CN203141798U - Fault early warning system of injection molding machine - Google Patents
Fault early warning system of injection molding machine Download PDFInfo
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- CN203141798U CN203141798U CN 201220748376 CN201220748376U CN203141798U CN 203141798 U CN203141798 U CN 203141798U CN 201220748376 CN201220748376 CN 201220748376 CN 201220748376 U CN201220748376 U CN 201220748376U CN 203141798 U CN203141798 U CN 203141798U
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Abstract
The utility model discloses an early warning system of an injection molding machine. The early warning system comprises a sensor group for detecting performance parameters of the injection molding machine, a threshold value signal generator for generating threshold values of the performance parameters, a parameter comparator and a display, wherein the sensor group is connected with the injection molding machine; the first input end of the parameter comparator is connected with the sensor group; the second input end of the parameter comparator is connected with the threshold value signal generator; and the output end of the parameter comparator is connected with the display. A worker can know a performance parameter which exceeds a preset range by checking the display, so that before the injection molding machine generates an obvious severe fault, and a fault alarm device sounds an alarm, the worker can take corresponding measures and recover the performance parameter to be within the normal range; and therefore, the generation of severe faults of the injection molding machine is avoided, and the service life of the injection molding machine is prolonged. Therefore, according to the early warning system disclosed by the embodiment of the utility model, the problem that the fault alarm device of an existing injection molding machine often sounds the alarm late is solved.
Description
Technical Field
The application relates to the technical field of detection, in particular to an injection molding machine fault early warning system.
Background
An injection molding machine is a main molding device for making thermoplastic plastics or thermosetting materials into plastic products with various shapes by using a plastic molding die. The main components of the injection molding machine include a driver, a motor, a pump, an oil cylinder and corresponding mechanical moving components. The components are connected in sequence, and under the control of the upper computer, the injection molding machine realizes the starting, stopping and rotating speed adjustment of the motor through the driver, so that the flow of the pump press is adjusted, the oil surface sectional area of the oil cylinder is further adjusted, and finally the mechanical motion component is controlled to complete corresponding actions. In order to ensure normal operation, the injection molding machine is also provided with a fault alarm, when the components of the injection molding machine are in fault, the fault alarm gives an alarm, and then a worker detects key components of the injection molding machine to determine the fault reason and further take corresponding measures to eliminate the fault.
However, there is a significant hysteresis in the malfunction alarm, i.e., when the malfunction alarm alarms, the injection molding machine has already experienced a significant catastrophic malfunction (e.g., motor stall), inevitably resulting in damage to the injection molding machine.
Disclosure of Invention
In view of this, the present application aims to provide an injection molding machine fault early warning system to solve the problem that the alarm of the existing injection molding machine fault alarm is delayed.
In order to achieve the above purpose, the present application provides the following technical solutions:
an injection molding machine fault early warning system, comprising: the device comprises a sensor group for detecting the performance parameters of the injection molding machine, a threshold signal generator for generating the threshold values of the performance parameters, a parameter comparator and a display; wherein,
the sensor group is connected with the injection molding machine; the first input end of the parameter comparator is connected with the sensor group, and the second input end of the parameter comparator is connected with the threshold signal generator; and the output end of the parameter comparator is connected with the display.
Preferably, the system further comprises: the injection molding machine power control system comprises an overrun counter, an overrun comparator and a power regulator for regulating the power of the injection molding machine to protection power; wherein,
the output end of the parameter comparator is connected with the low level enabling end of the over-limit counter; the output end of the overrun counter is connected with the first input end of the overrun comparator;
a second input end of the overrun comparator inputs a preset overrun reference signal; the output end of the overrun comparator is respectively connected with a stop control part of the injection molding machine and a zero level enabling end of the power regulator; the power regulator is connected with the injection molding machine.
Preferably, the sensor group comprises a motor torque sensor, a motor rotating speed sensor and a motor efficiency sensor for detecting the transmission efficiency of the motor;
the system further comprises: the system comprises a motor efficiency comparator, a torque comparator, a rotating speed comparator and a first timer;
the high level enabling end of the motor efficiency comparator is connected with the output end of the parameter comparator; a first input end of the motor efficiency comparator is connected with the motor efficiency sensor; a second input end of the motor efficiency comparator inputs a preset motor efficiency reference signal; the output end of the motor efficiency comparator is connected with the low-level enabling end of the torque comparator and the low-level enabling end of the rotating speed comparator;
the first input end of the torque comparator is connected with the motor torque sensor; a second input end of the torque comparator inputs a preset torque reference signal; the output end of the torque comparator is connected with the display and the low-level enabling end of the first timer; the first timer is connected with a parking control part of the injection molding machine;
the first input end of the rotating speed comparator is connected with the motor rotating speed sensor; a second input end of the rotating speed comparator inputs a preset rotating speed reference signal; and the output end of the rotating speed comparator is connected with the display and the low-level enabling end of the first timer.
Preferably, the system further comprises: a first divider, a motor characteristic comparator and a third timer;
the input current signal of the motor is input to a first input end of the first divider; a second input end of the first divider is connected with the motor rotating speed sensor; the output end of the first divider is connected with the first input end of the motor characteristic comparator; a second input end of the motor characteristic comparator inputs a preset motor characteristic reference signal; the high level enabling end of the motor characteristic comparator is connected with the output end of the motor efficiency comparator;
the output end of the motor characteristic comparator is connected with the low-level enabling end of the third timer; and the output end of the third timer is connected with a parking control part of the injection molding machine.
