Injection molding process parameter dynamic acquisition large model analysis system

Abstract

The invention discloses an injection molding process parameter dynamic acquisition large model analysis system, relates to the field of intelligent manufacturing, solves the problem of low finished product rate of injection molding products, and comprises a data acquisition module, a data analysis module and a monitoring module, the data acquisition module is used for acquiring real-time pressure values of corresponding injection stages and pressure maintaining stages and real-time temperature values of corresponding cooling stages of a plurality of groups of injection molding products and sending the real-time pressure values and the real-time temperature values to the data analysis module; the data analysis module comprises a pressure analysis unit and a temperature analysis unit and is used for constructing an injection molding process parameter analysis large model and sending the model to the monitoring module; the monitoring module is used for monitoring the injection molding process according to the injection molding process parameter analysis large model, obtaining a pressure rising signal and a pressure reducing signal, sending the pressure rising signal and the pressure reducing signal to the pressure regulation and control module, and obtaining a temperature rising signal or a temperature reducing signal and sending the temperature rising signal or the temperature reducing signal to the temperature regulation and control module; according to accurate adjustment of injection molding process parameters, the rate of finished products of injection molding products is guaranteed.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of intelligent manufacturing, and particularly relates to a dynamic acquisition large model analysis system for injection molding process parameters. BACKGROUND

[0002] The injection molding process parameters refer to key variables that need to be monitored and adjusted in the injection molding production process, including temperature, pressure, speed and time, etc.; the dynamic acquisition emphasizes the real-time and continuity of data acquisition, which is collected by sensors and industrial internet of things protocols at a millisecond or second level frequency; the parameter large model refers to an intelligent model constructed based on deep learning or machine learning algorithm, and the parameter quantity usually reaches billions, which has strong generalization ability.

[0003] However, at the present stage, different types of injection molding products share the same adjustment standard when the injection molding process parameters are analyzed and adjusted, and due to the different injection molding process parameters of different injection molding products in practice, there is deviation in adjusting the injection molding process parameters, which affects the yield of the injection molding products.

[0004] Therefore, the application provides a dynamic acquisition large model analysis system for injection molding process parameters. SUMMARY

[0005] The application aims to provide a dynamic acquisition large model analysis system for injection molding process parameters to solve the problems in the background.

[0006] In order to achieve the above-mentioned purpose, the application adopts the following technical scheme:

[0007] A dynamic acquisition large model analysis system for injection molding process parameters comprises a stage division module, a data acquisition module, a data analysis module, a monitoring module, a pressure control module and a temperature control module, the stage division module is used for dividing the injection molding process of the injection molding process into multiple injection molding stages; the data acquisition module is used for acquiring real-time pressure values of multiple groups of injection molding products corresponding to injection stages and holding pressure stages and real-time temperature values of cooling stages and sending them to the data analysis module; the data analysis module is used for constructing an injection molding process parameter analysis large model and sending it to the monitoring module;

[0008] The monitoring module is used for monitoring the injection molding process according to the injection molding process parameter analysis large model, obtaining a pressure rising signal and a pressure reducing signal and sending them to the pressure control module, and obtaining a temperature rising signal or a temperature reducing signal and sending them to the temperature control module;

[0009] The pressure control module is used for adjusting the pressure inside the injection cavity according to the pressure rising signal or the pressure reducing signal, and the temperature control module is used for adjusting the temperature inside the injection cavity according to the temperature rising signal or the temperature reducing signal.

[0010] Further, the injection molding stage comprises a feeding stage, a plasticizing stage, an injection stage, a pressure maintaining stage and a cooling stage; the real-time pressure value is the real-time injection pressure of the injection stage and the real-time pressure maintaining pressure of the pressure maintaining stage; the real-time temperature value is the cavity temperature value and the pipe temperature value corresponding to the same injection molding product.

[0011] Further, the data analysis module comprises a pressure analysis unit and a temperature analysis unit, the pressure analysis unit is used for analyzing the real-time pressure value of the injection stage and the pressure maintaining stage, and a golden pressure curve corresponding to the injection molding product is constructed, and the construction process of the golden pressure curve is specifically as follows:

[0012] The real-time pressure value of the injection molding product is obtained, and the real-time injection pressure and the real-time pressure maintaining pressure of the injection molding product in the injection stage are obtained.

[0013] The horizontal axis is regarded as the time axis T, the vertical axis is regarded as the pressure axis Y, the real-time injection pressure and the corresponding time are marked in the region composed of the time axis and the pressure axis, and then the injection pressure curve corresponding to the injection molding product is obtained through curve connection.

[0014] Similarly, the injection pressure curves corresponding to a plurality of different injection molding products are drawn, the starting points of the plurality of injection pressure curves are aligned, and the common part of the plurality of injection pressure curves is obtained by truncating at the end of the shortest injection pressure curve.

[0015] A plurality of injection collection points are set based on the duration corresponding to the common part.

[0016] The real-time injection pressure shown by any injection collection point is read, the real-time injection pressures of a plurality of injection molding products corresponding to the same injection collection point are added and averaged to obtain the injection pressure average value of the corresponding injection collection point, and the injection pressure average values of all injection collection points are calculated in the same way.

[0017] Further, the construction process of the golden pressure curve further comprises:

[0018] Based on the injection pressure average value of the same injection collection point and the real-time injection pressures of a plurality of injection molding products, the injection pressure standard deviation of the corresponding injection collection point is calculated, and the maximum value of the injection pressure standard deviation is selected as the curve fluctuation distance by traversing and comparing the injection pressure standard deviations corresponding to all injection collection points.

[0019] The injection pressure average values of different injection collection points are marked in the region composed of the time axis and the pressure axis, and the average injection pressure curve is obtained by connecting the curves, the average injection pressure curve is translated upward and downward by the curve fluctuation distance respectively, and the region formed is recorded as the injection curve fluctuation region.

[0020] Similarly, the real-time holding pressure and the corresponding time are marked in the region composed of the time axis and the pressure axis, and a plurality of holding pressure curves are obtained by connecting the curves;

[0021] A plurality of holding acquisition points are set in the common part of the holding pressure curve, and the real-time holding pressure corresponding to the holding acquisition points is read; the holding pressure mean and the holding pressure standard deviation corresponding to the holding acquisition points are calculated based on the real-time holding pressure of the holding acquisition points;

[0022] The average holding pressure curve and the holding curve fluctuation region are determined according to the holding pressure mean and the holding pressure standard deviation.

[0023] The average holding pressure curve and the average injection pressure curve are recorded as the golden pressure curve.

[0024] Further, the temperature analysis unit is used to analyze the real-time temperature value of the cooling stage, and to construct a golden temperature curve corresponding to the injection molded product, the construction process of the golden temperature curve comprising:

[0025] The real-time temperature value of the injection molded product is obtained, and the cavity temperature value and the pipe temperature value corresponding to the injection molded product at any time are obtained, and the cavity temperature value and the pipe temperature value at the same time are added and averaged to obtain the cooling temperature value at the corresponding time;

[0026] The horizontal axis is regarded as the time axis T, the vertical axis is regarded as the temperature value W, the cooling temperature value and the corresponding time are marked in the region composed of the time axis and the temperature axis, and then the cooling temperature curve corresponding to the injection molded product is obtained by connecting the curves;

[0027] The entire cooling temperature curve is traversed, the minimum temperature value and the maximum temperature value in the cooling temperature curve are identified, and the temperature difference value of the corresponding cooling temperature curve is obtained by subtracting the minimum temperature value from the maximum temperature value; then the curve tangent slope of the cooling temperature curve at any time is calculated; the maximum value of the absolute value of the curve tangent slope is identified as the curve peak change rate of the corresponding cooling temperature curve; the cooling intensity index of the corresponding cooling temperature curve is calculated by the formula;

[0028] The cooling intensity index is specifically:

[0029] Cooling intensity index = curve peak change rate x first coefficient + temperature difference value x second coefficient;

[0030] Similarly, a plurality of cooling temperature curves corresponding to different injection molded products are drawn, and the cooling intensity index of each cooling temperature curve is calculated.

[0031] Further, the construction process of the golden temperature curve further comprises:

[0032] If the cooling intensity index is less than the first intensity index, the corresponding cooling temperature curve is divided into the first temperature curve set; if the curve temperature value is greater than or equal to the first intensity index and less than the second intensity index, the corresponding cooling temperature curve is divided into the second temperature curve set; if the cooling intensity index is greater than or equal to the second intensity index, the corresponding cooling temperature curve is divided into the third temperature curve set; wherein the first intensity index is less than the second intensity index;

[0033] All cooling temperature curves in the first temperature curve set are identified, and the cooling temperature values of the cooling temperature curves in the first temperature curve set at the same time are added to obtain the cooling temperature mean value at the corresponding time, and the cooling temperature mean value is connected to obtain the preselected golden temperature curve corresponding to the first cooling temperature set;

[0034] The similarity distance between any cooling temperature curve and the preselected golden temperature curve is calculated;

[0035] The similarity distance between all cooling temperature curves in the first cooling temperature set and the preselected golden temperature curve is calculated in the same way, and the first similarity distance corresponding to the first cooling temperature set is obtained by adding and averaging all the similarity distances in the first cooling temperature set;

[0036] The second similarity distance of the second cooling temperature set and the corresponding preselected golden temperature curve and the third similarity distance of the third cooling temperature set and the corresponding preselected golden temperature curve are calculated in the same way.

[0037] Further, the construction process of the golden temperature curve further comprises:

[0038] The calculation weight corresponding to the first similarity distance is denoted as QZ1, the calculation weight corresponding to the second similarity distance is denoted as QZ2, and the calculation weight corresponding to the third similarity distance is denoted as QZ3; QZ1, QZ2 and QZ3 are assigned values;

[0039] The golden temperature curve corresponding to the injection molded product is calculated according to the preselected golden temperature curve and the corresponding calculation weight of the first cooling temperature set, the second cooling temperature set and the third cooling temperature set, and the process of obtaining the golden temperature curve is:

[0040] The cooling temperature mean value of the preselected golden temperature curve at any time in the first cooling temperature set is multiplied by QZ1, the cooling temperature mean value of the preselected golden temperature curve at any time in the second cooling temperature set is multiplied by QZ2, and the cooling temperature mean value of the preselected golden temperature curve at any time in the third cooling temperature set is multiplied by QZ3 = the golden cooling temperature mean value at the corresponding time in the golden temperature curve; all the golden cooling temperature mean values at all times are connected to obtain the golden temperature curve of the injection molded product;

[0041] The area formed by all the preselected golden temperature curves is referred to as a temperature curve fluctuation area.

[0042] Further, the injection molding process parameter analysis large model comprises a golden pressure curve, an injection curve fluctuation area, a holding pressure curve fluctuation area, a golden temperature curve, and a temperature curve fluctuation area.

