Injection molding machine intelligent control method and system based on injection molding part production

Abstract

The invention relates to an intelligent injection molding machine control method and system based on injection molding part production, and relates to the technical field of injection molding machining. Performing difference calculation according to a preset full-circle rotation angle and the effective rotation angle to determine an operation rollback angle; when the machining operation state is consistent with the preset starting operation state, a preset rotating base used for containing a workpiece to be machined is controlled to rotate by an effective rotating angle in the preset operation direction, all effective operation stations are controlled to operate after rotation, and calculation is conducted according to the effective rotating angle to determine the accumulated rotating angle; and when the accumulated rotation angle is consistent with the operation rollback angle, the rotating base is controlled to rotate by the operation rollback angle in the direction opposite to the operation direction. The machining device has the effect of improving the machining production efficiency of workpieces.

Description

Technical Field

[0001] This application relates to the field of injection molding technology, and in particular to an intelligent control method and system for injection molding machines based on injection molding part production. Background Technology

[0002] In recent years, with the increasing demand for plastic products, multi-station injection molding machines have been widely used in the field of complex injection molding parts manufacturing due to their high efficiency and flexible production capabilities.

[0003] In related technologies, when injection molded parts need to be processed and obtained by multiple workstations, the workpiece needs to move between multiple workstations. At this time, the movement of the workpiece between workstations is basically handled manually by the workers or by a robot.

[0004] In the aforementioned technologies, the use of manual labor or robotic arms is required when the workpiece moves between workstations for processing, which increases the time for workpiece movement and thus increases the total processing time, resulting in reduced processing efficiency. There is still room for improvement. Summary of the Invention

[0005] To improve the processing and production efficiency of workpieces, this application provides an intelligent control method and system for injection molding machines based on injection molding part production.

[0006] Firstly, this application provides an intelligent control method for injection molding machines based on injection molding part production, employing the following technical solution: A method for intelligent control of injection molding machines based on injection molding part production, comprising: Obtain the model of the workpiece to be processed and the processing status; The required workstation type and processing sequence corresponding to the workpiece type are determined based on the preset model matching relationship; Workstations with the same type of workstation requirement are combined to form a single workstation combination. One workstation is randomly selected from each single workstation combination as a simulated workstation. All simulated workstations are combined to form a simulated workstation scheme. In the simulated workstation scheme, the simulated workstations of each adjacent operation are calculated and analyzed according to the processing sequence of the type to determine the adjacent adjustment angle; The simulated workstation schemes where all adjacent adjustment angles are consistent are defined as effective workstation schemes, and the simulated workstations in the effective workstation schemes are defined as effective workstations, and the corresponding adjacent adjustment angles are defined as effective rotation angles. The working retraction angle is determined by calculating the difference between the preset full-circle rotation angle and the effective rotation angle. When the processing operation state is consistent with the preset start operation state, the preset rotating base for placing the workpiece to be processed is controlled to rotate along the preset operation direction by an effective rotation angle. After rotation, each effective operation station is controlled to operate. The cumulative rotation angle is calculated based on the effective rotation angle. When the cumulative rotation angle is consistent with the operation retraction angle, the rotating base is controlled to rotate in the opposite direction of the operation direction by an operation retraction angle.

[0007] Optionally, the step of randomly selecting one workstation from each combination of individual workstations as the simulated workstation includes: The required number of workstations is determined by analyzing the processing sequence based on the type, and the required interval angle is determined by calculating the required number of workstations and the full rotation angle. Based on the processing order of the type, the first single station combination is defined as the first station combination, and a station is randomly selected from the first station combination as the simulated operation station. Based on the analysis of simulated workstations and demand intervals, and according to the processing sequence of types, the required workstations for each type of workstation are determined. Determine whether each required workstation is within the corresponding individual workstation combination; If each required workstation is not within the corresponding single workstation combination, the analysis of the currently defined simulated workstation will not continue. If each required workstation is within the corresponding single workstation combination, then the currently determined required workstation is also defined as a simulated workstation.

[0008] Optionally, after the effective workstation scheme is determined, the intelligent control method for injection molding machines based on injection molded part production also includes: Determine if there is only one valid workstation solution; If there is only one valid workstation solution, then the injection molding machine production process is controlled according to the valid workstation solution; If there is more than one valid workstation solution, a load interval with the current time point as the end point and a width of the preset load duration is constructed on the preset time axis, and the load operation duration is determined in the load interval according to each simulated workstation in the valid workstation solution. The individual load factor corresponding to the load operation duration is determined based on the preset load matching relationship; The overall load factor is determined by calculating the load factor of all individual units in the effective workstation scheme. The minimum comprehensive load coefficient is determined according to the preset sorting rules, and the remaining effective workstation schemes other than the one corresponding to the comprehensive load coefficient are eliminated.

