Profile stepless adjusting method and device for injection mold

Abstract

The invention discloses a molded surface stepless regulation method and device for an injection mold, and relates to the technical field of injection molds, and the method comprises the following steps: obtaining projection point coordinates of a plurality of telescopic blocks correspondingly projected on a product contour; coordinates of a projection point with the lowest horizontal height are set as reference coordinates, and the displacement amount of each telescopic block is calculated; the telescopic distance of each telescopic block is adjusted according to the displacement to form an injection molding matching molded surface; injection molding simulation is conducted according to the injection molding matching type, an injection molding pressure distribution diagram in the mold cavity is obtained, and the hydraulic cavity is divided into a plurality of sub-areas according to the injection molding pressure distribution diagram; and a plurality of telescopic blocks corresponding to each sub-area are obtained, the hydraulic locking pressure of the telescopic blocks is set based on the injection molding pressure of each sub-area, and the injection molding matching molded surface is subjected to partitioned hydraulic locking. The mold with the adjustable injection molding surface is formed by arranging the multiple telescopic blocks, the injection molding requirements of different products can be met, the mold customization cost is reduced, and the flexible design and universality of the mold are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of injection mold, in particular to a type surface stepless adjustment method and device for injection mold. BACKGROUND

[0002] The existing injection mold is a key equipment for industrialized production of plastic products, the upper mold body and the lower mold body cooperate to form an injection mold cavity, and the injection surface formed by the upper mold body and the lower mold body determines the contour and shape of the final product. According to the processing requirements of the product, the existing injection mold sets the upper mold body and the lower mold body with fixed shape contour. For the production requirements of multi-variety, small batch or individual customization, the traditional fixed mold has obvious deficiency in adaptability. The whole mold or core module needs to be redesigned and processed according to the product update design, which leads to high mold production cost and long preparation period, and it is difficult to meet the urgent needs of modern manufacturing for flexibility and rapid response. SUMMARY

[0003] The purpose of the present application is to overcome the shortcomings of the prior art, and the present application provides a type surface stepless adjustment method and device for injection mold. By setting a plurality of telescopic blocks to form a mold with adjustable injection surface, the displacement of the telescopic blocks is adjusted according to the geometric contour of the product, so as to achieve automatic adjustment of the injection surface, adapt to the injection requirements of different products, reduce the cost of mold customization, improve the adaptability of the mold to different products, realize the flexible design and universality of the mold.

[0004] The present application provides a type surface stepless adjustment method for injection mold, the adjustment method comprising: Obtaining the geometric model data of the product, extracting the product contour data according to the geometric model data, and obtaining the projection point coordinates corresponding to the projection of the adjustable surface array composed of a plurality of telescopic blocks on the product contour according to the product contour data; Setting the projection point coordinate with the lowest horizontal height as the reference coordinate, calculating the height difference data of the projection point coordinate corresponding to each telescopic block according to the reference coordinate, and determining the displacement of each telescopic block according to the height difference data; Adjusting the telescopic distance of each telescopic block according to the displacement, and forming an injection matching surface in cooperation with a flexible cover layer arranged above the adjustable surface array; According to the injection matching type, an injection simulation is carried out, an injection pressure distribution diagram inside the mold cavity is obtained, and the hydraulic chamber is divided into a plurality of sub-regions according to the injection pressure distribution diagram; Obtaining a plurality of telescopic blocks corresponding to each sub-region, and setting the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-region, and partitioning and hydraulic locking the injection matching surface formed by a plurality of telescopic blocks based on the hydraulic locking pressure.

[0005] Further, the geometric model data of the product is acquired, the product contour data is extracted according to the geometric model data, and the projection point coordinates of the adjustable profile array composed of a plurality of telescopic blocks corresponding to the product contour are acquired according to the product contour data. The geometric model data of the product is imported into the system, the product contour data is extracted according to the geometric model data, and the injection molding processing profile model is generated based on the product contour data; The adjustable profile array of the rectangular structure formed by the coordinates of the telescopic blocks is generated in the space coordinate system with the geometric center coordinates of the telescopic blocks as the center; The injection molding processing profile model and the adjustable profile array are arranged along the vertical axial direction, the projection relationship between the injection molding processing profile model and the adjustable profile array is constructed, and the projection point coordinates of the plurality of telescopic blocks corresponding to the product contour are acquired.

[0006] Further, the injection molding processing profile model and the adjustable profile array are arranged along the vertical axial direction, the projection relationship between the injection molding processing profile model and the adjustable profile array is constructed, and the projection point coordinates of the plurality of telescopic blocks corresponding to the product contour are acquired. The adjustable profile array is subjected to corresponding parameterization processing, so that the physical arrangement of the adjustable profile array is mapped to the same parameter domain as the injection molding processing profile model; The center position of each telescopic block is assigned a corresponding parameter coordinate, and the array arrangement mode is kept consistent with the direction of the parameter domain coordinate system; The forward mapping network of the adjustable profile array to the injection molding processing profile model is constructed through the shared parameter domain, or the reverse mapping network of the injection molding processing profile model to the adjustable profile array is constructed through the shared parameter domain.

[0007] Further, the projection point coordinate with the lowest horizontal height is set as the reference coordinate, the height difference data of the projection point coordinate corresponding to each telescopic block is calculated according to the reference coordinate, and the displacement amount of each telescopic block is determined according to the height difference data. The center points of the top of all telescopic blocks are vertically projected onto the injection molding processing profile model, all the projection points of the injection molding processing profile model are traversed, and the projection point with the smallest Z coordinate value is identified as the reference coordinate point; The projection point coordinate corresponding to each telescopic block is compared with the reference coordinate point, the coordinate difference value of the projection point coordinate corresponding to each telescopic block and the reference coordinate point in the vertical direction is calculated, the height difference data is acquired, and the height difference data is set as the displacement amount of the telescopic block.

[0008] Further, the adjusting the telescopic distance of each telescopic block according to the displacement amount, cooperating with the flexible cover layer arranged above the adjustable profile array to form an injection molding profile includes: Setting a linear stepper motor for driving the telescopic block to act at each telescopic block of the adjustable profile array; Setting a digital signal for driving the linear stepper motor according to the numerical value of the displacement amount, controlling the rotation of each linear stepper motor through the digital signal, and feeding back the current position of the telescopic block in real time through the encoder on the motor to form a closed-loop control.

[0009] Further, the injection molding simulation according to the injection molding profile to obtain the injection pressure distribution diagram inside the mold cavity includes: Generating a grid model inside the injection mold cavity according to the three-dimensional profile data of the product, combining the injection molding process parameters with the obtained characteristics of the molten plastic material to simulate the filling process of the molten plastic in the mold cavity; Real-time calculation and recording of the transient pressure value of each grid point on the mold cavity wall at different time steps during the simulation process to generate an injection pressure distribution diagram of the mold cavity wall varying with time.

[0010] Further, the injection molding simulation according to the injection molding profile to obtain the injection pressure distribution diagram inside the mold cavity, and dividing the hydraulic chamber into several sub-regions according to the injection pressure distribution diagram further includes: Performing asymmetric analysis on the injection pressure distribution diagram to obtain the pressure concentration area, the pressure gradient change area, and the asymmetric characteristics of the overall pressure distribution of the injection pressure distribution diagram; Using a clustering algorithm based on pressure threshold to divide the injection pressure distribution diagram into several sub-regions according to the pressure gradient difference, calculating the average melt impact pressure of each sub-region, and calculating the hydraulic locking pressure of each sub-region according to the average melt impact pressure of each sub-region.

[0011] Further, the obtaining of several telescopic blocks corresponding to each sub-region and the setting of the hydraulic locking pressure of the telescopic block based on the injection pressure of each sub-region, and the partitioning of the injection molding profile formed by the combination of several telescopic blocks includes: Dividing the output end of the hydraulic system into several output partitions according to the distribution of the several sub-regions by setting high-precision proportional valves, and the several output partitions and the several sub-regions are in one-to-one corresponding connection relationship; The actual hydraulic locking pressure change data is monitored in real time by a pressure sensor of each hydraulic sub-area, and the control system adjusts the proportional valve of the corresponding area according to the hydraulic locking pressure change data, so that the dynamic compensation of the hydraulic locking power of each sub-area is realized.

[0012] Further, the obtaining of the plurality of telescopic blocks corresponding to each sub-area and the setting of the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-area further comprises: The current waveform and motion vibration signal of each telescopic block driving motor are collected in real time by a high-precision current meter and a vibration sensor. The current waveform and motion vibration signal are analyzed in real time in terms of frequency spectrum and characteristics, and the wear and degradation degree of the driving mechanism of each telescopic block is evaluated. According to the wear and degradation degree, the torque, acceleration and deceleration curve and braking strategy of the corresponding telescopic block are dynamically adjusted to compensate for performance degradation and maintain positioning accuracy.

[0013] The application also provides a surface stepless adjusting device for an injection mold, the adjusting device comprising: A coordinate construction module is used to obtain the geometric model data of a product, extract product contour data according to the geometric model data, and obtain the projection point coordinates of the adjustable surface array composed of a plurality of telescopic blocks corresponding to the product contour. A displacement amount calculation module is used to set the projection point coordinate with the lowest horizontal height as a reference coordinate, calculate the height difference data of the projection point coordinates corresponding to each telescopic block according to the reference coordinate, and determine the displacement amount of each telescopic block according to the height difference data. A mold adjusting module is used to adjust the telescopic distance of each telescopic block according to the displacement amount, and form an injection fitting surface with a flexible cover layer arranged above the adjustable surface array. An injection pressure analysis module is used to perform injection simulation according to the injection fitting surface, obtain an injection pressure distribution diagram inside a mold cavity, and divide the hydraulic chamber into a plurality of sub-areas according to the injection pressure distribution diagram. A hydraulic locking module is used to obtain a plurality of telescopic blocks corresponding to each sub-area, set the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-area, and perform sub-area hydraulic locking on the injection fitting surface formed by the plurality of telescopic blocks.

[0014] This invention provides a method and apparatus for stepless adjustment of the injection mold profile. By setting multiple telescopic blocks to form an adjustable injection mold profile, the displacement of the telescopic blocks is adjusted according to the geometric contour of the product to achieve automated adjustment of the injection mold profile. This method can adapt to the injection molding requirements of different products, reduce the cost of mold customization, and improve the mold's adaptability to different products, thus realizing flexible mold design and versatility. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a flowchart of the stepless adjustment method for the surface of an injection mold in an embodiment of the present invention; Figure 2 This is a schematic diagram of the injection molding surface model processing process in an embodiment of the present invention; Figure 3 This is a schematic diagram of a device for a stepless adjustment method for the surface of an injection mold in an embodiment of the present invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1: Figure 1 A flowchart of a stepless adjustment method for the surface of an injection mold is shown in an embodiment of the present invention; this application proposes a stepless adjustment method for the surface of an injection mold, the adjustment method comprising: S11: Obtain the geometric model data of the product, extract the product contour data based on the geometric model data, and obtain the coordinates of the projection points of the adjustable surface array composed of multiple telescopic blocks projected onto the product contour based on the product contour data.

[0019] The geometric model data describing the three-dimensional shape and size of the product obtained by CAD software or other three-dimensional scanning technology, according to the two-dimensional or three-dimensional boundary information of the geometric model data in a certain projection direction, the product contour data is obtained, in this embodiment, the product contour data is set as the three-dimensional boundary information of the injection molding processing surface of the product, so that the injection mold can adjust the arrangement of the plurality of telescopic blocks according to the shape of the injection molding processing surface.

[0020] Specifically, the injection mold comprises a plurality of telescopic blocks and a flexible cover layer, the plurality of telescopic blocks are basic units constituting an adjustable surface array, the telescopic distance of each telescopic block can be independently adjusted; the plurality of telescopic blocks are regularly arranged to form the adjustable surface array, and a complex curved surface can be formed through the cooperative movement of the telescopic blocks; the flexible cover layer is arranged above the adjustable surface array, and is used for forming an elastic material layer of a smooth and continuous injection molding matching surface, and cooperates with the adjustable surface array to form a mold surface directly contacting with molten plastic, so as to meet the injection mold surface structure of different product surface shapes.

[0021] Further, the material of the flexible cover layer can be high-temperature elastomers, which is an elastic material used in high-temperature environment and can withstand a temperature as high as 500 degrees Celsius. The high-temperature elastomers are made of a mixture of siloxane and fluorocarbon compounds, which can have good high-temperature stability and mechanical properties at the same time, and can meet the processing requirements of the injection molding process of the injection mold.

[0022] Specifically, Figure 2 A process diagram of the injection surface model processing in the embodiment of the application is shown, and the step S11 comprises: The geometric model data of the product is imported into the system, the product contour data is extracted according to the geometric model data, and the injection molding processing surface model is generated based on the product contour data; the complete three-dimensional geometric information of the product is obtained according to the image model file in the design data of the product, and after the geometric model data is obtained, the product contour data needs to be extracted according to these data.

[0023] The geometric center coordinates of the telescopic blocks are generated in the space coordinate system to form a rectangular structure of the adjustable surface array of the telescopic block coordinates; The injection molding processing surface model and the adjustable surface array are arranged along the vertical axial direction, the projection relationship between the injection molding processing surface model and the adjustable surface array is constructed, and the projection point coordinates of the plurality of telescopic blocks corresponding to the product contour are obtained.

[0024] The imported product geometry model data refers to loading the three-dimensional design data of the product to be injection molded, such as CAD model files (e.g. STEP, IGES format) or point cloud data obtained through three-dimensional scanning, into a computer aided design / manufacturing (CAD / CAM) system. The geometry model data contains complete geometric information of the product, including its shape, size, topological structure, etc. Based on the geometry model data, product contour data is extracted, which usually involves boundary detection, feature line extraction or cross-section analysis of the three-dimensional model to obtain two-dimensional or three-dimensional contour information of the product in a specific view or plane. Subsequently, based on the product contour data, an accurate injection processing surface model can be generated, which represents the final product surface shape to be formed in the mold cavity.

[0025] Further, a plurality of adjustable surface arrays of rectangular structures formed by the geometric center coordinates of the expansion blocks in the spatial coordinate system are generated. The expansion block array is arranged according to a predetermined rule (e.g. rectangular grid) by a plurality of independent and scalable units (i.e. expansion blocks), each expansion block having a definite geometric center coordinate. The overall structure of the adjustable surface array is defined in a three-dimensional spatial coordinate system, which aims to simulate or form any complex surface by adjusting the expansion distance of each expansion block.

[0026] On this basis, the injection processing surface model and the adjustable surface array are arranged along the vertical axial direction. This means that the product surface model and the expansion block array are aligned in space so that they have a definite relative positional relationship in the vertical direction. By constructing the projection relationship between the injection processing surface model and the adjustable surface array, the center point of each expansion block can be determined to correspond to the specific position projected on the product contour in the vertical direction. Thus, the projection point coordinates of a plurality of expansion blocks corresponding to the product contour are obtained, which will serve as the basis data for subsequent calculation of the displacement amount of the expansion block.

[0027] Specifically, the injection processing surface model and the adjustable surface array are arranged along the vertical axial direction, the projection relationship between the injection processing surface model and the adjustable surface array is constructed, and the projection point coordinates of a plurality of expansion blocks corresponding to the product contour are obtained, which includes: Performing corresponding parameterization processing on the adjustable surface array so that the physical arrangement of the adjustable surface array is mapped to the same parameter domain as the injection processing surface model; Assigning corresponding parameter coordinates to the center position of each expansion block, and keeping the array arrangement mode consistent with the direction of the parameter domain coordinate system; By sharing the parameter domain, a forward mapping network of the adjustable profile array to the injection molding profile model can be constructed, or by sharing the parameter domain, a reverse mapping network of the injection molding profile model to the adjustable profile array can be constructed.

[0028] Wherein, the parameterization of the adjustable profile array refers to the conversion of the discrete physical arrangement of the adjustable profile array into a continuous and operable parameter space through mathematical methods or computational geometry techniques. This parameterization aims to establish a unified mathematical framework, so that the physical position and geometric properties of each stretch block of the adjustable profile array can be accurately corresponded and operated with the corresponding region of the injection molding profile model in the same parameter domain. For example, the adjustable profile array can be parameterized as a two-dimensional grid, where each grid point corresponds to a stretch block, and its coordinate value is the parameter coordinate in the parameter domain.

[0029] Further, the center position of each stretch block is assigned a corresponding parameter coordinate, aiming to ensure the consistency between the physical arrangement of the adjustable profile array and the direction of the parameter domain coordinate system. This means that if the stretch blocks are arranged in a rectangular array in the physical space, their corresponding parameter coordinates in the parameter domain should also be organized in a similar grid or matrix form, thereby simplifying the subsequent mapping and calculation process. For example, for an M-row N-column stretch block array, the center position of each stretch block can be assigned a parameter coordinate in the form of (i, j), where i represents the row index and j represents the column index.

[0030] On this basis, by sharing the parameter domain, a forward mapping network of the adjustable profile array to the injection molding profile model can be constructed, or a reverse mapping network of the injection molding profile model to the adjustable profile array can be constructed. The forward mapping network refers to calculating the corresponding projection point coordinates of the stretch blocks in the adjustable profile array on the injection molding profile model according to their parameter coordinates. The reverse mapping network refers to determining the corresponding stretch block or its influence area in the adjustable profile array according to the parameter coordinates of a specific point (such as a product contour point) on the injection molding profile model. These mapping networks can be realized through interpolation algorithms, neural networks or other geometric mapping techniques, and their purpose is to establish an accurate and reversible geometric correspondence between the two.