[0043] Further, the detection process of the monitoring module is specifically as follows:

[0044] The golden pressure curve, the injection curve fluctuation area, and the holding pressure curve fluctuation area in the injection molding process parameter analysis large model are obtained; the golden pressure curve in the injection stage and the golden pressure curve in the holding pressure stage are obtained respectively; the golden temperature curve and the temperature curve fluctuation area of the injection product are obtained;

[0045] The golden injection duration corresponding to the golden pressure curve in the injection stage and the golden holding pressure duration corresponding to the golden pressure curve in the holding pressure stage are read; the duration of the injection stage of the injection molding machine is adjusted to the golden injection duration, and the duration of the holding pressure stage of the injection molding machine is adjusted to the golden holding pressure duration;

[0046] The actual pressure value of the injection molding machine in the injection stage is collected, and the first actual pressure value in the injection stage is aligned with the golden pressure curve in the injection stage;

[0047] The actual pressure value is compared with the injection curve fluctuation area, if the actual pressure value is located in the injection curve fluctuation area, no operation is performed, if the actual pressure value is located above the injection curve fluctuation area, a pressure reduction signal is generated, and if the actual pressure value is located below the injection curve fluctuation area, a pressure increase signal is generated.

[0048] Further, the detection process of the monitoring module further comprises:

[0049] The actual pressure value of the injection molding machine in the holding pressure stage is collected, and the first actual pressure value in the holding pressure stage is aligned with the golden pressure curve in the holding pressure stage;

[0050] The actual pressure value is compared with the holding pressure curve fluctuation area, if the actual pressure value is located in the holding pressure curve fluctuation area, no operation is performed, if the actual pressure value is located above the holding pressure curve fluctuation area, a pressure reduction signal is generated, and if the actual pressure value is located below the holding pressure curve fluctuation area, a pressure increase signal is generated.

[0051] The actual cavity temperature value and the actual pipe temperature value of the injection molding machine in the cooling stage are collected, the actual cavity temperature value is added to the actual pipe temperature value to obtain an actual cooling temperature value, and the first actual cooling temperature value is aligned with the golden temperature curve;

[0052] The actual cooling temperature value is compared with the temperature curve fluctuation region, if the actual cooling temperature value is located in the temperature curve fluctuation region, no operation is performed, if the actual cooling temperature value is located above the temperature curve fluctuation region, a temperature reduction signal is generated, and if the actual cooling temperature value is located below the temperature curve fluctuation region, a temperature increase signal is generated.

[0053] Therefore, by adopting the technical scheme, the present application has the beneficial effects:

[0054] 1、The injection molding process of the injection molding process is divided into multiple injection molding stages by the stage division module first, then the data acquisition module acquires multiple sets of real-time pressure values of the injection stage and the holding stage and the real-time temperature value of the cooling stage of the injection molding product and sends them to the data analysis module, then the data analysis module including the pressure analysis unit and the temperature analysis unit constructs an injection molding process parameter analysis large model and sends it to the monitoring module, the present application based on deep learning and analysis of the data of the injection molding product, obtains the injection pressure standard, the holding pressure standard and the cooling temperature standard corresponding to the injection molding product, and constructs an injection molding process parameter analysis large model.

[0055] 2、The monitoring module monitors the injection molding process according to the injection molding process parameter analysis large model, obtains the pressure increase signal and the pressure decrease signal and sends them to the pressure control module, obtains the temperature increase signal or the temperature decrease signal and sends them to the temperature control module, finally the pressure control module is used for adjusting the pressure inside the injection cavity according to the pressure increase signal or the pressure decrease signal, and the temperature control module is used for adjusting the temperature inside the injection cavity according to the temperature increase signal or the temperature decrease signal, the present application realizes accurate control of the injection molding process by using the injection pressure standard, the holding pressure standard and the cooling temperature standard corresponding to each injection molding product. BRIEF DESCRIPTION OF DRAWINGS

[0056] In order to facilitate the understanding of those skilled in the art, the present application will be further described below with reference to the accompanying drawings.

[0057] Figure 1 The overall system block diagram of the present application is shown in the figure;

[0058] Figure 2 The structure of the injection molding machine in the present application is shown in the figure;

[0059] Figure 3 The injection pressure curve in the present application is shown in the figure;

[0060] Figure 4 The injection pressure fluctuation region in the present application is shown in the figure;

[0061] Figure 5 The method flow chart of the method involved in the present application is shown in the figure. DETAILED DESCRIPTION

[0062] The technical solutions of the present application will be described clearly and completely below in conjunction with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work are within the protection scope of the present application.

[0063] Embodiment 1: Please refer to Figures 1-4 As shown in the figure, the technical solution provided by the present application is: an injection molding process parameter dynamic acquisition large model analysis system, comprising a stage division module, a data acquisition module, a data analysis module, a monitoring module, a pressure regulation module and a temperature regulation module.

[0064] The stage division module is used to divide the injection molding process of the injection molding process into multiple injection molding stages; wherein the injection molding stage includes: a feeding stage, a plasticizing stage, an injection stage, a pressure maintaining stage and a cooling stage.

[0065] The injection molding process refers to the industrialized production process of making various shaped products from thermoplastic or thermosetting plastics by an injection molding machine and a mold. The core principle is: heating and melting the raw plastics, and then injecting them into a closed injection molding cavity at high pressure and high speed, and obtaining the corresponding injection molding products after cooling and solidification.

[0066] Please refer to Figure 2 As shown in the figure, there is a rotating screw inside the injection molding machine and a heating ring outside. After the raw plastics are injected into the injection molding machine through the feeding port, the granular raw plastics are plasticized into molten plastics through the rotating shear of the screw and the external heating.