Preferably, the sensor group comprises a motor torque sensor, a motor rotating speed sensor, a pumping pressure sensor, a pumping flow sensor and a pumping efficiency sensor for detecting pumping transmission efficiency;
the system further comprises: the system comprises a pumping efficiency comparator, a pressure comparator, a flow comparator and a second timer;
the high level enabling end of the pumping efficiency comparator is connected with the output end of the parameter comparator; the first input end of the pumping efficiency comparator is connected with the pumping efficiency sensor; a second input end of the pumping efficiency comparator inputs a preset pumping efficiency reference signal; the output end of the pumping efficiency comparator is connected with the low-level enabling end of the pressure comparator and the low-level enabling end of the flow comparator;
the first input end of the pressure comparator is connected with the pumping pressure sensor; a second input end of the pressure comparator inputs a preset pressure reference signal; the output end of the pressure comparator is connected with the display and the low-level enabling end of the second timer; the second timer is connected with a parking control part of the injection molding machine;
the first input end of the flow comparator is connected with the pumping flow sensor; a second input end of the flow comparator inputs a preset flow reference signal; and the output end of the flow comparator is connected with the display and the low-level enabling end of the second timer.
Preferably, the system further comprises: a second divider, a pumping characteristic comparator and a fourth timer;
a first input end of the second divider is connected with the pumping pressure sensor; a second input end of the second divider is connected with the motor torque sensor; the output end of the second divider is connected with the first input end of the pumping characteristic comparator; a second input end of the pumping characteristic comparator inputs a preset pumping characteristic reference signal; the high level enabling end of the pumping characteristic comparator is connected with the output end of the pumping efficiency comparator;
the output end of the pumping characteristic comparator is connected with the low-level enabling end of the fourth timer; and the output end of the fourth timer is connected with a parking control part of the injection molding machine.
Preferably, the sensor group further comprises: a speed sensor connected with the mechanical moving part, and a current sensor, a voltage sensor and a transmission efficiency sensor connected with the driver.
According to the technical scheme, the performance parameters of the injection molding machine are detected through the sensor group, the performance parameters detected by the sensor group are compared with the corresponding preset threshold value through the parameter comparator, and the comparison result of the parameter comparator is displayed through the display; the staff can learn which performance parameter surpasses the preset range through looking at the display to before the injection molding machine produces obvious serious trouble, failure alarm report to the police, take corresponding measure, make performance parameter resume to normal within range, avoid the production of injection molding machine serious trouble, prolong the life of injection molding machine. Therefore, the problem that the alarm of the existing injection molding machine fault alarm is delayed is solved.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present application, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a structural diagram of a fault early warning system of an injection molding machine according to a first embodiment of the present application;
fig. 2 is a structural diagram of a fault early warning system of an injection molding machine provided in the second embodiment of the present application;
fig. 3 is a structural diagram of a fault early warning system of an injection molding machine provided in the third embodiment of the present application;
fig. 4 is a structural diagram of a fault early warning system of an injection molding machine provided in the fourth embodiment of the present application;
fig. 5 is a schematic diagram of a work of a fault warning system of an injection molding machine according to a first embodiment of the present application;
fig. 6 is a working schematic diagram of a fault early warning system of an injection molding machine provided in the second embodiment of the present application;
fig. 7 is a working schematic diagram of a fault early warning system of an injection molding machine provided in the third embodiment of the present application;
fig. 8 is a working schematic diagram of a fault early warning system of an injection molding machine provided in the fourth embodiment of the present application;
FIG. 9 is a schematic diagram of the relationship between the transmission efficiency and the temperature of the motor according to the embodiment of the present application;
FIG. 10 is a graph illustrating a relationship between a current-to-torque ratio Kt and a temperature t according to an embodiment of the present disclosure;
FIG. 11 is a diagram illustrating a relationship between a rotation speed n and an output frequency f according to an embodiment of the present disclosure;
FIG. 12 is a schematic diagram illustrating the relationship between the input current and the rotation speed of the motor according to the embodiment of the present application;
FIG. 13 is a graph illustrating the relationship between the pressure and torque ratio K and the temperature t provided by the embodiment of the present application;
FIG. 14 is a schematic diagram illustrating a relationship between a pumping flow and a motor rotation speed according to an embodiment of the present disclosure;
fig. 15 is a schematic diagram illustrating a relationship between a pumping pressure and a motor rotation speed according to an embodiment of the present application.
Detailed Description
The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
The embodiment of the application discloses an injection molding machine fault early warning system to solve the problem that the alarm of the existing injection molding machine fault alarm is lagged.
Referring to fig. 1, the injection molding machine fault early warning system provided in the first embodiment of the present application includes a sensor group 1 for detecting a performance parameter of the injection molding machine, a threshold signal generator 2 for generating a threshold value of the performance parameter, a parameter comparator 3, and a display 4.
Wherein, the sensor group 1 is connected with the injection molding machine 0; a first input end of the parameter comparator 3 is connected with the sensor group 1, and a second input end of the parameter comparator 3 is connected with the threshold signal generator 2; the output of the parameter comparator 3 is connected to a display 4.
The sensor group 1 may be a plurality of sensors or transmissions for detecting different performance parameters, such as a torque sensor for detecting motor torque, a pressure sensor for detecting pumping pressure, etc., according to actual needs. The threshold signal generator 2 may send a signal containing a preset range of performance parameters to the parameter comparator 3; each sensor corresponds to one parameter comparator and one threshold signal generator, and the overrun judgment of the performance parameters detected by the sensors is realized together, namely whether the performance parameters are in a preset range or not is confirmed, and the judgment result is displayed on a display.
By the structure, a worker can know which performance parameter exceeds the preset range by looking up the display, so that corresponding measures are taken before the injection molding machine generates obvious serious faults and the fault alarm gives an alarm, the performance parameters are recovered to the normal range, the serious faults of the injection molding machine are avoided, and the service life of the injection molding machine is prolonged. Therefore, the problem that the alarm of the existing injection molding machine fault alarm is delayed is solved.
