Data connecting line injection molding control system

Abstract

The invention relates to the technical field of injection molding, in particular to a data connecting line injection molding control system. The system comprises a data acquisition module, a comparative analysis module, a parameter adjustment module, a monitoring module, an exhaust module, a cooling module and a waste recovery module. Wherein the data acquisition module is used for acquiring real-time data in an injection molding process; the comparative analysis module is used for carrying out comparative analysis on the collected data and an ideal model and calculating a deviation value; the parameter adjusting module adjusts the heating temperature and the injection speed of the injection molding machine in real time according to the deviation value; the monitoring module is used for continuously monitoring the dimensional tolerance of the formed data connecting line and verifying the effectiveness of a control strategy; the exhaust module and the cooling module are respectively used for exhausting redundant gas and finely controlling the cooling time to avoid shrinkage deformation; and the waste recovery module is used for collecting, crushing, screening and recycling leftover materials. The effects of improving the injection molding precision, reducing the rejection rate and optimizing the production efficiency are achieved.

Description

Technical Field

[0001] The present application relates to the technical field of injection molding, and in particular to a data connection line injection molding control system. Background Art

[0002] As the miniaturization trend of electronic products continues to increase in the field of data cable manufacturing, the precision requirements for data cable are also getting higher and higher. The traditional injection molding method is difficult to accurately control the molding pressure and temperature, resulting in low product yield. In order to meet market demand and improve product quality, various companies continue to explore new injection molding technologies and methods, striving to improve production efficiency while ensuring product stability and reliability. In the existing data cable injection molding technology, fixed-parameter injection molding machines are usually used for automatic operation, and mechanical arm positioning and preset temperature and pressure values ​​are used to improve consistency and production efficiency. In addition, some manufacturers have also tried to improve product quality by improving mold design and optimizing injection molding process. However, most of these methods rely on fixed parameter settings and cannot flexibly respond to various variables that may occur in the production process. Although the above methods can improve the production quality of data cables to a certain extent, there are still obvious shortcomings. In particular, these methods ignore the impact of raw material batch differences and changes in ambient temperature and humidity on the injection molding effect, and cannot achieve real-time adjustment of molding conditions, resulting in low and unstable yields. Therefore, how to develop an injection molding control system that can dynamically adapt to various production conditions has become a technical problem that needs to be solved in this field. Summary of the invention

