Injection molding feeding mistake-proofing control system

Abstract

The invention provides an injection molding feeding mistake-proofing control system, and relates to the technical field of injection molding production feeding, and the injection molding feeding mistake-proofing control system comprises a raw material distribution station provided with a plurality of piping ports; the conveying hoses are correspondingly connected with different injection molding machines respectively; after receiving the raw material demand number, the error-proofing controller executes cyclic scanning so as to control each output terminal of the output terminal group to sequentially and independently output a high level, synchronously detects the signal state of the input terminal group and obtains the actual raw material number of the feeding end corresponding to the input terminal of which the signal state is a conducting state; and when the actual raw material number is consistent with the raw material demand number, feeding to the corresponding injection molding machine is controlled, and when the actual raw material number is inconsistent with the raw material demand number, feeding is forbidden and a piping error prompt is given. The device has the beneficial effects that the actual raw material number of the feeding end corresponding to the piping port manually inserted by an operator is automatically identified and is subjected to consistency verification with the raw material demand number, manual verification is not needed, raw material waste and product scrapping caused by piping errors are effectively avoided, and the feeding accuracy is improved.

Description

Technical Field

[0001] This invention relates to the field of injection molding material supply technology, and in particular to an injection molding material supply error prevention control system. Background Technology

[0002] In the injection molding process, different types of injection molding materials are typically distributed to multiple injection molding machines via conveyor hoses through a material distribution station to meet the production needs of different injection molded products. Because injection molding materials are diverse in type and similar in appearance, and because the material distribution station has a large number of piping ports and conveyor hoses, operators are prone to making mistakes when manually connecting the conveyor hoses and piping ports, resulting in the wrong type of material being delivered to the target injection molding machine.

[0003] In existing technologies, error prevention in injection molding feeding systems largely relies on manual verification by operators, which is not only inefficient but also cannot prevent piping errors caused by human negligence. Some simple error prevention systems only achieve coarse error prevention through mechanical structure limits, which cannot adapt to the flexible feeding needs of multiple raw materials and multiple machines, and lack signal detection and abnormal alarm functions. Once piping errors, signal failures, or port short circuits occur, they cannot be detected and dealt with in time, which can easily lead to material waste, product scrap, or even damage to injection molding equipment.

[0004] Therefore, there is an urgent need for an injection molding material feeding error prevention control system that can automatically verify the correctness of the delivery hose connection, accurately obtain the actual raw material number at the feeding end and complete the comparison and error prevention, and timely control the incorrect material supply, so as to solve the defects of the existing technology and meet the actual needs of injection molding production. Summary of the Invention

[0005] To address the problems existing in the prior art, the present invention provides an injection molding material feeding error prevention control system, comprising: The raw material distribution station is equipped with multiple piping ports, and each piping port is connected to the feeding end through a corresponding raw material distribution channel; Multiple delivery hoses, each connected to a different injection molding machine; The error prevention controller includes a controller body and an output terminal group and an input terminal group electrically connected thereto. The output terminal group and the input terminal group are respectively signal connected to each of the delivery hoses and each of the piping ports. When the delivery hose is inserted into the corresponding piping port, a detection loop is formed between the output terminal group, the delivery hose, the piping port, and the input terminal group. The controller body is used to perform a cyclic scan after receiving the raw material demand number, so as to control each output terminal of the output terminal group to output a high level in sequence, and simultaneously detect the signal status of the input terminal group and obtain the actual raw material number of the feeding terminal corresponding to the input terminal whose signal status is on. Then, when the actual raw material number is consistent with the raw material demand number, the controller controls the feeding of material to the corresponding injection molding machine, and when the actual raw material number is inconsistent with the raw material demand number, the controller prohibits the feeding and gives a piping error prompt, so as to realize automatic feeding error prevention.

[0006] Preferably, the delivery hose has an integrated signal transmission wire inside and a conductive connector is provided at one end facing the piping port; When the delivery hose is inserted into the corresponding piping port, the conductive connector makes electrical contact with the detection contact integrated within the piping port to form the detection circuit.

