Dual-color mold production equipment integrating self-checking and correction functions and production process thereof

Abstract

The technical scheme belongs to the technical field of double-color mold production equipment, and particularly relates to a double-color mold production equipment integrated with self-checking and correction functions and a production process thereof. The double-color mold production equipment comprises a double-color mold forming module, a benchmark bearing plate surface detection module, a servo turntable dynamic detection module, a self-adaptive correction module and an industrial control storage control module. The benchmark bearing plate surface detection module comprises a multi-point array laser sensor and a blowing mechanism fixed to a static end of a fixed mold side. The servo turntable dynamic detection module comprises a vibration acquisition sensor, a phase acquisition encoder and a frequency spectrum analysis unit. The self-adaptive correction module comprises an oil pressure adjusting unit, a slewing bearing pre-tightening compensation unit, a servo motion parameter adjusting unit and a damping compensation unit. The industrial control storage control module is electrically connected with the benchmark bearing plate surface detection module, the servo turntable dynamic detection module and the self-adaptive correction module respectively, and is used for realizing intelligent control of a whole process of signal acquisition, defect determination, parameter operation, real-time correction, data archiving, process linkage and model iteration.

Description

Technical Field

[0001] This technical solution relates to the field of two-color mold production equipment technology, specifically to a two-color mold production equipment and its production process that integrates self-inspection and calibration functions. Background Technology

[0002] Two-color injection molded products rely on two sets of moving molds working together with fixed molds to complete two injection molding processes. The two sets of moving molds can be interchanged using a servo turntable. They are widely used in the processing and production of two-color plastic parts such as daily necessities, auto parts, and electronic housings.

[0003] Chinese patent CN222245816U discloses a fixed two-color mold holder with two-movement operation. This two-color mold holder and existing two-color mold production lines have the following defects in long-term continuous mass production: 1. The reference bearing plate on the surface of the servo turntable is prone to warping and local uneven deformation due to mold closing pressure and long-term load. This directly causes misalignment in the moving mold assembly and misalignment between the moving mold and the fixed mold, resulting in quality defects such as flash, uneven wall thickness, and poor sealing in injection molded products. Conventional inspection methods require stopping the machine and disassembling it to check the accuracy of the reference plane, which seriously occupies the production cycle.

[0004] 2. When the servo turntable is continuously reciprocating at high speed, wear of the gear pair meshing and assembly deviation of the moving module can easily cause the turntable's center of gravity to shift and dynamic imbalance to cause eccentric vibration. Vibration drift during rotation will cause a decrease in the accuracy of secondary injection molding, aggravate wear on the mold parting surface, and shorten the mold's service life. Summary of the Invention

[0005] The purpose of this technical solution is to provide a two-color mold production process that can be embedded in mass production cycle time and can complete static self-check and correction of the reference board surface and dynamic eccentricity self-check and correction of the servo turntable without stopping the machine, thereby solving the problems of low quality and low efficiency in the production of two-color molds.

[0006] The purpose of this technical solution is achieved as follows: A two-color mold production process integrating self-inspection and calibration functions includes the following steps: S1. During the equipment initialization phase, the equipment is in the standby position. The purging mechanism cleans the reference bearing plate on the servo turntable. After the servo turntable returns to zero and is aligned, the initial positions of the first and second moving molds are calibrated. S2. Static inspection and correction of the reference bearing plate surface; S2.1 Static inspection of the reference bearing plate surface: The full-area height data of the reference bearing plate surface is collected by a multi-point array laser sensor. The least squares method is used to fit the standard reference plane to calculate the local unevenness, overall warping, and dynamic module fitting deviation of the reference bearing plate surface. Then, it is compared with the system's preset accuracy threshold for judgment. If the static inspection of the reference bearing plate surface is qualified, proceed to step S3; if the data after inspection does not reach the accuracy threshold, proceed to step S2.2; if the data after inspection exceeds the accuracy threshold, proceed to step S2.3. S2.2, during the fine-tuning stage of the reference bearing plate, the hydraulic locking mechanism is used to counteract the tilting of the moving module or the alignment offset when closing the fixed mold caused by the deformation of the reference bearing plate in real time. After the correction is completed, return to step S2.1. S2.3, During the fault protection phase, the system locks all equipment in operation and triggers an alarm to shut down the system; S3, servo turntable dynamic detection and calibration; S3.1 Servo turntable dynamic detection: Under no-load conditions, the equipment controls the servo turntable to rotate at the standard mass production speed. The vibration time domain signal of the slewing bearing base and the angle phase signal of the servo turntable are collected by the precision detection mechanism. Then, they are compared with the system's preset precision threshold. If the servo dynamic detection is qualified, proceed to step S4. If the data after detection does not reach the precision threshold, proceed to step S3.2. If the data after detection exceeds the precision threshold, proceed to step S3.3. S3.2, Servo turntable fine-tuning stage: The equipment control increases the preload torque on one side of the gear pair and cooperates with adaptive vibration damping compensation to dynamically suppress the eccentric vibration of the servo turntable. After the correction is completed, return to step S3.1. S3.3, Fault Protection Phase: The system locks all equipment in operation and triggers an alarm to shut down the system. S4. In the first injection stage, the first moving mold moves to the position directly opposite the fixed mold. After the two molds are closed, the first color plastic is injected through the injection mechanism. After the melt is held under pressure and cooled, the substrate semi-finished product is formed in the cavity of the first moving mold. S5. During the mold opening stage, after the substrate semi-finished product has cooled down, the servo turntable cooperates with the first moving mold and the second moving mold to open the mold. The servo turntable rotates half a turn to complete the exchange of the first moving mold and the second moving mold. After the rotation and position are completed, the servo turntable is omnidirectionally locked by the mechanical positioning pin and the hydraulic locking mechanism. S6. In the second injection stage, the fixed mold and the first moving mold after the change are closed to complete the injection of the second color plastic. After the melt is held under pressure and cooled, the mold is opened and the two-color finished product is ejected through the ejection mechanism. S7. In the data processing stage, the system automatically archives and stores the correction parameters and eccentricity compensation parameters formed in this phase, and iteratively updates the data model.