[0003] The purpose of this application is to overcome the above technical problems and provide a data connection line injection molding control system A data connection line injection molding control system includes: a data acquisition module for collecting real-time data during the injection molding process, including mold temperature, melt pressure, and ambient temperature and humidity; a comparison and analysis module for comparing and analyzing the collected data with a preset ideal model to calculate the deviation; a parameter adjustment module for adjusting the heating temperature and injection speed of the injection molding machine in real time according to the deviation using a PID control algorithm so that the molding conditions are always maintained in the optimal state; and a monitoring module for continuously monitoring the dimensional tolerance of the data connection line after molding to verify the effectiveness of the control strategy. By adopting the above technical solution, real-time monitoring and dynamic adjustment of key parameters in the injection molding process are realized, ensuring that the injection molding conditions are always maintained in the optimal state. Specifically, the data acquisition module obtains data such as mold temperature, melt pressure, and ambient temperature and humidity in real time, and the comparison and analysis module compares these data with the ideal model to calculate the deviation. Based on the deviation, the parameter adjustment module uses a PID control algorithm to adjust the heating temperature and injection speed of the injection molding machine in real time, thereby effectively coping with raw material batch differences and environmental changes, and improving the molding quality and stability of the product. The monitoring module continuously monitors the dimensional tolerance of the data connection line after molding, verifies the effectiveness of the control strategy, and further ensures the consistency and reliability of product quality. Preferably, it also includes: an exhaust module, which is used to briefly open the mold cavity at the beginning of injection molding to discharge excess gas. By adopting the above technical solution, the mold cavity can be briefly opened at the beginning of injection molding to discharge excess gas, effectively reduce the bubbles inside the product, and improve the compactness and appearance quality of the product. Preferably, it also includes: a cooling module, which is used to enter the cooling stage after exhausting, and avoid shrinkage deformation caused by rapid cooling by finely controlling the cooling time and appropriately increasing the pressure. By adopting the above technical solution, excess gas can be discharged through the exhaust module at the beginning after injection molding is completed, reducing the bubbles inside the product. Subsequently, the cooling module effectively prevents the shrinkage deformation of the product caused by rapid cooling by finely controlling the cooling time and appropriately increasing the pressure, thereby improving the quality and yield of the product. Preferably, the exhaust module fine-tunes the time length of the secondary exhaust according to the characteristics of each batch of raw materials, and the cooling module fine-tunes the pressure holding pressure according to the characteristics of each batch of raw materials. By adopting the above technical solution, the system can fine-tune the length of time and the holding pressure of the secondary exhaust according to the characteristics of each batch of raw materials during the injection molding process, thereby effectively reducing bubbles and shrinkage, and improving the dimensional stability and surface quality of the product. This not only improves the overall performance of the data cable, but also significantly increases the yield rate and reduces production costs. Preferably, the exhaust module extends the exhaust time and increases the holding pressure when processing specific materials. By adopting the above technical solution, especially extending the exhaust time and increasing the holding pressure when processing specific materials, internal stress can be effectively eliminated, product defects can be reduced, and the durability and molding quality of the product can be improved.This not only improves the overall performance of the data connection line, but also increases the yield rate, thereby improving production efficiency and economic benefits. Preferably, it also includes: a waste recovery module, which is used to collect the scraps generated during the processing, and reuse them in the subsequent injection molding process after crushing and screening. By adopting the above technical solution, the effective recovery and reuse of the scraps generated during the injection molding process is achieved. Specifically, the waste recovery module can collect the scraps generated during the processing, and through crushing and screening, it meets the requirements of injection molding again. This measure not only reduces resource waste, but also reduces production costs, improves production efficiency, and promotes the sustainable development of production. Preferably, the waste recovery module includes: a crushing device, which is used to crush the scraps into particles; a screening device, which is used to remove impurities and screen out particles that meet the requirements. By adopting the above technical solution, the waste generated during the injection molding process is effectively recovered and reused, which not only reduces resource waste, but also reduces production costs. In particular, through the two steps of crushing and screening, the quality of the recycled materials is ensured, so that these materials can be put into the injection molding process again, forming a closed-loop material circulation system, and further improving the environmental protection and economy of production. Preferably, the waste recycling module also includes: a storage device for temporarily storing the particles after crushing and screening; a conveying device for conveying the particles in the storage device to the feed port of the injection molding machine. By adopting the above technical solution, efficient recycling of waste is achieved, which not only reduces resource waste but also reduces production costs. Especially in a large-scale production environment, the application of this system can significantly improve resource utilization, reduce environmental pollution, and ensure the continuity and stability of the production process. Preferably, the data acquisition module also includes: a temperature sensor for real-time monitoring of the mold temperature; a pressure sensor for real-time monitoring of the melt pressure; a humidity sensor for real-time monitoring of the ambient temperature and humidity. By adopting the above technical solution, the mold temperature, melt pressure and ambient temperature and humidity can be monitored in real time during the injection molding process. Changes in these key parameters directly affect the quality of injection molding. Through real-time monitoring of temperature sensors and pressure sensors, deviations in temperature and pressure can be discovered in time. With the use of humidity sensors, the influence of environmental factors on the injection molding process can be more comprehensively grasped. This multi-dimensional real-time monitoring provides accurate data support for subsequent parameter adjustments, thereby ensuring that the working parameters of the injection molding machine are always kept in the best state, effectively improving the quality stability and consistency of the injection molding of the data connection line. Preferably, the monitoring module further comprises: a measuring device for measuring the dimensional tolerance of the formed data connection line; and a processing unit for analyzing the measurement result and comparing it with the standard value. By adopting the above technical solution, the dimensional tolerance of the formed data connection line can be measured in real time, and the measurement result can be analyzed by the processing unit and compared with the standard value, thereby verifying the effectiveness of the control strategy, ensuring the dimensional accuracy of the data connection line, and improving the quality and consistency of the product.

