Types of electrical control system of injection molding machines include traditional relay type, programmable controller type (PLC), microcomputer control type, all-electric control system, electro-hydraulic proportional control system, and programmable computer controller (PCC).
With the development of technology, modern control systems such as PLC and PCC have gradually become mainstream, improving the automation level and production efficiency of injection molding machines.
Then, choosing an injection molding machine equipped with the most precise control system according to your actual product production needs can make your production process more reasonable and efficient.
Types of electrical control system of injection molding machines
After years of technological research and development, we have developed various control systems with specific functions in the field of injection molding machine control systems.
- Traditional relay type
- Programmable logic controller (PLC)
- Microcomputer control
- All-electric control system
- Electro-hydraulic proportional control system
- Programmable Computer Controller (PCC)
Traditional relay type:
This control system adopts a wire connection and is suitable for fixed processes.
Due to its long development cycle, inconvenient modification, short life, poor reliability, fault-checking difficulties low control accuracy, and other shortcomings, it gradually lost market competitiveness.
Nevertheless, due to its simple structure and cheap price, there is still a certain market.
Programmable logic controller (PLC):
The injection molding machine widely uses PLC control systems due to their high reliability, high performance, easy maintenance, and strong anti-jamming ability.
Microcomputer control:
Based on the control system of microcomputer technology, it can achieve the process control of the injection molding machine.
Such as multi-stage injection speed control, multi-stage pressure holding control, etc.
All-electric control system:
This system adopts the EtherCAT bus to achieve real-time data sharing among the computer controller, servo drive, and servo motor, so as to control the injection molding process more accurately.
The all-electric controller provides high performance, high response, and low inertia injection motors to meet the demands of high-speed injection processes.
Electro-hydraulic proportional control system:
This type of system uses proportional valves to control the open table mold pressure, clamping pressure, injection pressure, injection speed, and pre-molding speed. high reliability and strong anti-interference capability are advantage for this type of control system.
Programmable Computer Controller (PCC):
PCC is a higher-level control system than PLC, designed for small and medium-sized, integrating the features of standard PLC and industrial control computers, with more powerful data computing and processing capabilities.
How does a PLC electrical control system work for Types of electrical control system of machines？
The PLC electrical control system of the injection molding machine directs every part of the machine to do the work of production in cooperation through efficient data processing and precise control instructions.
Workflow:
Input Signal Acquisition:
PLC collects key parameters in the injection molding process in real-time through various sensors (such as temperature sensors, pressure sensors, etc.), such as mold temperature, injection speed, and injection pressure.
Program control for Types of electrical control system of machines:
The written control program is inputted into the PLC, which processes the collected signals according to the program and makes corresponding decisions.
For example, when the mold temperature is detected to be lower than the set value, the PLC will automatically adjust the working status of the heater to increase the temperature.
Output control for Types of electrical control system of machines:
PLC generates control signals and drives the execution elements through the output module to achieve various actions of the injection molding machine, such as closing the mold, injecting, holding pressure, cooling, opening the mould, and ejecting the products.
Functional features:
High reliability and anti-interference ability:
PLC has high reliability and anti-interference ability, which can effectively deal with all kinds of interferences in the industrial environment and ensure the stability and continuity of the injection molding process.
Convenient programming and maintenance:
PLC programming is relatively simple and intuitive, easy for operators to adjust the control logic according to production requirements.
At the same time, the modular design of the PLC system makes maintenance and troubleshooting more convenient.
The high degree of automation:
PLC control system is able to achieve automated operation of the injection molding machine.
Including automatic cycle start-up, manual control, data modification, and system monitoring, etc., which greatly improves production efficiency and product quality.
In practical application, the PLC control system is not only limited to the basic action control of the injection molding machine, but also involves temperature control, closed-loop control of the pre-molding metering process, and other complex functions.
For example, in some high-end injection molding machines, PLC exchanges information with other equipment through a network communication function to achieve the collaborative work of the whole production line.
In addition, the PLC can also accurately regulate injection pressure, speed, and temperature through PID control algorithms to ensure high quality and consistency in the injection molding process.
How does the all-electric electrical control system manage the injection molding machine?
The electrical control system of the all-electric injection molding machine achieves precise control of the injection moulding process, at the same time, achieves the purpose of energy saving and consumption reduction is achieved at the same time.
- Servo motor control system for Types of electrical control system
- Intelligent process optimization technology
- Pressure control module
- High-efficiency and energy-saving design
- Soft PLC and CANopen bus
- Open CNC system and soft PLC technology
- Vector control technology
Servo motor control system for Types of electrical control system:
The all-electric injection molding machine adopts a servo motor control system, including multiple servo motor controllers for injection, mould closing, pressure holding and ejecting,
They are connected to the computer controller via CAN bus to achieve precise control of each servo motor.
This type of control enables synchronous control of several technical procedures, such as mold opening and closing, plastic injection, plasticizing pressure holding, and ejection, thus saving production time.
Intelligent process optimization technology:
Combine all-electric servo control with intelligent process optimization technology to design an intelligent all-electric injection machine control system.
The system uses initial process parameter generation and fuzzy reasoning optimization technology to achieve intelligent optimization, which improves product quality and shortens the production cycle.
Pressure control module:
For the control of injection pressure, which adopts a closed-loop serial PID control method of pressure based on the inner loop of speed , combined with the mathematical model of the corresponding link of the screw of the all-electric injection molding machine.
The PID controller to ensure accurate control of the output injection pressure adjusts the inner-loop speed parameter and outer-loop injection pressure parameter.
High-efficiency and energy-saving design:
The design of the all-electric injection moulding machine focuses on high efficiency and energy saving and solves the problem.
In addition, the energy utilization efficiency is further improved by using supercapacitors for peak power shaving.
Soft PLC and CANopen bus:
The new control system adopts soft PLC and CANopen bus to build the hardware architecture, and the software design adopts object-oriented ideas and methods, which improves the power, efficiency, simplicity, and flexibility of the system.
Open CNC system and soft PLC technology:
The injection molding process is designed and developed by a control system for an all-electric injection machine.
The system adopts a modular design method, including a logic control module and process control module, which realizes the control target of high precision and high efficiency.
Vector control technology:
Applying vector control technology to permanent magnet synchronous motor control, a control system design of an all-electric injection moulding machine is proposed.
Through analysis and research, the stability and high reliability of the precise control of the program are further improved to meet the precision and stability requirements of an all-electric injection moulding machine.
The electrical control system of an all-electric injection moulding machine achieves precise control of the injection moulding process through a variety of technologies and methods in order to improve productivity, product quality, and energy saving.
Advantages of PCC for Types of electrical control system of machines:
The application of a Programmable Computer Controller (PCC) in injection molding machine has various advantages, such as precise control, high degree of automation, high reliability, significant energy saving, easy operation and maintenance, and strong adaptability:
- Precise control
- The high degree of automation
- Strong reliability for the type of electrical control system
- Energy-saving effect is remarkable
- Easy to operate and maintain
- Strong adaptability
Precise control:
PCC can achieve precise control of the barrel temperature of the injection molding machine, and by adopting the PID intelligent control algorithm, the temperature error can be controlled within ±0.3 ℃, which significantly improves the injection quality and processing accuracy.
In addition, PCC can also provide variable control of speed and pressure, achieving the goals of convenient control and high reliability.
The high degree of automation:
The control system based on PCC can improve the automation degree of the machine, reduce system failure, and improve production efficiency.
For example, a PLC-based multi-axis injection molding machine robot control system realizes the intelligence and automation of injection molding production.
Strong reliability for the type of electrical control system:
The control system composed of PCC has strong anti-interference ability and high reliability, and it is very convenient for debugging and modification.
For example, the programmable controller used by Haichen has been running continuously for 500 hours under high temperatures and a strong interference environment with stable performance and the yield rate is as high as 98%.
Energy-saving effect is remarkable:
The new injection molding machine adopts a direct-drive electro-hydraulic servo system, which dynamically adjusts the rotational speed of the dosing pump, so as to achieve the purpose of energy saving.
The servo-pump injection molding machine improves the performance and reliability of the control system of the injection molding machine through the modification of the electrical system, which effectively reduces production cost.
Easy to operate and maintain:
The design of the PCC control system takes into account the ease of operation and maintenance.
For example, the design of an embedded programmable motion controller improves the overall response interruption performance and execution speed of the controller,
Strong adaptability:
PCC can adapt to different types of injection molding machines and process requirements, such as all-electric injection moulding machines, hydraulic injection moulding machines, etc., and can achieve precise control of complex machinery such as injection moulding robots.
In summary, the application of PCC can not only improve the injection quality and production efficiency but also significantly enhance the degree of automation and reliability of the injection molding machine,
At the same time has a good energy-saving effect and is easy to operate and maintain the characteristics.
Haichen injection molding machine using advanced electrical control system
The advanced electrical control system used in Haichen injection moulding machine includes servo energy-saving technology, intelligent control technology, efficient power drive system and optimised control algorithm.
- Application of servo energy-saving technology
- Intelligent control technology
- Efficient power drive system
- Optimized control algorithms for Types of electrical control system of machines
Application of servo energy-saving technology:
Haichen injection moulding machine adopts the servo energy-saving electric control system based on Techmation controller.
Which is able to control the pressure and flow of the whole machine in a closed loop, effectively reducing energy consumption and improving production efficiency.
We can also provide upgraded KEBA modular PLCs to meet your production needs.
In addition, the control system of the all-electric injection moulding machine also adopts the electro-hydraulic proportional closed-loop control system combining servo motor-driven dosing pump and electro-hydraulic proportional technology, which further improves the control precision and energy-saving effect.
Intelligent control technology:
The control system of Haichen injection molding machine integrates a variety of intelligent functions, such as melt backflow monitoring, mould visual on-line inspection and other advanced functions, which improve the automation level of the injection moulding process and product quality.
Meanwhile, the system also adopts the combination of fuzzy self-tuning PID and prognostic control to improve the precision of temperature control.
Efficient power drive system:
The control system of the all-electric injection moulding machine adopts the high-performance ARM and DSP dual-core architecture, and this design not only improves the processing capacity of the system but also ensures the efficient and high-speed operation of the whole machine.
In addition, the motor of the CNC servo system adopts high-strength rare-earth permanent magnet material, which greatly improves the energy density and efficiency of the motor.
Optimized control algorithms for Types of electrical control system of machines:
The electro-hydraulic system of the energy-saving injection molding machine system is a New control method and control algorithms.
Such as the optimal control algorithm, the application of these algorithms makes the energy-saving injection molding machine system has better dynamic responsiveness and system adaptability.
The advanced electrical control system used in Haichen injection molding machines not only includes servo energy-saving technology and intelligent control technology, but also adopts highly efficient power drive system and optimal control algorithms.
The application of which significantly improves the performance and productivity of the injection molding machines.
And at the same time, meets the requirements of the modern industry in terms of energy saving and environmental protection.
We can configure the suitable electrical control system for your injection molding machine according to your different injection molding production needs.
These types of control systems have their own advantages and disadvantages and are suitable for different production needs and process requirements.
With the development of technology, the modern injection molding machine electrical control system tends to a higher level of automation and intelligence to improve production efficiency and product quality.
