Electric box control system and control method based on independent module

Abstract

The invention provides an electric box control system and control method based on an independent module, and the method comprises the steps: creating a human-computer interface which is convenient for a user to use, and enabling the user to define at least one electric box and a plurality of input and output modules in the electric box; input and output points for realizing the same function are integrated into one electric box; when a machine is assembled, an electric box is placed in a corresponding system and is connected to a host through an internet access, and data interaction is carried out by utilizing Ethernet communication, so that the work of each system is controlled; when a new control system is added, only a new electric box needs to be added, newly-added input and output are put into the electric box, and then data interaction with a host is carried out through a network cable. The invention provides an electric box model based on an independent module and a control system and a control method thereof, aims to provide a solution which is more efficient, flexible and easy to maintain, is suitable for industrial equipment needing complex input and output management, such as an injection molding machine and a die-casting machine, and remarkably improves the control precision and the operation convenience of the equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial control, and particularly relates to an electric box control system and a control method based on independent modules. Background Art

[0002] For equipment such as injection molding machines and die casting machines that require complex input and output management, they are usually composed of multiple systems, including but not limited to injection systems, clamping systems, temperature control systems, lubrication systems, safety monitoring systems, and some peripherals (such as manipulators, dryer machines, etc.); each system needs to precisely control various types of hydraulic valves and analog outputs to ensure operation according to specific product process requirements; there are a wide variety of hydraulic control valves, including sequence valves, directional control valves, backpressure valves, throttle valves, speed control valves, etc., which are used to control the flow and pressure of hydraulic oil.

[0003] Deficiencies of the prior art: 1. Complex wiring: In the existing control methods, the host is directly connected to each control system, or each control system is connected through an input / output expansion board placed beside the host; this method leads to a large amount of wiring work, which not only increases the time for assembling the machine, but also greatly increases the amount of wire used, and it is difficult to sort out the wire relationships during maintenance.

[0004] 2. High error rate: Since each control system operates independently and has a complex wiring structure with the host, it is easy to make mistakes during the assembly or maintenance process of the system, increasing the possibility of faults.

[0005] 3. Inconvenient maintenance: When additional input / output control points need to be added, new wires must be led out from the host and connected to the corresponding positions. This not only takes time, but also makes it very difficult to troubleshoot problems once they occur, because all the cables are concentrated near the host.

[0006] 4. Low efficiency: Under the traditional control method, checking the situation of a specific part needs to be carried out through the host, which increases the detection time and difficulty and reduces the work efficiency.

[0007] 5. Resource waste: Since the number and layout of inputs and outputs cannot be flexibly adjusted according to actual needs, the traditional method often leads to unnecessary resource waste, such as excessive wire use and space occupation.

[0008] Therefore, the prior art has deficiencies and needs further improvement. Summary of the Invention

[0009] In view of the problems existing in the prior art, the present invention provides an electric box control system and a control method based on independent modules.

[0010] To achieve the above object, the specific solution of the present invention is as follows: The present invention provides an electrical box control system based on independent modules, which is characterized by including: At least one electrical box, each of the electrical boxes containing a plurality of input / output modules for processing digital or analog signals; Each of the input / output modules has an independent control function and communicates with the host and other modules through Ethernet; The electrical box is connected to the host through Ethernet and is used for centrally managing the input / output signals of different functions of an injection molding machine or other industrial equipment; A human-machine interface (HMI) module, which is used for the user to customize the layout of the electrical box and the input / output modules inside it to adapt to different machine requirements.

[0011] Further, the input / output modules are subdivided into digital input modules, digital output modules, analog input modules, and analog output modules, and each module is independently configured to adapt to different types of signal processing requirements.

[0012] Further, each module in the electrical box is equipped with a control chip, which acts as a microcontroller to process the input / output signals of its own module, thereby realizing the independent operation of the module.

[0013] Further, the number of the electrical boxes and the number of input / output points in each electrical box are customized according to actual usage conditions, improving the resource utilization rate and the flexibility of the system.

[0014] Further, the human-machine interface module further includes a fault diagnosis unit, which facilitates the user to quickly locate and solve problems of a specific electrical box or module, simplifying the maintenance process; The fault diagnosis unit adopts a fault diagnosis algorithm, and its formula is as follows:

[0015] Among them, F(x) represents the fault diagnosis result; n is the number of parameters of the electrical box or module; wi is the weight of the i-th parameter; xi is the actual value of the i-th parameter; The fault diagnosis result calculated by this formula can quickly locate the fault location and improve the maintenance efficiency.

[0016] The present invention also provides an electrical box control method based on independent modules. Based on the above system, the method includes the following steps: S1, using programming techniques to create a user-friendly human-machine interface, allowing the user to define at least one electrical box and a plurality of input / output modules therein; S2, Concentrate the input and output points that achieve the same function into one electrical box, and connect the electrical box to the host through Ethernet for high-speed and stable communication; S3, When assembling the machine, place the electrical box inside the corresponding system, connect it to the host through the network port, and use Ethernet communication for data interaction to control the operation of each system; S4, When adding a new control system, simply add a new electrical box, put the newly added input and output into the electrical box, and then perform data interaction with the host through the network cable, simplifying the machine assembly, inspection, and maintenance processes; S5, Define the input and output required for a single function to the same module, and place several modules together in one electrical box to achieve one electrical box controlling one action or a class of functions, improving the system integration and maintainability.

[0017] Furthermore, in step S1, it further includes the step: when creating the human-machine interface, provide a graphical tool so that users can intuitively design the electrical box and module layout by dragging and dropping, improving the design efficiency; The graphical tool adopts a layout optimization algorithm, and its formula is as follows:

[0018] Among them, L(x) represents the layout optimization objective; m is the number of electrical boxes, and n is the number of modules; dij is the distance between the i-th electrical box and the j-th module; xij is a layout decision variable, taking 1 when the j-th module is placed in the i-th electrical box, and 0 otherwise; By optimizing the layout with this formula, the design efficiency and system performance can be improved.

[0019] Furthermore, in step S1, it further includes the step: preset a series of standard protocols through the human-machine interface to ensure the communication compatibility and stability between the host and each electrical box.

[0020] Furthermore, it further includes step S6: when a failure occurs in the electrical box or module, remind the user through the indicator light or alarm information on the human-machine interface so that measures can be taken in a timely manner to solve the problem: The trigger of the indicator light or alarm information adopts a fault warning algorithm, and its formula is as follows:

[0021] Among them, W(y) represents the fault warning value, and p is the number of fault characteristic parameters of the electrical box or module; fi is the weight of the i-th fault characteristic parameter; $y_i$ is the actual value of the $i$-th fault characteristic parameter; When $W(y)$ is greater than the set threshold, the indicator light or alarm message is triggered to remind the user to handle the fault in time.

[0022] Further, in step S6, it further includes providing online help and document support for the user to guide the user to correctly configure and use the electric box and the module, reducing the operation difficulty and reducing the occurrence of errors.

[0023] Adopting the technical solution of the present invention has the following beneficial effects: 1. Simplify wiring and installation: Reduce the amount of wire used: By concentrating the input and output points that achieve the same function in one electric box, the number of lines led out from the host is reduced, significantly reducing the amount of wire used.

[0024] Facilitate assembly: When the user assembles the machine, they only need to place the electric box inside the corresponding system and connect it to the host through the network port, and use Ethernet communication for data interaction, simplifying the assembly process.

[0025] 2. Improve maintenance efficiency: Quick fault location: Since the input and output signals of each system are centrally managed in one electric box, when a problem occurs in a certain system, only the corresponding electric box module needs to be checked, and there is no need to troubleshoot the problem starting from the host, greatly improving the fault detection efficiency.

[0026] Easy to expand: When a new control system needs to be added, the operation is simple. Only a new electric box needs to be added, and the newly added input and output are placed in the electric box, and then data interaction is carried out with the host through the network cable, simplifying the machine assembly, inspection and maintenance process.

[0027] 3. Enhance system flexibility: Custom configuration: The user can create different electric boxes through the human-machine interface (HMI) and allocate the input and output signals to the corresponding electric boxes for unified processing according to the actual functional requirements to meet the needs of different machines.

[0028] Modular design: Each module in the electric box is equivalent to a small host and can simply process the input and output signals. Therefore, adding or removing modules will not affect the normal operation of other modules, providing a high degree of flexibility and scalability.

[0029] 4. Optimize resource allocation: Efficient resource utilization: The number of electric boxes and the number of input and output points in each electric box can be customized according to the actual usage situation, improving the resource utilization rate and avoiding unnecessary resource waste.

[0030] High integration level: The inputs and outputs required to define a single function are integrated into the same module, and several modules are placed together in an electrical box, achieving a higher degree of system integration and enhancing the compactness and stability of the system.

[0031] 5. Improve communication performance: High-speed and stable communication: The communication between modules inside the electrical box and between the electrical box and the host is connected by Ethernet, ensuring a high-speed data transmission rate and communication stability, and ensuring the efficient operation of the system.

[0032] 6. Reduce the error occurrence rate: Reduce human errors: Through centralized management and modular design, the complexity of wiring and the possibility of wiring errors are reduced, thereby reducing the probability of system failures and improving the reliability of the system. Brief description of the drawings

[0033] Figure 1 is the communication architecture between the electrical box and modules of the present invention and the host; Figure 2 is the schematic diagram of communication between modules and inside modules of the present invention; Figure 3 is the schematic diagram of Example 4 of the actual application mode of the present invention; Figure 4 is the overall flowchart of the present invention. Detailed implementation manners

[0034] The present invention will be further described in detail below with reference to the drawings and embodiments; it can be understood that the specific embodiments described herein are only used to explain the present invention, rather than limiting the present invention; in addition, it should be noted that for the convenience of description, only parts related to the present invention are shown in the drawings, rather than all.

[0035] Combined with Figures 1-4 As shown, the present invention provides an electrical box control system based on independent modules, and the system includes: At least one electrical box, each of the electrical boxes contains a plurality of input / output modules for processing digital or analog signals; Each of the input / output modules has an independent control function and communicates with the host and other modules through Ethernet; The electrical box is connected to the host through Ethernet and is used to centrally manage the input / output signals of different functions of an injection molding machine or other industrial equipment; A human-machine interface (HMI) module, which is used for users to customize the layout of the electrical box and the input / output modules inside it to adapt to different machine requirements.

[0036] The input / output module is subdivided into a digital input module, a digital output module, an analog input module, and an analog output module. Each module is independently configured to adapt to different types of signal processing requirements.

[0037] Each module in the electrical box is equipped with a control chip, which acts as a microcontroller to process the input / output signals of its own module, thus realizing the independent operation of the module.

[0038] The number of electrical boxes and the number of input / output points in each electrical box are customized according to the actual usage, improving resource utilization and system flexibility.

[0039] The human-machine interface module also includes a fault diagnosis unit, which facilitates users to quickly locate and solve problems of specific electrical boxes or modules, simplifying the maintenance process; The fault diagnosis unit adopts a fault diagnosis algorithm, and its formula is as follows:

[0040] Among them, F(x) represents the fault diagnosis result; n is the number of parameters of the electrical box or module; wi is the weight of the i-th parameter; xi is the actual value of the i-th parameter; The fault diagnosis result calculated by this formula can quickly locate the fault location and improve the maintenance efficiency.

[0041] The present invention also provides an electrical box control method based on independent modules. Based on the above system, the method includes the following steps: S1. Using programming techniques to create a user-friendly human-machine interface that allows users to define at least one electrical box and multiple input / output modules therein; S2. Concentrating the input / output points that implement the same function into one electrical box and connecting the electrical box to the host through Ethernet for high-speed and stable communication; S3. When assembling the machine, placing the electrical box inside the corresponding system and connecting it to the host through a network port, and using Ethernet communication for data interaction to control the operation of each system; S4. When adding a new control system, only need to add a new electrical box, put the newly added input / output into the electrical box, and then perform data interaction with the host through the network cable, simplifying the machine assembly, inspection, and maintenance processes; S5. Defining the input / output required for a single function to the same module and putting several modules together into one electrical box to achieve one electrical box controlling one action or one type of function, improving the system integration and maintainability.

[0042] In step S1, it further includes the steps of: when creating a human-machine interface, providing a graphical tool that enables users to intuitively design the electrical box and module layout by dragging and dropping, thereby improving the design efficiency; The graphical tool adopts a layout optimization algorithm, and its formula is as follows:

[0043] Among them, L(x) represents the layout optimization objective; m is the number of electrical boxes, and n is the number of modules; dij is the distance between the i-th electrical box and the j-th module; xij is a layout decision variable, which takes 1 when the j-th module is placed in the i-th electrical box, and 0 otherwise; In step S1, it further includes the steps of: presetting a series of standard protocols through the human-machine interface to ensure the communication compatibility and stability between the host and each electrical box.

[0044] It further includes step S6: when a fault occurs in the electrical box or module, remind the user through the indicator light or alarm information on the human-machine interface so that the user can take timely measures to solve the problem: The triggering of the indicator light or alarm information adopts a fault warning algorithm, and its formula is as follows:

[0045] Among them, W(y) represents the fault warning value, and p is the number of fault characteristic parameters of the electrical box or module; fi is the weight of the i-th fault characteristic parameter; yi is the actual value of the i-th fault characteristic parameter; When W(y) is greater than the set threshold, trigger the indicator light or alarm information to remind the user to handle the fault in time.