[0009] Optionally, after the comprehensive load factor is determined, the intelligent control method for injection molding machines based on injection molded part production also includes: Determine whether there are at least two effective workstation schemes with the same and smallest comprehensive load coefficient; If there are no at least two effective workstation schemes with the same and smallest comprehensive load coefficient, then the remaining effective workstation schemes other than the one with the smallest comprehensive load coefficient will be eliminated. If there are at least two effective workstation schemes with the same and smallest comprehensive load coefficient, then the effective workstation scheme corresponding to the smallest comprehensive load coefficient is defined as the alternative workstation scheme. Randomly select one unit load factor from the alternative workstation schemes and define it as the primary load factor, and define the remaining unit load factors as secondary load factors; The main representative parameter is determined by calculating based on the main load factor and each secondary load factor, and the main load factor corresponding to the largest main representative parameter is defined as the center load factor. The deviation load factor is determined by calculating the load factor of the center and the load factor of each individual unit, and the largest deviation load factor is defined as the deviation critical factor of the alternative workstation scheme. The minimum deviation threshold coefficient is determined according to the sorting rules, and the remaining valid workstation schemes other than the alternative workstation schemes corresponding to this deviation threshold coefficient are eliminated.

[0010] Optionally, after the deviation critical coefficient is determined, the intelligent control method for injection molding machines based on injection molded part production also includes: Determine whether there are at least two alternative workstation schemes with the same and smallest deviation critical coefficient; If there are no at least two alternative workstation schemes with the same and smallest deviation critical coefficient, then the remaining effective workstation schemes other than the alternative workstation scheme with the smallest deviation critical coefficient will be eliminated. If there are at least two alternative workstation schemes with the same and smallest deviation critical coefficient, the alternative workstation scheme corresponding to the smallest deviation critical coefficient is defined as the waiting workstation scheme, and the duration of the current task is obtained. The previous maintenance time of each simulated workstation is obtained from the waiting workstation plan, and the work maintenance interval is constructed based on the previous maintenance time and the current time. The total operation time of the simulated work station is obtained within the operation maintenance interval, and the remaining operation time is calculated based on the total operation time and the preset maintenance interval. Calculations and analyses are performed based on the remaining task duration and the corresponding duration of the current task to determine reasonable task parameters. Based on the sorting rules, determine the reasonable work parameter with the largest value, and then eliminate the other valid work station schemes that are not the waiting work station schemes corresponding to the reasonable work parameter.

[0011] Optionally, it also includes a step for determining the maintenance interval duration, which includes: Construct a historical interval with a preset historical duration on the timeline, with the current time point as the endpoint, and obtain each maintenance time point in the historical interval; The interval length of a single unit is determined by calculation based on adjacent maintenance time points, and one of the interval lengths of all units is selected as the first interval length, while the remaining interval lengths of the units are defined as the second interval length. The interval representative parameter is determined by calculation based on the first interval duration and each second interval duration, and the first interval duration corresponding to the largest interval representative parameter is defined as the reasonable interval duration. The reasonable nearest range is determined by calculation based on the reasonable interval duration and the preset nearest range duration, and the maintenance interval duration is determined by averaging the interval durations of individual units within the reasonable nearest range.

[0012] Secondly, this application provides an intelligent control system for injection molding machines based on injection molded part production, which adopts the following technical solution: An intelligent control system for injection molding machines based on injection molded part production includes: The acquisition module is used to acquire the model of the workpiece being processed and the processing status. The processing module, connected to the acquisition module, is used for information storage and processing; The processing module uses a preset model matching relationship to determine the required workstation type and processing sequence corresponding to the model of the workpiece to be processed; The processing module combines workstations of the same type to construct individual workstation combinations, randomly selects one workstation from each individual workstation combination as a simulated workstation, and combines all simulated workstations to form a simulated workstation scheme. The processing module performs calculations and analyses on the simulated workstations of each adjacent operation according to the processing sequence of the type to determine the adjacent adjustment angles. The processing module defines all simulated workstation schemes with the same adjacent adjustment angle as valid workstation schemes, defines the simulated workstations in the valid workstation schemes as valid workstations, and defines the corresponding adjacent adjustment angles as valid rotation angles. The processing module calculates the difference between the preset full-circle rotation angle and the effective rotation angle to determine the operation retraction angle; When the processing operation state is consistent with the preset start operation state, the processing module controls the preset rotating base for placing the workpiece to be processed to rotate along the preset operation direction by an effective rotation angle. After rotation, it controls each effective operation station to operate. It calculates the cumulative rotation angle based on the effective rotation angle, and controls the rotating base to rotate in the opposite direction of the operation direction by an operation retraction angle when the cumulative rotation angle is consistent with the operation retraction angle.

