Custom input and output control method and system for IO module of injection molding machine

Abstract

The invention relates to an injection molding machine IO module user-defined input and output control method and system, and relates to the field of injection molding machine PLC technology control, and the method comprises the steps: responding to a trigger instruction, and obtaining a selection control type; based on the selected control type, collecting controller timing controlled by PLC digital quantity input and output; if the timing of the controller does not reach the target delay time, continuing timing; if the timing of the controller reaches the target delay time, collecting a selection signal; and determining an operation scheme based on the selection signal and controlling a preset actuator to execute the operation scheme. The method has the effect of simplifying the operation process.

Description

Technical Field

[0001] This invention relates to the field of injection molding machine technology control, and in particular to a control method and system for custom input / output of injection molding machine I / O modules. Background Technology

[0002] The input / output module (IO module) in the injection molding machine control system is connected to the injection molding machine control system through an industrial bus. It acts as a bridge for external devices and is responsible for signal acquisition, processing, and output of control commands.

[0003] In the actual production of injection molding machines, the IO module works in three stages: signal acquisition, processing, and control output. First, the acquired signal is converted into a recognizable signal. Then, the controller performs calculations according to a preset program. Finally, the digital signal is converted into the drive signal required by the external device. When a fault occurs, the switch status and time can be forcibly set by technicians on the interface, so that the controller can recognize or output the corresponding signal.

[0004] When a malfunction occurs, the time setting needs to be manually controlled, which requires multiple clicks on the interface. This operation is complex and carries the risk of accidental touches. Furthermore, forced operation may violate safety regulations and pose compliance risks, leading to discrepancies between monitoring data and actual conditions, making it difficult to trace the source of the problem. Summary of the Invention

[0005] To simplify the operation process, this invention provides a control method and system for custom input and output of the injection molding machine's IO module.

[0006] In a first aspect, the present invention provides a control method for custom input / output of an injection molding machine's I / O module, employing the following technical solution: A method for controlling custom inputs and outputs of an injection molding machine's I / O module, comprising: In response to a trigger command, obtain the selected control type; Based on the selected control type, the controller timing of the PLC digital input / output control is collected; If the controller timing has not reached the target delay time, the timing will continue; If the controller timing reaches the target delay time, a selection signal is collected; The level information is determined based on the selected signal; After controlling the preset actuator to output the corresponding level using the level information, the preset PLC controller is controlled to start timing and obtain the running time; It determines whether the running time has reached the preset running time setting value. If the running time setting value has not been reached, it will continue to output the selection signal as the running plan. If the set running time is reached, the collected sensor signals are blocked, and a forced signal is generated in a simulated manner. The preset actuator is forcibly reset based on the forced signal control, and the time collected by the controller is used as the operation plan. The preset actuator is then controlled to execute the operation plan.

[0007] By adopting the above technical solution, after responding to the trigger command, the control type is obtained and timing begins. If the target delay is not reached, timing continues. After the target delay is reached, the signal is collected to determine the operation plan and control the actuator to execute. Through precise timing and signal collection, the operation process is simplified, ensuring that the injection molding machine runs accurately according to the preset logic, thereby improving production stability and product consistency.

[0008] Optionally, methods for determining the level information include: When the selected signal is a preset pulse signal, a fixed-period alternating level is set according to the pulse signal, and the fixed-period alternating level is used as the level information; When the selected signal is a preset continuous signal, a constant level is set according to the continuous signal, and the constant level is used as the level information.

[0009] By adopting the above technical solution, the level information is determined based on the selected signal, the actuator output is controlled and timed. If the set value of the running time is not reached, the signal continues to be output. If the set value of the running time is reached, the sensor signal is blocked and a forced signal is generated to reset the actuator. By selecting and processing pulse and continuous signals, complex fault scenarios can be simulated, improving the system testing efficiency and emergency handling capabilities.

[0010] Optional, also includes: Select optimization mode in response to digital input commands; If the optimization mode is selected as the preset signal superposition mode, the input signal type and signal superposition parameters will be collected. Signal superposition is initiated based on the signal type and signal superposition parameters to simulate complex fault scenarios. The superposition signal is received and responded to by a preset PLC controller, and test data is obtained and recorded.

