Synchronous temperature rise control system and method for hot runner temperature control box

Abstract

The invention discloses a synchronous temperature rise control system and method for a hot runner temperature control box, and the system comprises an industrial computer, a man-machine touch interaction interface, a main control chip, a power module, hot runner heaters installed in all temperature areas of a hot runner mold, and a thermocouple temperature sensor, and the main control chip is in communication connection with the industrial computer through a communication circuit. The industrial computer is electrically connected with the man-machine touch interaction interface. The output end of the power module is electrically connected with the main control chip and the industrial computer. The thermocouple temperature sensor is electrically connected with the main control chip through the temperature signal processing module; the system is provided with a heater driving circuit and a silicon controlled rectifier controller, and the main control chip is electrically connected with the hot runner heater through the heater driving circuit and the silicon controlled rectifier controller. According to the synchronous temperature rise control system and method for the hot runner temperature control box, synchronous temperature rise of all the temperature areas of the hot runner mold can be achieved, the power of all the heaters can be accurately controlled, and all the temperature areas of the hot runner mold can reach respective target temperatures at the same time.

Description

Technical Field

[0001] This invention relates to the field of hot runner temperature control technology, and in particular to a synchronous heating control system and method for a hot runner temperature control box. Background Technology

[0002] Hot runner systems use heating to keep the plastic in the runner and gate in a molten state. The core components of a hot runner system are a hot runner heater, a temperature sensor, and a hot runner temperature control box. The hot runner heater is installed in the hot runner mold to heat the mold. The temperature sensor is installed in the hot runner mold to collect temperature signals from the corresponding temperature zones of the mold. The hot runner heater and temperature sensor are connected to the hot runner temperature control box, which controls the heating action of the hot runner heater.

[0003] It should be noted that existing hot runner temperature control boxes have the following drawbacks, specifically:

[0004] Defect 1: Asynchronous heating in multiple temperature zones: Each temperature zone of the hot runner mold is controlled independently, which can easily lead to uneven heating of the material, thus affecting the injection molding quality of the hot runner mold.

[0005] Defect 2: It is prone to temperature overshoot, meaning that it is difficult to achieve precise temperature control during the injection molding process;

[0006] Defect 3: It cannot achieve precise control of the output power of the hot runner heater, resulting in high energy consumption. Summary of the Invention

[0007] The purpose of this invention is to provide a synchronous heating control system for a hot runner temperature control box, which addresses the shortcomings of existing technologies. This system can achieve synchronous heating of each temperature zone of the hot runner mold and accurately control the power of each heater so that each temperature zone of the hot runner mold reaches its target temperature simultaneously, thereby effectively improving the accuracy and efficiency of hot runner temperature control.

[0008] Another objective of this invention is to provide a synchronous heating control method for a hot runner temperature control box, which addresses the shortcomings of existing technologies. This method enables synchronous heating of each temperature zone of the hot runner mold and accurately controls the power of each heater, allowing each temperature zone of the hot runner mold to reach its target temperature simultaneously, thereby effectively improving the accuracy and efficiency of hot runner temperature control.

[0009] To achieve the above objectives, the present invention is implemented through the following technical solutions.

[0010] A synchronous temperature control system for a hot runner temperature control box is applied to a hot runner mold. The hot runner mold is provided with several temperature zones, and each temperature zone of the hot runner mold is equipped with a hot runner heater and a thermocouple temperature sensor.

[0011] The hot runner temperature control box synchronous heating control system includes an industrial computer, a human-machine touch interface, a main control chip electrically connected to the main controller of the injection molding machine, and a power module with 220V AC power input. The main control chip is connected to the industrial computer via a communication circuit, the industrial computer is electrically connected to the human-machine touch interface, and the output of the power module is electrically connected to the main control chip and the industrial computer respectively.

[0012] Thermocouple temperature sensors in each temperature zone of the hot runner mold are electrically connected to the main control chip through a temperature signal processing module.

[0013] The synchronous heating control system of the hot runner temperature control box is equipped with a heater drive circuit and a thyristor controller for each hot runner heater of the hot runner mold. The input terminal of each heater drive circuit is electrically connected to the main control chip, the output terminal of each heater drive circuit is electrically connected to the input terminal of the corresponding thyristor controller, and the output terminal of each thyristor controller is electrically connected to the corresponding hot runner heater.

[0014] Each of the thyristor controllers and the corresponding hot runner heaters is provided with a heating circuit current acquisition module for acquiring the current of the electrical connection circuit. The output terminal of each heating circuit current acquisition module is electrically connected to the main control chip through a current signal processing module.