[0007] Preferably, the controller body has a built-in first storage module and a second storage module, and further includes: The error prevention judgment module is connected to the first storage module and the second storage module respectively. It is used to store the received raw material requirement number into the first storage module, and when it is detected that the signal state of only one input terminal in the input terminal group is in a high-level conducting state, it stores the actual raw material number corresponding to the input terminal into the second storage module. Then, it performs consistency verification between the raw material requirement number and the actual raw material number to realize the error prevention judgment of piping.

[0008] Preferably, the error prevention judgment module includes a first alarm unit, which is used to give a piping port short circuit alarm prompt when it is detected that the number of input terminals in the input terminal group whose signal state is high-level conduction state exceeds one.

[0009] Preferably, the controller body controls each of the output terminals to output a high level sequentially and individually, with each high level lasting for a first preset duration and adjacent outputs spaced apart by a second preset duration; The error prevention judgment module includes a second alarm unit, which is used to provide an error prevention signal abnormality prompt when the signal state of any input terminal is detected to be in a high-level conduction state when all the output terminals of the output terminal group are in a low-level state.

[0010] Preferably, the error prevention judgment module includes a third alarm unit, which is used to start timing when the signal status of the input terminal group is detected, and to give a piping timeout prompt when the timing duration is longer than one complete scan cycle and no output terminal is detected to be in a high-level conducting state.

[0011] Preferably, the raw material distribution station integrates an input junction box, which contains two terminal blocks connected in series. One terminal block is connected to the input terminal group via a signal cable, and the other terminal block is electrically connected to the detection contacts integrated in each of the piping ports. An intermediate relay is connected in series between each terminal of the two terminal blocks.

[0012] Preferably, it also includes an output junction box, wherein a terminal block installed in the output junction box is connected to the output terminal group via a signal cable and electrically connected to each of the delivery hoses respectively.

[0013] Preferably, it also includes a visual interaction unit connected to the error prevention controller, used to display the actual raw material number, the raw material demand number, and alarm prompt information in real time.

[0014] Preferably, the visual interaction unit integrates an error prevention start switch. When the error prevention start switch is triggered, it generates an automatic error prevention signal, and the error prevention controller performs automatic error prevention for material feeding based on the automatic error prevention signal.

[0015] The above technical solution has the following advantages or beneficial effects: 1) By constructing a closed detection loop between the output terminal group, delivery hose, piping port, and input terminal group, and combining the controller's main body's cyclic scanning and raw material number comparison logic, the actual raw material number of the supply end corresponding to the piping port manually connected by the operator is automatically identified and verified against the raw material demand number. No manual verification is required, which effectively avoids raw material waste and product scrap caused by piping errors and improves the accuracy of material supply. 2) The error prevention controller outputs high level sequentially and individually through the output terminal group, synchronously detects the conduction status of the input terminal group, accurately identifies the feeding end and actual raw material number corresponding to the conducting input terminal, realizes the integrated process of detection circuit conduction, feeding end identification, raw material number comparison and feeding control, the error prevention logic is accurate and reliable, and can be adapted to feeding scenarios with multiple feeding ends and multiple injection molding machines. 3) When the actual material number at the feeding end is found to be inconsistent with the required material number, the error prevention controller immediately stops the feeding and gives a piping error prompt. It can quickly prevent the wrong material from being delivered to the injection molding machine, avoid material waste and product scrap, and at the same time reduce the potential damage to the injection molding machine equipment caused by incorrect feeding, effectively reducing the production and maintenance costs of injection molding production. 4) By detecting the continuity status of the detection circuit, the validity of the delivery hose connection can be identified. Combined with the raw material number comparison results, the start and stop of the material supply can be controlled. This not only prevents piping errors, but also indirectly detects the proper connection of the delivery hose, avoiding material supply interruption or signal abnormality caused by loose connection. This ensures the continuity and stability of the injection molding material supply process and improves the overall production efficiency. 5) The system can achieve the feeding error prevention function by simply matching the raw material distribution station, conveying hose and error prevention controller, without the need for complicated additional structures; the error prevention controller executes cyclic scanning and comparison logic, with fast response speed, high efficiency in detection and control, and clear connection logic of each component, which is easy to install, debug and maintain on site, and has good practicality and promotion value. Attached Figure Description

[0016] Figure 1 An electrical schematic diagram of an injection molding material feeding error prevention control system is provided in a preferred embodiment of the present invention. Figure 2 This is a wiring diagram of the error prevention controller in a preferred embodiment of the present invention.

