Injection Molding Machine Control Gain Tuning From Waveform Data
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Solution Overview
Problem
Existing control systems for equipment like injection molding machines face challenges in achieving consistent response due to machine differences, leading to variations in operation even when using the same control gain.
Innovation Solution
An information processing system that acquires waveform data from equipment operations, analyzes it to define characteristics, and outputs control information to reduce machine differences by adjusting control parameters based on the identified characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the same control gain is used for all equipment, then the control system is simple and easy to implement, but machine differences cause variations in operation response and reduce consistency
Solution Approach 1:
The patent changes the control parameter from a fixed control gain to a dynamically adjusted control gain that is modified based on observed waveform data and machine characteristics. The control gain is adjusted by adding a correction value derived from the relationship between drive values and actual response values, allowing each machine to adapt its control parameters to its specific characteristics while maintaining operational consistency across different machines
Solution Approach 2:
The patent implements a feedback mechanism where the actual operation response (waveform data) is observed and compared with the drive values. This feedback loop allows the system to calculate correction values for the control gain based on the difference between expected and actual responses, continuously improving control consistency by learning from each machine's specific behavior patterns
2Reliability
If control parameters are customized for each machine to account for machine differences, then operation consistency improves, but the complexity of control system setup and maintenance increases
Solution Approach 1:
The patent enables the control system to automatically adjust its own parameters through self-learning. The system observes waveform data, calculates machine-specific characteristics, and autonomously determines correction values for control gains without requiring manual intervention or complex setup procedures. This self-service approach simplifies deployment while achieving customized control for each machine
Solution Approach 2:
The patent performs preliminary learning and parameter adjustment during an initial observation period before full operation begins. By collecting waveform data and calculating control gain corrections in advance, the system prepares optimized control parameters for each machine before production starts, reducing the complexity of ongoing setup and maintenance while ensuring consistent operation from the beginning
Data Source
AI summary
An information processing system includes: an acquisition unit that acquires waveform data obtained through an operation of control target equipment; an analysis unit that extracts, based on a relationship of variables included in the acquired waveform data, a first variable that is at least a portion of the variables and a second variable that is at least another portion of the variables, that derives variables corresponding to the second variables based on the first variable, and that defines characteristics of the control target equipment based on the derived variables and the second variable; and an output unit that outputs information used in controlling the control target equipment based on the characteristics of the control target equipment.