[0013] In summary, this application includes at least one of the following beneficial technical effects: When an injection molding machine processes injection molded parts, the rotating base is controlled to rotate by identifying the workstation to be processed, thereby moving the workpiece to be processed and realizing automatic positioning and processing of the workpiece, thus improving the processing efficiency of the workpiece. During the injection molding process, each workpiece that rotates and moves to the station where the initial workpiece is placed is a finished injection molded part that has already been processed, making it easy to store the finished product. Attached Figure Description

[0014] Figure 1 This is a flowchart of an intelligent control method for injection molding machines based on injection molding part production.

[0015] Figure 2 This is a schematic diagram of the injection molding machine in operation.

[0016] Figure 3 This is a module flowchart of an intelligent control method for injection molding machines based on injection molding part production. Detailed Implementation

[0017] To make the purpose, technical solution, and advantages of this application clearer, the following is combined with Figures 1-3 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0018] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0019] This application discloses an intelligent control method for injection molding machines based on injection molded part production, referring to... Figure 1 The method flow of the intelligent control method for injection molding machines based on injection molding part production includes the following steps: Step S100: Obtain the model of the workpiece to be processed and the processing status.

[0020] The workpiece model refers to the model of the workpiece that needs to be processed by the injection molding machine through multiple stations. The processing status is a status signal indicating whether to start the processing operation. The signal can be input by the operator manually pressing the corresponding start button.

[0021] Step S101: Determine the required station type and processing sequence corresponding to the workpiece model based on the preset model matching relationship.

[0022] The required station type refers to the type of station needed to process the workpiece of the current model, such as ejection station, cooling station, injection station, etc. The type processing sequence refers to the order of station types that a workpiece needs to go through from the start of processing to the completion of processing. Conventionally, the processing sequence is injection station - cooling station - ejection station.

[0023] Step S102: Combine workstations of the same type to construct a single workstation combination, and randomly select one workstation from each single workstation combination as a simulated workstation, and combine all simulated workstations to form a simulated workstation scheme.

[0024] A single station combination is a combination of stations on an injection molding machine that have the same type of demand. For example, if there are multiple ejection stations, they are grouped together to form a single station combination. The actual production processing station is simulated by randomly selecting a simulated work station. The simulated work station scheme is a scheme that selects one station from each single station combination to process the injection molded part that needs to be processed.

[0025] Step S103: In the simulated workstation scheme, calculate and analyze the simulated workstations of each adjacent operation according to the processing sequence of the type to determine the adjacent adjustment angle.

[0026] The adjacent adjustment angle is the angle value between adjacent stations on the injection molding machine in terms of processing sequence. Each station is set along the circumference on the injection molding machine. That is, when the base rotates on the rotating turntable below, each base corresponds to a different injection head, which means that it is considered to be in a different station at this time. The angle of rotation of the base is the adjacent adjustment angle.

[0027] Step S104: Define all the simulated workstation schemes with the same adjacent adjustment angle as valid workstation schemes, define the simulated workstations in the valid workstation schemes as valid workstations, and define the corresponding adjacent adjustment angles as valid rotation angles.

[0028] When all adjacent adjustment angles are consistent, it means that after the base rotates, each workpiece on each base will correspond to an injection head for processing. In other words, compared to a single workpiece, each will be in a new work position, which meets the production requirements. Therefore, it can be defined as an effective work position scheme. At this time, the effective work position and effective rotation angle are defined to identify and distinguish different data, which is convenient for subsequent analysis.

[0029] Step S105: Calculate the difference between the preset full-circle rotation angle and the effective rotation angle to determine the operation retraction angle.

[0030] The full rotation angle is the rotation angle when the base completes one full rotation, which is 360°. The work retraction angle is the angle that the workpiece needs to rotate when it completes the last process and is waiting to move to the ejection station. It is determined by subtracting all the effective rotation angles traversed from the full rotation angle.

[0031] Step S106: When the processing operation state is consistent with the preset start operation state, control the preset rotating base for placing the workpiece to be processed to rotate along the preset operation direction by an effective rotation angle, and control each effective operation station to operate after rotation. Calculate the cumulative rotation angle based on the effective rotation angle, and when the cumulative rotation angle is consistent with the operation retraction angle, control the rotating base to rotate in the opposite direction of the operation direction by an operation retraction angle.