[0004] In summary, the present application includes at least one of the following beneficial technical effects: 1. The dynamically adaptive injection molding control algorithm can monitor the key parameters of the injection molding process in real time, and dynamically adjust the working parameters of the injection molding machine through a feedback mechanism to ensure that the molding conditions are always maintained in the optimal state, significantly improving the quality stability of the injection molding of the data cable; 2. Through the refined molding technology that combines secondary exhaust and pressure holding, product defects, especially bubbles and shrinkage, are reduced, and the yield rate is improved; 3. The efficient and environmentally friendly waste recycling and reuse system design not only reduces resource consumption, but also ensures the sustainability of production and enhances the economic benefits of the enterprise. DETAILED DESCRIPTION

[0005] The following will combine the content to clearly and completely describe the technical solutions in the embodiments of the present invention. The described embodiments are only possible technical implementations of the present invention, not all possible implementations. Those skilled in the art can fully combine the embodiments of the present invention to obtain other embodiments without creative work, and these embodiments are also within the scope of protection of the present invention. The inventors of the present application found that the existing data connection line injection molding control method lacks dynamic adaptability and cannot effectively cope with material fluctuations and environmental changes, resulting in unstable product quality. For this reason, the present application mainly adopts the following intelligent injection molding control system, which achieves the effect of significantly improving the quality stability of data connection line injection molding by dynamically adjusting the working parameters, and at the same time, through secondary exhaust and pressure holding measures, reducing product defects and improving the yield rate. A data connection line injection molding control system provided in the embodiment of the present application includes a data acquisition module, a comparative analysis module, a parameter adjustment module and a monitoring module. These modules work together to realize real-time monitoring and dynamic adjustment of the injection molding process, ensuring the consistency of molding quality. Specifically, the data acquisition module is responsible for collecting real-time data during the injection molding process, mainly including mold temperature, melt pressure and ambient temperature and humidity. The temperature sensor can be a thermocouple or an infrared thermometer to monitor the change of mold temperature in real time; the pressure sensor can be a piezoresistive or piezoelectric sensor to monitor the change of melt pressure in real time; the humidity sensor can be a resistive or capacitive sensor to monitor the change of ambient temperature and humidity in real time. The selection of these sensors can be adjusted according to the actual production environment and cost budget. The comparative analysis module compares and analyzes the collected data with the preset ideal model to calculate the deviation. The ideal model can be a mathematical model based on historical data or an empirical model. The deviation can be calculated using simple subtraction operations or more complex statistical methods such as least squares or Kalman filtering. The parameter adjustment module uses the PID control algorithm to adjust the heating temperature and injection speed of the injection molding machine in real time according to the calculated deviation. The PID control algorithm is a commonly used feedback control algorithm that can achieve precise control of the system through a combination of three parts: proportional, integral and differential. If the mold temperature is too high, the parameter adjustment module will reduce the heating temperature; if the melt pressure is too low, the parameter adjustment module will increase the injection speed. This dynamic adjustment ensures that the molding conditions are always maintained at the best state, thereby improving the quality and consistency of the product. The monitoring module is used to continuously monitor the dimensional tolerance of the data cable after forming and verify the effectiveness of the control strategy. The measuring device can be an optical measuring instrument or a laser rangefinder to measure the dimensional tolerance of the data cable; the processing unit can be a computer or an embedded controller to analyze the measurement results and compare them with the standard value. If the measurement result shows that the dimensional tolerance exceeds the predetermined range, the monitoring module will issue an alarm to remind the operator to check and adjust.The implementation principle of this embodiment is: through the coordinated work of the data acquisition module, the comparison and analysis module, the parameter adjustment module and the monitoring module, the comprehensive monitoring and dynamic adjustment of the injection molding process are realized. This intelligent control method can effectively cope with the batch differences of raw materials and environmental changes, and ensure the quality stability of the injection molding of the data connection line. Compared with the traditional fixed parameter injection molding method, this embodiment significantly improves the yield and consistency of the product, and has high practical value and technological advancement. The difference between this embodiment and the above embodiment is that the exhaust module and the cooling module are added, the injection molding process is further optimized, the product defects are reduced, and the yield rate is improved. The exhaust module is mainly used to open the mold cavity briefly at the beginning of the injection molding to discharge excess gas. This step can reduce bubbles and shrinkage in the product. For example, the exhaust module may include a solenoid valve and a time relay. The solenoid valve is used to control the opening and closing of the mold cavity, and the time relay is used to control the length of the exhaust time. According to the characteristics of different materials, the exhaust time can be fine-tuned. For example, for high molecular polymer materials, the exhaust time can be extended to completely discharge the internal gas and reduce the formation of bubbles. The cooling module enters the cooling stage after exhausting, and avoids shrinkage and deformation caused by rapid cooling by finely controlling the cooling time and appropriately increasing the pressure. For example, the cooling module may include a cooling water circulation system and a pressure regulating device. The cooling water circulation system is used to control the temperature of the mold, and the pressure regulating device is used to apply appropriate pressure during the cooling process. In this way, the product can be effectively prevented from deforming during the cooling process, and the dimensional accuracy and appearance quality of the product can be improved. The implementation principle of this embodiment is: by adding an exhaust module and a cooling module, the control steps in the injection molding process are further refined, and the bubbles and shrinkage in the product are reduced. This optimization measure not only