Runner design and rapid filling process of one-mold multi-cavity manufacturing equipment

Abstract

The invention discloses a runner design and rapid filling process of one-mold multi-cavity manufacturing equipment, and relates to the technical field of multi-mold cavity filling, and the runner design and rapid filling process comprises the following steps: arranging a runner valve on a sub-runner according to the runner layout of a multi-mold cavity mold, and arranging a sprue valve on a mold cavity sprue to establish a sub-runner cavity; a flow dividing cavity heating device and a mold vertical vibration device are arranged, the pressure and temperature of a flow dividing cavity are collected, data screening is carried out, and flow dividing cavity fluid data are obtained; performing primary adjustment according to the flow dividing cavity fluid data to obtain device balance setting data; the pressure and temperature of the mold cavity are obtained and recorded as mold cavity fluid data, and melt filling is conducted; the method is used for solving the problems that according to an existing multi-mold-cavity filling technology, under the condition that mold cavities and runners are arranged in an unbalanced mode, it cannot be guaranteed that the mold cavities are filled with molten materials at the same time, under the same pressure and at the same temperature, and meanwhile the temperature and pressure of each mold cavity cannot be accurately controlled for rapid filling.

Description

Technical Field

[0001] The present invention relates to the technical field of multi-cavity filling, and specifically to a runner design and rapid filling process for a multi-cavity manufacturing equipment with one mold and multiple cavities. Background Art

[0002] Multi-cavity filling technology refers to setting multiple cavities in a molding die, and through reasonable runner design and molding process control, filling materials into each cavity simultaneously or in a certain order to achieve forming multiple products of the same or different shapes and sizes in one molding.

[0003] Multi-cavity filling technology can improve production efficiency and reduce production costs because it can manufacture multiple products in one molding process, reducing the molding cycle and equipment usage time; at the same time, by precisely controlling the filling process, it can also ensure the quality consistency and dimensional accuracy of the products in each cavity; in the existing multi-cavity filling technology, the filling balance degree of each cavity is significantly related to the arrangement of the cavities and sub-runners; balanced arrangement of cavities and runners can improve the filling balance degree but will increase the length of each sub-runner, resulting in an increase in the melt flow resistance and a decrease in pressure; this not only increases the mold size but also increases the energy consumption of the molten material in the runner; for non-balanced arrangement of cavities and runners, due to different runner layouts and lengths, there are differences in the melt flow resistance in each cavity, which is likely to cause uneven filling, with some cavities being under-filled or over-filled; it is difficult to precisely control the temperature and pressure of each cavity, resulting in unstable product quality; for example, in the patent application with the publication number CN115320050A, a multi-cavity injection molding method is disclosed. Although this solution adjusts the needle valve according to the collected data during the filling process, in a non-balanced arrangement mold, it will cause inconsistent filling times for each cavity, making it difficult to ensure the dimensional consistency and accuracy of the products; therefore, in the case of non-balanced arrangement of cavities and runners in the existing multi-cavity filling technology, it is impossible to ensure that the molten material fills each cavity simultaneously, at the same pressure, and at the same temperature, while precisely controlling the temperature and pressure of each cavity for rapid filling. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems in the existing technology to some extent. By arranging a runner valve in the sub-runner of the multi-cavity mold and establishing a shunt cavity by arranging a gate valve at the cavity gate; setting a shunt cavity heating device and a mold vertical vibration device, collecting the pressure and temperature of the shunt cavity, and performing data screening to obtain the shunt cavity fluid data; making a primary adjustment according to the shunt cavity fluid data to obtain the device balance setting data; obtaining the pressure and temperature of the cavity and performing melt filling; to solve the problem that in the case of non-balanced arrangement of cavities and runners in the existing multi-cavity filling technology, it is impossible to ensure that the molten material fills each cavity simultaneously, at the same pressure, and at the same temperature, while precisely controlling the temperature and pressure of each cavity for rapid filling.

[0005] To achieve the above object, in a first aspect, the present application provides a runner design and rapid filling process for a multi-cavity manufacturing equipment, including the following steps:

[0006] Set runner valves in the sub-runners according to the runner layout of the multi-cavity mold, and set gate valves at the mold cavity gates to establish a sub-flow cavity;

[0007] Set a heating device for the sub-flow cavity and a vertical vibration device for the mold, collect the pressure and temperature of the sub-flow cavity, and perform data screening to obtain the fluid data of the sub-flow cavity;

[0008] Make a preliminary adjustment to the heating device for the sub-flow cavity, the vertical vibration device for the mold, the runner valves, and the gate valves according to the fluid data of the sub-flow cavity to obtain the device balance setting data;

[0009] Obtain the pressure and temperature of the mold cavity, denoted as the mold cavity fluid data, and perform melt filling according to the mold cavity fluid data and the device balance setting data.

[0010] Further, setting runner valves in the sub-runners according to the runner layout of the multi-cavity mold and setting gate valves at the mold cavity gates to establish a sub-flow cavity includes the following sub-steps:

[0011] Denote the mold cavities of the multi-cavity mold as mold cavity 1, mold cavity 2,..., mold cavity n in sequence; denote the sub-runners connected to mold cavity 1, mold cavity 2,..., mold cavity n as sub-runner 1, sub-runner 2,..., sub-runner n in sequence; obtain the runner layout of the multi-cavity mold, and set the cross-sectional areas of the main runner and the sub-runners to be the same;

[0012] Set valves on sub-runner 1, sub-runner 2,..., sub-runner n respectively, denoted as runner valve 1 - runner valve n in sequence, obtain the distances from all runner valves to the corresponding mold cavity gates, denoted as runner length 1 - runner length n in sequence; adjust the positions of runner valve 1 - runner valve n to ensure that all runner lengths are equal.

