Heater Temperature Control via Ambient Correction Lookup
Solution Overview
Problem
Existing temperature control methods for injection molding machines struggle to quickly and precisely maintain target temperatures due to environmental ambient temperature fluctuations, leading to overshoot or undershoot and prolonged convergence times.
Innovation Solution
A temperature control method that uses PID control to calculate a corrected energization rate by comparing the first energization rate based on the temperature difference between the actual and target temperatures with a second energization rate based on ambient temperature differences, allowing for rapid and precise convergence to the target temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If PID feedback control is used to maintain heater temperature, then temperature stability is improved, but response time to ambient temperature changes is delayed due to predetermined time delays in parameter recalculation
Solution Approach 1:
The patent pre-calculates and stores the relationship between ambient temperature and correction values in a lookup table during system initialization or calibration phase. When ambient temperature changes occur during operation, the controller directly retrieves the pre-computed correction value from the table without performing real-time PID parameter recalculation, thereby eliminating the predetermined time delay while maintaining temperature stability.
2Device complexity
If fixed electrical energy is applied to heaters based on trial and error, then device complexity is reduced, but adaptability to ambient temperature changes is lost
Solution Approach 1:
The patent implements a feedback mechanism where ambient temperature is continuously monitored by a sensor, and the measured ambient temperature is used to dynamically retrieve appropriate correction values from a pre-stored lookup table. This feedback loop enables the simple fixed-energy heater control system to adapt to ambient temperature changes without requiring complex real-time calculation algorithms, thus maintaining low device complexity while achieving environmental adaptability.
3Adaptability or versatility
If PID parameters are recalculated in real-time, then adaptability to ambient temperature changes is improved, but computational complexity and response time are increased
Solution Approach 1:
The patent performs the computationally intensive PID parameter recalculation work in advance during system initialization or calibration, storing the results in a lookup table that maps ambient temperature values to correction values. During normal operation, the controller simply queries this pre-computed table based on current ambient temperature readings, avoiding real-time mathematical computations and reducing both computational complexity and response time while maintaining full adaptability to ambient temperature changes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the heater temperature to quickly and accurately converge to the target temperature, even with fluctuating ambient temperatures, ensuring consistent resin molding product quality.
Implementation Method 1
heats a heating target with a heater
Implementation Method 2
The energy (heat) to be supplied to heaters is lost, mainly, due to heat release to an environment around the injection molding machine
Data Source
AI summary
A temperature control method includes: a step of obtaining, by means of PID control, a first energization rate based on a first temperature difference between an actually measured temperature and a target temperature; a step of obtaining a second energization rate based on a second temperature difference between the ambient temperature of the environment in which a heating barrel is disposed and the target temperature; a step of obtaining a corrected energization rate on the basis of the result of comparison of the first energization rate and the second energization rate; and a step of controlling the electrical power to be supplied to a heater on the basis of the corrected energization rate. The corrected energization rate is set to any of predetermined first, second, and third conditions on the basis of the comparison result.