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YaHei;font-size:12px;color:#868686;font-weight:normal;text-decoration:none;line-height:12px;background:#F5F5F5;border-style:solid solid solid solid;border-color:#E5E5E5 #E5E5E5 #E5E5E5 #E5E5E5;border-width:1px 1px 1px 1px;"> </div> <div id="h9fbtxb1v" class="artview_content" style="display:block;font-family:Microsoft YaHei;font-size:14px;color:#5A5A5A;font-weight:normal;text-decoration:none;"> <div id="h9fbtxb1v" class="artview_detail" setsid="article6003"> <p> <span style="line-height:30px;">　　<span style="color:#FFFFFF;background-color:#FF0000;">壓力調(diào)控及計量系統(tǒng)</span></span> </p> <p> <span style="line-height:30px;">　　在油壓式注塑機上，所有運動由負責(zé)以下操作的油路執(zhí)行：</span> </p> <p align="center"> <img style="padding-right:0px;" alt="" src="http://pro7850b0.pic12.websiteonline.cn/upload/5sof.png" /> </p> <p> <span style="line-height:30px;">　　<strong>1、</strong>塑化階段中的螺桿旋轉(zhuǎn)。</span> </p> <p> <span style="line-height:30px;">　　<strong>2、</strong>滑座料道(注嘴靠近注口襯套)。</span> </p> <p> <span style="line-height:30px;">　　<strong>3、</strong>注射和保壓期間射料螺桿的軸向運動。</span> </p> <p> <span style="line-height:30px;">　　<strong>4、</strong>將基材閉合於射料桿上，直到肘桿全部延伸或活塞合模行程已完成。</span> </p> <p> <span style="line-height:30px;">　　<strong>5、</strong>啟動裝配頂桿的頂出臺以頂出部件。</span> </p> <p> <span style="line-height:30px;">　　在全電壓機上，所有運動由配有永久磁鐵的無刷同步電動機執(zhí)行。通過機床業(yè)中一直采用的滾珠軸承螺桿，將旋轉(zhuǎn)運動變換為線性運動。整個流程的效率部分取決於塑化過程，其中，螺桿起十分關(guān)鍵的作用。</span> </p> <p> <span style="line-height:30px;">　　螺桿必須確保物料熔化和均化。這一過程可借助於反壓調(diào)整，以避免過熱?；鞜捲荒墚a(chǎn)生過高的流速，否則，會導(dǎo)致聚合物降解。每一種聚合物具有不同的最大流速，如果超過這一極限，分子會拉伸，出現(xiàn)聚合物主鏈斷裂現(xiàn)象。不過，重點仍然是在注射和保壓過程中控制螺桿的向前軸向運動。後續(xù)的冷卻過程，包括內(nèi)在應(yīng)力、公差和翹曲等方面，對於確保產(chǎn)品質(zhì)量十分重要。</span> </p> <p> <span style="line-height:30px;">　　這一切全由模具質(zhì)量決定，對於優(yōu)化冷卻料道、確保有效的閉環(huán)溫度調(diào)節(jié)時，尤其如此。該系統(tǒng)完全獨立，不會干擾機械調(diào)節(jié)。閉模和頂出等模具運動必須精確高效。通常采用速度分布曲線，以確?；顒硬考蚀_靠近。接觸維持力可調(diào)整。因此可斷定，在不考慮能耗和機械可靠性、附加條件相同(如模具質(zhì)量)的前提下，產(chǎn)品質(zhì)量主要決定於控制螺桿向前運動階段的系統(tǒng)。在油壓式注塑機上，這一調(diào)節(jié)通過探測油壓而實現(xiàn)。具體地說，油壓通過控制板而激活一套閥門，流體通過操縱器而產(chǎn)生作用，并得到調(diào)節(jié)及釋放。</span> </p> <p> <span style="line-height:30px;">　　注射速度控制包括開環(huán)控制、半閉環(huán)控制和閉環(huán)控制等選擇方案。開環(huán)系統(tǒng)依靠共用比例閥。比例張力施加於所需比例的流體上，從而使流體在注射機筒中產(chǎn)生壓力，讓注射螺桿以一定的前向速度運動。半閉環(huán)系統(tǒng)采用閉環(huán)比例閥。環(huán)路在閉合口所在的位置閉合，閉合口通過在閥門內(nèi)的移動而控制油料的流量比例。閉環(huán)系統(tǒng)在螺桿平移速度時閉合。閉環(huán)系統(tǒng)中采用速度傳感器(通常為電位計型)，定時探測張力下降。</span> </p> <p> <span style="line-height:30px;">　　比例閥流出的油料通過調(diào)節(jié)，可補償出現(xiàn)的速度偏差。閉環(huán)控制依靠與機器整合一體的專用電子元件。閉環(huán)壓力控制能在注射和保壓階段確保壓力均勻一致，以及在各個循環(huán)中確保反壓均勻。通過探測出的壓力值對比例閥進行調(diào)節(jié)，根據(jù)設(shè)定壓力值進行偏差補償。</span> </p> <p> <span style="line-height:30px;">　　一般來說，可對液壓進行監(jiān)控，但是，探測注嘴或模腔中的熔體壓力也是另一有效方法。更加可靠的方案是通過閱讀注嘴或模腔壓力讀數(shù)對比例閥進行管理。在壓力探測的基礎(chǔ)上增加溫度探測，特別有利於流程管理。了解物料可承受的實際壓力，還有助於根據(jù)設(shè)定壓力和溫度條件來預(yù)測模塑件的實際重量和尺寸。實際上，通過改變保壓壓力值，可將更多的物料引入模腔，以降低部件收縮，符合設(shè)計公差(其中包括預(yù)設(shè)注塑收縮)。接近熔化條件時，半晶體聚合物顯示出極大的比容變化。對此，過充模不會阻礙部件頂出。</span> </p> <p> <span style="line-height:30px;">　　<span style="color:#FFFFFF;background-color:#FF0000;">油壓設(shè)備與出料量及壓力調(diào)節(jié)</span></span> </p> <p> <span style="line-height:30px;">　　離心泵產(chǎn)生的平均液壓壓力可達140巴，這一壓力值特別適合於注塑。在周期的其它各個階段，要求明顯較低，除了需要快速塑化的特定情形(例如：PET注拉吹一步法注塑機)要求較高。</span> </p> <p> <span style="line-height:30px;">　　為降低能耗，在出料高峰期時可采用可變排量泵和儲壓缸。固定排量泵在每次旋轉(zhuǎn)時移動等量油量，因此，油泵選型由特定時間內(nèi)所需移動的油量而定。三相電動機轉(zhuǎn)速一般為1440轉(zhuǎn)/分，通常要求裝配雙泵。只有在塑化過程中(功率達100%)，油泵的利用率才達到最大限度。在停頓過程中，機械不需要能耗，即使需要，也屬功率損耗。</span> </p> <p> <span style="line-height:30px;">　　所有注塑機均采用質(zhì)量等級各異的比例伺服閥。兩套或以上的比例閥安裝於注射壓機上，目的是對以下各個方面進行準確控制：</span> </p> <p> <span style="line-height:30px;">　　開模速度(兩級)，閉模速度(兩級)，閉模安全性，注射(3-10級)，加料(3-5級)，吸入和頂桿(兩級)。</span> </p> <p> <span style="line-height:30px;">　　開模壓力，閉模壓力，模具安全性，機械夾具(料筒或肘桿)，注射(充模階段一次，後續(xù)階段3-10次)，吸入和反壓(3-5級)。螺桿旋轉(zhuǎn)速度(3-5級)。</span> </p> <p> <span style="line-height:30px;">　　滑座靠近速度(機械注嘴靠近模具固定半模上注射襯墊的速度)以及頂桿的運動速度(頂出臺速度)也可調(diào)整。輔助電動機通過微弱的輸入信號，將放大的信號(輸出信號)發(fā)送到閥門，使伺服閥執(zhí)行調(diào)節(jié)功能。在伺服閥中，微弱的輸入電信號被轉(zhuǎn)化為液壓輸出信號，以壓降的形式根據(jù)所需的出料要求進行改進。