新型二板式注塑机合模装置优化分析研究
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摘要
注塑机是集机械、电子、液压多方面技术于一体的先进制造装备,是塑料制品最主要的生产母机,现代制造业中80%以上的塑料制品采用注射成型。随着液压及电气控制技术的发展,元器件的性能日臻完善,使液压式合模装置液压系统结构大大简化、性能却得到不断地改善和提高、价格也越来越低,并且人们对塑料制品的要求越来越高,要求材料的强度也越来越高,其模具则更趋复杂,同时也要求生产效率不断提高,如何给客户提供高档精密的、能够满足各种功能甚至更加保护模具的注塑机将越来越重要,而其中决定这些性能的关键是注塑机的合模装置。合模装置成了注射成型机在发展过程中急需解决的一个重要问题,为提高机器的加工能力和效率,而需发展相应的合模装置,实现其大合模力、高速、低能耗、安全可靠、结构简单和重量轻等方面要求。本课题在前人的基础上经过改进和提高推出新型四缸直锁内循环二板式注塑机合模装置。
本论文结合虚拟样机技术和动力学系统建模理论,以新型全液压内循环二板式注塑机合模装置为研究对象,着眼二板式注塑机的发展前景,对新型的合模机构进行优化分析研究。利用ADAMS动力学分析软件的ADAMS/View模块建立经过简化的注塑机合模装置的几何模型,并联合ADAMS/Hydraulics模块对液压系统回路进行动态性能的耦合仿真。确立参数的目标函数,通过分析不同参数下液压缸的压力、流量、速度及受力情况,得到液压缸的速度和位移变化曲线,做出相应优化,并且在物理样机上结合实际条件进行实验验证,结合实验数据和模拟结果进行对比分析,证明仿真的正确性与有效性。最后利用ADAMS/Flex模块建立合模机构的刚柔耦合模型,进行碰撞仿真测试,对新型二板式注塑机液压合模机构模板之间可能存在的倾斜现象进行论证,并分析模拟仿真结果。
The injection molding machine is an advanced piece of manufacturing equipment integrating mechanics, electronics, hydraulics and so on. Injection molding is a major part of the plastics industry. More than 80% of all ther-moplastic products are injection molded, and more than half of all polymer-processing equipments are for injection molding. With the development of hydraulic and electrical control technology, and the performance of compo-nents is improving, hydraulic clamping device greatly simplifies the structure of the hydraulic system, the performance has been continuously improved and enhanced, and the price is getting lower and lower. Injection molding machine clamping device has become an important issue in the development process of injection Molding Machine, in order to improve the machine's processing ca-pacity and efficiency, while the need to develop appropriate clamping device, we need achieve large clamping force, high speed, low power, secure, reliable, simple structure and light weight requirements, etc. This paper introduces a new injection molding machine with four cylinders actuation lock for two-plates(Dominick et al.2000) and the developing prospects of mechani-cal-electrical-hydraulic integration on the basis of the previous.
The thesis focused on virtual prototyping technology and dynamic sys-tems modeling theory to a newly two plate inner loop hydraulic injection molding machine clamping device for the study, and make the optimal analy-sis based on the development prospects of two plate injection molding ma-chine.
The simplified geometric solid model of clamping unit is established by using ADAMS/View module and the simulation is started with coupling the hydraulics circuit in ADAMS/Hydraulics environment. Through the analysis of the different parameters of pressure, flow rate and stress, we can obtain the speed and displacement curve of hydraulic cylinder, and make optimization. And in light of actual conditions on the physical prototype experimental vali-dation, experimental data and simulation results were compared to prove the correctness and validity of simulation. Finally, using the ADAMS/Flex module to establish flexible coupling model for crash simulation testing, and prove the inclined phenomenon that may exist between templates, then analyze the si-mulation results.