[0007] Preferably, the reference bearing plate surface is subjected to static geometric accuracy detection, and data is collected only when the servo turntable is locked and stationary, which is used to identify planar deformation defects of the reference bearing plate surface itself and misalignment defects of the moving module; the servo turntable is subjected to dynamic eccentricity accuracy detection, and data is collected only when the servo turntable is rotating, which is used to identify overall centroid offset and rotational imbalance defects of the servo turntable.

[0008] Preferably, the precision inspection, defect determination, and adaptive correction processes of the reference bearing plate and the servo turntable can all be performed within the inherent idle time sequence of injection molding.

[0009] Preferably, in step S3.1, the low-frequency vibration time-domain waveform of the slewing bearing base is continuously acquired by a vibration acquisition sensor, and the real-time angle pulse and phase position signal of the servo turntable are synchronously acquired at high speed by a phase acquisition encoder, so that the vibration data and rotation angle data are completely aligned in time.

[0010] Preferably, the system performs FFT (Fast Fourier Transform) spectrum analysis on the synchronously acquired mixed signal, separates and filters out the inherent vibration frequency of the entire equipment and the random vibration interference frequency of the environment, accurately selects the dynamic imbalance characteristic component with the same frequency as the rotation speed of the servo turntable, and accurately calculates the overall eccentricity amplitude and eccentricity phase orientation parameters of the servo turntable by calculating the amplitude and phase distribution of the characteristic component.

[0011] Preferably, in step S3.2, the system iteratively optimizes the S-shaped acceleration and deceleration curve of the servo turntable in real time to weaken the vibration amplification effect caused by sudden changes in rotation speed. At the same time, it increases the preload torque on one side of the transmission gear pair to eliminate gear meshing clearance and superimposes dynamic adaptive vibration damping to attenuate periodic centrifugal vibration. From multiple dimensions such as servo control, transmission clearance, and vibration suppression, the system collaboratively suppresses the turntable's eccentric vibration and rotational positioning drift.

[0012] A two-color mold production device, based on a production process, includes: The dual-color mold forming module includes a fixed mold, a first moving mold, a second moving mold, and a servo turntable. The first moving mold and the second moving mold together form a moving module group. The upper end of the servo turntable is integrally formed with a reference bearing plate. The first moving mold and the second moving mold are tightly attached and fixed above the reference bearing plate by a moving mold pad. The reference bearing plate surface detection module includes a multi-point array laser sensor fixed to the stationary end of the fixed mold side and a purging mechanism; The servo turntable dynamic detection module includes a vibration acquisition sensor, a phase acquisition encoder, and a spectrum analysis unit. The vibration acquisition sensor is fixedly installed on the slewing bearing base. The spectrum analysis unit is used to remove the inherent vibration interference of the equipment and purify the eccentricity and imbalance characteristic components of the servo turntable. The adaptive correction module includes a hydraulic pressure adjustment unit, a slewing bearing preload compensation unit, a servo motion parameter adjustment unit, and a damping compensation unit. The hydraulic pressure adjustment unit is used for dynamically fine-tuning the servo turntable's locking hydraulic pressure; the slewing bearing preload compensation unit is used to eliminate the eccentric load clearance of the servo turntable's slewing bearing; the servo motion parameter adjustment unit is used to optimize the servo turntable's acceleration / deceleration curve and gear preload torque in real time; and the damping compensation unit is used for adaptively superimposing damping to suppress eccentric vibration of the servo turntable. The industrial control storage and control module is electrically connected to the reference bearing plate detection module, the servo turntable dynamic detection module, and the adaptive correction module, respectively, to realize intelligent control of the entire process, including signal acquisition, defect judgment, parameter calculation, real-time correction, data archiving, process linkage, and model iteration.

[0013] The key and beneficial technical effects of this technical solution compared to existing technologies are: 1. This technical solution is designed with two independent detection systems: static reference plate self-inspection and correction and dynamic turntable eccentricity self-inspection and correction. These systems control the static assembly accuracy of the mold and the dynamic running accuracy of the turntable, respectively, thus solving the problems of mold closing misalignment, product defects, and abnormal mold wear from the source. Furthermore, the detection and correction can reuse the injection molding idle time sequence, eliminating the need for machine downtime for maintenance and correction, and effectively improving the production utilization rate of the equipment.

[0014] 2. The vibration signal and rotation angle signal are time-aligned in the design of this technical solution, resulting in higher accuracy in eccentricity parameter calculation. The correction process combines servo curve optimization, gear preload, and adaptive damping to achieve multi-mode coordinated vibration reduction, which is superior to traditional single passive vibration reduction structures.

[0015] 3. The dual-color mold production equipment designed in this technical solution has a two-level processing mechanism: online adaptive correction for minor deviations and automatic machine locking alarm for serious deviations. This ensures normal continuous production and timely shutdown protection in case of major precision failures, thus avoiding irreversible damage to the molds and equipment. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of this technical solution.

