Chapter 69

MATLAB Modeling and Analysis

of the Electro-hydraulic Control System
of Injection Molding Machine

Dengxiu Yu, Gang Lu, Yong Zhou, Tao Zhang and Dengfei Yu

Abstract This paper introduces a kind of control servo system and its corre-
sponding control strategy for the electro-hydraulic injection molding machine.
A MATLAB simulating research was conducted on the system in which AC
Permanent Magnet Synchronous Motor (PMSM) was used, vector control mode of
id = 0 was applied, and fuzzy strategy was adopted for controlling pressure and
flow. One conclusion we draw from the results was that servo system driven by
PMSM and with vector control mode of id = 0 had good performance. Another
conclusion was that fuzzy strategy was useful in controlling the pressure of the
system and could allow the pressure to change according to the established
pressure curve.

Keywords The electro-hydraulic injection molding machine  Fuzzy control 

SVPWM

69.1 Introduction

As a new type of injection molding machine that can be driven by fluid power and
electronic power, the electro-hydraulic injection molding machine not only has the
characteristics of the fully electric injection machine, but also has the character-
istics of the hydraulic injection molding machine. So it is an energy-saving device
with accurate positioning and high thrust, and a trend in the development of
precision injection machine nowadays.

D. Yu (&)  G. Lu  Y. Zhou  T. Zhang

Northwestern Polytechnical University, Xi’an, China
e-mail: yudengxiu@126.com
D. Yu
Tianjin Branch of CNOOC Limited, Tianjin, China

J. Wang (ed.), Proceedings of the First Symposium on Aviation Maintenance 641

and Management-Volume I, Lecture Notes in Electrical Engineering 296,
DOI: 10.1007/978-3-642-54236-7_69,  Springer-Verlag Berlin Heidelberg 2014
642 D. Yu et al.

Fig. 69.1 Simulation system

In order to improve the response rate and precision and achieve the goal of
precise injection, a servo controller which was used by the mixed injection
molding machine applied vector control mode of id = 0 and adapted fuzzy control
strategy. The reliability of the control strategy of the controller was verified by
MATLAB modeling, simulation, and comparison.
The simulation system mainly includes: execution mechanism of injection
system, power source of servo motor driving constant pump, and pressure and
flow controller, which is shown in Fig. 69.1.

69.2 Modeling of the Execution Mechanism of Injection

System

69.2.1 Modeling of Injection Load

During injection phase, filling cavity pressure (PG) reflects the quality of the
device [1]. Pressure decreases when the melt goes through nozzle, runner, and gate
before entering into mold cavity. So injection pressure is distinctly higher than
filling cavity pressure (PG). The relation between PG and P can be described as
follows:
P ¼ PG þ RDP ¼ PG þ ðDPE þ DPN þ DPS þ DPR þ DPG Þ ð69:1Þ
DPE is the pressure drop caused by shear flow of melt from the screw head to
nozzle mouth; DPN is the pressure drop generated when melt flows through
cylindrical nozzle of injection molding machine; DPS, if the runner is cylindrical,
is the pressure drop generated when melt flows through the runner and its branches
or changes its original direction: DPR is the pressure drop when the melt flows
from the first channel to the second channel; DPG, if the gate is main channel, is
the pressure drop when the melt flows through the gate [2]. Mathematical model
of Injection load is shown in Fig. 69.2.
69 MATLAB Modeling and Analysis of the Electro-hydraulic Control System 643

Fig. 69.2 Simulation model

of injection load

69.2.2 Injection Cylinder Model

The injection system used nonsymmetrical hydraulic cylinder. In order to highlight

the main contradiction, the simulation has been simplified assuming that pressures
in working chambers are equal; the leakage of hydraulic cylinder is laminar flow;
and temperature and bulk modulus are a constant. Under this condition, the cyl-
inder model is as follows: [3].
The flow q1 that enters into the hydraulic cylinder is:
dx V1 dPi
q 1 ¼ A1 þ Cip ðPi  PÞ þ Cep Pi þ ð69:2Þ
dt b dt
The flow q2 that goes out of the hydraulic cylinder is:
dx V2 dP
q 2 ¼ A2 þ Cip ðPi  PÞ  Cep P  ð69:3Þ
dt b dt
V1 and V2 can be expressed as:

V1 ¼ A1 ð x 0 þ x Þ
ð69:4Þ
V2 ¼ A2 ðx0  xÞ
The load of the injection cylinder is very complex. In addition to the injection
pressure, it also includes oil damping, the friction of the contact surface, and so on,
which can be approximated as a two-order mass-spring-damping system. The
mathematical model is:

d2 x dx
A1 P i  A 2 P ¼ m þ B þ kx ð69:5Þ
dt dt
644 D. Yu et al.

Fig. 69.3 Simulation model of injection cylinder

In the formula, m is the mass of piston (kg), x is the location of the injection
(mm), Pi is the pressure of injection cylinder (Mpa), A1 is the cross-sectional area
of injection cylinder (mm2), A2 is the cross-sectional area of barrel (mm2), V1 is the
capacity of the polymer in injection cylinder (mm3), V2 is the capacity of the
polymer in cartridge (mm3), Cip is the leakage coefficient of hydraulic cylinder, b
is the bulk modulus of hydraulic oil (Mpa), B is viscous damping coefficient of
piston and load, k is spring stiffness of load (N/m), Cep is leakage coefficient of
hydraulic cylinder, x0 is the initial position of injection cylinder (mm).
The middle area was selected as the initial position of the piston rod which
exerts maximum effects on hydraulic oil compressibility, and where the system is
the worst in stability. The mathematical model of injection cylinder is shown in
Fig. 69.3.

69.2.3 Electromagnetic Reversing Valve and Circuit

Modeling

In the injection system, electromagnetic valve is mainly used to control the

direction of the flow of the hydraulic oil, in order to control the direction of
movement. It has little effect on the hydraulic oil flow and the pressure of the
system, so it is not considered in the process of simulation not as influence factor,
but as a constant link with a gain of 1. In practical work, the pressure in the various
pipelines is slightly different, and in turn has little effect on the dynamic simulation
characteristics of the system, so it is not consider as an effect link, but as a constant
with a gain of 1.
69 MATLAB Modeling and Analysis of the Electro-hydraulic Control System 645

69.3 Modeling of Servo Motor-Driven System

The main function of the servo motor is receiving speed signal which the pressure
and flow controller send, and change the motor speed and torque, so as to change
the output flow of hydraulic pump.
This system used AC permanent magnet synchronous motor PMSM. The motor
was composed of permanent magnetic material which reduced the torque ripples.
It also had some other advantages, such as small volume, low inertia, and it
ensured that quantitative pump produce constant output.
PMSM applied the vector control mode of id = 0. When this method was used,
the demagnetization did not occur because no direct-axis component of the
magneto motive force occurred in the armature reaction, which ensured that the
motor electromagnetic torque was proportional to armature current; the stator
MMF space vector and space vector magnetic rotor were orthogonal, stator current
and the flux of permanent magnet rotor were independent of each other. Therefore,
it could be used in control devices with high performance requirements.
The PMSM servo system using rotor field oriented control of id = 0, as shown
in Fig. 69.4, is basically closed-loop system of speed and current. Rotary Variable
Differential Transformer (RVDT) with PMSM rotor was installed on one axial.
The position angle of motor rotor h and rotating speed xr was obtained through the
calculation, respectively. The given speed x*r and xr as compared and the current
reference value i*q along q-axis was obtained by the speed PID controller. The
current feedback value along q-axis iq was obtained by Clark and Park transfor-
mation of ia, ib, and ic which were the phase current detected by current sensor. i*q
and iq was compared and vp was obtained by the current PID controller along the
q-axis. The rotor field oriented control of id = 0 was shown in the Fig. 69.4 by the
following calculation: i*d = 0, i*d, and id was compared and vd was obtained by the
current PID controller along the d-axis in the Figure The control signal Pa, Pb, and
Pc three-phase full controlled inverter circuit was obtained after Park and Clark
inversion of vq and vd and SVPWM. Commutation logic and duty ratio of the
inverter circuit was controlled so as to reclose the integrated magnetic potential of
PMSM by three-phase winding and q-axis.

69.3.1 Modeling of Servo Motor

MATLAB provides the inverter module and the PMSM module which is estab-
lished according to the d-axis and q-axis flux theory. Parameter settings of PMSM
module are shown in Fig. 69.5. The input of inverter module is the pulse signal of
PWM and the output is the three-phase sinusoidal voltage. The output of PMSM is
the current along the d-q axis, rotating speed and angle.
646 D. Yu et al.

