Injection molding machine automatic lubrication control method and system

Abstract

The application relates to an automatic lubrication control method and system based on an injection molding machine, and relates to the field of injection molding machines, which comprises the following steps: controlling the start of the injection molding machine, collecting the mold opening stroke of the injection molding machine, recording the running mold number, and calling the historical running mold number; determining the total running mold number according to the running mold number and the historical running mold number; calculating the total mold opening stroke based on the mold opening stroke and the total running mold number; comparing whether the total mold opening stroke is greater than a preset stroke threshold value; when the total mold opening stroke is greater than the stroke threshold value, sending a lubrication instruction; matching the lubricating oil output amount based on the total running mold number; and controlling the lubricating mechanism to output the lubricating oil to the structural components in the lubricating oil output amount according to the lubricating instruction. By adopting the technical scheme, the application has the effect of improving the accuracy of automatic lubrication control.

Description

Technical Field

[0001] This invention relates to the field of injection molding machines, and in particular to an automatic lubrication control method and system for injection molding machines. Background Technology

[0002] During the injection molding process, the structural components of the injection molding machine will experience wear due to the long-term repetitive relative motion. At this time, sufficient and reasonable lubrication is required to ensure the normal operation of the structural components of the injection molding machine and extend their service life.

[0003] The automatic lubrication principle of injection molding machines refers to the controller controlling the lubrication pump to operate via digital signals after the preset automatic lubrication conditions are met. Upon receiving the signal from the controller, the lubrication pump delivers lubricating oil to the structural components of the injection molding machine. Conventional automatic lubrication includes module lubrication and start-up lubrication. For module lubrication, automatic lubrication is triggered when the operating module of the injection molding machine reaches the set automatic lubrication module.

[0004] In modular lubrication mode, when the actual mold opening and closing stroke of the injection molding machine changes, the consumption rate of lubricating oil will also increase or decrease accordingly. If automatic lubrication is still performed according to the preset conditions, it will lead to insufficient or excessive lubrication of structural components. Summary of the Invention

[0005] To avoid insufficient or excessive lubrication of structural components and to improve the accuracy of automatic lubrication control, this invention provides an automatic lubrication control method and system for injection molding machines.

[0006] In a first aspect, the present invention provides an automatic lubrication control method for injection molding machines, employing the following technical solution: An automatic lubrication control method for injection molding machines includes: Control the injection molding machine to start, collect the mold opening stroke of the injection molding machine, record the number of running dies, and retrieve historical running dies; The total number of operating modules is determined based on the operating modules and the historical operating modules; Calculate the total mold opening stroke based on the mold opening stroke and the total number of operating modules; Compare whether the total mold opening stroke is greater than a preset stroke threshold; When the total mold opening stroke exceeds the stroke threshold, a lubrication command is sent. The lubricating oil output is matched based on the total operating modulus. The lubrication mechanism is controlled to output the lubricating oil to the structural components according to the lubrication command.

[0007] By adopting the above technical solution, since different models of injection molding machines have different mold opening strokes during operation, the mold opening stroke is used as the basis for the lubrication mechanism to lubricate structural components. The stroke threshold is calculated based on the mold opening stroke, improving the accuracy of automatic lubrication control. If the mold requires a small mold opening stroke, the actual lubrication output frequency is low, and the number of cycles within one lubrication cycle is increased, saving lubricating oil consumption. If the mold requires a large mold opening stroke, the actual lubrication output frequency is high, ensuring the machine's lubrication effect, guaranteeing stable machine operation, and extending its service life.

[0008] Optionally, the method for determining the travel threshold includes: Control the start of the injection molding machine and collect the internal temperature value of the lubrication mechanism of the injection molding machine; When the internal temperature of the lubrication mechanism is greater than the preset reference temperature, the cumulative modulus of temperature anomaly is recorded; When the cumulative modulus of the temperature anomaly exceeds the preset cumulative modulus standard, the current operating modulus of the injection molding machine is collected; The stroke threshold is calculated based on the current operating modulus and the mold opening stroke.

