A method for integrally injection molding a plastic wind deflector and a mold therefor

Abstract

The application relates to an integrated plastic wind guide cover injection molding method and a mold thereof, and relates to the technical field of injection molds.The method comprises the following steps: collecting mold information and oil information in response to a mold closing completion signal; determining a connecting portion wall thickness, a contact threshold value and a breaking value according to the mold information; matching an oil threshold value through the oil information; controlling an oil brush preset below a blade to move upwards and collecting a capacitance value until the capacitance value is greater than the breaking value, and defining the capacitance value at the moment as a contact capacitance value; controlling the blade to move based on the connecting portion wall thickness; injecting glue into a hard glue cavity in response to a blade stop signal; controlling the blade to reset based on the connecting portion wall thickness in response to a cooling completion signal, and then injecting glue into a soft glue cavity, and completing integrated injection molding operation after cooling. The application has the effects of avoiding color mixing and improving product quality.

Description

Technical Field

[0001] This invention relates to the field of injection mold technology, and in particular to an injection molding method for an integrated plastic air guide cover and its mold. Background Technology

[0002] Injection molds are tools used for mass production of plastic products. Molten plastic is injected into the mold cavity through injection molding equipment, and after cooling and solidification, a product with the same shape as the cavity is obtained. It is one of the core equipment for plastic molding.

[0003] A plastic air deflector is a functional component made of plastic through processes such as injection molding. Its core function is to guide the direction of airflow and optimize the airflow path. It typically consists of a hard plastic body that provides structural strength and a soft plastic edge that enhances sealing. Currently, it is produced using two-color injection molds, where the hard plastic and soft plastic are injected into corresponding areas to form a one-piece molded product.

[0004] However, when this production method is used, the molten hard plastic will enter the area corresponding to the unsealed soft plastic, which will cause the soft plastic part to be covered with hard plastic impurities after molding, resulting in color bleeding and reducing product quality. Summary of the Invention

[0005] To avoid color bleeding and improve product quality, this invention provides an injection molding method for an integrated plastic air guide cover and its mold.

[0006] In a first aspect, this application provides a method for injection molding an integrated plastic air guide cover, which adopts the following technical solution:

[0007] A method for injection molding an integrated plastic air guide cover, applied to an injection molding mold for an integrated plastic air guide cover, comprising:

[0008] Step 1: In response to the mold closing completion signal, collect mold information and oil information;

[0009] Step 2: Determine the wall thickness, contact threshold, and circuit breakage value at the connection point based on the mold information;

[0010] Step 3: Match the oil-carrying threshold using oil information;

[0011] Step 5: Control the oil brush preset under the blade to move upward and collect the capacitance value until the capacitance value is greater than the open circuit value. Define the capacitance value at this time as the contact capacitance value.

[0012] Step 6: Control the blade movement based on the wall thickness at the connection point;

[0013] Step 7: In response to the blade stop signal, inject adhesive into the hard plastic cavity;

[0014] Step 8: In response to the cooling completion signal, the control blade is reset based on the wall thickness at the connection point, and then the soft plastic cavity is injected with glue. After cooling, the one-piece injection molding operation is completed.

[0015] By adopting the above technical solution, the core control threshold is determined by collecting mold and oil information, and the contact state between the oil brush and the blade is accurately determined by the change in capacitance value between the two, thereby guiding the movement operation of the blade. The separation of the blade between the two glue injection operations avoids the occurrence of color mixing.

[0016] Optionally, methods for controlling the movement of the blade also include:

[0017] Step 610: If the contact capacitance value is less than the oil threshold, obtain the rising distance of the oil brush.

[0018] Step 611: Based on the rising distance, control the oil brush to reset and rotate to perform the oil dipping operation, and repeat step 5;

[0019] Step 62: If the contact capacitance value is not less than the oil threshold, control the blade extension based on the wall thickness at the connection point and simultaneously collect the sliding capacitance value;

[0020] Step 6200: When the sliding capacitance value drops below the oil threshold, control the blade to pause movement and send an oil replenishment signal;

[0021] Step 6201: In response to the oil replenishment signal, based on the rising distance, control the oil groove preset below the oil brush to rise upward until the sliding capacitance value is not less than the oil threshold, control the oil groove to reset, and control the blade to continue to perform the moving operation.

[0022] Step 621: When the sliding capacitance value is never less than the oil threshold, no refueling is performed.

[0023] By adopting the above technical solution, the degree of oil film coverage is distinguished based on the comparison results of contact capacitance value and oil threshold. When the oil film is insufficient, the oil brush is reset and rotated to dip and recoat the oil. During the blade sliding process, the change of sliding capacitance value is monitored to trigger the oil tank lifting and oil replenishment operation in time, ensuring that the blade surface can be covered with a sufficiently thick oil film, thereby facilitating the subsequent reset of the blade and avoiding the blade from sticking to the product.

[0024] Optionally, before controlling the movement of the brush, the following may be included:

[0025] Step 40: Collect product information;

[0026] Step 41: Read the required temperature from the product information, the safe temperature threshold from the oil information, and the thermal conductivity of the mold and the thermal conductivity of the blade from the mold information;

[0027] Step 420: If the required temperature is greater than the safe temperature threshold, match the oil type according to the required temperature;

[0028] Step 421: Replace the oil based on the oil type, update the oil information synchronously, and repeat step 41;

[0029] Step 43: If the required temperature is not greater than the safe temperature threshold, determine the cavity preheating temperature by combining the required temperature and the thermal conductivity of the mold, and determine the blade preheating temperature by combining the required temperature and the thermal conductivity of the blade.

[0030] Step 44: Heat the hard plastic cavity based on the cavity preheating temperature, and introduce heat exchange oil into the circulating cavity inside the blade based on the blade preheating temperature.

[0031] By adopting the above technical solution, it is determined whether the existing oil is suitable for the current process temperature. If the temperature does not match, the oil type is automatically changed. At the same time, the preheating temperature of the cavity and the blade is calculated by combining the thermal conductivity of the mold and the blade respectively. Targeted heating ensures that the temperature of each component of the mold meets the product molding requirements.

[0032] Optionally, methods for controlling blade reset include:

[0033] Step 80: Read the cavity parameters and reset threshold from the mold information, obtain the coolant flow rate at this time and define it as the stable flow rate;

[0034] Step 81: Determine the vibration reference value based on product information, mold information, and contact area;

[0035] Step 82: Determine the input angle by combining the vibration reference value, stable flow rate, and cavity parameters;

[0036] Step 83: Based on the input angle, control the preset vibrating ball to enter the cavity of the blade, control the blade to reset and move based on the wall thickness at the connection, and collect the reset resistance at the same time;

[0037] Step 8400: If the reset resistance is not less than the reset threshold, the vibration reference value is summed and corrected according to the preset up-adjustment frequency, and the input angle is corrected simultaneously.

[0038] Step 8401: Repeat step 83 based on the corrected input angle;

[0039] Step 841: If the reset resistance is less than the reset threshold, maintain the input angle until the blade reset is complete.

[0040] By adopting the above technical solution, the comparison result between the reset resistance and the reset threshold is used as the core control basis. When the reset resistance is too large, the vibration reference value is increased and the input angle of the vibration ball is corrected to increase the impact of the vibration ball on the blade, thereby improving the vibration effect of the blade and improving the separation effect between the blade and the product.

[0041] Optionally, methods for injecting adhesive into the rigid cavity include:

[0042] Step 70: Read the hard plastic cavity volume, inflation volume, injection cross-sectional area, injection buffer length, support pressure, and number of injection points from the mold information; and read the melt properties and total amount of hard plastic from the product information.

