Method for setting up and operating machines for processing plastics, and associated machine

Abstract

The invention relates to a method for setting up and operating machines for processing plasticisable material, comprising at least one electric motor for at least one machine shaft, the motor characteristics of which, in particular a torque speed characteristic, being present as parts of a machine-related mathematical model (190). In the method, machine-independent process parameter profiles of an ideal filling process are determined from a filling simulation (200) taking into account the domains of tool (10) and material (Mat). In the process, in a simulation, machine-specific setting parameters and machine-independent process parameters of a real filling process are determined in an iterative approach process based on the machine-independent process parameter profiles of the ideal filling process and the machine-dependent mathematical models (190). During setup of the machine, machine-specific setting parameters can be at least partially taught by an operator and the machine is operated based on the determined and optionally taught machine-specific setting parameters and determined machine-independent process parameters without manual parameter input in a process-phase-dependent optimal working point (AP) of a filling process.

Description

[0001]Method for setting up and operating machines for processing plastics and associated machine Description Reference to related applications The present application relates to and claims the priority of German patent application 102023119617.0, filed on July 25, 2023, the disclosure content of which is hereby expressly incorporated in its entirety into the subject matter of the present application. Field of the invention The present invention relates to a method for setting up and operating machines for processing plastics and other plasticizable materials, such as in particular injection molding machines or machines for additive manufacturing, having the features of claim 1. Furthermore, the invention relates to such a machine for processing plastics and other plasticizable materials, having the features of claim 13, which is set up, designed and / or constructed to implement the method for setting up andOperating machines for processing plasticizable materials, and a computer program product according to claim 14 with a program code stored on a computer-readable medium, comprising instructions that cause the machine of claim 13 to carry out the method steps according to any one of claims 1 to 12. The term "plasticizable material," as used here, is to be understood broadly and includes in particular, but not exclusively, in addition to plastics or silicone or other thermoplastic and / or elastomeric materials, e.g., ceramic, metallic and / or powdery masses, as well as paper, cellulose, starch, cork, etc., as well as mixed materials between such plasticizable materials. In principle, these can also be previously plasticized materials or plastic masses that harden automatically or with the use of aids after application. The term encompassesalso recyclates. The term "domain," as used here, refers in systems engineering, and particularly in software engineering, to a definable problem area or a specific area of ​​application for computer systems or software. Domains - or problem domains - typically place very specific requirements on a technical system that is to be used to simulate or solve domain-specific tasks and problems. These requirements are incorporated into the development process, particularly during the requirements analysis that precedes system development, and during the design of the system, and significantly determine the modeling or modeling that forms the basis of the subsequent implementation. State of the art In the field of machines for processing plasticizable materials, such as plastics and other plasticizable materials, the processes are characterized by the variance in theprocessed materials are becoming increasingly complex. At the same time, the sharp rise in energy prices is forcing machine operators to operate the process and thus the machine at an optimal operating point depending on the process phase. This is usually an optimum between productivity, energy consumption and output rate (proportion of good parts). Operators are increasingly forced to operate the machines in shifts 24 / 7 and have problems recruiting qualified personnel to operate and support the machines. This increases the demand for greater automation, which makes machine operation even more complex. DE 102017131032 A1 discloses a method for setting up a molding machine, in particular an injection molding machine, comprising the steps: a) at least one filling simulation is carried out with at least one process parameter describing physical conditions of the molding process, in particular the tool and thematerial, and at least one parameter that serves as the basis for at least one of the machine-specific setting parameters of the molding machine, in particular for at least one drive for at least one machine axis with drive characteristics that are present as parts of machine-related mathematical models in order to generate at least one characteristic curve field that specifies at least one quality parameter dependent on the process parameter and the machine-specific setting parameter. b) a process parameter is measured on the injection molding machine, with the aid of which a machine-specific setting parameter of the drive for a machine axis is determined from the characteristic curve field of the filling simulation in order to operate the injection molding machine without manual parameter input with a process-phase-dependent optimal value of the quality parameter in a real filling process. This solves the problem that the results of simulations often do not correspond to thereality, which is avoided there by using machine-related measurements of a process parameter. Therefore, in addition to a filling simulation with at least one process parameter describing the physical conditions of the molding process, at least one additional parameter is used that serves as the basis for at least one machine-specific setting parameter. In addition, a real process parameter is measured on the machine. DE 4025221 A1 discloses a method for running in new tools on a plastic injection molding machine, in which the machine operation is started from an initial operating point, which is specified by a control program in the form of operating parameter setpoints according to a computer-simulated filling of the respective tool. The operating point of the injection molding machine is determined depending on the quality and, if applicable, the demolding behavior of test-producedPlastic molded parts are tracked. An optimization program is used to track the operating point. This program includes basic knowledge of the rules of plastic injection molding and a characteristic curve field of