[0017] Reference numerals: 1. Two-color mold forming module; 11. Fixed mold; 12. First moving mold; 13. Second moving mold; 14. Servo turntable; 15. Reference bearing plate. Detailed Implementation

[0018] The specific implementation of this technical solution will be further described in detail below with reference to the accompanying drawings.

[0019] This invention includes two-color mold production equipment and a suitable production process, such as... Figure 1As shown, the two-color mold production equipment includes a two-color mold forming module, a reference bearing plate surface detection module, a servo turntable dynamic detection module, an adaptive correction module, and an industrial control storage module. The two-color mold production equipment integrates self-inspection and correction functions. The equipment can complete the static accuracy detection of the reference plate surface, the dynamic eccentricity detection of the servo turntable, the multi-condition adaptive correction, and the iterative optimization of the production data model without affecting the mass production cycle.

[0020] like Figure 1 As shown, the two-color mold forming module 1 is the base execution structure of this equipment, which undertakes the core functions of two-color injection molding, moving mold station switching, and mold bearing assembly. Specifically, it includes a fixed mold 11, a first moving mold 12, a second moving mold 13, and a servo turntable 14. The first moving mold 12 and the second moving mold 13 have symmetrical and consistent structural specifications and together form the overall moving module of this equipment, which is adapted to the two-color step-by-step injection molding process.

[0021] Furthermore, the servo turntable 14, as the core component for station switching and mold support, adopts a high-rigidity integrated disc structure. The upper surface of the servo turntable 14 is integrally machined into a reference support plate 15. The reference support plate 15 is precision ground and calibrated for flatness, serving as a unified reference surface for the assembly and fitting positioning of the moving module, effectively avoiding assembly errors and flatness deviations caused by splicing structures.

[0022] The bottoms of the first moving mold 12 and the second moving mold 13 are respectively attached and installed by high-strength moving mold pads. The double fixing method of bolt locking and positioning pin limiting is adopted to make the moving mold pads completely attached and pressed on the reference bearing plate 15. This ensures that the parallelism and coaxiality of the two sets of moving molds are consistent and prevents mold offset problems caused by assembly gaps and misalignment.

[0023] Furthermore, the servo turntable 14 is fitted with a large slewing bearing structure at its bottom, enabling high-precision slewing and stable rotation. It can accurately complete 180° forward and reverse rotation switching, stably achieving the interchange of positions between the first moving mold 12 and the second moving mold 13. Together with the fixed mold 11, it sequentially completes the first base material injection molding and the second overmolding injection molding process, providing a stable mechanical molding carrier for the entire precision self-checking and calibration process. The reference bearing plate surface detection module is the core unit for static accuracy detection of the equipment. It is used to realize the cleaning pretreatment of the reference bearing plate surface and the full-area planar accuracy detection, avoiding the molding accuracy defects caused by surface debris, planar deformation, and misalignment. Specifically, it consists of a multi-point array laser sensor and a blowing mechanism. The whole is fixedly installed on the stationary frame end of the fixed mold side, and remains absolutely stationary with the fixed mold. It does not rotate or move with the servo turntable, ensuring that the detection reference is fixed and uniform.

[0024] Specifically, the first moving mold and the second moving mold are fixed in the middle area of ​​the reference bearing plate by each automatic mold pad. The overall size of the reference bearing plate is larger than the total area of ​​the two sets of moving mold pads. Large areas of unobstructed reference surfaces are reserved in the annular area outside the pad, the middle gap area between the two pads, and the edge area of ​​the plate. The points collected by the multi-point array laser sensor are distributed in these exposed areas. Based on the planar state of the exposed areas, the warping and concave-convex deformation trend of the entire reference plate is characterized.

[0025] Furthermore, the purging mechanism adopts a fixed compressed air purging structure, which is deployed to cover the entire surface of the reference bearing plate. During the equipment initialization phase, it can output clean low-pressure compressed air to purge the entire surface of the reference bearing plate and the mating area of ​​the moving mold pad, thoroughly removing residual plastic debris, dust, oil stains and mold release agent residues from production. This prevents foreign objects from accumulating, raising the measuring points, or obstructing the laser detection area, thus providing a clean detection environment for high-precision planar detection.

[0026] Furthermore, the multi-point array laser sensor adopts a matrix-style multi-point layout, which can realize the height acquisition of the entire surface of the reference bearing plate without blind spots. It has the advantages of high sampling point density, high surface fitting accuracy, and full coverage. When the equipment is stationary and locked, the multi-point array laser sensor collects discrete height data of the plate surface in batches. Combined with the least squares algorithm of the control system to fit the standard reference plane, it accurately calculates the local concavity and convexity of the reference plate surface, the overall warping amount, and the virtual position deviation of the moving module. It completes the quantitative detection of the static geometric accuracy of the mold, and provides accurate data support for subsequent static deviation judgment and fine adjustment correction. The servo turntable dynamic detection module is the core unit for dynamic precision sensing of the equipment. It performs high-precision detection of dynamic defects such as dynamic imbalance, center of mass shift, and eccentric vibration under the rotation of the servo turntable. Specifically, it includes a vibration acquisition sensor, a phase acquisition encoder, and a spectrum analysis unit. The three work together to complete dynamic signal acquisition, timing alignment, interference removal, and eccentric parameter calculation.

[0027] Specifically, the vibration acquisition sensor adopts a high-sensitivity low-frequency vibration sensor, which is rigidly fixed at the fixed measuring point position of the slewing bearing base and fits the base without gap. It can acquire the low-frequency vibration time-domain waveform of the slewing bearing base in real time and continuously during the no-load rotation of the servo turntable, accurately capture the weak periodic vibration signal caused by the eccentric vibration of the turntable, and has the characteristics of strong anti-interference ability and high low-frequency signal recognition accuracy.