[0017] In the diagram: 1. Raw material distribution station; 11. Piping port; 12. Input junction box; 121. Intermediate relay; 13. Output junction box; 2. Conveying hose; 3. Error prevention controller; 31. Controller body; 311. First storage module; 312. Second storage module; 313. Error prevention judgment module; 3131. First alarm unit; 3132. Second alarm unit; 3133. Third alarm unit; 32. Output terminal group; 33. Input terminal group; 4. Visual interaction unit. Detailed Implementation

[0018] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The present invention is not limited to this embodiment; other embodiments that conform to the spirit of the present invention may also fall within the scope of the present invention.

[0019] In a preferred embodiment of the present invention, based on the above-mentioned problems existing in the prior art, an injection molding material feeding error prevention control system is provided, such as... Figure 1 As shown, it includes: Raw material distribution station 1, which is equipped with multiple piping ports 11, each of which is connected to the feeding end through a corresponding raw material distribution channel; Multiple delivery hoses 2 are connected to different injection molding machines, respectively; The error prevention controller 3 includes a controller body 31 and an output terminal group 32 and an input terminal group 33 electrically connected thereto. The output terminal group 32 and the input terminal group 33 are respectively connected to each delivery hose and each piping port. When the delivery hose 2 is inserted into the corresponding piping port 11, a detection circuit is formed between the output terminal group 32, the delivery hose 2, the piping port 11, and the input terminal group 33. The controller body 31 is used to perform a cyclic scan after receiving the raw material demand number, so as to control each output terminal of the output terminal group 32 to output a high level in sequence, and simultaneously detect the signal status of the input terminal group 33 and obtain the actual raw material number of the feeding terminal corresponding to the input terminal whose signal status is on. Then, when the actual raw material number is consistent with the raw material demand number, it controls the feeding to the corresponding injection molding machine, and when the actual raw material number is inconsistent with the raw material demand number, it prohibits feeding and gives a piping error prompt, so as to realize automatic feeding error prevention.

[0020] Specifically, in this embodiment, the raw material distribution station 1 integrates multiple branch pipes. The main input end of the branch pipe is connected to the feeding end, and the port of the branch pipe serves as the piping port 11. Each piping port 11 integrates a detection contact, which is preferably coaxially arranged with the mechanical interface of the piping port 11 and is used to make electrical contact with the conductive joint of the conveying hose 2.

[0021] Furthermore, the raw material distribution station 1 integrates an input junction box 12, which contains two terminal blocks connected in series. One terminal block is connected to the input terminal group 33 via a signal cable, and the other terminal block is electrically connected to the detection contacts integrated in each piping port 11. An intermediate relay 121 is connected in series between each terminal of the two terminal blocks.

[0022] Specifically, each terminal of one terminal block is electrically connected to a corresponding detection contact in each piping port 11, enabling centralized access of field detection signals. Each terminal of the other terminal block is electrically connected to a corresponding input terminal group 33 of the error-proof controller 3 via signal cables, enabling centralized output of isolated standard signals. An intermediate relay 121 is connected in series between corresponding terminals of both terminal blocks. The coil side and contact side of the intermediate relay 121 are electrically connected to the corresponding terminals of the two terminal blocks, converting the field detection signals into standard DC level signals recognizable by the error-proof controller, while simultaneously achieving strong and weak current isolation and suppressing interference.