operating parameters and quality data. The characteristic curve field is created and refined based on an empirical or systematic learning and memorization process during the running-in of the respective tool from the operating parameters and quality data that arise during this process. After the running-in process has been completed, the optimal operating point determined for each tool is stored in a retrievable manner. DE 102022102748 A1 discloses a method for controlling processes on at least one plastics processing machine. The method comprises the steps of: carrying out a simulation for producing at least one component by generating simulation data sets that relate to a shape contour of the component and / or material properties.properties; determining a process image for operating the machine with an idealized operating point based on the simulation data sets; generating a statistical experimental design matrix; iteratively simulating the experimental design matrix while calculating remaining variations of process parameters, reducing the experimental design matrix, and obtaining a trained process model for the machine with which a component can be manufactured on the machine; verifying the remaining variations of process parameters through real tests in which components are manufactured and evaluated on the machine, to generate a process parameter data set for operating the machine at an operating point, by an operator communicating interactively with a chatbot and / or an automated dialog with a control / regulation device that communicates with at least one evaluation system for evaluating the component; operating the machinewith the process parameter data set at the operating point. EP 3892440 A1 discloses a method for setting at least one parameter profile for controlling a cyclically operating injection molding machine for processing plasticizable materials. The method comprises the steps of: providing and / or selecting at least one 3D model of at least one geometry of at least one molded part to be molded and / or at least one geometry of at least one mold cavity, providing and / or selecting at least one simulation program for simulating the production of the at least one molded part on the injection molding machine and / or the filling of the at least one mold cavity, providing and / or selecting at least one injection molding material with at least one processing parameter, performing at least one simulation with respect to the at least one geometry using the simulation program. At least one machine-independentA process parameter profile is calculated from the simulation depending on the injection molding material, with the calculated process parameter being configured for an "idealized" injection molding process on an "ideal" injection molding machine. Then, the at least one machine-independent process parameter profile is converted into at least one machine-specific setting parameter for a presetting of the at least one parameter profile for controlling a real injection molding machine using design and machine expertise that takes into account the design features and / or limitations of the real injection molding machine, and the real injection molding machine is operated accordingly. This enables the operator to quickly and easily use the results obtained from the simulation to set up the injection molding machine for the next injection process. Furthermore, methods are known that aim toTo automate the setup and operation of an injection molding machine. In one of these processes, machine-independent process parameter profiles of an ideal filling process are determined based on a filling simulation, taking into account the mold and material domains. Here, the mold and material domains are taken into account. The machine domain is not considered. All known processes have in common that the operator must make numerous inputs on the control panel to set up the process. Ultimately, the operator must rely on specialist knowledge that will only be available to a limited extent in the future. Furthermore, the known processes do not operate the injection molding machines at an optimum balance between productivity, energy consumption, and output rate. The performance of injection molding machines is usually defined and evaluated for specific points based on EUROMAP recommendations such as EUROMAP 4.designed. It is common practice in the industry to define the performance of an injection molding unit at 2000 bar (200 MPa) injection pressure and to design the axis for holding pressures between 2000 bar (200 MPa) and 1600 bar (160 MPa). When designing the machine and, for example, the injection axis, the operating points in the drive design are taken into account. To do this, the specialist examines the motor characteristics of a servo motor and correlates the process requirements with motor data, available supply power, efficiencies, and reserves. It is irrelevant whether the servo drive drives a mechanically directly coupled system (ball screw, planetary roller screw, or rack and pinion), drives it via belt, or drives a hydraulic pump. This design represents the guaranteed performance of the machine axis for continuous operation, but is generally never the ideal operating point for operating a mold. There are known procedures thatOperation Analyze and optimize machine movements. For example, mold clamping forces are reduced from cycle to cycle until the mold begins to "breathe" during the injection process, i.e., based on the position of the moving mold half, it is recognized that the injection pressure is slightly pressing the mold open. The clamping force is then increased again by a safety reserve, and the machine is operated in this way. There are known processes in which, based on a filling simulation, an initial operating point for the injection pressure and temperature profile is found and transmitted to the machine. However, this is optimized "from the perspective of the filling process," i.e., the "ideal" operating point of the filling process is found. Here, the mold and material domains are taken into account. The optimal operating point of the machine is not the focus. The analysis of thousands of collected machine-tool data sets has shown that the machine / tool ​​rarely falls below themust be operated within the limit parameters. This means that in very rare cases, an injection pressure of 2000 bar (200 MPa) or more is programmed during operation. To protect the sensitive mold inserts, the injection pressure is often limited to well below 2000 bar. Surprisingly, however, a maximum clamping force is very frequently programmed, which increases tool wear and unnecessarily wastes energy. Summary of the Invention The invention is therefore based on the object of providing a method for setting up and operating a machine that supports the machine operator in such a way that he can set up the machine, e.g. with an injection mold, as well as operate the machine at an optimal operating point