[0067] A fixed amount of raw plastics is weighed, and the granules of raw plastics are added to the corresponding feeding port of the injection molding machine, so that they fall into the barrel of the injection molding machine under the action of gravity. This step is recorded as the feeding stage. After the raw plastics are completely dropped into the barrel, the raw plastics are heated to above the melting point through the combined action of the external heating ring and the rotating shear of the screw, and the raw plastics are plasticized into molten plastics. This step is recorded as the plasticizing stage.

[0068] It should be noted that the screw will move backward under the back pressure of the molten plastics while rotating, and when it retreats to the preset range, the screw stops rotating, and at this time the molten plastics are gathered at the head of the screw (i.e. the front end of the barrel).

[0069] The injection molding operation is started, the screw is driven forward at high speed under the drive of hydraulic or electric, the molten plastic gathered in the head of the screw is injected into the injection cavity of the mold through the nozzle at the front end of the cylinder at high pressure and speed, which is recorded as the injection stage; when the inside of the injection cavity is filled, the screw continues to maintain a certain pressure (less than the injection pressure) and slowly pushes forward to supplement the molten plastic into the injection cavity, which lasts for a preset time, which is recorded as the holding stage; after the injection stage ends, the molten plastic is cooled and solidified from the surface to the inside through the cooling pipeline inside the injection molding machine to obtain the final injection product;

[0070] It should be noted that, since the feeding stage and the plasticizing stage are pre-operation of the injection molding process, the present application only analyzes the injection stage, the holding stage and the cooling stage;

[0071] The data acquisition module is used for acquiring a plurality of groups of real-time pressure values of the injection stage and the holding stage and real-time temperature values of the cooling stage of the injection molding products and sending them to the data analysis module; wherein the real-time pressure values include real-time injection pressure of the injection stage and real-time holding pressure of the holding stage; the real-time temperature values include cavity temperature values and pipeline temperature values corresponding to the same injection molding product;

[0072] In practice, a pressure sensor is installed on the inner wall of the injection cavity corresponding to the injection molding machine, the real-time pressure value inside the injection cavity is acquired by the pressure sensor in real time, the real-time pressure value is one-to-one corresponding to the number of the corresponding time, and the real-time pressure value of the injection molding product is obtained;

[0073] A first temperature sensor is installed on the inner wall of the injection cavity corresponding to the injection molding machine, and a second temperature sensor is installed inside the cooling pipeline, the cavity temperature value of the injection cavity in the cooling stage is measured by the first temperature sensor in real time; the pipeline temperature value of the cooling pipeline in the cooling stage is measured by the second temperature sensor in real time; the cavity temperature value and the pipeline temperature value are one-to-one corresponding to the number of the corresponding time, and the real-time temperature value of the injection molding product in the cooling stage is obtained;

[0074] It should be noted that, the real-time pressure value and the real-time temperature value are produced under the same conditions of raw materials, environmental conditions and injection molding machines, and the defective and defective products in the injection molding products are discarded; specifically, the defective and defective products are injection molding products with appearance defects (such as shrinkage, pits, weld marks and cracking), size defects (such as warping or deformation) and functional defects (such as thread holes not passing or slipping teeth).

[0075] In the present application, the data analysis module includes a pressure analysis unit and a temperature analysis unit;

[0076] On the one hand, the pressure analysis unit is used to analyze the real-time pressure values ​​during the injection and holding stages, and construct the corresponding golden pressure curve for the injection molded product. The construction process is as follows:

[0077] Obtain the real-time pressure value of the injection molded product to obtain the real-time injection pressure and real-time holding pressure of the injection molded product during the injection stage;

[0078] like Figures 3-4 As shown, the horizontal axis is regarded as the time axis T, and the vertical axis is regarded as the pressure axis Y. The real-time injection pressure and the corresponding time are marked in the area formed by the time axis and the pressure axis. Then, the injection pressure curve of the corresponding injection molded product is obtained by connecting the curves.

[0079] Similarly, draw injection pressure curves for multiple different injection molded products, align the starting points of the multiple injection pressure curves, and truncate them at the end of the shortest injection pressure curve to obtain the common part of the multiple injection pressure curves.

[0080] Multiple injection collection points are set based on the duration of the common part; specifically, the longer the duration of the common part, the more injection collection points are set; preferably, 100 injection collection points are set per second.

[0081] Read the real-time injection pressure shown at any injection sampling point, add up the real-time injection pressures of multiple injection molded products corresponding to the same injection sampling point, and take the average to obtain the average injection pressure of the corresponding injection sampling point; similarly, calculate the average injection pressure of all injection sampling points.

[0082] Based on the average injection pressure at the same injection sampling point and the real-time injection pressure of multiple injection molded products, the standard deviation of injection pressure at the corresponding injection sampling point is calculated; the standard deviation of injection pressure at all injection sampling points is compared and the maximum value of the standard deviation of injection pressure is selected as the curve fluctuation distance.

[0083] The average injection pressure at different injection collection points is plotted within the area formed by the time axis and the pressure axis, and connected by a curve to obtain the average injection pressure curve. The area formed by shifting the average injection pressure curve upwards and downwards by the curve fluctuation distance is called the injection curve fluctuation area.

[0084] Similarly, the real-time holding pressure and the corresponding time are marked in the area formed by the time axis and the pressure axis, and connected by curves to obtain multiple holding pressure curves; the starting points of the multiple holding pressure curves are aligned and the ending points are truncated to obtain the common part of the holding pressure curves.

[0085] Multiple pressure holding points are set within the common part of the pressure holding curve, and the real-time pressure holding at the corresponding pressure holding points is read. The mean pressure holding and standard deviation of the pressure holding at the corresponding pressure holding points are calculated based on the real-time pressure holding at the corresponding pressure holding points.