[0011] Optionally, after selecting the optimization mode in response to a digital input command, the following may also be included: If the optimization mode is selected as the preset working condition linkage mode, the working condition signals that need to be forcibly input under the production working condition will be collected. Determine whether the operating condition signal meets the preset operating condition triggering conditions; If the operating condition signal does not meet the preset operating condition triggering conditions, the operating condition signal will continue to be monitored. If the operating condition signal reaches the preset operating condition triggering condition, the binding signal will be output according to the operating condition signal; Execute a preset forced input action based on the bound signal.

[0012] By adopting the above technical solutions, the system can select the optimization mode and signal superposition mode in response to digital input commands, simulate complex fault inputs to obtain test data, and monitor operating condition signals and output bound signals to execute forced actions in the working condition linkage mode, thereby enhancing the system's flexibility and adaptability and meeting diverse production needs.

[0013] Optional, also includes: Collect the output and feedback signals sent by the PLC after the forced output function is activated; By comparing the output signal and the feedback signal, the action status and target status can be obtained. Determine whether the action status matches the target status; If they match, continue outputting the output signal. If there is a discrepancy, pause the output and then resend the output signal.

[0014] Optionally, the step of pausing output and retransmitting the signal if there is a discrepancy also includes: Get the number of consecutive corrections and set the reference number of corrections; If the number of consecutive corrections does not reach the reference number of corrections, the signal is reacquired; When the number of consecutive corrections reaches the reference correction number, an HMI alarm is triggered and the anomaly is recorded.

[0015] By adopting the above technical solution, the PLC output signal and feedback signal are compared to determine whether the action status is consistent with the target. If they are inconsistent, the signal is retransmitted after a pause, the number of corrections is recorded, and an alarm is triggered if the limit is exceeded, thereby ensuring the accuracy of signal transmission and improving the reliability and stability of the system.

[0016] Optional, also includes: Collect preset operating parameters of the actuator during execution and set safe interruption conditions; If the operating parameters determine that the safety interrupt conditions are met, then a preset safety interrupt command is triggered and output. The type of security interruption condition is identified based on the security interruption instruction, and the HMI type, emergency stop type, and no-permission type are set. The security scheme is determined based on the type of security interruption condition, and then the security scheme is executed.

[0017] Optionally, methods for determining a security scheme include: When the security interruption condition type is HMI, all running programs will be shut down as a security measure. When the safety interruption condition type is emergency stop, a preset forced function command is output. Based on the forced function command, the actuator of the injection molding machine is controlled to stop urgently, which serves as a safety solution. When the security interruption condition type is "no permission", the operation instructions of the preset forced function will be blocked and a prompt will be displayed as a security solution.

[0018] By adopting the above technical solution, the actuator operating parameters are collected, and a safety command is triggered and output when the safety interruption condition is met. The corresponding solution is executed by identifying the condition type, such as closing the program, emergency stop, or blocking operation commands. By ensuring that the injection molding machine can respond quickly and safely in abnormal situations, the risk of equipment damage and production risks is reduced.

[0019] Secondly, this application provides a control system for custom input / output of an injection molding machine's I / O module, employing the following technical solution: A control system for custom input / output of an injection molding machine's I / O module includes: The acquisition module is used to acquire the selected control type; The memory is used to store programs that implement the control methods for custom input and output of any injection molding machine I / O module; The processor loads and executes programs from memory.

[0020] In summary, this application includes at least one of the following beneficial technical effects: 1. After responding to the trigger command, the control type is obtained and timing begins. If the target delay is not reached, timing continues. After the target delay is reached, the signal is collected to determine the operation plan and control the actuator to execute. This plan simplifies the operation process through precise timing and signal collection, ensuring that the injection molding machine runs accurately according to the preset logic, thereby improving production stability and product consistency. 2. The PLC output signal and feedback signal are compared to determine whether the action status is consistent with the target. If they are inconsistent, the signal is retransmitted after a pause. The number of corrections is recorded. If the limit is exceeded, an alarm is triggered, thereby ensuring the accuracy of signal transmission and improving the reliability and stability of the system. 3. Collect actuator operating parameters, trigger and output safety commands when safety interruption conditions are met, identify the condition type and execute the corresponding solution, such as shutting down the program, emergency stop or blocking operation commands, so as to ensure that the injection molding machine can respond quickly and safely in abnormal situations, thereby reducing equipment damage and production risks. Attached Figure Description