本论文结合虚拟样机技术和动力学系统建模理论,以新型全液压内循环二板式注塑机合模装置为研究对象,着眼二板式注塑机的发展前景,对新型的合模机构进行优化分析研究。利用ADAMS动力学分析软件的ADAMS/View模块建立经过简化的注塑机合模装置的几何模型,并联合ADAMS/Hydraulics模块对液压系统回路进行动态性能的耦合仿真。确立参数的目标函数,通过分析不同参数下液压缸的压力、流量、速度及受力情况,得到液压缸的速度和位移变化曲线,做出相应优化,并且在物理样机上结合实际条件进行实验验证,结合实验数据和模拟结果进行对比分析,证明仿真的正确性与有效性。最后利用ADAMS/Flex模块建立合模机构的刚柔耦合模型,进行碰撞仿真测试,对新型二板式注塑机液压合模机构模板之间可能存在的倾斜现象进行论证,并分析模拟仿真结果。
The injection molding machine is an advanced piece of manufacturing equipment integrating mechanics, electronics, hydraulics and so on. Injection molding is a major part of the plastics industry. More than 80% of all ther-moplastic products are injection molded, and more than half of all polymer-processing equipments are for injection molding. With the development of hydraulic and electrical control technology, and the performance of compo-nents is improving, hydraulic clamping device greatly simplifies the structure of the hydraulic system, the performance has been continuously improved and enhanced, and the price is getting lower and lower. Injection molding machine clamping device has become an important issue in the development process of injection Molding Machine, in order to improve the machine's processing ca-pacity and efficiency, while the need to develop appropriate clamping device, we need achieve large clamping force, high speed, low power, secure, reliable, simple structure and light weight requirements, etc. This paper introduces a new injection molding machine with four cylinders actuation lock for two-plates(Dominick et al.2000) and the developing prospects of mechani-cal-electrical-hydraulic integration on the basis of the previous.
The thesis focused on virtual prototyping technology and dynamic sys-tems modeling theory to a newly two plate inner loop hydraulic injection molding machine clamping device for the study, and make the optimal analy-sis based on the development prospects of two plate injection molding ma-chine.
The simplified geometric solid model of clamping unit is established by using ADAMS/View module and the simulation is started with coupling the hydraulics circuit in ADAMS/Hydraulics environment. Through the analysis of the different parameters of pressure, flow rate and stress, we can obtain the speed and displacement curve of hydraulic cylinder, and make optimization. And in light of actual conditions on the physical prototype experimental vali-dation, experimental data and simulation results were compared to prove the correctness and validity of simulation. Finally, using the ADAMS/Flex module to establish flexible coupling model for crash simulation testing, and prove the inclined phenomenon that may exist between templates, then analyze the si-mulation results.
引文
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[3]王兴天.国内注塑机发展概述[J].塑料科技,2000,4：28-29
[4]许颖,方子帆.注塑机合模装置的结构及发展[J].机械工程师,2006,1：119-122
[5]北京化工学院,华南理工学院合编.塑料机械设计[M].北京：中国轻工业出版社,1994：19-112
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[8]Kikuo Watanabe, Mitsuski Yoshioka. Two-Plate Type Injectiong Apparatus [P]. United States Patent, WO5129808.1992-6-14
