新型全电动注塑机合模机构的设计及性能分析
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摘要
随着国民经济的持续繁荣,我国塑料工业得到了快速的发展,尤其广泛的应用在汽车、电子、家电等行业。不同行业对塑料制品的精度、形状、功能以及成本都有了更高的要求,因此需要对注塑机的性能进行改进。合模装置是注塑机关键部件之一,它的结构和性能直接影响到塑料制品的尺寸精度、质量以及注塑机整机的工作性能和生产能力。因此提高合模机构性能迫在眉睫,只有保证合模机构在合模速度、合模精度以及锁模力上达到相关的要求才能满足这些制品的生产,所以我国要大力研发合模机构的核心技术。
本文对现有注塑机合模机构的优点与弊端进行分析,进一步提出新型注塑机合模机构的设计方案,以及对新型合模机构的结构进行分析并最终确定出差动式合模机构以及封闭加载式合模机构两种形式。然后对差动式齿轮机构的功率流向进行分析,差动式合模机构将异步电动机和步进电机生成的输入运动通过两个自由度的ZUWGW型2K-H差动轮系合成后,产生可编程的输出运动。同时异步电动机和步进电机混合驱动,其中异步电动机提供较大的功率,步进电机起调节的作用,二者的组合,有效地代替了大功率步进电机,从而能实现高锁模力、高效率、运行速度快、低能耗、低成本。本文还对封闭加载式合模机构传动原理进行说明,并对封闭加载式合模机构进行分析。封闭加载式合模机构的改进之处在于采用封闭式差动齿轮机构,以及利用步进电机对行星差动齿轮加载装置进行加载,使整个封闭轮系中形成大的功率流,步进电机提供较小的功率便可以得到较大的锁模力。
Along with the development of economic prosperity, plastic industry obtained fast development in our country, especially used in automobile, electronics,electrical appliances etc.Various industries required plastic products accuracy, shape, function and cost have a higher precision, so need to improve injection performance. Clamping system is one of the key parts for all electric injection molding machine, the structure and properties of injection molding machine directly affect plastic dimension precision and quality,it also influence the whole machine working performance and production capacity. So improvement the clamping system's performance is imminent, we should guarantee the mould speed, precision and the mould clamping force to meet these related products of the production.In one word, our country should improvement clamping system's core technology.
In this paper we found existing clamping system's advantages and disadvantages,and then put forward two new clamping system mould,2K-H differential gear trains clamping systems and the closed load pattern clamping systems of all electric injection molding machine.Based on design the 2K-H differential gear trains clamping systems of all electric injection molding machine and analysis power flow of differential gears.2K-H differential gear trains clamping systems make asynchronous motors and step-motor generated through two degrees of freedom ZUWGW 2K-H differential gear trains, this finally produce programmable output motion, while asynchronous motors and stepping motor hybrid drive, which effectively instead of high-power stepping motor, Thus can achieve high clamping force, high efficiency, high speed, low energy consumption.Based on design the closed load pattern clamping systems of all electric injection molding machine and analysis enclosed differential gear trains.The improvement of this institutions in using enclosed differential gears and using stepper motors load on differential gears loading device,and this can make big power flow in the whole enclosed gear trains,which also can make the stepping motor provides small power,but achieve high clamping force and low energy consumption.
本文对现有注塑机合模机构的优点与弊端进行分析,进一步提出新型注塑机合模机构的设计方案,以及对新型合模机构的结构进行分析并最终确定出差动式合模机构以及封闭加载式合模机构两种形式。然后对差动式齿轮机构的功率流向进行分析,差动式合模机构将异步电动机和步进电机生成的输入运动通过两个自由度的ZUWGW型2K-H差动轮系合成后,产生可编程的输出运动。同时异步电动机和步进电机混合驱动,其中异步电动机提供较大的功率,步进电机起调节的作用,二者的组合,有效地代替了大功率步进电机,从而能实现高锁模力、高效率、运行速度快、低能耗、低成本。本文还对封闭加载式合模机构传动原理进行说明,并对封闭加载式合模机构进行分析。封闭加载式合模机构的改进之处在于采用封闭式差动齿轮机构,以及利用步进电机对行星差动齿轮加载装置进行加载,使整个封闭轮系中形成大的功率流,步进电机提供较小的功率便可以得到较大的锁模力。
Along with the development of economic prosperity, plastic industry obtained fast development in our country, especially used in automobile, electronics,electrical appliances etc.Various industries required plastic products accuracy, shape, function and cost have a higher precision, so need to improve injection performance. Clamping system is one of the key parts for all electric injection molding machine, the structure and properties of injection molding machine directly affect plastic dimension precision and quality,it also influence the whole machine working performance and production capacity. So improvement the clamping system's performance is imminent, we should guarantee the mould speed, precision and the mould clamping force to meet these related products of the production.In one word, our country should improvement clamping system's core technology.
In this paper we found existing clamping system's advantages and disadvantages,and then put forward two new clamping system mould,2K-H differential gear trains clamping systems and the closed load pattern clamping systems of all electric injection molding machine.Based on design the 2K-H differential gear trains clamping systems of all electric injection molding machine and analysis power flow of differential gears.2K-H differential gear trains clamping systems make asynchronous motors and step-motor generated through two degrees of freedom ZUWGW 2K-H differential gear trains, this finally produce programmable output motion, while asynchronous motors and stepping motor hybrid drive, which effectively instead of high-power stepping motor, Thus can achieve high clamping force, high efficiency, high speed, low energy consumption.Based on design the closed load pattern clamping systems of all electric injection molding machine and analysis enclosed differential gear trains.The improvement of this institutions in using enclosed differential gears and using stepper motors load on differential gears loading device,and this can make big power flow in the whole enclosed gear trains,which also can make the stepping motor provides small power,but achieve high clamping force and low energy consumption.