[0032] The "Start Operation" state indicates that the injection molding machine needs to perform operations. This can be achieved by manually pressing a button or by setting a timer interval. When the processing operation state matches the "Start Operation" state, it indicates that the injection molded part needs processing. At this time, controlling the rotating base to rotate in the working direction by an effective rotation angle moves the injection molding machine to the next processing station. The cumulative rotation angle is recorded to determine the processing status of the workpiece. When the cumulative rotation angle matches the work retraction angle, it indicates that the workpiece has been processed. At this point, the workpiece needs to be moved to the ejector station for the operator to retrieve. Therefore, controlling the rotating base to rotate in the opposite direction of the working direction by an operation retraction angle moves the workpiece to the ejector station. See the example below. Figure 2When there are three stations: injection molding station, cooling station, and ejection station, the corresponding bases are A, B, and C, respectively, with an effective rotation angle of 120°. At this point, base A has a workpiece that has been injection-molded but not yet cooled, base B has a workpiece that has been injection-molded and cooled, and base C has no workpiece. When operation begins, the rotating bases are controlled to rotate, with base C corresponding to the injection molding station, base A to the cooling station, and base B to the ejection station. At this time, base C begins injection molding, the cooling station cools the workpiece on base A that has been injection-molded but not yet cooled, and the injection-molded part on base B is now complete and ejected from the ejection station for the operator to collect. After collection, the operation state is controlled to match the start-up state, and the bases rotate again to allow the injection molding station to... The corresponding base is B, the cooling station base is C, and the ejection station base is A. This allows any workpiece to be re-processed on base B, while the molded parts on base C that have been injection molded but not yet cooled undergo cooling. Meanwhile, the processed workpieces on base A are ejected for the operator to store. At this point, the cumulative rotation angle matches the retraction angle, and by controlling the reverse rotation and retraction angle, base C returns to the holding position. At this point, base C has processed workpieces on it, which are then held for the operator to store. Based on the above explanation, completing one work cycle and repeating the above steps achieves efficient product processing. Each time processing is completed, a product moves to the ejection position for the operator to store. Simultaneously, the reverse movement prevents excessive tangling of internal cables, ensuring the stable operation of the injection molding machine.

[0033] The steps for randomly selecting one workstation from each individual workstation combination as the simulated workstation include: Step S200: Analyze the processing sequence according to the type to determine the required number of workstations, and calculate the required interval angle based on the required number of workstations and the full rotation angle.

[0034] The required number of workstations is the total number of workstations needed for the entire processing of the workpiece. In the example above, the required number of workstations is 3. The required interval angle is the angle that each workstation needs to be spaced apart under theoretical conditions. It is determined by dividing the full rotation angle by the required number of workstations. In the example above, the required interval angle is 120°.

[0035] Step S201: According to the processing order of the type, define the first single station combination as the first station combination, and randomly select a station in the first station combination as the simulated operation station.

[0036] Define the first-end station combination to distinguish the individual station combinations of the first step. At this time, randomly select a simulated work station from the first-end station combination to fix a station, which is convenient for subsequent analysis.

[0037] Step S202: Analyze the simulated workstations and demand intervals, and determine the demand workstations for each type of workstation according to the processing sequence.

[0038] The required workstations are those that are continuously rotated at required intervals along the work direction, starting from the simulated workstation. In other words, they are all the processing workstations required when processing is performed using the current simulated workstation.

[0039] Step S203: Determine whether each required workstation is within the corresponding single workstation combination.

[0040] The purpose of the judgment is to determine whether the currently identified workstations can meet the work requirements.

[0041] Step S2031: If each required workstation is not within the corresponding single workstation combination, the analysis of the currently defined simulated workstation will not continue.

[0042] When each required workstation is not within the corresponding single workstation combination, it indicates that the simulated workstation scheme constructed based on the current simulated workstation is not feasible. Therefore, the current simulated workstation is not analyzed to reduce the definition of simulated workstations, thereby reducing the amount of data analysis.

[0043] Step S2032: If each required work station is within the corresponding single work station combination, then the currently determined required work station is also defined as a simulated work station.

[0044] When each required workstation is within the corresponding single workstation combination, it means that an effective workstation solution can be determined based on the current required workstation. Therefore, it can be defined as a simulated workstation for the purpose of determining a simulated workstation solution.

[0045] Once the effective workstation scheme is determined, the intelligent control method for injection molding machines based on injection molding part production also includes: Step S300: Determine whether there is only one valid workstation solution.

[0046] The purpose of the judgment is to determine whether there is only one production plan that meets the requirements.

[0047] Step S3001: If there is only one valid workstation solution, then control the injection molding machine production process according to the valid workstation solution.

[0048] When there is only one valid workstation solution, it means that there is only one production solution that meets the requirements. In this case, the workpiece can be produced and processed according to this solution.

[0049] Step S3002: If there is not only one valid workstation scheme, then construct a load interval on the preset time axis with the current time point as the end point and the width as the preset load duration, and determine the load operation duration in the load interval according to each simulated workstation in the valid workstation scheme.

[0050] When there is more than one valid workstation solution, it indicates that there are multiple production solutions that meet the requirements, which need to be further screened and processed. The time axis is a coordinate axis formed by the combination of various time points. This coordinate axis points from the time points that have been passed to the time points that have not yet been reached. The time points that have been passed are on the left side of the coordinate axis, and the left side of the coordinate axis is defined as the front side of the time axis. The load duration is a fixed duration set by the staff to reflect the recent operation of the injection head of each workstation, such as 12 hours. By constructing a load interval, it is convenient to obtain and analyze the data within the load duration. The load operation duration is the duration value of each simulated operation workstation in use within the load interval.

[0051] Step S301: Determine the individual load factor corresponding to the load operation duration based on the preset load matching relationship.

[0052] The individual unit load factor is a parameter value that reflects the workload of the current workstation. The smaller the value, the healthier the workstation is. Different workload durations correspond to different individual unit load factors. The load matching relationship between the two is determined and stored in advance by the staff. It is necessary to ensure that the longer the workload duration, the larger the corresponding individual unit load factor.

[0053] Step S302: Calculate the overall load factor based on the individual unit load factors in the effective workstation scheme.

[0054] The overall load factor is a parameter value that reflects the health status of all workstations under the current effective workstation scheme. The larger the value, the less healthy the workstation is. It is determined by averaging all individual workstation load factors.

[0055] Step S303: Determine the comprehensive load coefficient with the smallest value according to the preset sorting rules, and eliminate the other effective workstation schemes other than the effective workstation schemes corresponding to the comprehensive load coefficient.

[0056] The sorting rules are methods set by the staff to sort numerical values, such as the bubble sort method. By sorting the rules, the comprehensive load coefficient with the smallest value can be determined. That is, each workstation in the corresponding effective workstation plan can perform its work well. At this time, the effective workstation plan can be retained for subsequent work control.

[0057] After the comprehensive load factor is determined, the intelligent control method for injection molding machines based on injection molding part production also includes: Step S400: Determine whether there are at least two effective workstation schemes with the same and smallest comprehensive load coefficient.

[0058] The purpose of the judgment is to determine whether there are multiple valid workstation solutions that meet the requirements, so as to identify the only valid workstation solution to be used.

[0059] Step S4001: If there are no at least two effective workstation schemes with the same and smallest comprehensive load coefficient, then the remaining effective workstation schemes other than the one with the smallest comprehensive load coefficient will be eliminated.

[0060] When there are no at least two effective workstation schemes with the same and smallest comprehensive load coefficient, it means that there is only one effective workstation scheme that meets the requirements. In this case, the injection molding machine operation control can be performed according to the effective workstation scheme.

[0061] Step S4002: If there are at least two effective workstation schemes with the same and smallest comprehensive load coefficient, then the effective workstation scheme corresponding to the smallest comprehensive load coefficient is defined as the alternative workstation scheme.

[0062] When there are at least two effective workstation schemes with the same and smallest comprehensive load coefficient, it indicates that there are multiple effective workstation schemes that meet the requirements. In this case, they are defined as alternative workstation schemes to distinguish between different effective workstation schemes, which facilitates subsequent analysis.

[0063] Step S401: Randomly select one unit load factor from each alternative workstation scheme and define it as the primary load factor, and define the remaining unit load factors as secondary load factors.

[0064] Define primary and secondary load factors to differentiate the load factors of different individual units, which facilitates subsequent analysis.

[0065] Step S402: Calculate the main representative parameter based on the main load factor and each secondary load factor, and define the main load factor corresponding to the largest main representative parameter as the center load factor.

[0066] The main representative parameter is the value that reflects the proximity between the current main load factor and each secondary load factor. The larger the value, the closer the current main load factor is to each secondary load factor, which means that the current main load factor can better represent all secondary load factors. This value is determined by calculating the difference between the main load factor and each secondary load factor, summing the absolute values ​​and taking the reciprocal. A central load factor is defined to distinguish the parameter that best represents all the current individual load factors, which is convenient for subsequent analysis.

[0067] Step S403: Calculate and determine the deviation load coefficient based on the center load coefficient and the load coefficient of each individual unit, and define the largest deviation load coefficient as the deviation critical coefficient of the alternative workstation scheme.

[0068] The deviation load factor is the difference between the center load factor and the individual unit load factor. A deviation critical factor is defined to identify the deviation load factor with the most severe deviation, which facilitates subsequent analysis.

[0069] Step S404: Determine the minimum deviation critical coefficient according to the sorting rules, and eliminate the remaining valid workstation schemes other than the candidate workstation schemes corresponding to the deviation critical coefficient.

[0070] The minimum deviation critical coefficient can be determined by the sorting rules, which means that the fatigue levels of each workstation are most similar. When the work is carried out according to the alternative workstation plan corresponding to the deviation critical coefficient, it can be ensured that each workstation can perform well and that no single workstation is too fatigued and needs to be repaired during the processing.

[0071] After the critical deviation coefficient is determined, the intelligent control method for injection molding machines based on injection molding part production also includes: Step S500: Determine whether there are at least two alternative workstation schemes with the same and smallest deviation critical coefficient.

[0072] The purpose of the judgment is to determine whether there are multiple alternative workstation solutions that meet the requirements, so as to determine which alternative workstation solution to use.