without any parameter input. The operator is supported by an assistant who allows him to automatically find an optimum between productivity, energy consumption and output rate and toMachine to operate in this way. Description of the invention This object is achieved by a method according to the features of patent claim 1. This is a method for setting up and operating machines for processing plastics and other plasticizable materials, in particular injection molding machines, - hereinafter referred to as "machine" - comprising at least one electric motor, preferably a servo motor, for at least one machine axis. In a simulation, machine-specific setting parameters and machine-independent process parameters of a real filling process are determined in an iterative approximation process based on the machine-independent process parameter profiles of the ideal filling process and the machine-related mathematical models. During machine setup, machine-specific setting parameters can be at least partially learned by an operator, and the machine is operatedBased on the determined and, if applicable, learned machine-specific setting parameters and determined machine-independent process parameters without manual parameter input, at a process-phase-dependent optimal operating point of the actual filling process, which represents an optimum between productivity, energy consumption, and output rate. There is a growing problem throughout the industry that there are no longer sufficient skilled workers available. However, the machines should be able to be set up and operated in shifts. The invention is intended to ensure that even semi-skilled personnel or personnel with a language barrier can set up and operate the machines. This occurs without parameter input, i.e., after setting up and calculating the tool data set, the operator only has to press the start button to start production. The process flow or process cycle is thus advantageously built up during setup.itself and is then fully available in the process editor, e.g., via symbols, without any parameter input. Path markers or axis end markers can be additionally taught, e.g., by manually moving or controlling machine components to these markers. This advantageously allows the determination of the machine-specific setting parameters and machine-independent process parameters of the real filling process entirely without the use of a real injection molding machine and without the measurement of process parameters on this injection molding machine and the potentially necessary assessment of real products. This has the effect of a trouble-free determination of the machine-specific setting parameters and machine-independent process parameters of the real filling process, independent of the operator's specialist knowledge. The object is also achieved by a machine for processing plasticizable material according to claim 13, whichis configured, designed, and / or constructed to carry out the method for setting up and operating machines for processing plasticizable material, as well as by a computer program product according to claim 14 with a program code stored on a computer-readable medium, comprising instructions that cause the machine of claim 13 to carry out the method steps according to any one of claims 1 to 12. Advantageous further developments are the subject of the dependent patent claims. In order to advantageously accelerate the iterative process, the following further steps are preferably carried out according to the method: d) checking based on the motor characteristic curve whether the operating point is within the operating range of the electric motor, e) if the operating point is not within the operating range of the electric motor as an unreachable operating point, reducing the speed and repeating steps a) to c) of claim 1 and step d),f) if the operating point is within the operating range of the electric motor, operating the machine at this operating point. This allows a speed-optimized operating point to be quickly determined based on the motor characteristic curve, which advantageously takes into account the desired requirements for the optimal operating point. In an embodiment of the method that depicts the mathematical models of a preferred machine technology, the machine can have a central servo motor in which the machine axes are serially driven hydraulically, whereby the machine-related mathematical models include the servo motor for operating a pump, the cylinder surfaces of the machine axes, and the characteristics of an oil motor. This advantageously allows the entire machine to be depicted. Preferably, an electromechanical machine axis is used as the at least one machine axis, which, for example, depending on the design, can serve as additional elements in addition to the motor.elements comprises at least one of the components comprising a gear, spindle, gearwheel, belt or the like. In this way, the parameters of these components can advantageously be included in the simulation in order to further optimize the parameterization. Preferably, the machine can have several servomotors, wherein the hydraulically driven machine axes interact with several motor-pump units, optionally hydraulically added, wherein the machine-related mathematical models include the servomotors and motor-pump units. In this way, the effects of the method can advantageously also be used in machines with multiple drives that have a more complex structure. In a further preferred embodiment, each machine axis of the machine can be driven by a servomotor, wherein the machine-related mathematical models include the servomotors, gear ratios, efficiencies, inertias and the type of cooling.This advantageously optimizes the machine model. In an advantageous, particularly energy-saving embodiment of the method, in order to determine a process-phase-dependent, speed-optimized operating point of the at least one electric motor, an optimal operating point on the torque-speed characteristic curve can first be determined for each process phase by means of a simulation based on the mathematical motor characteristic models. The optimal operating point can then be adjusted in such a way that a speed-optimized operating point is set on the torque-speed characteristic curve for each process phase, torque-related. Preferably, the advantages can also be used in more complex systems if the machine-related mathematical models include combinations of motor-pump units and machine axes with a servo motor. In an advantageous further energy-saving embodiment of the method, the at least oneA servo motor can be operated in field-weakening mode. Although the field weakening induces a current, which also generates losses, a smaller or less powerful, and thus less sluggish, motor can be used at this point. The determined operating point is preferably located in the range in which the electric motor is operated in field-weakening mode, which enables, among other things, energy-saving operation. To advantageously