Temperature sensing integrated heater and control method

Abstract

The application discloses a temperature-sensing integrated heater and a control method. The temperature-sensing integrated heater comprises a heating assembly, a temperature measuring assembly, a control assembly, a communication assembly, a monitoring assembly and an alarm assembly. The heating assembly comprises a heating coil sleeved outside a flow channel and a heating rod embedded in the flow channel, so that continuous heating is realized to maintain a molten state of plastic. The temperature measuring assembly adopts a thermocouple to collect the temperature of the flow channel in real time and transmit the temperature to the control assembly. The control assembly cooperates with a PID temperature control system and a silicon-controlled voltage regulator to realize accurate constant-temperature control of the flow channel. The communication assembly establishes a remote control connection and supports remote control and data interaction. The monitoring assembly realizes visual monitoring through a network camera. The alarm assembly can monitor various system abnormalities and push accurate alarm information. A hierarchical management is adopted in the remote control platform to realize cooperative operation of various modules.

Description

Technical Field

[0001] This invention relates to the field of hot runner heating control technology, and more specifically, to a temperature-sensing integrated heater and control method. Background Technology

[0002] In the field of injection molding, the hot runner system is a core component for improving injection efficiency, reducing production costs, and ensuring product quality. Its main function is to keep the plastic delivered from the injection nozzle to the gate in a molten state, preventing solidified material from forming waste in the injection gap, thereby reducing raw material waste and improving production efficiency. The operational stability and temperature control accuracy of the hot runner system directly determine the quality of injection molded products and the continuity of production.

[0003] Currently, most existing hot runner heaters employ a design that separates heating and temperature measurement. The dispersed installation locations of the temperature sensing and heating elements lead to temperature detection lag and insufficient temperature control accuracy, making precise control of the runner temperature difficult. This can result in uneven plastic melting and material solidification, negatively impacting product quality. Furthermore, existing hot runner systems are mostly controlled locally, requiring operators to set parameters and perform equipment maintenance on-site. Remote monitoring and control are not possible. When a system malfunctions, maintenance personnel must troubleshoot each device individually, resulting in low maintenance efficiency and high costs.

[0004] Furthermore, the alarm mechanisms of existing hot runner temperature control systems are inadequate, only providing simple fault indications and failing to accurately push critical information such as fault type, equipment number, and location. They also lack intelligent visual monitoring methods, making it difficult to monitor the system's operating status in real time. While some existing technologies possess basic temperature control or alarm functions, they cannot achieve integrated management of heating, temperature measurement, control, monitoring, alarming, and remote management. This results in poor system coordination and makes it difficult to meet the demands of modern injection molding production for intelligence, efficiency, and precision. Summary of the Invention

[0005] To address at least one of the aforementioned technical problems, this invention proposes an integrated temperature-sensing heater and its control method.

[0006] The first aspect of the present invention provides a temperature-sensing integrated heater, comprising: a heating component, a temperature measuring component, a control component, a communication component, a monitoring component, and an alarm component;

[0007] The heating component is located near or at the center of the hot runner system for continuous heating of the hot runner. The heating component includes a heating coil and a heating rod. The heating coil is sleeved on the outside of the runner, and the heating rod is embedded inside the runner.

[0008] The temperature measuring component uses a thermocouple, which is embedded inside the hot flow channel or attached to the inner wall of the channel, to collect the actual temperature parameters of the channel in real time and transmit the actual temperature parameters to the control component.

[0009] The control component has a built-in PID temperature control system and a thyristor voltage regulator. The PID temperature control system is used to receive the actual temperature parameters transmitted by the temperature measuring component, compare the actual temperature parameters with the preset temperature control parameters, and output the corresponding PID current signal to the thyristor voltage regulator based on the comparison result. The thyristor voltage regulator outputs a pulse signal based on the PID current signal to adjust the conduction angle of the thyristor, thereby changing the heating power of the heating component and realizing constant temperature control of the hot runner.