[0043] Step 71: Determine the injection speed based on the melt properties;

[0044] Step 72: Determine the glue flow rate by using the glue injection speed, glue injection cross-sectional area, and number of glue injection points;

[0045] Step 73: Determine the total inflation volume based on the inflation volume and support pressure, and determine the venting parameters based on the glue inlet flow rate;

[0046] Step 74: Inject gas into the rigid rubber cavity based on the total inflation volume, and then control the movement of the blocking rod based on the rubber inlet buffer length;

[0047] Step 75: Inject glue into the first injection channel according to the injection speed and the total amount of hard glue, and simultaneously vent the gas according to the venting parameters to complete the hard glue injection molding operation.

[0048] By adopting the above technical solution, the total inflation volume is calculated by combining the inflation volume and the supporting pressure. Based on the total inflation volume, the rigid plastic cavity is inflated to provide sufficient support for the cavity seat, so as to avoid the cavity seat bending and causing product cavity deformation, which in turn leads to uneven wall thickness of the generated product.

[0049] Optionally, methods for determining exhaust parameters include:

[0050] Step 730: Read the transverse cross-sectional area, flow length, and venting section from the mold information, and read the injection pressure from the product information;

[0051] Step 731: Determine the pressure gradient based on the injection pressure and flow length;

[0052] Step 732: Determine the transverse flow component by combining the transverse cross-sectional area, pressure gradient, and melt properties;

[0053] Step 733: Determine the transverse exhaust velocity based on the transverse flow component and exhaust cross section, and use it as an exhaust parameter.

[0054] By adopting the above technical solution, the pressure gradient is determined based on the injection pressure and flow length. Combined with the cross-sectional area of ​​the cavity and the melting properties of the material, the transverse flow component of the molten adhesive is calculated, and then the transverse venting speed is derived. Based on the transverse venting speed, venting is performed simultaneously during the injection process, which can keep the pressure in the rigid adhesive cavity stable.

[0055] Optionally, methods for determining exhaust parameters may also include:

[0056] Step 734: Read the vertical cross-sectional area, flow height, and mold material from the mold information;

[0057] Step 735: Determine the coefficient of friction based on the mold material and melt properties;

[0058] Step 736: Calculate the correction factor based on the vertical cross-sectional area, friction coefficient, and flow height;

[0059] Step 737: Determine the vertical flow component using the glue inlet flow rate, the lateral flow component, and the correction factor;

[0060] Step 738: Determine the vertical exhaust velocity based on the vertical flow component and the exhaust cross section;

[0061] Step 739: Integrate and correct the vertical exhaust velocity with the exhaust parameters.

[0062] By adopting the above technical solution, the vertical flow component and vertical exhaust velocity are calculated based on the horizontal exhaust velocity, and then integrated and corrected with the horizontal exhaust parameters. The corrected exhaust parameters are used for exhaust, which further improves the pressure stability in the rigid rubber cavity.

[0063] Optionally, the process may also include:

[0064] Step 90: In response to the mold opening signal, obtain the product position and suction cup position;

[0065] Step 91: Determine the adsorption location, adhesion threshold, and sealing threshold based on the product information;

[0066] Step 92: Plan the movement path based on the adsorption location and the suction cup location;

[0067] Step 93: Control the bidirectional suction cup, which is preset at the suction cup position, to move according to the movement path;

[0068] Step 94: After the movement stops, control the two suction ends of the bidirectional suction cup to extend and collect the suction cup pressure until the suction cup pressure is not less than the adhesion threshold, then stop the extension.

[0069] Step 95: Control the bidirectional suction cup to perform suction operation until the suction cup pressure is not less than the sealing threshold, then stop suction and control the cavity seat to move away from the product.

[0070] By adopting the above technical solution and monitoring the pressure of the bidirectional suction cup, the effective adhesion and sealing of the suction cup to the inner wall of the product are ensured. The bidirectional suction cup provides adsorption support to the inner wall of the product, preventing the cavity seat from sticking to the product during the demolding process and causing product deformation.

[0071] Optional, after moving away from the product, it also includes:

[0072] Step 96: If the suction cup pressure drops below the sealing threshold, control the cavity seat to stop moving, update and record the number of abnormalities;

[0073] Step 970: When the suction cup pressure is less than the adhesion threshold, repeat step 93;

[0074] Step 971: When the suction cup pressure is not less than the adhesion threshold, repeat step 94;

[0075] Step 972: When the number of abnormal occurrences is not less than the preset safe number, stop all operations and issue an alarm.

[0076] By adopting the above technical solution, the changes in suction cup pressure are used as the monitoring basis to distinguish abnormal working conditions such as sealing failure and insufficient bonding. By accumulating the number of abnormalities, corresponding reset operations or shutdown alarms are triggered, thereby improving the safety and stability of the production line.

[0077] Secondly, the present invention provides an integrated plastic air guide injection mold, which adopts the following technical solution:

[0078] An integrated plastic air guide injection mold includes a base with a fixed mold seat, a cavity seat mounted on the base, and a moving mold seat that forms a product cavity with the fixed mold seat and the cavity seat. It also includes a blocking structure mounted on the cavity seat. The product cavity includes a hard plastic cavity and a soft plastic cavity.

[0079] The blocking structure corresponds one-to-one with the cavity seat and multiple blocking structures are provided. The blocking structure includes a blade that slides along the cavity seat to control the open / closed state between the hard plastic cavity and the soft plastic cavity.

[0080] The fixed mold base has multiple sets of injection structures, each set of injection structures consisting of multiple first injection channels and a sprue communicating with the hard plastic cavity;

[0081] The moving mold base is provided with a second injection channel for injecting glue into the soft glue cavity, and the port of the second injection channel is connected to the soft glue cavity;

[0082] The first and second glue inlet channels are also equipped with a blocking rod to control the on / off state.

[0083] By adopting the above technical solution, the blade of the blocking structure slides along the cavity seat, which can flexibly switch the connection or separation state of the hard plastic cavity and the soft plastic cavity, meet the process requirements of the integrated air guide hood first molding the hard plastic and then compounding the soft plastic, and avoid the occurrence of color mixing problem. At the same time, the first injection channel of the multiple injection structures cooperates with the gating to achieve uniform filling of the hard plastic cavity.

[0084] In summary, the present invention has at least one of the following beneficial technical effects:

[0085] 1. By collecting mold and oil information, the core control threshold is determined. Then, by utilizing the change in capacitance between the oil brush and the blade, the contact state between the two is accurately determined, thereby guiding the movement of the blade. The separation of the blade between the two glue injection operations avoids color mixing.

[0086] 2. Calculate the total inflation volume by combining the inflation volume and the supporting pressure. Based on the total inflation volume, inflate the rigid cavity to provide sufficient support for the cavity seat, so as to avoid deformation of the cavity seat and thus cause uneven wall thickness of the product.

[0087] 3. The blade of the blocking structure slides along the cavity seat, which can flexibly switch the connection or separation state of the hard plastic cavity and the soft plastic cavity, meet the process requirements of the integrated air guide hood first molding the hard plastic and then compounding the soft plastic, and avoid the occurrence of color mixing problem. At the same time, the first injection channel of the multiple injection structures cooperates with the gating to achieve uniform filling of the hard plastic cavity. Attached Figure Description

[0088] Figure 1 A partial structural diagram of an injection mold for an integrated plastic air guide cover. Figure 1 ;

[0089] Figure 2 This is a cross-sectional view of an injection mold for an integrated plastic air guide cover;

[0090] Figure 3 yes Figure 2 Enlarged view of point A in the middle;

[0091] Figure 4 A partial structural diagram of an injection mold for an integrated plastic air guide cover. Figure 2 ;

[0092] Figure 5 yes Figure 4 Enlarged view of point B in the middle.

