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.

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 rouse,dynamics of injection molding machine' sproduct models are analyzed.The performance knowledge is used to support the model evolvement andreuse.The driven factors of mechanical product model are concluded.The dynamic characteristics ofproduct model are described.The.performance knowledge is used to improve specific evolvement process.The upper-layer passing rules are adopted in the mechanical product comfiguration design.The rules ofproduct model evolvement are investigated.And the model evolvement of injection molding machine hasthree levels.Practical and effective realization arithmetic is given to roalize the performance knowledgereuse.Finally,HT1800X1N series injection molding machines are taken as examples to illuminate thatthe arithmetic is correct and practical.

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。

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。

参数快速自适应的电动注塑机的期望补偿自适应鲁棒控制

为了提高电动注塑机模具控制精度和稳定性,首先,针对由齿轮和滚珠丝杆结构组成的模具控制部分,建立了非线性动态模型。随后,提出了一种期望补偿自适应鲁棒控制器(desire compensate adaptive robust control,DCARC)。将参数估计过程和鲁棒控制律的设计分开,以提供更好的参数估计,并引入基于随机梯度下降法的模型补偿项以确保其瞬态性能,实现对其高精度的控制,并同时具备对参数的快速自适应能力。最后,设计了与传统控制器的对比实验,并在电动注塑机上进行了实验。对比实验结果验证了提出的方法具有较高的跟踪性能和较强的参数自适应性。

超声塑化微注射成型技术研究现状及展望

简述了超声塑化中界面摩擦生热、黏弹性生热和空化效应3种生热机理及其研究现状,从超声塑化微注射成型(UPMIM)工艺参数的影响效果和成品性能的影响因素两个角度分析概括了UPMIM工艺的研究现状。介绍了现有UPMIM装置的结构及加工步骤,概括了UPMIM在精密药物输送装置、智能定制植入物和微流控设备等领域的应用研究现状,指出了UPMIM技术大规模工业化生产应用所具有的技术优势和面临的诸多技术挑战,对UPMIM未来的主要研究方向与应用领域进行了总结与展望。

基于模糊解耦策略的小型注塑机料筒温度F-PI复合控制器

在塑料产品的生产过程中,注塑机料筒温度的响应速度和稳定性对最终塑料产品的质量具有重要影响。为了提高小型注塑机料筒温度的控制精度,针对料筒具有的惯性大、非线性、大滞后、强耦合等温度特性,在模糊控制不能满足控制要求的背景下,提出了基于相邻加热段之间温差的模糊解耦策略,通过利用相邻加热段之间的温差信息,建立模糊解耦控制器,对各段料筒之间的温度耦合进行解耦控制。实验结果表明,该控制方法效果良好,达到目标温度所用时间为1092 s,最大超调量只有3%,但稳态性能较差。为解决稳态性能较差的问题,在模糊解耦的基础上建立F-PI复合控制器,通过引入积分环节消除系统在稳态下的偏差。在Matlab/Simulink环境下进行仿真并在注塑机上进行验证,结果表明,F-PI复合控制方法不仅具有良好的动态响应,还具有更高的稳态精度,稳态偏差仅为±1℃。因此基于模糊解耦策略的F-PI复合控制方法不仅能对料筒的温度耦合进行解耦控制,还有效提高了系统的稳定性和控制精度,具有良好的鲁棒性。

基于机器学习与遗传算法的注塑产品工艺参数优化

注塑成型工艺可以高效成型高精度产品,被广泛使用。通过优化注塑产品工艺参数,可以获得更高的表面质量和尺寸精度。为了获得最佳工艺参数组合,设计了基于关键工艺参数组合的极端梯度提升决策树模型。为了解决训练数据不平衡问题,引入尺寸加权修正方法,提高对不合格产品尺寸的预测精度。使用遗传算法对改进极端梯度提升决策树模型以产品尺寸误差最小为目标进行全局寻优,得到最佳工艺参数组合。最佳工艺参数组合为模腔压力39.4 bar、切换压力33.8 bar、射嘴压力49.4 bar、回水温度72.6℃、模温机水流量58.7 cm^(3)/s。

注塑模具高效加工应用研究

注塑模具产品广泛应用于汽车、家电、 3C、玩具、航空航天等日常生产生活中。产品更新换代的周期越来越短。这就迫使产品设计者及生产厂家需要快速适应时代快速发展的节奏。为了提高加工效率,必须研究注塑模具高效加工创新工艺。此次生产实践证明采用深切削,高转速,快进给的方法,以及结合优化好的程序上机加工,可以有效提高加工效率30%以上。可为企业高效生产注塑模模具提供技术参考,为竞赛及培训提供借鉴参考作用。

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.