[0086] The average holding pressure curve and the fluctuation range of the holding pressure curve are determined based on the mean holding pressure and the standard deviation of the holding pressure.

[0087] The average holding pressure curve and the average injection pressure curve are denoted as the golden pressure curve.

[0088] On the other hand, the temperature analysis unit is used to analyze the real-time temperature values ​​during the cooling stage and construct the golden temperature curve for the corresponding injection molded product. The construction process is as follows:

[0089] The real-time temperature value of the injection molded product is obtained, and the cavity temperature value and pipe temperature value of the corresponding injection molded product at any time are obtained. The cavity temperature value and pipe temperature value at the same time are added together and the average is taken as the cooling temperature value at the corresponding time.

[0090] Treat the horizontal axis as the time axis T and the vertical axis as the temperature value W. Mark the cooling temperature value and the corresponding time within the area formed by the time axis and the temperature axis, and then connect them with curves to obtain the cooling temperature curve of the corresponding injection molded product.

[0091] Traverse the entire cooling temperature curve, identify the minimum and maximum temperatures, and subtract the minimum temperature from the maximum to obtain the temperature difference value of the corresponding cooling temperature curve. Then, calculate the slope of the tangent line of the cooling temperature curve at any time. Identify the maximum absolute value of the tangent line slope and record it as the curve peak change rate of the corresponding cooling temperature curve. Calculate the cooling intensity index of the corresponding cooling temperature curve using a formula. In practice, the quotient of the difference between the vertical axis and the difference between the horizontal axis of the two adjacent times on the left and right sides of the corresponding time is taken as the slope of the tangent line of the curve at the corresponding time.

[0092] The formula for calculating the cooling intensity index is as follows:

[0093] Cooling intensity index = curve peak change rate × first coefficient + temperature difference value × second coefficient; where the curve peak change rate and temperature difference value are calculated using only numerical values. The first and second coefficients are constants, and their values ​​depend on the degree of influence of the temperature change rate and temperature fluctuation range on the injection molded product.

[0094] Specifically, if the influence degree of the temperature change rate on the injection molded product is higher than the influence degree of the temperature fluctuation range on the injection molded product, the first coefficient is greater than the second coefficient, otherwise, the second coefficient is greater than the first coefficient; if the influence degrees of the temperature change rate and the temperature fluctuation range on the injection molded product cannot be confirmed, the first coefficient and the second coefficient are both 1;

[0095] The cooling intensity index is used to describe the temperature change intensity of the cooling temperature curve, and the intensity of the cooling process is quantified by capturing the information of the two dimensions of the temperature fluctuation range and the cooling temperature change rate;

[0096] Similarly, the cooling temperature curves corresponding to a plurality of different injection molded products are drawn, and the cooling intensity index of each cooling temperature curve is calculated;

[0097] If the cooling intensity index is less than the first intensity index, the corresponding cooling temperature curve is divided into the first temperature curve set; if the curve temperature value is greater than or equal to the first intensity index and less than the second intensity index, the corresponding cooling temperature curve is divided into the second temperature curve set; if the cooling intensity index is greater than or equal to the second intensity index, the corresponding cooling temperature curve is divided into the third temperature curve set; wherein the first intensity index is less than the second intensity index, and the first intensity index and the second intensity index can be obtained by analyzing the historical cooling temperature curve;

[0098] The cooling temperature curves in the first temperature curve set are identified, the cooling temperature values of the cooling temperature curves in the first temperature curve set at the same time are added to obtain the cooling temperature mean value at the corresponding time, and the preselected golden temperature curve corresponding to the first cooling temperature set is obtained by connecting the cooling temperature mean values;

[0099] The similarity distance XJ between any cooling temperature curve and the preselected golden temperature curve is calculated by the formula, and the formula is as follows:

[0100] ; wherein i is the number of different time in the first cooling temperature set, n is the upper limit value of i, WDi is the cooling temperature value corresponding to the cooling temperature curve at i time; HJi is the cooling temperature mean value of the preselected golden temperature curve at i time;

[0101] Similarly, the similarity distances between all cooling temperature curves in the first cooling temperature set and the preselected golden temperature curve are calculated; the similarity distances in the first cooling temperature set are added and averaged to obtain the first similarity distance corresponding to the first cooling temperature set;

[0102] Similarly, the second similarity distance of the second cooling temperature set and the corresponding preselected golden temperature curve, and the third similarity distance of the third cooling temperature set and the corresponding preselected golden temperature curve are calculated;

[0103] The calculation weight corresponding to the first similar distance is denoted as QZ1, the calculation weight corresponding to the second similar distance is denoted as QZ2, and the calculation weight corresponding to the third similar distance is denoted as QZ3; QZ1, QZ2 and QZ3 are assigned values;

[0104] Specifically, the maximum value in the first similar distance, the second similar distance and the third similar distance, the corresponding calculation weight is also larger, and the minimum value, the corresponding weight is also the minimum; preferably, the weight can be taken as 0.5, 0.3 and 0.2 respectively;

[0105] According to the preselected golden temperature curve corresponding to the first cooling temperature set, the second cooling temperature set and the third cooling temperature set and the corresponding calculation weight, the golden temperature curve corresponding to the injection molding product is calculated, and the process of obtaining the golden temperature curve is as follows: the average cooling temperature of the preselected golden temperature curve at any time in the first cooling temperature set is multiplied by QZ1, the average cooling temperature of the preselected golden temperature curve at any time in the second cooling temperature set is multiplied by QZ2, and the average cooling temperature of the preselected golden temperature curve at any time in the third cooling temperature set is multiplied by QZ3 = the average golden cooling temperature at the corresponding time in the golden temperature curve; all the average golden cooling temperatures at all times are connected to obtain the golden temperature curve of the injection molding product;