[0023] The aforementioned conveying hose 2 is preferably made of steel wire rubber tubing, serving both raw material conveying and signal transmission functions. Each conveying hose 2 integrates a shielded hose spiral wire inside, with both ends of the spiral wire electrically connected to the conductive connectors at both ends of the conveying hose 2 and the corresponding terminals of the output junction box. The end of the conveying hose 2 facing the piping port 11 is preferably equipped with an E-type conductive quick connector. The piping port 11 preferably uses a D-type connector seat compatible with the E-type conductive quick connector, and the E-type conductive quick connector is electrically connected to the hose spiral wire inside the conveying hose 2. When the conductive connector of the conveying hose 2 is manually inserted into the piping port 11, the conductive connector makes tight electrical contact with the detection contact inside the piping port 11, simultaneously achieving a sealed connection of the raw material pipeline and the closure of the detection circuit.

[0024] In a preferred embodiment of the present invention, an output junction box 13 is further included. A terminal block installed in the output junction box 13 is connected to the output terminal group 32 via a signal cable and electrically connected to each of the delivery hoses 2.

[0025] Specifically, the terminal block installed inside the output junction box 13 has multiple terminals, which are electrically connected to the output terminal group of the error prevention controller 3 one by one. For example, output junction box terminal 1 corresponds to output terminal Q0.0, output junction box terminal 2 corresponds to output terminal Q0.1, and so on. At the same time, each terminal of the terminal block is electrically connected to the signal transmission wire inside each conveying hose 2, that is, output junction box terminal 1 corresponds to conveying hose 2-1, output junction box terminal 2 corresponds to conveying hose 2-2, and so on, so as to realize the signal transfer and orderly wiring between the output terminal group of the error prevention controller 3 and the conveying hose 2.

[0026] Based on this, the detection circuit formed when the delivery hose 2 is inserted into place is as follows: Output terminal group 32 of error-proof controller 3 → Terminal block of output junction box 13 → Signal transmission wire inside delivery hose 2 → Conductive connector of delivery hose 2 → Detection contact inside piping port 11 → One terminal block of input junction box 12 → Coil side of intermediate relay 121 → Contact side of intermediate relay 121 → Another terminal block of input junction box 12 → Input terminal group 33 of error-proof controller 3 → Controller body 31 → Output terminal group 32.

[0027] The aforementioned error prevention controller 3 preferably uses a PLC controller as the controller body 31, which has a built-in first storage module 311, a second storage module 312, and an error prevention judgment module 313. The error prevention judgment module 313 is connected to the first storage module 311 and the second storage module 312 respectively. It is used to store the received raw material demand number into the first storage module 311, and when it detects that only one input terminal in the input terminal group 33 is in a high-level conducting state, it stores the actual raw material number corresponding to the input terminal into the second storage module 312. Then, it performs consistency verification between the raw material demand number and the actual raw material number to realize the piping error prevention judgment.

[0028] Preferably, the VW500 storage area can be pre-configured as the first storage module 311 to store the raw material demand number, and the VW1000 storage area can be pre-configured as the second storage module 312 to store the actual raw material number.

[0029] The controller body 31 has a built-in cyclic scanning program that controls each output terminal of the output terminal group to output a high level sequentially and individually. Each high level lasts for a first preset duration, and the interval between two adjacent outputs is a second preset duration. Preferably, the first preset duration can be set to 0.6s, the second preset duration to 0.4s, and a complete scan cycle is (0.6+0.4)×N=Ns, where N is the number of output terminals.

[0030] The error prevention judgment module 313 includes a first alarm unit 3131, a second alarm unit 3132, and a third alarm unit 3133, all of which are driven by a PLC program. The alarm signal is transmitted to the visual interaction unit 4 through wires, and corresponding alarm prompts are given.

[0031] The first alarm unit 3131 is used to provide a short circuit alarm prompt for the piping port when it is detected that the number of input terminals in the input terminal group 33 with the signal state of high level conduction exceeds one.

[0032] The second alarm unit 3132 is used to provide an error prevention signal abnormality prompt when the signal state of any input terminal is detected to be high-level conduction state when all output terminals of the output terminal group 32 are at low level.