[0046] In step S6, it further includes providing online help and document support for users to guide them to correctly configure and use the electrical box and module, reducing the operation difficulty and reducing the occurrence of errors.

[0047] The present invention provides an electrical box model based on independent modules for centrally managing and controlling various input and output signals of industrial equipment (such as injection molding machines, die casting machines). The components of the system include: Electrical Box: As a centralized management unit, each electrical box is responsible for managing a group of related input and output signals.

[0048] Multiple electrical boxes can be defined according to actual functional requirements, and each electrical box corresponds to a different control system or function.

[0049] Input / Output Modules: Inside each electrical cabinet, it is subdivided into various types of modules, such as digital input modules, digital output modules, analog input modules, and analog output modules.

[0050] These modules can be flexibly configured to meet the actual needs of different machines.

[0051] The modules are connected via Ethernet to ensure the speed and stability of data transmission.

[0052] Communication Interface: The communication between the electrical cabinet and the host computer uses Ethernet, ensuring a high-speed data transmission rate and communication stability.

[0053] Each module in the electrical cabinet is also interconnected via Ethernet to achieve efficient communication between modules.

[0054] Microcontroller Chips: Each input / output module is equipped with a small control chip, which serves as a microcontroller to process its own input / output signals.

[0055] The control chip enables each module to operate independently, enhancing the flexibility and scalability of the system.

[0056] Human-Machine Interface (HMI): Provides a user-friendly operation interface, allowing users to customize the layout of the electrical cabinet and its internal modules.

[0057] Users can create different electrical cabinets through the HMI and allocate relevant input / output signals to the corresponding electrical cabinets for unified management.

[0058] Host Computer: The host computer is the central control unit of the entire system. It communicates with each electrical cabinet via Ethernet to coordinate the work of each electrical cabinet.

[0059] The host computer is also responsible for interacting with the HMI, receiving user instructions, and executing the corresponding control logic.

[0060] Programming Environment: A human-machine interface and electrical cabinet management system developed using common programming technologies (such as C, C++, VC++, VERILOG, VHDL, etc.).

[0061] The programming environment supports users to define the characteristics of electrical cabinets and modules, and set the communication protocols between them.

[0062] These components together constitute a highly integrated and easy-to-maintain control system, suitable for industrial applications that require complex input / output management. Each part is designed to improve the efficiency, reliability, and usability of the system.

[0063] The present invention provides an effective method for centrally managing and controlling the input / output signals of industrial equipment (such as injection molding machines and die-casting machines). The following are the specific steps of this method: 1. Develop a human-machine interface (HMI) Using common programming techniques (such as: C, C++, VC++, VERILOG, VHDL, etc.), create a human-machine interface suitable for users.

[0064] Users can create different electrical cabinets through the HMI, and according to the actual functional requirements, allocate the input / output signals to the corresponding electrical cabinets for unified processing.

[0065] 2. Define electrical cabinets and modules On the human-machine interface, users can define multiple electrical cabinets as needed, and each electrical cabinet is used to manage a group of related input / output signals.

[0066] Each electrical cabinet is further divided into digital input modules, digital output modules, analog input modules, analog output modules, etc. Users can customize the configuration of these modules to meet the needs of different machines.

[0067] 3. Establish a communication connection Connect the host to each electrical cabinet through Ethernet to ensure a high-speed and stable communication rate.

[0068] The modules in the electrical cabinet are also interconnected through Ethernet, ensuring the speed and stability of data transmission.

[0069] 4. Place the electrical cabinet when assembling the machine During the process of assembling the machine, users place the corresponding electrical cabinets inside systems such as the mold opening and closing system, injection system, temperature control system, and safety monitoring system.

[0070] The electrical cabinet is connected to the host through a network port, and uses Ethernet communication to achieve data interaction with the host, thereby controlling the operation of each system.

[0071] 5. Add or remove the control system When an independent control system needs to be added, the operation is simple. Just add an electrical cabinet and put the newly added input / output signals into the electrical cabinet.

[0072] Then, it conducts data interaction with the host through a network cable, simplifying the machine assembly, inspection, and maintenance processes.

[0073] If a certain control system needs to be removed, the connection of the corresponding electrical box can also be easily disconnected and removed without affecting the normal operation of other systems.

[0074] 6. Independent modular design Each module in the electrical box is equivalent to a small host and can simply process input and output signals.

[0075] When adding a new module, since the modules exist independently and do not affect the control of other modules, only a network cable is needed to insert the new module between two modules for control.