[0073] Step S5001: If there are no at least two alternative workstation schemes with the same and smallest deviation critical coefficient, then the remaining effective workstation schemes other than the alternative workstation scheme with the smallest deviation critical coefficient shall be eliminated.

[0074] When there are no at least two alternative workstation schemes with the same and smallest deviation critical coefficient, it means that there is only one alternative workstation scheme that meets the requirements. In this case, the injection molding machine operation can be controlled according to the alternative workstation scheme.

[0075] Step S5002: If there are at least two alternative workstation schemes with the same and smallest deviation critical coefficient, the alternative workstation scheme corresponding to the smallest deviation critical coefficient is defined as the waiting workstation scheme, and the duration of the current task is obtained.

[0076] When there are at least two alternative workstation schemes with the same and smallest deviation critical coefficient, it indicates that there are multiple alternative workstation schemes that meet the requirements. At this time, it is defined as a waiting workstation scheme to distinguish between different alternative workstation schemes. When the duration of the task is the duration of the operation required to process the current batch of products, it is estimated and obtained by the staff based on the quantity of the current batch of products.

[0077] Step S501: Obtain the previous maintenance time of each simulated workstation from the waiting workstation plan, and construct the work maintenance interval based on the previous maintenance time and the current time.

[0078] The previous maintenance time is the specific time point of the previous maintenance of the simulated workstation, and the operation maintenance interval is the time interval during which the simulated workstation is used after maintenance.

[0079] Step S502: Obtain the total operation time of the simulated work station within the operation maintenance interval, and calculate the remaining operation time based on the total operation time and the preset maintenance interval.

[0080] The total operation time is the total time that the simulated workstation is put into production during the operation maintenance period. The remaining operation time is the time that can be operated even if a problem occurs at the workstation and maintenance is required, which is determined by subtracting the total operation time from the maintenance interval.

[0081] Step S503: Calculate and analyze the remaining operation time and the corresponding current task time to determine reasonable operation parameters.

[0082] Reasonable operation parameters are parameters that reflect the reasonableness of the selected effective workstation scheme. When the remaining operation time and the corresponding current task time are closer and the current task time does not exceed the remaining operation time, the reasonable parameters for a single workstation are larger. The reasonable operation parameters can be obtained by averaging the reasonable parameters of all workstations.

[0083] Step S504: Determine the reasonable work parameter with the largest value according to the sorting rules, and eliminate the other valid work station schemes other than the waiting work station schemes corresponding to the reasonable work parameter.

[0084] The sorting rules can determine the reasonable operating parameters with the largest values, which means that the overall operating effect of each station is the best under the current waiting station plan. Therefore, the injection molding machine can be controlled according to its waiting station plan.

[0085] It also includes a step for determining the maintenance interval, which includes: Step S600: Construct a historical interval with a preset historical duration on the timeline, with the current time point as the endpoint, and obtain each maintenance time point in the historical interval.

[0086] The historical duration is the time period set by the staff for acquiring data on the historical usage of each workstation, such as 180 days. By constructing historical intervals, it is convenient to acquire and analyze data within the historical duration. The maintenance time point is the specific time point at which each workstation is inspected and processed within the historical interval.

[0087] Step S601: Calculate the individual unit interval duration based on adjacent maintenance time points, select one of all individual unit interval durations as the first interval duration, and define the remaining individual unit interval durations as the second interval duration.

[0088] The unit interval duration is the interval between adjacent maintenance time points. The first interval duration and the second interval duration are defined to distinguish different unit interval durations, which facilitates subsequent analysis.

[0089] Step S602: Calculate the interval representative parameter based on the first interval duration and each second interval duration, and define the first interval duration corresponding to the largest interval representative parameter as the reasonable interval duration.

[0090] The interval representative parameter is a parameter value that reflects the feasibility of the first interval duration representing all individual interval durations. The calculation method is the same as the main representative parameters mentioned above, and will not be repeated here. The largest interval representative parameter indicates that the distance between the corresponding first interval duration and the other second interval durations is the closest. That is, the first interval duration can best represent all individual interval durations. Therefore, it is defined as a reasonable interval duration for identification, which is convenient for subsequent analysis.

[0091] Step S603: Calculate the reasonable nearest range based on the reasonable interval duration and the preset nearest range duration, and calculate the maintenance interval duration based on the average interval duration of the individual units within the reasonable nearest range.

[0092] The nearest duration is the maximum allowable difference between two durations that are considered to be close together, as set by the staff. The reasonable nearest range is the range that the durations that are close to the reasonable interval duration need to be within. At this time, the durations within the reasonable nearest range are the intervals of maintenance durations that will occur under normal use conditions at the current work site. At this time, the maintenance interval duration can be obtained by averaging the individual interval durations within this range.

