METHOD AND DEVICE FOR THE VARIOTHERMAL TEMPERATURE CONTROL OF INJECTION MOULDS
20200156301 · 2020-05-21
Inventors
Cpc classification
B29C2045/7393
PERFORMING OPERATIONS; TRANSPORTING
B29C2945/76949
PERFORMING OPERATIONS; TRANSPORTING
B29C35/007
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A method for the variothermal temperature control of an injection mould using a temperature control device, the method including at least the following steps: in a learning phase, determining a temperature control characteristic of the temperature-controllable system including at least the injection mould and the temperature control device, in order to obtain individual reference values for the system, with which the temperature control device can be controlled in order to obtain a nominal temperature profile; and in a production phase: temperature control of the injection mould with the reference values determined during the learning phase; determining deviations of an actual temperature profile of the injection mould in relation to the nominal temperature profile during the production cycle and calculating corrected reference values from these deviations; and carrying out a resulting production process using the corrected reference values.
Claims
1. A method for the variothermal temperature control of an injection mould using a temperature control device having at least the steps: A) In a learning phase: determining a temperature control characteristic of the system which is to be temperature-controlled comprising at least the injection mould and the temperature control device, in order to obtain individual control values for the system, with which control elements of the temperature control device can be actuated in order to obtain a nominal temperature profile and B) In a production phase: temperature control of the injection mould with the control values determined during the learning phase; determining deviations of an actual temperature profile of the injection mould in relation to the nominal temperature profile during the production cycle and calculating corrected control values or respectively control times for the control elements from these deviations; carrying out a resulting production process using the corrected control values.
2. The method according to claim 1, wherein A) In the learning phase: A1) for determining a temperature control characteristic of the system which is to be temperature-controlled; a calculating takes place of actuation times for heating- and/or cooling devices of the temperature control device for achieving a chronological nominal temperature profile of the injection mould for a moulded part which is to be produced; A2) an evaluation of the nominal temperature profile is carried out in at least one evaluation cycle and if necessary correcting of the actuation times is carried out and A3) a storing takes place at least of the corrected actuation times from step A3) as control values for the system which is to be temperature-controlled, in particular its control elements and B) In the production phase: B1) during a first production cycle a starting off of the temperature profile with the control values of step A3) takes place; B2) a determining takes place of the actual temperatures and a comparison with corresponding nominal temperatures of the nominal temperature profile of the injection mould; B3) a calculation takes place of corrected control values, namely actuation times for the control elements of the subsequent production cycle from deviations determined in step B2) and B4) a carrying out of the subsequent production cycle takes place with the corrected control values from step B3) and B5) the steps B2) to B5) are repeated during further production cycles.
3. The method according to claim 1, wherein heating and/or cooling devices of the temperature control device at least one or a combination of the group: water heatingand/or water cooling device; oil heatingand/or oil cooling device; electric heatingand/or electric cooling device; heating- and/or cooling cartridges; heating devices based on induction or by means of laser and ceramic heating arrangements; refrigerant cooling devices and/or CO.sub.2 cooling devices and/or a cooling by means of a gas, e.g. air; heating device and/or cooling device based on a heat transfer oil and/or on a superheated steam are used.
4. The method according to claim 1, wherein step A is carried out without filling the injection mould with moulding material.
5. The method according to claim 1, for determining the temperature control characteristic of the system which is to be temperature-controlled, at least comprising a heating device, a cooling device, control elements and an injection mould, a minimum achievable wall temperature (T.sub.min) of a cavity of the injection mould is determined and stored.
6. The method according to claim 1, for determining the temperature control characteristic of the system which is to be temperature-controlled, at least comprising a heating apparatus, a cooling apparatus, control elements and an injection mould, a maximum achievable wall temperature (T.sub.max) of a cavity of the injection mould is determined and stored.
7. The method according to claim 1, during a heating-up process according to claim 5, the maximum rise of a heating curve at its turning point (W) is determined in Kelvin per second (K/s.sub.heat).