[0021] Figure 1 This is a flowchart of a method for controlling the custom input and output of an injection molding machine's I / O module, according to an embodiment of the present invention. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0023] This application discloses a method for controlling the custom input and output of an injection molding machine's I / O module.

[0024] Reference Figure 1 A method for controlling the custom input and output of an injection molding machine's I / O module includes the following steps: Step S100: In response to the trigger command, obtain the selected control type.

[0025] Trigger command refers to the operation command that initiates the forced control function of the IO module. It can be initiated by clicking the "Confirm" button on the HMI interface, triggered by operating signals, or by remote control commands. The HMI interface is a comprehensive interactive system combining hardware devices and software programs. Its internal interface has preset functions and buttons, responsible for converting machine operating status and data into human-readable formats (such as text, charts, and lights), and also for converting human operation commands (such as clicks and parameter inputs) into signals that the machine can execute. It is widely used in industrial production. Control type refers to the control type selected by the user or system, which can be either digital input control or digital output control. The appropriate type can be selected according to requirements (such as analog sensor signals or actuator actions).

[0026] The forced control function of the IO module in the injection molding machine PLC control system allows the IO module to simulate input signals (replacing sensors) or force output signals (driving actuators) through preset parameter configuration (such as delay, signal mode, and runtime). This enables precise and automated control in scenarios such as debugging, fault diagnosis, and emergency control. The forced control function of the IO module is preset by technicians according to the actual situation and will not be elaborated here.

[0027] Once the device is started, the user synchronously selects whether it is an input or an output, thus obtaining the control type.

[0028] Step S101: Based on the selected control type, acquire the controller timing of the PLC digital input / output control.

[0029] PLC stands for Programmable Logic Controller, which is used to control automated equipment for injection molding machines.

[0030] PLC digital input / output control refers to the control of digital signal input and output through a programmable logic controller (PLC).

[0031] The PLC controller integrates a timer to collect time data. If the engineer selects "input control," the timing is associated with the sensor signal to simulate the start-up timing (e.g., simulating a fault after the mold closing is completed); if the engineer selects "output control," the timing is associated with the delayed start-up of the actuator action (e.g., triggering the ejector pin after holding pressure for 10 seconds), providing a time reference for the "precision, automation, and safety" of the injection molding machine's I / O forced control.

[0032] Step S102: If the controller timing has not reached the target delay time, then continue timing.

[0033] The target delay time refers to the timing target time that ensures the signal input matches the rhythm of the injection molding machine's operation, thereby providing a time reference. It is preset by technicians according to the actual situation and will not be elaborated here.

[0034] If the controller timing does not reach the target delay time, it means that there is not enough time and it is necessary to wait for the injection molding machine to stabilize before continuing the timing.

[0035] The specific method for setting the target delay time is to manually enter it in the "Parameter Configuration Page" of the HMI (e.g., 1s, 0.5s). After entering it, the PLC will write the parameter into the register.

[0036] Step S103: If the controller timing reaches the target delay time, then the selection signal is acquired.

[0037] The selection signal refers to the continuous or pulse signal selected by the user.

[0038] If the controller timing reaches the target delay time, it indicates that the injection molding machine is running stably after the mold opening is started, thus collecting the signal selected by the user.

[0039] Reference Figure 1 The method for determining the operating plan includes the following steps: Step S200: Determine the level information based on the selected signal.

[0040] Level information refers to the voltage level information in a circuit, which is a forced high level or a forced low level. It is the core signal parameter for driving actuators or analog sensors.

[0041] The method for determining the level information is described in steps S300 to S301, and will not be repeated here.

[0042] Step S201: After controlling the preset actuator to output the corresponding level with the level information, control the preset PLC controller to start timing and obtain the running time.