[0093] Reference Figure 3Based on the same inventive concept, embodiments of the present invention provide an intelligent control system for injection molding machines based on injection molding part production, comprising: The acquisition module is used to acquire the model of the workpiece being processed and the processing status. The processing module, connected to the acquisition module, is used for information storage and processing; The processing module uses a preset model matching relationship to determine the required workstation type and processing sequence corresponding to the model of the workpiece to be processed; The processing module combines workstations of the same type to construct individual workstation combinations, randomly selects one workstation from each individual workstation combination as a simulated workstation, and combines all simulated workstations to form a simulated workstation scheme. The processing module performs calculations and analyses on the simulated workstations of each adjacent operation according to the processing sequence of the type to determine the adjacent adjustment angles. The processing module defines all simulated workstation schemes with the same adjacent adjustment angle as valid workstation schemes, defines the simulated workstations in the valid workstation schemes as valid workstations, and defines the corresponding adjacent adjustment angles as valid rotation angles. The processing module calculates the difference between the preset full-circle rotation angle and the effective rotation angle to determine the operation retraction angle; When the processing operation state is consistent with the preset start operation state, the processing module controls the preset rotating base for placing the workpiece to be processed to rotate along the preset operation direction by an effective rotation angle. After rotation, it controls each effective operation station to operate. It calculates the cumulative rotation angle based on the effective rotation angle and controls the rotating base to rotate in the opposite direction of the operation direction by an operation retraction angle when the cumulative rotation angle is consistent with the operation retraction angle. The simulated workstation selection module is used to select the simulated workstation from each individual workstation combination; The workstation load analysis module is used to analyze and process the specific load conditions of each workstation. The effective workstation scheme filtering module is used to filter multiple effective workstation schemes that meet the requirements. The alternative workstation solution screening module is used to screen multiple alternative workstation solutions that meet the requirements. The maintenance interval determination module determines the appropriate maintenance interval based on the specific circumstances of each workstation.

[0094] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

Claims

1. An intelligent control method for injection molding machines based on injection molding part production, characterized in that, include: Obtain the model of the workpiece to be processed and the processing status; The required workstation type and processing sequence corresponding to the workpiece type are determined based on the preset model matching relationship; Workstations with the same type of workstation requirement are combined to form a single workstation combination. One workstation is randomly selected from each single workstation combination as a simulated workstation. All simulated workstations are combined to form a simulated workstation scheme. In the simulated workstation scheme, the simulated workstations of each adjacent operation are calculated and analyzed according to the processing sequence of the type to determine the adjacent adjustment angle; The simulated workstation schemes where all adjacent adjustment angles are consistent are defined as effective workstation schemes, and the simulated workstations in the effective workstation schemes are defined as effective workstations, and the corresponding adjacent adjustment angles are defined as effective rotation angles. The working retraction angle is determined by calculating the difference between the preset full-circle rotation angle and the effective rotation angle. When the processing operation state is consistent with the preset start operation state, the preset rotating base for placing the workpiece to be processed is controlled to rotate along the preset operation direction by an effective rotation angle. After rotation, each effective operation station is controlled to operate. The cumulative rotation angle is calculated based on the effective rotation angle. When the cumulative rotation angle is consistent with the operation retraction angle, the rotating base is controlled to rotate in the opposite direction of the operation direction by an operation retraction angle.

2. The intelligent control method for injection molding machines based on injection molded part production according to claim 1, characterized in that, The steps for randomly selecting one workstation from each individual workstation combination as the simulated workstation include: The required number of workstations is determined by analyzing the processing sequence based on the type, and the required interval angle is determined by calculating the required number of workstations and the full rotation angle. Based on the processing order of the type, the first single station combination is defined as the first station combination, and a station is randomly selected from the first station combination as the simulated operation station. Based on the analysis of simulated workstations and demand intervals, and according to the processing sequence of types, the required workstations for each type of workstation are determined. Determine whether each required workstation is within the corresponding individual workstation combination; If each required workstation is not within the corresponding single workstation combination, the analysis of the currently defined simulated workstation will not continue. If each required workstation is within the corresponding single workstation combination, then the currently determined required workstation is also defined as a simulated workstation.

3. The intelligent control method for injection molding machines based on injection molded part production according to claim 1, characterized in that, Once the effective workstation scheme is determined, the intelligent control method for injection molding machines based on injection molding part production also includes: Determine if there is only one valid workstation solution; If there is only one valid workstation solution, then the injection molding machine production process is controlled according to the valid workstation solution; If there is more than one valid workstation solution, a load interval with the current time point as the end point and a width of the preset load duration is constructed on the preset time axis, and the load operation duration is determined in the load interval according to each simulated workstation in the valid workstation solution. The individual load factor corresponding to the load operation duration is determined based on the preset load matching relationship; The overall load factor is determined by calculating the load factor of all individual units in the effective workstation scheme. The minimum comprehensive load coefficient is determined according to the preset sorting rules, and the remaining effective workstation schemes other than the one corresponding to the comprehensive load coefficient are eliminated.