[0093] The parts referred to by the numbers in the above attached figures are as follows: 1. Base; 2. Fixed mold base; 21. Inlet structure; 211. First inlet channel; 212. Sprue; 3. Moving mold base; 31. Second inlet channel; 4. Plug rod; 5. Cavity base; 6. Product cavity; 61. Hard cavity; 62. Soft cavity; 7. Blocking structure; 71. Push plate; 72. Blade. Detailed Implementation

[0094] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0095] This invention discloses an injection molding mold for an integrated plastic air guide cover.

[0096] Reference Figure 1 , Figure 2 and Figure 3 An integrated plastic air guide injection mold includes a base 1 with a fixed mold base 2, a cavity base 5 mounted on the base 1, and a moving mold base 3 that forms a product cavity 6 with the fixed mold base 2 and the cavity base 5. It also includes a blocking structure 7 mounted on the cavity base 5 and a glue injection structure 21 set on the fixed mold base 2. The product cavity 6 includes a hard plastic cavity 61 and a soft plastic cavity 62.

[0097] Reference Figure 2 , Figure 4 and Figure 5 The blocking structure 7 corresponds one-to-one with the cavity seat 5 and multiple blocking structures are provided. The blocking structure 7 includes a push plate 71 and multiple blades 72. One end of the push plate 71 is fixedly connected to the external driving structure. The push plate 71 is slidably mounted on the cavity seat 5 to drive the blades 72 to slide. Multiple blades 72 are detachably mounted on the push plate 71 and slide in contact with the cavity seat 5.

[0098] The glue inlet structure 21 is provided in multiple sets. Each set of glue inlet structure 21 consists of multiple first glue inlet channels 211 and gating channels 212. The port of the gating channel 212 is connected to the hard glue cavity 61, and the glue inlet channel is connected to the external glue injection equipment.

[0099] The moving mold base 3 is provided with a second injection channel 31 for injecting glue into the soft rubber cavity 62, and the port of the second injection channel 31 is connected to the soft rubber cavity 62.

[0100] The first glue inlet channel 211 and the second glue inlet channel 31 are also provided with a blocking rod 4 that can slide along the axial direction. The blocking rod 4 is fixedly connected to an external pushing structure to control the opening and closing state of the first glue inlet channel 211 or the second glue inlet channel 31.

[0101] When the drive structure drives the push plate 71 to move the blade 72 toward the center of the product cavity 6, the blade 72 extends to separate the hard plastic cavity 61 and the soft plastic cavity 62, achieving a separate seal for the hard plastic cavity 61. The injection equipment is started to inject molten hard plastic from the injection channel. The control push structure drives the blocking rod 4 to block the first injection channel 211. The molten hard plastic enters from the injection port along the gating 212 and fills the hard plastic cavity 61. After the molten hard plastic cools into a hard plastic product, the drive structure is started to drive the blade 72 to reset so that the hard plastic cavity 61 and the soft plastic cavity 62 are connected. Then, molten soft plastic is injected into the soft plastic cavity 62 from the second injection channel 31. The control push structure drives the blocking rod 4 to block the second injection channel 31. After the molten soft plastic cools into a soft plastic product, it forms an integral molded product with the hard plastic product.

[0102] Based on the same inventive concept, embodiments of the present invention provide an injection molding method for an integrated plastic air guide cover.

[0103] A method for injection molding an integrated plastic air guide cover includes the following steps:

[0104] Step 1: In response to the mold closing completion signal, collect mold information and oil information.

[0105] The mold closing completion signal refers to the confirmation signal issued by the mold travel switch or pressure sensor when the moving mold base 3, the fixed mold base 2, and the cavity base 5 are completely closed.

[0106] Mold information refers to the set of parameters related to the structure and performance of the moving mold base 3, the fixed mold base 2, and the cavity base 5, including but not limited to parameters such as cavity size and thermal conductivity. These parameters are determined in advance by staff through mold design drawings and material testing, and then entered into the system.

[0107] Oil information refers to the parameter information of the oil used to coat the blade 72 to improve demolding efficiency, including oil type, temperature and viscosity, etc. The staff collects and enters the parameters of all types of oils used in advance into the system.

[0108] Step 2: Determine the wall thickness, contact threshold, and break value at the connection point based on the mold information.

[0109] The wall thickness at the joint refers to the wall thickness at the joint between the hard plastic part and the soft plastic part of the product, which is the distance between the corresponding parts of the mold cavity. It is measured from the 3D model of the mold cavity design and integrated into the mold information, and can be read directly here.

[0110] The contact threshold is a capacitance reference value used to determine whether the oil brush and the blade 72 have made physical contact. It is obtained through calibration experiments and integrated into the mold information, and can be read directly here.

[0111] The open circuit value refers to the maximum capacitance value when the oil brush and the blade 72 are in a non-contact state. The capacitance at different spacings is collected under the condition that the oil brush and the blade 72 are not in contact, and the maximum value is taken as the open circuit value. This value is pre-integrated into the mold information and can be read directly here.

[0112] The oil brush is installed below the blade 72 and is used to adhere to the bottom of the blade 72 to apply oil to the surface of the blade 72 to form an oil film. In this embodiment, it consists of a brush body and brush bristles that absorb oil.

[0113] Step 3: Match the oil-containing threshold using oil information.

[0114] The oil-bearing threshold refers to the capacitance reference value used to determine whether the oil film on the surface of the blade 72 has reached the required thickness. The conductivity is read from the oil information, and the corresponding oil-bearing threshold is looked up from the threshold correspondence table based on the conductivity. The threshold correspondence table is a data table that records different conductivity and their corresponding oil-bearing thresholds under the same required thickness. It is obtained by technicians through pre-testing and will not be elaborated here.

[0115] The required thickness refers to the minimum oil film thickness that meets the process requirements. In this embodiment, it represents the minimum oil film thickness that facilitates the demolding of the product from the blade 72.

[0116] Before controlling the movement of the brush, the following steps are included:

[0117] Step 40: Collect product information.

[0118] Product information refers to the set of design and process parameters of the product to be injection molded, including parameters such as product size, material, melt temperature, required temperature and total injection volume. The product size and material parameters are extracted from the product design drawings, and the melt temperature and required temperature are determined through temperature testing and injection molding simulation results. After integration, the information is pre-entered into the system by the staff.

[0119] Step 41: Read the required temperature from the product information, the safe temperature threshold from the oil information, and the thermal conductivity of the mold and the thermal conductivity of the blade from the mold information.

[0120] The required temperature refers to the temperature value needed to preheat the product cavity 6 before injection molding. It is the temperature corresponding to the optimal molding effect selected based on parameters such as product size and material and through injection molding simulation results. This temperature is pre-integrated into the product information by the staff and can be directly read here.

[0121] The safe temperature threshold refers to the highest tolerable temperature value for maintaining the stability of the oil and improving the demolding effect. It is determined in advance by accelerating aging test to measure the changes in the viscosity and other properties of the oil at different temperatures. The temperature at which the properties begin to decline significantly is selected as the safe temperature threshold and integrated into the mold information, which can be read directly here.

[0122] The thermal conductivity of the mold and the thermal conductivity of the blade refer to the parameters of the ability of the mold base material and the blade 72 component material to conduct heat, respectively. They are obtained by measuring the mold and blade 72 in advance using a thermal conductivity meter and integrating the mold information, which can be read directly here.

[0123] Step 420: If the required temperature is greater than the safe temperature threshold, match the oil type according to the required temperature.