[0031] The scheme of the present application maps the physical arrangement to the same parameter domain as the injection molding profile model by parameterizing the adjustable profile array and assigning parameter coordinates to the center position of each telescopic block. Thus, in the unified parameter domain, the forward or reverse mapping network between the adjustable profile array and the injection molding profile model can be constructed. This mapping mechanism based on the parameter domain can ensure high-precision and high-efficiency geometric correspondence when constructing the projection relationship between the injection molding profile model and the adjustable profile array, avoiding errors and computational burden that may be caused by direct projection calculation in complex three-dimensional space.

[0032] Through the above technical scheme, more accurate and flexible geometric correspondence between the adjustable profile array and the injection molding profile model can be achieved. Parameterization processing and parameter coordinate assignment provide a unified and standardized data basis for subsequent projection relationship construction, greatly simplifying the mapping calculation between complex three-dimensional geometric bodies. In addition, the construction of the forward or reverse mapping network enables the system to flexibly obtain the projection point coordinates from either side according to actual needs, improving the efficiency and accuracy of data processing and laying a solid foundation for subsequent accurate calculation of telescopic block displacement.

[0033] S12: Set the projection point coordinate with the lowest horizontal height as the reference coordinate, calculate the height difference data of the projection point coordinate corresponding to each telescopic block according to the reference coordinate, and determine the displacement amount of each telescopic block according to the height difference data.

[0034] Specifically, the step S12 comprises: Vertically project the center points of the top of all telescopic blocks to the injection molding profile model, traverse all the projection points of the injection molding profile model, and identify the projection point with the smallest Z coordinate value as the reference coordinate point; Compare the projection point coordinate corresponding to each telescopic block with the reference coordinate point, calculate the coordinate difference value of the projection point coordinate corresponding to each telescopic block and the reference coordinate point in the vertical direction, obtain the height difference data, and set the height difference data as the displacement amount of the telescopic block.

[0035] After obtaining the projection point coordinates, the projection point coordinate with the lowest horizontal height needs to be set as the reference coordinate. For example, among all the obtained projection point coordinates, the point with the smallest Z value in the vertical direction (usually the Z axis) is selected as the reference point. This reference point will serve as the reference zero point for the subsequent displacement calculation of all the stretch blocks. Then, the height difference data of each projection point coordinate corresponding to each stretch block is calculated based on the reference coordinate. For example, for the projection point of each stretch block, the difference between its Z coordinate and the Z value of the reference coordinate is calculated. This difference is the relative height of the stretch block relative to the reference point. Subsequently, the displacement of each stretch block is determined based on the height difference data. For example, the calculated height difference data can be directly used as the displacement of each stretch block.

[0036] Further, by setting the point with the smallest Z value as the reference point, the reference coordinate of the reference point is the initial position coordinate of the plurality of stretch blocks, thereby unifying the stretching direction of the plurality of stretch blocks to simplify the calculation of the stretching displacement of the plurality of stretch blocks.

[0037] The center point of the top of each stretch block is projected vertically onto the injection molding processing surface model to ensure that the displacement calculation reference point of each stretch block accurately matches its actual corresponding position on the product surface, thereby ensuring the accuracy of the subsequent displacement determination. The injection molding processing surface model can be understood as a surface model obtained by processing the product geometric model data for injection molding.

[0038] Further, by traversing all the projection points of the injection molding processing surface model, the projection point with the smallest Z coordinate value is identified as the reference coordinate point. This can be understood as accurately finding the lowest point on the product surface as a unified reference by systematically scanning all the projection points. The purpose is to establish a global and physically meaningful zero reference, so that the displacement calculation of all stretch blocks can be relative to this lowest point, thereby achieving accurate replication of the product surface profile.

[0039] In practical applications, the projection point coordinates corresponding to each stretch block are compared with the reference coordinate point to calculate the coordinate difference in the vertical direction between the projection point coordinates corresponding to each stretch block and the reference coordinate point, and the height difference data is obtained. For example, the Z-axis difference calculation method in the three-dimensional coordinate system can be used, and the purpose is to quantify the relative height difference of each stretch block relative to the reference point.

[0040] As a preferred embodiment, the height difference data is set as the displacement of the stretch block, which aims to directly convert the calculated geometric height difference into the actual stretching distance of the stretch block, simplifying the determination process of the displacement and ensuring that the stretching of the stretch block accurately reflects the geometric characteristics of the product surface.

[0041] The scheme of the present application ensures that the displacement calculation of each telescopic block is based on its actual corresponding position on the product surface by first accurately vertically projecting the center points of the top of all telescopic blocks onto the injection molding processing surface model. It is precisely due to this accurate projection that the subsequent displacement calculation has a solid geometric basis. Secondly, by traversing all the projection points and identifying the projection point with the smallest Z coordinate value as the reference coordinate point, a unified and physically meaningful reference system is established, avoiding errors caused by improper selection of local reference points. On this basis, by calculating the coordinate difference between the projection point coordinates of each telescopic block and the reference coordinate point in the vertical direction, the relative height of each telescopic block relative to the lowest point of the product surface can be accurately quantified. Finally, setting these height difference data directly as the displacement of the telescopic block makes the telescopic distance of each telescopic block accurately reproduce the geometric profile of the product surface, thereby providing an accurate geometric basis for the subsequent injection molding matching surface formation.

[0042] Through the above technical scheme, the displacement of each telescopic block can be determined in a systematic and high-precision manner. Specifically, by accurately projecting the center points of the telescopic blocks onto the injection molding processing surface model and taking the projection point with the smallest Z coordinate value as the reference, the accuracy and consistency of the displacement calculation are ensured. This method avoids surface deviation caused by improper selection of reference points, enabling the adjustable surface array to more accurately reproduce the complex geometric profile of the product, thereby significantly improving the precision and reliability of injection mold surface adjustment and laying a solid foundation for the production of high-quality injection molded parts.

[0043] S13: Adjust the telescopic distance of each telescopic block according to the displacement, and form an injection molding matching surface with the flexible cover layer arranged above the adjustable surface array.

[0044] Specifically, the step S13 includes: A linear stepper motor is arranged in each telescopic block of the adjustable surface array for driving the telescopic block to act. After determining the displacement of each telescopic block, the telescopic distance of each telescopic block needs to be adjusted according to the displacement. For example, a micro-step motor or a servo motor integrated in each telescopic block can be used to drive the telescopic block to perform accurate linear motion. The control system sends instructions to each motor according to the preset displacement, so that it extends or retracts to the target position. At the same time, an injection molding matching surface is formed with the flexible cover layer arranged above the adjustable surface array. For example, a layer of high-elasticity, high-temperature-resistant, and corrosion-resistant silicone or fluororubber material can be laid on the telescopic block array. When the telescopic blocks are adjusted to the position, the flexible cover layer will form a continuous curved surface matching the product profile under the support of the telescopic blocks, serving as an injection molding matching surface directly contacting with the molten plastic.

[0045] According to the numerical value of the displacement amount, a digital signal for driving the linear stepper motor is set, the rotation of each linear stepper motor is controlled through the digital signal, and the current position of the telescopic block is fed back in real time through the encoder on the motor, forming a closed-loop control. After the injection molding surface is formed, the injection molding simulation needs to be carried out according to the injection molding surface to obtain the injection pressure distribution diagram inside the mold cavity. For example, professional injection molding simulation software (such as Moldflow) can be used to input the three-dimensional model of the injection molding surface formed, the selected plastic material parameters and the injection molding process parameters (such as injection speed, melt temperature, mold temperature, etc.), simulate the filling, pressure maintaining and cooling process of the molten plastic in the mold cavity. The simulation result will output the pressure distribution of the mold cavity wall surface during the entire injection molding cycle, forming an injection pressure distribution diagram. Subsequently, the hydraulic chamber is divided into several sub-regions according to the injection pressure distribution diagram. For example, the injection pressure distribution diagram can be analyzed to identify the pressure concentration area, the area with sharp pressure gradient change, and the overall pressure distribution asymmetry feature. Based on these features, the hydraulic chamber is physically or logically divided into multiple independent sub-regions, each corresponding to a specific range on the mold surface.

[0046] Specifically, the linear stepper motor is an actuator that can convert electrical pulse signals into precise linear displacement. Its purpose is to provide each telescopic block with precise and controllable telescopic driving force to achieve fine adjustment of the surface shape. Among them, the digital signal can be understood as a series of discrete electrical pulses used to accurately instruct the number of steps and direction of rotation of the linear stepper motor. Its purpose is to ensure that the displacement amount of each telescopic block can be accurately converted into motor action instructions, thereby achieving the expected telescopic distance. In practical applications, the encoder is a position sensor installed on the linear stepper motor or telescopic block, used to monitor the actual position of the telescopic block in real time. For example, optical or magnetic encoders can be used, which are designed to provide accurate position feedback and ensure consistency between the actual position of the telescopic block and the target position. Closed-loop control refers to comparing the current position of the telescopic block fed back in real time by the encoder with the pre-set target displacement amount, and adjusting the driving signal of the linear stepper motor according to the deviation until the telescopic block reaches the target position. Its purpose is to eliminate system errors and improve the accuracy and stability of the telescopic block positioning, thereby ensuring the accurate formation of the injection molding surface.

[0047] The technical scheme of the present application is configured with a linear stepper motor on each telescopic block, so that the telescopic action of each telescopic block can be independently and accurately controlled. When receiving a digital signal set according to the displacement value, the linear stepper motor is driven to rotate, thereby driving the telescopic block to perform linear displacement. At the same time, the current position of the telescopic block is monitored in real time by the encoder, and the position information is fed back to the control system. The control system compares the real-time position with the target displacement, and once a deviation is found, the digital signal sent to the linear stepper motor will be immediately adjusted, forming a dynamic closed-loop control circuit. It is precisely due to this accurate driving, real-time position feedback and dynamic closed-loop adjustment mechanism that each telescopic block can accurately reach its preset telescopic distance, thereby ensuring that the injection molding matching profile formed by the adjustable profile array and the flexible cover layer can accurately reproduce the contour of the product.

[0048] Through the above technical scheme, the telescopic distance of each telescopic block can be accurately adjusted and controlled. The application of the linear stepper motor provides fine displacement capability, and the accurate control of the digital signal ensures the accuracy of the instruction. More importantly, by real-time feedback of the current position of the telescopic block by the encoder and forming a closed-loop control, the cumulative error and external interference that may exist in the traditional open-loop control are effectively eliminated, and the positioning accuracy and repeatability of the telescopic block are significantly improved. Therefore, the injection molding matching profile can be matched with the product contour with extremely high precision, thereby laying a solid foundation for subsequent injection molding simulation and partitioning of hydraulic locking, and finally improving the molding quality and precision of the injection molded product.

[0049] S14: performing injection molding simulation according to the injection molding matching profile to obtain an injection pressure distribution diagram of the inside of the mold cavity, and dividing the hydraulic chamber into a plurality of sub-regions according to the injection pressure distribution diagram.

[0050] Specifically, the step S14 comprises: generating an internal grid model of the injection mold cavity according to the three-dimensional contour data of the product, simulating the filling process of the molten plastic in the mold cavity according to the obtained characteristics of the molten plastic material in combination with the injection molding process parameters; calculating and recording the transient pressure value of each grid point on the wall surface of the injection mold cavity at different time steps in the simulation process in real time to generate an injection pressure distribution diagram of the mold cavity wall surface varying with time.

[0051] generating an internal grid model of the injection mold cavity according to the three-dimensional contour data of the product, simulating the filling process of the molten plastic in the mold cavity according to the obtained characteristics of the molten plastic material in combination with the injection molding process parameters; calculating and recording the transient pressure value of each grid point on the wall surface of the injection mold cavity at different time steps in the simulation process in real time to generate an injection pressure distribution diagram of the mold cavity wall surface varying with time.

[0052] Specifically, the product three-dimensional contour data refers to the digital geometric information of the product to be injection molded, which is usually created by computer-aided design (CAD) software or obtained by three-dimensional scanning, and is the basis for defining the shape of the mold cavity. The internal grid model of the injection mold cavity refers to the discretization of the mold cavity space defined by the product three-dimensional contour data into a series of interconnected grid cells, in order to facilitate numerical simulation calculations such as finite element analysis or finite volume method. The properties of the molten plastic material include but are not limited to the viscosity, density, specific heat capacity, thermal conductivity and other physical parameters of the melt, which are crucial for accurately simulating the flow behavior of the plastic in the mold cavity. The injection molding process parameters refer to the operating conditions set during the injection molding process, such as melt temperature, mold temperature, injection speed, holding pressure, cooling time, etc. The filling process of the molten plastic in the mold cavity is usually simulated by professional injection molding simulation software (such as Moldflow, Moldex3D, etc.), which aims to predict the flow front, pressure distribution, temperature distribution and possible defects of the molten plastic in the mold cavity. Real-time calculation and recording of the transient pressure values of each grid point on the mold cavity wall at different time steps during the simulation process refers to continuous monitoring and recording of the pressure changes at each point on the mold cavity wall throughout the injection filling and holding stages, in order to capture the dynamic characteristics of the pressure. Thus, an injection pressure distribution map of the mold cavity wall over time can be generated, which intuitively shows the pressure field inside the mold cavity at different times, providing a data basis for subsequent hydraulic chamber division and locking pressure setting.

[0053] The scheme of the present application can accurately predict the pressure distribution inside the mold cavity during the injection molding process through the above detailed simulation steps. Specifically, first, a high-precision internal grid model of the injection mold cavity is generated based on the product three-dimensional contour data, ensuring the accuracy of the simulation geometry. Second, by combining the actual properties of the molten plastic material and the injection molding process parameters, the simulation process can highly restore the real injection molding environment. Thus, the filling process of the molten plastic in the mold cavity can dynamically capture the complex behavior of melt flow and pressure transmission. Further, real-time calculation and recording of the transient pressure values of each grid point on the mold cavity wall at different time steps ensure that the obtained injection pressure distribution map is not only static, but also reflects the dynamic process of pressure changes throughout the injection cycle. This dynamic and detailed pressure data is the key to achieving subsequent reasonable division of the hydraulic chamber and accurate hydraulic locking.

[0054] By the technical solution, the highly accurate and dynamically changing injection pressure distribution map inside the mold cavity can be obtained. Compared with pressure evaluation by experience or simplified model, the solution significantly improves the accuracy and reliability of pressure prediction by simulating the fine grid model, real material parameters and process conditions. Thus, a solid data foundation is provided for subsequent division of the hydraulic chamber into several sub-regions, ensuring the scientificity and effectiveness of the partitioned hydraulic locking, thereby avoiding product defects caused by uneven pressure distribution and prolonging the service life of the mold.

[0055] The step S14 further comprises: performing asymmetric analysis on the injection pressure distribution map to obtain a pressure concentration area, a region with sharp pressure gradient change and asymmetric characteristics of overall pressure distribution of the injection pressure distribution map; adopting a clustering algorithm based on a pressure threshold to divide the injection pressure distribution map into several sub-regions according to pressure gradient difference, calculate the average melt impact pressure of each sub-region, and calculate the hydraulic locking pressure of each sub-region according to the average melt impact pressure of each sub-region.

[0056] Specifically, the asymmetric analysis on the injection pressure distribution map means that the uneven distribution pattern of the injection pressure on the mold cavity wall surface is identified and quantified by advanced data analysis techniques such as statistical moment analysis, Fourier transform or wavelet analysis. Among them, the pressure concentration area refers to the local range where the melt impact pressure in the mold cavity is significantly higher than the surrounding area, which usually corresponds to the complex features of the product geometry or the convergence point of the melt flow; the region with sharp pressure gradient change refers to the region where the pressure value changes significantly in a short distance, which usually occurs at the turning, branching or contraction of the melt flow; the asymmetric characteristics of overall pressure distribution reflect the macro imbalance of the pressure distribution in the entire mold cavity.

[0057] Further, the clustering algorithm based on the pressure threshold means that each grid point or small region on the injection pressure distribution map is grouped according to the preset pressure threshold or pressure gradient threshold. This algorithm can automatically identify and divide regions with similar pressure characteristics or pressure change trends, thereby forming several sub-regions. For example, multiple pressure level thresholds can be set to classify points with pressure values within a certain range into a class, or clustering can be performed according to the absolute value of the pressure gradient. After each sub-region is divided, the average value of the transient pressure values of all grid points in the sub-region is calculated to obtain the average melt impact pressure. Based on the average melt impact pressure, combined with material properties and mold structure parameters, the hydraulic locking pressure required by each sub-region can be accurately calculated to ensure that the surface of the region can withstand melt impact without deformation during the injection molding process.

[0058] The scheme of the present application effectively solves the limitations of traditional methods in dealing with complex injection pressure distribution by introducing asymmetric analysis and clustering algorithm based on pressure threshold. Specifically, asymmetric analysis enables the system to deeply understand the real distribution of pressure in the mold cavity, identify those pressure concentration points and areas of sharp pressure change that are crucial to injection quality and mold stability. It is precisely due to the accurate capture of these key features that the subsequent hydraulic chamber division can be more fine and reasonable. On this basis, the clustering algorithm based on pressure threshold can divide the mold cavity wall into multiple sub-regions with clear pressure characteristics according to the actual pressure difference, rather than simply geometric division. This fine zoning ensures that the pressure characteristics in each sub-region are relatively consistent, thereby providing a reliable basis for independently calculating the average melt impact pressure of each sub-region. Finally, the average melt impact pressure of each sub-region is used to determine its hydraulic locking pressure, so that the hydraulic locking force can accurately act on each local of the mold surface, realizing dynamic and adaptive locking, thereby effectively offsetting the melt impact force and avoiding surface deformation.

