CN111098463A - Injection molding machine fault diagnosis system and diagnosis method - Google Patents
Injection molding machine fault diagnosis system and diagnosis method Download PDFInfo
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- CN111098463A CN111098463A CN201811262016.4A CN201811262016A CN111098463A CN 111098463 A CN111098463 A CN 111098463A CN 201811262016 A CN201811262016 A CN 201811262016A CN 111098463 A CN111098463 A CN 111098463A
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- 238000003745 diagnosis Methods 0.000 title claims abstract description 75
- 238000001746 injection moulding Methods 0.000 title claims abstract description 74
- 238000000034 method Methods 0.000 title claims abstract description 19
- 239000000243 solution Substances 0.000 claims abstract description 15
- 238000003860 storage Methods 0.000 claims abstract description 8
- 238000004891 communication Methods 0.000 claims description 13
- 238000012545 processing Methods 0.000 claims description 7
- 238000012544 monitoring process Methods 0.000 claims description 4
- 238000012423 maintenance Methods 0.000 claims description 3
- 230000002159 abnormal effect Effects 0.000 claims 2
- 238000010586 diagram Methods 0.000 description 7
- 238000003062 neural network model Methods 0.000 description 3
- 238000005070 sampling Methods 0.000 description 3
- 238000010924 continuous production Methods 0.000 description 2
- 238000007405 data analysis Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000009776 industrial production Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012795 verification Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000013480 data collection Methods 0.000 description 1
- 238000012774 diagnostic algorithm Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04W—WIRELESS COMMUNICATION NETWORKS
- H04W4/00—Services specially adapted for wireless communication networks; Facilities therefor
- H04W4/12—Messaging; Mailboxes; Announcements
- H04W4/14—Short messaging services, e.g. short message services [SMS] or unstructured supplementary service data [USSD]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/76163—Errors, malfunctioning
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76929—Controlling method
- B29C2945/76939—Using stored or historical data sets
- B29C2945/76946—Using stored or historical data sets using an expert system, i.e. the system possesses a database in which human experience is stored, e.g. to help interfering the possible cause of a fault
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76929—Controlling method
- B29C2945/76993—Remote, e.g. LAN, wireless LAN
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Computer Networks & Wireless Communication (AREA)
- Signal Processing (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Testing And Monitoring For Control Systems (AREA)
Abstract
The invention discloses a fault diagnosis system and a fault diagnosis method for an injection molding machine. The cloud platform comprises a cloud fault diagnosis module and a cloud storage module; the data acquisition module mainly comprises a sensor, an active power sensor, a noise monitor and a current transmitter. The invention collects various signals of the injection molding machine in real time, continuously updates the cloud data, calls the cloud diagnosis system, diagnoses the collected data in real time or not in real time, judges whether the injection molding machine is in a fault or predicts the future working state of the injection molding machine, and analyzes the diagnosis result according to the knowledge base and the inference machine, thereby providing a solution for solving the fault. The invention not only improves the efficiency of the fault diagnosis of the injection molding machine, but also provides a scheme for solving the fault.
Description
Technical Field
The invention belongs to the field of big data fault diagnosis of injection molding machines, and particularly relates to a fault diagnosis system and a fault diagnosis method of an injection molding machine.
Background
At present, the demand of plastic products in China is large, and most of the plastic products are formed by injection molding, so that higher requirements are put forward on the technology and development of an injection molding machine. Because the injection molding machine belongs to continuous production, in order to better master the running state of the injection molding machine, the fault of the injection molding machine can be diagnosed in time, and the future working state of the injection molding machine can be estimated in time, so that the accurate judgment can be carried out for the shutdown maintenance of the injection molding machine. The injection molding machine fault diagnosis system is an indispensable part for ensuring the normal and continuous operation of the injection molding machine.
So far, with the rapid development of an injection molding cloud platform, most cloud platforms only have the functions of work order processing, production management, data display and the like, do not have data processing, and do not acquire current signals, voltage signals, vibration signals and the like of an injection molding machine. Therefore, the existing injection molding machine cloud platform does not have the functions of fault diagnosis, state evaluation and the like at all, and does not need to provide a fault solving scheme aiming at the fault state automatically.
Disclosure of Invention
The invention aims to provide a fault diagnosis system and a fault diagnosis method for an injection molding machine, aiming at solving the problems that the normal industrial production is influenced because the injection molding machine is lack of a fault diagnosis system in the daily industrial production, the production cannot be normally carried out, the state of the injection molding machine cannot be well monitored, and the daily maintenance cannot be carried out in time.