Specifically, the operation principle of the first embodiment is shown in fig. 5:
s1: acquiring at least one performance parameter of the injection molding machine in real time;
specifically, the injection molding machine can be detected in real time through detection equipment such as a sensor and a transmission, so that performance parameters of the injection molding machine can be obtained.
S2: judging whether the performance parameters are in respective preset ranges;
specifically, whether the performance parameters are within respective preset ranges can be judged through data processing devices such as a single chip microcomputer and the like, and judgment results are generated.
S3: and respectively displaying the judgment result of each performance parameter.
Referring to fig. 2, the injection molding machine fault early warning system provided in the second embodiment of the present application includes a sensor group 1 for detecting a performance parameter of the injection molding machine, a threshold signal generator 2 for generating a threshold value of the performance parameter, a parameter comparator 3, a display 4, an overrun counter 71, an overrun comparator 72, and a power regulator 73 for regulating a power of the injection molding machine to a protection power.
Wherein, the sensor group 1 is connected with the injection molding machine 0; a first input end of the parameter comparator 3 is connected with the sensor group 1, and a second input end of the parameter comparator 3 is connected with the threshold signal generator 2; the output end of the parameter comparator 3 is connected with the low level enabling end of the overrun counter 71; the output end of the overrun counter 71 is connected with the first input end of the overrun comparator 72; a second input terminal of the overrun comparator 72 inputs a preset overrun reference signal; the output end of the overrun comparator 72 is connected to the stop control unit of the injection molding machine 0 and the zero level enable end of the power regulator 73, respectively; the power regulator 73 is connected with the injection molding machine 0; the output of the parameter comparator 3 and the output of the overrun comparator 72 are both connected to the display 4.
The working process of the system is as follows: the sensor group 1 acquires the performance parameters of the injection molding machine in real time and inputs the performance parameters into a first input end of a parameter comparator 3; the threshold signal generator 2 inputs a signal containing a preset range of performance parameters to a second input of the parameter comparator 3. The parameter comparator 3 compares the performance parameter obtained by the sensor group 1 with a corresponding preset range, that is, determines whether the performance parameter is within the preset range, and the determination result can be expressed as a high/low level signal output by the output end of the parameter comparator 3: the output end of the parameter comparator 3 outputs a low level to indicate that the performance parameter is not in the preset range, so that the overrun counter 71 is triggered, and the overrun counter 71 adds 1 to the overrun value x; when the output end of the corresponding parameter comparator 3 outputs a high level, it indicates that the performance parameter is within the preset range, and the overrun counter 71 can set the overrun value x to 0 through the corresponding connection port. The overrun reference signal, i.e. the maximum number of allowed overruns, is typically set to 1; the overrun comparator 72 compares the overrun value x recorded by the overrun counter 71 with the overrun reference signal "1", if x is greater than 1, a high level is output, a stop control part of the injection molding machine 0 is triggered to act, and the injection molding machine stops immediately; if x =1, a zero level is output, the power regulator 73 is triggered to operate, and the power of the injection molding machine is regulated to the protection power. At the same time, the display 4 displays the judgment result of each performance parameter by the parameter comparator 3 and the comparison result by the overrun comparator 72.
Specifically, the specific method of adjusting the power of the injection molding machine to the protection power varies depending on the performance parameters. The corresponding table of the performance parameters and the power adjusting parameters may be pre-stored in the power adjuster 73 or other storage media, and after the power adjuster 73 is started, the corresponding power adjusting parameters are obtained by querying the corresponding table, so as to adjust the power adjusting parameters, so that the power of the injection molding machine reaches the protection power. For example, if the performance parameter exceeding the preset range is the rotation speed of the motor, the power of the injection molding machine can reach the protection power by adjusting the output current of the driver, and if the performance parameter exceeding the preset range is the pressure of the pump, the power of the injection molding machine can reach the protection power by adjusting the output voltage of the driver. Therefore, the embodiment of the application realizes automatic diagnosis, early warning and automatic protection of the injection molding machine.
The operation principle of the above system can be represented as a flow chart shown in fig. 6:
s1: acquiring at least one performance parameter of the injection molding machine in real time;
s2: judging whether the performance parameters are in respective preset ranges, if at least one performance parameter is not in the corresponding preset range, executing step S4, otherwise, executing step S3;
s3: setting the overrun value x to 0, respectively displaying the judgment result of each performance parameter, and finishing the self-diagnosis;
s4: adding 1 to the overrun value x, and respectively displaying the judgment result of each performance parameter;
s5: when x is larger than 1, controlling the injection molding machine to stop immediately; and when x is equal to 1, adjusting the power of the injection molding machine to the protection power, and displaying corresponding prompt information.
Referring to fig. 3, the injection molding machine fault early warning system provided in the third embodiment of the present application includes a sensor group 1 for detecting a performance parameter of the injection molding machine, a threshold signal generator 2 for generating a threshold value of the performance parameter, a parameter comparator 3, a display 4, a motor efficiency comparator 51, a torque comparator 52, a rotation speed comparator 53, a first timer 54, a first divider 55, a motor characteristic comparator 56, and a third timer 57; the sensor group 1 includes a motor torque sensor, a motor speed sensor, and a motor efficiency sensor for detecting the transmission efficiency of the motor.
The connection relationship among the components of the system is as follows: the sensor group 1 is connected with the injection molding machine 0; a first input end of the parameter comparator 3 is connected with the sensor group 1, and a second input end of the parameter comparator 3 is connected with the threshold signal generator 2; the output end of the parameter comparator 3 is connected with the high-level enable end of the motor efficiency comparator 51; a first input of the motor efficiency comparator 51 is connected to the motor efficiency sensors in the sensor group 1; a second input terminal of the motor efficiency comparator 51 inputs a preset motor efficiency reference signal; an output terminal of the motor efficiency comparator 51 is connected to a low-level enable terminal of the torque comparator 52 and a low-level enable terminal of the rotation speed comparator 53.
