TWM626165U - Process stability monitoring and molding quality prediction system applied to batch production equipment - Google Patents

Abstract

This creation provides a process stability monitoring and molding quality prediction system applied to batch production equipment. The system will read and store the setting data of each molding and processing parameters of the batch molding equipment during the production and processing process and each molding process. The corresponding response data can be compared between the response data of each molding process and the set value of the molding process conditions. This system can be used to monitor the stability of the production process and predict the quality of the produced products.

Description

A process stability monitoring and molding quality prediction system applied to batch production equipment

This creation is a process stability monitoring and molding quality prediction system applied to batch production equipment, especially a system with analysis, comparison, fitting, calculation, and optimization program, which can be used for batch or continuous molding production process. , One of the characteristics of plastic materials and molding parameters is applied to the process stability monitoring and molding quality prediction system of batch production equipment.

The forming mold is assembled or assembled on the batch production equipment, and then batch-type continuous processing and production can be carried out. The power system and drive system of the equipment will be activated according to the input molding processing conditions to achieve the set molding processing conditions. Since each batch molding equipment has different equipment specifications and is equipped with different drive systems, the performance results of the power drive of the batch molding equipment will also be different. Therefore, when the batch processing production equipment is processed according to the set molding parameters It is driven by the equipment system to complete the batch periodic processing production. The actual processing conditions of the final production product are the forming processing condition states displayed by the response of the batch processing production equipment, and the forming processing conditions of this response are the same as the set forming conditions. There will be some differences between the processing conditions.

Among the production and processing conditions set by the batch processing production equipment, the more important processing condition parameters include the processing temperature setting of the plasticizing material tube, the setting conditions of the plasticizing screw speed and back pressure, the single-stage or multi-stage injection speed, and the multi-stage speed switching. position, injection pressure, single-stage or multi-stage holding pressure, single-stage or multi-stage holding time, etc. The molding die is continuously produced on batch production equipment, and the power drive system of the equipment is started and controlled by the set processing condition parameters, so that the production equipment can execute and achieve the set processing parameters. Therefore, in the batch processing and production of forming molds, in addition to the molding condition parameters (or "setting state of forming processing parameters") input on the controller, what needs to be paid attention to on the batch production equipment is the batch type. The actual correspondence of the production equipment responds to the parameters of the molding and processing conditions (or "the response state of the molding processing parameters").

Processing and production on different batch production equipment under the same molding setting conditions will result in different product quality. The quality of the produced product is determined by the actual drive of the production equipment in response to the processing conditions. Moreover, when batch-type production equipment is used to process a whole batch of products, although the molding processing conditions set for processing and production have not changed, in fact, the actual response condition of batch-type production equipment in each mold production will still be due to production. The difference between the mode and the mode occurs due to the change of the environmental impact factor. This phenomenon can generally be used to Judge the stability of batch production equipment in molding processing. When continuous production is carried out without changing the molding setting conditions, the degree of difference in the actual response state of each mold production of batch production equipment can be used to judge the production stability and product quality of batch processing equipment. stability. The new patent is to detect, measure, record, capture and store and compare the actual response molding conditions of each cycle of molding production in the continuous production process of batch production equipment, these conditions include speed, pressure, position, etc. Detect and capture data or change the response data measured in the process, and judge the stability of the continuous processing molding production process through data comparison or data statistics, calculation and analysis, which can be used as a production equipment in the molding process. A means of process stability monitoring during production. It can also be used to determine the stability of the product quality produced, or to predict whether the product quality can reach the required standard in the continuous production process.

In the process of batch molding production process, in order to effectively control and manage the consistency and stability of product quality, so that the products produced in each mold can meet the required product specifications, the most important work is to be able to observe Or check the actual molding processing status of each mold production. Using a set of forming processing parameters of batch forming processing equipment and a measurement and detection recording system corresponding to the corresponding processing parameters, the setting values of forming processing parameters and the response status data of actual equipment-driven forming processing can be detected and measured. , record, retrieve and save. Therefore, when batch continuous processing is carried out for batch molding equipment, the molding processing condition setting data of each mold and the response processing parameter data and response processing line graph data for processing by the equipment will be continuously obtained during the processing. Mainly contains speed line graph, pressure line graph, position line graph, etc.). The acquisition, detection, measurement, collection, recording, etc. of the response processing parameter data and response processing line graph data in the above-mentioned molding process can be done by the batch molding equipment's own controller or recorder, or by using externally installed equipment. Data collectors, image capture devices, IOM machine networking set-top boxes, data detection components, data connection devices with OPC UA communication protocol and other devices to obtain molding data.

Generally, the molding and processing conditions given by the commissioning and testing of batch production equipment or manufacturing in traditional processing sites are set by experienced commissioning personnel or equipment operators according to experience or self-judgment. However, due to differences in experience and personal cognitive factors, the set molding processing conditions may not be able to produce high-quality products in time, or it may take a lot of time to adjust the processing conditions. Most of the equipment does not have the function of providing the initial scientific trial and production and processing conditions of batch production equipment in a very short period of time, and cannot help reduce the time spent on confirming production conditions by trial and error on the processing site. This authoring system provides data and line graph detection, access, statistics, management, and optimization and modification suggestions for molding processing parameters and equipment response parameters other than the original equipment functions for such equipment.

In view of the above-mentioned creative background, in order to meet the special needs of the industry, the present invention provides a process stability monitoring and molding quality prediction system applied to batch production equipment to solve the above-mentioned problems that traditional techniques cannot achieve.

One of the purposes of this creation is to use the above-mentioned detected, measured, captured, and recorded molding parameters and data to compare with each other to understand the equipment drive of the molding equipment during the production process in each molding process. Variation and stability of the response to processing conditions. It is also possible to use the recorded molding processing parameter data of each mold response or the corresponding processing condition line graph (such as speed line graph, pressure line graph, stroke position line graph, etc.) The comparison can be used to monitor the stability of the processing process by using the specific parameter data of each mold processing or the mutual comparison results of the molding process history curve. Once the comparison data have obvious differences, or the difference degree of the comparison parameters deduced by numerical calculation method is larger than the allowable value, it can be judged that the continuous production process carried out has unacceptable instability; this production process stability The frequency of data comparison or the timing of the data comparison monitoring program can be compared every time, or it can be compared every five or ten times. In addition, the results of data comparison can not only monitor the stability of the molding process, but also relate the comparison results to the stability of product quality. If the important response parameters of the molding process have obvious variations, it can be determined that this condition The quality of the produced products will also vary, so it is also possible to predict and control the product quality by comparing the specific parameter data of each mold production process or the comparison results of the molding process curve and the corresponding data of the standard product. After the comparison, it can be determined whether the product quality is good or bad. If the product is compared on the production line every time the product is produced, immediate product quality control on the production line can be carried out.

Please refer to Figure 2, one of the purposes of this creation, to provide a batch of A data comparison system for forming and processing parameters of secondary forming processing equipment. This data comparison system will read and store the setting data of each forming processing parameter of batch forming processing equipment in the production and processing process and the corresponding response of each mould. Processing parameter data or response line graph data, the data comparison system can carry out each molding process response data or response line graph and molding processing condition setting values through the stored big data statistical distribution calculation program and custom mathematical operation program. The comparison between the different stability parameters and the difference correlation between the parameters were analyzed. In the continuous production process, if the product quality has met the requirements, the corresponding molding response processing parameter data or response processing line graph data corresponding to this product can be set as standardized molding conditions, and the corresponding specific processing parameter data can be regarded as standard values. , as long as the driving conditions of the batch processing equipment are consistent with the standardized molding response conditions during the processing, the quality of the produced products will also meet the requirements and be consistent. When the response molding data of a certain mold or the response processing line graph and the standardized molding conditions do not match or have obvious differences during the molding process, it can detect the process status instability in the production process and the production process. The quality of the product may not meet the specifications. Using this production parameter and molding condition data comparison system can be used to monitor the stability of the production process and predict the quality of the produced products.

The parameter setting of the molding processing conditions of the batch molding processing equipment. In the batch molding processing process or the injection molding processing production program, when the mold is completed, it is assembled on the batch production equipment (such as the injection molding machine) When doing batch-type continuous processing production. The batch production equipment must first be shaped The parameter setting of processing conditions, the parameters of forming processing conditions mainly include the setting of the material tube temperature condition of the forming processing equipment, the setting of the mold temperature condition, the parameter setting of the multi-stage shooting speed conditions and the shooting speed switching position in the filling stage, and the holding pressure in the holding pressure stage. Parameter settings such as numerical value and holding time, cooling time, molding cycle time, etc. The controller or control panel of the batch production equipment will input values according to the set processing conditions, and drive the equipment to form the operation to carry out continuous periodic processing production.