facilitate the operation of the machine, the machine can preferably be operated via a control panel, a mobile device, or an augmented reality device such as augmented reality glasses. The information content is reduced by displaying symbols instead of parameters. The machine-related mathematical models can preferably be stored in a controller and / or a control level higher than the controller. In these embodimentsThe method advantageously improves the immediate operational readiness and / or the modular application of the machine. In order to advantageously improve the automation of setup and operation, the following additional machine-specific setting parameters can preferably be included in the machine-related mathematical models: nominal torque, nominal speed, nominal power, maximum torque, maximum speed, continuous stall torque, and base speed. Furthermore, at least the following values ​​for machine operation can preferably be calculated from the machine-related mathematical models: injection pressure, injection pressure profile, holding pressure level, holding pressure time, holding pressure profile, dynamics, filling time, clamping force, maximum holding time, dosing volume, and dosing speed. The features listed individually in the patent claims can be combined with one another in a technologically expedient manner and can be explained by explanatory facts from the description.and are supplemented by details from the figures, whereby further embodiments of the invention are shown. Brief description of the figures The invention will now be explained in more detail using an embodiment shown in the attached figures. They show: Fig. 1 torque characteristics of an electric motor over the speed, Fig. 2 the torque characteristics according to Fig. 1 with hatched continuous and intermittent operation, Fig. 3 the torque characteristics according to Fig. 1 with hatched continuous operation, Fig. 4 the torque characteristics according to Fig. 1 with hatched field weakening operation, Fig. 5 the torque characteristics according to Fig. 1 with an example for determining the operating point, Fig. 6 a schematic representation of an injection molding machine and its components, Fig. 7 an associated process sequence. Detailed description of preferred embodiments The invention will now be explained in more detail by way of example with reference to the attached drawings. However,The exemplary embodiments are merely examples which are not intended to limit the inventive concept to a specific arrangement. Before the invention is described in detail, it should be pointed out that it is not limited to the respective components of the device or the respective method steps, since these components and methods can vary. The terms used here are intended solely to describe particular embodiments and are not used in a restrictive manner. Furthermore, if the singular or indefinite articles are used in the description or in the claims, this also refers to the plurality of these elements, unless the overall context clearly indicates otherwise. The method for setting up and operating machines 150 for processing plasticizable materials, in particular an injection molding machine, comprises at least one electric motor, preferably a servomotor 170, forat least one machine axis 160, whose motor characteristics, in particular a torque-speed characteristic curve M(n), are present as parts of machine-related mathematical models 190, wherein machine-independent process parameter profiles of an ideal filling process are determined from a filling simulation taking into account the domains tool 10 and material Mat. In a simulation, a) machine-specific setting parameters and machine-independent process parameters of a real filling process are then determined in an iterative approximation process based on the machine-independent process parameter profiles of the ideal filling process and the machine-related mathematical models 190. Thereafter, b) machine-specific setting parameters can be at least partially taught by an operator during machine setup. The machine is operated c) based on the determined and, if applicable, taught machine-specificmechanical setting parameters and determined machine-independent process parameters without manual parameter input in a process phase-dependent optimal operating point AP of the real filling process, which represents an optimum between productivity, energy consumption and output rate. Based on the simulation, ideal filling and optimal processing process are approximated to each other, such as an injection molding process. This is an iterative process that advantageously aims at the optimum of maximum productivity with simultaneous minimum energy consumption. The set forces are set exactly as they are required for optimal operation. Energy-consuming, unnecessary safety reserves are eliminated, and machine 150 and tool 10 are protected. The closing profile (travel movement and closing forces over time) is defined from information from the automatic setup and the iteratively determined values ​​of the calculation. Preferably, the method forDetermination of the operating point AP involves further steps that enable an iterative approximation to the desired optimal operating point: d) For this purpose, the motor characteristic curve is used to check whether the determined operating point AP is within the operating range of the electric motor. e) If the operating point, as an unreachable operating point 110, is not within the operating range of the electric motor, the speed n is reduced and steps a) to c) (see above) and d) are repeated. f) If the operating point 120 is within the operating range of the electric motor, the machine 150 is operated at this operating point. Advantageously, mathematical models 190 can represent a first preferred technology of the machine in which the machine has only a central servo motor 170, in which the machine axes 160 are serially driven hydraulically. The machine-related mathematical models 190 can thereby determine the servo motor for operating a pump, theCylindrical surfaces of the machine axes 160 and the characteristics of an oil motor are included. Mathematical models 190 can also advantageously represent a second preferred technology of the machine, in which each machine axis 160 of the machine 150 is driven by a servo motor 170. The machine-related mathematical models 190 can include the servo motors, gear ratios, efficiencies, inertias, and the type of cooling. Machines that have two or more servo motor / pump drives and / or a combination of these servo-electric drives, so-called hybrid machines (Fig. 6), are also conceivable. The upper part of Fig. 6 schematically shows a known machine 150 in the form of an injection molding machine in a front view, wherein a mold clamping unit can be seen above a machine base 130 on the left side and an injection molding unit on the right side. Schematically shown below are the symbols for variousMachine axes 160 are shown, which