A first input end of the torque comparator 52 is connected with a motor torque sensor in the sensor group 1; a second input end of the torque comparator 52 inputs a preset torque reference signal; the output terminal of the torque comparator 52 is connected to the display 4 and the low-level enable terminal of the first timer 54; the first timer 54 is connected to a stop control unit of the injection molding machine 0.
A first input end of the rotating speed comparator 53 is connected with a motor rotating speed sensor in the sensor group 1; a second input terminal of the rotation speed comparator 53 inputs a preset rotation speed reference signal; the output of the tacho comparator 53 is connected to the display 4 and to the low enable of the first timer 54.
A first input terminal of the first divider 55 inputs an input current signal of the motor; a second input end of the first divider 55 is connected with a motor speed sensor in the sensor group 1; an output of the first divider 55 is connected to a first input of a motor characteristic comparator 56; a second input terminal of the motor characteristic comparator 56 inputs a preset motor characteristic reference signal; the high-level enable terminal of the motor characteristic comparator 56 is connected to the output terminal of the motor efficiency comparator 51. The output terminal of the motor characteristic comparator 56 is connected to the low-level enable terminal of the third timer 57; the output of the third timer 57 is connected to the stop control unit of the injection molding machine 0.
The working process of the system is as follows: the sensor group 1 acquires the performance parameters of the injection molding machine in real time and inputs the performance parameters into a first input end of a parameter comparator 3; the threshold signal generator 2 inputs a signal containing a preset range of performance parameters to a second input of the parameter comparator 3. The parameter comparator 3 compares the performance parameter obtained by the sensor group 1 with a corresponding preset range, that is, determines whether the performance parameter is within the preset range, and the determination result can be expressed as a high/low level signal output by the output end of the parameter comparator 3: when the performance parameter is within the preset range, the output end of the parameter comparator 3 outputs a high level to trigger the motor efficiency comparator 51 to work.
After the motor efficiency comparator 51 is triggered, the motor efficiency sensor is acquiredMotor efficiency ηmComparing with a preset motor efficiency reference signal if etamThe motor efficiency comparator 51 outputs a low level to trigger the torque comparator 52 and the rotating speed comparator 53, which is not equal to the preset motor efficiency reference signal or is not in the range represented by the preset motor efficiency reference signal; conversely, the motor efficiency comparator 51 outputs a high level, triggering the motor characteristic comparator 56.
After the torque comparator 52 is triggered, the torque J detected by the motor torque sensor is compared with a preset torque reference signal, and if J is not equal to the preset torque reference signal or is not within the range indicated by the preset torque reference signal, the torque comparator 52 outputs a low level to trigger the first timer 54.
After the rotation speed comparator 53 is triggered, the current motor rotation speed n detected by the motor rotation speed sensor is compared with a preset rotation speed reference signal, and if n is not equal to the preset rotation speed reference signal, the rotation speed comparator 53 outputs a low level to trigger the first timer 54.
When the first timer 54 is triggered, timing is started, and when the first preset time is reached, the stop control part of the injection molding machine 0 is triggered to stop the injection molding machine 0.
The first divider 55 obtains the ratio In between the input current and the rotation speed of the motor by division, after the motor characteristic comparator 56 is triggered, the In is compared with a preset motor characteristic reference signal, and if the In is not equal to the preset motor characteristic reference signal, the motor characteristic comparator 56 outputs a low level to trigger the third timer 57.
When the third timer 57 is triggered, the timer starts to count time, and when the third preset time is reached, the stop control part of the injection molding machine 0 is triggered to stop the injection molding machine 0.
The display 4 displays the comparison results of the parameter comparator 3, the motor efficiency comparator 51, and the motor characteristic comparator 56, respectively.
The working principle of the system according to the third embodiment is further described below with reference to fig. 7:
s1: acquiring performance parameters of the injection molding machine in real time; the performance parameters at least comprise the torque J and the rotating speed n of the motor;
s2: judging whether the performance parameters are in respective preset ranges, if at least one performance parameter is not in the corresponding preset range, executing step S3, and if the performance parameters are in the respective preset ranges, executing step S5;
s3: respectively displaying the judgment result of each performance parameter, and adding 1 to the overrun value x;
s4: when x is larger than 1, controlling the injection molding machine to stop immediately; when x is equal to 1, adjusting the power of the injection molding machine to the protection power, displaying corresponding prompt information, and finishing the self-diagnosis;
s5: respectively displaying the judgment result of each performance parameter, and setting the overrun value x to be 0;
s6: calculating motor transmission efficiency etamIf ηmIs not equal to or within the range represented by the preset motor efficiency reference signal (i.e. the motor transmission efficiency eta)mAbnormal), go to step S7, otherwise go to step S9;
under normal conditions, the transmission efficiency eta of the motormThe relationship with the temperature t of the motor is shown in fig. 9. FIG. 9 may be implemented as a two-bit array (η)m[i],t[i]) If the current temperature is t 4]By querying the two-dimensional array (η)m[i],t[i]) Corresponding motor efficiency reference signal eta can be obtainedm[4]Further determine ηmWhether it is equal to ηm[4]Or at [ eta ]m[4]-Δη,ηm[4]+Δη]If yes, the transmission efficiency eta of the motor is judgedmNormal, otherwise, judge ηmAnd (6) abnormal. Wherein, the value of the delta eta can be set according to the actual situation.
