FLUID FLOW REAL-TIME CONTROL SYSTEM

Abstract

A real-time fluid flow control system comprises a valve manifold with an outlet port that receives fluid output from a fluid source and a return port that sends the fluid back to the fluid source; multiple outlet pipes that transfer the fluid from the outlet port to equipment to be temperature controlled; multiple return pipes that transfer the fluid from the equipment to be temperature controlled to the return port of the valve manifold; multiple sensors connected to the return lines that measure the fluid in the return lines to obtain measurement information such as temperature and flow rate; multiple flow control valves connected to the return lines; and a control module connected to the flow control valves and sensors to control the flow control valves in real time and adjust the flow rate.Therefore, the flow rate of the liquid can be controlled and adjusted in real time to achieve a uniform temperature faster and more accurately.

Description

BACKGROUND OF THE INVENTION 1. Field of the invention

[0001] The present invention relates to fluid flow control technology and in particular to a real-time fluid flow control system. 2. Description of the related prior art

[0002] German patent application TW M501931 discloses a temperature sensor installed in a mold to detect the temperature of each area, with a heating plate being used to warm areas with insufficient temperature to achieve a uniform temperature. According to TW M493150, a temperature sensor is also installed in the mold, but instead of a heating plate, liquids of different temperatures are directed to different areas of the mold based on the detected temperature to achieve a uniform temperature distribution. German patent application DE 202008014269 U1 discloses a modular fluid distribution system with several functional modules arranged between a base module and an end module. The base module has a supply valve and a return valve, as well as a compressed air line for purging the functional modules and a drainage line.DE 102020210777 A1 discloses a flow controller comprising a valve unit, a flow sensor, a pressure sensor arrangement, and a control unit. In a first operating mode, the controller performs a first flow control based on the flow rate detected by the flow sensor (5), and in a second operating mode, it performs a flow control based on the detected fluid pressure. Furthermore, CN 101797634 discloses the method of guiding cold or hot water through the channels to control the temperature of each channel and thus achieve a uniform temperature distribution on the mold surface. However, the method of using a heating plate for heating easily leads to overheating in certain areas, and the method of introducing liquids at different temperatures into the mold presents the inconvenience of having to provide different temperature-controlled liquids.Furthermore, the method of simply passing cold or hot water through the channels does not readily allow for mixing and fine-tuning to the desired temperature, resulting in less effective immediate temperature control and uniformity. Therefore, all these methods require further improvement. SUMMARY OF THE INVENTION

[0003] One object of the present invention is to provide a real-time control system for a liquid flow, with which the flow rate of the liquid can be controlled and adjusted in real time in order to achieve a uniform temperature more quickly and accurately.

[0004] To solve the aforementioned problem, the real-time fluid flow control system of the present invention comprises a valve manifold, multiple outlet tubes, multiple return tubes, multiple sensors, multiple flow control valves, and a control module. The valve manifold has an outlet port for receiving fluid from a fluid source and a return port for returning the fluid to the fluid source. The outlet tubes are connected to the outlet port of the valve manifold to direct the fluid from the outlet port to a device to be temperature-controlled. The return tubes are connected to the return port of the valve manifold to direct the fluid from the device to be temperature-controlled back to the return port of the valve manifold.The sensors are connected to the return lines and are used to measure the fluid in the return lines, providing measurement information including temperature and flow rate. Flow control valves are connected to the return lines to adjust the fluid flow rate. The control module is connected to the flow control valves and the sensors to control the flow control valves in real time and adjust the fluid flow rate. The valve manifold further comprises a first valve manifold with the outlet port and a second valve manifold connected to the first valve manifold and with the return port.

[0005] It is evident from the foregoing that the control module, by detecting the temperature of the liquid through the sensors and transmitting the information to the control module, controls the flow control valves in order to adjust the flow rate of the liquid so that the flow rate of the liquid can be controlled and adjusted in real time in order to achieve a uniform temperature faster and more accurately and thus fulfill the purpose of the present invention.