In order to achieve the purpose, the invention provides a fault diagnosis system and a fault diagnosis method for an injection molding machine, signals such as temperature, pressure, vibration, rotating speed, power, noise and the like of the injection molding machine are collected in real time through a data collection module, the collected data are transmitted to a cloud platform through a remote communication module, various signals of the injection molding machine are analyzed through a cloud diagnosis system of the cloud platform, the current state of the injection molding machine is obtained through a diagnosis model and a diagnosis algorithm, the current state of the injection molding machine is displayed on the cloud platform or a computer of an engineer and an APP client side, and meanwhile, if the injection molding machine is in a fault state, the fault reason is automatically judged according to an injection molding machine knowledge base and an inference machine, and a solution is provided for the fault reason. Meanwhile, the fault state and the fault reason are compared with historical fault states and reasons, the diagnosis result and the comparison result are stored in the cloud storage module, and the diagnosis result and the comparison result are automatically sent to engineering personnel in a mail or short message mode. The efficiency of injection molding machine fault diagnosis is improved, has guaranteed the continuous production of injection molding machine.
In order to realize the technical scheme, the injection molding machine fault diagnosis system and the injection molding machine fault diagnosis method mainly comprise a data acquisition module, a remote communication module, a cloud platform, a data processing module, a state monitoring module and an abnormity alarm module; the cloud platform comprises a cloud fault diagnosis module and a cloud storage module; the data acquisition module mainly comprises a sensor, an active power sensor, a noise monitor and a current transmitter.
The communication mode of the remote communication module can be wired transmission, and GPRS, CDMA, NB-loT or other communication modes suitable for the system can also be used.
The cloud diagnosis model can be a fuzzy model, and the state estimation model can be a BP neural network model or a predictive control model.
The cloud diagnostic algorithm as described above may be rule-based, expert knowledge-based, case-based, or any algorithm suitable for the present diagnostic system.
The diagnosis mode of the cloud diagnosis system can be divided into real-time diagnosis and non-real-time diagnosis; off-line diagnostics and on-line diagnostics or any diagnostic modality suitable for the present system.
The data acquisition module acquires signals of vibration, temperature, pressure, current, power, noise, rotating speed, torque and the like of the injection molding machine in real time, the remote communication module uploads the acquired data to the cloud platform, the cloud diagnosis system in the cloud platform is called, and the state of the injection molding machine is monitored in real time or not in real time, so that an engineer can master the current working state of the injection molding machine, if the injection molding machine is in a fault state, the reason of the fault is analyzed according to the knowledge base and the inference machine, and a scheme for solving the fault is provided for the reason of the fault.
The specific implementation steps are as follows:
the method comprises the following steps that firstly, a data acquisition module is used for acquiring various signals of an injection molding machine, and meanwhile, the signals are uploaded to a cloud platform through a remote communication module and are stored and backed up;
secondly, calling a cloud diagnosis system according to actual requirements, analyzing and processing the acquired data, judging the current working state of the injection molding machine, returning the result to the cloud platform, and storing the result;
thirdly, if the injection molding machine is in a fault state, calling a database for the fault state, searching a corresponding rule in a knowledge base, inquiring possible reasons of the fault through an inference machine, simultaneously proposing a solution for the reasons of the fault, storing the fault reasons and the solution in cloud storage, and simultaneously comparing the fault reasons and the solution with historical faults and the solution;
and fourthly, alarming abnormally, displaying the fault on a computer, a cloud platform and the like, and simultaneously informing engineering personnel to take corresponding countermeasures in a short message or mail mode.
The invention has the beneficial effects that: the working signal of the injection molding machine is acquired through the data acquisition module, the cloud platform is uploaded through the remote communication module, the cloud diagnosis system is called according to actual requirements, the working state of the injection molding machine is predicted and monitored, the working state of the injection molding machine is accurately judged through a cloud algorithm and a model, fault reasons are deduced according to a fault model and the algorithm, a scheme for solving faults is obtained through a knowledge base, a database and an inference machine in an expert system, and meanwhile, the future working state of injection molding is predicted through a neural network model.
Drawings
FIG. 1 is a block diagram of a fault diagnosis system for an injection molding machine according to the present invention;
FIG. 2 is a block diagram of a data acquisition structure in the fault diagnosis system of the injection molding machine of the present invention;
FIG. 3 is a block diagram of a cloud diagnostic system for an injection molding machine according to the present invention;
FIG. 4 is a flow chart of a method for diagnosing injection molding machine faults according to the present invention;
fig. 5 is a block diagram of a process for finding a cause and a solution of a failure of an injection molding machine according to the present invention.
Detailed Description
The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention.