[0028] Furthermore, the phase acquisition encoder is coaxially mounted on the servo turntable drive shaft and rotates synchronously with the servo turntable. It can acquire real-time angle pulses, rotation angles, and phase position signals of the servo turntable at high speed and output high-precision angle timing data. During the detection process, the vibration time-domain waveform data and the angle phase data are strictly time-aligned and matched one by one, ensuring that each set of vibration data corresponds to a unique turntable rotation angle and phase position, completely solving the defects of traditional vibration detection that have no phase correspondence and cannot locate the off-center orientation.

[0029] Furthermore, the spectrum analysis unit incorporates a built-in FFT (Fast Fourier Transform) analytical algorithm, which can decompose and reconstruct the spectrum of the acquired mixed original vibration signal. It can accurately separate and eliminate the inherent vibration frequency of the entire equipment, random vibration of the workshop environment, external noise interference from the hydraulic system, cooling fans, etc., and separately purify the dynamic imbalance characteristic component that is in sync with the rotation speed of the servo turntable. By calculating the amplitude and phase distribution of the characteristic component, it can accurately calculate the amplitude and phase orientation of the overall eccentricity of the servo turntable, achieving interference-free, high-precision dynamic eccentricity detection and providing accurate defect parameters for subsequent dynamic adaptive correction. The adaptive correction module is the core execution unit for the closed-loop accuracy correction of this equipment. It receives the defect data from the detection module and achieves comprehensive adaptive correction from four dimensions: reference surface locking, slewing bearing clearance, servo motion control, and vibration damping compensation. Specifically, it includes a hydraulic pressure adjustment unit, a slewing bearing preload compensation unit, a servo motion parameter adjustment unit, and a damping compensation unit. Each unit is independently controlled and works together to adapt to different types and degrees of accuracy deviation.

[0030] Furthermore, the hydraulic pressure adjustment unit is mainly used for static deviation correction of the reference plate surface. It can dynamically fine-tune the overall locking hydraulic pressure of the servo turntable based on the warping, unevenness, and misalignment detection data of the reference plate surface, balance the force state of the turntable, and compensate in real time for defects such as tilting of the moving module, parallelism offset of the mold closing, and alignment offset caused by slight deformation of the reference plate surface. It corrects the static assembly accuracy deviation of the mold and ensures that the mold closing accuracy of the moving module and the fixed mold meets the standards.

[0031] Furthermore, the slewing bearing preload compensation unit dynamically compensates for wear gaps and off-center load gaps generated during long-term operation of the slewing bearing. It can adjust the slewing bearing preload force in real time, eliminate support gap sway and off-center load offset problems during turntable rotation, improve the rigidity of the servo turntable rotation support, and suppress rotational micro-offset and vibration hazards from the mechanical structure level.

[0032] The servo motion parameter adjustment unit focuses on optimizing the dynamic motion accuracy of the servo turntable. It can iteratively optimize the S-shaped acceleration and deceleration curve of the servo turntable's start and stop based on real-time eccentric vibration data, weaken the vibration amplification effect caused by sudden speed changes, and achieve a smooth transition of turntable speed. At the same time, it dynamically adjusts the preload torque on one side of the gear pair to eliminate gear meshing backlash, prevent rotational positioning drift and impact vibration caused by transmission clearance, and optimize the dynamic operation stability of the turntable.

[0033] The damping compensation unit adopts an adaptive variable damping control structure, which can dynamically match the damping compensation amount according to the real-time vibration amplitude of the turntable, specifically attenuate the periodic centrifugal vibration and eccentric jitter of the turntable, dynamically suppress the eccentric vibration defects in the rotation process of the servo turntable, and realize real-time attenuation of vibration and dynamic accuracy adaptive repair. The industrial control storage control module serves as the intelligent control hub for the entire equipment. It connects to the reference bearing plate detection module, the servo turntable dynamic detection module, and the adaptive correction module via electrical connections, and coordinates the entire machine's signal interaction, logic judgment, parameter calculation, correction execution, process linkage, and data iteration into a fully closed-loop intelligent control system.

[0034] Furthermore, during the detection phase, the industrial control storage module uniformly receives laser height detection data, vibration time domain data, and angle phase data, completes data preprocessing, deviation calculation, and accuracy threshold comparison, accurately determines the type and magnitude of static planar defects and dynamic eccentric defects of the equipment, distinguishes between minor deviations that can be adaptively corrected and serious out-of-tolerance faults that require shutdown for maintenance, and matches corresponding correction strategies or fault protection logic.

[0035] Furthermore, during the calibration phase, the industrial control storage module issues precise control commands to each calibration unit according to the defect type, realizing adaptive and coordinated control of hydraulic pressure fine adjustment, slewing bearing preload compensation, servo curve optimization, gear preload adjustment, and damping compensation, completing the closed-loop correction of accuracy deviation, and automatically re-checking and verifying the calibration effect until the accuracy meets the standard.

[0036] Furthermore, during the production and data iteration phase, the industrial control storage control module provides full-process linkage control of the entire process, including injection molding, mold opening, repositioning, locking, and ejection. This ensures that the inspection and correction processes are embedded in the idle time sequence of mass production without occupying the molding cycle. At the same time, it automatically archives and stores the plate surface correction parameters, eccentricity compensation parameters, damping parameters, and servo motion parameters of each batch of production. Based on historical production data, it continuously iterates and updates the mold-specific precision model, enabling the equipment correction strategy to adapt to the long-term gradual changes in mold wear, structural deformation, and transmission aging, thus achieving intelligent iteration and continuous optimization of equipment precision.