基于机器视觉的注塑件缺陷检测系统研究

提出并设计了一种基于机器视觉的注塑件焦料杂质缺陷检测系统,通过对多光源非线性自动调光算法的研究,提高了复杂生产环境下注塑件图像采集质量,并经高斯滤波、灰度图像、自适应阈值处理、Canny边缘检测等图像处理技术,可实现注塑件不同检测精度下缺陷检测。经现场测试证明,在1 mm以上缺陷检测精度下,杂质缺陷的召回率为0.918,误检率为0.046,识别速度为每秒30帧,图像处理算法性能稳定,解决了复杂注塑件生产环境下检测精度低、检测效率低的问题。

肥皂盒注射模设计

探讨肥皂盒注射模的设计原理与实践应用。随着塑料工业的快速发展,注射成型技术已成为制造肥皂盒等塑料制品的主要手段。介绍了注射模设计的基本原理,包括模具结构、分型面选择、浇注系统设计、冷却系统设计等关键要素。本次肥皂盒注射模设计方法和具体步骤对相关领域的产品设计提供了一定参考。

盘式制动闸注射模设计

介绍了盘式制动闸塑件的结构特点,分析了盘式制动闸塑件的成型工艺特点,详细阐述了模具结构设计要点,通过模具布局、浇注系统、顶出系统等介绍,进而充分了解此类模具的结构特点。

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.

注塑机注射螺杆熔融段流固耦合分析及优化

针对注塑机螺杆长期受到的高黏度熔融塑料流体挤压发生塑性变形,降低螺杆寿命的问题,以1600 k N注塑机螺杆熔融段为研究对象,进行正交试验分析,在提高螺杆寿命的同时,保证了螺杆注射效率。以螺杆导程、棱宽和槽深为变量,以螺杆熔融段轴向流速、最大等效应力、最大变形以及最大容量为评价指标,经过设计正交试验,运用ANSYS Fluent以一种低密度聚乙烯为塑料流体材料进行单向流固耦合分析。结果表明,当螺杆导程为50 mm、棱宽为3.6 mm、槽深为3 mm时的优化效果最佳,与优化前相比,轴向流速提高了6%,等效应力降低了26%,最大变形降低了18%,最大容量提升了3%。优化后,螺杆等效应力和变形较小,流体轴向流速更快、流体最大容量更高。

注塑机故障诊断技术进展

随着塑料制品在航天军工、交通电子等领域的广泛应用,其几何精度和服役性能的要求在不断提升。注塑机作为塑料成型的主要加工装备,在连续化、快节拍的生产工况下,由于设备关键元件不可避免的磨损、冲击等会导致成型精度下降,进而使得产品出现缺陷。本文综述了注塑机故障诊断技术的发展现状,针对注塑机的故障诊断,从基于数学模型、经验知识和数据驱动三类故障诊断技术总结了当前的研究进展,最后对注塑机故障诊断的发展进行了展望。

注塑机螺杆的逆向重构技术研究

针对注塑机螺杆结构复杂、形状精度要求高、优化设计周期长等问题,运用逆向建模方法,利用Win3D型三维扫描仪及Geomagic Wrap软件采集该注塑机螺杆的点云数据,将其封装为曲面,导入逆向建模软件Geomagic Design X中,高精度创建其三维数字化模型,为注塑机螺杆的优化设计提供高精度模型。经误差分析软件Geomagic Control的检测,注塑机螺杆的逆向模型误差不超过0.02 mm,满足工业设计要求。