[0006] Preferably, the fluid flows first through the sensors and then through the flow control valves, or the fluid flows first through the flow control valves and then through the sensors.

[0007] The control module is preferably connected to several electromagnetic valves to control them so that they open or close the outlet pipes.

[0008] The control module preferably controls the flow control valves except for the return pipe with the lowest temperature in order to reduce the flow rate.

[0009] The control module preferentially controls the flow control valves except for the return pipe with the highest temperature in order to reduce the flow rate.

[0010] The sensor data preferably also includes a fluid pressure in each return pipe.

[0011] The control module preferably uses the MRAC algorithm to set a target temperature and performs calculations based on the temperatures and flow rates detected by the sensors to control the flow control valves to adjust the flow rate.

[0012] The MRAC algorithm preferably includes an adaptive formula that adjusts the parameters of the control module using the difference between parameter estimates and reference model parameters.

[0013] The temperature difference is preferably used between a reference model output and an actual system output as the basis for setting the control module, with the flow rate being adjusted by the unknown or changing parameters based on an error signal.

[0014] Further advantages and features of the present invention will be fully understood by reference to the following description in conjunction with the accompanying drawings, in which the same reference numerals denote the same structural components. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a perspective view of a real-time fluid flow control system of the present invention. Fig. Figure 2 is a perspective view of part of the real-time fluid flow control system of the present invention. Fig. Figure 3 is another perspective view of part of the real-time fluid flow control system of the present invention. Fig. Figure 4 is another perspective view of part of the real-time fluid flow control system of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] With reference to the Fig. 1, Fig. 2, Fig. 3 to Fig. 4 comprises a fluid flow real-time control system of the present invention, a valve manifold 10, several outlet pipes 30, several electromagnetic valves 40, several return pipes 50, several sensors 60, several flow control valves 70 and a control module 80.

[0016] The valve manifold 10 comprises a first valve manifold 10A and a second valve manifold 10B, which is directly or indirectly connected to the first valve manifold 10A. The first valve manifold 10A has an outlet port 11 connected to a fluid source (such as a heating and / or cooling device). The second valve manifold 10B has a return port 12 connected to the fluid source. The valve manifold 10 uses a compact design to reduce the module size for easier installation.

[0017] The outlet pipes 30 are connected to the outlet opening 11 of the valve manifold 10 to direct the liquid from the outlet opening 11 of the valve manifold 10 to equipment to be temperature-controlled. The equipment to be temperature-controlled can be, among other things, a plastic injection mold. Furthermore, the present invention is not limited to heating or cooling the equipment to be temperature-controlled.

[0018] The electromagnetic valves 40 are connected to the outlet pipes 30 to control the opening or closing of each outlet pipe 30 and to determine whether each outlet pipe 30 directs the fluid to the equipment to be tempered.

[0019] The return pipes 50 are connected to the return opening 12 of the valve manifold 10 to direct the fluid from the equipment to be tempered back to the return opening 12 of the valve manifold 10.

[0020] The sensors 60 are connected to the return lines 50 to detect the temperature and flow rate of the liquid in each return line 50, so that the condition of each return line 50 is known via the sensor 60. That is, each sensor 60 can detect the liquid in its corresponding return line 50 to obtain detection information. The sensor data includes the temperature and flow rate of the liquid, as well as the liquid pressure in each return line 50.

[0021] The flow control valves 70 are connected to the return lines 50 to control and adjust the flow rate of each return line 50. The flow control valve 70 is preferably a proportional needle valve. Compared to butterfly valves and ball valves, needle valves offer better flow control performance. In addition, needle valves are smaller than butterfly valves and ball valves, making them easier to install.

[0022] In this embodiment, the liquid flows first through the sensors 60 and then through the flow control valves 70. However, the liquid can flow first through the flow control valves 70 and then through the sensors 60.