[0015] The main control chip is electrically connected to an alarm signal output circuit, and the output terminal of the alarm signal output circuit is electrically connected to an alarm light, a buzzer, or the main controller of the injection molding machine.

[0016] The power module outputs either a 24V DC voltage or a 12V DC voltage.

[0017] A DC-DC conversion circuit is provided between the main control chip and the power module. The output terminal of the power module is electrically connected to the input terminal of the DC-DC conversion circuit, and the output terminal of the DC-DC conversion circuit is electrically connected to the main control chip.

[0018] The main control chip is model STM32F103VCT6.

[0019] Among them, each of the thermocouple temperature sensors is an IC-J sensor.

[0020] A method for synchronous heating control of a hot runner temperature control box, which is based on the above-mentioned synchronous heating control system for a hot runner temperature control box.

[0021] The synchronous temperature control method for the hot runner temperature control box includes the following steps:

[0022] Step a: Set the target temperature for each temperature zone of the hot runner mold through the human-machine interface or the main controller of the injection molding machine;

[0023] Step b: Start the heating of the hot runner mold through the human-machine touch interface or the main controller of the injection molding machine. The thermocouple temperature sensors of each temperature zone of the hot runner mold collect the actual temperature signal of the corresponding temperature zone in real time. The actual temperature signal collected by each thermocouple temperature sensor is amplified and filtered by the corresponding temperature signal processing module and then fed back to the main control chip.

[0024] Step c: The main control chip dynamically calculates the power demand of each temperature zone using a fuzzy PID algorithm, and calculates the heating power and heating rate of the hot runner heater in each temperature zone based on the temperature difference between the actual temperature and the target temperature.

[0025] Step d: The main control chip controls the corresponding hot runner heaters according to the calculated heating power and heating rate of each temperature zone hot runner heater. During this process, the weak electrical control signal sent by the main control chip is isolated and amplified by the heater drive circuit to control the corresponding thyristor controller. Each thyristor controller controls the corresponding hot runner heater according to the calculated heating power and heating rate, so that each temperature zone of the hot runner mold reaches its target temperature at the same time.

[0026] In step c, the heating rate is ≤5℃ / s.

[0027] Compared with the prior art, the present invention has the following beneficial effects, specifically:

[0028] 1. The main control chip dynamically calculates the power requirements of each temperature zone through a fuzzy PID algorithm, and calculates the heating power and heating rate of the hot runner heater in each temperature zone based on the temperature difference between the actual temperature and the target temperature. Then, according to the heating power and heating rate requirements, the hot runner heater is controlled by a thyristor controller so that each temperature zone of the hot runner mold can reach its target temperature at the same time.

[0029] 2. The synchronous heating control system of the hot runner temperature control box of the present invention can calculate the power demand of each temperature zone of the hot runner mold in real time during operation, and can accurately control the output power of each hot runner heater. That is, energy consumption optimization can be achieved through accurate control of output power, thereby achieving the purpose of reducing energy consumption.

[0030] 3. The synchronous heating control system of the hot runner temperature control box of the present invention adjusts the output power of the hot runner heater in real time according to the temperature difference between the actual temperature and the target temperature during operation, which can effectively avoid the phenomenon of temperature overshoot in the temperature zone and achieve precise temperature control of the hot runner mold during injection molding.

[0031] 4. Therefore, the synchronous heating control system of the hot runner temperature control box of the present invention can realize the synchronous heating of each temperature zone of the hot runner mold, and can accurately control the power of each heater and make each temperature zone of the hot runner mold reach its respective target temperature at the same time, thereby effectively improving the accuracy and efficiency of hot runner temperature control.

[0032] 5. The synchronous heating control method of the hot runner temperature control box of the present invention can realize synchronous heating of each temperature zone of the hot runner mold, and can accurately control the power of each heater so that each temperature zone of the hot runner mold can reach its respective target temperature at the same time, thereby effectively improving the accuracy and efficiency of hot runner temperature control. Attached Figure Description

[0033] The present invention will be further described below with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present invention.

[0034] Figure 1 This is a schematic diagram of the synchronous heating control system for the hot runner temperature control box of the present invention.

[0035] exist Figure 1 This includes:

[0036] 1-Industrial computer; 2-Human machine touch interface; 3-Main control chip; 4-Power supply module; 5-Communication circuit; 6-Temperature signal processing module; 7-Heater drive circuit; 8-SCR controller; 9-Heating circuit current acquisition module; 10-Current signal processing module; 11-Alarm signal output circuit; 12-DC-DC conversion circuit. Detailed Implementation

[0037] The present invention will now be described in conjunction with specific embodiments.