[0037] Working principle of two-color mold production equipment: After equipment initialization, the reference bearing plate detection module first completes cleaning and static accuracy detection, correcting the deviation of the mold reference plane; after the static accuracy meets the standard, the servo turntable dynamic detection module completes no-load dynamic eccentricity detection and parameter calculation; the adaptive correction module completes multi-dimensional accuracy repair based on the two types of detection data; after all accuracy meets the standard, the equipment can carry out two-color injection molding mass production normally; the production process industrial control and storage control module coordinates process linkage and data storage iteration in real time, ultimately realizing high-precision, unmanned self-inspection and correction and intelligent accuracy optimization throughout the two-color mold production process. A two-color mold production process integrating self-inspection and calibration functions, adapted to two-color mold production equipment, includes the following steps: S1. During the equipment initialization phase, the equipment is in the standby position. The purging mechanism cleans the reference bearing plate on the servo turntable. After the servo turntable returns to zero and is aligned, the initial positions of the first and second moving molds are calibrated. S2. Static inspection and correction of the reference bearing plate surface; S2.1 Static inspection of the reference bearing plate surface: The full-area height data of the reference bearing plate surface is collected by a multi-point array laser sensor. The least squares method is used to fit the standard reference plane to calculate the local unevenness, overall warping, and dynamic module fitting deviation of the reference bearing plate surface. Then, it is compared with the system's preset accuracy threshold for judgment. If the static inspection of the reference bearing plate surface is qualified, proceed to step S3; if the data after inspection does not reach the accuracy threshold, proceed to step S2.2; if the data after inspection exceeds the accuracy threshold, proceed to step S2.3. S2.2, during the fine-tuning stage of the reference bearing plate, the hydraulic locking mechanism is used to counteract the tilting of the moving module or the alignment offset when closing the fixed mold caused by the deformation of the reference bearing plate in real time. After the correction is completed, return to step S2.1. S2.3, During the fault protection phase, the system locks all equipment in operation and triggers an alarm to shut down the system; S3, servo turntable dynamic detection and calibration; S3.1 Servo turntable dynamic detection: Under no-load conditions, the equipment controls the servo turntable to rotate at the standard mass production speed. The vibration time domain signal of the slewing bearing base and the angle phase signal of the servo turntable are collected by the precision detection mechanism. Then, they are compared with the system's preset precision threshold. If the servo dynamic detection is qualified, proceed to step S4. If the data after detection does not reach the precision threshold, proceed to step S3.2. If the data after detection exceeds the precision threshold, proceed to step S3.3. S3.2, Servo turntable fine-tuning stage: The equipment control increases the preload torque on one side of the gear pair and cooperates with adaptive vibration damping compensation to dynamically suppress the eccentric vibration of the servo turntable. After the correction is completed, return to step S3.1. S3.3, Fault Protection Phase: The system locks all equipment in operation and triggers an alarm to shut down the system. S4. In the first injection stage, the first moving mold moves to the position directly opposite the fixed mold. After the two molds are closed, the first color plastic is injected through the injection mechanism. After the melt is held under pressure and cooled, the substrate semi-finished product is formed in the cavity of the first moving mold. S5. During the mold opening stage, after the substrate semi-finished product has cooled down, the servo turntable cooperates with the first moving mold and the second moving mold to open the mold. The servo turntable rotates half a turn to complete the exchange of the first moving mold and the second moving mold. After the rotation and position are completed, the servo turntable is omnidirectionally locked by the mechanical positioning pin and the hydraulic locking mechanism. S6. In the second injection stage, the fixed mold and the first moving mold after the change are closed to complete the injection of the second color plastic. After the melt is held under pressure and cooled, the mold is opened and the two-color finished product is ejected through the ejection mechanism. S7. In the data processing stage, the system automatically archives and stores the correction parameters and eccentricity compensation parameters formed in this phase, and iteratively updates the data model.

[0038] Step S1 is the process of initializing the equipment for precise alignment. After the equipment is powered on and in standby mode, the whole machine enters the initialization station lock state. First, the blowing mechanism is started, and low-pressure clean compressed air is used to blow the entire surface of the upper reference bearing plate of the servo turntable for 2-3 seconds to thoroughly remove dust, plastic debris, oil stains and mold release agent residues attached to the plate surface, so as to avoid foreign objects raising the measuring points and blocking the laser spot, which would cause the height data to be distorted.

[0039] After purging, the servo turntable performs a combined electrical zeroing and mechanical alignment calibration. Using the factory reference zero point as a reference, it completes the left and right symmetrical position calibration of the first and second moving molds to ensure that the initial assembly posture of the two sets of moving molds is parallel and the reference origin is unified. This provides a unified zero reference for subsequent plane fitting, deviation calculation, and eccentricity solution. After initialization, the equipment enters a high-precision standby mode for testing.

[0040] Step S2 is the implementation process of static detection and precise correction of the reference bearing plate. After initialization, the equipment remains completely stationary and the hydraulic locking mechanism is pre-locked. The multi-point array laser sensor arranged on the stationary side of the fixed mold is turned on synchronously to collect points in a matrix manner across the entire surface of the reference bearing plate. The point density covers the complete contact area of ​​the moving mold pad, with no detection blind spots. The system uses the least squares method to perform surface fitting on all discrete height measurement points to construct the optimal fitting standard reference plane under the current working conditions.