4. The intelligent control method for injection molding machines based on injection molded part production according to claim 3, characterized in that, After the comprehensive load factor is determined, the intelligent control method for injection molding machines based on injection molding part production also includes: Determine whether there are at least two effective workstation schemes with the same and smallest comprehensive load coefficient; If there are no at least two effective workstation schemes with the same and smallest comprehensive load coefficient, then the remaining effective workstation schemes other than the one with the smallest comprehensive load coefficient will be eliminated. If there are at least two effective workstation schemes with the same and smallest comprehensive load coefficient, then the effective workstation scheme corresponding to the smallest comprehensive load coefficient is defined as the alternative workstation scheme. Randomly select one unit load factor from the alternative workstation schemes and define it as the primary load factor, and define the remaining unit load factors as secondary load factors; The main representative parameter is determined by calculating based on the main load factor and each secondary load factor, and the main load factor corresponding to the largest main representative parameter is defined as the center load factor. The deviation load factor is determined by calculating the load factor of the center and the load factor of each individual unit, and the largest deviation load factor is defined as the deviation critical factor of the alternative workstation scheme. The minimum deviation threshold coefficient is determined according to the sorting rules, and the remaining valid workstation schemes other than the alternative workstation schemes corresponding to this deviation threshold coefficient are eliminated.

5. The intelligent control method for injection molding machines based on injection molded part production according to claim 4, characterized in that, After the critical deviation coefficient is determined, the intelligent control method for injection molding machines based on injection molding part production also includes: Determine whether there are at least two alternative workstation schemes with the same and smallest deviation critical coefficient; If there are no at least two alternative workstation schemes with the same and smallest deviation critical coefficient, then the remaining effective workstation schemes other than the alternative workstation scheme with the smallest deviation critical coefficient will be eliminated. If there are at least two alternative workstation schemes with the same and smallest deviation critical coefficient, the alternative workstation scheme corresponding to the smallest deviation critical coefficient is defined as the waiting workstation scheme, and the duration of the current task is obtained. The previous maintenance time of each simulated workstation is obtained from the waiting workstation plan, and the work maintenance interval is constructed based on the previous maintenance time and the current time. The total operation time of the simulated work station is obtained within the operation maintenance interval, and the remaining operation time is calculated based on the total operation time and the preset maintenance interval. Calculations and analyses are performed based on the remaining task duration and the corresponding duration of the current task to determine reasonable task parameters. Based on the sorting rules, determine the reasonable work parameter with the largest value, and then eliminate the other valid work station schemes that are not the waiting work station schemes corresponding to the reasonable work parameter.

6. The intelligent control method for injection molding machines based on injection molded part production according to claim 5, characterized in that, It also includes a step for determining the maintenance interval, which includes: Construct a historical interval with a preset historical duration on the timeline, with the current time point as the endpoint, and obtain each maintenance time point in the historical interval; The interval length of a single unit is determined by calculation based on adjacent maintenance time points, and one of the interval lengths of all units is selected as the first interval length, while the remaining interval lengths of the units are defined as the second interval length. The interval representative parameter is determined by calculation based on the first interval duration and each second interval duration, and the first interval duration corresponding to the largest interval representative parameter is defined as the reasonable interval duration. The reasonable nearest range is determined by calculation based on the reasonable interval duration and the preset nearest range duration, and the maintenance interval duration is determined by averaging the interval durations of individual units within the reasonable nearest range.

7. An intelligent control system for injection molding machines based on injection molded part production, characterized in that, include: The acquisition module is used to acquire the model of the workpiece being processed and the processing status. The processing module, connected to the acquisition module, is used for information storage and processing; The processing module uses a preset model matching relationship to determine the required workstation type and processing sequence corresponding to the model of the workpiece to be processed; The processing module combines workstations of the same type to construct individual workstation combinations, randomly selects one workstation from each individual workstation combination as a simulated workstation, and combines all simulated workstations to form a simulated workstation scheme. The processing module performs calculations and analyses on the simulated workstations of each adjacent operation according to the processing sequence of the type to determine the adjacent adjustment angles. The processing module defines all simulated workstation schemes with the same adjacent adjustment angle as valid workstation schemes, defines the simulated workstations in the valid workstation schemes as valid workstations, and defines the corresponding adjacent adjustment angles as valid rotation angles. The processing module calculates the difference between the preset full-circle rotation angle and the effective rotation angle to determine the operation retraction angle; When the processing operation state is consistent with the preset start operation state, the processing module controls the preset rotating base for placing the workpiece to be processed to rotate along the preset operation direction by an effective rotation angle. After rotation, it controls each effective operation station to operate. It calculates the cumulative rotation angle based on the effective rotation angle, and controls the rotating base to rotate in the opposite direction of the operation direction by an operation retraction angle when the cumulative rotation angle is consistent with the operation retraction angle.

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