improves the quality and yield of the product, but also enhances the flexibility and adaptability of the production process. Compared with the traditional injection molding method, this embodiment is more outstanding in reducing product defects and has high practical value and technological advancement. The difference between this embodiment and the above embodiment is that the functions of the exhaust module and the cooling module are further optimized to make it more suitable for injection molding of specific materials. When the exhaust module processes specific materials, the exhaust time is extended and the pressure holding strength is increased. For example, for some high molecular polymer materials, extending the exhaust time can better remove internal gas and reduce the formation of bubbles. Specifically, a programmable controller can be added to the exhaust module to automatically adjust the exhaust time and pressure holding intensity according to the material characteristics. For example, for polycarbonate materials, the exhaust time can be extended to 10 seconds and the pressure holding intensity can be increased to 100MPa; while for polyethylene materials, the exhaust time can be shortened to 5 seconds and the pressure holding intensity can be increased to 50MPa. The cooling module enters the cooling stage after exhausting, and avoids shrinkage and deformation caused by rapid cooling by finely controlling the cooling time and appropriately increasing the pressure.For example, a temperature sensor and a pressure sensor can be added to the cooling module to monitor the temperature and pressure of the mold in real time. In this way, the cooling process can be controlled more accurately to ensure that the product will not deform during the cooling process. For example, for high molecular polymer materials, the cooling time can be extended to 1 minute and the pressure can be increased to 100MPa; while for metal materials, the cooling time can be shortened to 30 seconds and the pressure can be increased to 50MPa. The implementation principle of this embodiment is: by further optimizing the functions of the exhaust module and the cooling module, it is more suitable for injection molding of specific materials. This personalized control strategy not only improves the quality and yield rate of the product, but also enhances the flexibility and adaptability of the production process. Compared with the traditional injection molding method, this embodiment is more outstanding in reducing product defects and has high practical value and technological advancement. The difference between this embodiment and the above embodiment is that a waste recovery module is added to achieve efficient recovery and reuse of injection molding waste, reduce resource consumption, and enhance the sustainability of production. The waste recovery module includes a crushing device, a screening device, a storage device and a conveying device. The crushing device is used to crush the scraps into granules, and a hammer crusher or a shear crusher can be selected. Hammer mills are suitable for processing soft materials, and shear mills are suitable for processing hard materials. The screening device is used to remove impurities and screen out particles that meet the requirements. A vibrating screen or a drum screen can be selected. The vibrating screen is suitable for processing fine particles, and the drum screen is suitable for processing large particles. The storage device is used to temporarily store the particles after crushing and screening. A storage bin or a storage barrel can be selected. The conveying device is used to convey the particles in the storage device to the feed port of the injection molding machine. A screw conveyor or a pneumatic conveyor can be selected. The screw conveyor is suitable for short-distance conveying, and the pneumatic conveyor is suitable for long-distance conveying. The implementation principle of this embodiment is: by adding a waste recovery module, efficient recycling and reuse of injection molding waste is achieved. This closed-loop material circulation system not only reduces resource consumption, but also enhances the sustainability of production. Compared with the traditional injection molding method, this embodiment is more outstanding in environmental protection and has higher practical value and technological advancement. The difference between this embodiment and the above embodiment is that the function of the waste recovery module is further optimized to make it more suitable for the recovery and reuse of different types of materials. The waste recovery module includes a crushing device, a screening device, a storage device and a conveying device. There are many types of crushing devices to choose from. For example, for plastic materials, you can choose a hammer mill or a shearing mill; for metal materials, you can choose a ball mill or a jaw crusher. Hammer mills are suitable for processing soft plastics, shear mills are suitable for processing hard plastics; ball mills are suitable for processing fine metal particles, and jaw crushers are suitable for processing large pieces of metal materials. The screening device can be selected according to the material characteristics and particle size. For example, for plastic particles, you can choose a vibrating screen or a drum screen; for metal particles, you can choose a magnetic separator or a gravity separator.Vibrating screens are suitable for processing fine plastic particles, and drum screens are suitable for processing large plastic particles; magnetic separators are suitable for removing metal impurities such as iron filings, and gravity separators are suitable for removing light impurities. The storage device can select a suitable type according to the capacity and storage time. For example, for short-term storage, a storage silo or a storage barrel can be selected; for long-term storage, a large warehouse or a storage tower can be selected. Storage silos are suitable for small-scale production, storage barrels are suitable for mobile production; large warehouses are suitable for large-scale production, and storage towers are suitable for long-term storage. The conveying device can select a suitable type according to the conveying distance and conveying speed. For example, for short-distance conveying, a screw conveyor or a belt conveyor can be selected; for long-distance conveying, a pneumatic conveyor or a chain conveyor can be selected. Screw conveyors are suitable for short-distance conveying, belt conveyors are suitable for horizontal conveying; pneumatic conveyors are suitable for long-distance conveying, and chain conveyors are suitable for vertical conveying. The implementation principle of this embodiment is: by further optimizing the function of the waste recovery module, it is more suitable for the recycling and reuse of different types of materials. This multifunctional waste recovery system not only improves resource utilization, but also enhances production flexibility and adaptability. Compared with the traditional injection molding method, this embodiment is more outstanding in terms of environmental protection and resource utilization, and has higher practical value and technological advancement. The above are all preferred embodiments of this application, and are not intended to limit the protection scope of this application. Therefore, any equivalent changes made based on the structure, shape, and principle of this application should be included in the protection scope of this application.