閥門必須對張力或通用指令做出快速、可重覆及低滯後的出料響應(yīng)。</span> </p> <p> <span style="line-height:30px;">　　實際上，當(dāng)前研究的目的是改進頻率響應(yīng)，使運行於數(shù)千赫(kHz)頻率的動力設(shè)備(液壓邊)和電子設(shè)備之間進行對話。由於有效出料取決於閥門上聚合度(DP)的作用，因此，液壓線路中的油溫必須保持在45-55℃的範圍內(nèi)(通常采用閉環(huán)調(diào)節(jié)系統(tǒng))，具體根據(jù)流體粘度和過渡口的幾何形狀而定。在閥內(nèi)沒有適當(dāng)?shù)恼{(diào)節(jié)系統(tǒng)，溫度上升會導(dǎo)致溶體粘度下降;若配有均衡開閥值，則可提高出料量。增加傳動系統(tǒng)的出料油量，意味注射速度隨之加快。對高科技伺服傳動閥進行精確控制，可基本消除滯後現(xiàn)象，增強所有功能的重復(fù)性。</span> </p> <p> <span style="line-height:30px;">　　<span style="color:#FFFFFF;background-color:#FF0000;">全電動壓機的力度測定</span></span> </p> <p> <span style="line-height:30px;">　　由於全電動注塑機上不存在引發(fā)運動的矢量流體，因此，不能進行液壓壓力探測。因此，通常采用載荷傳感器，利用伸縮儀測量彈性變形，從而直接測定其力度。全電動注塑機制造商開發(fā)了多種彈性部件，并裝配了相應(yīng)的伸縮儀。另一區(qū)別在於反壓及其控制，可通過向注射電動機產(chǎn)生的軸向移動增加阻力而實現(xiàn)，而另一電動機致使螺桿旋轉(zhuǎn)和後續(xù)物料塑化。以前，有些機械制造商采用安裝在注嘴內(nèi)換能器的測量系統(tǒng)，後來因為“功能性和可靠性不足”而放棄了該系統(tǒng)。</span> </p> <p> <span style="line-height:30px;">　　<span style="color:#FFFFFF;background-color:#FF0000;">注嘴壓力測定的優(yōu)點</span></span> </p> <p> <span style="line-height:30px;">　　以上已證明了壓力調(diào)節(jié)在注射和保壓過程中的重要性。因此，壓力探測的準確性和重復(fù)性是十分關(guān)鍵的因素。在閉環(huán)系統(tǒng)中，壓力探測十分重要，只有確保準確的壓力探測，調(diào)節(jié)器才能使實際壓力接近於或等於設(shè)定值。在開環(huán)系統(tǒng)中，由於直接與傳動系統(tǒng)相連接，因此壓力探測的準確性和重復(fù)性更加重要。</span> </p> <p> <span style="line-height:30px;">　　現(xiàn)在，開環(huán)系統(tǒng)仍在使用，在高噸位機型中的應(yīng)用更加廣泛。一般來說，基於設(shè)定值的速度控制在注射過程中進行(也就是說，速度變化由電位計或磁致收縮傳感器測定)，測定後轉(zhuǎn)換為壓力調(diào)節(jié)。通路可根據(jù)配額(配額通路)或壓力予以啟動。無論如何，當(dāng)壓力啟動通路同時也作為“截口”以限制充模壓力、防止溢料形成及模具受損時，均必須采用壓力啟動通路。</span> </p> <p> <span style="line-height:30px;">　　一旦形成通路，後續(xù)的保壓過程即由壓力調(diào)節(jié)(型材亦不例外)。液壓機的壓力一般在液壓線路中探測，很少在模具注嘴中進行。對於注塑而言，必須盡量將探測點靠近模腔。因此，模具壓力測定最好在注嘴處進行，即使不太直接，也可在液壓線路內(nèi)進行壓力測定。</span> </p> <p> <span style="line-height:30px;">　　與模具壓力探測不同的是，注嘴內(nèi)探測還能通過調(diào)節(jié)反壓而控制塑化過程。當(dāng)接近注射的壓力實際達到設(shè)定值并在材料注塑所需的時間內(nèi)保持這一壓力時，模具壓力探測可實現(xiàn)轉(zhuǎn)換。</span> </p> <p> <span style="line-height:30px;">　　測定可直接進行，也可通過探針進行(如：壓電傳感器)。在模具內(nèi)進行直接探測十分有效，唯一的局限性是會在模塑件上留下痕跡。間接探測往往受探針結(jié)構(gòu)和間隙的影響，例如，公差過大會導(dǎo)致材料傾瀉，致使探測準確性不足。