Engel速度开发注塑机控制器

Challenge

Accelerate the development of control systems for injection molding machinery

Solution

Use Model-Based Design with MATLAB and Simulink to model controllers and plants, run closed-loop simulations to minimize hardware testing, and generate PLC Structured Text

Results

Control algorithms developed and debugged without hardware
Controller quality improved
Test data analysis accelerated

“Model-Based Design reduces the time needed to produce quality control algorithms. Simulations help us understand the system, and code generation enables us to maintain a single source for the design. The results are faster development and higher-quality systems.”
Hannes Bernhard, ENGEL

The injection unit, which is driven by four synchronized drives.

As the global leader in injection molding machine manufacturing, ENGEL has delivered more than 60,000 tie-bar-less machines to customers in automotive, packaging, medical, and other industries. Tie-bar-less technology enables the plastic processors in many cases to use smaller injection molding machines that have a smaller footprint and require less energy.

To maximize machine efficiency and minimize operating costs, ENGEL develops optimized integrated control units for its tie-bar-less systems using Model-Based Design.

恩格尔（Engel）控制工程和开发主管Hannes Bernhard说：“借助基于模型的设计，我们可以在原型硬件之前开发和模拟控制算法，然后生成用于PLC实施的结构化文本。”“因此，在测试实际系统时，我们对算法和代码的质量有信心，并且我们的过程更快，因为原型上需要更少的迭代。”

ENGEL molding machine with an injection unit with two synchronized drives for the injection movement.

Challenge

过去，恩格尔工程师手工编码的结构化文本。对于简单的控制器，他们不使用建模或仿真。对于更复杂的控制器，他们仅模拟了初始设计。经过硬件测试后，他们分析了电子表格中的测试结果，然后根据此分析修改了手动编写的结构化文本。到那时，模拟不再有意义，因为实现与初始设计不符。

简单和复杂的控制器都需要对硬件进行大量测试。恩格尔想减少硬件测试，原因有几个。首先，这是昂贵且耗时的。其次，测试某些配置可能是危险的，并可能损坏机器。第三，在相同条件下通常不可能进行两个单独的测试。

ENGEL wanted a systematic approach for closed-loop controller development that would minimize the need for hardware tests and shorten the commissioning time for new machines.

Solution

恩格尔（Engel）通过使用基于模型的设计的新工作流程加速了注射模制控制器的开发。

In this workflow, ENGEL engineers create a plant model based on measured input and output values for the temperature and pressure of the melted plastics, as well as the velocity of machine components.

Working in Simulink^®, the team then creates a model of the controller and a set of test cases based on the system requirements.

They run closed-loop simulations of the controller and plant in Simulink to verify the test cases. Additional simulations are run to test sensor failures and other fault conditions.

Using Simulink PLC Coder™, the engineers generate hardware-independent IEC 61131-3 Structured Text from their Simulink controller model and deploy it to a PLC for hardware testing.

在MATLAB中，在原型硬件测试期间收集的数据进行了分析^®。工程师将硬件测试的结果与Simulink模拟的结果进行比较，以验证PLC实现。万博1manbetx他们在Simulink模型中完善控制器，然后再为下一次迭代重新生成代万博1manbetx码。

Results

Control algorithms developed and debugged without hardware。“For our first project with Simulink PLC Coder, our controller had to precisely synchronize two drives,” says Bernhard. “Because we were using Model-Based Design we could thoroughly test the algorithms before the hardware was available. Once the prototype was ready, only minimal algorithm modifications were needed.”

Controller quality improved。“The quality of our controllers has improved with Model-Based Design because we can perform many more tests via simulation than we can on the machine,” says Bernhard. “Simulations are faster, and we can automate test suites to run overnight.”

Test data analysis accelerated。Bernhard指出：“与使用电子表格分析测试测量值相比，MATLAB更快，更易于使用。”“我们可以快速过滤数据并创建图，以帮助我们更好地了解测试结果并最终优化产品质量。”

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