Fluid flow real-time regulation and control system

Abstract

A fluid flow real-time regulation and control system comprises a valve terminal which is provided with an outflow hole for receiving fluid output by a fluid source and a backflow hole for sending the fluid back to the fluid source; the plurality of flow removing pipelines are used for sending the fluid in the flow removing holes to equipment to be subjected to temperature control; the plurality of return pipelines are used for sending the fluid which is sent to the equipment to be subjected to temperature control by the return pipelines back to the return holes of the valve terminal; the plurality of sensors are respectively connected with the return pipelines, each sensor can sense the fluid in the corresponding return pipeline to obtain sensing information, and the sensing information comprises the temperature and the flow of the fluid; the plurality of flow control valves are respectively connected with the return pipelines; the control module is connected with the flow control valves and the sensors in a wired or wireless mode and controls the flow control valves to adjust the flow in real time. Therefore, the fluid flow can be controlled and adjusted in real time, and the temperature equalizing effect can be achieved faster and more accurately.

Description

Technical Field

[0001] This invention relates to fluid flow control technology, and more specifically to a real-time fluid flow control system. Background Technology

[0002] The known patent TWM501931 involves installing a temperature sensor inside the mold to sense the temperature of different areas and then using a hot plate to heat areas that are not heating up sufficiently to achieve uniform temperature. The known patent TWM493150 also installs a temperature sensor inside the mold, but instead of using a hot plate, it introduces fluids of different temperatures into different areas of the mold based on the sensed temperatures to achieve uniform temperature. The known patent CN101797634 introduces cold or hot water into the runners to regulate the temperature of each runner and achieve uniform temperature on the mold surface. However, heating with a hot plate can easily cause some areas to overheat, and introducing fluids of different temperatures into the mold is inconvenient due to the need for a variety of fluids. Furthermore, introducing cold or hot water into the runners makes it difficult to mix and adjust to the desired temperature. Therefore, the effectiveness of these methods in real-time temperature control is not ideal and requires improvement. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a fluid flow rate real-time control system that can control and adjust the fluid flow rate in real time, so as to achieve the effect of uniform temperature more quickly and accurately.

[0004] To achieve the above objectives, the present invention provides a real-time fluid flow control system comprising: a valve island having a discharge port to receive fluid output from a fluid source and a return port to return the fluid to the fluid source; multiple discharge lines connected to the discharge port of the valve island, respectively delivering the fluid in the discharge port to a temperature-controlled device; multiple return lines connected to the return port of the valve island, respectively returning the fluid delivered to the temperature-controlled device by each discharge line to the return port of the valve island; multiple sensors respectively connected to each return line, each sensor being capable of sensing the fluid in its corresponding return line to obtain sensing information, the sensing information including the fluid temperature and flow rate; multiple flow control valves respectively connected to each return line, capable of adjusting the flow rate; and a control module connected, via wired or wireless connection, to each flow control valve and each sensor, for real-time control of each flow control valve to adjust the flow rate.

[0005] By measuring the fluid temperature through each sensor and transmitting the data to the control module, the control module controls each flow control valve to adjust the fluid flow rate. This allows for real-time control and adjustment of the fluid flow rate, achieving a faster and more accurate temperature uniformity, thus fulfilling the purpose of this invention.

[0006] Preferably, the valve island includes a first valve island and a second valve island, the second valve island being directly or indirectly connected to the first valve island, the first valve island having the outflow hole, and the second valve island having the return hole.

[0007] Preferably, the fluid flows through the sensor first and then through the flow control valve, or the fluid flows through the flow control valve first and then through the sensor.

[0008] Preferably, it further includes multiple solenoid valves respectively connected to each of the pipelines, each solenoid valve being wired or wirelessly connected to the control module, and the control module controlling each solenoid valve to open or close each of the pipelines.

[0009] Preferably, the control module controls other flow control valves outside the return line with the lowest temperature to reduce the flow.

[0010] Preferably, the control module controls other flow control valves outside the return line with the highest temperature to reduce the flow.

[0011] Preferably, the sensing information of each sensor also includes the pressure of the fluid in its corresponding return pipeline.