[0106] The area formed by all the preselected golden temperature curves is denoted as the temperature curve fluctuation area;

[0107] The data analysis module records the golden pressure curve, the injection curve fluctuation area, the holding pressure curve fluctuation area, the golden temperature curve and the temperature curve fluctuation area as an injection molding process parameter analysis large model, and the data analysis module sends the injection molding process parameter analysis large model to the monitoring module;

[0108] In this embodiment, the injection pressure standard of the injection molding product in the injection stage is constructed by the golden pressure curve and the injection curve fluctuation area, the holding pressure standard of the injection molding product in the holding pressure stage is constructed by the golden pressure curve and the holding pressure curve fluctuation area, and the cooling temperature standard of the injection molding product in the cooling stage is constructed by the golden temperature curve and the temperature curve fluctuation area. Based on deep learning and analysis of the data of the injection molding product, the injection pressure standard, the holding pressure standard and the cooling temperature standard corresponding to the injection molding product are obtained, and finally the injection molding process is accurately controlled by using the injection pressure standard, the holding pressure standard and the cooling temperature standard corresponding to each injection molding product.

[0109] Specifically, the monitoring module is used to monitor the injection molding process according to the injection molding process parameter analysis large model, and the detection process of the monitoring module is as follows:

[0110] The golden pressure curve, the injection curve fluctuation area, and the pressure maintaining curve fluctuation area in the injection molding process parameter analysis large model are acquired; the golden pressure curve in the injection stage and the golden pressure curve in the pressure maintaining stage are obtained respectively; the golden temperature curve and the temperature curve fluctuation area of the injection molding product are acquired; the golden injection duration corresponding to the golden pressure curve in the injection stage and the golden pressure maintaining duration corresponding to the golden pressure curve in the pressure maintaining stage are read;

[0111] The duration of the injection stage of the injection molding machine is adjusted to the golden injection duration, and the duration of the pressure maintaining stage of the injection molding machine is adjusted to the golden pressure maintaining duration; it should be noted that adjusting the duration of the pressure maintaining stage and the injection stage can ensure that the injection molding product process flow is always within the best process window for stable production of qualified products; the cooling stage is the same;

[0112] The actual pressure value of the injection molding machine in the injection stage is collected, and the first actual pressure value in the injection stage is aligned with the golden pressure curve in the injection stage;

[0113] The actual pressure value is compared with the injection curve fluctuation area, if the actual pressure value is located in the injection curve fluctuation area, no operation is performed; if the actual pressure value is located above the injection curve fluctuation area, a pressure reduction signal is generated; if the actual pressure value is located below the injection curve fluctuation area, a pressure increase signal is generated; specifically, the specific values of pressure increase and decrease are the distance between the actual pressure value and the golden pressure curve;

[0114] In actual calculation, the distance formula between two points can be used to obtain;

[0115] The actual pressure value of the injection molding machine in the pressure maintaining stage is collected, and the first actual pressure value in the pressure maintaining stage is aligned with the golden pressure curve in the pressure maintaining stage;

[0116] The actual pressure value is compared with the pressure maintaining curve fluctuation area, if the actual pressure value is located in the pressure maintaining curve fluctuation area, no operation is performed; if the actual pressure value is located above the pressure maintaining curve fluctuation area, a pressure reduction signal is generated; if the actual pressure value is located below the pressure maintaining curve fluctuation area, a pressure increase signal is generated;

[0117] The actual cavity temperature value and the actual pipe temperature value of the injection molding machine in the cooling stage are collected, the actual cooling temperature value is obtained by averaging the actual cavity temperature value and the actual pipe temperature value; the first actual cooling temperature value is aligned with the golden temperature curve;

[0118] The actual cooling temperature value is compared with the temperature curve fluctuation region, if the actual cooling temperature value is in the temperature curve fluctuation region, no operation is performed, if the actual cooling temperature value is above the temperature curve fluctuation region, a temperature reduction signal is generated, and if the actual cooling temperature value is below the temperature curve fluctuation region, a temperature increase signal is generated.

[0119] The monitoring module sends the pressure increase signal or the pressure decrease signal to the pressure regulation module and sends the temperature increase signal or the temperature decrease signal to the temperature regulation module.

[0120] The pressure regulation module is used for adjusting the pressure inside the injection cavity according to the pressure increase signal or the pressure decrease signal, and the temperature regulation module is used for adjusting the temperature inside the injection cavity according to the temperature increase signal or the temperature decrease signal.

[0121] Embodiment 2: please refer to Figure 5 As shown, based on another concept of the same invention, an injection molding process parameter dynamic acquisition large model analysis method is proposed, comprising the following steps:

[0122] Step S1, multiple injection stages are divided, and multiple sets of real-time pressure values of injection stages and holding stages and real-time temperature values of cooling stages of injection products are collected;

[0123] Step S2, the real-time pressure values of the injection stage and the holding stage are analyzed, and the golden pressure curve, the injection curve fluctuation region and the holding curve fluctuation region corresponding to the injection product are constructed;

[0124] Step S3, the real-time temperature values of the cooling stage are analyzed, and the golden temperature curve and the temperature curve fluctuation region of the injection product are constructed;

[0125] Step S4, the injection process parameter analysis large model is obtained according to the golden pressure curve, the injection curve fluctuation region, the holding curve fluctuation region, the golden temperature curve and the temperature curve fluctuation region;

[0126] Step S5, the injection process parameter analysis large model is used to monitor and control the injection process.