[0076] 7. Function definition and integration According to the input and output signals required by a single function, it is defined in the same module.

[0077] Several modules are placed together in an electrical box to control one action or a type of function with one electrical box, improving the integration and maintainability of the system.

[0078] 8. Fault detection and maintenance Since the input and output signals of each system are centrally managed in an electrical box, when a problem occurs in a certain system, only the corresponding electrical box module needs to be checked, and there is no need to troubleshoot the problem starting from the host, greatly improving the fault detection efficiency.

[0079] Maintenance personnel can quickly locate the problem, reducing the downtime and improving the production efficiency.

[0080] Conclusion: The above steps describe the entire process from developing the human-machine interface to final fault detection and maintenance, demonstrating how to simplify the control and maintenance of industrial equipment by centrally managing input and output signals. This method not only improves the flexibility and scalability of the system but also enhances the stability and usability of the system.

[0081] Working principle of the present invention The present invention proposes an electrical box model based on independent modules, its control system, and control method, aiming to provide a more efficient, flexible, and easy-to-maintain solution applicable to industrial equipment that requires complex input and output management, such as injection molding machines, die-casting machines, etc. The following is the working principle of the present invention: System architecture Electrical Box: Each electrical cabinet serves as a centralized management unit, responsible for managing a group of related input and output signals. Multiple electrical cabinets are defined according to actual functional requirements, and each electrical cabinet corresponds to a different control system or function.

[0082] Input / Output Modules: The interior of the electrical cabinet is subdivided into various types of modules, such as digital input modules, digital output modules, analog input modules, and analog output modules. These modules can be flexibly configured to meet the actual needs of different machines.

[0083] The modules are connected via Ethernet to ensure the speed and stability of data transmission. Each module is equipped with a small control chip for processing its own input and output signals.

[0084] Communication Interface: The communication between the electrical cabinet and the host computer uses Ethernet, ensuring a high-speed data transmission rate and communication stability. Each module in the electrical cabinet is also interconnected via Ethernet to achieve efficient communication between modules.

[0085] Human-Machine Interface (HMI): Users can create different electrical cabinets through the HMI and allocate relevant input and output signals to the corresponding electrical cabinets for unified management. The HMI provides graphical tools that enable users to intuitively design the layout of electrical cabinets and modules by dragging and dropping.

[0086] Host Computer: The host computer is the central control unit of the entire system. It communicates with each electrical cabinet via Ethernet to coordinate the work of each electrical cabinet. The host computer is also responsible for interacting with the HMI, receiving user instructions, and executing the corresponding control logic.

[0087] Workflow: 1. Initialization Settings: Users define the required number of electrical cabinets and the types of input / output modules within each electrical cabinet through the human-machine interface. According to the specific application scenario, the input / output points that implement the same function are concentrated in one electrical cabinet, thus simplifying the wiring and installation process.

[0088] 2. System Integration: When assembling the machine, users place the electrical cabinet inside the corresponding system and connect the electrical cabinet to the host computer through a network port. The host computer communicates with each electrical cabinet via Ethernet to ensure high-speed and stable signal transmission.

[0089] 3. Real-time Monitoring and Control: The modules inside the electrical cabinet collect input signals from various parts of the machine in real time and send the processed information to the host computer. The host computer issues commands according to the preset control logic, transmits them to the corresponding electrical cabinet through Ethernet, and then the modules in the electrical cabinet execute specific output operations, such as controlling the actions of equipment like hydraulic valves and motors.

[0090] 4. Fault Detection and Maintenance: When a problem occurs in a certain system, the user can quickly locate the electrical cabinet or module where the problem lies through the indicator lights or alarm messages on the human-machine interface. Since the input and output signals of each system are centrally managed in one electrical cabinet, this greatly simplifies the process of troubleshooting and reduces the downtime.

[0091] 5. System Expansion: When a new control system needs to be added, only a new electrical cabinet needs to be added, and the newly added inputs and outputs are placed in this electrical cabinet, and then data interaction is carried out with the host computer through the network cable. This method not only simplifies the machine assembly and inspection process, but also does not affect the normal operation of other systems.

[0092] 6. Resource Optimization: Users can customize the number of electrical cabinets and the number of input and output points in each electrical cabinet according to actual needs, improve resource utilization rate, and avoid unnecessary resource waste. At the same time, defining the inputs and outputs required for a single function in the same module realizes a higher degree of system integration.

[0093] In summary, by introducing the electrical cabinet model and the modular design concept, combined with Ethernet communication technology, the centralized management and efficient control of the input and output signals of industrial equipment are realized, significantly improving the flexibility, reliability and usability of the system.

[0094] Example 1: Centralized Control of the Mold Opening and Closing System of an Injection Molding Machine Objective: For the mold opening and closing system of an injection molding machine, realize the centralized management and control of its input and output signals to simplify the wiring and maintenance process.

[0095] Composition and Configuration Electrical Cabinet: Place a dedicated electrical cabinet inside the mold opening and closing system of the injection molding machine.

[0096] Module: This electrical cabinet contains digital input modules, digital output modules, analog input modules and analog output modules, which are used to process various signals involved in the mold opening and closing process.

[0097] Communication Interface: The electrical cabinet is connected to the host computer through Ethernet to ensure high-speed and stable data transmission.

[0098] Human Machine Interface (HMI): Users can intuitively define the module layout inside the electrical cabinet through the HMI and monitor the operating status of the switch mold system.

[0099] Workflow When assembling the machine, the user places the above-configured electrical cabinet inside the switch mold system and connects it to the host through an Ethernet port.

[0100] When the switch mold system is working, the modules inside the electrical cabinet collect input signals from sensors and other devices in real time and send the processed information to the host.

[0101] The host issues commands according to the preset control logic, transmits them to the corresponding electrical cabinet through Ethernet, and then the modules in the electrical cabinet execute specific output operations, such as controlling the action of the hydraulic valve.

[0102] When a fault occurs, the user can quickly locate the electrical cabinet or module where the problem lies through the HMI, simplifying the process of fault troubleshooting.

[0103] Effect The number of wires led out from the host is reduced, significantly reducing the wire consumption.

[0104] The assembly and maintenance processes are simplified, improving work efficiency.

[0105] The reliability and stability of the system are enhanced, reducing the likelihood of faults.

[0106] Example 2: Adding an independent control system for the injection system Objective Based on the existing injection molding machine, add an independent control system for the injection system to meet the new process requirements.

[0107] Composition and configuration New electrical cabinet: Design and add a new electrical cabinet specifically for the injection system.

[0108] Modules: The new electrical cabinet is configured with sufficient input and output modules to meet the processing requirements of various signals during the injection process.

[0109] Communication interface: The new electrical cabinet is also connected to the host through Ethernet to ensure the efficiency and stability of communication.

[0110] Human Machine Interface (HMI): Users can conveniently define the functions of the new electrical cabinet and its internal modules through the HMI and perform parameter settings.

[0111] Workflow According to actual needs, the user creates a new electrical cabinet using the HMI and places it inside the injection system.

[0112] The newly added electrical box is connected to the host via network cable to achieve data interaction.

[0113] After the injection system starts working, the modules in the new electrical box are responsible for processing all relevant input and output signals and performing corresponding actions according to the instructions of the host.

[0114] If further function expansion is needed, more modules or electrical boxes can be easily added without affecting the normal operation of the existing system.

[0115] Effect Simplifies the machine assembly and inspection processes and improves the flexibility of the system.

[0116] Does not affect the normal operation of other systems and ensures the continuity of overall production.

[0117] Facilitates later maintenance and upgrade and enhances the scalability of the system.

[0118] Embodiment 3: Optimization and Integration of Safety Monitoring System Objective Integrate the safety monitoring system of the injection molding machine into the control system based on the electrical box model to improve the integration and reliability of the system.

[0119] Composition and Configuration Safety monitoring electrical box: A dedicated electrical box is designed to manage the input and output signals of the safety monitoring system.

[0120] Modules: Multiple types of input and output modules are integrated in this electrical box to process signals from devices such as emergency stop buttons and safety light curtains.

[0121] Communication interface: The safety monitoring electrical box is connected to the host via Ethernet to ensure real-time and efficient communication.

[0122] Human Machine Interface (HMI): Users can set various parameters of the safety monitoring system through the HMI and monitor its status in real time.

[0123] Workflow The safety monitoring electrical box is installed in the safety-critical area of the injection molding machine and connected to the host through a network port.

[0124] During operation, the safety monitoring electrical box continuously monitors all relevant signals. Once an abnormal situation is detected, it immediately feeds back the information to the host.

[0125] After receiving the alarm, the host immediately takes measures, such as stopping the machine operation, to ensure the safety of personnel and equipment.

[0126] Users can view the status of the safety monitoring system through the HMI and make adjustments or maintenance when necessary.

[0127] Effect The response speed and reliability of the security monitoring system are improved, and the security of the entire system is enhanced.

[0128] By centrally managing input and output signals, the wiring and maintenance work are simplified.

[0129] The collaborative work among subsystems is promoted, and the overall production efficiency is improved.

[0130] These three embodiments demonstrate how the present invention is applied to the control of industrial equipment in different scenarios. By introducing the electrical cabinet model and the modular design concept, combined with the Ethernet communication technology, the effective management and control of complex input and output signals are achieved, significantly enhancing the flexibility, reliability, and usability of the system.

[0131] Embodiment 4: The object of the present invention is a control method that can centrally process the modules of an injection molding machine. This method is simple and clear. Just like putting the functions related to each part into a box, when it is necessary to check the situation of a certain part, only this box needs to be checked, without the need to find problems through the host computer, and the specific situation of each part of the injection molding machine can be detected faster.

[0132] The technical solution of the present invention is implemented in the following manner: First, use ordinary programming technologies (such as C, C++, VC++, VERILOG, VHDL, etc.) to create a human-machine interface suitable for users. On the human-machine interface, users need to create different electrical cabinets, and according to the actual functional requirements, put the inputs and outputs into the electrical cabinets for unified processing.

[0133] The electrical cabinet is subdivided into digital input modules, digital output modules, analog input modules, analog output modules, etc. Each module can be placed arbitrarily, and data is transmitted between modules through Ethernet. Each module has a chip to control the input and output, which is equivalent to a small host computer, independently controlling its own functions. The communication between the host computer and the electrical cabinet is also realized through Ethernet, ensuring the communication rate and stability of high-speed data. The number of modules and the number of input and output points in an electrical cabinet are not fixed. In actual applications, each control system can be defined as an electrical cabinet. Because Ethernet communication is used, the communication rate and distance can be guaranteed.

[0134] When users assemble the machine, they only need to place an electrical cabinet inside the mold opening and closing system, injection system, temperature control system, security monitoring system, etc. Then, connect to the host computer through the network port and use Ethernet communication to interact with the host computer for data, so as to control the operation of each system.

[0135] When the user needs to add an independent control system, the operation is relatively simple. Only an electrical box needs to be added, and the newly added inputs and outputs are placed in the electrical box, and then data interaction is carried out with the host through the network cable. In this way, it is more convenient for the user to assemble, inspect, and repair the machine.

[0136] The specific implementation steps are as follows: 1. Using ordinary programming technologies (such as: C, C++, VC++, VERILOG, VHDL, etc.), develop an electrical box display control interface corresponding to the actual situation. The interface includes functions required for using the electrical box, each module, and each input and output signal. The operator can, according to needs, define the relevant inputs and outputs that control the same action in one electrical box, and then define multiple modules according to the characteristics of the action to facilitate the specific functions of controlling the action, and achieve centralized control of each part of the injection molding machine.

[0137] 2. In the present invention, the electrical box is used to uniformly manage the inputs and outputs. Assume that the injection molding machine needs to use 3 electrical box modules for controlling the input and output management of 3 actions. As Figure 1 shown, the CPU is connected to the first module of the first electrical box through the network cable. The modules inside the electrical box are also connected through the network cable, and then the last module of each electrical box is connected to the first module of the next electrical box through the network cable.

[0138] 3. When adding or deleting an electrical box, the electrical box is independent, and the modules of the electrical box are also independent. When modifying the number of electrical boxes, there is no need to consider whether it will affect other electrical boxes.

[0139] 4. Each module in the electrical box is equivalent to a small CPU and can simply process the input and output signals. Therefore, when adding a module, since the module exists independently, it will not affect the control of other modules. Only a network cable is needed to insert the new module between two modules for control.

[0140] 5. As Figure 2 shown, the modules are connected through Ethernet, which can fully ensure the rate and stability of signal transmission. The host transmits signals to all modules, and the modules confirm whether it is the signal of this module according to the protocol defined by the developer, ensuring the efficiency of data processing. In application, the inputs and outputs required by a single function can also be defined in the same module, and several modules are placed in one electrical box together, so as to achieve that one electrical box controls one action or one type of function.

[0141] 6. Suppose the user only needs 3 control electrical boxes to control the toggle mold system, injection system, and some other functions such as safety and lubrication respectively. The control of the toggle mold system and injection system of the injection molding machine is independent. If all the wires are concentrated in the control of the main machine, the wiring process of the main machine part will be very complicated and difficult to maintain. As Figure 3 shown in the electrical box distribution process, the CPU controls the input and output of the UI display screen and electrical box module. The electrical box for the action is directly placed in the corresponding part of the machine for the action. The two electrical boxes only need to be connected by network cables. If there is a problem with one action part, only the corresponding electrical box module needs to be checked, and there is no need to start checking from the main machine.

[0142] The above are only the preferred embodiments of the present invention, and do not limit the patent scope of the present invention. Any equivalent structural transformation made under the inventive concept of the present invention, or direct / indirect application in other related technical fields, is included in the protection scope of the present invention.

Claims

1. An electric box control system based on independent modules, characterized in that: The system includes: At least one electrical box, each of which comprises a plurality of input and output modules for processing digital or analog signals; Each of the input and output modules has independent control functions and communicates with the host and other modules via Ethernet; The electric box is connected to the host computer via Ethernet and is used to centrally manage the input and output signals of different functions of the injection molding machine or other industrial equipment; The human-machine interface module is used for users to customize the layout of the electrical box and its internal input and output modules to suit different machine requirements.

2. The system according to claim 1, characterized in that The input and output modules are subdivided into digital input modules, digital output modules, analog input modules and analog output modules, and each module is independently configured to meet different types of signal processing requirements.

3. The system according to claim 1, characterized in that Each module in the electrical box is equipped with a control chip, which serves as a microcontroller to process the input and output signals of the module itself, thereby realizing independent operation of the module.

4. The system according to claim 1, characterized in that The number of the electrical boxes and the number of input and output points in each electrical box are customized according to actual usage, thereby improving resource utilization and system flexibility.

5. The system according to claim 1, characterized in that The human-machine interface module also includes a fault diagnosis unit, which allows users to quickly locate and solve problems with specific electrical boxes or modules, simplifying the maintenance process; The fault diagnosis unit adopts a fault diagnosis algorithm, and its formula is as follows: Where, F(x) represents the fault diagnosis result; n is the number of parameters of the electrical box or module; wi is the weight of the i-th parameter; xi is the actual value of the ith parameter; The fault diagnosis results calculated by this formula can quickly locate the fault and improve maintenance efficiency.

6. A control method for an electric box based on an independent module, based on the control system according to any one of claims 1 to 5, characterized in that: The method comprises the following steps: S1, using programming technology to create a human-machine interface that is easy for users to use, allowing users to define at least one electrical box and multiple input and output modules therein; S2, centralizes the input and output points that realize the same function into one electrical box, and connects the electrical box to the host via Ethernet for high-speed and stable communication; S3, when assembling the machine, place the electric box inside the corresponding system and connect it to the host through the network port, and use Ethernet communication for data exchange to control the work of each system; S4, when adding a new control system, you only need to add a new electrical box, put the newly added input and output into the electrical box, and then exchange data with the host through the network cable, which simplifies the assembly, inspection and maintenance process of the machine; S5, define the input and output required for a single function to the same module, and put several modules together in one electrical box to achieve one electrical box controlling one action or one type of function, improving the system's integration and maintainability.

7. The method according to claim 6, characterized in that In step S1, the steps are further included: when creating a human-machine interface, a graphical tool is provided so that a user can intuitively design the layout of the electrical box and the module by dragging and dropping, thereby improving design efficiency; The graphical tool uses a layout optimization algorithm, the formula of which is as follows: Where L(x) represents the layout optimization objective; m is the number of electrical boxes, n is the number of modules; dij is the distance between the ith electrical box and the jth module; xij is the layout decision variable, which takes the value 1 when the jth module is placed in the ith electrical box and takes the value 0 otherwise; By optimizing the layout through this formula, the design efficiency and system performance can be improved.

8. The method according to claim 6, characterized in that In step S1, the step is further included: a series of standard protocols are preset through the human-machine interface to ensure the communication compatibility and stability between the host and each electrical box.

9. The method according to claim 6, characterized in that The method further comprises step S6: when a fault occurs in the electric box or module, the user is reminded through an indicator light or an alarm message on the human-machine interface so that measures can be taken to solve the problem in time: The triggering of the indicator light or alarm information adopts a fault warning algorithm, and its formula is as follows: Where W(y) represents the fault warning value, and p is the number of fault characteristic parameters of the electrical box or module; fi is the weight of the i-th fault characteristic parameter; yi is the actual value of the i-th fault characteristic parameter; When W(y) is greater than the set threshold, an indicator light or alarm message is triggered to remind the user to handle the fault in time.

10. The method according to claim 6, characterized in that In step S6, it further includes providing online help and document support to the user to guide the user to correctly configure and use the electrical box and modules, reduce the difficulty of operation and reduce the occurrence of errors.

Images