ωr* iq* vq Va Pa
PID PID Park vα Clark
Vb Three-Phase
- - iq vd Inverse Inverse SV Pb Full Bridge
id* = 0 vβ PWM
ωr PID
Transform Transform
Vc Pc Inverter Circuit
-
id .
ia
iα
Park Clark ib
Transform iβ Transform
ic

θ Calculation
Module of Rotor RVDT
Position and PMSM
Motor Speed

Fig. 69.4 The functional block diagram of PMSM servo system using the vector control mode of
id = 0

Fig. 69.5 Parameter

settings window of PMSM

69.3.2 Modeling of Speed and Current PID Controller

In the simulation model, both the current and the speed along the d-q axis adopt
PID control strategy. In the simulation process, the PID parameters can continue to
be adjusted to get the best results and to determine the optimal PID coefficient.
69 MATLAB Modeling and Analysis of the Electro-hydraulic Control System 647

69.3.3 The Modulation (SVPWM) Modeling of Pulse Width

of the Space Vector

The three-phase voltage inverter is shown in Fig. 69.6. The inverter was controlled
by state signal (Sa Sb Sc). The spatial flux Wi is caused by imposing the voltage Ui
(Sa Sb Sc) on the PMSM three-phase armature winding through the inverter. The
hexagonal rotating magnetic field can be formed using the voltage of
U4 ? U5 ? U1 ? U3 ? U2 ? U6 ? U4 on PMSM three-phase armature
windings, which is shown in Fig. 69.7.
When the proper voltage vector was chosen and the sequence and time of the
action was regulated, the flux space vector can turn into a circular trajectory. Thus
SVPWM modulation signal was controlled.
Implementation of SVPWM in DSP:
Considering the states (on or off) of six power tubes, line voltage and phase
voltage of PMSM can be obtained:
2 3 2 32 S 3 2 U 3
UAB 1 1 0 a A
6 7 4 5 6 7 6 7
4 UBC 5 ¼ Ud 0 1 1 4 Sb 5; 4 UB 5
UCA 0 1 1 Sc UC
2 32 S 3
2 1 1 a
1 6 7
¼ Ud 4 1 2 1 54 Sb 5 ð69:6Þ
3
1 1 2 Sc
To make it easier to calculate, Va, Vb, and Vc, the input of the SVPWM module,
was conversed into its equivalents in ab coordinate system. A rotating circular
magnetic field Wsi was produced by changing the voltage US, and US can be
obtained by weighted calculation of two zero vector and two adjacent nonzero
vector. Taking U4 and U6 as an example, the calculation formula is as follows:
t1 t2
Us ¼ U4 þ U6 ð69:7Þ
TPWM TPWM
According to the sine theorem, the following result can be obtained:
( pffiffiffi
t1 ¼ 3TPWM jUout j sinð60  hÞ=Ud
pffiffiffi ð69:8Þ
t2 ¼ 3TPWM jUout j sinðhÞ=Ud

The operation time of U4 and U6, is t1, t2, were calculated, respectively. Since
TPWM, the PWM cycle, is a constant, the operation time of zero vector can be
calculated by the formula: t0 ¼ TPWM  t1  t2 . In order to reduce the times of the
change of states of the power tubes, only one number was changed when zero
vectors were added. Considering all above factors, the zero vector U0, U7, and U4,
U6 should be combined and imposed on the inverter circuit, i.e.,
U0 ? U4 ? U6 ? U7 ? U6 ? U4 ? U0.
648 D. Yu et al.

Fig. 69.6 Three-

phase voltage-type Inverter

Fig. 69.7 Spatial flux

Considering all above factors, SVPWM simulation model was established as

shown in Fig. 69.8. This model could recognize all the sectors and could send
signal according to the corresponding output sector.

69.3.4 The Model of Servo Motor-Driven System

The simulation model of PMSM servo system established in MATLAB is shown

in Fig. 69.9. The main purposes of simulation are to: (1) determine the speed loop
and parameters of current loop PID controller so as to provide the reference for the
design of DSP process; (2) to validate the SVPWM algorithm; (3) to validate
whether the dynamic response performances of the system meet the requirements
when id = 0 rotor field oriented control was used as control strategy of servo
controller of electro-hydraulic injection molding machine.

