Pascal Ben Chen Ph.D.. 2006 l 2006 81.8% 9 3903 l 2005 -1.1% 42.9% l 2006 3 5125 2005 +16.3% l 51.1% 13.5%

液壓比例伺服技術在橡塑膠射出機上應用

Pascal 陳文慶 博士Ben Chen Ph.D.

2006 台灣橡塑膠射出機產值 2006 81.8% 出口 9 億 3903 萬美金 與 2005 -1.1% 大陸香港 42.9%

2006 進口 3 億 5125 萬美金 與 2005 +16.3% 日本 51.1% 德國 13.5%

光電 半導體 面板 通訊

橡塑膠射出機產品 塑膠射出機 橡膠射出機 吹瓶機機 押出機

橡塑膠射出機市場

塑膠射出機 每年產量 台灣 12000-15000 台 中國 10-12 萬台 ( 海天 3-4 萬台 ) 台灣定位

射出機

比例壓力流量閥

快速射出閥

開關模比例閥

KBSDG4VKBFDG5V DG4V-3 KBHDG5V CVCS/CVICustomized PQ Spools for

Injection Cylinder control

Developing the PQ Pump

Clamping Challenges

• Move huge mass smoothly, quickly, & precisely Close loop pressure

& velocity control• High performance, two-stage prop valve• Prop pressure control valve

Ejector Challenges• Protect mold (pressure limitation), eject on the fly (speed regulation), support robot (positioning).

• Close loop pressure, velocity, and positioning control • Servo performance, single stage prop valve

For Machine Setup

Single Stage NG6

Directional Valve

Injection Challenges•Smooth, accurate, & repeatable transition from velocity to pressure control

• Close loop pressure & velocity control• Servo performance, two-stage prop valve

Screw Rotation Challenges

• Constant velocity control•High flow

• Prop Slip-in Cartridge Valves

Plastics Injection MoldingClamping Cylinder

Ejector Carriage

Injection Cylinder

Metering Motor

KBHDG5V

Single Stage NG6 Directional

Valve

Clamping Challenges• Move huge mass smoothly, quickly, & precisely

• Close loop pressure & velocity control• High performance, two-stage prop direction valve• Prop pressure control valve

Plastics Blow Molding

KBHDG5V

KBSDG4V

Parison Control Challenges

• Wall thickness control

• Close loop positioning control• Servo performance, single stage prop directional valve

Injection Challenges• Smooth, accurate, & repeatable transition from velocity to pressure control

• Close loop pressure & velocity control• Servo performance, two-stage prop directional valve

KBFDG5V

Parison Control

Injection Control

Clamping Control

PQ 系統比例壓力流量閥1. Vane Pump (Fixed) 90-95% 開迴路 0-800mA Yuken EFBG 日系 閥軸 LVDT 迴授 0-2700mA Bosch Vickers 歐系2. Pistion Pump (Variable) 5-10% Yuken Rexroth Bosch

3. Pistion Pump + 伺服馬達 ( 控制轉速 )

PQ 開迴路 EFBG Valve 剖面

0-800mA

誤差 3-5%600LPM*0.05=30LPM

PQ EFBG Valve

PQ 閉迴路Proportional Throttle Valve NG10

2-Way Cartridge NG25

PQ Speed 快 & 準Proportional Throttle Valve NG10

KFTG4V-5-2B70N-Z-VM-U1-H7

Response 0.027s ( at 80 LPM)

Hysteresis <1%

2-Way Cartridge NG25

type CVU-25-EFP1-B29-45-31

Pressure Max 315bar

Response 0.040s ( at 210 LPM)

Hysteresis <1%

射出機 PQ NG32

CVU-32 流量速度曲線速度曲線圖

0 2.214.6

37

60

83

105

125.7

144.2

164.9

185.9

0102030405060708090

100110120130140150160170180190200

0 10 20 30 40 50 60 70 80 90 100

(%)輸入百分比

(mm

/s)

輸出

速度

NG32 閉迴路壓力控制曲線 KCG-3-160

壓力曲線圖

6

20.8

34

47.2

60.7

74.2

87.8

101.8

115.2

128.6

140

010

20304050

60708090

100110120130

140150

0 10 20 30 40 50 60 70 80 90 100

(%)輸入百分比

(bar

)輸

出壓

力

VOLTAGEVOLTAGE

CURRENTCURRENTPRESSUREPRESSURE FORCEFORCE

RATE OF CHANGEOF FORCE

RATE OF CHANGEOF FORCE

OPEN LOOP CONTROL

VOLTAGEVOLTAGE

CURRENTCURRENT PRESSUREPRESSURE FORCEFORCE

RATE OF CHANGEOF FORCE

RATE OF CHANGEOF FORCE

VOLTAGEVOLTAGE

++__

FORCE :VOLTAGEFORCE :VOLTAGE

P I DP I D

CLOSED LOOP CONTROL - FORCE

VOLTAGEVOLTAGE

CURRENTCURRENT FLOWFLOW VELOCITYVELOCITY

VOLTAGEVOLTAGE

++__ VOLTAGE : VELOCITYVOLTAGE : VELOCITY

P I DP I D

CLOSED LOOP CONTROL - VELOCITY

0.1mm/sec --2m/s --10m/s變動 壓力 & 負載 & 油溫0.1mm/sec --2m/s --10m/s變動 壓力 & 負載 & 油溫誤 差 1% 以內誤 差 1% 以內

VOLTAGEVOLTAGE

CURRENTCURRENT FLOWFLOW POSITIONPOSITION

VELOCITYVELOCITY

VOLTAGEVOLTAGE

++__ VOLTAGE : POSITIONVOLTAGE : POSITION

P I DP I D

PID

CLOSED LOOP CONTROL - POSITION

定位精度 0.01mm定位精度 0.01mm

SERVO VALVESERVO VALVE

Servo

高速比例閥 KHDG5V-7-2C200N 24ms at 375LPM KHDG5V-8-2C375N 37ms at 375LPM 精密射出 開關模

2007 現況 產量下降 20-30% 本質好公司 營業額不變 高階機台增加 低階機台減少 開發新機種 全球分散市場

Q & A