[0010] The communication component is used to establish a communication connection between the control component and the remote control platform, so as to realize remote monitoring, command transmission and data interaction, and support remote issuance of operation commands such as information collection, temperature setting, opening, closing and timing.

[0011] The monitoring component includes a network camera, which is used to collect real-time image information of the hot runner system and heater operating status and transmit it to a remote control platform to realize intelligent visual monitoring.

[0012] The alarm component is electrically connected to the control component and is used to monitor abnormal system operation. The abnormalities include excessively high temperature, excessively low temperature, short circuit of heating coil, open circuit of heating coil, reverse thermocouple, and blown fuse. When an abnormality is detected, alarm information containing fault type, equipment number and equipment location is automatically generated and pushed to the remote control platform and maintenance personnel terminal through the communication component.

[0013] The remote control platform adopts a hierarchical management model to classify and manage information on enterprise users, gateways, hot runner systems, cameras, and temperature control nodes, thereby enabling the coordinated operation of each module.

[0014] In a preferred embodiment of the present invention, the heating coil of the heating component is wrapped with a high-temperature resistant insulating material, and the heating rod is made of a corrosion-resistant alloy material. Both the heating coil and the heating rod are in close contact with the surface of the flow channel to ensure efficient heat conduction.

[0015] In a preferred embodiment of the present invention, the thermocouple of the temperature measuring component can be switched between J-type and K-type, has a temperature measurement accuracy compensation function, an adjustable sampling period, and improves the temperature measurement accuracy through data filtering processing, with a measurement error not exceeding ±0.5℃.

[0016] In a preferred embodiment of the present invention, the PID temperature control system has a PID self-tuning function, which can automatically analyze the capacitance of the heating element and the thermal constant of the mold, and automatically adjust the proportional segment, integral time and derivative time parameters according to environmental changes to ensure temperature control stability; the PID temperature control system supports switching between SSR mode and PWM mode, and the corresponding output mode can be selected according to the usage scenario.

[0017] In a preferred embodiment of the present invention, the communication component supports both wireless and wired communication methods. Wireless communication uses WiFi, Bluetooth, or LoRa technology, while wired communication uses Ethernet connection to ensure the stability and real-time performance of remote communication, with data transmission delay not exceeding 1 second.

[0018] In a preferred embodiment of the present invention, the alarm component includes a local alarm module and a remote alarm module. The local alarm module uses an audible and visual alarm method, while the remote alarm module sends alarm information via SMS, APP push, or platform message push. It also supports alarm level classification and pushes alarm notifications with corresponding priorities according to the severity of the fault.

[0019] In a preferred embodiment of the present invention, the remote control platform has a data storage function, which can store flow channel temperature parameters, heating power parameters, alarm records and operating status images in real time, with a storage period of not less than 1 year, and supports historical data query, statistics and export functions.

[0020] A second aspect of the present invention provides a control method for an integrated temperature-sensing heater, applied to an integrated temperature-sensing heater, comprising the following steps:

[0021] S1. System Initialization: The remote control platform completes hierarchical registration and permission allocation for enterprise users, gateways, hot runner systems, cameras, and temperature control nodes; sets preset temperature control parameters, PID control parameters, alarm thresholds, and operating parameters of heating components for the hot runner system; and completes system self-check to ensure that all components operate normally.

[0022] S2. Real-time monitoring and data acquisition: The heating component is activated to continuously heat the hot runner channel; the temperature measurement component collects the actual temperature parameters of the channel in real time; the monitoring component collects images of the hot runner system and heater operating status through a network camera; and each component transmits the collected data to the control component and remote control platform through the communication component.