[0033] The third alarm unit 3133 is used to start timing when the signal status of the input terminal group 33 is detected, and to give a piping timeout prompt when the timing duration is longer than one complete scan cycle and no output terminal is detected to be in a high-level conduction state.

[0034] Furthermore, each output terminal of the error-proof controller 3 is connected in parallel with an LED indicator. This LED indicator serves both as an output status indicator and an electrostatic discharge indicator, and is electrically connected to the grounding terminal of the error-proof controller. Therefore, the aforementioned alarm prompts are preferably presented as audible and visual alarms.

[0035] Furthermore, both the input terminal group 33 and the output terminal group 32 of the error prevention controller 3 preferably have reserved spare terminals for subsequent expansion of the injection molding machine, expansion of raw material types, or addition of material positions, thereby improving system scalability. Preferably, the number of terminals in the input terminal group 33 is greater than the number of terminals in the output terminal group 32, in order to adapt to actual production scenarios where an injection molding machine may switch between multiple raw materials.

[0036] In a preferred embodiment of the present invention, a visual interaction unit 4 is further included, which is connected to the error prevention controller 3 and is used to display the actual raw material number, raw material demand number and alarm prompt information in real time.

[0037] Specifically, the visual interaction unit 4 preferably adopts a touch screen, which preferably has a display area and an operation area. The display area displays in real time the raw material demand number, actual raw material number, detection circuit status (on / off) and alarm prompt information (including piping error, port short circuit, signal abnormality, piping timeout) corresponding to each injection molding machine.

[0038] Furthermore, the operating area integrates a fault-prevention start switch 41, which is preferably a touch button. After the operator triggers the switch, an automatic fault-prevention signal is generated and transmitted to the fault-prevention controller 3. The controller body 31 starts the cyclic scanning program and executes the automatic fault-prevention process for feeding. At the same time, the touch screen is preferably also equipped with an alarm reset button for resetting the alarm signal after troubleshooting.

[0039] As a preferred embodiment, such as Figure 2 As shown, the output terminal group 32 of the PLC controller contains 21 output terminals (Q0.0-Q2.4, ...). Figure 2 Only Q0.0-Q1.1 are shown; the remaining output terminals can be expanded sequentially. These correspond to P10V-P28V signal lines respectively. Input terminal group 33 contains 31 input terminals (I0.0-I3.7, ...). Figure 2 (Only I0.0-I1.3 are shown in the diagram; the remaining input terminals can be expanded sequentially.) Taking V01-V32 signal lines as an example, the material feeding error prevention process of the injection molding material feeding error prevention control system of this invention is explained, and the specific steps are as follows: Step 1: Material Preparation According to the production needs of each injection molding machine, the operator sets the corresponding raw material requirement number for each injection molding machine on the visual interaction unit 4 (for example: injection molding machine 1 requires raw material number 01, injection molding machine 2 requires raw material number 02... injection molding machine 6 requires raw material number 06). The set raw material requirement number is transmitted to the error prevention controller 3 via communication and stored in the first storage module 311 (VW500 storage area) by the error prevention judgment module 313.

[0040] Preferably, the injection molding material feeding error prevention control system of the present invention can also establish a communication connection with the injection molding system, and the injection molding system can obtain the above-mentioned material demand number and store it in the first storage module 311.

[0041] Step 2: Activate automatic error prevention The operator triggers the error prevention start switch 41 on the visual interaction unit 4, which generates an automatic error prevention signal and transmits it to the controller body 31. After receiving the signal, the controller body 31 starts the cyclic scanning program and begins to perform the feeding error prevention detection.

[0042] Meanwhile, according to the production instructions, the operator manually selects one of the conductive connectors of the conveying hose 2 to be inserted into the corresponding piping port 11. When the conveying hose 2 is inserted into place, the conductive connector at its end makes tight electrical contact with the detection contact in the piping port 11, simultaneously achieving the sealing connection of the raw material pipeline and the closure of the detection circuit. Each conveying hose 2 corresponds to an independent detection circuit. At this time, the coil of the corresponding intermediate relay 121 in the input junction box 12 is energized, and the contact is closed.

