature control circuit when the load is a thermocouple, it is expected that when the gain is reduced by a first predetermined step size and increased by a second predetermined step size, the thermocouple will not be falsely triggered to cause an erroneous disconnection of the temperature control circuit. Therefore, in response to the judgment result that the load type is a thermocouple, the first predetermined step size and the second predetermined step size are corrected.

[0044] For example, in one example, the first predetermined step size and the second predetermined step size may be corrected with a weighting parameter greater than 0.9 and less than 1.

[0045] Furthermore, the weighting parameters are set according to the specific parameters of the thermocouple. For various types of thermocouples, such as J type (iron-constantan), K type (nickel-chromium-nickel silicon), N type (nickel-chromium-copper-nickel alloy), S type (platinum-rhodium 10-platinum), etc., and their measurement ranges are also different, such as J type -40°C to +750°C or -210°C to +1200°C, K type -200°C to +1372°C, N type -200°C to +1300°C, S type -50°C to +1600°C, in the embodiment of the present application, preferably, for the action mechanism of the first predetermined step size and the second predetermined step size, that is, the percentage relationship between the maximum value exceeding 80% of the output range and the minimum value exceeding 20% ​​of the output range, the thermocouple accuracy is selected as one of the calibration reference parameters. Here, the thermocouple accuracy refers to the deviation between the thermocouple measurement result and the actual temperature, which usually includes ±0.75% and ±1.0%, which is recorded here as the first accuracy ratio. and the second precision ratio .

[0046] In addition, since the load voltage difference between the hot and cold ends of the thermocouple is also correlated with the potential, the temperature change error compensation of the hot and cold ends is required to ensure the compensation accuracy under high precision to reduce false triggering. Therefore, the voltage difference is obtained by averaging the load voltage difference between the hot and cold ends of each type of thermocouple under each type. For example, in the case of 59 μV / °C for J type, 41 μV / °C for K type, and 42 μV / °C for N type, , which is converted into gain form as .

[0047] Therefore, assuming that the first predetermined step length and the second predetermined step length are recorded as and , then: .

[0048] That is, the steady-state precision interference noise is maintained based on the accuracy error interference sum response form, and the load voltage difference gain is superimposed to appropriately reduce the first predetermined step size and the second predetermined step size, thereby avoiding false triggering of the thermocouple and causing false disconnection of the temperature control circuit.

[0049] Furthermore, since the accuracy parameters and load voltage difference parameters under different thermocouple types vary in a very small range, the above formula can be applied even when the thermocouple types are extended. For example, the accuracies of different thermocouple types are divided into high-precision and low-precision classes according to the mean, and the mean accuracy of each class is calculated to obtain the first accuracy ratio and the second accuracy ratio.

[0050] The present invention has the following advantages: through two independent and complementary signal collection and comparisons, not only can the characteristics of the load be examined from multiple angles, but also the reliability and accuracy of the judgment are increased. The traditional single parameter detection method is easily affected by external interference or measurement errors, resulting in misjudgment. The present invention introduces two comparisons of the starting power signal, which can not only effectively reduce the impact of a single measurement error, but also capture the subtle differences in the load under different conditions, thereby improving the recognition accuracy. In addition, this method can complete the identification process without damaging the load, ensuring the safety and reliability of the system. For example, some types of loads may be sensitive to the direction of current, and directly applying high voltage may cause damage; by first performing a low voltage test and combining the positive and negative terminal conversion method, accurate results can be obtained while protecting the load.

[0051] By dynamically adjusting the gain, it can be ensured that no matter how weak or strong the input signal is, it can be properly amplified without saturation or loss of useful information. At the same time, this adaptive gain adjustment mechanism not only improves the system's anti-interference ability, but also enables it to maintain stable operation in complex and changing working environments. For example, in an industrial environment, electromagnetic interference and noise generated by other electronic devices may be mixed into the signal, affecting the accuracy of the measurement. Through the filtering processing of the op amp circuit, these interferences can be effectively eliminated to make the signal purer. In addition, reasonable gain settings help extend the service life of sensors and other components, reduce the probability of failure, and ensure long-term stability and reliability.

[0052] Progressive gain adjustment can ensure a smooth transition of the system and prevent the instability caused by sudden changes. Each gain adjustment is limited to about ±1dB, avoiding the impact of a large one-time change on system stability. Specifically, whenever the gain adjustment conditions are met, the MCU will issue instructions to the programmable gain amplifier (PGA) to gradually adjust the gain in small steps. This not only prevents over-adjustment, but also ensures that each adjustment is based on the most accurate information, thereby improving the reliability of the entire process.

[0053] After each adjustment, the system will wait at least 10 milliseconds to regain steady state before continuing to monitor signal characteristics to ensure that the adjustment effect is as expected. This gradual adjustment method not only ensures a smooth transition of the system, but also reduces the possibility of false triggering. For example, a single threshold exceedance may be caused by transient noise or other temporary factors, and does not necessarily represent a true increase in signal strength. By requiring multiple consecutive samples (for example, 5) to exceed the threshold, these short-term anomalies can be effectively filtered out and the accuracy of judgment can be improved.