[9]Heinrich Leonhartsberger, Werner Kappelmuller, Stefan Eppich, InjectionMoulding Machine[P], United States Patent, WO5454709.1995-10-3
[10]A.L.Kelly, M. Woodhead, P.D.Coates. Comparison of Injection Molding Machine Performance [J]. Polymer Engineering and Science,2005:857-864
[11]黄步明.世纪之争-全液压式与全电动式注塑机的比较[J].中国塑料,2001,3(15)：1-4
[12]黄步明.四缸直锁二板式注塑机及精密注射成型技术关键[J].塑胶工业,2000,8：20-24
[13]章胜亮.二板式注塑机的技术探讨及发展前景[J].轻工机械,2001,9(1)：15-18
[14]张小萍.二板式锁模装置的结构改进[J].机械工程师,2002,2：65-66
[15]王兴天.注塑成型技术[M].北京：化学工业出版社,1991,286-290
[16]杨卫民,丁玉梅,谢鹏程.注射成型新技术[M].北京：化学工业出版社.2008,97-130
[17]张玉梅.从全液压式二板注塑机看机电一体化[J].科技情报开发与经济,2003,4(7)：124-125
[18]焦志伟.全液压内循环二板式注塑机的结构与性能研究[J].塑料,2009,38(6)：112-115
[19]Shu Huang Sun. Optimum topology design for the stationary platen of a plastic injection machine [J]. Computers in Industry,2004(55):147-158
[20]夏明,王兴天.注塑机合模机构优化设计研究[J].北京化工学院学报,1990,17(4)：58-68
[21]廖小平,兰芳,覃波.基于CAE的注塑件结构及成型工艺参数优化[J].工程塑料应用,2009,37(5)：42-44
[22]Zhe Wei, Yi-xiong Feng, Jian-rong Tan. Multi-objective performance optimal design of large scale injection molding machine [J], Int J Adv Manuf Technol,2009,41:242-249
[23]胡斌.虚拟样机技术及其在注塑机设计中的应用[J].轻工机械,2007,27(5)：4-6
[24]陈立平,张云清,任卫群,等.机械系统动力学分析及ADAMS应用教程[M].北京：清华大学出版社,2004,30-85
[25]王国强,张进平,马若丁.虚拟样机技术及其在ADAMS上的实践[M].西安：西北工业大学出版社,2002,112-113
[26]郭卫东.虚拟样机技术与ADAMS应用实例教程[M].北京：北京航空航天大学出版社.2005
[27]Aki Mikkola, Heikki Handroos, Erkki Niemi. Using ADAMS-simulation for predicting force histories for the fatigue analysis of a log crane [J]. Lappeenranta University of Technology De-partment of Mechanical Engineering,1995,4-9
[28]欧笛声,周雄新；刘旭红.注塑机拉杆与模板的整体应力分析[J].轻工机械,2008,26(4)：8-12
[29]续彦芳,崔俊杰,苏铁雄.虚拟样机技术及其在ADAMS中的应用[J].机械管理开发,2005, (3)：70-71
[30]Ching-Chih Tsai, Shih-Min Hsieh, Huai-En Kao. Mechatronic design and injection speed control of an ultra high-speed plastic injection molding machine[J]. C.-C. Tsai et al./Mechatronics, 2009,19:147-155
[31]程燕,鲍务均.综述基于ADAMS的液压仿真虚拟样机技术[J].机械研究与应用,2005,18(1)：94-95
[32]李增刚ADAMS入门详解与实例[M].北京：国防工业出版社.2006
[33]王金刚,崔根群,周志革.吊管机液压与机械一体化模型的建立和仿真[J],起重运输机械,2004,(12)：27-29
[34]MSC.Software Corporation. ADAMS/Hydraulics Component Reference [BD/OL].2006-12-05, PP.4-29
[35]杨永海.新型冲击式液压桩锤系统设计及仿真研究[D].吉林：吉林大学机械科学与工程学院,2008
[36]邓鹏,潘尚峰.基于ADAMS/Hydraulic的液压缸机械损失参数的研究[J].液压与气动,2006(12)：83-85
[37]方洋.混合驱动五干机构的分析与综合[D].北京：北京化工大学机电学院,2007
[38]吴墩明.基于ADAMS的液压破碎机液压系统仿真[J].安徽工业大学学报,2007,24(3)：288-292.
[39]万强,许平勇,潘玉龙.举升机构液压系统的动力学仿真分析[J],空军雷达学院学报,2006,20(1)：75-78
[40]余新康,王健.基于ADAMS的液压系统虚拟样机[J].工程机械,2003(11)：42-45
[41]郭金平,袁思聪,罗丹.基于ADAMS的多功能开沟机液压系统建模与仿真[J].建筑机械,2006，10：59-63
[42]MSC.Software Corporation. Getting Started Using ADAMS/Hydraulics [BD/OL].2006-10-05
[43]时培成,王幼民,王立涛.挖掘机液压机械复合系统建模与仿真研究[J].机械传动,2007,31(3)：26-29
[44]江涛,李洪平,翁海珊.基于ADAMS的自行式液压翻车机工作机构的动力学分析与仿真[J].矿山机械,2007,8(35)：79-82
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[50]Vincent Chang. Injection Drive Mechanism for a Servo Injection Molding Machine [P]. United States Patent Application Publication, WO0188597.2006-8-24
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[52]李军,邢俊文,覃文洁,等ADAMS实例教程[M].北京：北京理工大学出版社,2002,75-79