[0009] Optionally, the formula for calculating the travel threshold is: Y = M * S * 2; Where Y is the stroke threshold, M is the current running modulus, and S is the mold opening stroke.

[0010] Optionally, the method for determining the lubricating oil output includes: The state stage of the injection molding machine is determined based on the total number of operating modules. The state stages of the injection molding machine include the break-in stage, the normal operation stage, and the aging stage. The lubrication frequency is determined based on the stroke threshold and the mold opening stroke. During the break-in period, the first supplementary interval modulus is matched according to the state stage, and the lubricating oil output is determined according to the first supplementary interval modulus, the lubrication frequency, and the preset lubricating oil quantity. During normal operation, a second supplementary interval modulus is matched according to the state stage, wherein the second supplementary interval modulus is less than the first supplementary interval modulus; The lubricating oil output is determined based on the second supplementary interval modulus, the lubrication frequency, and the preset lubricating oil quantity. When in the aging stage, the third supplementary interval modulus is matched according to the state stage, and the lubricating oil output is determined according to the third supplementary interval modulus, the lubrication frequency and the preset lubricating oil quantity.

[0011] Optionally, the methods for dividing the stages of an injection molding machine include: Collect the lubricating oil consumption rate and record the operating modulus of the injection molding machine; When the lubricating oil consumption rate changes for the first time, a first limit modulus is determined based on the current operating modulus. The first limit modulus is the boundary between the break-in stage and the normal operation stage of the injection molding machine. When the lubricating oil consumption rate changes for the second time, the current operating modulus determines the second limit modulus, which is the boundary between the normal operation stage and the aging stage of the injection molding machine.

[0012] Optionally, the first limit modulus is 10,000 modulus and the second limit modulus is 1,000,000 modulus.

[0013] Secondly, this application provides an automatic lubrication control system for injection molding machines, employing the following technical solution: An automatic lubrication control system for injection molding machines, employing an automatic lubrication control method for injection molding machines, includes: The data acquisition module is used to acquire the mold opening stroke of the injection molding machine and the internal temperature value of the lubrication mechanism of the injection molding machine. The comparison module is used to compare the total mold opening stroke with the stroke threshold. The judgment module is used to determine the state stage of the injection molding machine based on the total number of operating modules; A memory for storing a program based on an automatic lubrication control method for injection molding machines; The processor can load and execute programs in memory to implement an automatic lubrication control method for injection molding machines.

[0014] In summary, this application includes at least one of the following beneficial technical effects: Using the mold opening stroke as the basis for lubrication of structural components by the lubrication mechanism, and calculating the stroke threshold through the mold opening stroke, improves the accuracy of automatic lubrication control. If the mold requires a small mold opening stroke, the actual lubrication output frequency is low, and the more molds run in one lubrication cycle, the less lubricating oil is used. If the mold requires a large mold opening stroke, the actual lubrication output frequency is high, ensuring the lubrication effect of the machine, ensuring stable machine operation, and extending its service life. The state stage of the injection molding machine is determined by the running module, and the amount of lubricating oil output varies in different state stages. This allows for control of the lubricating oil output, ensuring effective lubrication, stable machine operation, and extended service life. Attached Figure Description

[0015] Figure 1 This is a flowchart of an automatic lubrication control method for injection molding machines according to an embodiment of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0017] This application discloses an automatic lubrication control method for injection molding machines.

[0018] Reference Figure 1 An automatic lubrication control method for injection molding machines includes the following steps: Step S1: Control the injection molding machine to start, collect the mold opening stroke of the injection molding machine, record the number of running dies, and retrieve the historical number of running dies.

[0019] The mold opening stroke is the maximum distance that the moving and stationary mold plates can separate during the mold opening action of an injection molding machine. The mold opening stroke is a parameter set before starting the injection molding machine based on the product specifications. The data acquisition module can obtain the mold opening stroke by collecting data measured by the mold base position gauge.

