Structural Scheme Optimization Design for the Stationary Platen of a Precision Plastic Injection Molding Machine

The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine.

Nonlinear Modeling of a High Precision Servo Injection Molding Machine Including Novel Molding Approach

A nonlinear mathematical model of the injection molding process for electrohydraulic servo injection molding machine (IMM) is developed.It was found necessary to consider the characteristics of asymmetric cylinder for electrohydraulic servo IMM.The model is based on the dynamics of the machine including servo valve,asymmetric cylinder and screw,and the non-Newtonian flow behavior of polymer melt in injection molding is also considered.The performance of the model was evaluated based on novel approach of molding - injection and compress molding,and the results of simulation and experimental data demonstrate the effectiveness of the model.

Hydraulic cylinder control of injection molding machine based on differential evolution fractional order PID

Injection molding machine,hydraulic elevator,speed actuators belong to variable speed pump control cylinder system.Because variable speed pump control cylinder system is a nonlinear hydraulic system,it has some problems such as response lag and poor steady-state accuracy.To solve these problems,for the hydraulic cylinder of injection molding machine driven by the servo motor,a fractional order proportion-integration-diferentiation(FOPID)control strategy is proposed to realize the speed tracking control.Combined with the adaptive differential evolution algorithm,FOPID control strategy is used to determine the parameters of controller on line based on the test on the servo-motor-driven gear-pump-controlled hydraulic cylinder injection molding machine.Then the slef-adaptive differential evolution fractional order PID controller(SADE-FOPID)model of variable speed pump-controlled hydraulic cylinder is established in the test system with simulated loading.The simulation results show that compared with the classical PID control,the FOPID has better steady-state accuracy and fast response when the control parameters are optimized by the adaptive differential evolution algorithm.Experimental results show that SADE-FOPID control strategy is effective and feasible,and has good anti-load disturbance performance.

IMPROVE THE KINETIC PERFORMANCE OF THE PUMP CONTROLLED CLAMPING UNIT IN PLASTIC INJECTION MOLDING MACHINE WITH ADAPTIVE CONTROL STRATEGY

The kinetic characteristics of the clamping unit of plastic injection molding machine that is controlled by close loop with newly developed double speed variable pump unit are investigated. Considering the wide variation of the cylinder equivalent mass caused by the transmission ratio of clamping unit and the severe instantaneous impact force acted on the cylinder during the mold closing and opening process, an adaptive control principle of parameter and structure is proposed to improve its kinetic performance. The adaptive correlation between the acceleration feedback gain and the variable mass is derived. The pressure differential feedback is introduced to improve the dynamic performance in the case of small inertia and heavy impact load. The adaptation of sum pressure to load is used to reduce the energy loss of the system. The research results are verified by the simulation and experiment, The investigation method and the conclusions are also suitable for the differential cylinder system controlled by the traditional servo pump unit.

Kansei Engineering Applied to the Form Design of Injection Molding Machines

This study investigated the relationship between a subject’s evaluation of injection molding machines (IMMs) and formal design features using Kansei engineering. This investigation used 12 word pairs to evaluate the IMM configurations and employed the semantic differential method to explore the perception of 60 interviewees of 12 examples. The relationship between product feature design and corresponding words was derived by multiple regression analysis. Factor analysis reveals that the 12 examples can be categorized as two styles—advanced style and succinct style. For the advanced style, an IMM should use a rectangular form for the clamping-unit cover and a full-cover for the injection-unit. For the succinct style, the IMM configuration should use a beveled form for the safety cover and a vertical rectangular form for the clamping-unit cover. Quantitative data and suggested guidelines for the relationship between design features and interviewee evaluations are useful to product designers when formulating design strategies.

Model evolvement and reuse technology of injection molding machine based on performance knowledge

To illuminate the necessity of model evolvement and reuse, dynamics of injection molding machine＇s product models are analyzed. The performance knowledge is used to support the model evolvement and reuse. The driven factors of mechanical product model are concluded. The dynamic characteristics of reuse. Finally, HT1800X1N series injection molding machines are taken as examples to illuminate that the arithmetic is correct and practical.