[0013] Further, setting runner valves in the sub-runners according to the runner layout of the multi-cavity mold and setting gate valves at the mold cavity gates to establish a sub-flow cavity further includes the following sub-steps:

[0014] Set valves at the starting positions of all mold cavity gates, denoted as gate valve 1 - gate valve n in sequence, and denote the runners intercepted by gate valve 1 - gate valve n and the corresponding runner valve 1 - runner valve n on the sub-runner as sub-flow cavities, denoted as sub-flow cavity 1 - sub-flow cavity n in sequence according to the corresponding order;

[0015] Obtain the shortest distances from all gate valves along the runner to the main gate, denoted as LD1 - LDn in sequence; obtain the median of LD1 - LDn, denoted as LDn1, and obtain the cross-sectional area of the opening when the runner valve is fully opened as XM; calculate the balanced gate value BGVn1 corresponding to LDn1 and 0.5*XM; the BGV calculation formula is as follows: Where A0 represents the cross-sectional area of the opening of the runner valve, L represents the shortest distance from the gate valve along the runner to the main gate, and X0 represents the length of the runner valve;

[0016] Denote BGVn1 as the basic balance value BGV0, and denote 0.5*XM as the balanced opening area of the corresponding runner valve; calculate the balanced opening areas corresponding to all runner valves in sequence according to BGV0, the BGV calculation formula, and LD1 - LDn, denoted as valve balance information.

[0017] Furthermore, set a heating device for the shunt cavity and a vertical vibration device for the mold, collect the pressure and temperature of the shunt cavity, and perform data screening to obtain shunt cavity fluid data, including the following sub-steps:

[0018] Set a heating device for any shunt cavity and ensure that the heating devices for any two shunt cavities are the same; select a vibration device according to the size and weight of the multi-cavity mold, and install the vibration device at the center of the base of the multi-cavity mold so that the mold can only vibrate vertically up and down;

[0019] Collect the pressure and temperature inside all shunt cavities at the first time interval, denoted as cavity pressure data and cavity temperature data respectively, and the first time interval is t1.

[0020] Furthermore, set a heating device for the shunt cavity and a vertical vibration device for the mold, collect the pressure and temperature of the shunt cavity, and perform data screening to obtain shunt cavity fluid data, which also includes the following sub-steps:

[0021] Perform abnormal data screening on the cavity pressure data and cavity temperature data collected at the same moment respectively. After completion, obtain the screened pressure data and screened temperature data, denoted as shunt cavity fluid data;

[0022] Abnormal data screening includes: arranging all the same type of data collected at the same moment in ascending order, denoted as the first data sequence; removing the smallest k1 data and the largest k1 data in the first data sequence, and calculating the average value and standard deviation of the remaining first data sequence, denoted as P0 and P1 in sequence. For any data in the first data sequence, denoted as V0, if V0 < (P0 - k2 * P1) or V0 > (P0 + k2 * P1), then mark V0 as abnormal data, otherwise mark it as normal data, where k1 and k2 are set thresholds; repeat marking all the data in the first data sequence.

[0023] Further, according to the fluid data of the shunt channel, the shunt channel heating device, the mold vertical vibration device, the runner valve, and the gate valve are initially adjusted to obtain the device balance setting data, including the following sub-steps:

[0024] Obtain the temperature and pressure of the molten material filling the mold cavity in the ideal state, denoted as the ideal filling temperature LT and the ideal filling pressure LP respectively; and obtain the temperature and pressure changes inside the mold cavity with time when the molten material fills the mold cavity in the ideal state, denoted as the ideal temperature change curve and the ideal filling pressure change curve respectively; and denote the pressure when the molten material completely fills the mold cavity in the ideal state as the ideal melt pressure MP.

[0025] When the molten material starts to be injected through the main gate, close the gate valve; open the runner valve according to the valve balance information; turn on the mold vertical vibration device, set the frequency to K0, and the amplitude to F0; turn on the shunt channel heating device and set the heating temperature to the ideal filling temperature.

[0026] Further, according to the fluid data of the shunt channel, the shunt channel heating device, the mold vertical vibration device, the runner valve, and the gate valve are initially adjusted to obtain the device balance setting data, which also includes the following sub-steps:

[0027] For any shunt channel denoted as the first shunt channel, according to the fluid data of the shunt channel corresponding to the first shunt channel, adjust the runner valve and the shunt channel heating device corresponding to the first shunt channel;

[0028] Denote the temperature and pressure inside the first shunt channel as DT and DP in sequence. When DT < LT, increase the heating temperature of the corresponding shunt channel heating device; when DT > LT, decrease the heating temperature of the corresponding shunt channel heating device; when DT = LT, do not adjust the corresponding shunt channel heating device;

[0029] When DP < LP, increase the opening degree of the corresponding runner valve; when DP > LP, decrease the opening degree of the corresponding runner valve; when DP = LP, do not adjust the opening degree of the corresponding runner valve.