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[2]王兴天.中国塑料机械发展现状与出口前景[J].塑料制造,2008,7：34-37
[3]王兴天.国内注塑机发展概述[J].塑料科技,2000,4：28-29
[4]许颖,方子帆.注塑机合模装置的结构及发展[J].机械工程师,2006,1：119-122
[5]北京化工学院,华南理工学院合编.塑料机械设计[M].北京：中国轻工业出版社,1994：19-112
[6]黄步明.四缸直锁二板式精密注塑机的研制[J].中国塑料,1999,1(13)：70-74
[7]黄步明.二板式注塑机的技术发展[J].工程塑料应用,2000,1(6)：32-35
[8]Kikuo Watanabe, Mitsuski Yoshioka. Two-Plate Type Injectiong Apparatus [P]. United States Patent, WO5129808.1992-6-14
[9]Heinrich Leonhartsberger, Werner Kappelmuller, Stefan Eppich, InjectionMoulding Machine[P], United States Patent, WO5454709.1995-10-3
[10]A.L.Kelly, M. Woodhead, P.D.Coates. Comparison of Injection Molding Machine Performance [J]. Polymer Engineering and Science,2005:857-864
[11]黄步明.世纪之争-全液压式与全电动式注塑机的比较[J].中国塑料,2001,3(15)：1-4
[12]黄步明.四缸直锁二板式注塑机及精密注射成型技术关键[J].塑胶工业,2000,8：20-24
[13]章胜亮.二板式注塑机的技术探讨及发展前景[J].轻工机械,2001,9(1)：15-18
[14]张小萍.二板式锁模装置的结构改进[J].机械工程师,2002,2：65-66
[15]王兴天.注塑成型技术[M].北京：化学工业出版社,1991,286-290
[16]杨卫民,丁玉梅,谢鹏程.注射成型新技术[M].北京：化学工业出版社.2008,97-130
[17]张玉梅.从全液压式二板注塑机看机电一体化[J].科技情报开发与经济,2003,4(7)：124-125
[18]焦志伟.全液压内循环二板式注塑机的结构与性能研究[J].塑料,2009,38(6)：112-115
[19]Shu Huang Sun. Optimum topology design for the stationary platen of a plastic injection machine [J]. Computers in Industry,2004(55):147-158
[20]夏明,王兴天.注塑机合模机构优化设计研究[J].北京化工学院学报,1990,17(4)：58-68
[21]廖小平,兰芳,覃波.基于CAE的注塑件结构及成型工艺参数优化[J].工程塑料应用,2009,37(5)：42-44
[22]Zhe Wei, Yi-xiong Feng, Jian-rong Tan. Multi-objective performance optimal design of large scale injection molding machine [J], Int J Adv Manuf Technol,2009,41:242-249
[23]胡斌.虚拟样机技术及其在注塑机设计中的应用[J].轻工机械,2007,27(5)：4-6
[24]陈立平,张云清,任卫群,等.机械系统动力学分析及ADAMS应用教程[M].北京：清华大学出版社,2004,30-85
[25]王国强,张进平,马若丁.虚拟样机技术及其在ADAMS上的实践[M].西安：西北工业大学出版社,2002,112-113
[26]郭卫东.虚拟样机技术与ADAMS应用实例教程[M].北京：北京航空航天大学出版社.2005
[27]Aki Mikkola, Heikki Handroos, Erkki Niemi. Using ADAMS-simulation for predicting force histories for the fatigue analysis of a log crane [J]. Lappeenranta University of Technology De-partment of Mechanical Engineering,1995,4-9
[28]欧笛声,周雄新；刘旭红.注塑机拉杆与模板的整体应力分析[J].轻工机械,2008,26(4)：8-12
[29]续彦芳,崔俊杰,苏铁雄.虚拟样机技术及其在ADAMS中的应用[J].机械管理开发,2005, (3)：70-71
[30]Ching-Chih Tsai, Shih-Min Hsieh, Huai-En Kao. Mechatronic design and injection speed control of an ultra high-speed plastic injection molding machine[J]. C.-C. Tsai et al./Mechatronics, 2009,19:147-155
[31]程燕,鲍务均.综述基于ADAMS的液压仿真虚拟样机技术[J].机械研究与应用,2005,18(1)：94-95
[32]李增刚ADAMS入门详解与实例[M].北京：国防工业出版社.2006
[33]王金刚,崔根群,周志革.吊管机液压与机械一体化模型的建立和仿真[J],起重运输机械,2004,(12)：27-29
[34]MSC.Software Corporation. ADAMS/Hydraulics Component Reference [BD/OL].2006-12-05, PP.4-29
[35]杨永海.新型冲击式液压桩锤系统设计及仿真研究[D].吉林：吉林大学机械科学与工程学院,2008
[36]邓鹏,潘尚峰.基于ADAMS/Hydraulic的液压缸机械损失参数的研究[J].液压与气动,2006(12)：83-85
[37]方洋.混合驱动五干机构的分析与综合[D].北京：北京化工大学机电学院,2007
[38]吴墩明.基于ADAMS的液压破碎机液压系统仿真[J].安徽工业大学学报,2007,24(3)：288-292.
[39]万强,许平勇,潘玉龙.举升机构液压系统的动力学仿真分析[J],空军雷达学院学报,2006,20(1)：75-78
[40]余新康,王健.基于ADAMS的液压系统虚拟样机[J].工程机械,2003(11)：42-45
[41]郭金平,袁思聪,罗丹.基于ADAMS的多功能开沟机液压系统建模与仿真[J].建筑机械,2006，10：59-63
[42]MSC.Software Corporation. Getting Started Using ADAMS/Hydraulics [BD/OL].2006-10-05
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