高速射出成型機自我調整控制器之設計與實現

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姓名

張卓豪(Che-Hao Chang) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

高速射出成型機自我調整控制器之設計與實現
(Design and Realize the Self-tuning Controller on High-Speed Injection Molding Machine)

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摘要(中)

近年來，高分子材料已經廣泛地被使用在工業製造與日常生活中，因而高分子材料的加工技術也有大幅的進步。在所有高分子材料的加工方式中，由於射出成型製程之生產成本較低、產品成型週期較短，與可成型之形狀複雜度較高等特點，成為最重要的製程技術之一。隨著近年來塑膠製造業爆發性的發展，射出成型技術增進了全電式射出成型機械的發展並成為提昇企業競爭力的關鍵因素。對於製造業來說維持產品的品質是一項複雜且重要的工作。對塑膠射出成型產業來說，其主要目的在維持高品質的射出成品。因此，如何在每個成型週期中保持高品質的產品已成了一項重要的課題。
在早期對於射出成型產品並沒有很高的品質要求，所以為了降低生產成本，射出機只使用較簡單油壓積之比例閥或方向閥來做射出的控制，就可以大量的生產產品。但相對的也失去了產品的精密度及可靠度，使得這些產品都是以量取勝的廉價劣質品。直到最近對射出成型產品的精度要求愈來愈高，所以逐漸選用全電式射出成型機，並以伺服馬達來作控制，如此才能製作精確且複雜的產品。本論文的目的是研發全電式塑膠射出成型機控制系統之設計方法學與其實現製作技術。其控制目標為當使用者指定一射出速度曲線與保壓壓力值，在經由控制之下使系統輸出能達良好的追縱性能。此外，本論文亦提出人機界面及其控制模組，該項開發將促使全電式塑膠射出成型機控制應用技術之提昇與發揮。

摘要(英)

With the explosion of the plastic manufacturing in recent years, all-electric injection molding machines are the latest advancement in injection molding technology and business process improvement. To maintain the quality of products is a complicated and important undertaking in the manufacturing. In the injection molding manufacturing, cost-effective production of high-quality plastic moldings is the primary target of the plastic processor. Thus, how to maintain the quality of the manufacturing products in every molding cycle is a critical issue.
This thesis aims at developing control design methodologies and implementation technologies for an all-electric injection molding machine control system. The control objective is to achieve good tracking performance of a user specified injection molding control profile consisting of desired filling speed, holding pressure, and filling to holding switchover. In addition, a human-machine interface and control modules are developed in this thesis. These developed technologies are expected to be useful in improving and promoting the current and future control technologies for electric injection molding machines.

關鍵字(中)

★ 射出成型
★ 壓力控制
★ 自我調整

關鍵字(英)

★ pressure control
★ injection molding
★ self-tuning control

論文目次

Contents
ABSTRACT XII
CONTENTS XIII
LISTS OF FIGURES XV
LISTS OF TABLES XVII
CHAPTER1 INTRODUCTION 1
1.1 INTRODUCTION TO INJECTION MOLDING MACHINES 1
1.2 THESIS ARRANGEMENT 4
CHAPTER2 INJECTION MOLDING MACHINE 5
2.1 INTRODUCTION 5
2.2 MACHINE FUNCTION 5
2.2.1 The Machine Base Unit 5
2.2.2 The Injection Unit 6
2.2.3 The Clamping Unit 7
2.3 PHASES OF THE INJECTION MOLDING PROCESS 9
2.4 PARAMETERS NEED TO BE CONTROLLED 11
2.5 PLASTIC PROPERTIES 15
CHAPTER3 INJECTION SPEED PROFILING 16
3.1 INTRODUCTION 16
3.2 INJECTION SPEED 16
3.3 SPEED RELATED PROCESS VARIABLES 17
3.3.1 Injection Speed 17
3.3.2 Mold Opening and Closing Speeds 18
3.3.3 Screw Rotational Speed 18
3.3.4 Screw Recovery Speed 18
3.3.5 Ejection Speed 18
3.4 INJECTION PLANNING 19
3.4.1 Trapezoidal Velocity Profile 19
3.4.2 Blended S-Curve Velocity Profile 21
3.5 MOTION CONTROL 26
CHAPTER4 PRESSURE PROFILING 30
4.1 INTRODUCTION 30
4.2 PACKING AND HOLDING 30
4.3 RELATING SCREW PRESSURE TO CAVITY PRESSURE 32
4.4 PRESSURE RELATED PROCESS VARIABLES 34
4.4.1 Injection Pressure 34
4.4.2 Holding Pressure 34
4.4.3 Back Pressure 34
4.5 PROCESS MODEL 35
CHAPTER5 SELF-TUNING CONTROLLER DESIGN 38
5.1 INTRODUCTION 38
5.2 SELF-TUNING POLE PLACEMENT CONTROLLERS 39
5.2.1 The SISO Process Model 39
5.2.2 SISO System Identification 40
5.2.3 SISO Pole Placement Controller 41
5.3 SELF-TUNING PID CONTROLLER DESIGN 43
CHAPTER6 SIMULATION RESULT 46
6.1 SIMULATION ENVIRONMENT 46
6.2 SIMULATION RESULT 48
6.3 DISCUSSION 57
CHAPTER7 CONCLUSION AND FUTURE WORK 59
REFERENCES 60

參考文獻

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指導教授

董必正(Pi-Cheng Tung)

審核日期

2004-7-15

推文