[0043] PLC controller refers to a programmable logic controller.

[0044] The running time is the duration after the start of operation. The current value is transmitted to the status monitoring page of the HMI in real time through the preset timer in the PLC, displaying "Running for X seconds". This allows the operator to intuitively grasp the progress and solves the problem of signal duration loss due to traditional timeless operation.

[0045] Step S202: Determine whether the running time has reached the preset running time setting value. If the running time setting value has not been reached, continue to output the selection signal as the running plan.

[0046] The set value refers to the preset target running time value, which is set in advance by technicians according to the actual situation, and will not be elaborated here.

[0047] If the running time does not reach the set value, it indicates that the continuous action or analog signal is not stable, and the selection signal will continue to be output as the running scheme.

[0048] Step S203: If the set running time is reached, the collected sensor signals are blocked, and a forced signal is generated by simulation.

[0049] Sensor signals refer to the signals detected by the sensors on the injection molding machine.

[0050] Forced signal refers to the simulated alternative signal, which can be a superimposed signal triggered by the mold opening condition.

[0051] If the running time reaches the set value, it means that the running time has met the standard, the continuous operation or the analog signal is stable, the PLC sends a "mask command" to the IO module to disconnect the connection between the real sensor and the signal processing unit (by switching the circuit through an internal relay), and at the same time starts the signal generator to simulate and generate a forced signal through software tools.

[0052] Step S204: Based on the forced signal control, the preset actuator is forcibly reset, the controller timing is collected, and used as the running plan to control the preset actuator to execute the running plan.

[0053] An actuator is a device that executes control commands, such as a mold-opening motor or a valve.

[0054] The operating plan refers to the plan by which the actuator executes control commands.

[0055] Forced reset refers to forcing the actuator to return to its initial state.

[0056] During a forced reset, the PLC sends a forced signal (such as 0V level) to the actuator, causing the actuator to stop operating (such as when the motor is powered off or the valve is closed). At the same time, the IO module is unshielded, restoring the acquisition of real sensor signals. The forced signal is then used to control the actuator to force a reset as the operating scheme.

[0057] The method for determining level information includes the following steps: Step S300: When the selected signal is a preset pulse signal, a fixed-period alternating level is set according to the pulse signal, and the fixed-period alternating level is used as the level information.

[0058] A pulse signal refers to a periodic, abrupt electrical signal.

[0059] Fixed-period alternating level refers to a signal that alternates between high and low levels at a fixed period.

[0060] The HMI's "Pulse Parameter Area" allows input of the period (e.g., 2s) and duty cycle (e.g., 50%). Based on this, the PLC generates an alternating signal of "1s high level + 1s low level", which is then output to the controller through the IO module.

[0061] Step S301: When the selected signal is a preset continuous signal, a constant level is set according to the continuous signal, and the constant level is used as the level information.

[0062] A continuous signal refers to an electrical signal that exists continuously, and can be either high or low level.

[0063] A constant level refers to a voltage level that remains unchanged.

[0064] When the HMI selects "continuous high level," the PLC controls the IO module to continuously output 24V, simulating "safety door closed." Selecting "continuous low level" outputs 0V, simulating "safety door not closed." In actual testing, this can stably verify the equipment's response to continuous states (such as whether mold closing is prohibited when the safety door is not closed), replacing the traditional temporary solution of shorting with wires.

[0065] It also includes the following steps: Step S400: Select optimization mode in response to digital input command.

[0066] Digital input commands refer to digital signal commands input by the user or the system.

[0067] Optimization mode refers to a mode that optimizes the control input process.

[0068] When users want to optimize the digital input control of the injection molding machine, they only need to press the "Optimization Mode" button on the HMI interface (this step will trigger the digital input command), and two options, "Signal Overlay" and "Operating Condition Linkage", will pop up on the screen. The purpose is to make the input control more in line with actual needs.

[0069] Step S401: If the optimization mode is selected as the preset signal superposition mode, the input signal type and signal superposition parameters are collected.

[0070] Signal type refers to the type of normal signal or fault signal.

[0071] Signal superposition mode refers to the functional mode in which normal signals and fault signals are superimposed.