[0038] Example 1: A synchronous temperature rise control system for a hot runner temperature control box, applied to a hot runner mold. The hot runner mold has several temperature zones, and each temperature zone is equipped with a hot runner heater and a thermocouple temperature sensor. It should be explained that... Figure 1 The multiple sets of thermocouple temperature sensors shown are the thermocouple temperature sensors for all temperature zones of the hot runner mold. Figure 1 The multiple sets of hot runner heaters shown are the hot runner heaters for all temperature zones of the hot runner mold.

[0039] Among them, such as Figure 1As shown, the synchronous temperature control system of the hot runner temperature control box includes an industrial computer 1, a human-machine interface 2, a main control chip 3 electrically connected to the main controller of the injection molding machine, and a power module 4 with 220V AC power input. The main control chip 3 is connected to the industrial computer 1 through a communication circuit 5. The industrial computer 1 is electrically connected to the human-machine interface 2. The output of the power module 4 is electrically connected to the main control chip 3 and the industrial computer 1 respectively.

[0040] Furthermore, the thermocouple temperature sensors of each temperature zone of the hot runner mold are electrically connected to the main control chip 3 through the temperature signal processing module 6.

[0041] Furthermore, the synchronous heating control system of the hot runner temperature control box is equipped with a heater drive circuit 7 and a thyristor controller 8 for each hot runner heater of the hot runner mold. The input terminal of each heater drive circuit 7 is electrically connected to the main control chip 3, the output terminal of each heater drive circuit 7 is electrically connected to the input terminal of the corresponding thyristor controller 8, and the output terminal of each thyristor controller 8 is electrically connected to the corresponding hot runner heater.

[0042] It should be explained that the heater control circuit is connected between the main control chip 3 and the thyristor controller 8. The thyristor controller 8 is used to control the power of the hot runner heater. During operation, the heater control circuit is used to isolate and amplify the weak electrical control signals (such as PWM pulses) sent by the main control chip 3 in order to reliably drive the thyristor controller 8.

[0043] As for the main control chip 3 in this embodiment, it can be directly electrically connected to the main controller of the injection molding machine. That is, the main control chip 3 in this embodiment can receive signals from the injection molding machine, such as start, stop or temperature setpoint synchronization signals from the injection molding machine, thereby realizing linkage with the injection molding machine.

[0044] For the industrial computer 1 in this embodiment, its function is to run the operating system and HMI software, receive data from the main control chip 3 and generate display content, and transmit it to the human-machine touch interface 2 through interfaces such as VGA.

[0045] For the human-machine touch interaction interface 2 in this embodiment, it can be a touch screen; during operation, the touch signal is generated by the human-machine touch interaction interface 2 and the touch signal is transmitted back to the industrial computer 1 or the main control chip 3 to complete the instruction input.

[0046] It should be emphasized that when the synchronous heating control system of the hot runner temperature control box in this embodiment is working, the main control chip 3 dynamically calculates the power demand of each temperature zone through the fuzzy PID algorithm, and calculates the heating power and heating rate of the hot runner heater in each temperature zone based on the temperature difference between the actual temperature (the temperature collected in real time by the thermocouple temperature sensor) and the target temperature. Then, according to the heating power and heating rate requirements, the hot runner heater is controlled by the thyristor controller 8 to make each temperature zone of the hot runner mold reach its respective target temperature at the same time.

[0047] It should be further emphasized that the synchronous heating control system of the hot runner temperature control box in this embodiment can calculate the power demand of each temperature zone of the hot runner mold in real time during operation, and can accurately control the output power of each hot runner heater. That is, energy consumption optimization can be achieved through accurate control of output power, thereby achieving the goal of reducing energy consumption.

[0048] Furthermore, the synchronous heating control system of the hot runner temperature control box in this embodiment adjusts the output power of the hot runner heater in real time according to the temperature difference between the actual temperature and the target temperature during operation. This effectively avoids the phenomenon of temperature overshoot in the temperature zone and enables precise temperature control of the hot runner mold during injection molding.

[0049] In summary, the synchronous heating control system of the hot runner temperature control box in this embodiment can achieve synchronous heating of each temperature zone of the hot runner mold, and can accurately control the power of each heater so that each temperature zone of the hot runner mold can reach its target temperature at the same time, thereby effectively improving the accuracy and efficiency of hot runner temperature control.

