Injection Molding Machine (IMM) is one of the most important machines in the plastic industry. There are three main stages in the injection molding cyclic process: filling, packing-holding and cooling. Among all processes, filling is the initial stage and plays one of the most important roles. It affects the quality and quantity of products. In this stage, the period of filling and polymer melting quality are decided by two crucial factors of which torque and rotary screw plasticization speed. Torque determination is required in advance to optimize the plasticization screw and increase IMM working efficiency. Normally, torque is measured by torque sensor. But it is difficult to apply widely this method because the torque sensor cost is very high. New approach is using the AC servo motor to measure the torque of the plasticization screw. This study is concentrated on three research aspects: simulation the AC servo motor by MATLAB Simulink, measurement the torque of IMM plasticization screw and control the rotary speed of IMM plasticization screw. The AC servo motor simulation in MATLAB Simulink will analyze the relationship between the torque generated by AC servo motor and the external loading. Based on the simulation results, the experiments will be conducted on hydraulic system and IMM system to measure the torque of IMM plasticization screw through the torque generated by AC servo motor. Moreover, the PID controller is designed to control the rotary speed of IMM plasticization screw. In the experiments, the torque generated by AC servo motor will be determined by the stator current with rotary speed of AC servo motor shaft is 200 rpm and 800 rpm. Similarly, in the rotary speed IMM plasticization screw control, the reference speed is set at 200 rpm and 800 rpm respectively to control.

ABSTRACT I
ACKNOWLEDGEMENTS II
TABLE OF CONTENTS III
LIST OF TABLES VI
LIST OF FIGURES VII
CHAPTER 1 INTRODUCTION 1
1.1. Preface 1
1.2. Introduction of injection molding machine 2
1.3. Literature review 3
1.3.1. Injection unit 3
1.3.2. AC servo motor 4
1.3.3. PID controller 6
1.3.4. MATLAB Simulink 8
1.4. Research purpose 8
1.5. Articles Outline 9
CHAPTER 2 SIMULATION AC SERVO MOTOR 10
2.1. Mathematic model of AC servo motor 10
2.2. Vector control 13
2.2.1. Clarke transformation 13
2.2.2. Park transformation 15
2.3. Simulation AC servo motor and PID controller by MATLAB Simulink 16
2.3.1. MATLAB Simulink environment 16
2.3.2. Construction and simulation AC servo motor in MATLAB Simulink 19
CHAPTER 3 EXPERIMENT METHODS 25
3.1. Experiment equipment 25
3.1.1. Power supply 25
3.1.2. Introduction the LinPAC-8781 25
3.1.3. AC servo motor 29
3.1.4. AC servo motor driver 30
3.1.5. Encoder 31
3.1.6. Injection unit 32
3.2. Methodology 32
3.2.1. Measure the torque of plasticization screw 32
3.2.2. Control the speed of plasticization screw 38
CHAPTER 4 SIMULATION AND EXPERIMENT RESULTS 42
4.1. Simulation AC servomotor results 42
4.1.1. The relationship between external loading and torque of AC servo motor 42
4.1.2. Speed of AC servo motor shaft 43
4.2. Experiment results 45
4.2.1. Introduction of hydraulic system 46
4.2.2. Measurement of hydraulic system torque 47
CHAPTER 5 CONCLUSION AND FUTURE WORK 51
5.1. Conclusion 51
5.1.1. Simulate AC servo motor conclusion 51
5.1.2. Do experiments to measure torque of AC servo motor 52
5.1.3. Do experiments to control AC servo motor shaft speed 52
5.2. Future work 53
REFERENCES 54

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