Intelligent management and control system for injection molding process

Abstract

The invention provides an intelligent management and control system for an injection molding process, and relates to the technical field of injection molding production, and the system comprises boundary humidity sensors which are linearly arranged along the boundary of each processing area, form a linear monitoring network, and are used for monitoring and recording the air humidity data of the boundary part of each processing area in real time; the air curtain machines are arranged on the two sides of the boundary humidity sensors which are linearly arranged, generated air walls are vertically arranged on the two sides of the boundary humidity sensors to form air curtain isolation, and air flow exchange among the areas is controlled by adjusting the air speeds of the air curtain machines; the central humidifier is arranged across the machining areas, and the humidification output ends of the central humidifier extend into the machining areas at the same time to provide basic humidity for the whole production workshop. According to the system, through comprehensive application of high-precision monitoring, air curtain isolation, central humidification and local dehumidification and integration of an intelligent control system, accurate zoning control over humidity of different areas in the injection molding production workshop is achieved.

Description

Technical Field

[0001] The present invention relates to the field of injection molding production technology, and specifically to a humidity zoning control system and method for an injection molding production workshop through high-precision humidity monitoring, wind curtain isolation, central humidification and local dehumidification combined with automatic adjustment by an intelligent control system. Background Art

[0002] In the plastic products manufacturing industry, humidity control is one of the key factors to ensure product quality and production efficiency. Especially in the injection molding process, changes in humidity will directly affect the performance of plastic raw materials and the quality of the final product. However, traditional humidity control methods often face many challenges, especially in large, open or semi-open injection molding production workshops.

[0003] Injection molding workshops usually contain multiple processing areas with different functions. Although these areas are interconnected to facilitate material flow and personnel operation, their humidity requirements are different. For example, some areas may require delicate injection molding operations, which require extremely high humidity control accuracy; while other areas may involve the storage or pretreatment of raw materials, which require relatively low humidity. Such differentiated humidity requirements make the traditional unified humidity control method seem inadequate.

[0004] Traditionally, workshops usually use central humidification or dehumidification systems to try to meet the needs of the entire workshop through unified humidity adjustment. However, this "one-size-fits-all" approach often fails to take into account the special needs of each area. When a certain area adjusts the humidity due to production needs, the change will quickly spread to adjacent areas, causing the humidity of the entire workshop to be unbalanced. This humidity imbalance will not only affect the production quality and efficiency of the product, but may also cause a series of production problems, such as damp raw materials, product deformation, dimensional instability, etc.

[0005] In addition, traditional humidity control methods also rely on manual adjustment and monitoring, which is not only time-consuming and labor-intensive, but also difficult to achieve the desired control effect. Manual adjustment often has a lag and cannot respond to humidity changes in a timely manner. Moreover, human judgment is easily affected by various factors, resulting in inaccurate adjustment. At the same time, frequent manual adjustment also increases production costs and defective product rates, reducing overall production efficiency.

[0006] With the development of Industry 4.0 and intelligent manufacturing, the requirements for humidity control in injection molding workshops are getting higher and higher. Traditional humidity control methods can no longer meet the needs of modern injection molding production, and a humidity control system that can achieve high-precision, partition control, and automated management is urgently needed. Summary of the invention

[0007] In order to solve the problems mentioned in the above background technology, the present invention provides an intelligent control system for injection molding process, comprising:

[0008] Boundary humidity sensors are arranged linearly and evenly along the boundaries of each processing area, with a spacing of 2-3m, forming a linear monitoring network for real-time monitoring and recording of air humidity data at the boundaries of each processing area. The sampling frequency of each boundary humidity sensor is once per minute;

[0009] The air curtain machine is arranged on both sides of the linearly arranged boundary humidity sensors, and the wind walls generated are vertically arranged on both sides of the boundary humidity sensors to form air curtain isolation. The air curtain machine adopts a variable frequency speed regulating motor with a wind speed adjustment range of 0 to 10m / s. The air flow exchange between the areas is controlled by adjusting the wind speed of the air curtain machine;

[0010] A central humidifier is arranged across each processing area, and the humidification output end extends to each processing area at the same time to provide basic humidity for the entire production workshop. The humidification amount of the central humidifier can be adjusted in the range of 0 to 100L / h;

[0011] A dehumidifier and a matching key-station humidity sensor are arranged at key-stations in each processing area. The dehumidifier further adjusts the humidity of the key-stations according to the real-time monitoring data of the key-station humidity sensor. The dehumidifier has a dehumidification capacity adjustment range of 0 to 50 L / h.