[0050] Example 2, as Figure 1 As shown, the difference between this embodiment 2 and embodiment 1 is that: each thyristor controller 8 and the corresponding hot runner heater are respectively provided with a heating circuit current acquisition module 9 for acquiring the current of the electrical connection circuit, and the output terminal of each heating circuit current acquisition module 9 is electrically connected to the main control chip 3 through the current signal processing module 10.

[0051] It should be noted that the heating circuit current acquisition module 9 in this embodiment can be connected in series in the heating circuit (i.e., the electrical connection circuit of the hot runner heater). During operation, the heating circuit current acquisition module 9 is used to acquire the output current of the hot runner heater in real time to determine the working state of the hot runner heater, such as open circuit, short circuit or overcurrent. The current signal acquired by the heating circuit current acquisition module is processed by the current signal processing module 10 and then fed back to the main control chip 3.

[0052] Example 3, as Figure 1As shown, the difference between this embodiment 3 and embodiment 1 is that the main control chip 3 is electrically connected to an alarm signal output circuit 11, and the output terminal of the alarm signal output circuit 11 is electrically connected to an alarm light, a buzzer, or the main controller of the injection molding machine.

[0053] When the hot runner temperature control box synchronous heating control system in this embodiment 3 is working, when the system detects faults such as overheating, broken wires, or short circuits, the main control chip 3 controls the alarm signal output circuit 11 to output an alarm signal, and the alarm signal output circuit 11 drives the external alarm light and buzzer to start and provide an alarm prompt, or the alarm signal output circuit 11 transmits the alarm signal to the injection molding machine main controller.

[0054] Example 4, as Figure 1 As shown, the difference between this embodiment four and embodiment one is that the output terminal of the power module 4 outputs a 24V DC voltage or a 12V DC voltage.

[0055] A DC-DC conversion circuit 12 is provided between the main control chip 3 and the power module 4. The output terminal of the power module 4 is electrically connected to the input terminal of the DC-DC conversion circuit 12, and the output terminal of the DC-DC conversion circuit 12 is electrically connected to the main control chip 3.

[0056] It should be explained that the function of the DC-DC conversion circuit 12 is to perform high-efficiency voltage conversion and isolation.

[0057] Example 5 differs from Example 1 in that the main control chip 3 is an STM32F103VCT6.

[0058] Example 6 differs from Example 1 in that each thermocouple temperature sensor is an IC-J sensor.

[0059] Example 7: A method for synchronous heating control of a hot runner temperature control box, which is based on the above-mentioned synchronous heating control system for a hot runner temperature control box.

[0060] The synchronous temperature control method for the hot runner temperature control box includes the following steps:

[0061] Step a: Set the target temperature for each temperature zone of the hot runner mold through the human-machine interface 2 or the main controller of the injection molding machine;

[0062] Step b: Start the heating of the hot runner mold through the human-machine touch interface 2 or the main controller of the injection molding machine. The thermocouple temperature sensors of each temperature zone of the hot runner mold collect the actual temperature signal of the corresponding temperature zone in real time. The actual temperature signal collected by each thermocouple temperature sensor is amplified and filtered by the corresponding temperature signal processing module 6 and then fed back to the main control chip 3.

[0063] Step c: The main control chip 3 dynamically calculates the power demand of each temperature zone using a fuzzy PID algorithm, and calculates the heating power and heating rate of the hot runner heater in each temperature zone based on the temperature difference between the actual temperature and the target temperature.

[0064] Step d: The main control chip 3 controls the corresponding hot runner heater to operate according to the calculated heating power and heating rate of the hot runner heater in each temperature zone. During this process, the weak electrical control signal sent by the main control chip 3 is isolated and amplified by the heater drive circuit 7 to control the corresponding thyristor controller 8. Each thyristor controller 8 controls the corresponding hot runner heater to operate according to the calculated heating power and heating rate, so that each temperature zone of the hot runner mold can reach its target temperature at the same time.

[0065] Through the above steps, the synchronous heating control method of the hot runner temperature control box in Embodiment 7 can realize the synchronous heating of each temperature zone of the hot runner mold, and can accurately control the power of each heater so that each temperature zone of the hot runner mold can reach its target temperature at the same time, thereby effectively improving the accuracy and efficiency of hot runner temperature control.

[0066] Example 8 differs from Example 7 in that, in step c, the heating rate is ≤5℃ / s.

[0067] It should be explained that, by controlling the heating rate, the synchronous heating control method of the hot runner temperature control box in this embodiment eight can effectively avoid the material deformation of the hot runner mold caused by the excessively fast heating rate.