[0059] Through the above technical scheme, the present application can significantly improve the precision and stability of injection mold surface adjustment. Since the injection pressure distribution is deeply analyzed and finely clustered, the hydraulic locking force can be locally optimized and accurately applied according to the actual pressure distribution in the mold cavity. This not only effectively prevents surface deformation or product defects such as flash, size instability, etc. caused by uneven pressure during injection molding, but also prolongs the service life of the mold and reduces production costs. In addition, this fine zoning hydraulic locking strategy enables the mold to better adapt to the injection needs of complex product structures, improving the flexibility and adaptability of the injection molding process.

[0060] In some preferred embodiments, the following is described by a specific example. Suppose a product with complex geometry needs to be injection molded, such as an electronic product shell with multiple thin-walled and thick-walled regions. During injection simulation, it is found that the pressure of the molten plastic rises rapidly when filling the thin-walled region, while it is relatively stable in the thick-walled region, and there are obvious pressure concentration and sharp pressure gradient changes at some corners or flow channel junctions.

[0061] Firstly, the system will perform asymmetric analysis on the obtained injection pressure distribution graph. Through analysis, it can identify the pressure concentration areas at the ends of thin-walled regions and corners, as well as the areas of sharp pressure gradient changes at flow channel bifurcations. At the same time, the overall pressure distribution may exhibit asymmetricity gradually decaying from the gate to the distal end.

[0062] Next, a clustering algorithm based on pressure thresholds is applied. For example, a high pressure threshold (e.g., above 80 MPa) can be set to identify high pressure areas, a medium pressure threshold (e.g., 50-80 MPa) to identify medium pressure areas, and a low pressure threshold (e.g., below 50 MPa) to identify low pressure areas. Additionally, further subdivision can be made based on the absolute value of the pressure gradient (e.g., areas with a pressure change of more than 10 MPa per mm).

[0063] For each divided sub-area, the system calculates its average melt impact pressure. For example, the average melt impact pressure of high pressure sub-area 1 can reach 90 MPa, while the average melt impact pressure of low pressure sub-area 1 may only be 40 MPa. Based on these average melt impact pressures, the system calculates and sets the corresponding hydraulic locking pressure for each sub-area. For example, high pressure sub-area 1 may require a hydraulic locking pressure of 100 MPa to counteract the melt impact, while low pressure sub-area 1 may only require a hydraulic locking pressure of 50 MPa. Through this refined zoning and pressure calculation, each local area is ensured to receive the right amount of hydraulic locking support, effectively avoiding product defects and protecting the mold.

[0064] S15: Obtain a number of telescopic blocks corresponding to each sub-area, and set the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-area, and partition the injection fit surface formed by the combination of a number of telescopic blocks based on the hydraulic locking pressure.

[0065] After the sub-areas are divided, the telescopic blocks contained in each sub-area are determined, and the hydraulic locking pressure required by the telescopic blocks in the sub-area is calculated and set according to the average or maximum injection pressure of the sub-area in the injection simulation. This locking pressure needs to be sufficient to resist the impact and extrusion of the molten plastic on the surface during the injection process. Based on the hydraulic locking pressure, the injection fit surface formed by the combination of a number of telescopic blocks is partitioned and hydraulically locked. For example, independent hydraulic control circuits or high-precision proportional valves can be used to provide independent hydraulic locking force for each sub-area. In this way, the telescopic blocks in different areas can be subjected to different hydraulic locking forces according to the size of the injection pressure they bear, thereby achieving partitioning, dynamic, and accurate locking of the entire injection fit surface.

[0066] The profile stepless adjustment method for injection mold of the present application realizes high flexibility and accurate control of the profile of the injection mold through a series of closely connected steps. First, by obtaining the geometric model data of the product and extracting the contour, an accurate digital basis is provided for subsequent profile construction. Then, by calculating the projection point coordinates and height difference of the telescopic blocks, the complex product contour can be converted into the accurate displacement amount of each telescopic block, ensuring the accuracy of the profile adjustment. Subsequently, according to these displacement amounts, the telescopic distance of the telescopic blocks is adjusted, and combined with the flexible cover layer, the injection fitting profile highly matched with the product contour can be quickly and steplessly formed, greatly shortening the mold preparation period.

[0067] The step S15 comprises: By setting a high-precision proportional valve, the output end of the hydraulic system is divided into several output partitions according to the distribution of several sub-regions, and the several output partitions and the several sub-regions are in one-to-one corresponding connection relationship; The actual hydraulic locking pressure change data is monitored in real time by the pressure sensor of each hydraulic sub-region, and the control system adjusts the proportional valve of the corresponding region according to the hydraulic locking pressure change data to realize dynamic compensation of the hydraulic locking force of each sub-region.

[0068] Specifically, the high-precision proportional valve refers to a valve that can accurately control the hydraulic flow and pressure according to the electrical signal, and its characteristics are fast response speed and high control precision, which can realize fine and stepless adjustment of the hydraulic locking force. The purpose is to accurately distribute and adjust the total output pressure of the hydraulic system according to the actual needs of different sub-regions in the mold cavity. The pressure sensor can be understood as a device that can convert the pressure signal in the hydraulic sub-region into an electrical signal, and its purpose is to obtain the actual hydraulic locking pressure data of each sub-region in real time and accurately, and provide feedback information for the control system. In practical application, the output end of the hydraulic system is divided into several output partitions, and these output partitions are in one-to-one corresponding connection with the several sub-regions divided inside the mold cavity, ensuring that the hydraulic locking force of each sub-region can be controlled independently. The control system compares the real-time hydraulic locking pressure change data fed back by the pressure sensor with the preset or simulated ideal pressure value, and adjusts the high-precision proportional valve of the corresponding output partition slightly, so as to realize dynamic compensation of the hydraulic locking force of each sub-region. Dynamic compensation refers to automatically adjusting the hydraulic locking force according to the real-time change of the pressure in the mold cavity during the injection molding process, so as to maintain the stability and precision of the mold profile.

[0069] The scheme of the present application introduces a high-precision proportional valve and a pressure sensor to build a closed-loop control system, thereby effectively solving the limitation that the hydraulic locking force in the basic scheme may not adapt to the dynamic pressure changes in the injection molding process. Specifically, during the injection molding process, the molten plastic inside the mold cavity will generate transient impact pressure and sustained holding pressure on the mold surface. Without real-time monitoring and dynamic adjustment mechanism, the preset hydraulic locking force may not be sufficient to resist local high pressure at some moments, resulting in surface deformation or flash; while at other moments, it may be too large, causing unnecessary energy consumption or mold wear. Through real-time monitoring of the actual locking pressure of each hydraulic sub-region by the pressure sensor, the control system can timely obtain the real load information borne by the mold surface. In view of this, the control system adjusts the output of the hydraulic system accurately through the high-precision proportional valve according to these real-time data, so that the hydraulic locking force of each sub-region can dynamically match the injection pressure inside the mold cavity. It is precisely due to this real-time and regional dynamic compensation mechanism that the injection molding matching surface can maintain the best locking state throughout the injection molding cycle.

[0070] Through the above technical scheme, the present application can realize fine and dynamic control of the hydraulic locking force of the injection mold surface. Compared with the basic scheme, this scheme can respond to the transient changes of the injection pressure inside the mold cavity in real time, effectively avoiding defects such as flash, unstable product size caused by insufficient locking force, or mold wear and increased energy consumption caused by excessive locking force. Further, through the dynamic compensation of the partitioned hydraulic locking power, the forming precision and surface quality of the injection molded product can be significantly improved, the service life of the mold can be prolonged, and the stability and efficiency of the injection molding process can be optimized.

[0071] The step S15 further comprises: The high-precision current meter and the vibration sensor are used to collect the current waveform and motion vibration signal of each telescopic block driving motor in real time. The high-precision current meter can be understood as a sensor capable of accurately measuring small current changes, and its purpose is to monitor the current consumption of the telescopic block driving motor during operation in real time. The change of the current waveform can reflect the abnormality of the motor load, internal friction or winding state. The vibration sensor is used to detect the mechanical vibration generated by the telescopic block driving mechanism during motion, and its purpose is to judge mechanical faults such as bearing wear, poor gear engagement or structural looseness through the frequency, amplitude and other characteristics of the vibration signal.

[0072] The current waveform and motion vibration signal are subjected to real-time spectrum and feature analysis to evaluate the wear degradation degree of the driving mechanism of each telescopic block. The real-time spectrum and feature analysis refers to mathematical processing such as Fourier transform on the collected current waveform and motion vibration signal, converting it from the time domain to the frequency domain, and extracting the feature parameters related to wear degradation, such as vibration energy at a specific frequency, harmonic component change, etc. The purpose is to quantify the health status of the driving mechanism through analysis of these feature parameters.