can be machine axes for opening and closing the mold 10, for ejection 20, for core pulling 30, for nozzle movement 40 (placement of the injection nozzle on the mold sprue), for injection 60, or for dosing 70. A controller 185, which is usually integrated into the machine, is assigned to the machine 150. An operating unit 180 can be seen on the top right side. All of these machine axes can be driven by an electric motor, preferably a servo motor 170. The machine can be equipped in different ways, as shown in the lower panel of Fig. 6. It can be equipped as a hydraulic injection molding machine (SGM) with servo-hydraulics, or as an electric injection molding machine with servo-electrics. Various hybrid machine designs are possible in between, with some machine axes being servo-hydraulic and others being servo-electric.In order to achieve particularly energy-efficient production, an optimal operating point on the torque-speed characteristic curve M(n) can be determined for each process phase by means of a simulation based on the mathematical motor characteristic models in order to determine a process-phase-dependent, preferably speed-optimized operating point AP of the at least one electric motor. The optimal operating point can then be adjusted in such a way that a speed-optimized operating point is set on the torque-speed characteristic curve for each process phase, torque-related. If the at least one electric motor is a servomotor 170 that is operated in field-weakening mode FSB, energy can also be saved. For this purpose, the electric motor can be operated outside its nominal torque range M as shown in Fig. 4. nenn(Continuous operation S1), which is shown hatched in Fig. 2, as well as outside the area of ​​intermittent operation S3, so that the motor can be driven to a different operating point, the so-called field weakening operation FSB, which only allows a lower torque, but at the same time higher speeds and thus, for example, a higher injection speed. However, a higher injection speed also means a higher injection pressure. Field weakening does induce a current, which also generates losses. However, savings are achieved by using, for example, a smaller or less powerful and thus less sluggish motor. Field weakening is a method of increasing the speed of rotating electrical machines significantly above the rated speed. This is accompanied by a drop in torque M as soon as the speed n exceeds the characteristic curve of the voltage limit M UmaxAs a result, field weakening is used where high torque is required at low speeds and lower torque at high speeds. By field weakening, the speed can be increased beyond the nominal speed in order to achieve the desired maximum range. Advantageously, the machine can also be operated according to Fig. 6 via an operating unit 180 such as a control panel, a mobile device or an augmented reality device such as augmented reality glasses. The information content is reduced by displaying symbols instead of parameters, which makes operation easier. With the help of an extended setup assistant E, the setup of the tool 10 is thus processed sequentially without requesting parameter input. The axes are moved automatically for setup, forces are limited, paths and positions are taught. This defines tool movements and ejector movements.The machine-related mathematical models 190 can be stored, as shown in Fig. 6, in a controller 185 for the machine 150 and / or a control level higher than the controller. In these embodiments of the method, the direct operational readiness and / or the modular application possibilities of the machine are improved. Preferably, the machine-related mathematical models 190 can also include the following additional machine-specific setting parameters: Nominal torque M. nenn , rated speed, rated power, maximum torque M max , Maximum speed n max, continuous stall torque M0, cut-off speed 50. In a plastic injection molding machine, the maximum injection speed (or the injection flow related to the screw diameter) is reached at the max. defined injection pressure at the point cut-off speed / maximum torque 50 (at maximum power). The maximum permanently achievable holding pressure is defined by the continuous stall torque M0. From the machine-related mathematical models 190, at least the following values ​​for the operation of the machine can be calculated, as explained below: injection pressure, holding pressure level, holding pressure time, dynamics, filling time, clamping force, maximum holding time. From the motor characteristic curve of a servo motor, essential values ​​for the operation of a function of a processing operation such as an injection molding process can be calculated. For example, the torque M is a parameter that mathematically correlates with the injection pressure. The speed n at maximum torque (nominal speed atRated power), gear ratio, inertia, and efficiency determine the dynamics and thus the filling time. The continuous stall torque M0 is an indicator of the achievable holding pressure level. The type of cooling (air-cooled or water-cooled) is crucial for the cyclically achievable holding pressure time. For this purpose, the holding pressure profile is limited using an I²t evaluation (I = current, t = time) and the achievable cooling capacity. The same applies to the tool movement axis function, where the clamping force, dynamics (dry running time), and maximum holding time can also be calculated from the motor characteristic curve. Such a calculation can be carried out, for example, as follows. The following notations are used in the formulas: Formula symbols: ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^äℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^_( ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^): ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ä ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^. ^^ ^^ ^^ ^^ℎ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^äℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^^^௧^^^^ೈ^ೋ: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^( ^^_ ^^ ^^ ^^ ): Ü ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎä ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ℎä ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ℎ_(^^ ^^ ^^ ) ^^ ^^ ^^ ℎ_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ∶ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_( ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_0: ^^ ^^ ^^ ^^ ^^ ^^_0: ^^ ^^ ^^ ): ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ä ^^ ^^^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ü ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^: ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ The injection force depends on the injection pressure (max. 2000 bar) and the screw diameter: ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ = ^^ ∗〖 ^^ ^^〗^2 / 4 ∗ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ The drive torque required for this injection force with an electric