[0072] Signal superposition parameters refer to the parameters required for signal superposition, such as superposition timing, delay time, signal mode, and runtime.

[0073] After the user selects the signal overlay mode, the input signal type and signal overlay parameters are collected to complete the acquisition.

[0074] Step S402: Start signal superposition according to signal type and signal superposition parameters to simulate complex fault scenario input. Receive and respond to the superposition signal through the preset PLC controller to obtain and record test data.

[0075] Complex fault scenarios refer to scenarios that simulate multiple faults occurring simultaneously.

[0076] Test data refers to data obtained through simulation testing in the response.

[0077] Select the normal and fault signals to be used, and then set the parameters such as the timing of superposition, delay time, and running time. Next, start the signal superposition function to superimpose the normal and fault signals to simulate the complex faults that may be encountered in the actual operation of the injection molding machine. Then, let the PLC controller receive the superimposed signal to determine whether there are any abnormalities (such as whether the operation is stable or whether an alarm is triggered). Finally, record all abnormal data in the PLC test data for easy review and analysis later.

[0078] After selecting the optimization mode in response to a digital input command, the following steps are also included: Step S500: If the optimization mode is selected as the preset working condition linkage mode, the working condition signals that need to be forcibly input under the production working condition are collected.

[0079] The working condition linkage mode refers to a forced input mode that is bound to the production working conditions of the injection molding machine (injection, pressure holding, mold opening, etc.).

[0080] Operating condition signals refer to signals that reflect the real-time production status of the injection molding machine, such as the mold opening signal and the injection pressure signal.

[0081] The working condition linkage mode is suitable for automated testing. The HMI "working condition selection area" can select working conditions such as "mold opening", "mold closing" and "pressure holding". The PLC collects the corresponding sensor signal (such as the 24V signal when the mold is in place) as the trigger source to determine whether the working condition trigger condition is triggered.

[0082] Step S501: Determine whether the operating condition signal meets the preset operating condition triggering conditions.

[0083] The working condition triggering condition refers to the preset linkage triggering threshold of the working condition signal, such as the triggering threshold of the mold opening position signal or the triggering threshold of the ejector pin failure signal. These are preset by the technicians according to the actual situation and will not be elaborated here.

[0084] Step S502: If the operating condition signal does not meet the preset operating condition triggering conditions, continue to monitor the operating condition signal.

[0085] If the operating condition signal does not meet the operating condition triggering conditions, the PLC remains in "monitoring state" and does not activate the forced function.

[0086] For example, if the mold opening is not in place, even if "mold opening linkage" is preset, the system will not output a fault signal to avoid interfering with the normal operation process.

[0087] Step S503: If the operating condition signal reaches the preset operating condition triggering condition, then output the binding signal according to the operating condition signal.

[0088] Binding signals refer to forced input signals bound to the working conditions, such as the ejector pin high-level signal and the encoder fault superimposed signal. The ejector pin high-level signal means that the real signal of the ejector pin sensor is shielded. It starts after a delay of 0.5s after the mold is opened and outputs a high level continuously. The running time is synchronized with the total mold opening time. The encoder fault superimposed signal means that the normal pulse signal of the encoder is superimposed with the 10% pulse loss signal. It is output synchronously with the ejector pin signal. After receiving the signal, the PLC verifies the linkage logic between the mold opening and the ejector pin and the encoder fault handling capability. After the mold opening is completed, it automatically resets and restores the real signal acquisition.

[0089] If the operating condition signal meets the operating condition triggering condition, the PLC automatically calls the bound signal (such as "mold opening linkage" bound to "encoder pulse loss signal"). This signal is output to the controller through the IO module. No manual triggering is required, realizing the automation of operating condition to signal and improving testing efficiency.

[0090] Step S504: Execute a preset forced input action based on the binding signal.

[0091] Forced input action refers to the operation of shielding the real sensor signal and outputting a preset analog signal to provide the PLC controller with a precise analog input signal.

[0092] When the injection molding machine reaches the preset working condition, the system automatically outputs a pre-bound analog signal to replace the real sensor signal and complete the preset forced input operation without manual triggering, which is suitable for scenarios such as fault diagnosis and working condition testing.