[0068] The above description is only a preferred embodiment of the present invention. For those skilled in the art, there will be changes in the specific implementation and application scope based on the ideas of the present invention. The content of this specification should not be construed as a limitation of the present invention.

Claims

1. A synchronous temperature control system for a hot runner temperature control box, applied to a hot runner mold, wherein the hot runner mold is provided with several temperature zones, and each temperature zone of the hot runner mold is respectively equipped with a hot runner heater and a thermocouple temperature sensor. Its features are: The synchronous heating control system of the hot runner temperature control box includes an industrial computer (1), a human-machine touch interface (2), a main control chip (3) electrically connected to the main controller of the injection molding machine, and a power module (4) with 220V AC power input. The main control chip (3) is connected to the industrial computer (1) through a communication circuit (5). The industrial computer (1) is electrically connected to the human-machine touch interface (2). The output of the power module (4) is electrically connected to the main control chip (3) and the industrial computer (1) respectively. Thermocouple temperature sensors in each temperature zone of the hot runner mold are electrically connected to the main control chip (3) through the temperature signal processing module (6); The synchronous heating control system of the hot runner temperature control box is equipped with a heater drive circuit (7) and a thyristor controller (8) for each hot runner heater of the hot runner mold. The input terminal of each heater drive circuit (7) is electrically connected to the main control chip (3), the output terminal of each heater drive circuit (7) is electrically connected to the input terminal of the corresponding thyristor controller (8), and the output terminal of each thyristor controller (8) is electrically connected to the corresponding hot runner heater.

2. The synchronous heating control system for a hot runner temperature control box according to claim 1, characterized in that: Each of the thyristor controllers (8) and the corresponding hot runner heaters is provided with a heating circuit current acquisition module (9) for acquiring the current of the electrical connection circuit. The output terminal of each heating circuit current acquisition module (9) is electrically connected to the main control chip (3) through a current signal processing module (10).

3. The synchronous heating control system for a hot runner temperature control box according to claim 1, characterized in that: The main control chip (3) is electrically connected to an alarm signal output circuit (11), and the output terminal of the alarm signal output circuit (11) is electrically connected to an alarm light, a buzzer, or the main controller of an injection molding machine.

4. The synchronous heating control system for a hot runner temperature control box according to claim 1, characterized in that: The power module (4) outputs a 24V DC voltage or a 12V DC voltage; A DC-DC conversion circuit (12) is provided between the main control chip (3) and the power module (4). The output terminal of the power module (4) is electrically connected to the input terminal of the DC-DC conversion circuit (12), and the output terminal of the DC-DC conversion circuit (12) is electrically connected to the main control chip (3).

5. The synchronous heating control system for a hot runner temperature control box according to claim 1, characterized in that: The main control chip (3) is an STM32F103VCT6.

6. The synchronous heating control system for a hot runner temperature control box according to claim 1, characterized in that: The thermocouple temperature sensors described are all IC-J sensors.

7. A method for synchronous temperature control of a hot runner temperature control chamber, characterized in that: The hot runner temperature control box synchronous heating control method is based on the hot runner temperature control box synchronous heating control system described in any one of claims 1-6; The synchronous temperature control method for the hot runner temperature control box includes the following steps: Step a: Set the target temperature of each temperature zone of the hot runner mold through the human-machine touch interface (2) or the main controller of the injection molding machine; Step b: Start the heating of the hot runner mold through the human-machine touch interface (2) or the main controller of the injection molding machine. The thermocouple temperature sensors of each temperature zone of the hot runner mold collect the actual temperature signal of the corresponding temperature zone in real time. The actual temperature signal collected by each thermocouple temperature sensor is amplified and filtered by the corresponding temperature signal processing module (6) and then fed back to the main control chip (3). Step c: The main control chip (3) dynamically calculates the power demand of each temperature zone through the fuzzy PID algorithm, and calculates the heating power and heating rate of the hot runner heater of each temperature zone based on the temperature difference between the actual temperature and the target temperature. Step d: The main control chip (3) controls the corresponding hot runner heaters to operate according to the calculated heating power and heating rate of each temperature zone hot runner heater. During this process, the weak electrical control signal issued by the main control chip (3) is isolated and amplified by the heater drive circuit (7) to control the corresponding thyristor controller (8). Each thyristor controller (8) controls the corresponding hot runner heater to operate according to the calculated heating power and heating rate, so that each temperature zone of the hot runner mold can reach its target temperature at the same time.

8. The synchronous temperature control method for a hot runner temperature control box according to claim 7, characterized in that: In step c, the heating rate is ≤5℃ / s.

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