The batch-type molding and processing equipment corresponds to the actual processing condition response of the set value of the molding and processing conditions. The batch-type molding and processing equipment drives the equipment according to the set molding and processing condition parameters, which will generate the actual equipment response of each cycle of batch production. Processing conditions. Although the molding parameters set in each batch production process are fixed, the actual equipment response processing conditions of each cycle will vary according to the actual production conditions. For example, the actual response of the injection speed condition in the filling stage or the actual response of the holding pressure in the holding pressure stage to the holding pressure change, that is, the actual driving speed and pressure of the equipment or the screw position during the molding process. The actual change state of the history, the actual collected data of each period (or each mold) molding parameter change can display the actual response speed curve and pressure curve of the molding equipment or the change of screw position with time.

Because the mechanical specifications or drive systems of each batch forming processing equipment are different, and the service life of the equipment, the degree of wear and tear of the old and new equipment, and the changes and changes in the actual processing and production environmental conditions, etc. The drive response performance of batch forming processing equipment is also different. When the set value of the batch processing equipment's molding processing condition parameters is given, start the equipment for batch or continuous periodic molding, and respond to the data or response speed, pressure, position, etc. of the equipment for each cycle of periodic molding Detect, measure, collect and record corresponding parameter data or response line graph. The response data or response line graph of the processing and molding can be obtained by the built-in data acquisition device of the batch molding processing equipment, or an externally installed data acquisition device, or an external response line graph acquisition device, or a line graph. An image capture device, or an Internet device, or an online data acquisition device, or a data acquisition device conforming to the OPC UA communication framework, etc., are used to collect and obtain the response data of the molding processing equipment.

For batch-type continuous molding and production in batch-type molding equipment, the equipment's molding performance status measurement or data acquisition and recording can be used to perform full mold times (the entire molding process) or specific mold times (in the molding process). Molding processing response data and response line graph detection, measurement, collection and recording of specific time and mold collection data). The data stored in these measurements or records or the response line graph information of molding processing can be used for quick calculation and numerical comparison by means of statistical or numerical calculation during or after the production and processing. It is also possible to use comparison or calculation statistical results to manage and adjust product quality or the stability of production and processing parameters during or after production and processing.

Using these recorded processing and production condition response parameters and response data, it is possible to compare with each other to understand the difference in the response processing conditions driven by the equipment during each molding process of the molding equipment during the production process. can also Use the recorded molding processing parameter data or corresponding processing condition line graphs (such as speed graph, pressure graph, stroke position graph, etc.) For comparison, once there is an obvious difference under the comparison, numerical calculation methods (including differential calculation, discrete mathematical calculation, heterodyne and inner difference evaluation calculation, etc.) can be used to deduce the degree of difference and numerical display.

Common processing parameters that can be used for data comparison in the molding processing parameter data, including molding cycle time, injection filling time, VP switching position, VP switching point injection pressure value, minimum buffer position, injection pressure peak pressure value, plasticization start position , plasticizing end position, actual injection speed response value, injection speed response line graph, injection pressure response line graph, injection stroke response line graph, etc., through the comparison of the response data of the molding parameters, the direct data can be used to make Graphic method, statistical drawing and calculation method, numerical analysis method, standard deviation calculation method, etc. to display the results of data comparison. From the comparative analysis results, the stability monitoring of the molding process and the online monitoring and prediction of product quality can be carried out.

Normalized corresponding response process parameter data or response process line graphs may be assigned corresponding to molded product quality. For example, in the continuous production process, if the product quality has met the requirements, the corresponding molding response processing parameter data or response processing line graph data corresponding to this product can be set as the standardized molding conditions. When the data of the processing parameters or the corresponding processing line graph data collected in the continuous processing production process can be compared with the standardized data, if there are obvious differences in the comparison of the data of some molding processing parameters, the data can be analyzed by data analysis. with numerical methods (Including differential calculation, discrete mathematical calculation, evaluation calculation of heterodyne and inner difference, etc.) The degree of calculation difference is derived to determine the degree of process stability and product quality consistency.

One objective of the present invention is to provide a process stability monitoring and molding quality prediction system applied to batch production equipment, comprising: at least one electronic computer, and at least one external electronic device, wherein the electronic computer receives calculation data to The network connection method is transmitted to the external electronic device, and provided by the external electronic device for use by the administrator.