S7: respectively judging whether the torque J of the motor is equal to a first preset value or not and whether the rotating speed n of the motor is equal to a second preset value or not;
the specific method for judging whether the torque J of the motor is equal to the first preset value is as follows: under normal conditions, the relationship between the ratio Kt of the input current I to the torque J of the motor and the temperature t of the motor is as shown in fig. 10, and similarly, fig. 10 is stored in the form of a two-dimensional array (Kt [ I ], t [ I ]), if the current temperature is t [4], a normal value of the ratio of the input current I to the torque J should be Kt [4] can be obtained by querying the two-dimensional array (Kt [ I ], t [ I ]), and then it can be determined that the first preset value (i.e. the normal value of the current torque of the motor, the preset torque reference signal) is J' = I/Kt [4 ]. Therefore, it is determined whether the torque J of the motor is equal to the first predetermined value, i.e., the torque comparator 52 compares J and J' for equality.
The specific method for judging that the rotating speed n of the motor is equal to the second preset value is as follows: as shown in fig. 11, normally, the rotation speed n of the motor increases with the increase of the output frequency f, and the relationship is n =60 f/p (p is the number of pole pairs of the motor, and is generally 4), so that the second preset value (i.e. the normal value of the current motor rotation speed, the preset rotation speed reference signal) can be determined according to the output frequency f of the motor, and the normal rotation speed n' =60 f/p of the current motor can be determined. Therefore, it is determined whether the rotation speed n of the motor is equal to the second preset value, i.e., whether n is equal to n'.
It should be noted that, during the operation of the injection molding machine, the motor torque and the input voltage will inevitably float, and a certain margin can be set for the torque J and the voltage, for example, it is determined whether J is within the interval [ J- Δ 1, J + Δ 1], and n is within the interval [ n '- Δ 2, n' + Δ 2], so as to avoid the injection molding machine from frequently stopping.
S8: displaying the judgment result of the step S7, and controlling the injection molding machine to stop after the first preset time when the torque J is not equal to the first preset value or the rotating speed n of the motor is not equal to the second preset value, and finishing the self-diagnosis;
in addition to displaying direct judgment results such as 'the torque J is equal to the first preset value' and 'the n is not equal to the second preset value', fault information can be further displayed, and a worker can conveniently and directly take corresponding measures. When n > n' is shown as a point in fig. 11A, a fault message "motor parameter setting error" can be further prompted, and after seeing the message, the operator immediately checks and resets a series of parameters of the motor, so that the motor operates normally.
S9: and judging whether the ratio In of the input current I of the motor to the rotating speed n is within a fifth preset range, displaying the judgment result, controlling the injection molding machine to stop after third preset time when judging that In is not within the fifth preset range, and finishing the self-diagnosis.
As shown In the motor characteristic diagram of fig. 12, normally, the input current I increases with the increase of the rotation speed n, and the ratio of I to n should be a constant value In 0; therefore, the fifth predetermined range can be set to [ In0- Δ 3, In0+ Δ 3 ]; if the current ratio In of I to n is not within the fifth preset range [ In 0-delta 3, In0+ delta 3], indicating that the motor is abnormal, displaying information of abnormal ratio of input current I to rotating speed n on a display, and controlling the injection molding machine to stop after the third preset time.
In addition, the first preset time and the third preset time may be one minute or one operation cycle of the injection molding machine, and the like. When the fault is not serious, the injection molding machine is stopped after the preset time, so that the damage to the injection molding machine caused by immediate stop can be avoided. After the injection molding machine is stopped, the operator can further maintain the injection molding machine according to the display result, and thoroughly eliminate the fault.
According to the structure and the working principle, when the performance parameters are judged to be abnormal, the injection molding machine is not directly determined to be normal, but the motor transmission efficiency eta is determinedmTorque J, rotational speed n and motor characteristic In are further judged, so that fault early warning of the injection molding machine is realized, hidden dangers existing In the injection molding machine are found In time, the hidden dangers are eliminated In advance before a fault alarm gives an alarm, and damage to the injection molding machine is reduced.
Referring to fig. 4, the injection molding machine fault early warning system according to the fourth embodiment of the present disclosure includes a sensor group 1 for detecting a performance parameter of the injection molding machine, a threshold signal generator 2 for generating a threshold value of the performance parameter, a parameter comparator 3, a display 4, a pumping efficiency comparator 61, a pressure comparator 62, a flow comparator 63, a second timer 64, a second divider 65, a pumping characteristic comparator 66, and a fourth timer 67; the sensor group 1 includes a motor torque sensor, a motor speed sensor, a pumping pressure sensor, a pumping flow sensor, and a pumping efficiency sensor for detecting pumping transmission efficiency.
The connection relationship among the components of the system is as follows: the sensor group 1 is connected with the injection molding machine 0; a first input end of the parameter comparator 3 is connected with the sensor group 1, and a second input end of the parameter comparator 3 is connected with the threshold signal generator 2; the output end of the parameter comparator 3 is connected with the high level enable end of the pumping efficiency comparator 61; a first input end of the pump efficiency comparator 61 is connected with the pump efficiency sensor in the sensor group 1; a second input terminal of the pumping efficiency comparator 61 inputs a preset pumping efficiency reference signal; the output terminal of the pump efficiency comparator 61 is connected to the low-level enable terminal of the pressure comparator 62 and the low-level enable terminal of the flow comparator 63.
A first input end of the pressure comparator 62 is connected with a pumping pressure sensor in the sensor group 1; a second input terminal of the pressure comparator 62 inputs a preset pressure reference signal; the output terminal of the pressure comparator 62 is connected to the display 4 and the low-level enable terminal of the second timer 64; the second timer 64 is connected to a stop control section of the injection molding machine 0.
A first input end of the flow comparator 63 is connected with a pumping flow sensor in the sensor group 1; a second input end of the flow comparator 63 inputs a preset flow reference signal; the output of the flow comparator 63 is connected to the display 4 and to the low enable of the second timer 64.