8. The method according to claim 1, at the turning point of the heating curve, a tangent (T) is applied to the heating curve, and an intersection of the tangent (T) with the abscissa is formed, wherein the chronological interval between the start of the heating and the intersection of the tangent (T) with the abscissa is defined as delay time (tu.sub.heat).
9. The method according to claim 1, proceeding from the temperature (T.sub.max) the cooling is started with heating switched off, wherein a maximum negative rise is determined in Kelvin per second at the turning point (W) of the cooling curve (TK) (K/s.sub.cool) and a tangent (T) is applied at the turning point (W) of the cooling curve (TK), wherein the intersection of the tangent (T) with the abscissa is determined and a delay time (tu.sub.cool) is defined as a chronological interval between the start of the cooling and the intersection of the tangent (T) with the abscissa.
10. The method according to claim 1, wherein a mean temperature (T.sub.Basis) is calculated between the minimum temperature (T.sub.min) and the maximum temperature (T.sub.max).
11. The method according to claim 1, wherein from the formula
t.sub.basisheat=((T.sub.BasisT.sub.min)/K/s.sub.heat)+tu.sub.heat the actuation time (t.sub.basisheat) is calculated for a pulse heating from the minimum temperature (T.sub.min) to the mean temperature (T.sub.Basis).
12. The method according to claim 1, wherein after the switching off of the heating, i.e. after the time (t.sub.basisheat) has elapsed, a time span is measured until no further significant temperature change occurs at the temperature sensor (7), wherein a temperature (T.sub.basisheat) and a reverberation time (dead time) (t.sub.Basisheatdead) is measured and stored.
13. The method according to claim 1, wherein a deviation is calculated between the mean temperature (T.sub.Basis) and the temperature (T.sub.Basisheat) according to the formula
T.sub.Basisheaterror=T.sub.BasisheatT.sub.Basis.
14. The method according to claim 1, wherein the cooling is actuated, while the heating is switched off, until the maximum temperature (T.sub.max) is reached at the temperature sensor (7) and from the formula
t.sub.basiscool=((T.sub.maxT.sub.Basis)/K/s.sub.cool)+tu.sub.cool the actuation time (t.sub.basiscool) for a pulse cooling from the maximum temperature (T.sub.max) to the mean temperature (T.sub.Basis) is calculated.
15. The method according to claim 1, wherein proceeding from the maximum temperature (T.sub.max) from a previous learning step the cooling is actuated and is switched off after the time (t.sub.basiscool), wherein following thereon, the time is measured until no more significant temperature change is measurable at the temperature sensor (7) in the cavity (8), wherein the temperature (T.sub.basiscool) and the reverberation time (dead time) (t.sub.Basiscooldead) is measured and stored, and the deviation is calculated from (T.sub.Basis) to (T.sub.Basiscool according to the formula
T.sub.Basiscoolerror=T.sub.BasisT.sub.Basiscool.
16. The method according to claim 1, wherein in a process sequence for at least one pulse heating or at least one pulse cooling step, actuation times of the heating device and/or of the cooling device are measured and stored proceeding from the current temperature of the cavity wall (T.sub.actMld), wherein the nominal temperature (T.sub.Soll) is determined from the current step and when the nominal temperature (T.sub.Soll) is greater than the temperature (T.sub.actMld), in the first optimisation run the time (t.sub.Prozess1) is calculated according to the formula
t.sub.Prozess1=((T.sub.Soll1T.sub.actMld)/K/s.sub.heat)+tu.sub.heat+T.sub.Basisheaterror/K/s.sub.heat.
17. The method according to claim 1, wherein for the case where the nominal temperature T.sub.Soll is lower than the actual temperature T.sub.actMld, the time (t.sub.Prozess1) is calculated from the formula
t.sub.Prozess1=((T.sub.Soll1T.sub.actMld)/K/s.sub.cool)+tu.sub.cool+T.sub.Basiscoolerror/Ks.sub.cool.
