注塑機集成模具冷卻系統開發

0 背景

注塑成型係一種高效到極嘅塑料，材料浪費好少

加工方法. 呢種加工方法可以加工形狀複雜嘅產品, 精確嘅尺寸或插入零件, 生產效率高，易於實現自動化生產. 注塑機主要生產設備, 注塑機完成一個注塑周期大致可分為以下步驟: 合模, 增塑, 注塑, 保壓壓力, 冷卻, 開模, 排出物, 所以往復.

(1) 模具冷卻對配料周期嘅影響.

機器嘅冷卻時間由保溫階段開始，到模具打開時結束. 在每個批處理周期期間, 冷卻時間佔比 1 / 2 整個周期. 注塑成型中嘅配料周期對生產效率和設備利用率有直接影響. 因此, 為咗提高效率, 首先要考慮嘅係佔成個循環好大比例嘅冷卻時間. 研究表明，良好嘅冷卻系統設計和控制可以減少大約 20% 冷卻時間.

(2) 模具冷卻對注塑質量嘅影響

模具冷卻不僅影響配料周期, 都影響注射產品嘅質素. 塑料製品嘅評價主要有三個方面, 首先係外觀質素, 包括誠信, 顏色, 光等; 二係尺寸同相對位置嘅精度; 三係物理, 與用途相對應的化學和電氣性能. 三個屬性直接関係到成型過程中嘅模具溫度.

1. 表面質素. 過低的模具溫度會使產品輪廓不清晰，產生明顯的熔合線, 改善表面粗糙度.
2. 尺寸精度. 保持模具溫度恆定可以減少成型收縮率的波動，提高產品尺寸精度的穩定性.
3. 機械性能. 如果冷卻系統嘅溫度設置合理, 內部溫度場將得到有效改善, 機械性能將得到增強，同時降低塑料部件中嘅應力.

1 注塑機模具冷卻嘅現狀表明，模具冷卻喺注塑成型中起著非常重要的作用.

作為成型生產嘅核心設備, 注塑機應詳細監控工藝重要環節. 然而, 與成型工藝嘅其他參數相比, 模具冷卻嘅過程監控經常被忽視. 現時, 注塑機生產工藝參數 (如注射速度, 保壓比, 氣缸溫度, 等。) 具有準確的檢測, 及時反饋和過程數據存儲, 然而, 模具冷卻過程仍處於無監控或人工監控狀態.

現時, 大多數注塑機設備模具冷卻一般有兩種方形.

(1) 把水分離塊安裝喺注塑機嘅糢闆上, 如圖所示 1.

(2) 在注塑機外圍安裝機械流量調節器, 如圖所示 2.

1.1 安裝喺注塑機糢闆上嘅水分離塊具有管道佈置簡單清潔嘅優點, 只有總進水和模具冷卻的主回水管連接到水分離塊, 然後將引水塊各分支嘅配水閥連接到模具嘅冷卻水上.

連接. 這樣, 支路短，壓力損失細. 然而, 這樣就無法測量水嘅流量同溫度, 並且無法知道模具嘅冷卻水是否正常連接以及水是否堵塞. 而喺生產過程中如果模具溫度機出現故障或供水管道上嘅閥門誤操作等埋, 注塑機感應不到. 另外, 隨著生產時間長, 模具中嘅冷卻管道會產生水垢, 水銹等, 不僅影響水流量, 而且重形成咗一種隔熱層, 影響傳熱效率. 此時, 會導致產品缺陷, 並且可能生產咗好多有缺陷嘅產品, 造成損失. 1.2 在注塑機外圍安裝機械流量調節器

流量調節器集成了浮子流量指示和指針溫度計. 由模具冷卻嘅總進水同回水連接到流量調節器, 流量調節器嘅每個分支都有一個流量指示同一個溫度計. 帶流量同溫度指示, 有效避免模具安裝初期的水路誤差, 並且可以及時發現成型生產過程中嘅水路障礙.

然而, 因為流量調節器嘅咪錶係機械嘅, 為方便設備管理員查看, 流量調節器只能安裝喺機器周圍人們易睇到嘅地方. 流量調節器嘅分支越多, 所需嘅安裝空間越大. 講真, 隨著模具設計越嚟越精細, 模具上嘅冷卻分支增加緊. 流量調節器需要一根長支管把注塑機周邊支線嘅出入口連接到模具. 特別係喺移動糢闆側面嘅模具上, 連接嘅長度將好長. 因為注塑電動糢闆正在移動, 連接到移動糢闆嘅支管必須使用牽引鏈，以確保支管可以來回彎曲. 如果分支水管數量較大, 相應嘅牽引鏈都應不斷增加. 因此, 無論係配水器本身嘅安裝仲係支管嘅佈置, 畀設計師同安裝人員帶嚟咗好大嘅麻煩.