[0073] The torque, acceleration-deceleration curve and braking strategy of the corresponding telescopic block are dynamically adjusted according to the wear degradation degree to compensate for performance degradation and maintain positioning accuracy. In practical applications, evaluating the wear degradation degree of the driving mechanism of each telescopic block means that according to the results of spectrum and feature analysis, combined with the preset threshold or machine learning model, the wear, fatigue or aging degree of the driving mechanism (such as motor, reducer, screw, etc.) is judged. Specifically, it can be judged by setting a safety threshold, when the vibration amplitude of the driving mechanism at a specific frequency exceeds the safety threshold, it can be determined that there is a certain degree of wear.

[0074] Further, dynamically adjusting the torque, acceleration-deceleration curve and braking strategy of the corresponding telescopic block means that according to the evaluated wear degradation degree, the intelligent control system will modify the operating parameters of the driving motor in real time. The adjustment of the torque can compensate for the lack of driving force due to increased friction; the adjustment of the acceleration-deceleration curve can avoid excessive impact on the worn parts during acceleration or deceleration; the adjustment of the braking strategy can optimize the smoothness and positioning accuracy when stopping. The purpose is to offset the negative effects of wear through fine-tuning of these parameters, ensuring the accuracy of the motion trajectory and final positioning of the telescopic block.

[0075] The scheme of the present application realizes real-time, multi-dimensional monitoring of the running state of the telescopic block driving motor by introducing high-precision current meters and vibration sensors. When the driving mechanism is worn due to long-term operation, its current waveform and motion vibration signal will change in a recognizable way. Through real-time spectrum and feature analysis of these signals, the wear degradation degree of the driving mechanism can be accurately identified and quantified. It is precisely because the wear state can be accurately evaluated that the control system can dynamically adjust the torque, acceleration-deceleration curve and braking strategy of the corresponding telescopic block. For example, when it is detected that the driving mechanism of a telescopic block is worn and its response is slow, the system can appropriately increase its driving torque and optimize its acceleration-deceleration curve, thereby compensating for the performance degradation caused by wear without replacing parts, ensuring that the telescopic block maintains the expected motion characteristics and final positioning accuracy throughout the adjustment process. This adaptive adjustment mechanism effectively solves the problem of decreased positioning accuracy caused by mechanical wear in traditional methods, thereby maintaining the high-precision molding of injection-molded mating surfaces.

[0076] By the technical solution, the health condition of the telescopic block driving mechanism can be monitored and evaluated in real time, so that dynamic compensation can be performed in time when wear occurs, and the problem of positioning accuracy decline caused by mechanical component wear can be effectively avoided. Compared with the scheme of relying only on initial calibration, the long-term stability and reliability of the stepless adjustment method of the injection mold surface are significantly improved, the injection fit surface is ensured to maintain high precision throughout the mold life cycle, thereby improving the quality consistency of the injection molded product, prolonging the service life of the mold, and reducing the downtime maintenance cost caused by mechanical failure.

[0077] In the injection molding process, the injection pressure distribution diagram inside the mold cavity is obtained through injection simulation, and the hydraulic chamber is divided into several sub-regions accordingly. This innovative step makes the locking of the mold no longer uniformly pressurized as a whole, but finely and zonally managed according to the actual pressure distribution inside the mold cavity. By setting the hydraulic locking pressure of each sub-region telescopic block based on the actual injection pressure and performing zonal hydraulic locking, the application can ensure that the mold surface can maintain sufficient rigidity and stability when subjected to high pressure impact during the injection molding process, effectively avoiding the problems of surface deformation and product precision decline caused by insufficient or uneven locking force in traditional molds. Each technical feature cooperates to form a complete closed-loop control system, from product design data to the accurate formation and stable locking of the final mold surface, comprehensively improving the adaptability, molding precision and production efficiency of the injection mold.

[0078] The core innovation of the application lies in the introduction of the "adjustable surface array" and "zonal hydraulic locking" mechanism, which realizes stepless, accurate and dynamic adjustment and stable locking of the mold surface. The adjustable mold cavity scheme in the prior art, such as replacing the insert or mechanically adjusting the local block, can usually only achieve discrete and limited adjustment, which is difficult to adapt to complex and variable curved profiles, and the surface continuity is poor. By obtaining the geometric model data of the product and converting it into the precise displacement of the telescopic block, the application can form a continuous injection fit surface that is highly matched with the product profile in cooperation with the flexible cover layer, realizing true "stepless adjustment". This adjustment method not only improves the flexibility of the mold, but also greatly shortens the preparation time for product switching.

[0079] More importantly, in terms of mold locking, the prior art generally has the problem of insufficient locking rigidity, especially when subjected to high-temperature and high-pressure melt impact, the profile is prone to shift or elastic deformation, which directly affects the product precision. The present application obtains the injection pressure distribution diagram inside the mold cavity through injection simulation, and divides the hydraulic chamber into several sub-regions according to the injection pressure distribution diagram, and then sets the hydraulic locking pressure of each sub-region based on the actual injection pressure, and carries out partitioned hydraulic locking. This partitioned and dynamic hydraulic locking strategy can provide differentiated support force according to the actual pressure borne by different regions inside the mold cavity, ensuring that the entire injection-molded mating profile always maintains sufficient rigidity and stability during the injection molding process, effectively solving the technical problems of traditional molds in terms of locking reliability. Therefore, the present application not only improves the adaptability and adjustment accuracy of the mold, but also fundamentally guarantees the molding quality and consistency of the injection-molded products, having significant technical advantages and economic benefits.

[0080] In some preferred embodiments, when the injection mold has been running continuously for several months, the system detects abnormal fluctuations in the current waveform of the drive motor of a certain telescopic block through a high-precision ammeter, and at the same time, the vibration sensor detects that the motion vibration signal of the telescopic block during the telescopic process has significantly increased in energy at a certain frequency band. After receiving these data, the control system immediately performs real-time frequency spectrum and feature analysis on the current waveform and motion vibration signal. The analysis result shows that the wear degree of the bearing of the telescopic block drive mechanism has reached the preset mild degradation threshold. Based on this evaluation, the control system dynamically adjusts the operating parameters of the telescopic block drive motor. Specifically, in order to compensate for the increased friction caused by bearing wear, the system may fine-tune the output torque of the motor by 5%; at the same time, in order to reduce the impact on the worn parts, the acceleration and deceleration curve is modified to a more gentle transition mode; and the braking strategy is also optimized to ensure that the target position can be reached more smoothly when stopping, avoiding overshoot or undershoot. Through this series of dynamic adjustments, even in the presence of some wear of the drive mechanism, the telescopic block can still accurately extend and retract to the predetermined position, thereby maintaining the overall accuracy of the injection-molded mating profile, ensuring the effectiveness of the subsequent partitioned hydraulic locking, and ensuring that the quality of the injection-molded products is not affected.

[0081] Embodiment two: Figure 2 A schematic diagram of a profile stepless adjustment device for an injection mold in an embodiment of the present application is shown, the adjustment device comprising: A coordinate construction module 10 is used to obtain the geometric model data of the product, extract the product contour data from the geometric model data, and obtain the projection point coordinates of the adjustable profile array composed of a plurality of telescopic blocks projected on the product contour according to the product contour data; The displacement amount calculation module 20 is configured to set the projection point coordinate with the lowest horizontal height as a reference coordinate, calculate the height difference data of the projection point coordinate corresponding to each telescopic block according to the reference coordinate, and determine the displacement amount of each telescopic block according to the height difference data. The mold adjustment module 30 is configured to adjust the telescopic distance of each telescopic block according to the displacement amount, and form an injection molding matching profile in cooperation with a flexible cover layer arranged above the adjustable profile array. The injection pressure analysis module 40 is configured to perform injection molding simulation according to the injection molding matching profile, obtain an injection pressure distribution diagram inside a mold cavity, and divide the hydraulic chamber into a plurality of sub-regions according to the injection pressure distribution diagram. The hydraulic locking module 50 is configured to obtain a plurality of telescopic blocks corresponding to each sub-region, set the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-region, and perform partitioned hydraulic locking on the injection molding matching profile formed by the plurality of telescopic blocks in combination based on the hydraulic locking pressure.

[0082] The adjustment device of the present application can realize stepless and accurate adjustment and stable locking of the injection mold profile through the cooperative work of the above-mentioned modules, thereby effectively solving many technical problems existing in the flexible production and forming precision of the traditional mold. Specifically, the coordinate construction module 10 is responsible for providing accurate digital basis, the displacement amount calculation module 20 converts the product profile into accurate displacement amount of the telescopic block, and the mold adjustment module 30 quickly forms an injection molding matching profile matched with the product profile height according to the displacement amount. Subsequently, the injection pressure analysis module 40 obtains the pressure distribution inside the mold cavity through injection molding simulation, and divides the hydraulic chamber sub-region according to the pressure distribution, and the hydraulic locking module 50 performs partitioned hydraulic locking on the injection molding matching profile formed by the telescopic block combination according to the partitioned pressure, thereby ensuring that the mold profile can still maintain sufficient rigidity and stability when bearing high pressure impact during the injection molding process.

[0083] The stepless adjustment device for the injection mold surface presented in this application aims to realize the stepless, accurate adjustment and stable locking of the injection mold surface through the synergistic effect of precise digital modeling, displacement calculation, surface adjustment, injection simulation and partitioned hydraulic locking function modules. Among them, "geometric model data" refers to the digital information describing the three-dimensional shape and size of the product obtained by CAD software or other three-dimensional scanning technology, which is processed by the coordinate construction module 10; "product contour data" is the two-dimensional or three-dimensional boundary information of the geometric model data in a specific projection direction, also extracted by the coordinate construction module 10; "telescopic block" is the basic unit that constitutes the adjustable surface array, whose telescopic distance can be independently adjusted, whose displacement is determined by the displacement calculation module 20, and adjusted by the mold adjustment module 30; "adjustable surface array" is composed of a plurality of telescopic blocks arranged regularly, which can form a complex curved surface through the coordinated movement of each telescopic block; "flexible cover layer" is an elastic material layer covering the adjustable surface array, used to form a smooth and continuous injection fit surface, working with the mold adjustment module 30; "injection fit surface" refers to the mold surface that accurately matches the product contour and directly contacts with the molten plastic, which is formed by the mold adjustment module 30 and simulated by the injection pressure analysis module 40; "injection pressure distribution map" is the pressure distribution of the molten plastic on the mold wall during the injection simulation process, obtained by the injection pressure analysis module 40; "hydraulic chamber" is a spatial structure that provides hydraulic locking force for the telescopic block, which is divided into sub-regions by the injection pressure analysis module 40; "sub-region" is a local region of the hydraulic chamber divided according to the injection pressure distribution map; "hydraulic locking pressure" is the hydraulic pressure applied to the telescopic block to resist the injection pressure, which is set and applied by the hydraulic locking module 50.

[0084] Specifically, the coordinate construction module 10 of the present application is configured to obtain the geometric model data of a product. For example, the module can integrate a data interface for importing point cloud data generated by scanning a physical product with a three-dimensional scanner and converting it into an editable CAD model, or directly obtaining an existing CAD file from the product design department. After obtaining the geometric model data, the coordinate construction module 10 is further configured to extract product contour data from the data. For example, the module can include a processing unit that uses the functions of professional CAD / CAM software to project a three-dimensional geometric model onto a two-dimensional plane by setting a specific projection direction (such as the injection direction), thereby extracting the outer contour line or curved surface boundary of the product. These contour data are the basis for determining the displacement of the stretch blocks. Subsequently, the coordinate construction module 10 is further configured to obtain the projection point coordinates of the adjustable profile array composed of multiple stretch blocks projected on the product contour according to the product contour data. For example, the module can pre-store an array model composed of regularly arranged stretch blocks, and then align the array with the product contour in a virtual space through a calculation unit to calculate the vertical projection coordinates of the center point or top of each stretch block on the product contour. These projection point coordinates reflect the mapping relationship of the product contour on the stretch block array.

[0085] Further, the displacement calculation module 20 of the present application is configured to set the projection point coordinate with the lowest horizontal height as the reference coordinate after obtaining the projection point coordinates. For example, the module can include a data analysis unit that selects the point with the smallest Z value as the reference point by comparing the values in the vertical direction (usually the Z axis) among all the obtained projection point coordinates. This reference point will serve as the reference zero point for the subsequent calculation of the displacement of all stretch blocks. Next, the displacement calculation module 20 is configured to calculate the height difference data of each stretch block corresponding to the projection point coordinate according to the reference coordinate. For example, for each projection point of a stretch block, the calculation unit of the module can calculate the difference between its Z coordinate and the Z value of the reference coordinate. This difference is the relative height of the stretch block relative to the reference point. Subsequently, the displacement calculation module 20 is configured to determine the displacement of each stretch block according to the height difference data. For example, the module can directly use the calculated height difference data as the displacement of each stretch block. This means that if the projection point of a stretch block is higher than the reference point, its displacement is positive, indicating that it needs to be extended; if it is lower than the reference point, its displacement is negative, indicating that it needs to be retracted.

[0086] On this basis, the mold adjusting module 30 of the present application is used to adjust the extension distance of each telescopic block according to the displacement amount determined. For example, the module can contain a drive control unit, which drives the telescopic block to make precise linear motion through the micro stepping motor or servo motor integrated inside each telescopic block. The control system sends instructions to each motor according to the preset displacement amount, so that it extends or retracts to the target position. At the same time, the mold adjusting module 30 is also used to form the injection molding matching surface with the flexible cover layer arranged above the adjustable profile array. For example, the module can work with the flexible cover layer. When the telescopic block is adjusted to the position, the flexible cover layer will form a continuous curved surface under the support of the telescopic block, which is highly matched with the product profile, as the injection molding matching surface directly contacting with the molten plastic.

[0087] In addition, the injection pressure analysis module 40 of the present application is used to perform injection simulation according to the injection molding matching surface after the injection molding matching surface is formed, so as to obtain the injection pressure distribution diagram inside the mold cavity. For example, the module can integrate the injection simulation software interface and computing resources, which are used to input the three-dimensional model of the formed injection molding matching surface, the selected plastic material parameters and the injection molding process parameters (such as injection speed, melt temperature, mold temperature, etc.), simulate the filling, pressure maintaining and cooling process of the molten plastic in the mold cavity. The simulation result will output the pressure distribution of the mold cavity wall surface in the whole injection molding cycle, forming the injection pressure distribution diagram. Subsequently, the injection pressure analysis module 40 is also used to divide the hydraulic chamber into several sub-regions according to the injection pressure distribution diagram. For example, the module can contain a data analysis algorithm, which is used to analyze the injection pressure distribution diagram, identify the pressure concentration area, the area with sharp pressure gradient change and the asymmetric characteristics of the overall pressure distribution. Based on these characteristics, the hydraulic chamber is physically or logically divided into multiple independent sub-regions, and each sub-region corresponds to a specific range on the mold surface.

[0088] Finally, the hydraulic locking module 50 of the present application is used to obtain a number of telescopic blocks corresponding to each sub-region, and set the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-region. For example, the module can contain a sensor interface and control logic to determine which telescopic blocks are included in each sub-region after the sub-regions are divided. Then, according to the average or maximum injection pressure that the sub-region bears in the injection simulation, the required hydraulic locking pressure of the telescopic blocks in the sub-region is calculated and set. This locking pressure needs to be sufficient to resist the impact and extrusion of the molten plastic on the mold surface during the injection molding process. Based on the hydraulic locking pressure, the hydraulic locking module 50 is also used to partition and hydraulically lock the injection-molding matching mold surface formed by a number of telescopic blocks. For example, the module can provide independent hydraulic locking force for each sub-region through independent hydraulic control circuits or high-precision proportional valves. In this way, the telescopic blocks in different regions can be applied with different hydraulic locking forces according to the size of the injection pressure they bear, thereby achieving partitioning, dynamic, and accurate locking of the entire injection-molding matching mold surface.

[0089] The surface stepless adjustment device for injection mold of the present application has significant progress and innovation compared to the prior art. Traditional molds often need to be frequently replaced or the mold core needs to be frequently replaced when facing multi-variety and small-batch production, resulting in high production cost, long production cycle, and difficulty in achieving continuous adjustment of complex curved surfaces. The core innovation of the present application is to achieve stepless, accurate, and dynamic adjustment and stable locking of the mold surface through modular design.

[0090] Specifically, the adjustable mold cavity device in the prior art, such as replacing the insert block or mechanically adjusting the local mold block, can usually only achieve discrete and limited adjustment, which is difficult to adapt to complex and variable curved profiles, and the surface continuity is poor. The present application obtains the geometric model data of the product through the coordinate construction module 10 and converts it into the accurate displacement amount of the telescopic block, and then forms a continuous injection-molding matching mold surface highly matched with the product profile by cooperating with the flexible cover layer through the mold adjustment module 30, thereby realizing true "stepless adjustment". This modular adjustment method not only improves the flexibility of the mold, but also greatly shortens the preparation time for product switching.

[0091] More importantly, in the aspect of mold locking, the prior art generally has the problem of insufficient locking rigidity, especially when subjected to the impact of high-temperature and high-pressure melt, the profile is prone to deviation or elastic deformation, which directly affects the product precision. The present application carries out injection molding simulation through the injection pressure analysis module 40 and divides the hydraulic chamber sub-region, and then sets the hydraulic locking pressure based on the actual injection pressure for the expansion block of each sub-region by the hydraulic locking module 50, and carries out partitioned hydraulic locking. This partitioned and dynamic hydraulic locking strategy can provide differentiated support force according to the actual pressure borne by different regions inside the mold cavity, ensuring that the entire injection-molded mating profile always maintains sufficient rigidity and stability during the injection molding process, effectively solving the technical problem of locking reliability of traditional molds. Therefore, the adjusting device of the present application not only improves the adaptability and adjustment accuracy of the mold, but also fundamentally guarantees the molding quality and consistency of the injection-molded product, having significant technical advantages and economic benefits.