基于Moldflow的汽车牌照灯护板注塑模拟与成型缺陷的分析

以汽车外饰件牌照灯护板为研究对象,利用Moldflow软件,对其注射成型过程进行模拟;针对分析结果预测可能出现的成型缺陷并提出相应的优化措施,找出最佳方案,最后将结果应用于该牌照灯护板的模具型腔设计。经验证表明,Moldflow在设计阶段可以找出未来产品可能出现的缺陷,通过优化产品结构、模具设计和注塑工艺参数,提高一次试模成功率,从而降低生产成本,提高生产效率。

基于UG和Moldflow的塑料外壳注塑模具设计与数控加工

以某塑料外壳为例,采用Moldflow软件进行注塑成型分析,得到了优化的浇注系统和冷却系统,并对塑件翘曲变形进行比较分析,获得了最优工艺参数。应用UG Moldwizard模块进行注塑模设计,并利用UG CAM模块对模具型腔进行数控加工工艺分析、生成刀路轨迹仿真并进行联机加工。该方法实现了模具CAD/CAE/CAM的一体化设计,缩短了开发周期,改善了塑件质量,对指导企业生产有一定的实用价值。

基于PROFIBUS的注塑机网络控制系统

针对注塑成型行业发展趋势,采用PLC加PC机的监控站模式,以PLC为1类主站,PC机为2类主站,现场设备及从站接口电路一起构成智能从站,应用PROFIBUS现场总线把PC机与现场注塑机连接起来,构建注塑机网络控制系统。采用单片机加协议芯片方式开发PROFIBUS-DP从站接口电路,使注塑机能够连入整个PROFIBUS总线网络,实现生产管理与过程控制的信息化。

基于Moldflow的塑料齿轮四板模设计

采用Moldflow Plastic Insight(MPI)软件对一模两腔塑料齿轮的填充过程进行模拟分析,得到填充不平衡的原因,并采用两级点浇口浇注系统解决了填充的不平衡,最后根据分析结果设计了塑料齿轮四板模并阐述了模具的开模过程。

基于UG和MoldFlow的卷发机外壳注塑模设计与数控加工

采用MoldFlow软件对卷发机外壳注塑模进行工艺分析,得到最佳浇口位置及最佳工艺参数,并运用UG Mold-Wizard模块设计其注塑模。利用UG/CAM模块分析该模具型腔的数控加工工艺,生成刀具加工轨迹并进行加工过程仿真,生成数控程序,从而实现了模具设计与制造的一体化。

基于MoldFlow的洗衣机上面板浇注系统优化设计

以洗衣机上面板为研究对象,结合塑件和模具结构特点,建立了2种不同的顺序针阀式热流道转冷流道潜入式进浇浇注方案,并运用MoldFlow进行了注射成型模拟分析,通过分析结果确定了最终的浇注系统方案.经试模生产,塑件质量良好,表明采用MoldFlow技术能有效改善塑件成型质量,提高生产效率.

Moldflow在键盘面板成型中的应用

分析了键盘面板的结构特点,使用Moldflow软件对注塑件的成型过程进行CAE分析,确定浇口数量及位置,并预测可能出现的翘曲、气孔和熔接痕等缺陷。结果表明,通过CAE模拟计算,可有效地消除产品设计、模具设计及产品制造成型过程中可能出现的不足,取代传统的反复试模、修模等过程,从而降低产品制造成本,缩短产品开发周期。

基于Moldflow的打印机上盖制件注塑成型翘曲变形分析

以平板型薄壁注塑制件打印机上盖为研究对象,应用CAE软件Moldflow与正交试验相结合的方法,找出对平板型薄壁制件在注塑成型优化方面最重要的工艺参数。正交试验证明:对平板型注塑件而言,熔体温度和保压压力是其成型过程中影响翘曲变形的两个最重要的工艺参数。

Model predictive control of servo motor driven constant pump hydraulic system in injection molding process based on neurodynamic optimization

In view of the high energy consumption and low response speed of the traditional hydraulic system for an injection molding machine,a servo motor driven constant pump hydraulic system is designed for a precision injection molding process,which uses a servo motor,a constant pump,and a pressure sensor,instead of a common motor,a constant pump,a pressure proportion valve,and a flow proportion valve.A model predictive control strategy based on neurodynamic optimization is proposed to control this new hydraulic system in the injection molding process.Simulation results showed that this control method has good control precision and quick response.