[0124] A required temperature greater than the safe temperature threshold means that the temperature required for preheating the current product during injection molding exceeds the maximum tolerance temperature of the oil. The existing oil cannot meet the process requirements and needs to be replaced with an oil suitable for higher temperature conditions.

[0125] The oil model refers to the product specification code of the oil. Different models of oil have different parameters such as viscosity and high temperature resistance. Therefore, the oil model corresponds one-to-one with the maximum withstand temperature. According to the required temperature, the corresponding maximum withstand temperature is found in the oil model correspondence table and the oil model is matched. The oil model correspondence table is a data table that records different required temperatures and their corresponding maximum withstand temperatures. It is obtained by technicians through pre-testing and will not be elaborated here. It is important to ensure that the maximum withstand temperature corresponding to the oil model is higher than the required temperature.

[0126] Step 421: Replace the oil based on the oil type, update the oil information synchronously, and repeat step 41.

[0127] Replace the oil based on its type, and replace the corresponding oil tank and oil brush at the same time to ensure that the oil brush, oil tank and oil are one-to-one correspondence. At the same time, update the oil parameter information, and continue to step 41 after the update to ensure the correctness of the oil type selection.

[0128] Step 43: If the required temperature is not greater than the safe temperature threshold, determine the cavity preheating temperature by combining the required temperature and the thermal conductivity of the mold, and determine the blade preheating temperature by combining the required temperature and the thermal conductivity of the blade.

[0129] A required temperature not exceeding the safe temperature threshold means that the temperature required for preheating the current product injection molding does not exceed the maximum tolerance temperature of the oil, and the existing oil can meet the process requirements and subsequent steps can be performed.

[0130] The cavity preheating temperature and the blade preheating temperature refer to the temperatures at which the product cavity 6 and the blade 72 are heated to meet the product molding requirements. After the mold base or the blade 72 conducts heat, it is ensured that the surface temperature of the product cavity 6 and the blade 72 can reach the required temperature. The required temperature is calculated by dividing the required temperature by the thermal conductivity of the mold and the thermal conductivity of the blade, respectively. The related formula is: Required temperature = Cavity preheating temperature * Mold thermal conductivity = Blade preheating temperature * Blade thermal conductivity.

[0131] Step 44: Heat the hard plastic cavity 61 based on the cavity preheating temperature, and introduce heat exchange oil into the circulating cavity inside the blade 72 based on the blade preheating temperature.

[0132] Based on the cavity preheating temperature, the hard plastic cavity 61 is heated. In this embodiment, the heating requirement can be achieved by introducing high-temperature heat exchange oil into the cooling pipes preset in the fixed mold base 2 and the cavity base 5.

[0133] Based on the blade preheating temperature, heat exchange oil with high temperature is continuously injected into the circulating cavity inside the blade 72. The temperature of the heat exchange oil is the blade preheating temperature. After the heat is conducted by the blade 72, it ensures that the surface temperature of the blade 72 reaches the required temperature.

[0134] Step 5: Control the oil brush preset below the blade 72 to move upward and collect the capacitance value until the capacitance value is greater than the open circuit value. Define the capacitance value at this time as the contact capacitance value.

[0135] The capacitance value refers to the capacitance formed between the oil brush and the blade 72. Its value is related to the distance between the oil brush and the blade 72, the thickness of the oil film on the surface of the blade 72, and whether the oil brush is oily. Both the brush body and the bristles of the oil brush are conductive. The oil brush and the blade 72 are used as the two plates of the capacitor, respectively, and are connected to an external capacitance detection device to collect data in real time.

[0136] A capacitance value greater than the open circuit value indicates that the brush and the surface of blade 72 have made physical contact.

[0137] The contact capacitance value refers to the real-time capacitance value collected after the oil brush comes into contact with the surface of the blade 72. It reflects the capacitance characteristics of the oil brush and the blade 72 in the initial contact state. As the oil brush continues to approach the blade 72, when the capacitance value is greater than the open circuit value, the oil brush stops moving and collects the stable capacitance value at this time as the contact capacitance value.

[0138] Step 6: Control the movement of the blade 72 based on the wall thickness at the connection point.

[0139] The thickness of the wall at the connection point is used as the moving distance to control the movement of the blade 72, ensuring that the blade 72 can seal and isolate the hard plastic cavity 61 and the soft plastic cavity 62 after the movement is completed.

[0140] The method for controlling the movement of blade 72 also includes the following steps:

[0141] Step 610: If the contact capacitance value is less than the oil threshold, obtain the rising distance of the oil brush.

[0142] If the contact capacitance value is less than the oil threshold, it means that the thickness of the oil film formed when the oil brush and the blade 72 are in contact does not reach the minimum thickness required by the process, indicating that there is not enough oil on the oil brush and it needs to be replenished.

[0143] The rising distance refers to the vertical distance the oil brush moves from the start of its movement until it contacts the blade 72 and stops. The position of the oil brush is recorded in real time by a displacement sensor installed on the oil brush, and the difference between the position at the point of contact and the position at the start of movement is calculated as the rising distance.

[0144] Step 611: Based on the rising distance, control the oil brush to reset and rotate to perform the oiling operation, and repeat step 5.

[0145] The brush is reset based on the rising distance. After resetting, it is rotated so that the brush bristles can directly pick up the oil, thus achieving rapid oiling. After oiling is completed, it is rotated to reset and the rising and bonding operation in step 5 is continued.

[0146] Step 62: If the contact capacitance value is not less than the oil threshold, control the blade 72 to extend based on the wall thickness at the connection point, and simultaneously collect the sliding capacitance value.

[0147] If the contact capacitance value is not less than the oil threshold, it means that the oil film thickness on the surface of the blade 72 meets the minimum thickness required by the process, and no oiling operation is required, so the blade 72 can be extended.

[0148] The sliding capacitance value refers to the real-time capacitance value when the oil brush slides relative to the surface of the blade 72 during the extension process, which is obtained by continuous detection by a capacitance detection device.

[0149] As the oil on the brush gradually covers the surface of the blade 72, the thickness of the oil film on the blade 72 will gradually decrease, which in turn will cause the sliding capacitance value to decrease gradually.

[0150] Step 6200: When the sliding capacitance value drops below the oil threshold, control the blade 72 to pause movement and send an oil replenishment signal.

[0151] When the sliding capacitance value drops below the oil threshold, it means that the sliding capacitance value gradually decreases to below the minimum thickness required by the process before the blade 72 completes its movement, and an oil replenishment operation is required. At this time, the blade 72 stops moving.

[0152] The oil replenishment signal is a control signal issued by the system to trigger the oil replenishment operation when the oil film thickness is insufficient. It is automatically issued when the system detects that the slip capacitance value is less than the oil threshold.

[0153] Step 6201: In response to the oil replenishment signal, the oil groove preset below the oil brush is lifted upward based on the rising distance until the sliding capacitance value is not less than the oil threshold. Then, the oil groove is reset and the blade 72 continues to perform the moving operation.

[0154] An oil trough is a trough-shaped device that is fixedly installed under an oil brush to store oil. When one end of the oil brush is immersed in the oil, the oil will move along the oil-absorbing structure inside the brush to the bristles.

[0155] If the sliding capacitance value is not less than the oil threshold, it means that the oil on the brush bristles covers the blade 72 to make the oil film thickness meet the standard. Then, the oil groove is controlled to reset, and the blade 72 continues to move along the surface of the oil brush.

[0156] Step 621: When the sliding capacitance value is never less than the oil threshold, no refueling is performed.

[0157] The fact that the sliding capacitance value is always not less than the oil threshold means that the surface oil film thickness of the blade 72 always meets the process requirements during the sliding process, and no oiling operation is required.

[0158] Step 7: In response to the blade stop signal, inject adhesive into the hard glue cavity 61.

