全電式塑膠射出成型機控制系統設計與研製

Control System Design and Implementation of an all-Electric Injection Molding Machine

全電式塑膠射出成型機是一個結合精密製造、伺服馬達驅動與高等數位控制機電整合之產品，其控制系統包括無刷馬達伺服運動控制、溫度控制、PLC控制、人機介面技術、射膠速度追蹤以及保壓控制等。本文旨在研發此全電式塑膠射出成型機控制系統之射膠速度、保壓控制設計與其實現製作技術。首先以扭力控制模式為基礎結合雙自由度比例積分控制、前饋控制與數位信號處理技術，設計此一高性能的射膠速度控制系統，並發展一修正型可變增益比例積分滑動模態保壓控制技術，用以改善保壓切換點的壓力突波、過激與穩態誤差等問題。各項實驗證實所提出的方法與技術之可行性與有效性，本研究的開發，將可提昇全電式塑膠射出成型機之應用技術並增強改善現有之功能。

The all-electric injection modling machine is a mechatronic product,consisting of a synthesis of precision manufacturing, servomotor drivingand advanced digital control. The controllers for the machine are responsiblefor achieving motion control, temperature control, PLC control,man-machine interfacing, injection speed tracking and holding-pressurecontrol. This paper develops control design methodologies and implementationtechnologies for an all-electric injection molding machine controlsystem. A novel digital signal processor (DSP)-based, proportional-integral(PI) controller together with feedforward control is presented based onmotor torque control mode, in order to accomplish injection speed profiletracking for the machine. To have good control at the holding-pressure stage, a modified-gainscaling PI control based on sliding mode control isproposed to improve the performance of the pressure-holding processwithout overshoots. Several experimental results have shown that the proposedmethods together with the system prototype built for this study arefeasible and effective. These developed technologies may be useful in improvingand promoting current control system technology for electric injectionmolding machines.