[0043] When the error-proof start switch 41 is triggered, the controller body 3 preferably first detects that VW500≠0 and no raw material input signal is detected (i.e. no tube is inserted), and then starts the cyclic scanning program to avoid invalid alarms when there is no demand.

[0044] Step 3: Loop Scanning and Signal Detection The controller body 31 controls each output terminal (Q0.0-Q2.4) of the output terminal group to output a high level sequentially according to a preset timing sequence. Specifically, Q0.0 outputs a high level for 0.6s → sets to low for 0.4s → Q0.1 outputs a high level for 0.6s → sets to low for 0.4s → ... → Q0.5 outputs a high level for 0.6s → sets to low for 0.4s ..., completing one complete scan cycle and executing it cyclically. While each output terminal outputs a high level, the controller body 31 synchronously detects the signal status of the input terminal group (I0.0-I3.7), receives the standard DC 5V signal converted by the intermediate relay 121 through the terminal block in the input junction box 12, and determines whether the input terminal is in a conducting state (high level).

[0045] During this process, the LED indicator lights corresponding to the output terminal group 32 light up synchronously. The operator can intuitively determine which output terminal is currently outputting a high level through the indicator lights, which is convenient for on-site observation and troubleshooting. At the same time, since the detection circuit uses shielded signal cables and the intermediate relay in the input junction box 12 achieves strong and weak current isolation, it effectively suppresses strong current interference and signal crosstalk on site, ensuring that the signal detected by the input terminal is stable and accurate.

[0046] Specifically, by sequentially and individually outputting high-level signals from each output terminal, active verification of each piping path is achieved. This ensures that only the piping corresponding to the demand number is conductive. In other words, the high-level outputs from each terminal act as probes, actively scanning each piping path to ultimately find the one matching the VW500 demand number. This avoids the potential for incorrect piping connections. For example, if a piping from an injection molding machine that does not require raw materials is connected to a channel that does, this error will not be detected without the corresponding Q output, potentially leading to material mixing during subsequent material feeding. Furthermore, the sequential and individual high-level outputs from each terminal allow for timely detection of channel malfunctions. If a Q output is damaged, the corresponding LED will not light up during polling, allowing for immediate detection.

[0047] Step 4: Raw material number comparison and error prevention control The error prevention judgment module 313 receives the signal status of the input terminal group 33 in real time. When it detects that only one input terminal in the input terminal group 33 is in a high-level conducting state (e.g., when Q0.0 outputs a high level, I0.0 detects a high level), it indicates that the corresponding delivery hose 2 is correctly connected and the detection circuit is normal. At this time, the error prevention judgment module 313 obtains the actual material number of the feeding terminal corresponding to the conducting input terminal (e.g., I0.0 corresponds to feeding terminal 1, actual material number 01) and stores the actual material number in the second storage module 312 (VW1000 storage area). Subsequently, the error prevention judgment module 313 calls the material demand number in the first storage module 311 (e.g., injection molding machine 1 demands material number 01) and performs consistency verification between the actual material number and the material demand number.

[0048] If the actual material number matches the material requirement number (e.g., 01=01), the error prevention judgment module 313 determines that the piping is correct, and the controller body 31 controls the material supply to the corresponding injection molding machine. If the actual material number does not match the material requirement number (e.g., I0.0 is on, the actual material number is 01, but the injection molding machine 1 requires material number 02), the error prevention judgment module 313 determines that the piping is incorrect, the controller body 31 prohibits material supply, and triggers an alarm signal. The "piping error" prompt is displayed on the visual interaction unit 4, and the error channel and the corresponding actual material number and required material number are marked. The operator can quickly know the cause of the error and reconnect the delivery hose to prevent the wrong material from entering the injection molding machine.