[0023] S3. PID Temperature Control: The PID temperature control system of the control component receives the actual temperature parameters transmitted by the temperature measuring component, compares them with the preset temperature control parameters, and calculates the temperature deviation. Based on the temperature deviation, the PID temperature control system outputs the corresponding PID current signal to the thyristor voltage regulator. The thyristor voltage regulator outputs a pulse signal based on the PID current signal to adjust the thyristor conduction angle, thereby changing the heating power of the heating component and maintaining the actual temperature of the flow channel within the preset temperature control parameter range, thus achieving constant temperature control.

[0024] S4. Remote Control and Hierarchical Management: The remote control platform displays all collected data and operating status in real time. Users can issue operation commands such as information collection, temperature setting, turning on, turning off, and timing through the remote control platform. The commands are transmitted to the control component through the communication component, and the control component executes the corresponding operation. At the same time, the remote control platform performs hierarchical management of enterprise users, gateways, hot runner systems, cameras, and temperature control nodes to achieve collaborative control of various modules.

[0025] S5. Abnormal Alarms and Handling: The alarm component monitors the system's operating status in real time. When abnormal conditions such as excessively high or low temperature, short circuit in the heating coil, open circuit in the heating coil, reverse thermocouple operation, or blown fuse are detected, alarm information including the fault type, equipment number, and equipment location is automatically generated. This information is simultaneously notified to maintenance personnel through local audible and visual alarms and remote information push. Maintenance personnel locate the faulty equipment and fault type based on the alarm information and perform targeted maintenance. After maintenance is completed, the system automatically resets and resumes normal operation.

[0026] S6. Cyclic Operation: Repeat steps S2-S5 to continuously achieve constant temperature control, real-time monitoring, remote control and abnormal alarm of the hot runner system, ensure the stable operation of the hot runner system, and allow the solidified material retained in the hot runner system to be injected into the cavity again for use in the next injection, reducing waste generation.

[0027] In a preferred embodiment of the present invention, in step S3, the control process of the PID temperature control system includes proportional regulation, integral regulation and derivative regulation. The proportional regulation is used to quickly respond to temperature deviations, the integral regulation is used to eliminate steady-state errors, and the derivative regulation is used to suppress temperature fluctuations.

[0028] In a preferred embodiment of the present invention, in step S5, when a thermocouple open circuit or reverse is detected, the system automatically switches to manual control mode to maintain the basic heating function of the heating component and ensure production continuity. After the maintenance personnel complete the fault handling, the system automatically switches back to automatic constant temperature control mode.

[0029] The technical solution of the present invention has the following advantages over the prior art:

[0030] 1. The integrated design of heating and temperature measurement is achieved. The temperature measurement component and the heating component are closely fitted. Combined with PID precise temperature control technology, the temperature measurement response is sensitive and the temperature control accuracy is high (error does not exceed ±0.5℃). It can effectively maintain the constant temperature of the hot runner, avoid problems such as uneven plastic melting and solidification, improve the quality of injection molded products, and reduce waste and raw material waste.

[0031] 2. It integrates remote control and hierarchical management functions, and realizes real-time communication between the control components and the remote control platform through the communication component. It supports remote parameter setting, equipment operation and data monitoring. Operators do not need to be on-site and can remotely grasp the system operation status, which greatly improves the convenience of operation and management efficiency. It adapts to the intelligent needs of modern injection molding production and helps domestic brands to replace and upgrade in the field of hot runner.

[0032] 3. It has a complete intelligent alarm mechanism that can accurately monitor various system anomalies and automatically push alarm information including fault type, equipment number and location. Combined with local audible and visual alarms and remote message push, maintenance personnel can quickly locate faults and handle them in a targeted manner without having to check each device one by one, which greatly improves maintenance efficiency, reduces maintenance costs and has significant economic benefits.

[0033] 4. It integrates intelligent visual monitoring functions, which can collect images of the system's operating status in real time through network cameras, realizing the combination of visual monitoring and data monitoring. Operators can have a comprehensive understanding of the system's operation, promptly detect potential faults, and improve the stability and reliability of the system's operation.