69.4 The Design of Fuzzy Pressure and Flow Controller

The servo control system of electro-hydraulic injection molding machine is a

multivariable, nonlinear, time-varying system, so it is difficult to build an accurate
mathematical model. The system we built used fuzzy controller to control pressure
and flow in the process of injection.
The system used T-S typed fuzzy logic reasoning and two-dimensional fuzzy
inference system. The input was a given pressure, an error of feedback pressure
and the change rate of the error. The output was the speed of AC servo motor [4].
69 MATLAB Modeling and Analysis of the Electro-hydraulic Control System 649

Fig. 69.8 SVPWM simulation model

Fig. 69.9 The simulation model of servo system (id = 0)

69.5 Simulation Results and Analysis

69.5.1 Simulation Results of the System Driven by Servo

Motor

The simulation model of PMSM servo system with ‘‘id = 0’’ field oriented control
built according to Fig. 69.9 was used to simulate the servo motor-driven system.
Figure 69.10 is the results output from the SVPWM module which is a horseshoe
curve containing third harmonic. Figure 69.11 is the curve of id, iq and ia, ib
obtained by Park and Clark transformation of phase winding electricity, in which
ia and ib was orthogonal, and id is close to zero [5].
650 D. Yu et al.

Fig. 69.10 The output from

the SVPWM module

Fig. 69.11 id, iq and ia, ib

69.5.2 The Simulation of the Entire Servo Injection System

Based on the above analysis, the simulation model of the entire injection system
was established. As shown in Fig. 69.12, the model included fuzzy control module,
PMSM motor, the module of injection cylinder, and the module of injection load.
After analyzing the working process of the injection action, we found that the
packing stage of injection molding is the key stage. Therefore, pressure controlling
process during injection stage was simulated on this model.
Pressure simulation used four pressure values, which were 10, 8, 6, and 4. It lasted
for 2 s under any specific pressure. The simulation results were shown in Fig. 69.13.

69.5.3 The Test

All the test equipments of electro-hydraulic injection molding machine were

shown in Fig. 69.14, including AC permanent magnet synchronous servo motor,
pump, coupling, simulation load, pressure sensor, flow meter, rotary transducer,
low-voltage power supply, and fuel tank.
69 MATLAB Modeling and Analysis of the Electro-hydraulic Control System 651

Fig. 69.12 The simulation of the entire servo injection system

Fig. 69.13 Pressure–time curve

Fig. 69.14 The test equipments

652 D. Yu et al.

Fig. 69.15 SVPWM modulation wave sent by DSP

Fig. 69.16 The wave of PMSM winding current after Clark transformation

Fig. 69.17 The current wave of id and iq after Park transformation

Figure 69.15 is a three-phase SVPWM modulation wave sent by DSP when

PMSM is running. Computer control was used to obtain these curves. The lon-
gitudinal coordinate is the modulation amplitude, while the horizontal coordinate
is data point. From the chart we can see that the current curve is close to the
standard sine, and the result is similar to that of the simulation, which show that
SVPWM can be well controlled in such algorithm.
69 MATLAB Modeling and Analysis of the Electro-hydraulic Control System 653

Fig. 69.18 The pressure curve when the fuzzy control strategy was adopted

Figure 69.16 is the curve of ia and ib observed from the computer. Figure 69.17
is the waveform of id and iq generated from the Park transformation of ia and ib.
The longitudinal coordinate is A/D conversion value to which signal amplitude is
corresponding, while the horizontal coordinate is uploading point. As can be seen
from the diagram that ia and ib is orthogonal, which is consistent with the result of
the simulation. Id is close to zero, and thus the control object’’ id = 0’’ is achieved.
Figure 69.18 is the pressure curve drawn when the fuzzy control strategy is
adopted. In the Figure, black curve is the pressure curve set, and red curve is the
pressure curve measured.
It could be seen from Fig. 69.18 that the measured pressure value was close to
the value set, which showed that the fuzzy strategy had an outstanding perfor-
mance on the injection system.

69.6 Summary

In this paper, the basic components of servo injection system of the electro-
hydraulic injection molding machine were introduced; the injection load, and the
injection cylinder and the nonlinear mathematical model of hydraulic oil pipeline
were analyzed and a model diagram was drawn in MATLAB/Simulink. A math-
ematical model of servo motor was established, an id = 0 vector control method
was proposed, why SVPWM wave sent by DSP was well controlled was analyzed,
T-S typed fuzzy controller was designed, and the model of the corresponding
object was established using Sim Power Systems toolbox in MATLAB.
654 D. Yu et al.

Based on the simulation, an experimental platform was setup to further verify

the reliability of the control system. The test showed that (1) id = 0 vector control
had good servo performance on a PMSM servo system; (2) fuzzy control strategy
could ensure that the measured pressure value was close to the value set.

Acknowledgments This work was supported by the National Natural Science Foundation of
China (Nos. 51207129 and 51307137). The authors would also like to thank the anonymous
reviewers for their valuable comments and suggestions to improve the quality and readability of
the paper.

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