[0092] Those skilled in the art can understand that all or part of the steps in the above-mentioned various methods of the embodiments can be completed by instructing the relevant hardware through a program, and the program can be stored in a computer-readable storage medium, which can include a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, etc.

[0093] In addition, the above describes the embodiments of the present application in detail, and the principles and implementation manners of the present application are described by using specific examples in this paper. The above description of the embodiments is only used to help understand the method of the present application and its core idea; at the same time, for those skilled in the art, according to the idea of the present application, the specific implementation manner and application range will be changed; in summary, the content of the specification should not be understood as a limitation of the present application.

Claims

1. A method for stepless adjustment of the profile of an injection mold, characterized in that, The adjustment method includes: Obtain the geometric model data of the product, extract the product outline data based on the geometric model data, and obtain the coordinates of the projection points of the adjustable surface array composed of multiple stretchable blocks projected onto the product outline based on the product outline data. Set the coordinates of the projection point with the lowest horizontal height as the reference coordinates, calculate the height difference data of the projection point coordinates corresponding to each telescopic block based on the reference coordinates, and determine the displacement of each telescopic block based on the height difference data. The telescopic distance of each telescopic block is adjusted according to the displacement, and a flexible covering layer is set above the adjustable surface array to form an injection molding mating surface; Injection simulation is performed based on the injection molding fit type to obtain the injection pressure distribution map inside the mold cavity. The hydraulic chamber is then divided into several sub-regions based on the injection pressure distribution map. Obtain several telescopic blocks corresponding to each sub-region, and set the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-region. Based on the hydraulic locking pressure, perform zoned hydraulic locking on the injection mating surface formed by the combination of several telescopic blocks.

2. The method for stepless adjustment of the profile of an injection mold according to claim 1, characterized in that, The steps of acquiring the geometric model data of the product, extracting the product contour data based on the geometric model data, and acquiring the coordinates of the projection points of the adjustable surface array composed of multiple stretchable blocks projected onto the product contour based on the product contour data include: Import the product's geometric model data into the system, extract the product's contour data based on the geometric model data, and generate an injection molding surface model based on the product contour data; An adjustable surface array of rectangular structures formed by the coordinates of several stretch blocks is generated in a spatial coordinate system using the geometric center coordinates of the stretch blocks. Arrange the injection molding surface model and the adjustable surface array along the vertical axis to construct the projection relationship between the injection molding surface model and the adjustable surface array, and obtain the coordinates of the projection points of several telescopic blocks projected onto the product outline.

3. The method for stepless adjustment of the profile of an injection mold according to claim 2, characterized in that, The step of arranging the injection molding surface model and the adjustable surface array along the vertical axis, constructing the projection relationship between the injection molding surface model and the adjustable surface array, and obtaining the coordinates of the projection points of several telescopic blocks projected onto the product outline includes: The adjustable surface array is parameterized so that the physical arrangement of the adjustable surface array is mapped to the same parameter domain as the injection molding surface model. The center position of each scaling block is assigned a corresponding parameter coordinate to maintain the consistency between the array arrangement and the direction of the parameter domain coordinate system. By using a shared parameter domain, a forward mapping network from the adjustable surface array to the injection molding surface model can be constructed, or a reverse mapping network from the injection molding surface model to the adjustable surface array can be constructed.

4. The method for stepless adjustment of the profile of an injection mold according to claim 1, characterized in that, The coordinates of the projection point with the lowest horizontal height are set as the reference coordinates. The height difference data of the projection point coordinates corresponding to each telescopic block is calculated based on the reference coordinates. The displacement of each telescopic block is determined based on the height difference data, including: Vertically project the center point of the top of all the expansion blocks onto the injection molding surface model, traverse all the projection points of the injection molding surface model, and identify the projection point with the smallest Z coordinate value as the reference coordinate point. The coordinates of the projection point corresponding to each telescopic block are compared with the reference coordinate point. The coordinate difference between the projection point coordinates of each telescopic block and the reference coordinate point in the vertical direction is calculated to obtain the height difference data. The height difference data is set as the displacement of the telescopic block.

5. The method for stepless adjustment of the profile of an injection mold according to claim 1, characterized in that, The step of adjusting the telescopic distance of each telescopic block according to the displacement, and forming an injection molding mating surface with the flexible covering layer disposed above the adjustable surface array, includes: A linear stepper motor is provided for driving the movement of each telescopic block in the adjustable surface array; The digital signal used to drive the linear stepper motor is set according to the displacement value. The rotation of each linear stepper motor is controlled by the digital signal, and the current position of the telescopic block is fed back in real time through the encoder on the motor, forming a closed-loop control.

6. The method for stepless adjustment of the profile of an injection mold according to claim 1, characterized in that, The step of performing injection molding simulation based on the injection molding fit type to obtain the injection pressure distribution map inside the mold cavity, and dividing the hydraulic chamber into several sub-regions based on the injection pressure distribution map, includes: A mesh model of the injection mold cavity is generated based on the product's 3D contour data. The filling process of the molten plastic in the mold cavity is simulated based on the obtained molten plastic material properties and injection molding process parameters. The transient pressure value of each grid point on the injection mold cavity wall is calculated and recorded in real time at different time steps during the simulation, generating an injection pressure distribution map of the mold cavity wall that changes over time.

7. The method for stepless adjustment of the profile of an injection mold according to claim 6, characterized in that, The step of performing injection molding simulation based on the injection molding fit type to obtain the injection pressure distribution map inside the mold cavity, and dividing the hydraulic chamber into several sub-regions based on the injection pressure distribution map, further includes: Asymmetric analysis is performed on the injection pressure distribution map to obtain the pressure concentration area, the area with drastic pressure gradient change, and the asymmetric characteristics of the overall pressure distribution. A clustering algorithm based on pressure thresholds is used to divide the injection pressure distribution map into several sub-regions according to the pressure gradient difference. The average melt impact pressure of each sub-region is calculated, and the hydraulic locking pressure of each sub-region is calculated based on the average melt impact pressure of each sub-region.

8. The method for stepless adjustment of the profile of an injection mold according to claim 1, characterized in that, The step of obtaining several telescopic blocks corresponding to each sub-region, setting the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-region, and performing zoned hydraulic locking on the injection mating surface formed by the combination of several telescopic blocks based on the hydraulic locking pressure includes: By setting a high-precision proportional valve, the output end of the hydraulic system is divided into several output zones according to the distribution of several sub-regions, and the several output zones and several sub-regions are connected in a one-to-one correspondence. The control system monitors the actual hydraulic locking pressure changes in real time using pressure sensors in each hydraulic sub-region. Based on these changes, the control system makes minor adjustments to the proportional valves in the corresponding regions, thereby achieving dynamic compensation of the hydraulic locking power in each sub-region.

9. The method for stepless adjustment of the profile of an injection mold according to claim 1, characterized in that, The step of obtaining several telescopic blocks corresponding to each sub-region, setting the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-region, and performing zoned hydraulic locking of the injection mating surface formed by the combination of several telescopic blocks based on the hydraulic locking pressure further includes: The current waveforms and motion vibration signals of the drive motors of each telescopic block are collected in real time using high-precision ammeters and vibration sensors. Real-time spectrum and feature analysis of current waveforms and motion vibration signals are performed to evaluate the wear and degradation degree of the drive mechanism of each telescopic block; The torque, acceleration / deceleration curves, and braking strategy of the corresponding telescopic block are dynamically adjusted according to the degree of wear and degradation in order to compensate for performance degradation and maintain positioning accuracy.

10. A stepless adjustment device for the profile of an injection mold, characterized in that, The regulating device includes: Coordinate construction module: used to acquire the geometric model data of the product, extract the product outline data based on the geometric model data, and acquire the coordinates of the projection points of the adjustable surface array composed of multiple stretch blocks projected onto the product outline based on the product outline data. Displacement calculation module: used to set the coordinates of the projection point with the lowest horizontal height as the reference coordinates, calculate the height difference data of the projection point coordinates corresponding to each telescopic block based on the reference coordinates, and determine the displacement of each telescopic block based on the height difference data. Mold adjustment module: used to adjust the extension distance of each telescopic block according to the displacement, and cooperate with the flexible covering layer set above the adjustable surface array to form an injection molding mating surface; Injection pressure analysis module: used to perform injection simulation based on the injection molding fit type, obtain the injection pressure distribution map inside the mold cavity, and divide the hydraulic chamber into several sub-regions based on the injection pressure distribution map; Hydraulic locking module: used to acquire several telescopic blocks corresponding to each sub-region, and set the hydraulic locking pressure of the telescopic blocks based on the injection pressure of each sub-region, and perform zoned hydraulic locking on the injection mating surface formed by the combination of several telescopic blocks based on the hydraulic locking pressure.

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