[0159] The blade stop signal is a confirmation signal issued by the blade 72 limit switch or pressure sensor after the blade 72 has completed its movement based on the wall thickness at the connection point.

[0160] At this time, the rigid glue cavity 61 is in a sealed state, and glue can be injected into the rigid glue cavity 61.

[0161] The method for injecting adhesive into the rigid adhesive cavity 61 includes the following steps:

[0162] Step 70: Read the hard plastic cavity volume, inflation volume, injection cross-sectional area, injection buffer length, support pressure, and number of injection points from the mold information; and read the melt properties and total amount of hard plastic from the product information.

[0163] The volume of the hard plastic cavity refers to the cavity volume of the hard plastic component used to mold the product in the mold. The cavity volume corresponding to the hard plastic component is measured and calculated from the three-dimensional design model of the mold, and the results are integrated into the mold information in advance.

[0164] The inflation volume refers to the target volume of gas injected into the mold cavity to improve the molding quality of the product. In this embodiment, it is the sum of the volume of the hard plastic cavity and the volume of the runner 212. The volume of the runner 212 and the volume of the hard plastic cavity are obtained by the same method.

[0165] The injection cross-sectional area refers to the cross-sectional area of ​​the first injection channel 211. The cross-sectional dimensions are extracted from the design drawings of the injection channel and calculated, and then pre-integrated into the mold information.

[0166] The injection buffer length refers to the distance that the blocking rod 4 in the first injection channel 211 needs to move from the blocked state to the connected state. The cross-sectional dimensions are extracted from the design drawings of the injection channel and the blocking rod 4 and calculated, and then integrated into the mold information in advance.

[0167] Support pressure refers to the auxiliary support pressure applied to the cavity seat 5 to prevent deformation. The required pressure, i.e. support pressure, is determined by mold strength simulation calculation and is pre-integrated into the mold information.

[0168] Since the rigid cavity 61 is L-shaped and has a long horizontal section, the cavity seat 5 above the horizontal section may not have enough support. When it deforms, the product cavity 6 changes, which will cause uneven wall thickness of the product. Therefore, it is necessary to inject gas into the rigid cavity 61 to support the cavity seat 5, and at the same time increase the thickness of the cavity seat 5 to reduce deformation.

[0169] The number of injection points refers to the number of injection ports on the mold base 2 that inject glue into the hard glue cavity 61. In this embodiment, the number of first injection channels 211 is obtained from the design drawings of the fixed mold base 2 and pre-integrated into the mold information.

[0170] Melt properties refer to the set of physical property parameters of the molten rigid plastic injected into the rigid plastic cavity 61, including melt viscosity, flowability, etc. The corresponding material is melted in advance according to the material of the product, and the relevant data is obtained by testing the plastic in the molten state and integrated into the product information, which can be read directly here.

[0171] The total volume of rigid plastic refers to the total volume of molten rigid plastic required when injecting the rigid plastic cavity of a single product. The volume of the rigid plastic component, i.e. the total volume of rigid plastic, is calculated in advance using the product's three-dimensional model and integrated into the product information.

[0172] Step 71: Determine the injection speed based on the melt properties.

[0173] The injection speed refers to the flow rate of molten rigid plastic in the first injection channel 211. Based on the melt properties, the flow state under different injection speeds is simulated by injection molding simulation software, and the corresponding parameters are selected as the injection speed.

[0174] Step 72: Determine the glue flow rate by using the glue feeding speed, glue feeding cross-sectional area, and number of glue feeding points.

[0175] The glue flow rate refers to the volume of molten glue injected into the hard glue cavity 61 through the first glue inlet channel 211 per unit time. It is calculated according to the formula: Glue flow rate = Glue inlet speed * Glue inlet cross-sectional area * Number of glue inlet points.

[0176] Step 73: Determine the total inflation volume based on the inflation volume and support pressure, and determine the venting parameters based on the glue inlet flow rate.

[0177] The total inflation volume refers to the total mass of gas injected into the hard plastic cavity 61 before injection molding to apply pressure to the cavity seat 5. The calculation formula is: Total inflation volume = (support pressure + atmospheric pressure) * inflation volume / (gas constant * ambient temperature), where the atmospheric pressure and gas constant are known, and the ambient temperature is obtained by detecting the temperature sensor set on the mold.

[0178] The venting parameters refer to parameters such as the venting speed and venting position of the hard plastic cavity 61 during the injection molding process. The specific determination method will be explained in detail in the following steps, and will not be repeated here.

[0179] Methods for determining exhaust parameters include:

[0180] Step 730: Read the transverse cross-sectional area, flow length and venting section from the mold information, and read the injection pressure from the product information.

[0181] The transverse cross-sectional area refers to the cross-sectional area of ​​the rigid plastic cavity 61 in the horizontal direction. The horizontal cross-section is extracted from the design 3D model of the rigid plastic cavity 61 and the area is calculated and pre-integrated into the mold information.

[0182] The flow length refers to the distance that molten plastic flows from the injection point to the farthest horizontal end in the rigid cavity 61. The distance from the first injection channel 211 to each horizontal endpoint of the cavity is measured from the three-dimensional model of the rigid cavity 61, and the maximum value is taken as the flow length and pre-integrated into the mold information.

[0183] The venting section refers to the cross-sectional area of ​​the venting groove located at the end of the hard plastic cavity 61. The venting groove of the solid mold is measured in advance and integrated into the mold information.

[0184] Specifically, there are two venting channels. One venting channel is located at the horizontal end away from the first glue inlet channel 211, and the other venting channel is located below the blade 72. The connection between the venting channel and the hard plastic cavity 61 is provided with a filter structure that can only pass gas and intercept molten plastic.

[0185] The injection pressure refers to the pressure that drives the molten rigid plastic to flow in the first injection channel 211. It is obtained in advance through injection molding simulation software based on different product simulation calculations and integrated into the corresponding product information.

[0186] Step 731: Determine the pressure gradient based on the injection pressure and flow length.

[0187] The pressure gradient refers to the pressure change per unit length of molten rigid plastic flowing in the rigid plastic cavity 61, which is calculated by dividing the injection pressure by the flow length.

[0188] Step 732: Determine the transverse flow component by combining the transverse cross-sectional area, pressure gradient, and melt properties.

[0189] The transverse flow component refers to the horizontal flow mass of molten rigid plastic in the rigid plastic cavity 61 per unit time. It is obtained from the dynamic viscosity of the melt and calculated based on Hagen-Poiseuille's law combined with the transverse cross-sectional area, pressure gradient and dynamic viscosity.

[0190] Step 733: Determine the transverse exhaust velocity based on the transverse flow component and exhaust cross section, and use it as an exhaust parameter.

[0191] The lateral exhaust velocity refers to the velocity of the gas in the rigid cavity 61 in the horizontal direction, that is, the velocity of the gas discharged from the exhaust groove at the horizontal end. It is determined by substituting the lateral flow component and the exhaust section into the fluid dynamics formula.

[0192] The position of the exhaust groove at the horizontal end and its corresponding lateral exhaust velocity are taken as exhaust parameters.

[0193] Methods for determining exhaust parameters also include:

[0194] Step 734: Read the vertical cross-sectional area, flow height, and mold material from the mold information.

[0195] The vertical cross-sectional area refers to the cross-sectional area of ​​the rigid plastic cavity 61 in the vertical direction. The vertical cross-section is extracted from the design 3D model of the rigid plastic cavity 61 and the area is calculated and pre-integrated into the mold information.

[0196] The flow height refers to the distance from the injection point to the highest vertical point in the rigid cavity 61. The distance from the first injection channel 211 to each vertical endpoint of the cavity is measured from the three-dimensional model of the rigid cavity 61, and the maximum value is taken as the flow length, which is pre-integrated into the mold information.