[0020] The running module refers to the number of production cycles an injection molding machine completes within a certain time period. One cycle is defined as the reciprocating motion between the moving and stationary mold plates from mold closing to mold separation. During operation, the system automatically records the running module. Each time the injection molding machine starts operating, the system begins recording the running module from zero.

[0021] Historical operating data refers to the total number of cycles completed by the injection molding machine from its manufacture to the current operation. This historical operating data is recorded in the injection molding machine's system and can be retrieved directly from the system.

[0022] Step S2: Determine the total number of operating modules based on the operating modules and the historical operating modules.

[0023] Total running modules refer to the total number of modules completed by the injection molding machine from the time it left the factory until this current operation. The total running modules are the sum of the current running modules and the historical running modules.

[0024] Step S3: Calculate the total mold opening stroke based on the mold opening stroke and the total number of runs.

[0025] The total mold opening stroke refers to the total distance the injection molding machine travels relative to the moving and stationary mold plates from the time it leaves the factory until the current operation. The total mold opening stroke is the product of the mold opening stroke and the total number of cycles.

[0026] Step S4: Compare whether the total mold opening stroke is greater than the preset stroke threshold.

[0027] The stroke threshold is a reference value set by the technician for the lubrication mechanism to begin lubricating the structural components of the injection molding machine, based on the total stroke of the relative movement between the moving and stationary platens. The method for determining the stroke threshold will not be elaborated here, but will be described in detail in subsequent embodiments.

[0028] By comparing the relationship between the total mold opening stroke and the stroke threshold, it can be determined whether lubrication of the injection molding machine is required.

[0029] Step S5: When the total mold opening stroke is greater than the stroke threshold, a lubrication command is sent.

[0030] When the total mold opening stroke is not greater than the stroke threshold, the operating temperature of the structural components of the injection molding machine does not rise abnormally and remains in normal operation, requiring no lubrication.

[0031] When the total mold opening stroke exceeds the stroke threshold, the operating temperature of the injection molding machine's structural components rises abnormally due to friction, requiring lubrication. The system will then issue a lubrication command to the lubrication mechanism. This lubrication command is a control signal used to control the lubrication mechanism to perform the lubrication operation.

[0032] Step S6: Match the lubricating oil output based on the total operating modulus.

[0033] Lubricating oil output refers to the amount of lubricating oil added by the lubrication mechanism each time it lubricates a structural component. Lubricating oil output is related to the total number of operating modules, which indirectly represents the usage time of the injection molding machine. Different usage times indicate different states of the injection molding machine, and each state requires a different amount of lubricating oil output. The specific correspondence between the two will not be elaborated here but will be detailed in subsequent embodiments.

[0034] Step S7: Control the lubrication mechanism to output the lubricating oil to the structural components according to the lubrication command.

[0035] When the total mold opening stroke of the injection molding machine reaches the lubrication stroke threshold, the system issues a lubrication command and controls the lubrication mechanism to lubricate the structural components.

[0036] The method for determining the travel threshold includes the following steps: Step S40: Control the injection molding machine to start and collect the internal temperature value of the lubrication mechanism of the injection molding machine.

[0037] Temperature sensors are installed in the lubrication parts of the injection molding machine. Under fully automatic operation, the temperature changes inside the lubrication mechanism are monitored by the data fed back by the temperature sensors, thereby collecting the internal temperature value of the lubrication mechanism.

[0038] Step S41: When the internal temperature of the lubrication mechanism is greater than the preset reference temperature value, record the cumulative modulus of temperature anomaly.

[0039] The reference temperature value is the normal temperature of the lubrication mechanism set by the technicians, which will not be elaborated here.