[0012] An intelligent control system integrates data from the humidity sensor, the air curtain machine, the central humidifier and the dehumidifier to build an intelligent control platform and automatically adjust equipment operating parameters.

[0013] In some embodiments, a humidity prediction system is also included, which is used to predict the required humidity in the area in the future based on the historical humidity data recorded in the area, combined with external environmental factors and internal production activity patterns, through an LSTM algorithm model based on deep learning. The LSTM algorithm model is trained with daily humidity change data in the past year, the schedule of workshop production activities and external weather forecast data to obtain the humidity prediction results within the next 24 hours, and the prediction results are fed back to the intelligent control system.

[0014] In some embodiments, a compensation system is also included for performing local humidity compensation for areas where the humidity does not meet the standard. The compensation system is composed of a distributed small humidifier network and is connected to the intelligent control system. When the humidity in a certain area is lower than 5% of the set value, the intelligent control system automatically starts the small humidifier in the area and compensates at a rate of increasing 1% RH per hour until the humidity reaches the set value.

[0015] In some embodiments, each humidity sensor is equipped with a self-calibration function for automatic calibration every month. During the calibration process, standard gas with known humidity is used as input data, and the data is compared with the current measurement value of the sensor through a comparison circuit to automatically adjust the parameters of the sensor to ensure the accuracy of the data.

[0016] In some embodiments, a fault diagnosis and alarm system is also included. The system is connected to the intelligent control system and is used to monitor the working status of the humidity sensor, the air curtain machine, the central humidifier and the dehumidifier in real time. When it is detected that the equipment has been working abnormally for 5 consecutive minutes or the humidity deviation exceeds 10% of the set value, the system automatically triggers the alarm mechanism and notifies the maintenance personnel via SMS or email.

[0017] In some embodiments, an energy efficiency management system is also included, and the energy efficiency management system includes:

[0018] An energy consumption data collection module is used to collect energy consumption data of the humidity sensor, the air curtain machine, the central humidifier and the dehumidifier in real time, and the data includes the power, operating time and total energy consumption of each device;

[0019] The energy consumption analysis module processes and analyzes the collected energy consumption data, compares the energy consumption under different humidity setting values, and evaluates the energy efficiency of each device under different working modes, so as to identify the links and devices with higher energy consumption;

[0020] The optimization control strategy module proposes specific energy-saving suggestions and optimization control strategies based on the energy consumption analysis results;

[0021] The energy consumption monitoring and reporting module monitors the energy consumption during the humidity control process in real time and generates energy consumption reports, including energy consumption trend graphs and energy consumption comparison tables.

[0022] In some embodiments, a remote monitoring and control system is also included. The system is connected to the intelligent control system via a network to achieve remote monitoring and control of the humidity control process. Users can view the workshop humidity, equipment status and energy consumption data in real time through a mobile phone APP or a web page, and can remotely adjust the humidity setting value and equipment working mode.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] The present invention forms a dense monitoring network by setting linearly arranged boundary humidity sensors at the boundaries of each processing area, which can capture the slight changes in humidity in each area in real time and accurately, and provide reliable data support for subsequent humidity adjustment. Combined with the intelligent control system, dynamic and fine adjustment of humidity is achieved to ensure that each area can be maintained within the most suitable humidity range.

[0025] The present invention introduces an air curtain machine and utilizes the air curtain isolation principle, which not only effectively prevents the direct exchange of airflow between different areas and reduces the mutual interference of humidity, but also flexibly adjusts the wind speed according to actual needs through the variable frequency speed regulation function, thereby further optimizing the humidity distribution between areas and improving the flexibility and accuracy of humidity control.

[0026] The present invention provides a stable basic humidity for the entire workshop through a central humidification system, while a local dehumidification system performs precise dehumidification on key processing stations. The combination of the two not only ensures the overall humidity balance of the workshop, but also meets the special humidity requirements of specific stations, effectively avoiding production problems caused by improper humidity.