[0197] The mold material refers to the material grade used to manufacture the fixed mold base 2, cavity base 5 and related components. It is obtained in advance through material composition analysis experiments and integrated into the mold information.

[0198] Step 735: Determine the coefficient of friction based on the mold material and melt properties.

[0199] The coefficient of friction refers to the friction coefficient between molten hard plastic and the inner wall of the hard plastic cavity 61. The friction coefficient is determined by simulating the contact state between molten hard plastic with corresponding molten properties and the inner wall of the hard plastic cavity 61 with corresponding mold material using a friction and wear testing machine.

[0200] Step 736: Calculate the correction factor based on the vertical cross-sectional area, friction coefficient, and flow height.

[0201] The correction factor is a coefficient used to correct the calculation results of the vertical flow component. It takes into account the influence of factors such as frictional resistance and cavity structure. Through multiple injection molding experiments, the theoretical calculation value and the actual measurement value of the vertical flow component are compared and fitted to obtain the correction factor.

[0202] Step 737: Determine the vertical flow component using the glue inlet flow rate, the lateral flow component, and the correction factor.

[0203] The vertical flow component refers to the vertical flow mass of molten rigid plastic in the rigid plastic cavity 61 per unit time. It is calculated by combining the inlet flow rate, the lateral flow component, and the correction factor. The calculation formula is: Vertical flow component = (Inlet flow rate - Lateral flow component) * Correction factor.

[0204] Step 738: Determine the vertical exhaust velocity based on the vertical flow component and the exhaust cross section.

[0205] The vertical exhaust velocity refers to the velocity of the gas in the rigid cavity 61 in the vertical direction, that is, the velocity of the gas discharged from the exhaust groove at the blade 72. It is determined by substituting the vertical flow component and the exhaust section into the fluid dynamics formula.

[0206] Step 739: Integrate and correct the vertical exhaust velocity with the exhaust parameters.

[0207] The position of the exhaust groove at blade 72 and its corresponding vertical exhaust velocity and exhaust parameters are integrated and corrected to obtain new exhaust parameters.

[0208] Step 74: Inject gas into the hard plastic cavity 61 based on the total inflation volume, and then control the movement of the blocking rod 4 based on the glue inlet buffer length.

[0209] Gas is injected into the rigid plastic cavity 61 according to the total inflation volume so that the pressure in the rigid plastic cavity 61 reaches the supporting pressure. After inflation is completed, the blocking rod 4 is moved according to the glue inlet buffer length so that the blocking rod 4 no longer blocks the first glue inlet channel 211. At this time, the molten rigid plastic can enter the rigid plastic cavity 61 from the first glue inlet channel 211.

[0210] Step 75: Inject glue into the first glue injection channel 211 according to the glue injection speed and the total amount of hard glue, and simultaneously vent the gas according to the venting parameters to complete the hard glue injection molding operation.

[0211] The molten hard plastic is controlled by the injection speed to enter the hard plastic cavity 61 from the first injection channel 211. At the same time, the gas is discharged synchronously from the two venting grooves according to the venting parameters to ensure that the pressure in the hard plastic cavity 61 is maintained at the supporting pressure. When the total amount of injection reaches the total amount of hard plastic, the injection stops. At this time, the hard plastic cavity 61 is full of molten hard plastic. The control of the plug rod 4 is reset to re-seal the first injection channel 211, and the injection molding operation is completed.

[0212] Step 8: In response to the cooling completion signal, the control blade 72 is reset based on the wall thickness at the connection point, and then the soft plastic cavity 62 is injected with glue. After cooling, the one-piece injection molding operation is completed.

[0213] After injection molding, the product needs to be cooled. The cooling method is to replace the heat exchange oil in the cooling pipes and circulating cavity with cooling water to lower the temperature. Once the cooling is complete, a cooling completion signal is issued.

[0214] The cooling completion signal is a confirmation signal issued after the product in the hard plastic cavity 61 has reached the demolding condition. When the product temperature drops below the curing temperature, the system issues a cooling completion signal.

[0215] Methods for controlling blade reset include:

[0216] Step 80: Read the cavity parameters and reset threshold from the mold information, obtain the coolant flow rate at this time, and define it as the stable flow rate.

[0217] Cavity parameters refer to the set of structural parameters of the internal circulating cavity of the blade 72, including the shape, size, volume, etc. The structural parameters of the cavity are extracted from the design 3D model of the blade 72 and pre-integrated into the mold information.

[0218] The reset threshold refers to the maximum resistance threshold between the blade 72 and the product during the reset process. Through demolding experiments, the resistance value between the blade 72 and different products is measured, and the maximum resistance value that does not cause product deformation is selected as the reset threshold, which is pre-integrated into the mold information.

[0219] Stable flow rate refers to the flow rate of coolant in the circulating cavity after cooling is complete, which is obtained in real time by a flow sensor installed in the circulating cavity.

[0220] After cooling is complete, there is no need to adjust the product temperature, meaning the coolant flow rate is relatively stable at this point.

[0221] Step 81: Determine the vibration reference value based on product information, mold information, and contact area.

[0222] The vibration reference value refers to the reference vibration parameters that trigger the vibration of the blade 72, including vibration frequency and amplitude. Based on product information, mold information and contact area, the demolding effect under different vibration parameters is simulated by vibration simulation software, and the optimal parameter is selected as the vibration reference value.

[0223] Step 82: Determine the input angle by combining the vibration reference value, stable flow rate, and cavity parameters.

[0224] The input angle refers to the angle at which the vibrating ball enters the circulating cavity of the blade 72. By combining the stable flow rate and cavity parameters, vibration parameters at different angles are simulated using vibration simulation software. The angle at which the vibration parameters are consistent with the vibration reference value is the input angle.

[0225] The vibrating ball refers to multiple spherical components stored at the inlet of the circulating cavity. After entering the circulating cavity with the coolant at a certain angle, it will continuously strike the inner wall of the circulating cavity to achieve the vibration of the blade 72. The input angle of the vibrating ball can be adjusted by controlling the angle of the guide plate at the inlet.

[0226] Step 83: Based on the input angle, control the preset vibrating ball to enter the cavity of the blade 72, control the blade 72 to reset and move based on the wall thickness at the connection, and collect the reset resistance at the same time.

[0227] The reset resistance refers to the resistance value collected in real time during the reset movement of the blade 72. The resistance value is collected in real time by a force sensor installed on the drive mechanism of the blade 72, which is the reset resistance.

[0228] Step 8400: If the reset resistance is not less than the reset threshold, the vibration reference value is summed and corrected according to the preset up-adjustment frequency, and the input angle is corrected simultaneously.

[0229] The reset resistance is not less than the reset threshold, which means that the resistance encountered by the blade 72 during the reset process exceeds the preset maximum allowable value. Continuing to reset may cause product deformation or damage to the blade 72.

[0230] Frequency adjustment refers to the adjustment step size used to increase the vibration frequency in the vibration reference value. Through multiple demolding experiments, the relationship curve between demolding resistance and vibration frequency is fitted to determine the optimal frequency adjustment step size and store it in the system in advance.

[0231] The vibration reference value is summed with the up-adjusted frequency, and the result is used as the corrected vibration reference value. Since the vibration reference value has changed, the input angle needs to be recalculated. The calculation method of the input angle is the same as that in step 82 above, and will not be repeated here.

[0232] Step 8401: Repeat step 83 based on the corrected input angle.

[0233] After the input angle is corrected, the angle of the guide plate at the inlet of the circulation cavity is controlled to control the vibrating ball to enter the circulation cavity at the input angle.