According to another aspect of the present invention, the process stability monitoring and molding quality prediction system applied to batch production equipment can perform a process stability monitoring and molding quality prediction program, and the process stability monitoring and molding quality prediction program further includes The following procedures: carry out a parameter setting procedure for the molding processing conditions of a batch of production equipment, then carry out a batch-type molding processing equipment corresponding to the actual processing condition response program of the molding processing condition setting value, and then carry out a collection of the response data of the forming processing equipment And the acquisition program, the molding equipment responds to the data collection and acquisition program followed by a continuous production process stability monitoring program, and the molding equipment responds to the data collection and acquisition program followed by a continuous production product quality monitoring program.

According to another aspect of the present invention, the continuous production process stability monitoring program further includes the following program: performing a program for inputting process stability standard reference values, and then performing a data comparison process for data collection and response obtained by a molding equipment Stability standard reference value program, and then carry out an output process to stabilize Qualitative state program.

According to another aspect of the present invention, the continuous production product quality monitoring program further includes the following program: performing a program for inputting production product quality monitoring values, and then performing a molding processing device to collect and obtain response data to compare the production product quality Monitor the value program, and then carry out a program to output the quality status of the production product.

100: Process stability monitoring and molding quality prediction system applied to batch production equipment

110: External Electronics

120: Electronic Computers

200: Process stability monitoring and molding quality prediction program

210: Parameter setting procedure for batch production equipment molding processing conditions

220: The actual processing condition response program of the batch type forming processing equipment corresponding to the setting value of the forming processing conditions

230: Forming and processing equipment response data collection and acquisition program

240: Continuous production process stability monitoring program

250: Quality Control Procedures for Continuous Production Products

241: Input process stability standard reference value program

242: Comparing process stability standard reference value program with data collected and obtained by forming processing equipment

243: Output process stability state program

251: Input production product quality monitoring value program

252: Forming and processing equipment collects and obtains response data to compare production products Quality Control Value Program

253: Output production product quality status program

[Picture 1] This is a block diagram of the process stability monitoring and molding quality prediction system applied to batch production equipment.

[Picture 2] The flow chart of the process stability monitoring and molding quality prediction of this creation applied to batch production equipment.

[Picture 3] Schematic diagram of the process of stability monitoring and molding quality prediction in this creative process.

[Picture 4] A schematic diagram of the stability monitoring program of the continuous production process of this creation.

[Picture 5] A schematic diagram of the quality monitoring program of the continuous production product of this creation.

The direction of the present invention discussed here is a process stability monitoring and molding quality prediction system applied to batch production equipment. In order to thoroughly understand the present invention, the detailed structure, its components and method steps will be proposed in the following description. . Obviously, the implementation of the present invention is not limited to the special features familiar to those skilled in the art of process stability monitoring and molding quality prediction systems applied to batch production equipment. special details. In other instances, well-known structures and elements thereof have not been described in detail to avoid unnecessarily limiting the invention. In addition, in order to provide a clearer description and enable those skilled in the art to understand the creative content of the present invention, the various parts in the drawings are not drawn according to their relative dimensions, and the ratio of certain dimensions to other relative dimensions will be highlighted However, it is exaggerated, and irrelevant details are not completely drawn for the sake of simplicity. The preferred embodiments of the present invention will be described in detail as follows, but in addition to these detailed descriptions, the present invention can also be widely implemented in other embodiments, and the scope of the present invention is not limited, and the following patent scope shall prevail.

Please refer to FIG. 1 , the present invention is an embodiment of a process stability monitoring and molding quality prediction system 100 applied to batch production equipment, and the process stability monitoring and molding quality prediction system 100 applied to batch production equipment , which mainly includes: at least one external electronic device 110 and an electronic computer 120 .

As described above, the process stability monitoring and molding quality prediction system 100 applied to batch production equipment, wherein the electronic computer 120 transmits the data received and calculated to the external electronic device 110 in a wired or wireless manner, and the external electronic device 110 provides a manager use.