18. The method according to claim 1, wherein the calculation of the time (t.sub.Prozess1) for further process steps is carried out in an analogous manner.
19. The method according to claim 1, wherein determining of the time (t.sub.Prozess1) for a pulse heating process or for a pulse cooling process is carried out repeatedly.
20. The method according to claim 1, wherein during further passages the actuation times of the heating device and/or of the cooling device are corrected by a start temperature deviation (T.sub.startOffset) and/or an end temperature deviation (T.sub.endOffset), wherein formulae listed below are used:
T.sub.startOffsetx=T.sub.actMldxT.sub.(actMldx)n1
T.sub.endOffset=T.sub.ProzessxT.sub.(Prozessx)n1 Wherein (n1) is the corresponding temperature from the preceding passage.
21. The method according to claim 1, wherein a time (t.sub.startOffset) and (t.sub.endOffset) corresponding to the start temperature deviation (T.sub.startOffset) and/or to the end temperature deviation (T.sub.endOffset) is calculated depending on pulse heating (K/S.sub.heat) or pulse cooling (K/s.sub.cool), wherein:
For pulse heating:t.sub.startOffset=T.sub.startOffset/Ks.sub.heat
t.sub.endOffset=T.sub.endOffset/K/s.sub.heat
For pulse cooling:t.sub.startOffset=T.sub.startOffset/K/s.sub.cool
t.sub.endOffset=T.sub.endOffset/K/s.sub.cool.
22. The method according to claim 1, wherein an actuation time (t.sub.Prozess(x)) for a heating process and/or a cooling process is determined from the actuation time a (t.sub.Prozess(x1)) from the previous process plus the time (t.sub.startOffset) from the current process plus the time (t.sub.endOffset) from the preceding process, which can be represented according to a formula as:
t.sub.Prozess(x)=t.sub.Prozess(x1)+t.sub.startOffsetx+t.sub.endOffset(x1).
23. A device for carrying out the method according to claim 1 having at least one temperature control apparatus (2; 3) with a heating device, at least one temperature control apparatus (2, 3) with a cooling device and an injection mould (4), control elements (5) and a regulating unit (6), which can act in a regulating manner on the control elements (5), wherein the regulating unit (6) provides signals as a function of a cavity wall temperature of a cavity (8) of an injection mould (4) for the regulating of the control elements (5).
24. The device according to claim 23, wherein the heating device ( ) is at least one device selected from the group water heating device; oil heating device; electric heating device; heating cartridges; heating devices based on induction or by means of laser and ceramic heating arrangements; heating device based on a heat transfer oil and/or a superheated steam and/or the cooling device is at least one device selected from the group water cooling device; oil cooling device; electric cooling device; cooling cartridges; cooling arrangements by means of refrigerant and/or CO.sub.2 and/or by means of a gas, eg. air; cooling device based on a heat transfer oil and/or carbon dioxide.
25. The device according to claim 23, wherein the device has in addition a buffer (14) which is arranged and formed to provide cold temperature control medium (10) and hot temperature control medium (9) and, if required, to feed in additional cold temperature control medium (10) and/or additional warm temperature control medium (9) into temperature control circuits
26. The device according to claim 23, wherein the regulating device (6) is or comprises a data processing device which is able to carry out the calculationand/or storage steps according to above-mentioned claims.
Description
[0108] The invention is explained in further detail below by way of example with the aid of the drawings. There are shown:
[0109]
[0110]
[0111]
[0112]
[0113] A device 1 for carrying out the method according to the invention is illustrated schematically in
[0114] The temperature control apparatus 2 with a heating device provides a relatively hot temperature control medium 9 compared to the temperature control apparatus with a cooling device 3, which provides a relatively cold temperature control medium 10.