[0034] 5. The PID temperature control system has self-tuning and output mode switching functions. It can automatically optimize control parameters according to environmental changes and usage scenarios to adapt to different working conditions. At the same time, the system supports manual and automatic mode switching, which can maintain production continuity in case of failure and reduce losses caused by production interruption. Attached Figure Description

[0035] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, some of the drawings in the following description are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the integrated temperature-sensing heater structure according to an embodiment of the present invention;

[0037] Figure 2 This is a flowchart of the control method for the integrated temperature-sensing heater according to an embodiment of the present invention. Detailed Implementation

[0038] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0039] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0040] Example 1

[0041] See Figure 1 As shown, the present invention proposes an integrated temperature-sensing heater, including a heating component, a temperature measuring component, a control component, a communication component, a monitoring component, and an alarm component;

[0042] The heating component includes a heating coil and a heating rod. The heating coil is wrapped with high-temperature resistant ceramic insulating material and is fitted on the outside of the hot runner channel. The heating rod is made of stainless steel corrosion-resistant alloy material and is embedded in the center of the hot runner channel. Both the heating coil and the heating rod are in close contact with the surface of the channel to ensure efficient heat conduction. The heating power can be adjusted within the range of 0-1000W.

[0043] The temperature sensing component uses a K-type thermocouple embedded in the inner wall of the hot runner channel. The sampling period is set to 0.5s. It has a temperature measurement accuracy compensation function. Through data filtering, the measurement error is controlled within ±0.3℃. It collects the actual temperature parameters of the flow channel in real time and transmits the temperature parameters to the control component.

[0044] The control component incorporates a PID temperature control system and a SCR voltage regulator. The PID temperature control system has a self-tuning function, which can automatically adjust the proportional band (P=5.0), integral time (I=10s), and derivative time (D=2s) parameters. It supports switching between SSR mode and PWM mode, and defaults to SSR mode to achieve precise temperature control. The SCR voltage regulator receives the PID current signal and outputs a corresponding pulse signal to adjust the SCR conduction angle range from 0-180°, thereby changing the heating power of the heating component.

[0045] The communication component adopts a dual communication method of WiFi + Ethernet. WiFi communication uses the 802.11b / g / n protocol, and Ethernet uses an RJ45 interface. The data transmission delay is controlled within 0.8s, realizing real-time communication between the control component and the remote control platform, and supporting remote command transmission and data interaction.

[0046] The monitoring component uses a high-definition network camera with a resolution of 1080P and a frame rate of 25fps to capture real-time images of the hot runner system and heaters. The image data is transmitted to the remote control platform through the communication component, supporting real-time viewing and historical playback.

[0047] The alarm components include a local audible and visual alarm and a remote alarm module. The local audible and visual alarm uses a red LED light and a buzzer. When an alarm is triggered, the LED light flashes and the buzzer emits an 80dB alarm sound. The remote alarm module sends alarm information via SMS and APP push to the mobile terminal of maintenance personnel. The alarm levels are divided into emergency alarms (such as heating coil short circuit), general alarms (such as slight temperature fluctuations), and reminder alarms (such as timed task completion). Different alarm levels use different push frequencies.

[0048] The remote control platform adopts a hierarchical management model, divided into administrator, operator, and maintenance personnel levels. Administrators have full access, including user management, parameter settings, and data export. Operators can view parameters and perform remote control operations. Maintenance personnel can view alarm information and handle faults. The remote control platform has data storage capabilities, using cloud storage with a two-year storage period, and supports querying, statistical analysis, and exporting historical temperature data, alarm records, and operational images.