[0040] By comparing the internal temperature of the lubrication mechanism with the reference temperature, when the internal temperature of the lubrication mechanism exceeds the reference temperature, an abnormal temperature condition may be occurring in the lubrication mechanism. This could be an isolated incident, requiring further investigation using the cumulative modulus of temperature anomaly. The cumulative modulus of temperature anomaly refers to the operating modulus of the injection molding machine during which the abnormal temperature rise in the lubrication mechanism persists.

[0041] Step S42: When the cumulative modulus of the temperature anomaly exceeds the preset cumulative modulus standard, the current operating modulus of the injection molding machine is collected.

[0042] The cumulative modulus standard is a benchmark set by technicians to determine if the lubrication mechanism is indeed experiencing an abnormal temperature rise. If the cumulative modulus of the abnormal temperature does not exceed the standard, it indicates that the injection molding machine is operating normally and has not yet reached the point where lubrication is required. When the cumulative modulus of the abnormal temperature exceeds the standard, the internal temperature of the lubrication mechanism shows an abnormal temperature rise for multiple consecutive cycles, indicating that the optimal time for lubrication has been reached. At this moment, the system automatically reads the current operating modulus of the injection molding machine. The current operating modulus refers to the total number of cycles completed by the injection molding machine from its factory origin to this current operation.

[0043] Step S43: Calculate the stroke threshold based on the current operating modulus and the mold opening stroke.

[0044] The stroke threshold is the product of the current running modulus and the mold opening stroke.

[0045] The formula for calculating the travel threshold is: Y = M * S * 2; Where Y is the stroke threshold, M is the current running modulus, and S is the mold opening stroke.

[0046] For example, if the current operating modulus of the injection molding machine is 2000 and the mold opening stroke is 500 mm, then the stroke threshold Y = 2000 * 500 * 2 = 2000000 mm can be calculated using the formula:

[0047] The method for determining the output of lubricating oil includes the following steps: Step S60: Determine the state stage of the injection molding machine based on the total number of cycles. The state stages of the injection molding machine include the break-in stage, the normal operation stage, and the aging stage.

[0048] In this embodiment, through experimental measurement, the state stages of the injection molding machine are divided into three stages: the break-in stage, the normal operation stage, and the aging stage. During the break-in stage, the machining of parts in a newly assembled injection molding machine cannot be absolutely precise. Errors in machining accuracy exist at the contact surfaces between components during operation, leading to uneven stress and resulting in wear, i.e., break-in wear. Therefore, a larger amount of lubricating oil is needed during the break-in stage to prevent wear between components during operation. After the break-in period, during the normal operation stage, the machine runs more smoothly, and the fit between components is tight. At this time, only periodic lubrication is needed to replenish the lubricating oil to meet the normal operation requirements. As the machine's service life increases, the wear of its structural components intensifies, the clearance between parts increases, and the consumption of lubricating oil also increases accordingly.

[0049] The state stage of the injection molding machine corresponds to the total number of modules the injection molding machine operates in. The system can determine the state stage of the injection molding machine based on the total number of modules operated through the judgment module.

[0050] Step S61: Determine the lubrication frequency based on the stroke threshold and the mold opening stroke.

[0051] Lubrication frequency refers to the number of cycles required for each lubrication cycle of an injection molding machine. The lubrication frequency is the quotient of the stroke threshold and the mold opening stroke.

[0052] Step S62: During the break-in period, match the first supplementary interval modulus according to the state stage, and determine the lubricating oil output based on the first supplementary interval modulus, the lubrication frequency, and the preset lubricating oil quantity.

[0053] The first replenishment interval module refers to the number of operating cycles during which the lubricating oil stored in the lubrication mechanism needs to be replenished each time the injection molding machine is in the break-in stage. After the first replenishment interval module, the lubricating oil stored in the lubrication mechanism will be exhausted.

[0054] The amount of lubricating oil refers to the total amount of lubricating oil stored in the lubrication mechanism. It is determined by the storage structure in the lubrication mechanism and is a fixed parameter, so it will not be elaborated here.