[0012] Preferably, the control module includes using the MRAC algorithm to set a target temperature, calculate the flow rate using the temperature and flow rate measured by each sensor, and control each flow control valve to adjust the flow rate.

[0013] Preferably, the MRAC algorithm includes an adaptive formula that adjusts the parameters of the control module by using the difference between the estimated parameter values ​​and the reference model parameters.

[0014] Preferably, the temperature difference between the reference model output and the actual system output is used as the basis for adjusting the control module. Based on the error signal, the unknown or changing parameters of the system are estimated to adjust the flow rate.

[0015] Detailed construction, features, and usage of the fluid flow real-time control system provided by this invention will be described in the subsequent detailed description of embodiments. However, those skilled in the art will understand that such detailed descriptions and the specific embodiments listed for implementing this invention are for illustrative purposes only and are not intended to limit the scope of protection of this invention. Attached Figure Description

[0016] The following description, with reference to the accompanying drawings and embodiments, further illustrates the real-time fluid flow control system provided by the present invention, wherein:

[0017] Figure 1 This is a schematic diagram of a preferred embodiment of the fluid flow real-time control system architecture of the present invention.

[0018] Figure 2 This is a perspective view of a portion of the fluid flow real-time control system according to a preferred embodiment of the present invention.

[0019] Figure 3This is another perspective view of a preferred embodiment of the fluid flow real-time control system of the present invention.

[0020] Figure 4 This is another perspective view of a preferred embodiment of the fluid flow real-time control system of the present invention.

[0021] The meanings of the reference numerals in the above figures are as follows:

[0022] 10: Valve Island

[0023] 10A: First valve island

[0024] 10B: Second valve island

[0025] 11: Remove flow holes

[0026] 12: Return hole

[0027] 30: To the pipeline

[0028] 40: Solenoid valve

[0029] 50: Return pipeline

[0030] 60: Sensor

[0031] 70: Flow control valve

[0032] 80: Control Module Detailed Implementation

[0033] First, it should be noted that the technical features provided by this invention are not limited to the specific structures, uses, and applications described in the embodiments. The terminology used in this description is illustrative and descriptive, and is intended to be understood by those skilled in the art. The directional terms such as "front," "upper," "lower," "rear," "left," "right," "top," "bottom," "inner," and "outer" mentioned in this specification are merely illustrative descriptive terms based on normal usage directions and are not intended to limit the scope of protection.

[0034] Please see Figures 1 to 4 A preferred embodiment of the present invention provides a fluid flow real-time control system, including a valve island 10, multiple outgoing pipelines 30, multiple solenoid valves 40, multiple return pipelines 50, multiple sensors 60, multiple flow control valves 70, and a control module 80.

[0035] The valve island 10 includes a first valve island 10A and a second valve island 10B. The second valve island 10B can be directly or indirectly connected to the first valve island 10A. The first valve island 10A has a drain hole 11 connected to a fluid source (e.g., a heater and / or a cooler). The second valve island 10B has a return hole 12 connected to the fluid source. The valve island 10 adopts a compact design, reducing the module size for easier installation.

[0036] Each of the drain pipes 30 is connected to the drain hole 11 of the valve island 10, and the fluid in the drain hole 11 of the valve island 10 is respectively sent to a temperature control device, such as, but not limited to, a plastic injection mold, and the present invention does not limit the heating or cooling of the temperature control device.

[0037] Each solenoid valve 40 is connected to each of the respective outlet pipes 30, and is used to control the opening or closing of each outlet pipe 30, and to determine whether each outlet pipe 30 sends fluid to the temperature control device.

[0038] Each return pipe 50 is connected to the return hole 12 of the valve island 10, and the fluid supplied to the temperature-controlled equipment flows back.

[0039] Each sensor 60 is connected to each return pipe 50 to sense the temperature and flow rate of the fluid in each return pipe 50. The flow state of each return pipe 50 can be determined through each sensor 60. That is, each sensor can sense the fluid in its corresponding return pipe to obtain sensing information, which includes the temperature and flow rate of the fluid. The sensing information of each sensor 60 also includes the pressure of the fluid in its corresponding return pipe 50.