[0093] It also includes the following steps: Step S600: Collect the output signals and feedback signals sent by the PLC after the forced output function is started.

[0094] Output signals refer to the signals sent by the PLC to control the actuators.

[0095] Feedback signals refer to the confirmation signals returned by the actuator to the PLC after completing the operation.

[0096] The output signal is sent through the PLC's output module, and the feedback signal is transmitted back to the PLC's input module by the actuator's built-in sensor. In actual wiring, the output and feedback signals are connected to the PLC through different circuits for acquisition.

[0097] Step S601: Compare the output signal and the feedback signal to obtain the action status and target status.

[0098] The operating status refers to the actual operating state of the actuator, which is obtained by comparing the output signal and the feedback signal.

[0099] The PLC compares the level states of the output signal and the feedback signal in the program. If they are consistent, the action status is consistent; if they are inconsistent, the action status is inconsistent and the target status is consistent. This replaces the inefficient method of manually observing the actuator status.

[0100] Step S602: Determine whether the action status is consistent with the target status.

[0101] The target status refers to the operating state of the actuator, which is preset by technicians according to the actual situation, and will not be elaborated here.

[0102] If the actions are consistent, then they are consistent; if the actions are inconsistent, then they are inconsistent.

[0103] Step S603: If they match, continue to output the output signal.

[0104] Maintaining the output signal means keeping the current control signal output to ensure the actuator continues to operate.

[0105] If the action status matches the target status, the PLC outputs a signal, and the actuator continues to operate, ensuring that the testing or production process is not disturbed.

[0106] Step S604: If there is a discrepancy, pause the output and resend the output signal.

[0107] Pause output refers to temporarily stopping the output of control signals.

[0108] If the operating status is inconsistent with the target status, the PLC first pauses the actuator, delays, and then sends the control signal again to ensure that the actuator operates as expected and outputs again.

[0109] The step of pausing output and retransmitting the signal if there is a discrepancy also includes the following steps: Step S700: Obtain the number of consecutive corrections and set the reference number of corrections.

[0110] The number of consecutive correction attempts refers to the number of times the action status is continuously attempted to be corrected.

[0111] The number of "pause and retransmission" is recorded by a preset counter on the PLC. The counter is incremented by 1 after each correction (e.g., 1 retry is recorded as 1, 3 retry is recorded as 3). The counter value is displayed in real time on the HMI alarm page, and a reference correction number can be set for easy operator monitoring.

[0112] Step S701: If the number of consecutive corrections does not reach the reference number of corrections, the signal is reacquired.

[0113] The reference correction count refers to the preset maximum number of correction attempts, which is set in advance by technicians according to the actual situation, and will not be elaborated here.

[0114] Reacquiring signals refers to acquiring the output and feedback signals again.

[0115] If the number of consecutive corrections does not reach the reference number of corrections, the signal will be reacquired.

[0116] For example, the reference correction count is preset to 3 times (which can be modified by the HMI). If less than 3 times are reached, the PLC will re-acquire the output and feedback signals and repeat the comparison and correction process to avoid misjudging the fault due to momentary interference.

[0117] Step S702: When the number of consecutive corrections reaches the reference number of corrections, an HMI alarm is triggered and the anomaly is recorded.

[0118] HMI alarms refer to alarms issued through the human-machine interface.

[0119] For example, when the failure occurs 3 times, the PLC sends an alarm command to the HMI (audio-visual alarm + red pop-up window), and locks the output function (password required to unlock). Abnormal information (such as "Mold opening correction failed 3 times, time 14:30") is stored in the system log for easy tracing of the cause of the failure.

[0120] It also includes the following steps: Step S800: Collect the preset operating parameters of the actuator and set the safety interruption conditions.

[0121] Operating parameters refer to various parameters of the actuator during operation, such as speed and pressure.