[0055] Based on the quotient of the first supplementary interval modulus and the lubrication frequency, it can be determined how many times the lubricating oil stored in the lubrication mechanism can be used to lubricate the structural components and be consumed. Combined with the amount of lubricating oil, it can be determined how much lubricating oil is output each time the structural components are lubricated.

[0056] Step S63: When in the normal operation phase, match the second supplementary interval modulus according to the state phase, where the second supplementary interval modulus is less than the first supplementary interval modulus.

[0057] The same as step S62, so it will not be repeated here.

[0058] Step S64: Determine the lubricating oil output based on the second supplementary interval modulus, the lubrication frequency, and the preset lubricating oil quantity.

[0059] Same as step S62, so it will not be repeated here. The second replenishment interval module refers to the number of operating cycles during which the lubricating oil stored in the lubrication mechanism needs to be replenished each time the injection molding machine is in normal operation.

[0060] Step S65: When in the aging stage, match the third supplementary interval modulus according to the state stage, and determine the lubricating oil output based on the third supplementary interval modulus, the lubrication frequency, and the preset lubricating oil quantity.

[0061] Same as step S62, so it will not be repeated here. The third replenishment interval refers to the number of operating cycles during which the lubricating oil stored in the lubrication mechanism needs to be replenished each time the injection molding machine is in the aging stage.

[0062] The method for dividing the state stages of an injection molding machine includes the following steps: Step S600: Collect the lubricating oil consumption rate and record the operating modulus of the injection molding machine.

[0063] The lubricating oil consumption rate refers to the rate at which the lubricating oil stored in the lubrication structure is consumed. The lubricating oil consumption rate can be determined by collecting the liquid level change measured by the liquid level sensor in the lubrication mechanism.

[0064] During the operation of the injection molding machine, the lubricating oil consumption rate is collected in real time, and the number of cycles is recorded.

[0065] Step S601: When the lubricating oil consumption rate changes for the first time, a first limit modulus is determined based on the current operating modulus. The first limit modulus is the boundary between the break-in stage and the normal operation stage of the injection molding machine.

[0066] Under normal circumstances, the lubricating oil consumption rate remains constant when the injection molding machine is in the same state. When the injection molding machine transitions from the break-in stage to normal operation, the lubricating oil consumption rate changes; this change is the first significant shift. When the system detects this change in lubricating oil consumption rate, the current operating modulus of the injection molding machine is the first boundary modulus. The first boundary modulus refers to the dividing line between the break-in stage and the normal operation stage of the injection molding machine.

[0067] Step S602: When the lubricating oil consumption rate changes for the second time, the current operating modulus determines the second limit modulus, which is the boundary between the normal operation stage and the aging stage of the injection molding machine.

[0068] When an injection molding machine transitions from the normal operating phase to the aging phase, the rate of lubricant consumption changes; this change is the second significant shift. When the system detects this change in lubricant consumption rate, the current operating modulus of the injection molding machine is the second boundary modulus. The second boundary modulus refers to the dividing line between the normal operating phase and the aging phase of the injection molding machine.

[0069] In this embodiment, the first limit modulus is 10,000 modulus and the second limit modulus is 1,000,000 modulus. That is, when the machine's operating modulus is within 10,000 modulus, the lubricating oil consumption rate is relatively fast. Between 10,000 modulus and 1,000,000 modulus, the machine's lubricating oil consumption rate is normal. After 1,000,000 modulus, the machine's lubricating oil consumption rate is relatively fast.

[0070] Based on the same inventive concept, embodiments of the present invention provide an automatic lubrication control system for injection molding machines.

[0071] An automatic lubrication control system for an injection molding machine includes a data acquisition module, a comparison module, a judgment module, a memory, and a processor. The data acquisition module acquires the mold opening stroke and the internal temperature of the lubrication mechanism of the injection molding machine. The comparison module compares the total mold opening stroke with a stroke threshold. The judgment module determines the current state of the injection molding machine based on the total number of cycles. The memory stores a program for an automatic lubrication control method for the injection molding machine. The program in the memory can be loaded and executed by the processor to implement the automatic lubrication control method for the injection molding machine.