[0049] Example 2

[0050] like Figure 2 As shown, this invention proposes a control method for an integrated temperature-sensing heater, applied to the aforementioned integrated temperature-sensing heater, comprising the following steps:

[0051] S1. System Initialization: The administrator completes hierarchical registration and permission allocation for enterprise users, gateways, hot runner systems, cameras, and temperature control nodes through the remote control platform. The preset temperature control parameters for the hot runner are set to 180℃, PID control parameters P=5.0, I=10s, D=2s, alarm thresholds are set for temperatures above 190℃ or below 170℃, and the initial heating power of the heating components is set to 500W. The system self-test is completed to check the connection status and operation of each component to ensure that each component is operating normally.

[0052] S2. Real-time monitoring and data acquisition: The heating component is activated, and the heating coil and heating rod work simultaneously to continuously heat the hot runner channel; the K-type thermocouple of the temperature measuring component collects the actual temperature parameters of the channel every 0.5 seconds, and after data filtering, the temperature data is transmitted to the control component; the high-definition network camera of the monitoring component collects images of the hot runner system and heater in real time, and each component transmits the collected data to the control component and remote control platform via WiFi communication.

[0053] S3. PID Temperature Control: The PID temperature control system of the control component receives the actual temperature parameters transmitted by the temperature measuring component, compares them with the preset temperature control parameter of 180℃, and calculates the temperature deviation. When the actual temperature is 175℃, the temperature deviation is -5℃. The PID temperature control system outputs a corresponding PID current signal to the SCR voltage regulator. The SCR voltage regulator outputs a pulse signal, increasing the SCR conduction angle to 120°, increasing the heating power to 700W, and accelerating the heating rate. When the actual temperature reaches 180℃, the temperature deviation is 0. The PID temperature control system outputs a stable PID current signal, the SCR conduction angle is maintained at 90°, and the heating power is maintained at 500W to keep the flow channel temperature stable. When the actual temperature rises to 185℃, the temperature deviation is +5℃. The PID temperature control system outputs a corresponding PID current signal, the SCR conduction angle is reduced to 60°, and the heating power is reduced to 300W to slow down the heating rate and ensure that the actual flow channel temperature is maintained within the range of 180℃±0.3℃.

[0054] S4. Remote Control and Hierarchical Management: The remote control platform displays the actual flow channel temperature, heating power, equipment operating status, and images captured by the camera in real time. Operators can issue temperature adjustment commands through the remote control platform to adjust the preset temperature control parameter to 185℃. The commands are transmitted to the control component via WiFi communication, and the control component executes the temperature adjustment operation to stabilize the flow channel temperature at 185℃. Administrators can view the operation records of users at each level and the system operation data through the remote control platform for hierarchical management.

[0055] S5. Abnormal Alarm and Handling: When a short circuit fault occurs in the heating coil, the alarm component detects the abnormality and automatically generates an emergency alarm message containing the fault type (heating coil short circuit), equipment number (HR-001), and equipment location (production line 1 in the injection molding workshop). The local audible and visual alarm is activated, the LED light flashes, and the buzzer sounds an alarm. Simultaneously, the remote alarm module pushes the alarm message to the maintenance personnel's mobile terminal via SMS and APP push, with a push frequency of once per minute. After receiving the alarm message, the maintenance personnel quickly go to the designated location to troubleshoot and replace the faulty heating coil. After the fault is resolved, the system automatically resets and resumes normal operation. When a thermocouple reverses its direction, the system automatically switches to manual control mode, maintaining the heating power at 400W to ensure production continuity. After the maintenance personnel adjust the thermocouple direction, the system automatically switches back to automatic constant temperature control mode.

[0056] S6. Cyclic Operation: Repeat steps S2-S5 to continuously achieve constant temperature control, real-time monitoring, remote control, and abnormal alarms in the hot runner system, ensuring stable operation of the hot runner system. The solidified material retained in the hot runner system is injected back into the cavity for reuse in the next injection, reducing waste and improving production efficiency.