[0115] The temperature control apparatuses 2, 3 are connected with the control elements 5 via suitable pipe lines (illustrated schematically by the arrows 11). The control elements 5 are connected with the injection mould 4 via suitable piping systems or hose systems (arrows 12). The injection mould 4 has at least one temperature control circuit 13, through which hot temperature control medium 9 or cold temperature control medium 10 is able to be directed alternately. Alternatively, it is also possible that the injection mould has two temperature control circuits 13, which are separated from one another hydraulically. One of the two temperature control circuits 13 serves for the directing of the cold temperature control medium 10, the other temperature control circuit serves for the directing of the hot temperature control medium 9 through the injection mould 4 or an injection mould half.
[0116] Preferably, the device 1 has a buffer 14 which keeps available a certain store of hot temperature control medium 9 and a store of cold temperature control medium 10. For example, the buffer 14 is equipped with a displaceable piston element 15, which divides a buffer chamber into a compartment for hot temperature control medium 9 and a compartment for cold temperature control medium 10. The compartment containing hot temperature control medium 9 and also the compartment containing cold temperature control medium 10 are respectively connected via suitable pipe lines 16 with corresponding inlets of the control elements 5. By movement of the piston 15 in the double arrow direction 17, an additional amount of cold temperature control medium 10 (movement of the piston 15 in
[0117] The control elements 5 are for example an arrangement of various valves 18, which are only indicated schematically. The valves 18 are, for example, electrically actuatable valves, which are connected with the regulating unit 6 and are able to be actuated by the latter. Depending on the actuation of the valves 18, either cold temperature control medium 10 or warm temperature control medium 9 can be fed into the temperature control circuits 13, wherein, as required, additional cold temperature control medium 10 or hot temperature control medium 9 can be fed in through the buffer 13 for example for achieving high cooling- or heating gradients. The provision of a buffer 14 makes it possible to use relatively small heating/cooling- and/or pump units for the temperature control apparatuses 2, 3, and nevertheless to capture injection loads which occur in a learning- and/or production cycle, by means of the buffer 14. This contributes to a saving of energy and reduces the system costs.
[0118] The temperature sensor 7 is connected with the regulating unit 6 via a suitable signal line 19. Of course, it is possible that a plurality of temperature sensors 7 are arranged distributed over the cavity wall of the cavity 8 and send separate signals, which represent a local cavity wall temperature, to the regulating unit 6 or respectively make them available to it.
[0119] In the present example embodiment according to
[0120] Furthermore, in the embodiment according to
[0121] Of course, other types of heating/cooling are also conceivable. For example, electric heating- and/or cooling elements or gases can be used as temperature control medium.
[0122] When now for example with the temperature control apparatus 3 switched off or clamped off with cool temperature control medium hot temperature control medium 9 is pumped through the cooling circuits 13, the cavity wall of the cavity 8 will heat up.
[0123] Vice versa, it will cool down when instead of the hot temperature control medium 9 cold temperature control medium 10 is sent through the temperature control circuits 13.
[0124] With this device, the method according to the invention, described in the following, can be carried out advantageously.
[0125] A method according to the invention for the variothermal temperature control of the injection mould 4 is carried out in two phases, a learning phase A and a production phase B. Within the learning phase A, a determining takes place of the temperature control characteristic of the system which is to be temperature-controlled, which has at least the injection mould 4, the temperature control devices 2, 3 and the corresponding (pipe-) line connections and the control elements 5 and the regulating unit 6. Of course, a temperature sensor 7 is to be provided in the cavity 8 of the injection mould 4.
[0126] This entire system which is to be temperature-controlled (the injection mould 4) or respectively is to provide for the temperature control (temperature control apparatuses 2, 3, control elements 5 and the corresponding connections with the injection mould 4), has a particular temperature control characteristic which is influenced for example by the cavity shape of the cavity 8 in the injection mould 4. Further influencing variables can be the efficiency of the temperature control apparatuses 2, 3 and the maximum possible through-flow quantity of cold temperature control medium 10 and/or hot temperature control medium 9.
[0127] Such a system of the above-mentioned components has a particular temperature control characteristic, i.e. on a particular activity of the temperature control apparatuses 2 or 3 a particular temperature reaction takes place of the cavity wall of the cavity 8 in the injection mould 4. This is to be determined in the learning phase A.