A first input end of the second divider 65 is connected with a pumping pressure sensor in the sensor group 1; a second input end of the second divider 65 is connected with a motor torque sensor in the sensor group 1; an output of the second divider 65 is connected to a first input of a pump characteristic comparator 66; a second input terminal of the pumping characteristic comparator 66 inputs a preset pumping characteristic reference signal; the high level enable terminal of the pump characteristic comparator 66 is connected to the output terminal of the pump efficiency comparator 61; the output terminal of the pumping characteristic comparator 66 is connected to the display 4 and the low-level enable terminal of the fourth timer 67; the output of the fourth timer 67 is connected to the stop control section of the injection molding machine 0.
The working process of the system is as follows: the sensor group 1 acquires the performance parameters of the injection molding machine in real time and inputs the performance parameters into a first input end of a parameter comparator 3; the threshold signal generator 2 inputs a signal containing a preset range of performance parameters to a second input of the parameter comparator 3. The parameter comparator 3 compares the performance parameter obtained by the sensor group 1 with a corresponding preset range, that is, determines whether the performance parameter is within the preset range, and the determination result can be expressed as a high/low level signal output by the output end of the parameter comparator 3: when the performance parameter is within the preset range, the output end of the parameter comparator 3 outputs a high level to trigger the pumping efficiency comparator 61 to work.
After the pumping efficiency comparator 61 is triggered, comparing the pumping efficiency eta b acquired by the pumping efficiency sensor with a preset pumping efficiency reference signal, and if eta b is not equal to the preset pumping efficiency reference signal or is not in the range represented by the preset pumping efficiency reference signal, the pumping efficiency comparator 61 outputs a low level to trigger the pressure comparator 62 and the flow comparator 63; conversely, the pump efficiency comparator 61 outputs a high level, triggering the pump characteristic comparator 66.
After the pressure comparator 62 is triggered, the pressure P detected by the pumping pressure sensor is compared with a preset pressure reference signal, and if P is not equal to or within the range indicated by the preset pressure reference signal, the pressure comparator 62 outputs a low level to trigger the third timer 64.
After the flow comparator 63 is triggered, the flow Q detected by the pumping flow sensor is compared with a preset flow reference signal, and if Q is not equal to the preset flow reference signal or is not within the range represented by the preset flow reference signal, the flow comparator 63 outputs a low level to trigger the third timer 64.
The second timer 64 starts timing after being triggered, and triggers the stop control part of the injection molding machine 0 to stop the injection molding machine 0 when the second preset time is reached.
The increase rate Pn of the pumping pressure P increasing with the motor rotation speed n is calculated by the second divider 65, and after the pumping characteristic comparator 66 is triggered, Pn is compared with a preset pumping characteristic reference signal, and if the Pn is not equal to the preset pumping characteristic reference signal, the pumping characteristic comparator 66 outputs a low level to trigger the third timer 67.
When the fourth timer 67 is triggered, the timer starts to count time, and when the fourth preset time is reached, the stop control part of the injection molding machine 0 is triggered to stop the injection molding machine 0.
The display 4 displays the comparison results of the parameter comparator 3, the pump efficiency comparator 61, and the pump characteristic comparator 66, respectively.
The working principle of the system according to the fourth embodiment is further described below with reference to fig. 8:
s1: acquiring performance parameters of the injection molding machine in real time; the performance parameters at least comprise the torque J and the rotating speed n of the motor, and the pressure P and the flow Q of the pump;
s2: judging whether the performance parameters are in respective preset ranges, if at least one performance parameter is not in the corresponding preset range, executing step S3, and if the performance parameters are in the respective preset ranges, executing step S5;
s3: respectively displaying the judgment result of each performance parameter, and adding 1 to the overrun value x;
s4: when x is larger than 1, controlling the injection molding machine to stop immediately; when x is equal to 1, adjusting the power of the injection molding machine to the protection power, displaying corresponding prompt information, and finishing the self-diagnosis;
s5: respectively displaying the judgment result of each performance parameter, and setting the overrun value x to be 0;
s6: calculating the pumping transmission efficiency eta b, if the pumping transmission efficiency eta b is not equal to the preset pumping efficiency reference signal or is not in the range represented by the preset pumping efficiency reference signal (namely the pumping transmission efficiency eta b is abnormal), executing the step S7, otherwise executing the step S9;
the specific method for determining the abnormality of eta b can refer to the third embodiment for determining the transmission efficiency eta of the motormWhether the abnormality occurs is not described herein.
S7: respectively judging whether the pressure P is equal to a third preset value or not and whether the flow Q is equal to a fourth preset value or not;
the specific method for judging whether the pressure P is equal to the third preset value is as follows: under normal conditions, the relationship between the ratio K of the pressure P to the motor torque J and the pumping temperature t is as shown in fig. 13, fig. 13 is stored in the form of a two-bit array (ki, ti), if the current temperature is t [4], a normal value of the ratio of the input current I to the torque J should be K [4] by querying the two-dimensional array (ki, ti), and it can be determined that the third preset value (i.e. the normal value of the current pumping pressure) is P' = J × K [4 ]. Therefore, it is determined whether the pressure P is equal to the third predetermined value, i.e., P and P' are compared by the pressure comparator 63.
Similarly, the specific method for determining whether the flow Q is equal to the fourth preset value is as follows: normally, as shown in fig. 14, Q and n satisfy the relationship Q = n0+k*n（n0And k is an inherent parameter of the injection molding machine, which can be measured experimentally beforehand); the torque n is detected by the motor torque sensor, so that the fourth preset value (i.e. the normal value of the current pumping flow) can be determined as Q' = n0+ k × n. Therefore, it is determined whether the flow Q is equal to the fourth predetermined value, i.e., whether Q is equal to Q'.