[0030] Further, the initial adjustment of the flow splitting cavity heating device, the die vertical vibration device, the runner valve, and the gate valve is performed according to the fluid data of the flow splitting cavity. The obtained device balance setting data further includes the following sub-steps:

[0031] Repeat the adjustment of all flow splitting cavities, and ensure that the pressure and temperature of all flow splitting cavities when completely filled with the molten material are respectively equal to the ideal filling pressure LP and the ideal filling temperature LT; record the opening degrees of the runner valves corresponding to all flow splitting cavities at this time, and the heating temperatures of the flow splitting cavity heating devices corresponding to all flow splitting cavities, denoted as device balance setting data, and record the state of the flow splitting cavity at this time as the balanced state.

[0032] Further, obtain the pressure and temperature of the mold cavity, denoted as mold cavity fluid data, and the melt filling based on the mold cavity fluid data and the device balance setting data includes the following sub-steps:

[0033] Perform segmented processing on the ideal temperature change curve and the ideal filling pressure change curve respectively, including: for any change curve, denoted as the first transformation curve, set the unit time as t2; divide the first transformation curve into multiple change line segments at the unit time t2, and obtain the data corresponding to each division point, denoted as division point data; denote the division point data corresponding to the ideal temperature change curve as xt1, xt2,..., xtm in sequence; denote the division point data corresponding to the ideal filling pressure change curve as xp1, xp2,..., xpm in sequence.

[0034] When all flow splitting cavities reach the balanced state, open all gate valves simultaneously, collect the pressure and temperature of all mold cavities at intervals of the unit time t2, record the number of collections, and then perform abnormal data screening to obtain the mold cavity pressure data and the mold cavity temperature data, denoted as mold cavity fluid data.

[0035] Further, obtain the pressure and temperature of the mold cavity, denoted as mold cavity fluid data, and the melt filling based on the mold cavity fluid data and the device balance setting data further includes the following sub-steps:

[0036] For any real-time acquisition of cavity pressure data and cavity temperature data that are normal data, they are respectively denoted as the first pressure data ypi and the first temperature data yti. According to the acquisition times i of the first pressure data and the first temperature data, the data with the same serial number as the acquisition times of the first pressure data among xp1, xp2, …… xpm is denoted as xpi; and the data with the same serial number as the acquisition times of the first temperature data among xp1, xp2, …… xpm is denoted as xti;

[0037] If ypi < xpi or yti < xti, then increase the opening degree of the corresponding gate valve; if ypi > xpi or yti > xti, then decrease the opening degree of the corresponding gate valve; if ypi = xpi and yti = xti, then do not adjust the opening degree of the corresponding gate valve;

[0038] When the cavity pressure data of any cavity is greater than k3 * MP, then turn off the mold vertical vibration device;

[0039] Denote the maximum opening degree of the gate valve as R0. If there exists any gate valve opening degree greater than k4 * R0, and the corresponding ypi < xpi or yti < xti, then increase the temperature of the molten material injected into the main gate; if there exists any gate valve opening degree less than k5 * R0, and the corresponding ypi > xpi or yti > xti, then decrease the temperature of the molten material injected into the main gate; otherwise, increase the injection speed of the molten material into the main gate, where k3, k4, and k5 are set proportionality coefficients.

[0040] Advantages of the present invention: The present invention sets a runner valve in the runner according to the runner layout of the multi-cavity mold, and sets a gate valve at the cavity gate to establish a shunt cavity; sets a shunt cavity heating device and a mold vertical vibration device, collects the pressure and temperature of the shunt cavity, and performs data screening to obtain the shunt cavity fluid data; initially adjusts the shunt cavity heating device, the mold vertical vibration device, the runner valve, and the gate valve according to the shunt cavity fluid data to obtain the device balance setting data; obtains the pressure and temperature of the cavity, denoted as the cavity fluid data, and performs melt filling according to the cavity fluid data and the device balance setting data; can ensure that the molten material fills each cavity simultaneously, with the same pressure and the same temperature, and at the same time accurately control the temperature and pressure of each cavity to solve the problem of rapid filling in the case of unbalanced arrangement of the cavity and the runner;

[0041] By establishing a shunt cavity and allowing the molten material to reach an equilibrium state in each shunt cavity before entering the mold cavity, it is possible to ensure that the filling conditions in each mold cavity are consistent, making the filling situation in each mold cavity similar and the cooling and shrinkage processes more consistent. This effectively reduces the product size deviation caused by uneven filling and ensures product consistency. By collecting and analyzing the temperature and pressure data of the shunt cavity and the mold cavity and dynamically adjusting the valve opening, the temperature and speed of the injected melt, it is possible to adapt to different filling situations, improve the filling efficiency and quality while ensuring that the temperature and pressure in each mold cavity meet the ideal filling conditions. By vibrating the mold up and down during the filling process, the influence of material viscosity can be reduced, allowing the material to flow into each mold cavity more smoothly, accelerating the escape of gas, and reducing the generation of defects such as air holes. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 is a flowchart of the steps of the process of the present invention;

[0043] Figure 2 is a schematic diagram of the principle of the shunt cavity of the present invention;

[0044] Figure 3 is a schematic diagram of the principle of the mold cavities with balanced arrangement of the present invention;

[0045] Figure 4 is a schematic diagram of the principle of the mold cavities with unbalanced arrangement of the present invention;

[0046] Figure 5 is a schematic diagram of the structure of the electronic device of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0047] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0048] Example 1, please refer to Figure 1 As shown, the present application provides a runner design and rapid filling process for a multi-cavity manufacturing equipment, including the following steps:

