The protocol for the calibration of RC parameters in injection molding machines is divided into several critical phases:
I. Pre-deployment Phase
All hardware components-including the industrial communication gateway, PTP synchronization switch, and RC parameter acquisition module-must be confirmed as operational. Additionally, baseline parameter files for all machines should be entered into the MES (Manufacturing Execution System) in advance, completing the configuration of automatic unlocking judgment rules. It's essential to verify a bidirectional communication link between the temperature controller and the MES system, ensuring a data upload latency of ≤1 second and 100% communication connectivity.
II. Calibration Task Triggering and Access Locking Phase
The MES system generates RC calibration tasks automatically, either based on preset cycles or RC drift monitoring data, and dispatches them to maintenance personnel's terminals. Concurrently, the MES system issues a production access lock command to the relevant injection molding machine, which displays a message indicating that RC calibration is in progress, thereby prohibiting operation. The access lock time and reason for triggering are logged in the process traceability file.
III. On-site RC Calibration and Data Upload Phase
Maintenance personnel arrive on-site with the necessary calibration tools to conduct parameter calibration according to established procedures. Post-calibration, all collected data-such as RC capacitance, filter cutoff frequency, and temperature fluctuations-are uploaded to the MES system through a field acquisition module or handheld terminal. The MES system verifies the completeness of the uploaded data and prompts for any missing key parameters, ensuring integrity.
IV. Automatic System Verification and Unlocking Phase
The MES system performs a comparison of the uploaded measured data with preset benchmark parameters, evaluating indicators including RC capacitance deviation, ripple amplitude, and temperature fluctuation. Once all criteria are met, and data stability is confirmed for 30 seconds, the system issues a command to unlock access to the injection molding machine. At this point, the lock prompt on the control panel is removed, allowing the production start button to be activated.
V. Anomaly Handling and Closed-Loop Archiving Phase
If the calibration data fails to meet established standards, the system retains the access lock status, issues a second calibration task, and alerts maintenance personnel through a warning message. Should the unlock command fail after three attempts, the system triggers both audible and visual alarms, along with notifications to personnel to verify communication links onsite. The entire process-including access lock times, calibration data, unlock timestamps, and operator details-is automatically archived for reference and to inform adjustments to future calibration cycles. After unlocking, the system monitors production temperature data for 30 minutes to confirm stable operation and to identify any abnormalities in RC parameter performance.