[0023] The control module 80 is connected to the electromagnetic valves 40, the flow control valves 70 and the sensors 60 via cables or wirelessly to receive signals from the sensors 60, to control the opening or closing of the electromagnetic valves 40 and to control the flow control valves 70 to adjust the flow rate of the liquid.

[0024] The control module 80 controls the flow control valve 70, which is not the return line 50 with the lowest temperature, in order to reduce the flow rate. However, the control module 80 can also control the flow control valve 70, which is not the return line 50 with the highest temperature, in order to reduce the flow rate.

[0025] The control module 80 also offers monitoring of the flow path status to display real-time information about the status of each flow path, including temperature, flow rate, pressure and other relevant data.

[0026] By using the control module 80 to control the opening or closing of each electromagnetic valve 40, the fluid flow can be controlled quickly and precisely. Furthermore, by using the control module 80 to adjust the flow rate through each flow control valve 70, the fluid flow can be regulated quickly and precisely. This ensures that the fluid in each outlet pipe 30 achieves a uniform temperature distribution across all areas of the temperature control system, thus fulfilling the purpose of the present invention.

[0027] The control module 80 uses the MRAC (Model Reference Adaptive Control) algorithm to set a target temperature. Calculations are performed based on the temperatures and flow rates measured by the sensors 60 to control the flow control valves 70 and adjust the flow rate. The MRAC algorithm includes an adaptive formula that adjusts the parameters of the control module 80 using the difference between parameter estimates and reference model parameters. This adaptive formula is used to automatically adjust the flow rate of the liquid in the mold, thus achieving a uniform temperature distribution. The MRAC algorithm can adjust the flow rates of multiple channels for hot and cold liquids.It uses the temperature difference between the channels and the target temperature of the mold as the basis for control and automatically adjusts the flow rates to improve the temperature uniformity of the mold surface.

[0028] The PID algorithm is better suited for injection molding processes with a fixed shape. However, if the mold is changed or the target temperature deviates, the parameters must be retested and adjusted. In contrast, the MRAC algorithm controls multiple batches simultaneously and achieves both temperature uniformity and convergence time that meet the set targets. The comparative results show that the control module 80, which incorporates the MRAC algorithm, effectively achieves the objectives of the present invention.

[0029] Conventional mold temperature control systems typically use single- or dual-channel outputs. Since there is no feedback mechanism for the channel temperature, the uniformity of the mold surface temperature is insufficiently controlled, with a deviation of approximately ±10 °C. This often leads to product defects such as flow marks during injection molding. The control module 80 of the present invention offers multiple sets of supply channels for hot and cold liquids and, in combination with the MRAC algorithm, can adjust the flow rate in real time within a range of 1-30 l / min with a control accuracy of ±2% and a temperature tolerance of up to 180 °C. The module integrates sensors 60 with a temperature sensing range of 0-200 °C and a flow sensing range of 0-30 l / min, thereby achieving a mold temperature uniformity of ±5 °C.

[0030] Each flow channel is equipped with a sensor 60. Based on the target process mold temperature, adaptive control is used to deliver the required flow rate, reduce fluid energy loss, and optimize the fluid supply process. To compensate for temperature variations caused by the different distances between various flow channels within the mold and the mold surface, the control module 80 adjusts the flow rates of each channel within the mold, thereby improving overall temperature uniformity and optimizing the process.

[0031] The adaptive MRAC control includes a reference gain that defines an ideal control loop model and specifies the target trajectory the system should follow. The adaptive MRAC control also incorporates an error calculation, where the temperature difference between the reference model output and the actual system output serves as the basis for adjusting the control module 80. Based on the error signal, the outputs of the control module 80 estimate the unknown or varying system parameters and adjust the flow rate accordingly. The adaptive formula uses the difference between the estimated parameter values ​​and the reference model parameters to adjust the parameters of the control module 80. The advantage of the adaptive MRAC control is its strong disturbance suppression capability, which allows it to adapt to unknown or changing system parameters and follow the ideal characteristics of a closed-loop control system.

[0032] The present invention enables real-time display of the flow channel's status, including the channel temperature (40-180 °C), temperature deviation from the setpoint, current flow rate (0-30 l / min), and the recording of mold data. During mold changes, the system automatically applies the optimal flow parameters. The present invention also issues warnings in case of irregularities, including temperature anomalies (over- or under-temperature), pressure anomalies (overpressure), and warnings of flow channel blockages.

[0033] Among the advantages of the present invention is the ability to individually control the flow rates of multiple channels within the mold, thereby improving surface temperature uniformity. By using the adaptive MRAC algorithm, the system automatically adjusts the flow rates to the process targets and provides the required fluid supply to each individual flow channel, thus reducing energy loss. The present invention improves the fluid supply process by adapting the flow rates to the process requirements and thus reducing energy consumption. Conventional systems require manual adjustments, but the present invention upgrades the system to adaptive adjustment, eliminating human factors that could lead to product defects or energy waste.The present invention is not only suitable for single-mold applications, but can also be used in general heating or cooling systems for multiple molds, thereby saving on equipment costs and floor space.

[0034] The invention is described in such a way that it is obvious it can be varied in many ways. Such variations are not to be considered as a deviation from the scope of the invention, and all such modifications, which would be obvious to a person skilled in the art, are to be included in the scope of the following claims.

Claims

Fluid flow real-time control system comprising: a valve manifold (10) with an outlet port (11) for receiving fluid dispensed from a fluid source and a return port (12) for returning the fluid to the fluid source; several outlet pipes (30) connected to the outlet port (11) of the valve terminal (10) to direct the fluid from the outlet port (11) to equipment to be temperature controlled; several return lines (50) connected to the return port (12) of the valve manifold (10) to direct the fluid from the equipment to be temperature controlled back to the return port (12) of the valve manifold (10); several sensors (60) connected to the return lines (50) to detect the fluid in the return lines (50) and thus obtain detected information including the temperature and flow rate of the fluid;several flow control valves (70) connected to the return lines (50) to adjust the fluid flow rate; and a control module (80) connected to the flow control valves (70) and the sensors (60) to control the flow control valves (70) in real time and to adjust the fluid flow rate, wherein the valve manifold (10) comprises a first valve manifold (10A) equipped with the outlet port (11) and a second valve manifold (10B) connected to the first valve manifold (10A) and equipped with the return port (12). Fluid flow real-time control system according to claim 1, wherein the fluid first flows through the sensors (60) and then through the flow control valves (70) or the fluid first flows through the flow control valves (70) and then through the sensors (60). Fluid flow real-time control system according to claim 1, further comprising several electromagnetic valves (40) connected to the outlet pipes (30), wherein the control module (80) is connected to the electromagnetic valves (40) to control the electromagnetic valves (40) to open or close the outlet pipes (30). Fluid flow real-time control system according to claim 1, wherein the control module (80) controls the flow control valves (70) that are not the return line (50) with the lowest temperature in order to reduce the flow rate. Fluid flow real-time control system according to claim 1, wherein the control module (80) controls the flow control valves (70) except for the return line (50) with the highest temperature in order to reduce the flow rate. Fluid flow real-time control system according to claim 1, wherein the acquisition information further includes a fluid pressure in each return line (50). Fluid flow real-time control system according to claim 1, wherein the control module (80) uses an MRAC algorithm to set a target temperature and performs calculations based on the temperatures and flow rates measured by the sensors (60) to control the flow control valves (70) to adjust the flow rate. Fluid flow real-time control system according to claim 7, wherein the MRAC algorithm includes an adaptive formula that adjusts parameters of the control module (80) using the difference between parameter estimates and reference model parameters. Fluid flow real-time control system according to claim 8, wherein the temperature difference between a reference model output and an actual system output is used as the basis for setting the control module (80) and the flow rate is set by the unknown or changing parameters on the basis of an error signal.

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