引文
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[2]Johannaber F.Injection molding machines-a user's guide [M].New York:Hanser Publishers,1994
[3]林宏权,蒋卫东,林达.全电动式注塑机的发展现状及展望[J].塑料工业,2005,33(4)：1-4
[4]黄步明.细数全液压与全电动之短长[J].世界塑料,2006,124(1)：30-32
[5]黄步明.世纪之争-全液压与全电动式注塑机的比较[J].中国塑料,2001,15(3)：1-4
[6]张春伟,刘海江.肘杆式注塑机合模机构合模点配置方法研究[J].塑料工业,2008,36(6)：34-36
[7]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
[8]耿孝正,刘第宇.塑料成型机械[M].北京：中国轻工业出版社：1982
[9]Wang YS.The investigation of hydraulic servo system design for high-speed injection molding [J].MS thesis,Chung Yuan University,Jhongli,TaiWan;2001
[10]Su PM.Control system design and implementation of a hydraulic plastic injection molding machine [J].Department of Electrical Engineering,Chung Hsing University. Taichung,Taiwan;2004
[11]黄步明.四缸直锁二板式精密注塑机的研制[J].中国塑料,1999,13(1)：70-74
[12]陈明,刘兴华,肘杆式合模机构的优化设计[J].塑料科技,1990,(1)：42-47
[13]Stefan Engleder.Time-optimal motion planning and control of an electrohydraulically actuated toggle mechanism [J].Mechatronics, Volume 17, Issue 8, October 2007, Pages 448-456
[14]Wen Yi Lin, Kuo Mo Hsiao, Investigation of the friction effect at pin joints for the five point double-toggle clamping mechanisms of injection molding machines [J],International Journal of Mechanical Sciences, Volume 45, Issue 11, November 2003, Pages 1913-1927
[15]A.L.Kelly, M.Woodhead, P.D.Coates. CoMParison of Injection Molding Machine Performance [M],2005
[16]傅南红,张建国.环保式伺服电动注塑机控制技术研究[J].塑料工业,2002,30(2)：34-36
[17]Liao FS. Control system design and implementation of an all-electric plastic injection molding machine [J]. MS thesis, Department of Electrical Engineering,National Chung Hsing University, Taichung, Taiwan:2002
[18]章泽英.无拉杆注塑机的特点[J].塑料,1993,22(1)：26-27
[19]王向东,杨惠娣.注塑成型技术进展[J].中国塑料,2001,15(10)：1-6
[20]任鸿烈,曹贤武.由NPE2000看世界注塑成型技术的发展[J].轻工机械,2002,15(2)：4-6
[21]黄步明,许忠斌.高速超精密注塑机的技术进展及发展动向[J].工程塑料应用,2002,12(2)： 47-49
[22]李汉堂.世界上最大的全电动注压成型机[J].橡塑技术与装备,2002,12(10)：10
[23]Asami, Muneaki, Yoshikawa. Development of a desktop micro Injection molding machine [J].Key Engineering Materials,2002,238
[24]金波,宁德胜.注塑机控制系统的现状及发展趋势[J].液压与气动,2006,12(1)：7-11
[25]Smock,Doug. New electric machine reduces cycle times [J].Plastics World,1996,54(6):4
[26]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]. Mechatronics,2009,19:147-155
[27]黄灿军.注塑机合模装置的技术及研究进展[J].广东塑料,2006,12(2)：46-48
[28]向鹏.全电动注塑机的特点及应用领域[J].现代塑料加工应用,2007,19(1)：52-54
[29]杨卫民,邵珠娜,谢鹏程.全电动注塑机混合驱动式合模机构[P].中国专利,ZL2008201241274.2009-12-2
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[31]肖正义.滚珠丝杠副的发展趋势[J].制造技术与机床,2000(4)：11-12
[32]谢应善.滚珠丝杠副的结构及调整方法[J].机械工人,2006(5)：21-22
[33]王志民,张西忠,厉勇.滚珠丝杠传动使用与发展[J].机电工程技术,2004,33(9)：88-89
[34]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
[35]Dominic S. Guevarra, Akira Kyusojin, Hiromi Isobe and so on.Development of a new lapping method for high precision ball screw-feasibility study of a prototyped lapping tool for automatic lapping process [J].Journal of the International Societies for Precision Engineering and Nanotechnology,2001,25:63-69
[36]Dietmar Kuhn.滚轴丝杠传动机构[J].现代制造,2002(16)：50
[37]丁东升.电动注塑机合模机构的常用结构及其对比[J].轻工机械,2006,24(1)：141-143
[38]罗远强,施优优,王珏等.精密注塑机新型合模机构[J].轻工机械,2008,26(5)：10-13
[39]饶振纲,王勇卫.滚珠丝杠副及自锁装置[M].北京：国防工业出版社,1990
[40]列维茨卡娅,列维茨基.机械原理教程[M].北京：人民教育出版社,1981
[41]杨廷栋.渐开线齿轮行星传动[M].成都：成都科技大学出版社,1986
[42]安子军,张善璞,李纯德.机械原理教程[M].北京：机械工业出版社,2003
[43]Jose M,del Castillo.The analytical expression of the efficiency of planetary gear trains [J].Mechanism and Machine Theory,2002,37:197-214
[44]王成,方宗德.2K-H型差动轮系传动效率简化计算的研究[J].北京联合大学学报(自然科学版),2007,21(2)：23-26
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