[0040] Each flow control valve 70 is connected to each return pipe 50 and controls the flow rate of each return pipe 50 to regulate the fluid flow rate. Preferably, each flow control valve 70 is a proportional needle valve, which offers superior flow control performance compared to butterfly valves and ball valves. Needle valves are also smaller in size than butterfly valves and ball valves, making them easier to assemble.

[0041] In this embodiment, the fluid first flows through each sensor 60 and then through each flow control valve 70; however, in another embodiment, the fluid may flow through each flow control valve 70 first and then through each sensor 60.

[0042] The control module 80 can be wired or wirelessly connected to each solenoid valve 40, each flow control valve 70 and each sensor 60. The control module 80 receives signals from each sensor 60, controls each solenoid valve 40 to open or close, and controls each flow control valve 70 to adjust the flow rate.

[0043] In this configuration, the control module 80 controls other flow control valves 70, excluding the one with the lowest temperature (the return line 50), to reduce the flow rate. Alternatively, the control module 80 may control other flow control valves 70, excluding the one with the highest temperature (the return line 50), to reduce the flow rate.

[0044] The control module 80 can also monitor the flow channel status and display the status of each flow channel in real time, including information such as temperature, flow rate, and pressure.

[0045] By controlling the opening or closing of each solenoid valve 40 through the control module 80, the fluid can be quickly and accurately controlled to be delivered. By controlling the flow control valves 70 through the control module 80, the flow rate can be adjusted quickly and accurately, so that each pipeline 30 can achieve a uniform temperature effect on each part of the equipment to be temperature controlled, thus achieving the purpose of this invention.

[0046] The control module 80 includes an MRAC (Model Reference Adaptive Control) algorithm. It sets a target temperature and calculates the flow rate using the temperature and flow rate measured by the sensors 60, thereby controlling the flow control valves 70 to adjust the flow rate. The MRAC algorithm includes an adaptive formula that uses the difference between the estimated parameter values ​​and the reference model parameters to adjust the parameters of the control module 80. The adaptive algorithm automatically adjusts the flow rate of each water channel in the mold to ensure uniform temperature rise and fall. The MRAC adaptive flow control calculation can adjust the flow rates of multiple sets of hot and cold media in the flow channels, automatically adjusting the flow rate based on the temperature difference between the flow channel and the target mold temperature, thus improving the temperature uniformity of the mold surface.

[0047] PID control is more suitable for injection molding processes with fixed molds. If the mold is changed or the target temperature is different, the parameters need to be retested and adjusted. MRAC algorithm allows for simultaneous control of multiple groups, ensuring that both temperature uniformity and convergence time meet the set targets. Comparison shows that the control module 80 in this embodiment, which uses the MRAC algorithm, effectively achieves the purpose of this invention.

[0048] Traditional mold temperature control only provides output for single-channel and dual-channel systems. Due to the lack of a channel temperature feedback mechanism, mold surface temperature control is poor, typically within ±10°C, leading to defects such as flow marks during injection molding. This invention's flow control module 80 provides multiple channels for supplying hot and cold media and, combined with the MRAC algorithm, can adjust the flow rate in real-time, ranging from 1 to 30 LPM, with a control accuracy of ±2% and a temperature resistance of 180°C. The module integrates a sensor 60 with a temperature detection range of 0 to 200°C and a flow rate detection range of 0 to 30 LPM, achieving mold temperature control within ±5°C.

[0049] Each flow channel is equipped with a sensor 60, which uses adaptive control to supply the required flow rate based on the target mold temperature, reducing fluid energy loss and optimizing the fluid supply method. To address temperature unevenness caused by differences in the distance between each flow channel and the mold surface, the control module 80 adjusts the flow rate of each flow channel within the mold, improving overall mold temperature uniformity and optimizing process performance.