[0127] The preferred embodiments of the above disclosed application are only used to help explain the application. The preferred embodiments do not describe all the details and do not limit the application to the specific embodiments. Obviously, according to the content of the specification, many modifications and changes can be made. The specification selects and describes these embodiments in order to better explain the principles and practical applications of the application, so that those skilled in the art can well understand and utilize the application. The application is limited by the claims and their entire scope and equivalents.

Claims

1. A large-scale model analysis system for dynamic acquisition of injection molding process parameters, characterized in that, The injection molding process is divided into multiple injection molding stages by the stage division module; the data acquisition module is used for collecting real-time pressure values of multiple groups of injection molding products corresponding to injection stages and pressure maintaining stages and real-time temperature values of cooling stages and sending them to the data analysis module; the data analysis module is used for constructing an injection molding process parameter analysis large model and sending it to the monitoring module; The monitoring module is used for monitoring the injection molding process according to the injection molding process parameter analysis large model, obtaining a pressure increase signal and a pressure decrease signal and sending them to the pressure control module, and obtaining a temperature increase signal or a temperature decrease signal and sending them to the temperature control module; The pressure control module is used for adjusting the pressure inside the injection cavity according to the pressure increase signal or the pressure decrease signal, and the temperature control module is used for adjusting the temperature inside the injection cavity according to the temperature increase signal or the temperature decrease signal.

2. The injection molding process parameter dynamic acquisition large model analysis system according to claim 1, characterized in that, The injection molding stage includes a feeding stage, a plasticizing stage, an injection stage, a pressure maintaining stage and a cooling stage; the real-time pressure value is the real-time injection pressure of the injection stage and the real-time pressure maintaining pressure of the pressure maintaining stage; the real-time temperature value is the cavity temperature value and the pipe temperature value corresponding to the same injection molding product.

3. The system of claim 1, wherein the system is configured to: The data analysis module includes a pressure analysis unit and a temperature analysis unit, the pressure analysis unit is used for analyzing the real-time pressure values of the injection stage and the pressure maintaining stage, and constructing the golden pressure curve corresponding to the injection molding product, the construction process of the golden pressure curve is as follows: Obtain the real-time pressure value of the injection molding product, obtain the real-time injection pressure and the real-time pressure maintaining pressure of the injection molding product in the injection stage; The horizontal axis is regarded as the time axis T, the vertical axis is regarded as the pressure axis Y, the real-time injection pressure and the corresponding time are marked in the area composed of the time axis and the pressure axis, and then the injection pressure curve corresponding to the injection molding product is obtained by connecting the curves; Similarly, draw the injection pressure curves corresponding to multiple different injection molding products, align the starting points of multiple injection pressure curves, and truncate at the end of the shortest injection pressure curve to obtain the common part of multiple injection pressure curves; Based on the duration of the common part, multiple injection collection points are set; Read the real-time injection pressure shown by any injection collection point, add and average the real-time injection pressures of multiple injection molding products corresponding to the same injection collection point to obtain the injection pressure average of the corresponding injection collection point; similarly, calculate the injection pressure average of all injection collection points.

4. The injection molding process parameter dynamic acquisition and large model analysis system according to claim 3, characterized in that, The construction process of the golden pressure curve also includes: Based on the injection pressure average of the same injection collection point and the real-time injection pressure of multiple injection molding products, the injection pressure standard deviation corresponding to the injection collection point is calculated; all injection collection points corresponding to the injection pressure standard deviation are traversed and compared, and the maximum value of the injection pressure standard deviation is selected as the curve fluctuation distance; The injection pressure averages of different injection collection points are marked in the area composed of the time axis and the pressure axis, and connected by curves to obtain the average injection pressure curve; the average injection pressure curve is translated upward and downward by the curve fluctuation distance respectively to form an injection curve fluctuation area; Similarly, the real-time holding pressure and the corresponding time are marked in the region composed of the time axis and the pressure axis, and a plurality of holding pressure curves are obtained by connecting the curves; The starting points of the plurality of holding pressure curves are aligned, and the endpoints are intercepted to obtain a common part of the holding pressure curve; A plurality of holding pressure collection points are set in the common part of the holding pressure curve, and the real-time holding pressure corresponding to the holding pressure collection points is read; The holding pressure mean and the holding pressure standard deviation corresponding to the holding pressure collection points are calculated based on the real-time holding pressure of the holding pressure collection points; 5. The injection molding process parameter dynamic acquisition and large model analysis system according to claim 4, characterized in that, The average holding pressure curve and the holding pressure curve fluctuation region are determined according to the holding pressure mean and the holding pressure standard deviation; The average holding pressure curve and the average injection pressure curve are recorded as the golden pressure curve. The temperature analysis unit is used to analyze the real-time temperature value of the cooling stage, and to construct the golden temperature curve corresponding to the injection molded product. The construction process of the golden temperature curve includes: Obtain the real-time temperature value of the injection molded product, and obtain the cavity temperature value and the pipe temperature value of the injection molded product at any time. The cavity temperature value and the pipe temperature value at the same time are added and averaged to obtain the cooling temperature value at the corresponding time; The horizontal axis is regarded as the time axis T, and the vertical axis is regarded as the temperature value W. The cooling temperature value and the corresponding time are marked in the region composed of the time axis and the temperature axis, and then the cooling temperature curve corresponding to the injection molded product is obtained by connecting the curves; Traverse the entire cooling temperature curve, identify the minimum temperature value and the maximum temperature value in the cooling temperature curve, and obtain the temperature difference value of the corresponding cooling temperature curve by subtracting the minimum temperature value from the maximum temperature value. Then calculate the curve tangent slope of the cooling temperature curve at any time. Identify the maximum value of the absolute value of the curve tangent slope as the curve peak change rate of the corresponding cooling temperature curve. Calculate the cooling intensity index of the corresponding cooling temperature curve by formula; The calculation formula of the cooling intensity index is:

6. The injection molding process parameter dynamic acquisition and large model analysis system according to claim 5, characterized in that, Cooling intensity index=curve peak change rate×first coefficient+temperature difference value×second coefficient; Similarly, a plurality of cooling temperature curves corresponding to different injection molded products are drawn, and the cooling intensity index of each cooling temperature curve is calculated. The construction process of the golden temperature curve also includes: If the cooling intensity index is less than the first intensity index, the corresponding cooling temperature curve is divided into the first temperature curve set. If the curve temperature value is greater than or equal to the first intensity index and less than the second intensity index, the corresponding cooling temperature curve is divided into the second temperature curve set. If the cooling intensity index is greater than or equal to the second intensity index, the corresponding cooling temperature curve is divided into the third temperature curve set. Wherein, the first intensity index is less than the second intensity index; Identify all cooling temperature curves in the first temperature curve set, add and sum the cooling temperature values of the cooling temperature curves in the first temperature curve set at the same time to obtain the cooling temperature mean at the corresponding time, and connect the cooling temperature mean to obtain the preselected golden temperature curve corresponding to the first cooling temperature set; Calculate the similarity distance between any cooling temperature curve and the preselected golden temperature curve; Similarly, the similarity distance between all cooling temperature curves in the first cooling temperature set and the preselected golden temperature curve is calculated; the first similarity distance corresponding to the first cooling temperature set is obtained by adding and averaging all similarity distances; Similarly, the second similarity distance of the second cooling temperature set and the corresponding preselected golden temperature curve and the third similarity distance of the third cooling temperature set and the corresponding preselected golden temperature curve are calculated.

7. The system of claim 6, wherein, The construction process of the golden temperature curve further includes: The calculation weight corresponding to the first similarity distance is denoted as QZ1, the calculation weight corresponding to the second similarity distance is denoted as QZ2, and the calculation weight corresponding to the third similarity distance is denoted as QZ3; QZ1, QZ2, and QZ3 are assigned values; The golden temperature curve corresponding to the injection molded product is calculated according to the preselected golden temperature curve and the corresponding calculation weight of the first cooling temperature set, the second cooling temperature set, and the third cooling temperature set, and the process of obtaining the golden temperature curve is: The average cooling temperature of the preselected golden temperature curve at any time in the first cooling temperature set is multiplied by QZ1, the average cooling temperature of the preselected golden temperature curve at any time in the second cooling temperature set is multiplied by QZ2, and the average cooling temperature of the preselected golden temperature curve at any time in the third cooling temperature set is multiplied by QZ3 = the average golden cooling temperature at the corresponding time in the golden temperature curve; all average golden cooling temperatures at all times are connected to obtain the golden temperature curve of the injection molded product; The area formed by all preselected golden temperature curves is denoted as the temperature curve fluctuation area.

8. The system of claim 1, wherein the system is configured to dynamically collect the injection molding process parameters from the injection molding machine. The injection molding process parameter analysis large model includes: the golden pressure curve, the injection curve fluctuation area, the holding pressure curve fluctuation area, the golden temperature curve, and the temperature curve fluctuation area.

9. The system of claim 8, wherein, The detection process of the monitoring module is as follows: The golden pressure curve, the injection curve fluctuation area, and the holding pressure curve fluctuation area in the injection molding process parameter analysis large model are obtained; the golden pressure curve in the injection stage and the golden pressure curve in the holding stage are obtained respectively; the golden temperature curve and the temperature curve fluctuation area of the injection molded product are obtained; The golden injection time corresponding to the golden pressure curve in the injection stage and the golden holding time corresponding to the golden pressure curve in the holding stage are read; the duration of the injection stage corresponding to the injection molding machine is adjusted to the golden injection time, and the duration of the holding stage corresponding to the injection molding machine is adjusted to the golden holding time; The actual pressure value of the injection molding machine in the injection stage is collected, and the first actual pressure value in the injection stage is aligned with the golden pressure curve in the injection stage; The actual pressure value is compared with the injection curve fluctuation area, and if the actual pressure value is located in the injection curve fluctuation area, no operation is performed; If the actual pressure value is located above the injection curve fluctuation area, a pressure reduction signal is generated; if the actual pressure value is located below the injection curve fluctuation area, a pressure increase signal is generated.

10. The system of claim 9, wherein the system is configured to: The detection process of the monitoring module further includes: The actual pressure value of the injection molding machine in the holding stage is collected, and the first actual pressure value in the holding stage is aligned with the golden pressure curve in the holding stage; The actual pressure value is compared with the pressure curve fluctuation region, if the actual pressure value is in the pressure curve fluctuation region, no operation is performed; if the actual pressure value is above the pressure curve fluctuation region, a pressure reduction signal is generated; if the actual pressure value is below the pressure curve fluctuation region, a pressure increase signal is generated; The actual cavity temperature value and the actual pipe temperature value of the injection molding machine in the cooling stage are collected, the actual cavity temperature value is averaged with the actual pipe temperature value to obtain an actual cooling temperature value; the first actual cooling temperature value is aligned with the golden temperature curve; The actual cooling temperature value is compared with the temperature curve fluctuation region, if the actual cooling temperature value is in the temperature curve fluctuation region, no operation is performed; if the actual cooling temperature value is above the temperature curve fluctuation region, a temperature reduction signal is generated; if the actual cooling temperature value is below the temperature curve fluctuation region, a temperature increase signal is generated.

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