As shown in fig. 1, the invention provides a structural block diagram of a diagnosis system of an injection molding machine, which mainly comprises a data acquisition module, a remote communication module, a cloud platform, a data processing module, a state monitoring module and an abnormity alarm module; the cloud platform comprises a cloud fault diagnosis module and a cloud storage module; the data acquisition module mainly comprises a sensor, an active power sensor, a noise monitor and a current transmitter. The system comprises a data acquisition module, a cloud platform, a diagnosis module, a state monitoring module, a data acquisition module, a data analysis module and a data analysis module.
As shown in fig. 2, the invention provides a structural diagram of data acquisition in a fault diagnosis system of an injection molding machine, which mainly comprises an acquisition object, a sensor, an amplifier, a filter, a multi-way sampling switch, a sampling holder and an a/D converter; the collected objects mainly comprise oil pump motor power, machine barrel heating power, current, pressure, temperature, rotating speed torque, vibration, noise and the like; the collected data are subjected to sampling selection through a multi-path switch by a preamplifier and a filter, are amplified by program control, and are transmitted to the cloud platform through the A/D conversion module after being sampled and held.
As shown in fig. 3, the present invention provides a structural block diagram of a cloud diagnosis system of an injection molding machine; the cloud diagnosis system mainly comprises cloud data, a cloud diagnosis system and a cloud diagnosis algorithm; the cloud diagnosis algorithm comprises a fault diagnosis algorithm and a state estimation algorithm, the cloud diagnosis system is called by acquiring real-time data in the cloud data, and the diagnosis mode is selected to be real-time diagnosis, non-real-time diagnosis or on-line diagnosis, off-line diagnosis and the like according to actual requirements. And calling a diagnosis algorithm, storing the diagnosis result in the cloud data, performing state estimation according to actual requirements if no fault exists, and storing the estimation result in the cloud data.
As shown in fig. 4, the present invention provides a flow chart of a method for diagnosing a fault of an injection molding machine; judging the current working state of the injection molding machine through a model estimation and verification algorithm in a cloud diagnosis algorithm, if the current working state is a fault state, carrying out fault diagnosis, notifying engineering personnel of a diagnosis result in a mail or short message mode, and storing the diagnosis result; if the state is not the fault state, state estimation is carried out according to the actual requirement, if the state estimation is needed, an estimation model and an algorithm are called to estimate the future working state, and the result is stored.
As shown in fig. 5, the present invention provides a flow chart of the cause and solution search for the injection molding machine failure; and fuzzifying the result, calling a knowledge base and an inference machine simultaneously to obtain a matching rule of response, clarifying simultaneously to obtain possible reasons of the fault, carrying out algorithm verification, eliminating the possible reasons one by one, finding a real reason of the fault, outputting the fault result, fuzzifying the reason of the fault, obtaining the matching rule, clarifying, carrying out possible solutions, and verifying one by one to provide a final solution.
The working signal of the injection molding machine is acquired through the data acquisition module, the working signal is uploaded to the cloud platform through the remote communication module, the cloud diagnosis system is called according to actual requirements, the working state of the injection molding machine is predicted and monitored, the working state of the injection molding machine is accurately judged through a cloud algorithm and a model, fault reasons are deduced according to a fault model and the algorithm, a fault solving scheme is obtained through a knowledge base, a database and an inference machine in an expert system, and the future working state of injection molding is predicted through a neural network model.
The above description is provided for the specific apparatus and process conditions of the present invention, and is illustrated with reference to the drawings. The present invention is not limited to the specific apparatus and process described above, and any modification or replacement of the related apparatus or any local adjustment of the related process based on the above description is within the spirit and scope of the present invention.
Claims (5)
1. A fault diagnosis system and a diagnosis method for an injection molding machine mainly comprise a data acquisition module, a remote communication module, a cloud platform, a data processing module, a state monitoring module and an abnormity alarm module; the cloud platform comprises a cloud fault diagnosis module and a cloud storage module.
2. The system and the method for diagnosing the faults of the injection molding machine according to claim 1, wherein the data acquisition module is communicated with a cloud platform through a remote communication module;
the data acquisition module comprises a sensor, an active power sensor, a noise monitor and a current transmitter; the data acquisition module is mainly used for acquiring field data of the injection molding machine, transmitting the acquired injection molding real-time signal data to the cloud platform in a remote communication mode, and storing and backing up the data.
3. The injection molding machine fault diagnosis system and method according to claim 1, wherein the cloud platform comprises a cloud fault diagnosis module and a cloud storage module;
the cloud fault diagnosis module is mainly used for diagnosing and detecting the state of the injection molding machine, calling a cloud diagnosis system according to actual requirements, analyzing and processing the acquired data, judging the current working state of the injection molding machine, returning the result to the cloud platform and storing the result;
the cloud diagnosis module comprises a cloud diagnosis algorithm, and the cloud diagnosis algorithm comprises a fault diagnosis algorithm and a state estimation algorithm; calling a fault diagnosis algorithm according to actual requirements, and judging the current working state of the injection molding machine; if the injection molding machine is in a fault state, calling a database for the fault state, searching a corresponding rule in a knowledge base, inquiring possible reasons of the fault through an inference machine, simultaneously proposing a solution for the reasons of the fault, storing the fault reasons and the solution in cloud storage, and simultaneously comparing the fault reasons and the solution with historical faults and the solution.