[0054] The basic principles of the present application are described above in conjunction with specific embodiments. However, it should be noted that the advantages, strengths, effects, etc. mentioned in the present application are only examples and not limitations, and it cannot be considered that these advantages, strengths, effects, etc. are required by each embodiment of the present application. In addition, the specific details disclosed above are only for the purpose of illustration and ease of understanding, not for limitation, and the above details do not limit the present application to being implemented by adopting the above specific details.

[0055] The block diagrams of the devices, apparatuses, equipment, and systems involved in this application are only illustrative examples and are not intended to require or imply that they must be connected, arranged, and configured in the manner shown in the block diagram. As will be appreciated by those skilled in the art, these devices, apparatuses, equipment, and systems can be connected, arranged, and configured in any manner. Words such as "including", "comprising", "having", etc. are open words, referring to "including but not limited to", and can be used interchangeably with them. The words "or" and "and" used here refer to the words "and / or" and can be used interchangeably with them, unless the context clearly indicates otherwise. The words "such as" used here refer to the phrase "such as but not limited to", and can be used interchangeably with them.

[0056] It should also be noted that in the apparatus, device and method of the present application, each component or each step can be decomposed and / or recombined. Such decomposition and / or recombination should be regarded as equivalent solutions of the present application.

[0057] The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use the present application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other aspects without departing from the scope of the present application. Therefore, the present application is not intended to be limited to the aspects shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

[0058] The above description has been given for the purpose of illustration and description. In addition, this description is not intended to limit the embodiments of the present application to the forms disclosed herein. Although multiple example aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, changes, additions and sub-combinations thereof.

Claims

1. A hot runner temperature control system capable of identifying a thermocouple and a heater, comprising: A load, a relay control circuit, an operational amplifier circuit and an MCU control circuit, wherein the load is bidirectionally connected to the relay control circuit, the other output end of the relay control circuit is connected to the operational amplifier circuit, the output end of the operational amplifier circuit is connected to the MCU control circuit, and the output end of the MCU control circuit is further connected to the other input end of the relay control circuit, characterized in that the operation process of the hot runner temperature control system includes: the load generates a first power; the first power passes through the operational amplifier circuit to obtain a first power signal, and the operational amplifier circuit adaptively adjusts its gain based on the signal characteristics of the first power; the first power signal is compared with the standard data pre-stored in the MCU control circuit to obtain a first comparison result; the MCU control circuit controls the relay control circuit to realize the positive and negative terminal conversion of the load; the load generates a second power; the second power passes through the operational amplifier circuit to obtain a second power signal; the second power signal is compared with the standard data pre-stored in the MCU control circuit to obtain a second comparison result; based on the first comparison result and the second comparison result, the load type of the load is judged, and the load type is a thermocouple or a heater.

2. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 1, characterized in that: The first starting power is the initial starting power generated after the load is powered on at normal temperature.

3. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 2, characterized in that: The load type of the load is judged based on the first comparison result and the second comparison result, and the load type is a thermocouple or a heater, including: judging whether the first comparison result and the second comparison result are both within the data range of the heater; if so, determining that the load type is a heater; if not, judging that the load type is a thermocouple.

4. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 1, characterized in that: The operational amplifier circuit adaptively adjusts its gain based on the signal characteristics of the first electric power, including: sampling the first electric power by the operational amplifier circuit to obtain a continuous data set of discrete potential sampling points; analyzing the continuous data set of discrete potential sampling points based on a predefined rule set to obtain a gain adjustment strategy.

5. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 4, characterized in that: The continuous data set of the potential discrete sampling points is analyzed based on a predefined rule set to obtain a gain adjustment strategy, including: in response to the maximum value of five consecutive potential discrete sampling points in the continuous data set of the potential discrete sampling points exceeding 80% of the output range, reducing the gain with a first predetermined step size.

6. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 5, characterized in that: The first predetermined step size is reduced by 1 dB each time.

7. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 5, characterized in that: The continuous data set of the potential discrete sampling points is analyzed based on a predefined rule set to obtain a gain adjustment strategy, including: in response to a minimum value of five consecutive potential discrete sampling points in the continuous data set of the potential discrete sampling points exceeding 20% ​​of the output range, increasing the gain with a second predetermined step size, wherein the second predetermined step size is greater than the first predetermined step size.

8. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 7, characterized in that: The second predetermined step size increases by 1.2 dB each time.

9. The hot runner temperature control system capable of identifying thermocouples and heaters according to claim 7, characterized in that: It is characterized in that When the load is a thermocouple, the setting process of the first predetermined step length and the second predetermined step length includes: extracting an initial value of the first predetermined step length and an initial value of the second predetermined step length; extracting a first precision ratio and a second precision ratio of the thermocouple; obtaining a voltage difference of the thermocouple and converting the voltage difference into a gain form; based on the first precision ratio, the second precision ratio and the gain form, optimizing the first predetermined step length and the second predetermined step length to obtain an optimized first predetermined step length and an optimized second predetermined step length.

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