injection drive is in turn dependent on the spindle pitch and the efficiency of the drive spindle: ^^_( ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ) = 〖 ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ∗ ℎ〗_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ / (2 ∗ ^^ ∗ ^^) If the engine and the gearbox are not considered as a unit, thenthe gear ratio / efficiency should still be added to the formula. Otherwise the relationship between injection pressure and drive torque at the drive for the injection movement can be derived as: ^^_( ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ )~ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ The same applies to the holding pressure phase - the holding pressure is generally lower than the injection pressure, so the required torque is also lower and for long holding pressure times should on average be below the mentioned continuous standstill torque M0. If necessary the level of the holding pressure should be automatically adjusted depending on the duration by reducing it such that the root mean square of the holding pressure time and the pause time, e.g. during the cooling phase, is below the continuous standstill torque M0. The clamping force of the tool depends on the injection pressure and the projected area of ​​the injection part: ^^_( ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^) = ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ∗ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ During the holding pressure phase, the clamping force of the tool depends on the level of the holding pressure and the projected area of ​​the injection part: ^^_( ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^) = ^^_ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ∗ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ The torque requirement of the tool drive during the build-up of the clamping force is proportional to the required clamping force and the torque applied over the tool path variable gear ratio of the toggle lever: ^^_( ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^) ~ ^^_( ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^) ∗ ^^( ^^_ ^^ ^^ ^^) (Note: The relationship between M and F for a drive spindle with spindle pitch is omitted here.In order to determine the setting parameters, the limit torque can be converted into a limit pressure. ^^_( ^^ ^^ ^^ ^^ ^^ ^^ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ )~ ^^_ ^^ ^^ ^^ ^^ ^^ ^^ The speed n at the operating point 120 can be converted into an injection speed. ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ = ^^_( ^^ ^^ ^^ ^^ ^^_120) ∗ ^^_( ^^ ^^ ^^, ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^) Other setting parameters that utilize material properties, such as pressures, temperatures, etc., can be determined in this way. In addition, a rough estimate of the dynamics can be made from the maximum moment less the load (injection pressure, clamping force, etc.).Friction is neglected. ^^ _ ^̇^ ^^ ^^ ^^ ^^ ^^ ^^ = ^^ ^^ ^^(( ^^_(〖 ^^ ^^ ^^ ^^ ^^ ^^ ^^〗_ ^^ ^^ ^^ ) − ^^_ ^^ ^^ ^^ ^^) / ^^_ ^^ ^^ ^^ , ^^_(〖 ^^ ^^ ^^〗_ ^^ ^^ ^^ ) ) Where a_max_zul is the acceleration specified in the control system, which may under certain circumstances be smaller than that starting from M. max possible acceleration The smaller value determines the dynamics. M_drive_max does not describe the maximum possible engine torque, but rather the maximum torque enabled in the control system. If the filling time is to be calculated, the filling time can be estimated from the following equation for a trapezoidal movement in which the specified acceleration is reached (torque limit is not reached) (assumption: single-stage injection, cavity filled at the switchover point to pressure control, braking in the post-compression phase, system dynamics neglected, i.e.no following error): ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ = ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ / ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ + ( ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ − 1 / 2 ∗〖 ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^〗^2 / ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ) / ^^_ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ However, the braking phase of the trapezoidal movement is neglected in this formula for the filling time, so that strictly speaking it is more of a “ramp-like” movement. Special cases such as triangular operation, multi-stage injection, etc., are not considered with this formula, but can be determined in a similar way. From the perspective of the injection axis, the tool domain 10 and the material domain Mat can be determined as the ideal filling process using filling simulation and then calculated with the machine domain as the optimal operating point AP (optimum between productivity, energy consumption, and output rate).The injection speed, which is synonymous with the volume flow of the melt of plasticizable material, which depends on, for example, the viscosity and thus also on the material to be processed, the temperature profile of the plasticizing unit and the mold hot runners, results in an injection pressure profile during the filling of the cavity in the injection mold / in the mold. The required holding pressure can also be simulated, which correlates with the continuous stall torque M0 in the motor characteristic curve. The required clamping force can be calculated from the injection pressure and holding pressure and the projected area of ​​the plastic in the mold 10 known from the filling simulation. The injection pressure profile and holding pressure profile thus directly determine the clamping force profile.With the simulated temperature profile for the plasticizing unit temperature and the mold / hot runner temperature, as well as the simulated holding pressure duration, the essential parameters for the operation of the injection mold in a specific, defined machine are now calculated and known. This is illustrated by way of example with reference to the attached Figures 1 to 5, which show the torque characteristics of an electric motor, preferably a servo motor 170, represented as torque M versus speed n. Figure 1 shows the typical operating range in solid lines. The upper line shows the speed-dependent maximum torque M. max . The maximum power is generated at the so-called base speed 50. After that, the maximum torque decreases to the rated power at the rated torque M nenn The continuous stall torque M0 is the torque that the electric motor can build up continuously when stationary. After reaching the nominal torque M nennthe power decreases along the voltage limit M Umax In Fig. 1, dashed lines are drawn to the right of the solid lines. These lines refer to field weakening operation, which will be discussed below in connection with Fig. 4. Figs. 2 and 3 show, in the representation of Fig. 1, the hatched areas for continuous operation S1, which forms the nominal torque