[0049] Step S1, set a runner valve in the runner according to the runner layout of the multi-cavity mold, and set a gate valve at the mold cavity gate to establish a shunt cavity; Step S1 includes the following sub-steps:

[0050] Step S101, sequentially denote the cavities of the multi-cavity mold as cavity 1, cavity 2, ……, cavity n; sequentially denote the runner channels connecting cavity 1, cavity 2, ……, cavity n as runner channel 1, runner channel 2, ……, runner channel n; obtain the runner layout of the multi-cavity mold, and set the cross-sectional areas of the main runner and the runner channels to be the same; the main runner is the channel between the sprue and the runner channel or cavity, usually located at the center of the mold, and is the initial channel for the molten material to enter the mold; the runner channel is the channel connecting the main runner and the gate, and its function is to distribute the molten material coming from the main runner to each gate and then enter different cavities;

[0051] Step S102, set valves on runner channel 1, runner channel 2, ……, runner channel n respectively, and sequentially denote them as runner valve 1 - runner valve n, obtain the distances from all runner valves to the corresponding cavity gates, and sequentially denote them as runner length 1 - runner length n; adjust the positions of runner valve 1 - runner valve n to ensure that all runner lengths are equal; the gate is a narrow channel connecting the runner channel and the cavity, and is the last "checkpoint" for the molten material to enter the cavity;

[0052] Step S103, please refer to Figure 2 As shown, set valves at the starting positions of all cavity gates, and sequentially denote them as gate valve 1 - gate valve n, denote the runner channels intercepted by gate valve 1 - gate valve n and the corresponding runner valve 1 - runner valve n on the runner channel as shunt cavity channels, and sequentially denote them as shunt cavity channel 1 - shunt cavity channel n according to the corresponding order;

[0053] Step S104, obtain the shortest distances from all gate valves along the runner to the sprue, and sequentially denote them as LD1 - LDn; that is, the distance that the molten material needs to pass from the sprue to the gate valve; obtain the median of LD1 - LDn, denoted as LDn1, and obtain the cross-sectional area of the opening when the runner valve is fully open as XM; calculate the balanced gate value BGVn1 corresponding to LDn1 and 0.5*XM; the BGV calculation formula is as follows: Where, A0 represents the cross-sectional area of the opening of the runner valve, L represents the shortest distance from the gate valve along the runner to the sprue, and X0 represents the length of the runner valve;

[0054] That is, approximately regard the shunt cavity channel as a cavity for calculation. BGV refers to the balanced gate value; it is an important parameter for measuring and designing the balance of the gating system of a multi-cavity injection mold. For a multi-cavity mold with the same cavities, the balance condition is that the BGV values calculated for each gate must be equal. Therefore, in order to ensure that the molten material in the subsequent shunt cavity channels can reach equilibrium, the BGVs corresponding to each shunt cavity channel should be equal;

[0055] Step S105, denote BGVn1 as the basic balance value BGV0, and denote 0.5*XM as the balance opening area of the corresponding runner valve; calculate the balance opening areas corresponding to all runner valves in sequence according to BGV0, the BGV calculation formula, and LD1-LDn, and denote it as valve balance information; that is, according to the BGV calculation formula, calculate A0 when BGV, X0, and L are known.

[0056] In the specific implementation process, the valve types of the gate valve and the runner valve can be selected according to the actual application scenario. Commonly used ones are needle valves, piezoelectric ceramic valves, and pneumatic valves. In this embodiment, a needle valve is used, and the advantage is high control accuracy.

[0057] Step S2, set up a heating device for the split cavity channel and a vertical vibration device for the mold, collect the pressure and temperature of the split cavity channel, and perform data screening to obtain the split cavity channel fluid data; Step S2 includes the following sub-steps:

[0058] Step S201, set up a heating device for any split cavity channel and ensure that the heating devices for any two split cavity channels are the same; select a vibration device according to the size and weight of the multi-cavity mold, and install the vibration device at the center of the base of the multi-cavity mold so that the mold can only vibrate vertically up and down; the heating device can be selected according to the actual application scenario.

[0059] The vibration device can be an electromagnetic vibrator or a hydraulic vibrator, and select an appropriate power and model according to the size and weight of the mold; the electromagnetic vibrator has a fast response speed and is easy to control; the hydraulic vibrator can provide a large vibration force; the vibration parameters should be adjusted according to factors such as the characteristics of the molten material, the mold structure, and the number of cavities.

[0060] Step S202, collect the pressure and temperature inside all split cavity channels at the first time interval, and denote them as cavity channel pressure data and cavity channel temperature data respectively. The first time interval is t1; in this embodiment, the first time interval is 0.1 s.

[0061] Step S203, perform abnormal data screening on the cavity channel pressure data and cavity channel temperature data collected at the same moment respectively. After completion, obtain the screened pressure data and screened temperature data, and denote them as split cavity channel fluid data.

[0062] Step S204. The abnormal data screening includes: arranging all the same type of data collected at the same moment in ascending order, denoted as the first data sequence; removing the smallest k1 data and the largest k1 data in the first data sequence, and calculating the average value and standard deviation of the remaining first data sequence, denoted as P0 and P1 in sequence. For any data in the first data sequence, denoted as V0, if V0 < (P0 - k2 * P1) or V0 > (P0 + k2 * P1), then mark V0 as abnormal data, otherwise mark it as normal data, where k1 and k2 are set thresholds; repeat marking all the data in the first data sequence; in this embodiment, k1 = 1 and k2 = 2;

[0063] In the specific implementation process, vibration can make the molecules of the molten material more active, reduce the cohesive force between molecules, and thus improve its fluidity. And during the vibration process, the gas in the mold cavity is more easily discharged, reducing the generation of defects such as air holes; by vibrating the mold up and down, the molten material can also be more evenly distributed in each mold cavity, reducing the difference in filling degree between different mold cavities and improving the consistency of product quality.