Claims

1. A data connection line injection molding control system, characterized in that: include: Data acquisition module, used to collect real-time data during the injection molding process, including mold temperature, melt pressure, and ambient temperature and humidity; The comparison and analysis module is used to compare and analyze the collected data with the preset ideal model and calculate the deviation. The parameter adjustment module is used to adjust the heating temperature and injection speed of the injection molding machine in real time according to the deviation using the PID control algorithm to keep the molding conditions at the best state at all times. The monitoring module is used to continuously monitor the dimensional tolerance of the data connection line after molding and verify the effectiveness of the control strategy.

2. The data connection line injection molding control system according to claim 1, characterized in that: Also includes: The exhaust module is used to open the mold cavity briefly at the beginning of injection molding to exhaust excess gas.

3. The data connection line injection molding control system according to claim 2, characterized in that: Also includes: The cooling module is used to enter the cooling stage after exhaust, and avoid shrinkage and deformation caused by rapid cooling by finely controlling the cooling time and appropriately increasing the pressure.

4. The data connection line injection molding control system according to claim 3, characterized in that: The exhaust module fine-tunes the length of time for secondary exhaust according to the characteristics of each batch of raw materials, and the cooling module fine-tunes the size of the pressure holding pressure according to the characteristics of each batch of raw materials.

5. The data connection line injection molding control system according to claim 4, characterized in that: The exhaust module prolongs the exhaust time and increases the pressure holding intensity when processing specific materials.

6. The data connection line injection molding control system according to claim 1, characterized in that: Also includes: The waste recycling module is used to collect the scraps generated during the processing, and reuse them in the subsequent injection molding process after crushing and screening.

7. The data connection line injection molding control system according to claim 6, characterized in that: The waste material recycling module comprises: a crushing device for crushing the scraps into particles; and a screening device for removing impurities and screening out particles that meet the requirements.

8. The data connection line injection molding control system according to claim 7, characterized in that: The waste recycling module also includes: a storage device for temporarily storing the particles that have been crushed and screened; and a conveying device for conveying the particles in the storage device to the feed port of the injection molding machine.

9. The data connection line injection molding control system according to claim 1, characterized in that: The data acquisition module also includes: a temperature sensor for real-time monitoring of the mold temperature; a pressure sensor for real-time monitoring of the melt pressure; and a humidity sensor for real-time monitoring of the ambient temperature and humidity.

10. The data connection line injection molding control system according to claim 1, characterized in that: The monitoring module further comprises: a measuring device for measuring the dimensional tolerance of the formed data connection line; and a processing unit for analyzing the measurement result and comparing it with the standard value.