[0027] The present invention realizes the automatic management of the whole process of humidity control through the integration of intelligent control system. The system can automatically adjust the operation status of each device according to the preset humidity threshold and real-time monitoring data, greatly reducing manual intervention and operating costs, while improving the response speed and control accuracy, ensuring the continuity and stability of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a flowchart of the operation process of the present invention;

[0029] Figure 2 This is a schematic diagram of the installation distribution of the components involved in the present invention.

[0030] In the figure: 100, factory building; 100a, first processing area; 100b, second processing area; 100c, third processing area; 100d, fourth processing area; 1, central humidifier; 2a, boundary humidity sensor; 2b, key workstation humidity sensor; 3, air curtain machine; 4, dehumidifier. DETAILED DESCRIPTION

[0031] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0032] like Figure 1 As shown, this embodiment provides an intelligent control system for injection molding process, and the operation process of the system is as follows:

[0033] a) At the boundaries of each processing area of ​​the milk powder can plastic cover production workshop, boundary humidity sensors 2a are linearly arranged at an equal interval of 2.5 meters. The specific deployment is as follows:

[0034] The boundary between the raw material preparation area (first processing area 100a) and the injection molding area (second processing area 100b): 10 boundary humidity sensors 2a are installed, with the sensor interval being 2.5 meters and the height being 2 meters from the ground;

[0035] The boundary between the injection molding area (the second processing area 100b) and the cooling area (the third processing area 100c): 10 boundary humidity sensors 2a are also installed, and the configuration is the same as above;

[0036] The boundary between the cooling area (third processing area 100c) and the packaging area (fourth processing area 100d): 10 boundary humidity sensors 2a are installed;

[0037] Boundary between the packaging area (fourth processing area 100d) and the raw material preparation area (first processing area 100a): Finally, 10 boundary humidity sensors 2a are installed to complete the construction of the linear monitoring network of the entire workshop;

[0038] Each boundary humidity sensor 2a adopts a high-precision capacitive humidity sensor with a sampling frequency of once per minute, ensuring real-time and accurate monitoring and recording of air humidity data at the boundary of each processing area.

[0039] b) On both sides of the boundary humidity sensor 2a, an air curtain machine 3 is installed to form an air curtain isolation. The specific configuration of the air curtain machine 3 is as follows:

[0040] Adopt frequency conversion speed regulating industrial air curtain machine, the wind speed adjustment range is 0 to 10m / s;

[0041] Vertical to the boundary humidity sensor 2a, ensuring the formation of effective air curtain isolation;

[0042] A total of 8 air curtain machines 3 are installed, with 2 machines configured at the border of every two adjacent areas;

[0043] The wind curtain machine 3 adjusts the wind speed through an intelligent control system, which is initially set to 5m / s and dynamically adjusted according to the humidity requirements of each area to reduce air flow exchange and humidity interference between areas.

[0044] c) Install a large central humidifier 1 in the center of the workshop, with the following configuration:

[0045] Use a high-efficiency ultrasonic humidifier with a humidification capacity adjustment range of 0 to 100L / h;

[0046] Located in the center of the workshop, it extends to each processing area through the pipeline system;

[0047] The initial setting is to maintain the overall humidity of the workshop at about 45% RH as the starting point for humidity regulation in each area;

[0048] d) Dehumidifiers 4 and matching humidity sensors 2b for key processing stations are installed at the key processing stations in the injection molding area (second processing area 100b) and the cooling area (third processing area 100c). The specific configuration is as follows:

[0049] A total of 4 dehumidifiers 4 are installed, and the dehumidification capacity of each dehumidifier can be adjusted from 0 to 50L / h;

[0050] A total of 8 humidity sensors 2b are installed at key workstations, with 2 sensors configured at each key processing station to ensure accurate monitoring;

[0051] The dehumidifier 4 automatically adjusts the working mode according to the real-time monitoring data of the humidity sensor 2b at the key workstations to ensure that the humidity in these key areas is accurately controlled within the preset range;

[0052] e) The intelligent control system integrates the data of humidity sensors, air curtain machines 3, central humidifiers 1 and dehumidifiers 4 to build an intelligent control platform. The specific integration method is as follows:

[0053] Adopt high-precision AD converter to collect data from each device in real time to ensure the accuracy and real-time nature of the data;

[0054] Use machine learning algorithms and deep learning algorithms to intelligently analyze and predict humidity data to determine whether the humidity conditions in each processing area meet the preset threshold requirements;

[0055] According to the results of the data processing and analysis module, formulate and implement corresponding control strategies to automatically adjust the working parameters of each device;

[0056] Adopt standard communication protocols to ensure reliable communication between the intelligent control system and other systems (such as humidity prediction system, compensation system, fault diagnosis and alarm system, energy efficiency management system, remote monitoring and control system);

[0057] It provides multiple user interaction interfaces such as touch screen, web page and mobile APP, allowing users to view humidity data, equipment status and energy consumption reports, and adjust control parameters remotely.

[0058] The specific working principle of the intelligent control system for the injection molding process of the present invention is as follows:

[0059] Build a humidity monitoring network: First, set up linearly arranged boundary humidity sensors 2a at the boundaries of each processing area to form a monitoring network. These sensors can monitor and record the air humidity data at the boundaries of each processing area in real time to ensure high accuracy and real-time performance of the data.

[0060] Constructing an air curtain isolation system: air curtain machines 3 are respectively arranged on both sides of the boundary humidity sensor 2a, and the generated wind walls are vertically arranged on both sides of the boundary humidity sensor 2a to form an air curtain isolation. The air curtain machine 3 not only plays a role in heat insulation and dust prevention, but more importantly, the air flow exchange between different areas can be controlled by adjusting the wind speed. The air curtain machine 3 is equipped with a variable frequency speed regulation function. When a certain processing area requires higher humidity, the power of the air curtain machine 3 in the area on this side can be increased to increase the wind speed. Based on the Bernoulli effect, after the wind speed increases, the pressure in the area decreases, forming a pressure difference, causing more humid air output by the central humidifier 1 to be diverted and enter the area, thereby increasing the humidity in the area.

[0061] Build a central humidification system: Set up a central humidifier 1 across each processing area, and its humidification output extends to each processing area at the same time to provide a stable basic humidity for the entire production workshop. This ensures that the entire workshop has a stable basic humidity level, which is convenient for subsequent fine-tuning according to the needs of each area.

[0062] Build a local dehumidification system: Dehumidifiers 4 and matching key processing station humidity sensors 2b are installed at key processing stations in each processing area. Dehumidifiers 4 accurately adjust the humidity of key processing stations based on real-time monitoring data from key processing station humidity sensors 2b, eliminate excess moisture, and ensure that the humidity of these key locations is controlled within the optimal range.

[0063] Build an intelligent control system: The data of humidity sensors, air curtain machines 3, central humidifiers 1 and dehumidifiers 4 are integrated through an intelligent control system to build an intelligent control platform. The system automatically adjusts the power of air curtain machines 3, the output of central humidifiers 1 and the working mode of dehumidifiers 4 according to the preset humidity threshold and real-time monitoring data. For example, when the humidity in a certain area is lower than the set value, the system will increase the wind speed of the air curtain machines 3 and the output of the central humidifier 1 in the area, and reduce or shut down the dehumidifier 4 in the area; conversely, when the humidity is higher than the set value, the system will reduce the wind speed of the air curtain machines 3 and the output of the central humidifier 1, and start or increase the working intensity of the dehumidifier 4.

[0064] In summary, the present invention realizes accurate and dynamic control of the humidity in different areas of a plastic products production workshop through high-precision humidity monitoring, wind curtain isolation, the organic combination of central humidification and local dehumidification, and automatic adjustment of the intelligent control system, thereby significantly improving production efficiency and product quality.

[0065] Preferably, the present invention also includes a humidity prediction system, which predicts the required humidity in the region for a period of time in the future based on historical humidity data, external environmental factors (such as seasonal changes, weather conditions) and internal production activity patterns through a LSTM algorithm model based on deep learning. The specific configuration is as follows:

[0066] Collect daily humidity change data, workshop production activity schedules, and external weather forecast data over the past year;

[0067] The LSTM algorithm model is used for training to obtain the humidity forecast results for the next 24 hours;

[0068] Feedback the prediction results to the intelligent control system, and set the wind speed adjustment program of the air curtain machine 3, the humidification plan of the central humidifier 1, and the working strategy of the dehumidifier 4 in advance;

[0069] The humidity prediction system is used to predict the required humidity in the region in the future through an AI algorithm model based on the historical humidity data recorded in the region, combined with external environmental factors (such as seasonal changes, weather conditions) and internal production activity patterns. The algorithm model can choose a prediction model based on machine learning (such as support vector machines, neural networks, random forests, etc.) or deep learning (such as recurrent neural networks, long short-term memory networks LSTM, etc.). The model learns the law of humidity changes by training historical data and predicts future humidity based on this.