[0064] Step S3. Make a primary adjustment to the shunt cavity channel heating device, the mold vertical vibration device, the runner valve, and the gate valve according to the fluid data of the shunt cavity channel to obtain the device balance setting data; Step S3 includes the following sub-steps:

[0065] Step S301. Obtain the temperature and pressure of the molten material filling the mold cavity in the ideal state, denoted as the ideal filling temperature LT and the ideal filling pressure LP respectively;

[0066] Step S302. And obtain the changes of the temperature and pressure inside the mold cavity with time when the molten material fills the mold cavity in the ideal state, denoted as the ideal temperature change curve and the ideal filling pressure change curve respectively;

[0067] Step S303. And denote the pressure when the molten material completely fills the mold cavity in the ideal state as the ideal melt pressure MP; The ideal state refers to an ideal working condition in which the molten material can be filled evenly, stably and efficiently in the mold cavity during the whole filling process, producing equipment with high dimensional accuracy, good appearance quality and stable performance;

[0068] Step S304. When the molten material starts to be injected through the main gate, close the gate valve; open the runner valve according to the valve balance information; turn on the mold vertical vibration device, set the frequency to K0 and the amplitude to F0; turn on the shunt cavity channel heating device and set the heating temperature to the ideal filling temperature; The frequency and amplitude can be determined through experiments and simulation analysis to obtain the optimal frequency and amplitude; Generally, the vibration frequency range is between 20 - 100Hz, and the amplitude is between 0.1 - 1mm;

[0069] Step S305: For any shunt channel denoted as the first shunt channel, adjust the flow channel valve and the shunt channel heating device corresponding to the first shunt channel according to the shunt channel fluid data corresponding to the first shunt channel;

[0070] Step S306: Denote the temperature and pressure inside the first shunt channel as DT and DP in sequence. When DT < LT, increase the heating temperature of the corresponding shunt channel heating device; when DT > LT, decrease the heating temperature of the corresponding shunt channel heating device; when DT = LT, do not adjust the corresponding shunt channel heating device;

[0071] Step S307: When DP < LP, increase the opening degree of the corresponding flow channel valve; when DP > LP, decrease the opening degree of the corresponding flow channel valve; when DP = LP, do not adjust the opening degree of the corresponding flow channel valve;

[0072] Step S308: Repeat the adjustment for all shunt channels, and ensure that the pressure and temperature of all shunt channels when they are completely filled with the molten material are equal to the ideal filling pressure LP and the ideal filling temperature LT respectively; record the opening degrees of the flow channel valves corresponding to all shunt channels at this time, and the heating temperatures of the shunt channel heating devices corresponding to all shunt channels, denoted as the device balance setting data, and denote the state of the shunt channels at this time as the balanced state;

[0073] Since the layout of the mold cavity and the flow channel has an important impact on the product quality and production efficiency, the layout of the mold cavity and the flow channel is divided into balanced layout and unbalanced layout; please refer to Figure 3 As shown, for the mold cavity and flow channel with balanced layout, the distances from each mold cavity to the flow channel are equal, the flow channel layout is symmetrical, and the molten plastic can fill each mold cavity simultaneously with the same pressure and speed, ensuring the consistency of filling of each mold cavity; however, the flow channel design is relatively complex, and the lengths of each shunt channel are relatively long, resulting in higher mold design and manufacturing costs;

[0074] Please refer to Figure 4 As shown, for the mold cavity and flow channel with unbalanced layout, the mold cavities can be flexibly arranged according to the shape, size and production requirements of the product, and more mold cavities can be arranged within the limited mold space, improving the utilization rate of the mold; the distances from each mold cavity to the flow channel are different, resulting in inconsistent filling times, pressures and speeds of each mold cavity during the filling process of the molten plastic, and it is easy to have problems of inconsistent filling;

[0075] In the specific implementation process, by establishing a diversion cavity and allowing the molten material to reach an equilibrium state in each diversion cavity before entering the mold cavity, it is possible to make the filling condition of the molten material the same in each mold cavity in the non-equilibrium arranged mold cavities and runners, and the cooling and shrinkage processes are also relatively consistent. Thus, it can effectively reduce the product size deviation caused by uneven filling in the non-equilibrium arranged mold cavities and runners, and ensure the consistency of the product.

[0076] Step S4: Obtain the pressure and temperature of the mold cavity, denoted as mold cavity fluid data, and perform melt filling according to the mold cavity fluid data and the device balance setting data. Step S4 includes the following sub-steps:

[0077] Step S401: Perform segmented processing on the ideal temperature change curve and the ideal filling pressure change curve respectively, including: for any change curve, denoted as the first transformation curve, set the unit time as t2; divide the first transformation curve into multiple change line segments with the unit time t2, and obtain the data corresponding to each division point, denoted as division point data; sequentially denote the division point data corresponding to the ideal temperature change curve as xt1, xt2,..., xtm; sequentially denote the division point data corresponding to the ideal filling pressure change curve as xp1, xp2,..., xpm.