</span> </p> <p> <span style="line-height:30px;">　　注嘴壓力探測比模腔壓力探測的有效性較低，因為材料還得經(jīng)過一段流道路線(或冷或熱)。但是，注嘴壓力探測具有某些優(yōu)點，主要包括：探測在材料上進行;不需要對模具進行改造;模塑件上不留下任何痕跡。通過熔體壓力控制(最好在模腔內(nèi)進行)，可避免在初始壓力下造成充模過量(隨後形成溢料)的風(fēng)險。由此，可提高控制的有效性，避免材料燒焦，防止充模不足，縮短周期時間，增強重復(fù)性。</span> </p> <p> <span style="line-height:30px;">　　生產(chǎn)能確保系統(tǒng)可靠性且使用方便的傳感器確實存在一些技術(shù)問題。</span> </p> <p> <span style="line-height:30px;">　　如果要求均勻調(diào)節(jié)反壓，流程相關(guān)的難度確實不小。</span> </p> <p> <span style="line-height:30px;">　　<span style="color:#FFFFFF;background-color:#FF0000;">注嘴壓力探測所用的傳感器必須符合以下要求：</span></span> </p> <p> <span style="line-height:30px;">　　▲不能干擾模塑過程。</span> </p> <p> <span style="line-height:30px;">　　▲能在高壓(2500巴)及高溫(350-400℃)下確保探測精確度。</span> </p> <p> <span style="line-height:30px;">　　▲體積小巧，結(jié)構(gòu)堅實，在發(fā)生故障時便於更換。</span> </p> <p> <span style="line-height:30px;">　　▲與充模料接觸時，具有優(yōu)良的耐磨性。</span> </p> <p> <span style="line-height:30px;">　　▲能長期保證探測有效性(長時間使用後出現(xiàn)磨擦、污染時，能確保測量無偏差、無誤差、無滯後)。</span> </p> <p> <span style="line-height:30px;">　　▲提供高速取樣(2-5微秒)和標準化通信協(xié)議，如：CAN開放式版本CANbus或DeviceNet。</span> </p> <p> <span style="line-height:30px;">　　因此，問題較為復(fù)雜。不難理解的是，迄今為止，液壓機仍然將傳感器配置於液壓線路內(nèi)，全電動機則采用力度探測，兩者均未采用熔體傳感器。多年來，熔體傳感器廣泛用於擠塑機上，但是，擠塑機對探測範圍、精確度、響應(yīng)時間和結(jié)構(gòu)堅實度等方面的要求較低(與擠塑機上的靜態(tài)應(yīng)力相比，安裝於注射機上時，傳感器薄膜上承受的機械疲勞應(yīng)力要大得多)。</span> </p> <p align="center"> <span style="color:#FF0000;line-height:30px;font-size:14px;"><strong>專業(yè)液態(tài)硅膠設(shè)備生產(chǎn)制造廠商</strong></span> </p> <p align="center"> <span style="color:#FF0000;line-height:30px;font-size:14px;"><strong>歡迎來電</strong></span> </p> <p align="center"> <span style="color:#FF0000;line-height:30px;font-size:14px;"><strong>肖經(jīng)理：18321638559</strong></span> </p> <div style="clear:both;"></div> </div> </div> <div id="h9fbtxb1v" class="artview_prev_next"> <div style="margin-top:20px;width:100%;"> <div style="float:right;" > <div class="prevlist"> <a class="prev_next_link" style="display:block;float:left;" 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