基于Moldflow软件对塑壳断路器盖板翘曲变形的研究

为解决塑壳断路器盖板在注塑成型过程中常发生的翘曲变形的问题,利用Moldflow软件对盖板进行模拟,从充填、冷却和翘曲3个方面进行合理的分析,从而找出盖板翘曲变形的主要原因。再针对性地采取不同的优化方案对盖板的成型效果进行验证,分析不同的优化方案对盖板翘曲的变形量,从而确定最合理的方案以解决该类产品的缺陷问题。这为技术人员在解决类似盖板翘曲的问题上提供了一定的借鉴。

基于ProfiBus的注射成形机网络控制系统设计

介绍了应用PLC和PC的网络监控系统,PLC作为1类主站,PC机作为2类主站,应用ProfiBus-DP现场总线把监控站与现场设备连接起来构成注射成形机网络控制系统,并开发出能使不具备ProfiBus接口的检测及执行部件连入ProfiBus网络的硬件接口电路及相应接口程序。该系统结构简单、设计灵活、成本低。

汽车激光雷达盖板的双色注塑模具设计

根据某车型激光雷达盖板的双色结构及形状,采用动模型芯旋转式结构的模具方案,设计了一套一出二的热流道双色注塑模具。利用Moldflow软件进行了双色成型分析,双色注塑第一次注射成型透明的PMMA材料的产品,第二次注射成型黑色ASA材料的产品。为实现该双色产品的结构成型,在定模处设计了2组不同结构的型腔,在动模处设计了2组左右对称的型芯,并且,在型芯侧设计了双斜导柱抽芯机构,冷却系统设计为“直通式+隔水片”的随形循环水路;顶出系统设计为2组独立的液压油缸,在产品顶出取件中,第一次注射成型的PMMA产品不顶出,第二次注射成型的ASA材料的产品采用“直顶+斜顶”的组合机构将双色产品推出,最终通过机械手完成产品的取件。实践生产证明了该双色模具结构合理、运行稳定、成型的双色塑件表面无缺陷。

打印机滚筒导板多点浇口注塑模设计

针对打印机滚筒导板塑件的工业设计结构特点及使用改性合金聚碳酸酯/丙烯腈-丁二烯-苯乙烯塑料成型的生产要求,设计了一副多点点浇口三板模具用于该塑件的注射成型。模具中的模腔布局为一模一腔,以使塑件成型精度控制在MT3~4级。不同于常规三板模具,在该模具中采取了以下设计措施来保证塑件的成型要求:一是通过主导柱、副导柱、模仁定位锥台等的设置,保证了塑件基本成型尺寸的成型精度;二是通过增加镶件排气措施、优化注射成型工艺参数等措施,有效降低和控制了塑件成型后的变形量,保证了塑件的成型形状精度,所增设的成型镶件有益于模腔排气,镶件间隙小于0.02 mm,镶件设计时须设计孔边扩距为1 mm,以降低镶件配模难度,避免镶件间隙飞边发生;三是为提高流道废料和塑件的冷却效率,脱料板中开设有2条?10 mm冷却水路,模腔成型件中开设有10条?10 mm冷却水路。模具中还设置了2个斜导柱滑块侧抽芯机构用于塑件两侧端面的脱模,塑件的最终脱模由多根顶针均衡顶出脱模。

基于STM32的动态注塑信号调节器设计

文中设计了一种基于STM32芯片与UCOSIII操作系统的动态注塑信号调节器。采用DDS芯片AD9833与数字电位器MCP41010配合实现了P/Q信号的发生与调幅;采用运算放大器OP07组成的加法器实现P/Q振动信号与P/Q静态信号的合成;基于RS485接口与Modbus通讯协议实现动态注塑信号调节器与上位机的实时通讯;基于emWin图形库设计了人机交互界面,可以在触摸屏上设定选定注塑参数。试验测试表明:动态注塑信号调节器能够根据上位机反馈的通讯信息在不同工序下输出不同波形、频率与幅值的P/Q动态注塑信号,满足泵控液压激振系统与动态注塑的应用需求。