[0078] Step S402: When all the diversion cavities reach an equilibrium state, open all the gate valves simultaneously, and collect the pressure and temperature of all the mold cavities at intervals of the unit time t2, and record the number of collections, and then perform abnormal data screening to obtain the mold cavity pressure data and the mold cavity temperature data, denoted as mold cavity fluid data; collecting at intervals of the unit time t2 is convenient for subsequent comparison.

[0079] Step S403: For the mold cavity pressure data and the mold cavity temperature data collected in any real-time collection and being normal data, respectively denoted as the first pressure data ypi and the first temperature data yti, according to the collection number i of the first pressure data and the first temperature data, denote the data with the same serial number as the collection number of the first pressure data in xp1, xp2,..., xpm as xpi; and denote the data with the same serial number as the collection number of the first temperature data in xp1, xp2,..., xpm as xti; for example, compare the normal mold cavity pressure data yp2 collected in the second collection with xp2.

[0080] Step S404: If ypi < xpi or yti < xti, then increase the opening degree of the corresponding gate valve; if ypi > xpi or yti > xti, then decrease the opening degree of the corresponding gate valve; if ypi = xpi and yti = xti, then do not adjust the opening degree of the corresponding gate valve; that is, if the pressure is too small or the temperature is too low, then increase the valve opening degree; if the pressure is too large or the temperature is too high, then decrease the valve opening degree.

[0081] Step S405: When the cavity pressure data of any cavity is greater than k3*MP, the mold vertical vibration device is turned off. In this embodiment, k3 = 0.8, that is, the mold vertical vibration device is turned off when any cavity is about to be filled. Because when the cavity is about to be filled, continuously applying vertical vibration may cause the plastic melt to overfill the cavity under pressure, exceeding the normal design size, and may even overflow from the parting surface or other gaps of the mold, forming flash.

[0082] Step S406: Denote the maximum opening of the gate valve as R0. If there is any gate valve opening greater than k4*R0 and the corresponding ypi < xpi or yti < xti, the temperature of the molten material injected into the main gate is increased; if there is any gate valve opening less than k5*R0 and the corresponding ypi > xpi or yti > xti, the temperature of the molten material injected into the main gate is decreased; otherwise, the injection speed of the molten material injected into the main gate is increased, where k3, k4, and k5 are set proportionality coefficients. In this embodiment, k4 = 0.9 and k5 = 0.4, that is, simply adjusting the gate valve opening can no longer adjust the temperature and pressure of the molten material to the ideal state. Therefore, it is necessary to adjust the temperature of the molten material injected into the main gate.

[0083] In the specific implementation process, when the gate valve opening is within a reasonable range, in this case, the states of the mold and the material are relatively stable. Appropriately increasing the injection speed can shorten the molding cycle and improve production efficiency on the premise of ensuring the product quality. A faster injection speed can enable the plastic melt to fill the cavity faster, reduce the cooling time, and thus increase the output per unit time.

[0084] Example 2, please refer to Figure 5 as shown in Figure 5Schematically illustrates the structure of an electronic device, which may include: a processor, a communication interface, a memory, and a communication bus. Among them, the processor, the communication interface, and the memory complete communication with each other through the communication bus. The memory stores computer-readable instructions, and the processor can call the instructions in the memory. When the computer-readable instructions are executed by the processor, the steps in a runner design and rapid filling process of a multi-cavity manufacturing equipment are run to achieve the following functions: set runner valves in the sub-runners according to the runner layout of the multi-cavity mold, and set gate valves at the mold cavity gates to establish a sub-cavity channel; set a sub-cavity channel heating device and a mold vertical vibration device, collect the pressure and temperature of the sub-cavity channel, and perform data screening to obtain sub-cavity channel fluid data; perform an initial adjustment on the sub-cavity channel heating device, the mold vertical vibration device, the runner valves, and the gate valves according to the sub-cavity channel fluid data to obtain device balance setting data; obtain the pressure and temperature of the mold cavity, denoted as mold cavity fluid data, and perform melt filling according to the mold cavity fluid data and the device balance setting data.

[0085] In addition, when the logical instructions in the above-mentioned memory are implemented in the form of software functional units and sold or used as an independent product, they can be stored in a computer-readable storage medium. Based on such an understanding, the technical solution of the present application, in essence, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium and includes several instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in various embodiments of the present application. The aforementioned storage medium includes: various media such as USB flash drives, mobile hard disks, read-only memories (ROM, Read-Only Memory), random access memories (RAM, Random Access Memory), magnetic disks, or optical discs that can store program codes.

[0086] Embodiment 3. The present application further provides a computer-readable storage medium. The present application provides a storage medium on which a computer program is stored. When the computer program is executed by a processor, it runs the steps in the above-mentioned runner design and rapid filling process of a one-mold multi-cavity manufacturing equipment to achieve the following functions: Set runner valves in the sub-runners according to the runner layout of the multi-cavity mold, and set gate valves at the mold cavity gates to establish a sub-flow cavity; Set a sub-flow cavity heating device and a mold vertical vibration device, collect the pressure and temperature of the sub-flow cavity, and perform data screening to obtain the sub-flow cavity fluid data; Make a preliminary adjustment to the sub-flow cavity heating device, the mold vertical vibration device, the runner valves, and the gate valves according to the sub-flow cavity fluid data to obtain the device balance setting data; Obtain the pressure and temperature of the mold cavity, denoted as the mold cavity fluid data, and perform melt filling according to the mold cavity fluid data and the device balance setting data.