Please refer to FIG. 3 , as described above in the process stability monitoring and molding quality prediction system 100 applied to batch production equipment, a process stability monitoring and molding quality prediction program 200 is performed, and processing parameters and molding parameters are received by the electronic computer 120 . Responds to processing status. As mentioned above, the process stability monitoring and molding quality prediction program 200 further includes the following program: first, perform molding processing of a batch of production equipment The parameter setting program 210 of the conditions is followed by a batch-type molding equipment corresponding to the actual processing condition response program 220 of the molding condition setting value, followed by a molding equipment response data collection and acquisition program 230, the molding equipment responds The data collection and acquisition program 230 is followed by a continuous production process stability monitoring program 240 , and the molding equipment responds to the data collection and acquisition program 230 followed by a continuous production product quality monitoring program 250 . The parameter setting program 210 for batch production equipment to perform molding processing conditions is used to set parameters for batch production equipment to perform molding processing conditions. , Multi-stage firing rate conditions in the filling stage and parameter setting of the firing rate switching position, parameter settings such as the holding pressure value and holding time in the holding pressure stage, cooling time, molding cycle time, etc. The actual processing condition response program 220 of the batch-type forming and processing equipment corresponding to the set value of the forming and processing conditions is for the batch-type forming and processing equipment to drive the equipment according to the set parameters of the forming and processing conditions, and a batch production cycle of each cycle will be generated. The actual equipment responds to the processing conditions. Although the molding parameters set in each batch production process are fixed, the actual equipment response processing conditions of each cycle will vary according to the actual production conditions. The collection and acquisition program 230 of the response data of the molding processing equipment is used to shape the response data or the response line graph, through the built-in data acquisition device of the batch molding processing equipment, or the externally installed data acquisition device , or an additional response line graph acquisition device, or a line graph image capture device, or an Internet device, or an online data acquisition device, or a data acquisition device that conforms to the OPC UA communication framework. According to the collection device, etc., to collect. The continuous production process stability monitoring program 240 is used to monitor the production process stability. The continuous production product quality monitoring program 250 is used to monitor the production product quality.

Please refer to FIG. 4. As shown in the above-mentioned continuous production process stability monitoring program 240, the following program is further included: performing an input process stability standard reference value program 241, and then performing a data comparison between the data collected by the molding equipment and the obtained response The process stability standard reference value process 242 is followed by an output process stability state process 243 . The input process stability standard reference value program 241 is used for inputting the process stability standard reference value into the electronic computer 120 , and the molding processing equipment collects and obtains the response data and compares the process stability standard reference value program 242 for the molding process. The data collected and obtained by the processing equipment are compared with the process stability standard reference value, and the output process stability state program 243 is used to compare the data collected and obtained by the molding equipment with the process stability standard reference value program 242. result output.

Please refer to FIG. 5. As shown in the above-mentioned continuous production product quality monitoring program 250, the following procedures are further included: performing a program 251 for inputting production product quality monitoring values, and then performing a molding processing equipment to collect and obtain the response data to compare the production products The quality monitoring value program 252 then performs an output production product quality status program 253 . The program 251 for inputting the production product quality monitoring value is used to enter the production product quality monitoring value into the electronic computer 120, and the molding processing equipment collects and obtains the corresponding data to compare the production product quality monitoring value program 252. Obtain response data and production product quality monitoring values The program 253 for comparing and outputting the quality status of the produced product is the result output of the program 252 for comparing the data collected by the molding equipment and the response obtained with the produced product quality monitoring value program 252 .

100: Process stability monitoring and molding quality prediction system applied to batch production equipment

110: External Electronics

120: Electronic Computers

Claims (4)

A process stability monitoring and molding quality prediction system applied to batch production equipment, comprising: At least one electronic computer and at least one external electronic device, wherein the one electronic computer transmits the data received and calculated to the external electronic device by means of a network connection, and is provided by the external electronic device for the administrator to use. According to the process stability monitoring and molding quality prediction system applied to batch production equipment as described in claim 1, a process stability monitoring and molding quality prediction program can be performed, and the process stability monitoring and molding quality prediction program further includes the following procedures: A batch production equipment parameter setting program for molding processing conditions, followed by a batch molding processing equipment response program corresponding to the actual processing conditions set value of the molding processing conditions, followed by a molding processing equipment response data collection and acquisition program, After the collection and acquisition procedure of the response data of the forming processing equipment, a continuous production process stability monitoring procedure is carried out. After the gathering and acquisition procedure of the response data of the forming processing equipment, a continuous production product quality monitoring procedure is carried out. The process stability monitoring and molding quality prediction system applied to batch production equipment as described in claim 2, wherein the continuous production process stability monitoring program further includes the following program: performing a program for inputting process stability standard reference values, and then A procedure for comparing the process stability standard reference value with the data collected and obtained by the forming processing equipment is carried out, and then a procedure for outputting the process stability status is carried out. The process stability monitoring and molding quality prediction system applied to batch production equipment as described in claim 2, wherein the continuous production product quality monitoring program further includes the following program: performing a program for inputting production product quality monitoring values, and then performing a The molding processing equipment collects and obtains the response data and compares the production product quality monitoring value program, and then performs an output production product quality status program.

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