range in which an electric motor is usually operated, and for intermittent operation S3, which is arranged above this. While in continuous operation S1 the electric motor can be operated continuously, as the name suggests, in the more power-intensive intermittent operation there is a percentage or temporary duty cycle so that the excess temperature can be dissipated during the operating breaks by appropriate cooling. The intermittent operation therefore consists of the duty cycle and the cooling breaks. In Fig. 4, the area to the right is beyond the voltage limit M Umax(without field weakening operation) at high speed n is hatched. This range of field weakening operation FSB lies outside the nominal torque range, which is shown hatched in Fig. 2, so that the engine can be driven to a different operating point, the so-called field weakening operation FSB, which only allows a lower torque M, but at the same time higher speeds n and thus, for example, a higher injection speed. However, a higher injection speed also means a higher injection pressure. This range is limited in the figure by the voltage limit M Umax FSB in field weakening operation and to the right by the maximum engine speed n max. In field-weakening operation, a high torque can be achieved at low speeds and a lower torque at high speeds. This allows the speed to be increased beyond the nominal speed in order to reach the desired maximum range. Fig. 5 shows an inventive procedure in this torque characteristic diagram. The starting point in this diagram is an unattainable operating point 100, which was determined based on a simulation. This simulation incorporates machine-specific setting parameters and machine-independent process parameters of a real filling process in an iterative approximation process based on machine-independent process parameter profiles of an ideal filling process and machine-related mathematical models 190. Material-specific properties of the material to be processed are also taken into account.During machine setup, machine-specific setting parameters can be at least partially learned by an operator, and the operation of the machine 150 is based on the determined and, if applicable, learned machine-specific setting parameters and determined machine-independent process parameters without manual parameter input at a process-phase-dependent optimal operating point 100 of the actual filling process, which represents an optimum between productivity, energy consumption, and output rate. If this optimal operating point 100 lies beyond the effective range of the electric motor, as in Fig. 5, it makes sense to remain at the torque level. With this approach, one reaches operating point 110, which, however, is not speed-optimized. The iterative process results in operating point 120 by utilizing the material and machine properties.Once the operating point 120 has been found, the machine-specific setting parameters can be determined using the calculation explained above based on the motor characteristic curve, simulation of machine-specific setting parameters, and machine-independent process parameters of a real filling process. Fig. 7 shows an example of a schematic method sequence. The method is intended for setting up and operating machines 150 for processing plastics and other plasticizable materials, in particular injection molding machines. The machine has at least one electric motor, preferably a servomotor 170, for at least one machine axis 160, whose motor characteristic curves K, in particular a torque-speed characteristic curve M(n), are available as parts of machine-related mathematical models 190. In step 200 of Fig.7, a filling simulation is first performed taking into account the domains tool 10 and material Mat to determine machine-independent process parameter profiles of an ideal filling process in step 210. In step 220, machine-specific setting parameters and machine-independent process parameters of a real filling process are then determined in a simulation. For this purpose, machine-related mathematical models 190 are provided so that the machine-specific setting parameters can be determined based on the machine-independent process parameter profiles of the ideal filling process and the machine-related mathematical models 190 (step 230). During the setup of the machine 150, machine-specific setting parameters can additionally be at least partially taught by an operator in step 240.Using this information, in conjunction with the motor characteristic curve K, an operating point AP of the actual filling process can be determined in step 250, based on the determined and, if applicable, learned machine-specific setting parameters and the determined machine-independent process parameters. This process may be iterative. This determination of an operating point takes place without manual parameter input. The operating point is a process-phase-dependent optimal operating point AP, which represents an optimum between productivity, energy consumption, and output rate. The machine can, in principle, be operated at this operating point according to step 270. The possibly additionally required iterative process includes, with query 260, checking based on the motor characteristic curve whether the operating point AP is within the operating range of the electric motor. If the operating point turns out to be an unattainable operating point 110 (Fig.5) turns out to be outside the operating range of the electric motor, steps 220 to 250 are repeated at a reduced speed. If the operating point 120 (Fig. 5) is already within the operating range of the electric motor, the machine 150 is operated at this operating point according to step 270. The method can be used in a machine for processing plasticizable material that is set up, designed and / or constructed to carry out the method for setting up and operating machines for processing plasticizable material. Furthermore, the method can be used in a computer program product with program code stored on a computer-readable medium, comprising instructions that cause the machine 150 to carry out the method steps.It goes without saying that this description is subject to a wide variety of modifications, changes, and adaptations within the range of equivalents to the appended claims. List of reference symbols 10 Tool 20 Ejector 30 Core pull 40 Nozzle movement 50 Corner speed (maximum power) 60 Injection 70 Dosing 100 Unattainable operating point 110 Possible operating point 120 Operating point 150 Machine 160 Machine axis 170 Servo motor 180 Operating unit 185 Control system 190 Machine-related mathematical models 200 to 270 steps (Fig. 7) AP Operating point E Setup assistant FSB Field weakening operation range K Characteristic curve M0 Continuous stall torque M nenn Nominal torque M max Maximum torque n Speed ​​n max maximum speed S1 continuous operation S3 intermittent operation M Umax Voltage limit without field weakening operation M Umax FSB Voltage limit during field weakening operation