[0087] Through the description of the above embodiments, the embodiments of the present invention can be provided as a method, a system, or a computer program product. Based on such an understanding, the above technical solutions, in essence, or the part that contributes to the prior art can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disc, etc., and includes several instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the methods described in each embodiment or some parts of the embodiments.

[0088] In the embodiments provided by the present application, it should be understood that the disclosed system or method can be implemented in other ways. The above-described embodiments are merely illustrative. For example, the division of modules or units is only a logical function division, and there may be other division methods in actual implementation. Also, for example, multiple modules or units can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections to each other can be through some communication interfaces. The indirect couplings or communication connections of systems, modules, and units can be in electrical, mechanical, or other forms.

[0089] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application and are not intended to limit them. Although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of each embodiment of the present application.

Claims

1. A runner design and rapid filling process for a multi-cavity manufacturing equipment with one mold, characterized in that, It includes the following steps: Set a runner valve in the sub-runner according to the runner layout of the multi-cavity mold, and set a gate valve at the cavity gate to establish a sub-runner cavity; Set a heating device for the sub-runner cavity and a vertical vibration device for the mold, collect the pressure and temperature of the sub-runner cavity, and perform data screening to obtain the fluid data of the sub-runner cavity; Make a primary adjustment to the heating device for the sub-runner cavity, the vertical vibration device for the mold, the runner valve, and the gate valve according to the fluid data of the sub-runner cavity to obtain the device balance setting data; Obtain the pressure and temperature of the cavity, denoted as the cavity fluid data, and perform melt filling according to the cavity fluid data and the device balance setting data.

2. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 1, characterized in that Setting a runner valve in the sub-runner according to the runner layout of the multi-cavity mold, and setting a gate valve at the cavity gate to establish a sub-runner cavity includes the following sub-steps: Denote the cavities of the multi-cavity mold as cavity 1, cavity 2,..., cavity n in sequence; denote the sub-runners connected to cavity 1, cavity 2,..., cavity n as sub-runner 1, sub-runner 2,..., sub-runner n in sequence; obtain the runner layout of the multi-cavity mold, and set the cross-sectional areas of the main runner and the sub-runners to be the same; Set valves on sub-runner 1, sub-runner 2,..., sub-runner n respectively, denoted as runner valve 1 - runner valve n in sequence, obtain the distances from all runner valves to the corresponding cavity gates, denoted as runner length 1 - runner length n in sequence; adjust the positions of runner valve 1 - runner valve n to ensure that all runner lengths are equal.

3. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 2, characterized in that, Setting a runner valve in the sub-runner according to the runner layout of the multi-cavity mold, and setting a gate valve at the cavity gate to establish a sub-runner cavity further includes the following sub-steps: Set valves at the starting positions of all cavity gates, denoted as gate valve 1 - gate valve n in sequence, and denote the runners intercepted by gate valve 1 - gate valve n and the corresponding runner valve 1 - runner valve n on the sub-runner as sub-runner cavities, denoted as sub-runner cavity 1 - sub-runner cavity n in the corresponding order; Obtain the shortest distances from all gate valves along the runner to the main gate, denoted as LD1 - LDn in sequence; Obtain the median of LD1-LDn, denoted as LDn1, and obtain the cross-sectional area of the opening when the runner valve is fully opened as XM; calculate the balanced gate value BGVn1 corresponding to LDn1 and 0.5*XM; the BGV calculation formula is as follows: Where, A0 represents the cross-sectional area of the opening of the runner valve, L represents the shortest distance from the gate valve along the runner to the main gate, and X0 represents the length of the runner valve; Denote BGVn1 as the basic balance value BGV0, and denote 0.5*XM as the balanced opening area of the corresponding runner valve; calculate the balanced opening areas corresponding to all runner valves in sequence according to BGV0, the BGV calculation formula, and LD1 - LDn, denoted as valve balance information.

4. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 3, characterized in that, Setting a heating device for the sub-runner cavity and a vertical vibration device for the mold, collecting the pressure and temperature of the sub-runner cavity, and performing data screening to obtain the fluid data of the sub-runner cavity includes the following sub-steps: Set a heating device for any one sub-runner cavity, and ensure that the heating devices for any two sub-runner cavities are the same; select a vibration device according to the size and weight of the multi-cavity mold, and install the vibration device at the center of the base of the multi-cavity mold so that the mold can only vibrate vertically up and down; Collect the pressure and temperature inside all sub-runner cavities at the first time interval, denoted as cavity pressure data and cavity temperature data respectively, and the first time interval is t1.

5. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 4, characterized in that, A shunt cavity heating device and a die vertical vibration device are set up, the pressure and temperature of the shunt cavity are collected, and data screening is carried out to obtain the shunt cavity fluid data, which also includes the following sub-steps: For the cavity pressure data and cavity temperature data collected at the same moment, abnormal data screening is carried out respectively. After completion, the screened pressure data and screened temperature data are obtained, which are recorded as the shunt cavity fluid data; The abnormal data screening includes: arranging all the same kind of data collected at the same moment in ascending order, which is recorded as the first data sequence. Remove the smallest k1 data and the largest k1 data in the first data sequence, and calculate the average value and standard deviation of the remaining first data sequence, which are recorded as P0 and P1 in sequence. For any data in the first data sequence, which is recorded as V0, if V0 < (P0 - k2 * P1) or V0 > (P0 + k2 * P1), then V0 is marked as abnormal data, otherwise it is marked as normal data, where k1 and k2 are set thresholds; repeat marking all the data in the first data sequence.