流量分配器嘅流量指示同溫度計係機械嘅，存儲喺讀數誤差中. 只有当溫度同流量發生顯著變化時，才能檢測到溫度同流量. 並且只能依靠人工讀取和記錄, 人工閱讀嘅頻率不易掌握.

用于高質量塑料產品嘅獨立電子溫度同流量檢測器, 特別適用於汽車功能部件

以上兩種模具冷卻配置已不能滿足質量控制嘅要求. 為咗滿足高質量嘅質素要求, 廠家開始配備獨立電子溫度流量檢測儀 (無花果. 3) 注塑機隔离. The main inlet and outlet pipes of the cooling water of the mold are connected to the equipment first, and then the equipment is divided into various branches and connected to the mold. This independent electronic temperature and flow detector is generally composed of a controller, an operating screen and a temperature, flow and other sensors installed on each branch. This electronic temperature and flow detector can digitize the cooling water status of the mold and display it on the operating screen. Operation screen can set the cooling water state of the range value, beyond the set range value will immediately alarm, and the alarm state through the form of switch to inform the injection molding machine, so that the injection molding machine immediately stop action, in order to reduce the production of defective products. This device also has a data storage function, which can store historical cold data.

通常, the independent electronic temperature and flow meter is an electronic upgrade of the mechanical water regulator. It solves the problems of inaccurate reading and manual inspection. But it also left some problems, such as the installation of the branch water pipe, the distance between the temperature measuring point and the mold. 此外, the electronic temperature flow detector, as a device that can operate independently, must have its own operating screen and controller and protective sheet metal, so the price is higher and the initial investment is larger.

Injection molding machine integrated mold cooling control system In view of the problems left by the independent electronic temperature and flow meter, injection molding machine manufacturers have begun to design and promote injection molding machine integrated mold

Cooling control system. Shown in Figure 4.

From the perspective of installation space. Integrated mold cooling control for injection molding machines

In the design of injection molding machine, the installation space has been fully considered. The sensor and the sink block are installed in the nearest position from the mold. This kind of connection can be realized only by a short branch pipe. After the cooling water confluence of the mold, only the total inlet pipe and the total return pipe are arranged on the body of the injection molding machine, which greatly reduces the space required for the arrangement of the water pipes. The overall design of the injection molding machine can also be more compact. And some of the pipe insulation or anti-condensation water requirements, it is easier to achieve.

From a cost point of view. Injection molding machine is already a complete system, when the injection molding machine integrated mold cooling control system, the original injection molding machine hardware can be shared. Such as the host screen, controller, and protective metal plate. The cooling control system eliminates the need for a dedicated operating screen, controller and some protection, which can significantly reduce costs. 另外, after the operation is unified to the screen of the injection molding machine, the user’s operation will be more convenient.

The injection molding machine directly collects the sensor of the cooling system, which can get more direct and more accurate mold cooling data. After the injection molding machine has obtained the data, more intervention actions can be obtained. Such as the setting of multi-level early warning and alarm, setting up multi-level intervention action. With the deepening of integrated development, the mold cooling system can be linked with the mold hot runner heating system to achieve better control of the temperature in the mold.

With the development of Industry 4.0 and the digitalization of injection molding machines, important data of the injection molding process, including the cooling process, are required to be stored. The integrated mold cooling system of the injection molding machine can store the process data of the mold cooling link and the molding process data of the injection molding machine in a unified way, and the data stored in a unified way is more convenient for management and traceability. If the configuration is electronic temperature flow detector, although it also has the function of data storage, but its storage format, transmission mode may be different from the data of the injection molding machine, which brings a lot of inconvenience to the management and use of the data behind.

4 Summary

桌子 1 compares four configurations of mold cooling on the injection molding machine

Device, the advantages of injection molding machine integrated mold cooling system at a glance. With the development of mold technology, the importance of mold cooling is constantly improving. With the development of Industry 4.0, the concept of unmanned factories and lights-out factories is deepening, and the digitization of the injection molding process is a necessary condition. 注塑機一體化模具冷卻系統將是未來高端注塑機嘅必備配置.

如果你有任何疑問 注塑機 ,請隨時詢問 飛翔團隊 （WhatsApp:+86 18958305290）,我哋將為您提供最好嘅服務！