[0128]
[0129] Within the determining of the temperature control characteristic of the system, proceeding from a current moulding tool temperature (cavity wall temperature T.sub.actMld) with the temperature control apparatus 3 with cooling device switched off, the temperature control apparatus 2 with heating device is switched on. The switching on of the heat temperature control takes place in the illustrated example according to
[0130] The graph TW has in its course a turning point W. For determining a characteristic value for the temperature control characteristic of the system, it has proved to be successful to apply in the turning point W a tangent T to the graph TW. The maximum rise of the heating curve (graph TW) is present in the turning point W. The tangent forms an intersection S with the abscissa. The period of time between the start of the heating (time t.sub.1) and the intersection S is defined as delay time tu.sub.heat. The maximum rise of the tangent T is defined by a quotient of temperature and heating time, which is indicated in Kelvin per heating time (K/s.sub.heat).
[0131] With this procedure, starting from a current temperature T.sub.actMld of the injection mould 4, its heating-up characteristic up to the temperature T.sub.max is able to be determined and herefrom the values K/s.sub.heat and tu.sub.heat are able to be determined.
[0132] In an analogous manner, a determining takes place of the cooling-down characteristic of the injection mould 4 starting from a maximum achievable temperature T.sub.max (cf.
[0133] This tangent likewise intersections the abscissa S, so that a cooling delay time tu.sub.cool results, which results from the time t.sub.1 (switching on of the cooling unit) to the intersection S of the tangent T with the abscissa.
[0134] This characterizing of the heating up or respectively cooling down behaviour of the system takes place preferably with an empty injection mould, i.e. still entirely without melt. Hereby, it is not necessary to carry out the learning phase with an injection mould which is mounted on a plastic injection moulding machine. A further advantage is that the use of plastic melt does not influence the tool temperature control characteristic or respectively the system temperature control characteristic.
[0135] The determined temperature control characteristic of the system is preferably stored in the form of tool-specific, in particular system-specific control values for control elements or is otherwise assigned to the tool/system.
[0136] Further steps in the learning phase A are:
[0137] From this temperature control characteristic for example through differentiation between the maximum achievable temperature T.sub.max and the minimum achievable temperature T.sub.min a mean temperature T.sub.Basis can be calculated. With the mean temperature T.sub.Basis an activation time can be determined for the corresponding heating valves, which is necessary, which becomes necessary with a heating (pulse heating) from the minimum temperature T.sub.min to the mean temperature T.sub.Basis. This takes place using the determined heating gradient K/s.sub.heat and the correspondingly determined delay time tu.sub.heat according to the formula:
T.sub.basisheat=((T.sub.BasisT.sub.min)/K/s.sub.heat)+tu.sub.heat.
[0138] It has been found that after the switching-off of the heating with a temperature of the injection mould 4 below the maximum achievable temperature T.sub.max, an overshooting of the temperature beyond a desired target value takes place. In order to compensate this overshooting, the time span is measured until after the switching-off of the heating a significant temperature change no longer occurs. The temperature excess occurring here (T.sub.basisheat) and the measured reverberation time (t.sub.basisheatdead) is likewise measured and stored. From this, a deviation is calculated between the mean temperature T.sub.Basis and the temperature T.sub.basisheat according to the formula:
T.sub.Basisheaterror=T.sub.BasisheatT.sub.Basis
[0139] In an analogous manner, the determining of an undershooting takes place in the case of cooling, whereby a reverberation time in the case of cooling (t.sub.basiscool) and a minimum temperature T.sub.basiscool occurring in the case of undershooting is measured and stored. Herefrom, a deviation results between the mean temperature T.sub.Basis and the minimum occurring undershoot temperature T.sub.basiscool according to the formula:
T.sub.Basiscoolerror=T.sub.BasisT.sub.Basiscool.