6. The runner design and rapid filling process of a multi-cavity manufacturing equipment with one mold as claimed in claim 5, characterized in that According to the shunt cavity fluid data, the shunt cavity heating device, the die vertical vibration device, the runner valve and the gate valve are initially adjusted to obtain the device balance setting data, which also includes the following sub-steps: Obtain the temperature and pressure of the molten material filling the mold cavity under the ideal state, which are recorded as the ideal filling temperature LT and the ideal filling pressure LP respectively; and obtain the temperature and pressure changes inside the mold cavity with time when the molten material fills the mold cavity under the ideal state, which are recorded as the ideal temperature change curve and the ideal filling pressure change curve respectively; and record the pressure when the molten material completely fills the mold cavity under the ideal state as the ideal melt pressure MP; When the molten material starts to be injected through the main gate, close the gate valve; open the runner valve according to the valve balance information; turn on the die vertical vibration device, set the frequency to K0 and the amplitude to F0; turn on the shunt cavity heating device and set the heating temperature to the ideal filling temperature.

7. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 6, characterized in that According to the shunt cavity fluid data, the shunt cavity heating device, the die vertical vibration device, the runner valve and the gate valve are initially adjusted to obtain the device balance setting data, which also includes the following sub-steps: For any shunt cavity, which is recorded as the first shunt cavity, according to the shunt cavity fluid data corresponding to the first shunt cavity, adjust the runner valve and the shunt cavity heating device corresponding to the first shunt cavity; Record the temperature and pressure inside the first shunt cavity as DT and DP in sequence. When DT < LT, increase the heating temperature of the corresponding shunt cavity heating device. When DT > LT, decrease the heating temperature of the corresponding shunt cavity heating device. When DT = LT, do not adjust the corresponding shunt cavity heating device; When DP < LP, increase the opening degree of the corresponding runner valve. When DP > LP, decrease the opening degree of the corresponding runner valve. When DP = LP, do not adjust the opening degree of the corresponding runner valve.

8. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 7, characterized in that, Perform initial adjustment on the shunt channel heating device, die vertical vibration device, runner valve, and gate valve according to the shunt channel fluid data, and the obtained device balance setting data further includes the following sub-steps: Repeat the adjustment for all shunt channels, and ensure that the pressure and temperature of all shunt channels when fully filled with molten material are equal to the ideal filling pressure LP and the ideal filling temperature LT respectively; record the opening degrees of the runner valves corresponding to all shunt channels at this time, and the heating temperatures of the shunt channel heating devices corresponding to all shunt channels, denoted as device balance setting data, and record the state of the shunt channels at this time as the balanced state.

9. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 8, characterized in that, Obtain the pressure and temperature of the mold cavity, denoted as mold cavity fluid data, and perform melt filling according to the mold cavity fluid data and the device balance setting data, including the following sub-steps: Perform segmented processing on the ideal temperature change curve and the ideal filling pressure change curve respectively, including: for any change curve, denoted as the first transformation curve, set the unit time as t2; divide the first transformation curve into multiple change line segments with the unit time t2, and obtain the data corresponding to each division point, denoted as division point data; denote the division point data corresponding to the ideal temperature change curve as xt1, xt2,..., xtm in sequence; denote the division point data corresponding to the ideal filling pressure change curve as xp1, xp2,..., xpm in sequence. When all shunt channels reach the balanced state, open all gate valves simultaneously, collect the pressure and temperature of all mold cavities at intervals of unit time t2, record the number of collections, and then perform abnormal data screening to obtain the mold cavity pressure data and the mold cavity temperature data, denoted as mold cavity fluid data.

10. The runner design and rapid filling process of a multi-cavity manufacturing equipment according to claim 9, characterized in that, Obtain the pressure and temperature of the mold cavity, denoted as mold cavity fluid data, and perform melt filling according to the mold cavity fluid data and the device balance setting data further includes the following sub-steps: For the mold cavity pressure data and the mold cavity temperature data of any real-time collection and normal data, denoted as the first pressure data ypi and the first temperature data yti respectively, according to the collection times i of the first pressure data and the first temperature data, denote the data with the same serial number as the collection times of the first pressure data in xp1, xp2,..., xpm as xpi; and denote the data with the same serial number as the collection times of the first temperature data in xp1, xp2,..., xpm as xti. If ypi < xpi or yti < xti, then increase the opening degree of the corresponding gate valve; if ypi > xpi or yti > xti, then decrease the opening degree of the corresponding gate valve; if ypi = xpi and yti = xti, then do not adjust the opening degree of the corresponding gate valve. When the mold cavity pressure data of any mold cavity is greater than k3 * MP, turn off the die vertical vibration device; Denote the maximum opening degree of the gate valve as R0. If there exists any gate valve opening degree greater than k4*R0, and the corresponding ypi < xpi or yti < xti, then increase the temperature of the molten material injected into the main gate; if there exists any gate valve opening degree less than k5*R0, and the corresponding ypi > xpi or yti > xti, then decrease the temperature of the molten material injected into the main gate; otherwise, increase the injection speed of the molten material into the main gate, where k3, k4, and k5 are set proportionality coefficients.

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