Claims

1. A method for setting up and operating machines (150) for processing plastics and other plasticizable materials, in particular injection molding machines, comprising at least one electric motor, preferably a servo motor (170), for at least one machine axis (160), whose motor characteristics (K), in particular a torque-speed characteristic curve M(n), are present as parts of machine-related mathematical models (190), wherein machine-independent process parameter profiles of an ideal filling process are determined from a filling simulation taking into account the tool and material domains, characterized in thatthat a) in a simulation, machine-specific setting parameters and machine-independent process parameters of a real filling process are determined in an iterative approximation process based on the machine-independent process parameter profiles of the ideal filling process and the machine-related mathematical models (190), b) during machine setup, machine-specific setting parameters can be at least partially taught by an operator, and c) the operation of the machine takes place based on the determined and optionally taught machine-specific setting parameters and determined machine-independent process parameters without manual parameter input at a process-phase-dependent optimal operating point (AP) of the real filling process, which represents an optimum between productivity, energy consumption, and output rate.

2. Method according to claim 1,characterized by the further steps: d) checking, based on the motor characteristic curve, whether the operating point (AP) is within the operating range of the electric motor; e) if the operating point, as an unreachable operating point (110), is not within the operating range of the electric motor, reducing the speed (n) and repeating steps a) to c) of claim 1 in this order and step d); f) if the operating point (120) is within the operating range of the electric motor, operating the machine at this operating point.

3. Method according to claim 1 or 2, characterized in that an electromechanical machine axis is used as the at least one machine axis.

4. Method according to one of the preceding claims, characterized in that the machine has a central servomotor, the machine axes being serially hydraulically driven, the machine-related mathematical models (190) comprising the servomotor (170) for operating a pump, the cylinder surfaces of the machine axes (160), and the characteristics of an oil motor.

5. Method according to one of claims 1 to 3, characterized in that the machine has several servomotors (170), the hydraulically driven machine axes (160) interacting with several motor-pump units (195), optionally hydraulically added, the machine-related mathematical models (190) comprising the servomotors and motor-pump units.Method according to one of claims 1 to 3, characterized in that each machine axis (160) of the machine (150) is driven by a servomotor (170), wherein the machine-related mathematical models (190) include the servomotors, gear ratios, efficiencies, inertias, and the type of cooling.

7. Method according to one of claims 4 to 6, characterized in that the machine-related mathematical models (190) include combinations of motor-pump units (195) and machine axes (160) with a servomotor (170). 8.Method according to one of the preceding claims, characterized in that in order to determine a process-phase-dependent speed-optimized operating point (AP) of the at least one electric motor, an optimal operating point on the torque-speed characteristic curve M(n) is first determined for each process phase by means of a simulation based on the mathematical motor characteristic curve models, and then the optimal operating point (AP) is adjusted in such a way that a speed-optimized operating point is set on the torque-speed characteristic curve for each process phase in relation to the torque.

9. Method according to one of the preceding claims, characterized in that the at least one electric motor is a servomotor (170) which is operated in a field-weakening mode (FSB), wherein the determined operating point (AP) is preferably in field-weakening mode.

10. Method according to one of the preceding claims, characterized in that the machine is operated via an operating unit (180) such as an operating panel, a mobile device or an augmented reality device such as augmented reality glasses.

11. Method according to one of the preceding claims, characterized in that the machine-related mathematical models (190) are stored in a controller (185) of the machine (150) and / or a control level superordinate to the controller.

12. Method according to one of the preceding claims, characterized in that the machine-related mathematical models (190) include at least the following further machine-specific setting parameters: Nominal torque (M nenn ), rated speed, rated power, maximum torque (M max ), maximum speed (n max), continuous stall torque (M0), baseline speed (50), and that at least the following values ​​for machine operation are calculated from the machine-related mathematical models (190): injection pressure, injection pressure profile, holding pressure level, holding pressure time, holding pressure profile, dynamics, filling time, clamping force, maximum holding time, dosing volume, dosing speed.

13. A machine (150) for processing plastics and other plasticizable materials, in particular an injection molding machine for processing plasticizable material, which is configured, designed, and / or constructed to carry out the method for setting up and operating machines for processing plasticizable material according to one of the preceding claims. 14.A computer program product comprising program code stored on a computer readable medium comprising instructions causing the machine (150) of claim 13 to perform the method steps of any one of claims 1 to 12.

Images