[0049] Furthermore, during the cyclic scanning and detection process, the three alarm units of the error prevention judgment module 313 monitor the system status in real time and provide specific alarm prompts for different abnormal situations: (1) Piping port short circuit alarm: If the error prevention judgment module 313 detects that the number of input terminals in the input terminal group with the signal status of high level conduction exceeds one (e.g., when Q0.0 outputs a high level, I0.0 and I0.1 are simultaneously detected to be high level), the first alarm unit 3131 is triggered, and a "piping port short circuit" prompt is displayed on the visual interaction unit, while all material feeding is prohibited.

[0050] Operators can check for short circuits at the corresponding piping port 11 and whether the delivery hose has been mistakenly connected to multiple ports, based on the prompts. Since the terminal blocks in the input junction box correspond one-to-one with the channels, the short circuit channel can be quickly located, improving the efficiency of troubleshooting.

[0051] (2) Error prevention signal abnormality alarm: If all output terminals of the output terminal group 32 are in a low level state, the error prevention judgment module 313 detects that any input terminal is in a high level conduction state (e.g., when there is no output, I0.2 detects a high level), then the second alarm unit 3132 is triggered, and the "error prevention signal abnormality" prompt is displayed on the visual interaction unit 4.

[0052] Operators can check for loose connections in the corresponding detection circuits and whether intermediate relays are faulty. Since the input junction box integrates signal conversion and isolation functions, it can quickly locate fault nodes and reduce maintenance time.

[0053] (3) Piping timeout alarm: The error prevention judgment module 313 starts timing when it starts detecting the signal status of the input terminal group. If the timing time exceeds one complete scan cycle and no input terminal is detected to be in a high-level conduction state, the third alarm unit 3133 is triggered and a "piping timeout" prompt is displayed on the visual interaction unit.

[0054] This indicates that the operator has not completed the effective manual connection, or that the delivery hose 2 is not properly connected or the detection circuit is not closed. The operator can check the connection status of the delivery hose 2 according to the prompts to avoid production delays caused by the lack of piping.

[0055] When the injection molding machine finishes production or needs to change materials, the operator turns off the error prevention start switch 41, the controller body 31 stops the cyclic scanning, and the control stops the material supply; the operator unplugs the conveying hose 2, the detection circuit is disconnected, the input terminal group signal becomes low level, the system returns to the initial state, and waits for the next round of material supply piping and error prevention detection.

[0056] In summary, the injection molding material feeding error prevention control system of the present invention is as follows: 1. It completely solves the problem of manual verification and error-prone piping in existing technologies. Through automatic scanning, signal detection and material number comparison, it realizes automatic error prevention of material supply piping, reduces the piping error rate to zero, avoids material waste and product scrap, and improves the pass rate and efficiency of injection molding production.

[0057] 2. The combination of two series terminal blocks and intermediate relays in the input junction box effectively achieves strong and weak current isolation and standardized signal conversion. Combined with the use of shielded signal cables, it greatly improves the stability of signal transmission, avoids misjudgments caused by on-site interference, and ensures reliable system operation.

[0058] 3. The three alarm units comprehensively cover three common faults: piping short circuit, signal abnormality, and piping timeout. Combined with the real-time prompts from the visual interactive unit, operators can quickly locate the fault location and troubleshoot the cause of the fault, effectively shortening the fault troubleshooting time and reducing production downtime.

[0059] 4. The setting of input and output junction boxes enables centralized transfer and orderly wiring of field signals. The terminal block corresponds one-to-one with each channel and controller terminal group, which can quickly trace the source in case of fault, reducing maintenance difficulty and cost. At the same time, the spare terminals reserved by the error-proof controller facilitate subsequent system expansion and adapt to the large-scale production needs of multiple machines and multiple raw materials.

[0060] 5. The inclusion of a visual interactive unit and a fault-proof start switch makes the system easy to operate and user-friendly. Operators can operate the system and handle faults without professional skills, thus reducing labor costs.

[0061] The above description is merely a preferred embodiment of the present invention and does not limit the implementation and protection scope of the present invention. Those skilled in the art should realize that any equivalent substitutions and obvious changes made using the content of this specification and illustrations should be included within the protection scope of the present invention.