[0140] With the temperature T.sub.Basiscoolerror or respectively with the temperatures T.sub.Basiscoolheaterror, taking into account the overshoot/undershoot phenomena in the heating/cooling, the process times t.sub.Prozess1 for the case of heating and the case of cooling can be determined more precisely, in order to reach as precisely as possible a nominal temperature T.sub.Soll starting from a current injection mould temperature (cavity wall temperature T.sub.actMld).
[0141] A previously described determining of the times t.sub.Prozess1 both for the case of cooling and for the case of heating is carried out several times for a better delimitation and a more precise determining of the error temperatures T.sub.Basisheaterror and T.sub.Basiscoolerror. Here, a repetition several times has proved to be successful.
[0142] The actuation times of the heating device and/or of the cooling device are corrected from one process to the next through corresponding start offset temperatures T.sub.startOffset or respectively end temperature deviations T.sub.endOffset in order to also take into account at the start/end of the one process the start/end temperatures of the preceding process. With these offset temperatures T.sub.startOffset and T.sub.endOffset corresponding offset times t.sub.startOffset and t.sub.endOffset can be determined both for the heating and for the cooling. This takes place according to the formulae
For pulse heating:t.sub.startOffset=T.sub.startOffset/K/s.sub.heat
t.sub.endOffset=T.sub.endOffset/K/s.sub.heat
For pulse cooling:t.sub.startOffset=T.sub.startOffset/K/s.sub.cool
t.sub.endOffset=T.sub.endOffset/K/s.sub.cool
[0143] Therefore, from the process time t.sub.Prozess(x1) of the preceding process and the start offset time t.sub.startOffset(x) of the current process and the end offset time t.sub.endOffset(x1) of the preceding process, the process time t.sub.Prozess(x) can be calculated for the current process, which is used for the current case of heating/case of cooling. Hereby, a learning is successful for the current process from the environmental conditions and the sequence of the preceding process.
[0144] As a result, by the method according to the invention and a device 1 suitable for carrying out the method, a targeted start-off of a nominal temperature profile, in particular achieving explicit nominal temperatures T.sub.Soll1, T.sub.Soll2 is possible in a very precise manner and adaptably to varying environmental conditions (cf.
[0145] The graph TW, which indicates the tool temperature over the time t is represented in
[0146] Therefore, for achieving the temperature T.sub.Soll1 a so-called pulse heating takes place. Proceeding from the temperature T.sub.Soll a so-called pulse cooling takes place for achieving the temperature T.sub.Soll2, whereas the achieving of the temperature T.sub.Soll3 takes place proceeding from the temperature T.sub.Soll2 by means of a pulse heating.
[0147] It has proved to be expedient to bring about the temperature control exclusively through switching on either the temperature control apparatus 2 with heating device or the temperature control apparatus 3 with cooling device. A mixing of the temperature control media preferably does not take place. A system with separate cold temperature control medium 10 and hot temperature control medium 9, viewed as a whole is essentially more dynamic than a system which attempts to achieve a particular temperature by the mixing of cold and warm temperature control medium. Therefore, through the separate temperature control circuits, more dynamic pulse heatingand pulse cooling processes are possible.
LIST OF REFERENCE NUMBERS
[0148] 1 device [0149] 2, 3 temperature control apparatus [0150] 4 injection mould [0151] 5 control elements [0152] 6 regulating unit [0153] 7 temperature sensor [0154] 8 cavity [0155] 9 hot temperature control medium [0156] 10 cold temperature control medium [0157] 11, 12 arrows [0158] 13 temperature control circuit [0159] 14 buffer [0160] 15 displaceable piston element [0161] 16 pipe lines [0162] 17 double arrow direction [0163] 18 valves [0164] 19 signal line [0165] A learning phase [0166] B production phase [0167] S intersection [0168] VH graph [0169] TK graph [0170] TW graph [0171] T.sub.max maximum achievable temperature [0172] t1 switch-on time [0173] Tmin minimum achievable temperature [0174] T tangent [0175] W turning point