[0070] The system can feed back the prediction results to the intelligent control system, so that the wind speed adjustment program of the air curtain machine 3, the humidification plan of the central humidifier 1, and the working strategy of the dehumidifier 4 can be set in advance. After the humidity prediction system is introduced, the intelligent control system of the injection molding process of the present invention realizes the transformation from passive response to active prevention, and further improves the accuracy and efficiency of humidity control. Specifically, through the humidity prediction system, the changing trend of regional humidity can be predicted in advance, and the intelligent control system pre-adjusts the wind speed of the air curtain machine 3, the output of the central humidifier 1 and the working mode of the dehumidifier 4 accordingly, effectively reducing humidity fluctuations and maintaining a more stable humidity environment, which is crucial for preventing raw materials from getting damp and ensuring product quality in the production of plastic products. Moreover, the humidity prediction system can take into account changes in external environmental factors and internal production activities, making the humidity control scheme more flexible and adaptable to the needs of different seasons and different production batches, and enhancing the adaptability and robustness of the system.

[0071] Preferably, the present invention also includes a compensation system, which is composed of a distributed small humidifier network and is used to perform local humidity compensation for areas where the humidity does not meet the standard. The specific configuration is as follows:

[0072] Prepare to install 16 small humidifiers in total, each with adjustable humidification capacity to ensure accurate humidification;

[0073] Distribute the small humidifiers evenly in each processing area and connect them to the intelligent control system;

[0074] When the intelligent control system detects that the humidity in a certain area is 5% lower than the preset threshold, it automatically starts the small humidifier in the area to compensate at a rate of 1% RH per hour until the humidity reaches the set value.

[0075] The compensation system is used to compensate for the local humidity in the area where the humidity does not meet the standard without the help of the central humidifier 1. The compensation system is composed of a distributed small humidifier network, which is distributed inside each processing area and connected to the intelligent control system. When the intelligent control system detects that the humidity in a certain area is lower than the preset threshold, it will automatically start the small humidifier in the area to perform precise local humidification to quickly make up for the lack of humidity while avoiding affecting the humidity balance in other areas. After adding the compensation system, the intelligent control system for the injection molding process of the present invention realizes more sophisticated and flexible humidity regulation, further improves the accuracy and response speed of humidity control, and specifically, the compensation system can quickly identify and respond to the area where the humidity does not meet the standard, and perform precise local humidification through distributed small humidifiers, effectively shortening the humidity adjustment time, and ensuring that the humidity in each area is always kept within the optimal range. And because the compensation system uses distributed small humidifiers, it can avoid unnecessary humidity interference to other areas when performing local humidification, and maintain the stability and balance of the humidity environment of the entire workshop. In addition, as a supplement to the central humidification system, the compensation system enhances the reliability and redundancy of the entire humidity control system. Even if the central humidifier 1 fails or cannot meet the local humidity demand, the compensation system can intervene in time to ensure that production is not affected.

[0076] Preferably, each humidity sensor is equipped with a self-calibration function, and the specific configuration is as follows:

[0077] Built-in standard humidity source and comparison circuit, automatic calibration without external intervention;

[0078] Automatic calibration once a month to ensure long-term data accuracy;

[0079] A known humidity value is generated by a standard humidity source, and compared with the current measured value of the sensor through a comparison circuit to automatically adjust the sensor parameters and eliminate deviations.

[0080] This function can automatically calibrate regularly or under specific conditions to eliminate deviations caused by long-term use or environmental factors, ensuring the long-term accuracy of the data. This function is achieved through the built-in calibration module, which contains a standard humidity source and a comparison circuit, which can accurately calibrate the sensor without external intervention. The self-calibration function can automatically trigger the calibration procedure regularly or under specific conditions (such as when the ambient temperature changes beyond a certain threshold, the sensor working time reaches a preset value, etc.). During the calibration process, the built-in calibration module uses a standard humidity source to generate a known humidity value and compares it with the current measurement value of the sensor through a comparison circuit. If a deviation is found, the calibration module automatically adjusts the sensor parameters to eliminate the deviation and ensure the accuracy of the data.

[0081] This design not only improves the accuracy and stability of humidity control, but also reduces system misoperation and unnecessary energy waste caused by sensor deviation. At the same time, the self-calibration function reduces the frequency and cost of manual calibration, and improves the maintenance convenience and economy of the system. In addition, since the self-calibration function can automatically complete the calibration operation without external intervention, it also improves the automation and intelligence level of the system.

[0082] Preferably, the present invention also includes a fault diagnosis and alarm system, which is connected to the intelligent control system to monitor the working status of the humidity sensor, the air curtain machine 3, the central humidifier 1 and the dehumidifier 4 in real time. The specific configuration is as follows:

[0083] Built-in diagnostic algorithms to perform regular or real-time performance testing on each device, analyze operating data, and determine whether there are any faults or performance degradation issues;

[0084] Once the device is detected to be working abnormally for 5 consecutive minutes or the humidity deviation exceeds 10% of the set value, the system automatically triggers the alarm mechanism and notifies the maintenance personnel via SMS or email;

[0085] Provides the specific location of faulty equipment and possible causes of the fault, allowing maintenance personnel to quickly locate and resolve the problem.

[0086] The fault diagnosis and alarm system can monitor the working status of the humidity sensor, air curtain machine 3, central humidifier 1 and dehumidifier 4 in real time. Once an abnormal situation is found, it will automatically trigger the alarm mechanism and promptly notify the maintenance personnel to carry out maintenance.

[0087] Preferably, the present invention also includes an energy efficiency management system, which is integrated with the intelligent control system to monitor and analyze the energy consumption during the humidity control process. The specific configuration is as follows:

[0088] Real-time collection of energy consumption data of humidity sensors, air curtain machines 3, central humidifiers 1 and dehumidifiers 4, including power, operating time and total energy consumption;

[0089] Process and analyze the collected energy consumption data, identify the links and equipment with higher energy consumption by comparing the energy consumption under different humidity setting values ​​and evaluating the energy efficiency of each device under different working modes;

[0090] Based on the energy consumption analysis results, specific energy-saving suggestions and optimization control strategies are proposed, such as adjusting the wind speed of the air curtain machine 3, the humidification amount of the central humidifier 1, and the working mode of the dehumidifier 4;

[0091] Real-time monitoring of energy consumption during humidity control and generation of energy consumption reports, including energy consumption trend charts, energy consumption comparison tables, etc., to provide decision support for users

[0092] The energy efficiency management system can collect energy consumption data of humidity sensors, air curtain machines 3, central humidifiers 1 and dehumidifiers 4 in real time, process and analyze them, find out the links and equipment with high energy consumption, and put forward energy-saving suggestions. At the same time, the system can also automatically adjust the working mode and parameters of the equipment according to production needs and humidity control targets to achieve the best energy efficiency ratio. The energy efficiency management system can find out the links and equipment with high energy consumption by real-time monitoring and analyzing energy consumption data, providing a basis for energy-saving transformation and optimization control. At the same time, the system can also automatically adjust the working mode and parameters of the equipment according to production needs and humidity control targets, achieving a balance between energy consumption and humidity control effects, ensuring product quality and production efficiency, and reducing energy consumption costs.

[0093] Preferably, the present invention also includes a remote monitoring and control system, which is connected to the intelligent control system via a network to achieve remote monitoring and control of the humidity control process. The specific configuration is as follows:

[0094] Use high-speed and stable network connection to ensure real-time data transmission and smooth remote operation;

[0095] Provides two remote monitoring interfaces: mobile APP and web page, allowing users to check workshop humidity, equipment status and energy consumption data anytime and anywhere;

[0096] Users can remotely adjust the humidity setting value and device working mode through the remote monitoring interface to achieve precise management of humidity control;

[0097] Record historical data to provide decision support for users, helping them better manage production processes and optimize humidity control solutions.

[0098] Users can view the humidity conditions, equipment operation status, and energy consumption data in the workshop at any time through terminal devices such as mobile phones and computers, and remotely adjust control parameters as needed to achieve precise management of humidity control.

[0099] Through the above specific configuration, the intelligent management and control system for the injection molding process of the present invention realizes precise zoning control of the humidity in different areas of the plastic lid production workshop for milk powder cans, significantly improving production efficiency and product quality. At the same time, the system also has multiple functions such as humidity prediction, local humidity compensation, self-calibration, fault diagnosis and alarm, energy efficiency management, and remote monitoring and control, further improving the intelligence level and reliability of the system.

[0100] Exemplarily, as Figure 2 shown, in a 1000-square-meter plastic lid production workshop for milk powder cans, according to the production process requirements, the factory building 100 is divided into four production areas arranged in a "field" shape, with each area having an area of approximately 250 square meters, corresponding to the raw material preparation area (the first processing area 100a), the injection molding area (the second processing area 100b), the cooling area (the third processing area 100c), and the packaging area (the fourth processing area 100d). The preset humidity thresholds are 45%-50%RH for the raw material preparation area, 50%-55%RH for the injection molding area, 40%-45%RH for the cooling area, and 35%-40%RH for the packaging area; for the specific humidity requirements of each area, the above intelligent management and control system for the injection molding process is implemented:

[0101] Deployment of boundary humidity sensors 2a:

[0102] At the junction of each processing area, that is, on the boundaries between the first processing area 100a and the second processing area 100b, the second processing area 100b and the third processing area 100c, the third processing area 100c and the fourth processing area 100d, and the fourth processing area 100d and the first processing area 100a, linearly arranged boundary humidity sensors 2a are respectively installed. A total of 40 sensors are installed, with 10 sensors arranged on each area boundary, and the sensor spacing is about 2.5 meters, and the height is set at 2 meters from the ground to ensure that the air humidity at the boundaries of each area can be accurately monitored;

[0103] Configuration of air curtain machines 3:

[0104] On both sides of the boundary humidity sensors 2a between every two adjacent areas, 1 air curtain machine 3 is set respectively, with a total of 8; the air wall generated by the air curtain machine is perpendicular to the boundary humidity sensors 2a to form an effective air curtain isolation; the wind speed of the air curtain machine 3 is adjustable, initially set at 5m / s, and can be dynamically adjusted through the intelligent control system according to the actual humidity control requirements to reduce the air flow exchange and humidity interference between areas;

[0105] Installation of central humidifier 1:

[0106] A large central humidifier 1 is installed in the center of the workshop. Its humidification output is extended to each processing area through a pipeline system to provide basic humidity for the entire production workshop. The humidifier is set to maintain the overall humidity of the workshop at around 45% RH, which serves as the starting point for humidity regulation in each area.

[0107] Configuration of dehumidifier 4 and key station humidity sensor (2b):

[0108] Two dehumidifiers 4 are installed at each of the key processing stations in the injection molding area (the second processing area 100b) and the cooling area (the third processing area 100c), and key station humidity sensors 2b are provided in combination, for a total of four dehumidifiers and eight sensors; the dehumidifiers automatically adjust the working mode according to the real-time monitoring data of the sensors to ensure that the humidity in these key areas is accurately controlled within a preset range;

[0109] Intelligent control system integration:

[0110] All humidity sensors, air curtain machines 3, central humidifiers 1 and dehumidifiers 4 are connected to the intelligent control system via wired or wireless means; the system automatically adjusts the working parameters of each device according to the preset humidity threshold and real-time monitoring data to achieve intelligent and automated control of workshop humidity.

[0111] This specific embodiment is merely an explanation of the present invention and is not a limitation of the present invention. After reading this specification, those skilled in the art may make non-creative modifications to the present embodiment as needed. However, as long as they are within the scope of the claims of the present invention, they are protected by the patent law.

