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Mould temperature controller with mould load adaptation

2024/12/18 By Topstar

The mould temperature controller is a core product among the auxiliary equipment around the injection molding machine. Its temperature control accuracy will directly affect the quality of the injection moulded product. Especially in industrial automation control, there is a common problem when performing temperature control: a time delay in the system response, which leads to difficulties in the control process. To better solve this problem and ensure the accuracy and stability of temperature control, Topstar proposed the method of “mold load adaptive temperature intelligent control” to upgrade the traditional PID control algorithm of the mould temperature controller so that the equipment can automatically adapt to load changes and make intelligent adjustments like unmanned driving.

Market size and technical challenges of mould temperature controller

According to the “In-depth Research and Future Trend Analysis Report on the Development of Global and Chinese Injection Molding Machine Auxiliary Equipment Industry from 2023 to 2029”, the global mould temperature controller sales reached US$520 million in 2023, accounting for 32% of the auxiliary equipment market.

Although the market size of mould temperature controllers accounts for one-third of the auxiliary machine market, there are still technical challenges. Through in-depth research on the actual application scenarios of 15,000 customers, Topstar found that although the control technology of the mould temperature controller had reached the “semi-automation” stage after several iterations, external load changes, such as mould size adjustments or seasonal temperature shifts, could cause the temperature control accuracy to decline if users did not adjust the parameters in time. Product quality will be difficult to guarantee. In addition, traditional PID controllers rely heavily on setting control parameters and require skilled operators to make professional adjustments.

Market size and technical challenges of mold temperature controller

What is the PID algorithm in the mould temperature controller?

PID is a proportional (P), integral (I), and differential (D) control algorithm that can dynamically adjust the control input according to the difference between the expected output and the actual output of the system. By adjusting the three parameters in the PID controller, the system can reduce its hysteresis effect, enhance its stability, avoid strong oscillations, and improve control accuracy.

The upgraded PID control algorithm is the unmanned driving system of the car:

“P” is adjusted according to the current error size to help the system approach the target value faster. “I” is adjusted according to the accumulation of past errors to eliminate the deviation accumulated by the system. “D” is adjusted according to the rate of change of the error to improve the system’s stability and prevent system oscillation.

New temperature control solution

“Speed ​​and accuracy” are two key indicators to measure the quality of the mould temperature controller. Adjusting the three parameters P, I, and D in the PID control algorithm is the key to achieving these indicators. We hope the equipment can automatically operate in the customer’s factory with just one button. Therefore, Topstar uses evaluation functions and mathematical models to adjust the parameters of the control algorithm in real-time based on traditional PID control.

After adopting the “mould load adaptive temperature intelligent control” method, the mould temperature controller increases the heating speed by 20% and reaches the target state quickly and stably. At the same time, it can also reduce preparation time and improve production efficiency. In addition, the temperature control accuracy reaches ±0.1℃, which reduces the fluctuation of mould temperature so that the mould temperature controller can meet the production needs of precision products such as aerospace, electronics, and new energy vehicles.

mould temperature controller 15-1

Trends in digitalization and intelligence

At the digital level, the injection molding machine interconnects with the mould temperature controller, supports host call signals, and achieves seamless connection with the Internet through the digital MES system. Customers can access the equipment data in real-time on their computers, tablets, mobile phones, and other terminals, making management more convenient. In addition, future advancements in artificial intelligence technology will plan and implement equipment health assessments and predictions, allowing users to detect potential equipment problems in advance through cloud models. At the same time, customers can be notified to carry out planned equipment maintenance and maintenance, reduce the risk of unexpected equipment downtime, and ensure the continuity and efficiency of the production process.

Meet the needs of the market application end.

Every technology upgrade is to implement customer production better and solve problems in customers’ actual applications. By adopting the mould temperature controller with “mold load adaptive temperature intelligent control,” the system reduces the fluctuation of mould temperature and improves stability to meet the production needs of precision products.

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