[0234] Step 841: If the reset resistance is less than the reset threshold, maintain the input angle until the blade 72 is reset.

[0235] If the reset resistance is less than the reset threshold, it means that the resistance encountered by the blade 72 during the reset process is within the preset allowable range, and the reset operation can continue until the blade 72 completes the reset movement based on the wall thickness at the connection.

[0236] After completing the one-piece injection molding operation, the following are also included:

[0237] Step 90: In response to the mold opening signal, obtain the product position and suction cup position.

[0238] The mold opening signal is a confirmation signal issued by the system after the integral injection molding is completed and the moving mold base 3 is demolded from the product. After the integral injection molding operation is completed, the moving mold base 3 and the cavity base 5 are controlled to demold in sequence. Since the product has many cavity positions, the product may deform when the cavity base 5 performs the demolding operation.

[0239] Product position refers to the specific spatial coordinates after mold opening. A three-dimensional coordinate system is established based on the position of the mold itself by using a vision sensor or displacement sensor installed on the mold, and the position coordinates of the product are collected in real time.

[0240] The suction cup position refers to the original position of the bidirectional suction cup before the operation is performed. It is determined by recording the position coordinates of the bidirectional suction cup by an encoder installed on the bidirectional suction cup.

[0241] A bidirectional suction cup is a device whose two ends can extend and both have suction functions, and it is controlled by a robotic arm.

[0242] Step 91: Determine the adsorption location, adhesion threshold, and sealing threshold based on the product information.

[0243] The adsorption position refers to the optimal contact position between the bidirectional suction cup and the inner wall of the product. It is used to ensure the stability of adsorption and prevent the product from falling off or deforming. The optimal contact position, i.e. the adsorption position, is determined by analyzing the center of gravity and inner wall structure of the product based on the three-dimensional model of the product and is pre-integrated into the product information.

[0244] The adhesion threshold refers to the minimum pressure threshold when the bidirectional suction cup adheres to the inner wall of the product. It is used to determine whether the adsorption end is in effective contact with the product. Through calibration experiments, the pressure values ​​under different degrees of adhesion between the suction cup and the inner wall of the product are recorded. The minimum pressure value that ensures stable adsorption is selected as the adhesion threshold and is pre-integrated into the product information.

[0245] The sealing threshold refers to the minimum pressure threshold at which the bidirectional suction cup forms a sealed adsorption state with the inner wall of the product. At this point, the vacuum degree inside the suction cup meets the adsorption requirements. Through a vacuum adsorption experiment, the relationship between the pressure of the suction cup and the vacuum degree is determined, and the pressure value corresponding to the vacuum degree reaching the preset value is selected as the sealing threshold and pre-integrated into the product information.

[0246] Step 92: Plan the movement path based on the adsorption position and the suction cup position.

[0247] The movement path refers to the trajectory of the bidirectional suction cup as it moves from the adsorption position to the adsorption position. The optimal movement trajectory, i.e., the movement path, is calculated by a path planning algorithm based on the adsorption position and the position of the suction cup. The path planning algorithm can be Dijkstra's algorithm.

[0248] Step 93: Control the bidirectional suction cup, which is preset at the suction cup position, to move according to the movement path.

[0249] The bidirectional suction cup is controlled to move from the suction cup position to the adsorption position according to the movement path. At this time, the two ends of the bidirectional suction cup are facing the inner walls of the two sides of the product.

[0250] Step 94: After the movement stops, control the two suction ends of the bidirectional suction cup to extend and collect the suction cup pressure until the suction cup pressure is not less than the adhesion threshold, then stop the extension.

[0251] Suction cup pressure refers to the pressure value at the suction end of a bidirectional suction cup, which is obtained in real time by a pressure sensor installed inside the suction cup.

[0252] A suction cup pressure not less than the adhesion threshold indicates that the bidirectional suction cup has reached effective contact with the inner wall of the product, and the adhesion meets the requirements for adsorption preparation.

[0253] The two ends of the bidirectional suction cup are extended and the pressure inside the suction cup is collected until the suction cup pressure is not less than the adhesion threshold, that is, both ends of the bidirectional suction cup are in contact with the product, and the existing extension length is maintained.

[0254] Step 95: Control the bidirectional suction cup to perform suction operation until the suction cup pressure is not less than the sealing threshold, then stop suction and control the cavity seat 5 to move away from the product.

[0255] A suction cup pressure not less than the sealing threshold indicates that the bidirectional suction cup and the inner wall of the product have formed a good seal, and the vacuum inside the suction cup meets the requirements for stable adsorption of the product.

[0256] The bidirectional suction cup is controlled to perform suction. The pressure inside the suction ends of the bidirectional suction cup gradually increases until the collected suction cup pressure is not less than the sealing threshold, that is, the bidirectional suction cup is stably adsorbed with the product and the existing adsorption force is maintained.

[0257] Staying away from the product also includes:

[0258] Step 96: If the suction cup pressure drops below the sealing threshold, control the cavity seat 5 to stop moving, update and record the number of abnormalities.

[0259] When the suction cup pressure drops below the sealing threshold, it means that the seal between the suction cup and the inner wall of the product has been compromised, the vacuum level has decreased, and this may lead to product deformation.

[0260] The number of abnormal occurrences refers to the cumulative number of times the seal fails during the process of the suction cup adsorbing the product. The system automatically counts the number of times the suction cup pressure is lower than the sealing threshold, updates and records it in real time.

[0261] Step 970: When the suction cup pressure is less than the adhesion threshold, repeat step 93.

[0262] If the suction cup pressure is less than the adhesion threshold, it means that the bidirectional suction cup has not reached an effective contact state with the inner wall of the product, the adhesion is insufficient, and a stable adsorption cannot be formed. This indicates that the product has been deformed and separated from the bidirectional suction cup. It is necessary to adjust the extension length of the bidirectional suction cup to re-adhere to the inner wall of the product, i.e., repeat step 93.

[0263] Step 971: When the suction cup pressure is not less than the adhesion threshold, repeat step 94.

[0264] If the suction cup pressure is not less than the adhesion threshold, it means that the seal between the suction cup and the inner wall of the product has not reached the effective adsorption standard. However, the suction cup is still in contact with the product, and the seal can be completed again by suction operation, i.e., repeat step 94.

[0265] Step 972: When the number of abnormal occurrences is not less than the preset safe number, stop all operations and issue an alarm.

[0266] The safe number of times refers to the maximum number of abnormalities allowed during the suction cup adsorption process. If this number is exceeded, the machine must be stopped for inspection. This number is preset in the system by the staff based on production experience and product quality requirements.

[0267] If the number of abnormalities is not less than the safe number of times, it means that the number of abnormalities in the suction cup adsorption of the product has reached the maximum allowable value. Continuing production may result in a large number of scrapped products or equipment failure, and it is necessary to stop the machine immediately for inspection.