[0050] MRAC adaptive control includes a reference gain, defining a model of ideal closed-loop characteristics, and providing the target trajectory the system wants to follow. MRAC adaptive control includes error calculation; the temperature difference between the reference model output and the actual system output serves as the basis for adjusting the control module 80. The output of control module 80 includes flow adjustment based on the error signal to estimate unknown or changing system parameters. The adaptive formula includes adjusting the parameters of control module 80 using the difference between the estimated parameter values ​​and the reference model parameters. The advantages of MRAC adaptive control are strong anti-interference capability against system disturbances, adaptive adjustment of unknown or changing system parameters, and the ability to follow ideal closed-loop characteristics.

[0051] This invention can display the flow channel status in real time, including the flow channel temperature (40~180℃), the temperature difference with the target, the current flow rate (0~30LPM), record mold information, and automatically apply the optimal flow parameters when changing molds. This invention can provide abnormal alarms, including temperature abnormality (over-temperature, under-temperature) alarms, pressure abnormality (over-pressure) alarms, and flow channel blockage alarms.

[0052] The benefits of this invention include individual flow rate control for multiple flow channels in a mold, improving the temperature uniformity of the mold surface. Employing the MRAC adaptive algorithm, flow rate is automatically controlled according to process objectives, ensuring adequate fluid supply to individual flow channels and reducing energy loss. This invention improves the fluid supply method by adjusting flow rate according to process requirements, reducing energy consumption. Traditional methods use manual machine adjustment; this invention upgrades this to adaptive adjustment, eliminating product defects and energy losses caused by human factors. In addition to supporting single mold sets, this invention can also function as a general heating and / or cooling machine for multiple mold sets, saving equipment costs and floor space.

Claims

1. A real-time fluid flow control system, comprising: A valve island has a flow outlet to receive fluid from a fluid source and a return outlet to return the fluid to the fluid source. Multiple pipelines connect to the outflow orifices of the valve island, and each fluid in the outflow orifice is sent to a temperature-controlled device. Multiple return lines connect to the return holes of the valve island, respectively sending the fluid sent to the temperature-controlled equipment by each of the return lines back to the return holes of the valve island; Multiple sensors are connected to each return pipe. Each sensor can sense the fluid in its corresponding return pipe to obtain sensing information, including the fluid temperature and flow rate. Multiple flow control valves are connected to each return pipeline to adjust the flow rate; A control module is connected to each flow control valve and each sensor via wired or wireless connection, and controls each flow control valve to adjust the flow rate in real time.

2. The fluid flow real-time control system according to claim 1, wherein the valve island includes a first valve island and a second valve island, the second valve island being directly or indirectly connected to the first valve island, the first valve island having the outflow orifice, and the second valve island having the return orifice.

3. The fluid flow real-time control system according to claim 1, wherein the fluid first flows through the sensor and then through the flow control valve, or the fluid first flows through the flow control valve and then through the sensor.

4. The fluid flow real-time control system according to claim 1 further includes a plurality of solenoid valves respectively connected to each of the feed lines, each of the solenoid valves being wired or wirelessly connected to the control module, and the control module controlling each of the solenoid valves to open or close each of the feed lines.

5. The fluid flow real-time control system according to claim 1, wherein the control module controls other flow control valves besides the return pipeline with the lowest temperature to reduce the flow.

6. The fluid flow real-time control system according to claim 1, wherein the control module controls other flow control valves in the return pipeline with the highest temperature to reduce the flow.

7. The real-time fluid flow control system according to claim 1, wherein the sensing information of each sensor further includes the pressure of the fluid in the corresponding return pipeline.

8. The fluid flow real-time control system according to claim 1, wherein the control module includes using the MRAC algorithm to set a target temperature, calculate the flow rate using the temperature and flow rate measured by each sensor, and control each flow control valve to adjust the flow rate.

9. The real-time fluid flow control system according to claim 8, wherein the MRAC algorithm includes an adaptive formula that adjusts the parameters of the control module by using the difference between the estimated parameter value and the reference model parameter.

10. In the real-time fluid flow control system according to claim 9, the temperature difference between the output of the reference model and the output of the actual system is used as the basis for adjusting the control module, and the flow rate is adjusted based on the error signal to estimate unknown or changing parameters of the system.

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