Abstract:
The present invention discloses a control system and method for injection molding machine. The control method comprises the following steps: establishing a work command according to a plurality of production process parameters; receiving a position information directly from an injection molding machine; and controlling a servo pump to drive the injection molding machine according to the position information and the work command.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to Taiwan Application Serial Number 105106629, filed Mar. 4, 2016, which is herein incorporated by reference. 
       BACKGROUND 
       [0002]    Field of Invention 
         [0003]    The present invention relates to a control system and method of injection molding machine. 
         [0004]    Description of Related Art 
         [0005]    A host controller controls the operation process of an injection molding machine and outputs single-motion control commands to a driver. In accordance with the control commands, the driver directs a servo pump to drive a hydraulic-cylinder and operate injection molding procedures. Due to the operation of the injection molding machine having a response delay time, the control commands cannot keep up with real-time variations. This causes issues such as: the provided actual pressure being greater than the required pressure; insufficient material provisions; and unsmooth product surfaces. The resulting defective rate of the products is therefore higher. 
       SUMMARY 
       [0006]    Embodiments of the present invention described herein provide a control system and control method for injection molding and an injection molding machine. The control commands outputted by a host controller include work commands with a plurality of continuous motions. The work command defines a required pressure, a required flow, and a position information of the hydraulic-cylinder of each motion of the injection molding machine. Embodiments of the injection molding control system of the present invention establish the work command in the driver to perform calculations in advance. The driver controls the operation parameters of the servo pump according to the position of the hydraulic-cylinder, provided by a hydraulic-cylinder position measurement module. 
         [0007]    According to an aspect of the present disclosure, an injection molding control system is provided, which includes a servo pump, an injection molding machine, and driver. The injection molding machine is coupled to the servo pump and includes a hydraulic-cylinder and a hydraulic-cylinder position measurement module configured to obtain a position information of the hydraulic-cylinder. The driver coupled to the servo pump and is configured to use a work command for driving the injection molding machine by the servo pump. The driver is further configured to receive the position information directly from the injection molding machine and control the servo pump to drive the injection molding machine according to the position information and the work command. 
         [0008]    In one embodiment of the present invention, the injection molding control system further comprises a host controller coupled to the driver, the host controller being configured to establish the work command according to a plurality of production process parameters, and transmit the work command to the driver for storage in a driver&#39;s memory. 
         [0009]    In one embodiment of the present invention, the servo pump comprises a motor and a hydraulic-pump. The motor is controllable by the driver to control the motor&#39;s torque and rotating speed according to the work command and the position information. The hydraulic-pump is coupled to the motor, and is configured to generate an output pressure and an output flow controlled according to the motor&#39;s torque and rotating speed. 
         [0010]    In one embodiment of the present invention, the servo pump is configured to drive the hydraulic-cylinder of the injection molding machine to perform injection molding. 
         [0011]    In one embodiment of the present invention, the driver is configured to detect the motor&#39;s torque and rotating speed in real-time. 
         [0012]    In one embodiment of the present invention, the driver is configured to detect the output pressure and the output flow of the hydraulic-pump in real-time. 
         [0013]    In one embodiment of the present invention, the position information includes a location and/or a movement of the hydraulic-cylinder and the hydraulic-cylinder position measurement module includes a sensor configured to detect the location and/or the movement of the hydraulic-cylinder. 
         [0014]    In one embodiment of the present invention, the hydraulic-cylinder position measurement module is further configured to transmit the position information directly to the driver. 
         [0015]    According to another aspect of the present disclosure, an injection molding control method is provided, the method comprising the following steps: establishing a work command according to a plurality of production process parameters and providing the work command to a driver of an injection molding machine; the driver receiving a position information directly from the injection molding machine; and the driver controlling a servo pump to drive the injection molding machine according to the position information and the work command. 
         [0016]    In one embodiment of the present invention, the method further comprises the following steps: controlling a motor&#39;s torque and rotating speed according to the work command and the position information; and controlling an output pressure and an output flow of a hydraulic-pump generated according to the motor&#39;s torque and rotating speed. 
         [0017]    In one embodiment of the present invention, the method further comprises the following steps: detecting the motor&#39;s torque and rotating speed in real-time; and detecting the output pressure and the output flow of the hydraulic-pump in real-time. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a block diagram of an injection molding control system according to an embodiment of the present invention; and 
           [0019]      FIG. 2  is a block diagram of an injection molding control method according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The invention can be more fully understood by reading the following detailed description of embodiments, with reference to the accompanying drawings. 
         [0021]    The present invention provides a control system and method for an injection molding machine, which establishes work commands in a driver to perform calculations in advance. Further, the driver controls the operation parameters of a servo pump according to the positions of the hydraulic-cylinder, the position information being provided by a hydraulic-cylinder position measurement module. 
         [0022]    According to an embodiment of the present invention, referring to  FIG. 1 , an injection molding control system  100  comprises a host controller  140 , a driver  110 , a servo pump  120 , and an injection molding machine  130 . The driver  110  is coupled to the servo pump  120 , the injection molding machine  130 , and the host controller  140 . The injection molding machine  130  is coupled to the servo pump  120  and the host controller  140 . 