[0268] 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 method for controlling the injection molding of an integrated plastic air guide cover, characterized in that, include: Step 1: In response to the mold closing completion signal, collect mold information and oil information; Step 2: Determine the wall thickness, contact threshold, and circuit breakage value at the connection point based on the mold information; Step 3: Match the oil-carrying threshold using oil information; Step 5: Control the oil brush preset below the blade (72) to move upward and collect the capacitance value until the capacitance value is greater than the circuit breaking value. Define the capacitance value at this time as the contact capacitance value. Step 6: Control the movement of the blade (72) based on the wall thickness at the connection point; Step 7: In response to the blade stop signal, inject adhesive into the hard plastic cavity (61); Step 8: In response to the cooling completion signal, the blade (72) is reset based on the wall thickness at the connection point, and then the soft plastic cavity (62) is injected with glue. After cooling, the one-piece injection molding operation is completed. The method of controlling the movement of the blade (72) also includes: Step 610: If the contact capacitance value is less than the oil threshold, obtain the rising distance of the oil brush. Step 611: Based on the rising distance, control the oil brush to reset and rotate to perform the oil dipping operation, and repeat step 5; Step 62: If the contact capacitance value is not less than the oil threshold, control the blade (72) to extend based on the wall thickness at the connection point, and simultaneously collect the sliding capacitance value; Step 6200: When the sliding capacitance value drops below the oil threshold, control the blade (72) to stop moving and send an oil replenishment signal; Step 6201: In response to the oil replenishment signal, the oil groove preset below the oil brush is lifted upward based on the rising distance until the sliding capacitance value is not less than the oil threshold. The oil groove is then reset and the blade (72) continues to perform the moving operation. Step 621: When the sliding capacitance value is never less than the oil threshold, no refueling is performed.

2. The control method for injection molding of an integrated plastic air guide cover according to claim 1, characterized in that, Before controlling the movement of the brush, the following should be included: Step 40: Collect product information; Step 41: Read the required temperature from the product information, the safe temperature threshold from the oil information, and the thermal conductivity of the mold and the thermal conductivity of the blade from the mold information; Step 420: If the required temperature is greater than the safe temperature threshold, match the oil type according to the required temperature; Step 421: Replace the oil based on the oil type, update the oil information synchronously, and repeat step 41; Step 43: If the required temperature is not greater than the safe temperature threshold, determine the cavity preheating temperature by combining the required temperature and the thermal conductivity of the mold, and determine the blade preheating temperature by combining the required temperature and the thermal conductivity of the blade. Step 44: Heat the hard plastic cavity (61) based on the cavity preheating temperature, and introduce heat exchange oil into the circulating cavity inside the blade (72) based on the blade preheating temperature.

3. The control method for injection molding of an integrated plastic air guide cover according to claim 2, characterized in that, Methods for controlling blade reset include: Step 80: Read the cavity parameters and reset threshold from the mold information, obtain the coolant flow rate at this time and define it as the stable flow rate; Step 81: Determine the vibration reference value based on product information, mold information, and contact area; Step 82: Determine the input angle by combining the vibration reference value, stable flow rate, and cavity parameters; Step 83: Based on the input angle, control the preset vibrating ball to enter the cavity of the blade (72), control the blade (72) to reset and move based on the wall thickness at the connection, and collect the reset resistance at the same time; Step 8400: If the reset resistance is not less than the reset threshold, the vibration reference value is summed and corrected according to the preset up-adjustment frequency, and the input angle is corrected simultaneously. Step 8401: Repeat step 83 based on the corrected input angle; Step 841: If the reset resistance is less than the reset threshold, maintain the input angle until the blade (72) is reset.

4. The control method for injection molding of an integrated plastic air guide cover according to claim 1, characterized in that, Methods for injecting adhesive into the rigid cavity (61) include: Step 70: Read the hard plastic cavity volume, inflation volume, injection cross-sectional area, injection buffer length, support pressure, and number of injection points from the mold information; and read the melt properties and total amount of hard plastic from the product information. Step 71: Determine the injection speed based on the melt properties; Step 72: Determine the glue flow rate by using the glue injection speed, glue injection cross-sectional area, and number of glue injection points; Step 73: Determine the total inflation volume based on the inflation volume and support pressure, and determine the venting parameters based on the glue inlet flow rate; Step 74: Inject gas into the hard plastic cavity (61) based on the total inflation volume, and then control the movement of the blocking rod (4) based on the glue inlet buffer length; Step 75: Inject glue into the first glue injection channel (211) according to the glue injection speed and the total amount of hard glue, and simultaneously discharge the gas according to the venting parameters to complete the hard glue injection molding operation.

5. The control method for injection molding of an integrated plastic air guide cover according to claim 4, characterized in that, Methods for determining exhaust parameters include: Step 730: Read the transverse cross-sectional area, flow length, and venting section from the mold information, and read the injection pressure from the product information; Step 731: Determine the pressure gradient based on the injection pressure and flow length; Step 732: Determine the transverse flow component by combining the transverse cross-sectional area, pressure gradient, and melt properties; Step 733: Determine the transverse exhaust velocity based on the transverse flow component and exhaust cross section, and use it as an exhaust parameter.

6. The control method for injection molding of an integrated plastic air guide cover according to claim 5, characterized in that, Methods for determining exhaust parameters also include: Step 734: Read the vertical cross-sectional area, flow height, and mold material from the mold information; Step 735: Determine the coefficient of friction based on the mold material and melt properties; Step 736: Calculate the correction factor based on the vertical cross-sectional area, friction coefficient, and flow height; Step 737: Determine the vertical flow component using the glue inlet flow rate, the lateral flow component, and the correction factor; Step 738: Determine the vertical exhaust velocity based on the vertical flow component and the exhaust cross section; Step 739: Integrate and correct the vertical exhaust velocity with the exhaust parameters.

7. The control method for injection molding of an integrated plastic air guide cover according to claim 1, characterized in that, After completing the one-piece injection molding operation, the following are also included: Step 90: In response to the mold opening signal, obtain the product position and suction cup position; Step 91: Determine the adsorption location, adhesion threshold, and sealing threshold based on the product information; Step 92: Plan the movement path based on the adsorption location and the suction cup location; Step 93: Control the bidirectional suction cup, which is preset at the suction cup position, to move according to the movement path; Step 94: After the movement stops, control the two suction ends of the bidirectional suction cup to extend and collect the suction cup pressure until the suction cup pressure is not less than the adhesion threshold, then stop the extension. Step 95: Control the bidirectional suction cup to perform suction operation until the suction cup pressure is not less than the sealing threshold, then stop suction and control the cavity seat (5) to move away from the product.

8. The control method for injection molding of an integrated plastic air guide cover according to claim 7, characterized in that, Staying away from the product also includes: Step 96: If the suction cup pressure drops below the sealing threshold, control the cavity seat (5) to stop moving, update and record the number of abnormalities; Step 970: When the suction cup pressure is less than the adhesion threshold, repeat step 93; Step 971: When the suction cup pressure is not less than the adhesion threshold, repeat step 94; Step 972: When the number of abnormal occurrences is not less than the preset safe number, stop all operations and issue an alarm.

9. An injection molding mold for an integrated plastic air guide cover, controlled by a control method for injection molding of an integrated plastic air guide cover as described in any one of claims 1 to 8, comprising a base (1) on which a fixed mold base (2) is mounted, a cavity base (5) mounted on the base (1), and a moving mold base (3) that forms a product cavity (6) with the fixed mold base (2) and the cavity base (5), characterized in that, It also includes a blocking structure (7) installed on the cavity seat (5), and the product cavity (6) includes a hard plastic cavity (61) and a soft plastic cavity (62). The blocking structure (7) corresponds one-to-one with the cavity seat (5) and multiple of them are provided. The blocking structure (7) includes a blade (72) that slides along the cavity seat (5) to control the open / closed state between the hard plastic cavity (61) and the soft plastic cavity (62). The fixed mold base (2) has multiple sets of injection structures (21), each set of injection structures (21) consists of multiple first injection channels (211) and a gating system (212) that communicates with the hard plastic cavity (61); The moving mold base (3) is provided with a second glue inlet channel (31) for injecting glue into the soft glue cavity (62), and the port of the second glue inlet channel (31) is connected to the soft glue cavity (62); The first glue inlet channel (211) and the second glue inlet channel (31) are also equipped with a blocking rod (4) to control the on / off state.

Images