[0057] Example 3

[0058] The difference between this embodiment and Embodiment 1 is that the temperature measuring component uses a J-type thermocouple with a sampling period of 1 second and the measurement error is controlled within ±0.5℃; the communication component uses LoRa + Ethernet dual communication methods, with a LoRa communication distance of up to 1000m, suitable for large injection molding workshops; the PID temperature control system uses PWM mode by default to reduce current noise and is suitable for noise-sensitive production scenarios; the alarm component's remote alarm method adds platform message push, adapting to the usage habits of different maintenance personnel.

[0059] Its control method is basically the same as that of Embodiment 1, except that in step S3, the PID temperature control system uses PWM mode to output signals, which reduces current noise while ensuring temperature control accuracy; in step S5, the remote alarm module sends alarm information through three methods: SMS, APP push and platform message push, to ensure that maintenance personnel receive alarm notifications in a timely manner.

[0060] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0061] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to the above embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0062] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A temperature-sensing integrated heater, comprising: The heating component, temperature measuring component, control component, communication component, monitoring component, and alarm component are characterized in that: The heating component is located near or at the center of the hot runner system for continuous heating of the hot runner. The heating component includes a heating coil and a heating rod. The heating coil is sleeved on the outside of the runner, and the heating rod is embedded inside the runner. The temperature measuring component uses a thermocouple, which is embedded inside the hot flow channel or attached to the inner wall of the channel, to collect the actual temperature parameters of the channel in real time and transmit the actual temperature parameters to the control component. The control component has a built-in PID temperature control system and a thyristor voltage regulator. The PID temperature control system is used to receive the actual temperature parameters transmitted by the temperature measuring component, compare the actual temperature parameters with the preset temperature control parameters, and output the corresponding PID current signal to the thyristor voltage regulator based on the comparison result. The thyristor voltage regulator outputs a pulse signal based on the PID current signal to adjust the conduction angle of the thyristor, thereby changing the heating power of the heating component and realizing constant temperature control of the hot runner. The communication component is used to establish a communication connection between the control component and the remote control platform to realize remote monitoring, command transmission and data interaction; The monitoring component includes a network camera, used to collect real-time image information of the operating status of the hot runner system and heater, and transmit it to a remote control platform; The alarm component is electrically connected to the control component and is used to monitor abnormal system operation. When an abnormality is detected, it automatically generates alarm information containing fault type, equipment number and equipment location, and pushes it to the remote control platform and maintenance personnel terminal through the communication component. The remote control platform adopts a hierarchical management model to classify and manage information on enterprise users, gateways, hot runner systems, cameras, and temperature control nodes.

2. The integrated temperature-sensing heater according to claim 1, characterized in that, The heating coil of the heating component is wrapped with a high-temperature resistant insulating material, and the heating rod is made of a corrosion-resistant alloy material. Both the heating coil and the heating rod are in close contact with the surface of the flow channel to ensure efficient heat conduction.

3. The integrated temperature-sensing heater according to claim 2, characterized in that, The thermocouple of the temperature measuring component can be switched between J-type and K-type, has a temperature measurement accuracy compensation function, an adjustable sampling period, and improves temperature measurement accuracy through data filtering processing, with a measurement error not exceeding ±0.5℃.

4. The integrated temperature-sensing heater according to claim 3, characterized in that, The PID temperature control system has a PID self-tuning function, which can automatically analyze the capacitance of the heating element and the thermal constant of the mold, and automatically adjust the proportional segment, integral time and derivative time parameters according to environmental changes to ensure temperature control stability. The PID temperature control system supports switching between SSR mode and PWM mode, and the corresponding output mode can be selected according to the usage scenario.

5. A temperature-sensing integrated heater according to claim 4, characterized in that, The communication component supports both wireless and wired communication modes. Wireless communication uses WiFi, Bluetooth, or LoRa technology, while wired communication uses Ethernet connection to ensure the stability and real-time performance of remote communication, with data transmission delay not exceeding 1 second.