[0122] First, physical signals such as pressure, position, and action status of the injection molding machine are collected by the sensor actuator. These signals are then converted into digital signals by the IO module (such as ADC to analog signal or optocoupler isolation switch signal), and then transmitted to the PLC via the industrial bus. The PLC reads and records these digital signals according to the preset control logic, binds them with timestamps to form operating parameters, and technicians set safety interruption conditions. The data is then synchronously stored in the data register or uploaded to the HMI or host computer via the communication module to complete the acquisition of operating parameters.

[0123] Step S801: If the running parameters determine that the safety interrupt conditions are met, then trigger and output the preset safety interrupt command.

[0124] Safety interruption conditions refer to the preset conditions that trigger safety interruptions. These are pre-set by technicians based on actual conditions and will not be elaborated upon here.

[0125] Safety interrupt instructions are instructions used to interrupt the execution of mandatory functions by the actuator.

[0126] If the running parameters determine that the safety interrupt conditions are met, then a safety interrupt command is triggered and output.

[0127] Step S802: Based on the security interrupt instruction, identify the security interrupt condition type and set the HMI type, emergency stop type, and no-permission type.

[0128] The security interruption condition type refers to the specific type that triggers the security interruption, such as HMI type, emergency stop type, and no permission type.

[0129] The PLC analyzes safety interruption instructions to determine the type of safety interruption condition. When an engineer operates the IO forced control function on the HMI, if they switch pages midway, the system will detect that the current page has a unique code of "HMI type". If the injection molding machine is operating normally under IO forced control, and the physical emergency stop button is pressed, the PLC will detect that the emergency stop signal changes from the default 24V high level to 0V low level, which is the "emergency stop type". When the on-site operator attempts to start the IO forced control function, they need to enter an authorization code in the HMI. If the authorization code does not match, it is the "no authorization type", providing a basis for subsequent differentiated processing.

[0130] Step S803: Determine the security scheme based on the security interruption condition type and execute the security scheme.

[0131] A security scheme refers to a solution for handling different security interruption conditions.

[0132] The method for determining the security scheme is described in steps S900 to S902, and will not be repeated here.

[0133] The method for determining a security plan includes the following steps: Step S900: When the security interruption condition type is HMI type, all running programs will be shut down as a security measure.

[0134] HMI type refers to the type of safety interruption associated with the human-machine interface.

[0135] When switching pages in the HMI, the PLC detects the status change through a communication interrupt and immediately sends a "reset command" (output 0V) to all IO modules, forcing the function menu to automatically close and return to the home page, thus avoiding the risk caused by the operator forgetting to close the forced function after switching pages.

[0136] Step S901: When the safety interruption condition type is emergency stop, output a preset forced function command, control the actuator of the injection molding machine to stop urgently based on the forced function command, and use it as a safety solution.

[0137] Emergency stop type refers to the safety interruption type when the user presses the emergency stop button.

[0138] Forced function commands are commands used for emergency stops.

[0139] When the emergency stop button is pressed, the PLC outputs a forced function command to the main control circuit (the 24V signal triggers the emergency stop relay), cutting off the power to the actuators (motor, solenoid valve) and shutting down all forced signals. The equipment enters a "safety lockout" state, and the emergency stop button must be reset and a password entered to restart it, ensuring personnel safety in emergency situations.

[0140] Step S902: When the security interruption condition type is "no permission type", the operation instructions of the preset forced function will be blocked and a prompt will be displayed as a security solution.

[0141] "No permission type" refers to the scenario where a user without permission performs a forced function.

[0142] Blocking operation instructions means preventing the execution of specific operation instructions.

[0143] A pop-up prompt refers to a prompt message displayed on the human-computer interface.

[0144] For example, when a user clicks the "Force Control" button, the PLC fails to verify the authorization code and immediately blocks the operation command (the button becomes grayed out and cannot be clicked). The HMI then displays a "Please contact an engineer to obtain authorization" message to prevent non-professionals from accidentally operating the equipment and causing damage or safety accidents.

[0145] Based on the same inventive concept, embodiments of the present invention provide a control system for custom input / output of an injection molding machine's I / O module, comprising: The acquisition module is used to obtain the selected control type.

[0146] The memory is used to store programs that implement custom input / output control methods for any injection molding machine I / O module.

[0147] The processor loads and executes programs from memory.