[0041] Three types of core deviation data are obtained by fitting plane calculation: local unevenness of the reference plate surface, overall warping deformation, and misalignment deviation between the moving mold pad and the reference plate surface. The system has two built-in accuracy thresholds: qualified threshold and shutdown out-of-tolerance threshold, realizing three-state judgment: qualified, slight correctable deviation, and serious out-of-tolerance fault.

[0042] When the test data is slightly substandard and within the correctable range, the system activates the reference plate fine-tuning logic: dynamically fine-tuning the locking pressure and uniformity of the servo turntable hydraulic locking mechanism to compensate for the slight elastic and plastic deformation caused by long-term pressure on the reference plate surface, and correcting problems such as slight tilting of the moving module, offset of mold parallelism, and local misalignment caused by plate warping and local unevenness. After the correction is completed, the system automatically re-inspects and iteratively fine-tunes until all planar accuracy parameters enter the qualified range.

[0043] If the detection deviation exceeds the system's set safety threshold, it is determined that the structural deformation of the reference plate exceeds the standard and cannot be fine-tuned and repaired online. The system will immediately lock all injection molding and turntable repositioning actions, and simultaneously trigger an audible and visual alarm to stop the machine, prompting staff to disassemble and level the machine, replace the pad, or repair and maintain the plate.

[0044] Importantly, in this embodiment, step S2 is a prerequisite for the normal operation of the equipment, but it can also be performed within the normal operating timeline of the equipment. The specific time period can be any time when there is no mold closing pressure, including but not limited to: the initial stage of equipment power-on, the cooling stage after a single injection, and the finished product ejection stage. This incorporates the static detection of the reference bearing plate into the normal production cycle, which ensures that real-time monitoring can be carried out to detect abnormal problems in a timely manner without affecting normal production efficiency.

[0045] Step S3 is the implementation process of dynamic eccentricity detection and multi-dimensional adaptive correction of the servo turntable. After the static plane accuracy test is qualified, the equipment enters the no-load dynamic accuracy test process. The equipment maintains a safe no-load state without mold load and injection pressure, and controls the servo turntable to rotate smoothly and at a constant speed according to the mass production standard working speed to simulate the actual production rotation conditions.

[0046] During the testing process, the vibration acquisition sensor fixed to the slewing bearing base continuously acquires the low-frequency vibration time-domain waveform of the base, while the synchronous phase acquisition encoder acquires the servo turntable angle pulse, real-time rotation angle position and phase information at high speed. The two sets of signals are strictly time-aligned and correspond one-to-one, ensuring that each vibration waveform point corresponds to a unique turntable rotation angle, providing a synchronous data source for subsequent accurate calculation of the eccentric phase.

[0047] The system performs FFT (Fast Fourier Transform) spectrum analysis on the collected mixed raw signals to remove the inherent mechanical vibration frequency of the equipment, random vibration of the workshop environment, and interference noise from the fan and hydraulic system. It accurately selects the dynamic imbalance characteristic frequency component that is in sync with the rotation speed of the servo turntable. By calculating the amplitude and phase distribution of the characteristic component, it accurately solves the amplitude of the overall eccentricity of the servo turntable and the eccentricity azimuth phase, achieving interference-free and high-precision dynamic eccentricity detection.

[0048] The system adaptively corrects based on the magnitude of the eccentricity: for slight eccentric vibration deviations, the system simultaneously initiates a three-dimensional collaborative correction strategy. First, the S-shaped acceleration and deceleration curve of the servo turntable is iteratively optimized in real time to weaken the instantaneous vibration amplification effect caused by sudden changes in start-stop speed and achieve smooth speed transition. Second, increase the preload torque on one side of the gear pair to eliminate gear meshing backlash and prevent positioning drift and impact vibration caused by backlash wobble during rotation. Third, the system adaptively superimposes dynamic vibration damping compensation to dampen and attenuate the periodic centrifugal vibration of the turntable, suppressing the periodic shaking caused by eccentric rotation.

[0049] Through multi-dimensional coordinated control of servo motion optimization, transmission backlash elimination, and vibration damping attenuation, the system effectively suppresses the dynamic imbalance eccentric vibration and rotational positioning drift of the servo turntable. After each correction, the system automatically returns to the dynamic detection process for retesting until the eccentric vibration parameters meet the accuracy requirements. If the eccentricity is seriously out of tolerance and exceeds the adaptive correction capability range, the system immediately locks the high-speed rotation process of the turntable and the injection molding process, forcibly stopping the machine for protection, avoiding mold offset, batch defects, and abnormal wear of the slewing bearing and gear pair caused by excessive eccentricity.

[0050] Importantly, in this embodiment, step S3 serves as a prerequisite for the normal operation of the equipment, but it can also be performed within the normal operating timeline of the equipment. The specific time periods can be when the servo turntable is rotating under no load, when there is no mold closing pressure, and when there is no injection load. Specifically, it includes, but is not limited to, the initial stage of equipment power-on, the cooling stage after a single injection, the finished product ejection stage, and the standby interval between batches of mass production. In this way, the dynamic detection of the servo turntable is incorporated into the normal production process cycle, which ensures that real-time monitoring can be performed to detect abnormal problems in a timely manner without affecting normal production efficiency.

[0051] Specifically, the cooling stage after a single injection is as follows: after the injection is completed, the product enters the cooling and curing stage. When there is sufficient cooling time, the mold remains closed and locked, but the turntable itself is not subjected to radial or axial additional impact loads. The locking structure can be briefly opened to allow the servo turntable to run at low speed and rated speed under no-load for testing. After the test is completed, the turntable is locked again to perform a 180° repositioning action. The extra cooling time is used to complete dynamic eccentricity sampling and small vibration compensation without increasing the overall molding cycle.

[0052] The finished product ejection stage is completed after the two-color finished product is ejected, the robot arm picks up the part, and the cavity is cleaned by blowing air. Both sets of moving molds are in a free state of mold opening, and the turntable has no clamping load. This static gap can be used to start the turntable to rotate without load and carry out dynamic eccentricity detection and vibration correction.

[0053] Step S4 is the first injection molding process of the substrate. After all static and dynamic double precision tests are qualified, the equipment enters the formal mass production process. The first moving mold moves with the sliding frame to the position opposite the fixed mold. The moving and static molds are precisely closed. After the mold is closed, the injection mechanism is started to inject the first color plastic melt into the cavity of the first moving mold. After the melt is held under the set pressure and cooled at a constant temperature, a substrate semi-finished product with a stable structure is formed in the cavity, which provides a molding base for subsequent secondary overmolding.

[0054] Step S5 is the process of mold opening, turntable repositioning, and omnidirectional locking. After the substrate semi-finished product cools and solidifies to the standard, the mold performs a smooth mold opening action. After the mold opening is completed, the servo turntable rotates precisely 180° to complete the complete interchange of the first moving mold and the second moving mold station. At this time, the first moving mold carrying the substrate semi-finished product switches to the secondary coating molding station, and the empty second moving mold switches to the initial standby station. After the rotation and repositioning action is completed, the system achieves mechanical hard positioning through mechanical positioning pins. At the same time, it cooperates with the hydraulic locking mechanism to implement omnidirectional locking of the servo turntable, eliminating the turntable rotation gap, micro-shaking and off-center displacement, and ensuring zero offset and zero vibration of the turntable during the secondary mold closing process.

[0055] Step S6 is the second two-color overmolding and finished product ejection process. After the turntable is rigidly locked, the fixed mold and the first moving mold after the change are precisely aligned and closed to perform the second color plastic injection molding. After the second color plastic melt is filled, pressure is maintained, and it is cooled and solidified, it is fused with the first substrate semi-finished product to form a two-color structure. After the second molding and cooling is completed, the equipment opens the mold, and the ejection mechanism smoothly ejects the molded complete two-color finished product, completing a single molding cycle.

[0056] Step S7 is the parameter archiving and model iteration optimization process. After a single molding cycle is completed, the industrial control system automatically archives and stores the key precision parameters of the entire production process, including: reference plate surface concavity and warping correction parameters, hydraulic pressure fine-tuning compensation amount, gear preload torque parameters, adaptive damping compensation parameters, turntable eccentricity and phase compensation parameters. The system continuously iterates and updates the mold-specific precision data model based on big data from previous production cycles, so that the self-inspection judgment and adaptive correction strategy of subsequent batches are more in line with the gradual changes in mold wear, plate surface deformation, and transmission wear, realizing an intelligent closed-loop effect of continuous optimization of equipment precision with each production batch and increasing accuracy with use.

[0057] It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and objectives of the invention, should still fall within the scope of the technical content disclosed herein. Furthermore, the terms "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0058] It should also be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on the other component or may be connected to an intermediary component. When a component is referred to as being "connected to" another component, it can be directly connected to the other component or indirectly connected to the other component through an intermediary component.

[0059] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0060] The foregoing has shown and described the basic principles, main features, and advantages of this technical solution. Those skilled in the art should understand that this technical solution is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this technical solution. Various changes and modifications can be made to this technical solution without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed technical solution. The scope of protection of this technical solution is defined by the appended claims and their equivalents.

Claims

1. A two-color mold production process integrating self-inspection and calibration functions, characterized in that, Includes the following steps: S1. During the equipment initialization phase, the equipment is in the standby position. The purging mechanism cleans the reference bearing plate on the servo turntable. After the servo turntable returns to zero and is aligned, the initial positions of the first and second moving molds are calibrated. S2. Static inspection and correction of the reference bearing plate surface; S2.1 Static inspection of the reference bearing plate surface: The full-area height data of the reference bearing plate surface is collected by a multi-point array laser sensor. The least squares method is used to fit the standard reference plane to calculate the local unevenness, overall warping, and dynamic module fitting deviation of the reference bearing plate surface. Then, it is compared with the system's preset accuracy threshold for judgment. If the static inspection of the reference bearing plate surface is qualified, proceed to step S3; if the data after inspection does not reach the accuracy threshold, proceed to step S2.

2. If the detected data exceeds the accuracy threshold, proceed to step S2.3; S2.2, during the fine-tuning stage of the reference bearing plate, the hydraulic locking mechanism is used to counteract the tilting of the moving module or the alignment offset when closing the fixed mold caused by the deformation of the reference bearing plate in real time. After the correction is completed, return to step S2.

1. S2.3, During the fault protection phase, the system locks all equipment in operation and triggers an alarm to shut down the system; S3. Servo turntable dynamic detection and calibration; S3.1 Servo turntable dynamic detection: Under no-load conditions, the equipment controls the servo turntable to rotate at the standard mass production speed. The vibration time domain signal of the slewing bearing base and the angle phase signal of the servo turntable are collected by the precision detection mechanism. Then, they are compared with the system's preset precision threshold. If the servo dynamic detection is qualified, proceed to step S4. If the data after detection does not reach the precision threshold, proceed to step S3.