4. The system and method of claim 1, wherein the state estimation algorithm is used to predict the future operating state of the injection molding machine, and the state estimation algorithm is invoked to estimate the future operating state of the injection molding machine according to actual requirements and provide corresponding time and location for maintenance and repair of equipment.
5. The system and the method for diagnosing the faults of the injection molding machine according to claim 1, wherein the abnormal alarm module is used for alarming the faults, if the current working state of the injection molding machine is diagnosed to be in a fault state through the cloud diagnosis module, the faults are displayed on a computer, a cloud platform and the like through the abnormal alarm module, and engineering personnel are informed to take corresponding measures through short messages or mails.
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| CN201811262016.4A CN111098463A (en) | 2018-10-27 | 2018-10-27 | Injection molding machine fault diagnosis system and diagnosis method |
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| CN201811262016.4A CN111098463A (en) | 2018-10-27 | 2018-10-27 | Injection molding machine fault diagnosis system and diagnosis method |
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112988843A (en) * | 2021-03-26 | 2021-06-18 | 桂林电子科技大学 | SMT chip mounter fault management and diagnosis system based on SQL Server database |
| CN113176764A (en) * | 2021-04-21 | 2021-07-27 | 深圳市浦联智能科技有限公司 | Injection molding machine based data acquisition and cloud-up method |
| CN113352569A (en) * | 2021-07-08 | 2021-09-07 | 广州中和互联网技术有限公司 | Injection molding cloud molding machine data acquisition and monitoring control system and method |
| CN113504769A (en) * | 2021-05-24 | 2021-10-15 | 温州大学 | Injection molding equipment state monitoring system based on industry 4.0 |
| CN113942203A (en) * | 2020-07-17 | 2022-01-18 | 伊之密精密机械（苏州）有限公司 | Vibration self-adaptive adjusting method and injection molding machine |
| CN114770889A (en) * | 2022-02-28 | 2022-07-22 | 海天塑机集团有限公司 | Monitoring data acquisition system and method for injection molding machine in monitoring process |
| TWI775285B (en) * | 2021-01-21 | 2022-08-21 | 正鉑雷射股份有限公司 | Maintenance system and methodof cloud-based laser processing device |
| CN115302728A (en) * | 2022-10-12 | 2022-11-08 | 江苏瑞坤医疗器械有限公司 | Abnormity monitoring method for heating system of injection molding machine |
| CN116451109A (en) * | 2023-03-09 | 2023-07-18 | 西诺控股集团有限公司 | Intelligent fault diagnosis method for injection molding machine based on fault knowledge base |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112988843A (en) * | 2021-03-26 | 2021-06-18 | 桂林电子科技大学 | SMT chip mounter fault management and diagnosis system based on SQL Server database |
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| CN113504769A (en) * | 2021-05-24 | 2021-10-15 | 温州大学 | Injection molding equipment state monitoring system based on industry 4.0 |
| CN113352569A (en) * | 2021-07-08 | 2021-09-07 | 广州中和互联网技术有限公司 | Injection molding cloud molding machine data acquisition and monitoring control system and method |
| CN113352569B (en) * | 2021-07-08 | 2022-02-11 | 广州中和互联网技术有限公司 | Injection molding cloud molding machine data acquisition and monitoring control system and method |
| CN114770889A (en) * | 2022-02-28 | 2022-07-22 | 海天塑机集团有限公司 | Monitoring data acquisition system and method for injection molding machine in monitoring process |
| CN115302728B (en) * | 2022-10-12 | 2022-12-30 | 江苏瑞坤医疗器械有限公司 | Abnormity monitoring method for heating system of injection molding machine |
| CN115302728A (en) * | 2022-10-12 | 2022-11-08 | 江苏瑞坤医疗器械有限公司 | Abnormity monitoring method for heating system of injection molding machine |
| CN116451109A (en) * | 2023-03-09 | 2023-07-18 | 西诺控股集团有限公司 | Intelligent fault diagnosis method for injection molding machine based on fault knowledge base |
| WO2024183119A1 (en) * | 2023-03-09 | 2024-09-12 | 西诺控股集团有限公司 | Intelligent injection molding machine fault diagnosis method based on fault knowledge base |
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