[0072] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An automatic lubrication control method for injection molding machines, characterized in that, include: Control the injection molding machine to start, collect the mold opening stroke of the injection molding machine, record the number of running dies, and retrieve historical running dies; The total number of operating modules is determined based on the operating modules and the historical operating modules; Calculate the total mold opening stroke based on the mold opening stroke and the total number of operating modules; Compare whether the total mold opening stroke is greater than a preset stroke threshold; When the total mold opening stroke exceeds the stroke threshold, a lubrication command is sent. The lubricating oil output is matched based on the total operating modulus. According to the lubrication command, the lubrication mechanism is controlled to output the lubricating oil to the structural components at the specified output amount; The method for determining the output of the lubricating oil includes: The state stage of the injection molding machine is determined based on the total number of operating modules. The state stages of the injection molding machine include the break-in stage, the normal operation stage, and the aging stage. The lubrication frequency is determined based on the stroke threshold and the mold opening stroke. During the break-in period, the first supplementary interval modulus is matched according to the state stage, and the lubricating oil output is determined according to the first supplementary interval modulus, the lubrication frequency, and the preset lubricating oil quantity. During normal operation, a second supplementary interval modulus is matched according to the state stage, wherein the second supplementary interval modulus is less than the first supplementary interval modulus; The lubricating oil output is determined based on the second supplementary interval modulus, the lubrication frequency, and the preset lubricating oil quantity. When in the aging stage, the third supplementary interval modulus is matched according to the state stage, and the lubricating oil output is determined according to the third supplementary interval modulus, the lubrication frequency and the preset lubricating oil quantity.

2. The automatic lubrication control method for injection molding machines according to claim 1, characterized in that, The method for determining the travel threshold includes: Control the start of the injection molding machine and collect the internal temperature value of the lubrication mechanism of the injection molding machine; When the internal temperature of the lubrication mechanism is greater than the preset reference temperature, the cumulative modulus of temperature anomaly is recorded; When the cumulative modulus of the temperature anomaly exceeds the preset cumulative modulus standard, the current operating modulus of the injection molding machine is collected; The stroke threshold is calculated based on the current operating modulus and the mold opening stroke.

3. The automatic lubrication control method for injection molding machines according to claim 1, characterized in that, The formula for calculating the travel threshold is: Y = M * S * 2; Where Y is the stroke threshold, M is the current running modulus, and S is the mold opening stroke.

4. The automatic lubrication control method for injection molding machines according to claim 1, characterized in that, The methods for classifying the stages of an injection molding machine include: Collect the lubricating oil consumption rate and record the operating modulus of the injection molding machine; When the lubricating oil consumption rate changes for the first time, a first limit modulus is determined based on the current operating modulus. The first limit modulus is the boundary between the break-in stage and the normal operation stage of the injection molding machine. When the lubricating oil consumption rate changes for the second time, a second limit modulus is determined based on the current operating modulus. The second limit modulus is the boundary between the normal operation stage and the aging stage of the injection molding machine.

5. The automatic lubrication control method for injection molding machines according to claim 4, characterized in that, The first limit modulus is 10000 modulus, and the second limit modulus is 1000000 modulus.

6. An automatic lubrication control system for an injection molding machine, wherein the automatic lubrication control method for an injection molding machine as described in any one of claims 1 to 5 is used for control, characterized in that, include: The data acquisition module is used to acquire the mold opening stroke of the injection molding machine and the internal temperature value of the lubrication mechanism of the injection molding machine. The comparison module is used to compare the total mold opening stroke with the stroke threshold. The judgment module is used to determine the state stage of the injection molding machine based on the total number of operating modules; A memory for storing a program based on an automatic lubrication control method for injection molding machines; The processor can load and execute programs in memory to implement an automatic lubrication control method for injection molding machines.

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