It should be noted that, during the operation of the injection molding machine, the pumping pressure and flow rate will inevitably fluctuate, and a certain margin can be set for the pressure P and flow rate Q, for example, if P is determined to be within the interval [ P- Δ 4, P + Δ 4], Q is determined to be within the interval [ Q '- Δ 5, Q' + Δ 5], so as to avoid frequent stop of the injection molding machine.
S8: displaying the judgment result of the step S7, and controlling the injection molding machine to stop after the second preset time when P is not equal to the third preset value or Q is not equal to the fourth preset value, and ending the self-diagnosis;
in addition to displaying direct judgment results such as 'P is not equal to the third preset value' and 'Q is not equal to the fourth preset value', the embodiment of the application can further display fault information, and is convenient for workers to directly take countermeasures. The failure information "unstable pump wave pressure" can be further displayed as Q > Q 'shown by point a in fig. 14, or Q < Q' shown by point B in fig. 14.
S9: and judging whether the increase rate Pn of the pressure P along with the increase of the rotating speed n is in a sixth preset range, displaying the judgment result, controlling the injection molding machine to stop after fourth preset time when judging that the increase rate Pn is not in the sixth preset range, and finishing the self-diagnosis.
As shown in fig. 15, normally, as n increases, the increase rate Pn of P increases with n increases first and then decreases. The curve shown in FIG. 15 can be stored in the form of two-dimensional array (Pn [ i ], n [ i ]), if the current rotation speed is n [3], the two-dimensional array (Pn [ i ], n [ i ]) can be inquired to obtain the corresponding growth rate normal value Pn [3 ]; therefore, the sixth predetermined range can be set to be within [ Pn 3] - Δ 6, Pn 3 + Δ 6 ]. If Pn is not within [ Pn 3- Δ 6, Pn 3 + Δ 6], indicating that the pumping characteristic is abnormal, the fault information 'pumping characteristic is abnormal' can be displayed, and the injection molding machine is controlled to stop after a fourth preset time.
In addition, the second preset time and the fourth preset time may be one minute or one operation cycle of the injection molding machine, and the like. When the fault is not serious, the injection molding machine is stopped after the preset time, so that the damage to the injection molding machine caused by immediate stop can be avoided. After the injection molding machine is stopped, the operator can further maintain the injection molding machine according to the display result, and thoroughly eliminate the fault.
According to the steps of the method, when the performance parameters are judged to be abnormal, the injection molding machine is not directly determined to be normal, but the pump transmission efficiency eta is determinedbP, Q and the motor characteristic Pn are further judged, thereby realizing the fault early warning of the injection molding machine, finding the hidden trouble existing in the injection molding machine in time, eliminating the hidden trouble in advance before the fault alarm gives an alarm, and reducing the damage to the injection molding machine.
In other system embodiments of the present application, in order to realize self-diagnosis of the components of the injection molding machine, such as the cylinder, the mechanical moving component, and the driver, the sensor group 1 of all the embodiments may include: a speed sensor connected with the mechanical moving part, and a current sensor, a voltage sensor and a transmission efficiency sensor connected with the driver.
It will be understood by those skilled in the art that all or part of the processes of the methods of the embodiments described above can be implemented by a computer program, which can be stored in a computer-readable storage medium, and can include the processes of the embodiments of the methods described above when the computer program is executed. The storage medium may be a magnetic disk, an optical disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), or the like.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the application. Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (7)
1. An injection molding machine fault early warning system, comprising: the device comprises a sensor group for detecting the performance parameters of the injection molding machine, a threshold signal generator for generating the threshold values of the performance parameters, a parameter comparator and a display; wherein,
the sensor group is connected with the injection molding machine; the first input end of the parameter comparator is connected with the sensor group, and the second input end of the parameter comparator is connected with the threshold signal generator; and the output end of the parameter comparator is connected with the display.
2. The system of claim 1, further comprising: the injection molding machine power control system comprises an overrun counter, an overrun comparator and a power regulator for regulating the power of the injection molding machine to protection power; wherein,
the output end of the parameter comparator is connected with the low level enabling end of the over-limit counter; the output end of the overrun counter is connected with the first input end of the overrun comparator;
a second input end of the overrun comparator inputs a preset overrun reference signal; the output end of the overrun comparator is respectively connected with a stop control part of the injection molding machine and a zero level enabling end of the power regulator; the power regulator is connected with the injection molding machine.
3. The system of claim 1 or 2, wherein the sensor group comprises a motor torque sensor, a motor speed sensor, a motor efficiency sensor detecting a motor transmission efficiency;
the system further comprises: the system comprises a motor efficiency comparator, a torque comparator, a rotating speed comparator and a first timer;
the high level enabling end of the motor efficiency comparator is connected with the output end of the parameter comparator; a first input end of the motor efficiency comparator is connected with the motor efficiency sensor; a second input end of the motor efficiency comparator inputs a preset motor efficiency reference signal; the output end of the motor efficiency comparator is connected with the low-level enabling end of the torque comparator and the low-level enabling end of the rotating speed comparator;
the first input end of the torque comparator is connected with the motor torque sensor; a second input end of the torque comparator inputs a preset torque reference signal; the output end of the torque comparator is connected with the display and the low-level enabling end of the first timer; the first timer is connected with a parking control part of the injection molding machine;
the first input end of the rotating speed comparator is connected with the motor rotating speed sensor; a second input end of the rotating speed comparator inputs a preset rotating speed reference signal; and the output end of the rotating speed comparator is connected with the display and the low-level enabling end of the first timer.
4. The system of claim 3, further comprising: a first divider, a motor characteristic comparator and a third timer;
the input current signal of the motor is input to a first input end of the first divider; a second input end of the first divider is connected with the motor rotating speed sensor; the output end of the first divider is connected with the first input end of the motor characteristic comparator; a second input end of the motor characteristic comparator inputs a preset motor characteristic reference signal; the high level enabling end of the motor characteristic comparator is connected with the output end of the motor efficiency comparator;
the output end of the motor characteristic comparator is connected with the low-level enabling end of the third timer; and the output end of the third timer is connected with a parking control part of the injection molding machine.