[0148] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0149] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A control method of an injection molding machine (IO) module custom input / output, characterized by, The method comprises the following steps: In response to a trigger instruction, a selection control type is obtained, and a target delay time is set; Based on the selection control type, a controller timing of PLC digital quantity input and output control is collected; If the controller timing does not reach the target delay time, the timing is continued; If the controller timing reaches the target delay time, a selection signal is collected; The level information is determined according to the selection signal; After the preset actuator output corresponding to the level information is controlled, the preset PLC controller starts timing, and a running time is obtained; It is judged whether the running time reaches a preset running time setting value, and if the running time does not reach the preset running time setting value, the selection signal will continue to be output as a running scheme; If the running time reaches the preset running time setting value, the collected sensor signal is shielded, and a forced signal is generated by simulation; Based on the forced signal, the preset actuator is forced to reset, the collection of the controller timing is returned, and the preset actuator is controlled to execute the running scheme.

2. The control method of claim 1, wherein, The method for determining the level information comprises the following steps: When the selection signal is a preset pulse signal, a fixed period alternating level is set according to the pulse signal, and the fixed period alternating level is taken as the level information; When the selection signal is a preset continuous signal, a constant level is set according to the continuous signal, and the constant level is taken as the level information.

3. The control method of claim 1, wherein, The method further comprises the following steps: In response to a digital quantity input instruction, an optimization mode is selected; If the optimization mode is a preset signal superposition mode, the input signal type and signal superposition parameters are collected; According to the signal type and signal superposition parameters, signal superposition is started to simulate complex fault scene input, the superimposed signal is received by the preset PLC controller and responds, test data is obtained and recorded.

4. The control method of claim 3, wherein, After the optimization mode is selected in response to the digital quantity input instruction, the method further comprises the following steps: If the optimization mode is a preset working condition linkage mode, a working condition signal that needs to be forced to input under the production working condition is collected; It is judged whether the working condition signal reaches a preset working condition trigger condition; If the working condition signal does not reach the preset working condition trigger condition, the working condition signal is continuously monitored; If the working condition signal reaches the preset working condition trigger condition, a binding signal is output according to the working condition signal; Based on the binding signal, a preset forced input action is performed.

5. The control method of claim 1, wherein, The method further comprises the following steps: The output signal and the feedback signal sent by the PLC after the forced output function is started are collected; The action condition and the target condition are obtained by comparing the output signal and the feedback signal; It is judged whether the action condition is consistent with the target condition; If they are consistent, the output of the output signal is continued; If they are not consistent, the output is paused and the output signal is re-sent.

6. The control method of claim 5, wherein, After the output is paused and the signal is re-sent if they are not consistent, the method further comprises the following steps: The number of continuous corrections is obtained, and a reference correction number is set; When the number of continuous corrections does not reach the reference correction number, the signal is re-collected; When the number of continuous corrections reaches the reference correction number, an HMI alarm is triggered and an exception is recorded.

7. The control method of claim 1, wherein, The method further comprises the following steps: The running parameters in the execution of the preset actuator are collected, and a safety interruption condition is set; If the running parameters meet the safety interruption condition, a preset safety interruption instruction is triggered and output; Based on the safety interruption instruction, the safety interruption condition type is identified, and an HMI type, an emergency stop type and a no authority type are set. Determine a safety scheme based on the safety interrupt condition type, and execute the safety scheme.

8. The control method of claim 7, wherein, The safety scheme determination method comprises: When the safety interrupt condition type is an HMI type, shutting down all programs being executed as the safety scheme; When the safety interrupt condition type is an emergency stop type, outputting a preset forced function instruction, controlling an emergency stop of an actuator of the injection molding machine based on the forced function instruction, and taking the forced function instruction as the safety scheme; When the safety interrupt condition type is a no permission type, shielding a preset forced function operation instruction and popping up a prompt as the safety scheme.

9. A control system for injection molding machine IO module custom input output, characterized in that, Comprise: An acquisition module for acquiring a selection control type; A memory for storing a program for implementing the control method of the injection molding machine IO module self-defined input and output according to any one of claims 1 to 8; A processor for loading and executing the program in the memory.

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