2. If the data after detection exceeds the precision threshold, proceed to step S3.

3. S3.2, Servo turntable fine-tuning stage: The equipment control increases the preload torque on one side of the gear pair and cooperates with adaptive vibration damping compensation to dynamically suppress the eccentric vibration of the servo turntable. After the correction is completed, return to step S3.

1. S3.3, During the fault protection phase, the system locks all equipment in operation and triggers an alarm to shut down the system; S4. In the first injection stage, the first moving mold moves to the position directly opposite the fixed mold. After the two molds are closed, the first color plastic is injected through the injection mechanism. After the melt is held under pressure and cooled, the substrate semi-finished product is formed in the cavity of the first moving mold. S5. During the mold opening stage, after the substrate semi-finished product has cooled down, the servo turntable cooperates with the first moving mold and the second moving mold to open the mold. The servo turntable rotates half a turn to complete the exchange of the first moving mold and the second moving mold. After the rotation and position are completed, the servo turntable is omnidirectionally locked by the mechanical positioning pin and the hydraulic locking mechanism. S6. In the second injection stage, the fixed mold and the first moving mold after the change are closed to complete the injection of the second color plastic. After the melt is held under pressure and cooled, the mold is opened and the two-color finished product is ejected through the ejection mechanism. S7. In the data processing stage, the system automatically archives and stores the correction parameters and eccentricity compensation parameters formed in this process, and iteratively updates the data model.

2. The two-color mold production process integrating self-inspection and calibration functions according to claim 1, characterized in that: The reference bearing plate surface is subjected to static geometric accuracy detection, and data is collected only when the servo turntable is locked and stationary. This data is used to identify planar deformation defects of the reference bearing plate surface itself and misalignment defects of the moving module. The servo turntable is used for dynamic eccentricity accuracy detection. Data is collected only when the servo turntable is rotating, and it is used to identify overall centroid offset and rotational imbalance defects of the servo turntable.

3. The two-color mold production process integrating self-inspection and calibration functions according to claim 1, characterized in that: The precision inspection, defect determination, and adaptive correction processes for the reference bearing plate and servo turntable can all be performed within the inherent idle time sequence of injection molding.

4. The two-color mold production process integrating self-inspection and calibration functions according to claim 1, characterized in that: In step S3.1, the low-frequency vibration time-domain waveform of the slewing bearing base is continuously acquired by the vibration acquisition sensor, and the real-time angle pulse and phase position signal of the servo turntable are synchronously acquired at high speed by the phase acquisition encoder, so that the vibration data and rotation angle data are completely aligned in time.

5. The two-color mold production process integrating self-inspection and calibration functions according to claim 1, characterized in that: The system performs FFT (Fast Fourier Transform) spectrum analysis on the synchronously acquired mixed signals, separates and filters out the inherent vibration frequency of the entire equipment and the random vibration interference frequency of the environment, accurately selects the dynamic imbalance characteristic component with the same frequency as the rotation speed of the servo turntable, and accurately calculates the overall eccentricity amplitude and eccentricity phase orientation parameters of the servo turntable by calculating the amplitude and phase distribution of the characteristic component.

6. The two-color mold production process integrating self-inspection and calibration functions according to claim 1, characterized in that: In step S3.2, the system iteratively optimizes the S-shaped acceleration and deceleration curve of the servo turntable in real time to reduce the vibration amplification effect caused by sudden changes in speed. At the same time, it increases the preload torque on one side of the transmission gear pair to eliminate gear meshing clearance and superimposes dynamic adaptive vibration damping to attenuate periodic centrifugal vibration. From multiple dimensions such as servo control, transmission clearance and vibration suppression, the system collaboratively suppresses the turntable's eccentric vibration and rotational positioning drift.

7. A two-color mold production equipment, based on the production process described in any one of claims 1-6, characterized in that, include: The dual-color mold forming module includes a fixed mold (11), a first moving mold (12), a second moving mold (13), and a servo turntable (14). The first moving mold (12) and the second moving mold (13) together form a moving mold group. The upper end of the servo turntable (14) is integrally formed with a reference bearing plate (15). The first moving mold (12) and the second moving mold (13) are tightly attached and fixed above the reference bearing plate (15) by the moving mold pad. The reference bearing plate surface detection module includes a multi-point array laser sensor fixed to the stationary end of the fixed mold side and a purging mechanism; The servo turntable dynamic detection module includes a vibration acquisition sensor, a phase acquisition encoder, and a spectrum analysis unit. The vibration acquisition sensor is fixedly installed on the slewing bearing base. The spectrum analysis unit is used to remove the inherent vibration interference of the equipment and purify the eccentricity and imbalance characteristic components of the servo turntable. The adaptive correction module includes a hydraulic pressure adjustment unit, a slewing bearing preload compensation unit, a servo motion parameter adjustment unit, and a damping compensation unit. The hydraulic pressure adjustment unit is used to dynamically fine-tune the locking hydraulic pressure of the servo turntable; the slewing bearing preload compensation unit is used to eliminate the off-center load clearance of the servo turntable's slewing bearing; the servo motion parameter adjustment unit is used to optimize the acceleration / deceleration curve of the servo turntable and the gear preload torque in real time; and the damping compensation unit is used to adaptively superimpose damping to suppress the eccentric vibration of the servo turntable. as well as The industrial control storage and control module is electrically connected to the reference bearing plate detection module, the servo turntable dynamic detection module, and the adaptive correction module, respectively, to realize intelligent control of the entire process, including signal acquisition, defect judgment, parameter calculation, real-time correction, data archiving, process linkage, and model iteration.

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