5. The system of claim 1 or 2, wherein the sensor group comprises a motor torque sensor, a motor speed sensor, a pump pressure sensor, a pump flow sensor, and a pump efficiency sensor that detects pump transmission efficiency;
the system further comprises: the system comprises a pumping efficiency comparator, a pressure comparator, a flow comparator and a second timer;
the high level enabling end of the pumping efficiency comparator is connected with the output end of the parameter comparator; the first input end of the pumping efficiency comparator is connected with the pumping efficiency sensor; a second input end of the pumping efficiency comparator inputs a preset pumping efficiency reference signal; the output end of the pumping efficiency comparator is connected with the low-level enabling end of the pressure comparator and the low-level enabling end of the flow comparator;
the first input end of the pressure comparator is connected with the pumping pressure sensor; a second input end of the pressure comparator inputs a preset pressure reference signal; the output end of the pressure comparator is connected with the display and the low-level enabling end of the second timer; the second timer is connected with a parking control part of the injection molding machine;
the first input end of the flow comparator is connected with the pumping flow sensor; a second input end of the flow comparator inputs a preset flow reference signal; and the output end of the flow comparator is connected with the display and the low-level enabling end of the second timer.
6. The system of claim 5, further comprising: a second divider, a pumping characteristic comparator and a fourth timer;
a first input end of the second divider is connected with the pumping pressure sensor; a second input end of the second divider is connected with the motor torque sensor; the output end of the second divider is connected with the first input end of the pumping characteristic comparator; a second input end of the pumping characteristic comparator inputs a preset pumping characteristic reference signal; the high level enabling end of the pumping characteristic comparator is connected with the output end of the pumping efficiency comparator;
the output end of the pumping characteristic comparator is connected with the low-level enabling end of the fourth timer; and the output end of the fourth timer is connected with a parking control part of the injection molding machine.
7. The system of any one of claims 1 to 6, wherein the sensor group further comprises: a speed sensor connected with the mechanical moving part, and a current sensor, a voltage sensor and a transmission efficiency sensor connected with the driver.
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| CN 201220748376 CN203141798U (en) | 2012-12-30 | 2012-12-30 | Fault early warning system of injection molding machine |
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104416868A (en) * | 2013-08-27 | 2015-03-18 | 发那科株式会社 | Control device of injection molding machine |
| CN107632196A (en) * | 2017-06-08 | 2018-01-26 | 浙江科技学院 | A kind of injection machine state recognition and abnormity early warning method |
| CN107818271A (en) * | 2016-09-14 | 2018-03-20 | 国民技术股份有限公司 | Direct fault location analysis method and system based on chip layout |
| CN107942941A (en) * | 2017-11-30 | 2018-04-20 | 海天塑机集团有限公司 | A kind of method and system of injection molding machine and electric turntable interactive signal |
| CN108845550A (en) * | 2018-08-30 | 2018-11-20 | 红塔烟草(集团)有限责任公司 | Production control executes the error protection method of parameter |
| CN109483841A (en) * | 2018-11-01 | 2019-03-19 | 海天塑机集团有限公司 | A kind of method and system that control injection molding machine is intelligently shut down |
| CN112454842A (en) * | 2020-10-15 | 2021-03-09 | 宁波创基机械有限公司 | Remote maintenance method for injection molding machine |
| CN113492503A (en) * | 2020-04-03 | 2021-10-12 | 恩格尔奥地利有限公司 | Method for diagnosing the condition of at least one component of a molding machine |
| CN113655307A (en) * | 2021-07-27 | 2021-11-16 | 珠海格力电器股份有限公司 | Abnormity monitoring method, device and equipment for production equipment and injection molding machine |
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- 2012-12-30 CN CN 201220748376 patent/CN203141798U/en not_active Expired - Lifetime
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104416868A (en) * | 2013-08-27 | 2015-03-18 | 发那科株式会社 | Control device of injection molding machine |
| CN107818271A (en) * | 2016-09-14 | 2018-03-20 | 国民技术股份有限公司 | Direct fault location analysis method and system based on chip layout |
| CN107818271B (en) * | 2016-09-14 | 2023-08-29 | 国民技术股份有限公司 | Fault injection analysis method and system based on chip layout |
| CN107632196A (en) * | 2017-06-08 | 2018-01-26 | 浙江科技学院 | A kind of injection machine state recognition and abnormity early warning method |
| CN107942941A (en) * | 2017-11-30 | 2018-04-20 | 海天塑机集团有限公司 | A kind of method and system of injection molding machine and electric turntable interactive signal |
| CN108845550A (en) * | 2018-08-30 | 2018-11-20 | 红塔烟草(集团)有限责任公司 | Production control executes the error protection method of parameter |
| CN109483841A (en) * | 2018-11-01 | 2019-03-19 | 海天塑机集团有限公司 | A kind of method and system that control injection molding machine is intelligently shut down |
| CN109483841B (en) * | 2018-11-01 | 2020-02-07 | 海天塑机集团有限公司 | Method and system for controlling intelligent shutdown of injection molding machine |
| CN113492503A (en) * | 2020-04-03 | 2021-10-12 | 恩格尔奥地利有限公司 | Method for diagnosing the condition of at least one component of a molding machine |
| CN112454842A (en) * | 2020-10-15 | 2021-03-09 | 宁波创基机械有限公司 | Remote maintenance method for injection molding machine |
| CN113655307A (en) * | 2021-07-27 | 2021-11-16 | 珠海格力电器股份有限公司 | Abnormity monitoring method, device and equipment for production equipment and injection molding machine |
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