6. The integrated temperature-sensing heater according to claim 1, characterized in that, The alarm component includes a local alarm module and a remote alarm module. The local alarm module uses audible and visual alarms, while the remote alarm module sends alarm information via SMS, APP push, or platform message push. It also supports alarm level classification and pushes alarm notifications with corresponding priorities based on the severity of the fault.

7. A temperature-sensing integrated heater according to claim 1, characterized in that, The remote control platform has a data storage function, which can store flow channel temperature parameters, heating power parameters, alarm records and operating status images in real time. The storage period is not less than 1 year, and it supports historical data query, statistics and export functions.

8. A method for controlling an integrated temperature-sensing heater, applied to the integrated temperature-sensing heater described in any one of claims 1-7, characterized in that, Includes the following steps: S1. System Initialization: The remote control platform completes hierarchical registration and permission allocation for enterprise users, gateways, hot runner systems, cameras, and temperature control nodes; sets preset temperature control parameters, PID control parameters, alarm thresholds, and operating parameters of heating components for the hot runner system; and completes system self-check to ensure that all components operate normally. S2. Real-time monitoring and data acquisition: Activate the heating components to continuously heat the hot runner channel; The temperature measurement component collects the actual temperature parameters of the flow channel in real time, and the monitoring component collects images of the hot runner system and heater through a network camera. Each component transmits the collected data to the control component and remote control platform through the communication component. S3. PID Temperature Control: The PID temperature control system of the control component receives the actual temperature parameters transmitted by the temperature measuring component, compares them with the preset temperature control parameters, and calculates the temperature deviation. Based on the temperature deviation, the PID temperature control system outputs the corresponding PID current signal to the thyristor voltage regulator. The thyristor voltage regulator outputs a pulse signal based on the PID current signal to adjust the thyristor conduction angle, thereby changing the heating power of the heating component and maintaining the actual temperature of the flow channel within the preset temperature control parameter range, thus achieving constant temperature control. S4. Remote Control and Hierarchical Management: The remote control platform displays all collected data and operating status in real time. Users can issue operation commands such as information collection, temperature setting, turning on, turning off, and timing through the remote control platform. The commands are transmitted to the control component through the communication component, and the control component executes the corresponding operation. The remote control platform performs hierarchical management of enterprise users, gateways, hot runner systems, cameras, and temperature control nodes to achieve collaborative control of various modules. S5. Abnormal Alarms and Handling: The alarm component monitors the system's operating status in real time. When abnormal conditions such as excessively high or low temperature, short circuit in the heating coil, open circuit in the heating coil, reverse thermocouple operation, or blown fuse are detected, alarm information including the fault type, equipment number, and equipment location is automatically generated. This information is simultaneously notified to maintenance personnel through local audible and visual alarms and remote information push. Maintenance personnel locate the faulty equipment and fault type based on the alarm information and perform targeted maintenance. After maintenance is completed, the system automatically resets and resumes normal operation. S6. Cyclic Operation: Repeat steps S2-S5 to continuously achieve constant temperature control, real-time monitoring, remote control and abnormal alarm of the hot runner system, ensure the stable operation of the hot runner system, and allow the solidified material retained in the hot runner system to be injected into the cavity again for use in the next injection, reducing waste generation.

9. The method for controlling an integrated temperature-sensing heater according to claim 8, characterized in that, In step S3, the control process of the PID temperature control system includes proportional regulation, integral regulation and derivative regulation. Proportional regulation is used to quickly respond to temperature deviations, integral regulation is used to eliminate steady-state errors, and derivative regulation is used to suppress temperature fluctuations.

10. A method for controlling an integrated temperature-sensing heater according to claim 9, characterized in that, In step S5, when a thermocouple open circuit or reverse direction is detected, the system automatically switches to manual control mode to maintain the basic heating function of the heating component and ensure production continuity. After the maintenance personnel complete the fault handling, it automatically switches back to automatic constant temperature control mode.

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