Claims

1. An intelligent control system for injection molding process, characterized in that: include: Boundary humidity sensors (2a) are arranged linearly and evenly spaced along the boundaries of each processing area, the spacing being 2-3 m, to form a linear monitoring network for real-time monitoring and recording of air humidity data at the boundaries of each processing area, with each boundary humidity sensor (2a) sampling once per minute; The wind curtain machine (3) is arranged on both sides of the linearly arranged boundary humidity sensors (2a), and the generated wind walls are arranged vertically on both sides of the boundary humidity sensors (2a) to form air curtain isolation. The wind curtain machine (3) adopts a variable frequency speed regulating motor, and the wind speed adjustment range is 0 to 10 m / s. The air flow exchange between the various areas is controlled by adjusting the wind speed of the wind curtain machine (3); A central humidifier (1) is arranged across each processing area, and a humidification output end extends into each processing area at the same time, providing basic humidity for the entire production workshop. The humidification amount of the central humidifier (1) can be adjusted in a range of 0 to 100 L / h; A dehumidifier (4) and a matching key processing station humidity sensor (2b), which are arranged at the key processing station of each processing area, the dehumidifier (4) further adjusts the humidity of the key processing station according to the real-time monitoring data of the key processing station humidity sensor (2b), and the dehumidifier (4) has a dehumidification adjustment range of 0 to 50 L / h; An intelligent control system integrates data from a humidity sensor, the air curtain machine (3), the central humidifier (1) and the dehumidifier (4), constructs an intelligent control platform, and automatically adjusts equipment operating parameters.

2. According to claim 1, the intelligent control system for injection molding process is characterized in that: It also includes a humidity prediction system, which is used to predict the required humidity in the area in the future based on the historical humidity data recorded in the area, combined with external environmental factors and internal production activity patterns, through an LSTM algorithm model based on deep learning. The LSTM algorithm model is trained with daily humidity change data in the past year, the schedule of workshop production activities and external weather forecast data to obtain the humidity prediction results within the next 24 hours, and the prediction results are fed back to the intelligent control system.

3. The intelligent control system for injection molding process according to claim 1, characterized in that: It also includes a compensation system for performing local humidity compensation for areas where the humidity does not meet the standard. The compensation system is composed of a distributed small humidifier network and is connected to the intelligent control system. When the humidity in a certain area is lower than 5% of the set value, the intelligent control system automatically starts the small humidifier in the area and compensates at a rate of increasing 1% RH per hour until the humidity reaches the set value.

4. The intelligent control system for injection molding process according to claim 1, characterized in that: Each humidity sensor is equipped with a self-calibration function for automatic monthly calibration. During the calibration process, standard gas with known humidity is used as input data, which is compared with the current measurement value of the sensor through a comparison circuit to automatically adjust the parameters of the sensor to ensure the accuracy of the data.

5. The intelligent control system for injection molding process according to claim 1, characterized in that: The invention also comprises a fault diagnosis and alarm system, which is connected to the intelligent control system and is used to monitor the working status of the humidity sensor, the air curtain machine (3), the central humidifier (1) and the dehumidifier (4) in real time. When it is detected that the equipment has been working abnormally for 5 consecutive minutes or the humidity deviation exceeds 10% of the set value, the system automatically triggers the alarm mechanism and notifies the maintenance personnel via SMS or email.

6. The intelligent control system for injection molding process according to claim 1, characterized in that: Also included is an energy efficiency management system, the energy efficiency management system comprising: An energy consumption data collection module, used for collecting energy consumption data of the humidity sensor, the air curtain machine (3), the central humidifier (1) and the dehumidifier (4) in real time, the data including the power, operating time and total energy consumption of each device; The energy consumption analysis module processes and analyzes the collected energy consumption data, compares the energy consumption under different humidity setting values, and evaluates the energy efficiency of each device under different working modes, so as to identify the links and devices with higher energy consumption; The optimization control strategy module proposes specific energy-saving suggestions and optimization control strategies based on the energy consumption analysis results; The energy consumption monitoring and reporting module monitors the energy consumption during the humidity control process in real time and generates energy consumption reports, including energy consumption trend graphs and energy consumption comparison tables.

7. The intelligent control system for injection molding process according to claim 1, characterized in that: It also includes a remote monitoring and control system, which is connected to the intelligent control system through a network to achieve remote monitoring and control of the humidity control process. Users can view the workshop humidity, equipment status and energy consumption data in real time through a mobile phone APP or a web page, and can remotely adjust the humidity setting value and equipment working mode.

Images