Claims

1. A material feeding error prevention control system for injection molding, characterized in that, include: The raw material distribution station is equipped with multiple piping ports, and each piping port is connected to the feeding end through a corresponding raw material distribution channel; Multiple delivery hoses, each connected to a different injection molding machine; The error prevention controller includes a controller body and an output terminal group and an input terminal group electrically connected thereto. The output terminal group and the input terminal group are respectively signal connected to each of the delivery hoses and each of the piping ports. When the delivery hose is inserted into the corresponding piping port, a detection loop is formed between the output terminal group, the delivery hose, the piping port, and the input terminal group. The controller body is used to perform a cyclic scan after receiving the raw material demand number, so as to control each output terminal of the output terminal group to output a high level in sequence, and simultaneously detect the signal status of the input terminal group and obtain the actual raw material number of the feeding terminal corresponding to the input terminal whose signal status is on. Then, when the actual raw material number is consistent with the raw material demand number, the controller controls the feeding of material to the corresponding injection molding machine, and when the actual raw material number is inconsistent with the raw material demand number, the controller prohibits the feeding and gives a piping error prompt, so as to realize automatic feeding error prevention.

2. The material feeding error prevention control system according to claim 1, characterized in that, The delivery hose has an integrated signal transmission wire inside and a conductive connector is provided at one end facing the pipe port. When the delivery hose is inserted into the corresponding piping port, the conductive connector makes electrical contact with the detection contact integrated within the piping port to form the detection circuit.

3. The material feeding error prevention control system according to claim 1, characterized in that, The controller body has a built-in first storage module and a second storage module, and also includes: The error prevention judgment module is connected to the first storage module and the second storage module respectively. It is used to store the received raw material requirement number into the first storage module, and when it is detected that the signal state of only one input terminal in the input terminal group is in a high-level conducting state, it stores the actual raw material number corresponding to the input terminal into the second storage module. Then, it performs consistency verification between the raw material requirement number and the actual raw material number to realize the error prevention judgment of piping.

4. The material feeding error prevention control system according to claim 3, characterized in that, The error prevention judgment module includes a first alarm unit, which is used to give a short circuit alarm prompt for the piping port when it is detected that the number of input terminals in the input terminal group whose signal state is high-level conduction exceeds one.

5. The material feeding error prevention control system according to claim 1, characterized in that, The controller body controls each of the output terminals to output a high level sequentially and individually. Each high level lasts for a first preset duration, and the interval between two adjacent outputs is a second preset duration. The error prevention judgment module includes a second alarm unit, which is used to provide an error prevention signal abnormality prompt when the signal state of any input terminal is detected to be in a high-level conduction state when all the output terminals of the output terminal group are in a low-level state.

6. The material feeding error prevention control system according to claim 1, characterized in that, The error prevention judgment module includes a third alarm unit, which is used to start timing when the signal status of the input terminal group is detected, and to give a piping timeout prompt when the timing duration is longer than one complete scan cycle and no output terminal is detected to be in a high-level conduction state.

7. The material feeding error prevention control system according to claim 1, characterized in that, The raw material distribution station integrates an input junction box, which contains two terminal blocks connected in series. One terminal block is connected to the input terminal group via a signal cable, and the other terminal block is electrically connected to the detection contacts integrated in each of the piping ports. An intermediate relay is connected in series between the terminals of the two terminal blocks.

8. The material feeding error prevention control system according to claim 1, characterized in that, It also includes an output junction box, in which a terminal block is installed, which is connected to the output terminal group via a signal cable and electrically connected to each of the delivery hoses.

9. The material feeding error prevention control system according to claim 1, characterized in that, It also includes a visual interaction unit, which is connected to the error prevention controller and is used to display the actual raw material number, the raw material demand number, and alarm prompts in real time.

10. The material feeding error prevention control system according to claim 9, characterized in that, The visualization interaction unit integrates an error prevention start switch. When the error prevention start switch is triggered, it generates an automatic error prevention signal. The error prevention controller performs automatic error prevention for material feeding based on the automatic error prevention signal.

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