         [0023]    The servo pump  120  further comprises a motor  122  and a hydraulic-pump  124  coupled to each other. The injection molding machine  130  comprises a hydraulic-cylinder position measurement module  132  and a hydraulic-cylinder  134 . The hydraulic-cylinder position measurement module  132  may be a sensor which detects a location and/or a movement of the hydraulic-cylinder and being capable of providing the location/movement information to indicate hydraulic-cylinder&#39;s position (or the injection molding process) of the hydraulic-cylinder  134 . 
         [0024]    The hydraulic-cylinder position measurement module  132  may provide the hydraulic-cylinder&#39;s position information by transmitting directly to the driver  110 , or provide the hydraulic-cylinder&#39;s position information to the host controller  140 . 
         [0025]    The host controller  140  can be a mainframe computer system or a personal computer or an electric device with a computation capability. The host controller  140  is coupled to the driver  110 , and the host controller  140  establishes the work commands according to a plurality of production process parameters. The work command is a set of instructions that include a plurality of production process motions. The work command indicates a required rotating speed of the motor  122  and a required flow of the hydraulic-pump  124  corresponding to different motions, such as closing the mold, injection, pressure holding, material stirring, cooling, opening the mold, and ejection etc. The work command may be a digital signal which the host controller  140  transmits to a memory of the driver  110  through hardware connections, and the driver  110  controls the motor  122  of the servo pump  120  according to the work command. The motor  122  drives the hydraulic-pump  124 , and the hydraulic-pump  124  drives the hydraulic-cylinder  134  of the injection molding machine  130  to perform the injection molding. With a feedback loop provided as shown in  FIG. 1 , the host controller  140  can detect the injection molding process status/progress of the of the injection molding machine  130  in real-time. 
         [0026]    In one operation mode, the host controller  140  establishes the work command according to a plurality of production process parameters. Next, the host controller  140  transmits the work command through hardware connections to a memory of the driver  110  to be stored. In accordance with the work command, the driver  110  controls the motor  122  of the servo pump  120  and the motor  122  drives the hydraulic-pump  124  to operate the hydraulic-cylinder  134  of the injection molding machine  130  to perform the injection molding process. 
         [0027]    However, if the operation is just based on the work command, there may be errors due to mismatch between work command instructions and the actual real-time molding process caused by delays in feedback response from the injection molding machine. According to an embodiment of the present invention, the injection molding control method of the present invention provides a real-time detection and of the injection molding machine  130  and faster feedback response for controlling the performance of the injection molding process.  FIG. 2  describes an injection molding control method according to an embodiment of the present invention. Referring to  FIG. 1  and  FIG. 2 , after the initial establishment of work command according to production process parameters (S 210 ), the injection molding machine  130  operates according to the work command, and the driver  110  also detects the real-time position of the hydraulic-cylinder  134  by the hydraulic-cylinder position measurement module  132  (Step S 220 ). The position information can be a location of the hydraulic-cylinder  134 , and/or indication a movement or molding progress of the hydraulic-cylinder  134 . The real-time position information is provided directly to the driver  110  so as to let the driver  110  know the injection molding status of the injection molding machine  130  at any time. With the faster and more rapid response feedback, the driver  110  then controls the servo pump  120  to operate the injection molding machine  130  to perform injection molding according to the work command and the real-time position of the hydraulic-cylinder position measurement module  132  (Step S 230 ). 
         [0028]    At Step S 230 , the servo pump  120  drives the injection molding machine  130  to perform injection molding, wherein the servo pump  120  includes the motor  122  and the hydraulic-pump  124 . The driver  110  controls a torque and a rotating speed of the motor  122  according to the work command and the real-time position of the hydraulic-cylinder position measurement module  132 . The motor  122  controls an output pressure and an output flow of the hydraulic-pump  124  according to the motor&#39;s torque and the rotating speed, and the output pressure of the hydraulic-pump  124  drives the hydraulic-cylinder  134  of the injection molding machine  130  to perform the injection molding. 
         [0029]    According to an embodiment of the present invention, the driver  110  detects the torque and the rotating speed of the motor  122  in real-time, and also detects the output pressure and the output flow of the hydraulic-pump  124  in real-time. Through real-time detection, the driver  110  can detect the actual torque and actual rotating speed of the motor  122 , and the actual output pressure and actual output flow of the hydraulic-pump  124 . Therefore, the driver  110  can know in real-time if an error has occurred with the injection molding process. 
         [0030]    Embodiments of the present invention described herein provides a control system and control method for injection molding machine. The control commands outputted by the host controller include work commands with a plurality of production process motions. The work command defines the required pressure, the required flow, and the position information of the hydraulic-cylinder of each motion of the injection molding machine. The injection molding control system of the present invention establishes the work command in the driver to perform calculations in advance. The driver controls the operation parameters of the servo pump according to the position of the hydraulic-cylinder position measurement module. In the injection molding control system of the embodiment/s of the present invention, the driver obtains the complete work command in advance so as to reduce the response time. Further, the feedback operation of the hydraulic-cylinder position measurement module directly to the driver reduces control error, so that the pressure control and the flow control can be more accurate and faster. This could lead to improvements to the yield rate of products and reduce the manufacturing cost. That is, the work command is stored in the driver and the work command can be calculated in an inner control loop without having to go through the host controller, and so may improve calculation efficiency and control response. 
         [0031]    It will be apparent to those skilled in the art that modifications and variations can be made to the embodiments of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims.