DE102004052499B4 - Injection molding tool and electronic module - Google Patents

Abstract

Injection molding tool with
Means (110) for storing parameters,
Means (122) for evaluating the parameters,
Means (126; 128) for generating a message (144, 154, 156) as a function of the evaluation of the parameters,
- means (130, 132) for sending the message, and
- means for receiving at least one operating parameter from an external sensor (138).

Description

The The invention relates to an injection molding tool and an electronic module Bierfür.

The Adjustment of an injection molding machine is a complex process which requires a lot of experience of the operating staff. Usually For injecting an injection molding machine several injections executed the machine parameters of the injection molding machine as long as changed the operating personnel be until a desired quality of injection molded parts is reached.

From the DE 40 02 398 A1 For example, a method and apparatus for operating an injection molding machine is known. The casting conditions are automatically changed during the settling time according to the metal mold temperature, the resin temperature, and the temperature of the heating cylinder supplied with resin from a hopper. This is intended to reduce the number of injections required for the adjustment.

From the DE 44 46 857 A1 For example, a method of automatically adjusting an injection molding speed condition in an injection molding machine is known. A reference pressure of molten material injected into an injection mold cavity is set as a function of the injection elapsed time or moving distance of an injection piston, and the piston is started at a constant speed.

From the DE 199 25 458 A1 is a sensor module for injection molding tools known. The tool has a thin film sensor mounted on the functional surface of the tool for measuring the local temperature, tool deflection, and / or forces acting on the tool surface. The tool consists of one or more segments, wherein at least one segment is designed as a module, which has an integratable into the tool base body with a tool-adapted surface with integrated sensory elements.

From the DE 103 08 386 A1 An injection molding machine with a component characterized by specific parameters and a control device is known. The control device is connected to a component and controls the component by means of component-specific parameters.

The German Utility Model DE 202 04 360 U1 discloses an injection molding machine having at least one internal machine control system for computer controlled process monitoring and control of the injection molding machine.

From the publication DE 102 28 250 A1 is an injection molding machine for producing molded plastic parts known. A machine control with several electrical components is provided, which are wirelessly networked with each other. The wireless networking is preferably carried out according to the Bluetooth standard.

The publication DE 42 19 259 A1 discloses a method of controlling a plastic injection molding machine. For this purpose, in a form leading to the operator, the operating parameters required for the course of a spraying cycle are input via an input unit into a data processing unit storing this operating parameter. The subsequent injection cycles are performed according to the stored operating parameters.

The US patent specification US 5,792,395 discloses a plasticization control method for an injection molding machine. The plasticization state of a resin in an injection cylinder is controlled.

The European Published Application EP 0 047 305 discloses a method of preventing injection molding from exiting a mold during operation.

From the European patent application EP 0 704 293 A2 For example, a method for tempering injection molding machine units and molding units for plastics processing is known.

The European patent application EP 0 727 297 relates to a temperature control method for an injection molding machine. The control is temperature stable regardless of the heat capacity of the object whose temperature is controlled.

Of the Invention is opposite the task is based on an improved injection molding tool as well an electronics module for to create an injection mold.

The The object underlying the invention is in each case with the features the independent one claims solved. Preferred embodiments The invention are set forth in the dependent claims.

The invention provides an injection molding tool which has means for acquiring parameters, means for evaluating the parameters, means for generating a message as a function of the evaluation of the parameters, means for Transmitting the message and having means for receiving at least one operating parameter from an external sensor.

For example are detected by the injection tool tool parameters. Under Tool parameters are understood to be such parameters that a state of the injection mold, the mold cavity of Injection molding tool and / or injected into the mold cavity pertain plasticized plastic material.

For example are on and / or in the mold cavity pressure sensors for sensing the Injection pressure of the plasticized plastic into the mold cavity arranged and / or temperature sensors for sensing the tool temperature and / or the temperature of the injected plasticized plastic. Alternatively or additionally, too the kind, that is For example, the composition of the injected plasticized plastic material, and / or the color of the injected material through and / or in the Mold cavity sensors are measured.

alternative or additionally The injection mold can operate parameters of one or more receive external sensors. Operating parameters mean such parameters, the framework conditions for concern the operation of the injection molding machine, so for example environmental data, such as humidity, air pressure and / or the ambient temperature, and / or parameters relating to the starting materials, such as the moisture of the plastic granules used. Such external Sensors can also be arranged on modules of the injection molding machine, such. to the Cascade controller module, the hot runner controller module (so-called Hot Runner controller), on temperature control devices, on the sampling system (so-called. Handling system), the granulate heating for drying the granules, and / or the granule promotion. The corresponding sensor values relate to e.g. Temperature values, conveying speeds and the like.

Further An external sensor for quality monitoring can also be present. For this purpose, the injection-molded parts produced, for example, with an electronic camera, preferably a CCD camera, to check the dimensional accuracy. The corresponding dimensional information obtained by evaluation of the CCD image transmitted to the electronic module of the injection molding tool, so this according to the process can readjust. If e.g. an injection molded part is too small, so will increased by the electronics module of the reprint. Alternatively or additionally also the weight of the injection molded part can be determined. The corresponding The measured value is transmitted to the electronic module and evaluated there.

The present invention enables it so that the electronics module on a change in production conditions responding regulatively. In particular, the electronics module can regulate engage when a component of the injection molding machine fails to despite the failure to maintain production. Furthermore, can regulating the electronics module when an environmental condition changes, such as e.g. the humidity and / or that of an external sensor Measured water temperature of the supplied cooling water. The latter is special advantageous if the cooling water temperature in Course of a day, as the e.g. due to strong sunlight the case may be. If the cooling water temperature rises, This is how the electronic module generates a setting command to increase the throughput of cooling water to increase, for example, by increasing the speed of the cooling water pump.

To a further embodiment is the electronics module with an optimization and / or learning function equipped, which allows the electronics module e.g. the cycle time dependent on optimally regulated by the current production conditions. This is particularly advantageous, since thus the profitability of the injection molding machine can be optimized, even if e.g. a part of the injection molding machine fails.

To a further embodiment the invention are received by the electronics module and / or transferred data to an external database and stored there persistently. With that you can e.g. legal requirements for The supervision the product quality Fulfills become. Furthermore, can the persistently stored data serves to ward off unjustified product liability claims.

alternative or additionally Machine parameters are taken into account in the evaluation. Under Machine parameters become here parameters concerning the injection molding machine understood, that is For example, the number of screw revolutions per unit time or per injection and / or the degree of opening a flow rate adjustment valve, which is used to control the injection speed and the injection pressure.

According to one embodiment of the invention, the injection molding tool has an electronic memory for storing desired parameters. When evaluating the recorded parameters, the setpoint parameters are included. For example, if a detected actual parameter deviates from a corresponding desired parameter, then a result of the evaluation may be that a message with a control command is sent to a controller of the injection molding machine and / or a message with a warning, error or diagnostic information.

To a further embodiment the injection molding tool has means for adapting the desired parameters. The adaptation of the desired parameters, for example, depending on the tool parameter, the operating parameter and / or the machine parameter respectively. For example, to adapt the desired parameters corresponding characteristic fields, a plant model and / or a neural network can be used.

If For example, the humidity increases, generates the injection mold an adjusting command to enlarge the Temperature of a heating cylinder of the injection molding machine. The corresponding Relationship between the humidity of the ambient air and the temperature of the heating cylinder can be determined by a characteristic field, which is stored in a memory of the injection molding tool, given a calculation rule and / or a neural network be.

To a further embodiment are limits for the evaluation used. The limits may be to peak or Minimum values of machine parameters of the injection molding machine act. When one of the machine parameters meets its corresponding limit approaches or reaches this, the result of the evaluation is a message with warning information, error information, diagnostic information and / or a service request is generated and sent.

To a further embodiment Each limit value is assigned an address. This is it preferably an electronic address, such as an e-mail address or phone number to send a SMS. approaches a machine parameter is its corresponding limit or if he reaches this, then the message generated then automatically sent to the address associated with the relevant limit value. This can be wired or wireless.

To a further embodiment the injection molding tool has a communication interface to the Receiving parameters and / or reading data from an electronic Memory of the injection molding tool. For example, data can be from the electronic memory of a mobile computing device, such as Example of a portable computer, a personal digital assistant (PDA), a so-called smart phone or the like, over the Communication interface retrieved from the electronic memory become.

In In another aspect, the invention relates to a method of control an injection molding machine. The regulation of the injection molding machine takes place with the aid of an injection molding tool, which is a data processing unit Has. The data processing unit of the injection molding tool is as master for operated a control of the injection molding machine.

Of Furthermore, the invention relates to a corresponding computer program product, in particular a digital storage medium, for an injection molding tool, which a data processing unit. The computer program will executed by a microprocessor of the injection molding tool. For example is the computer program designed as so-called firmware and operates the data processing unit of the injection molding tool as Master for a control of the injection molding machine, which accordingly as a slave acts.

The present invention enables the adjustment of an injection molding machine with greatly reduced effort or even fully automatic. In addition to the simplified or automatic Einregelung of the injection molding machine is another advantage of Invention that during the operation of the injection molding machine adhering to quality standards of produced injection-molded parts due to the regulation of the injection molding machine can be better ensured by the injection molding tool as a master. Especially depends on that quality of the molded parts no longer significantly depends on the individual qualification and the experience of the operating staff.

Further It is particularly advantageous that the injection molding tool monitoring the injection molding machine can afford, for example, early a warning regarding an imminent malfunction or a Requirement for to generate a service technician.

in the Further preferred embodiments the invention with reference to the drawings explained in more detail. It demonstrate:

1 a block diagram of an embodiment of an injection molding tool according to the invention, which is located in an injection molding machine,

2 a block diagram of the electronic module of the injection molding of the 1 .

3 a flow chart of an embodiment of a method according to the invention,

4 a flowchart of another embodiment of a method according to the invention.

The 1 shows an injection molding machine 100 , The injection molding machine 100 has an injection device with a heating cylinder. In the heating cylinder is a worm, an injection cylinder and a worm drive motor. Further, the injection molding machine has a flow rate adjustment valve which controls the amount of pressure oil supplied to the injection cylinder, and a pressure adjusting valve which controls the pressure of the pressure oil supplied to the injection cylinder. Structure and mode of operation of said components of the injection molding machine 100 are known per se from the prior art.

The injection molding machine 100 has a controller 102 for controlling the various components of the injection molding machine 100 such as for adjusting the temperature of the heating cylinder, the amount and pressure of the pressure oil and the opening degree of the flow rate adjustment valve and other machine parameters.

In the injection molding machine is an injection molding tool 104 , The injection molding tool has a mold cavity in the plasticized plastic of the injection molding machine 100 is injected. On the injection mold 104 is an electronic module 106 attached. Preferably located between the electronic module 106 and the injection mold 104 an insulation layer 108 to the electronics module 106 to protect. Preferably, the electronic module 106 through the insulation layer 108 encapsulated against environmental influences.

The electronics module 106 serves as master for the controller 102 , which accordingly performs a slave function. The electronics module 106 So can for example control commands for the controller 102 to generate. Such control commands are wired or wireless from the electronic module 106 to the controller 102 transfer.

The 2 shows a more detailed embodiment of the electronic module. Elements of 2 , the elements of 1 correspond, are marked with the same reference numerals. The electronics module 106 has a memory 110 with storage areas 112 . 114 . 116 . 118 and 120 ,

The storage area 112 is used to store operating parameter values, the memory area 114 for storing actual parameter values, the memory area 116 for storing nominal parameter values, the memory area 118 for storing machine parameter values and the memory area 120 for storing limits and addresses associated with the limits, such as e-mail addresses.

The electronics module 106 has a microprocessor 122 for executing program components 124 . 126 . 128 and 130 ,

The program component 124 serves to adapt the in the memory area 116 stored desired parameter values in dependence on one or more of the other parameter values. For example, the adaptation depends on one or more of the in the memory area 116 stored desired parameter values from one or more of the operating parameter values, the actual parameter values and / or the machine parameter values.

The program component 126 is used to generate positioning commands to set the injection molding machine to achieve the setpoint parameter values. The program component is used for this 126 on the storage areas 114 and 116 to read the actual parameter values and the setpoint parameter values. If there is a sufficiently large discrepancy between an actual parameter value and the associated setpoint parameter value, the program component generates it 126 a Stellkommando, for a component of the injection molding machine 100 so that the desired parameter value is reached or approximated in one or more control steps.

The program component 128 is used for diagnostics in the memory area 118 stored machine parameter values. The program component 128 reads the machine parameter values from the memory area 118 and the limits of the memory area 120 to compare them with each other.

If a machine parameter value has a tendency to approach its boundary, the program component may 128 generate a corresponding message containing a warning about this. If the relevant machine parameter has reached or exceeded its limit, the program component generates 128 a message with a corresponding error message.

It is also possible that the program component 128 generates an adjustment command if it diagnoses an inadmissible operating state of the injection molding machine. Due to this command, the injection molding machine is automatically shut down.

It is also possible that the program component 128 automatically generates a message to request a service technician. For this purpose, for example, the limit is assigned an e-mail address. If the machine If the parameter value tends to approach the limit, the program component 128 Automatically generate a message that will be sent via e-mail to the e-mail address associated with the relevant limit.

The program component 130 of the processor 122 Provides the communication functions required to send the control commands or messages. The processor 122 is with a communication interface 132 connected via the the program component 130 can send the positioning commands or the messages. Alternatively, separate communication interfaces for sending the positioning commands and the messages may be provided.

Via the communication interface 132 Data may also be received, such as operating parameter values from external sensors as well as machine parameter values from the control of the injection molding machine. The reception of the actual parameter values from the sensors 134 of the injection mold 104 is in principle also via the communication interface 132 possible. Preferably, however, the sensors 134 immediately with corresponding inputs of the processor 122 connected.

The program components 124 . 126 . 128 and 130 can be completely or partially realized as firmware. Alternatively, at least some of these functionalities are implemented by a so-called Application Specific Integrated Circuit (ASIC).

The sensors 134 of the injection mold 104 are on or in the mold cavity 136 arranged. With the sensors 134 These are, for example, pressure sensors for sensing a pressure of the pressure in the mold cavity 136 injected plasticized plastic and / or temperature sensors for sensing its temperature. With the sensors 134 they may also be sensors for sensing a material property or material composition of the injected plasticized plastic or its color. The ones from the sensors 134 supplied actual parameters are provided by the processor 122 received and in the storage area 114 saved.

From external sensors 138 the operating parameter values are recorded. With the sensors 138 These are, for example, sensors for sensing the air humidity, the air pressure and / or the air temperature or for sensing the moisture of the plastic granules with which the injection molding machine is charged.

The sensors 138 are not part of the injection molding tool, but arranged at a suitable location such as the production hall. The ones from the sensors 138 detected operating parameters are, for example via a network 140 , such as a fieldbus, to a communications interface 142 from where the operating parameter values to the communication interface 132 be transmitted wirelessly or by wire.

The control 102 the injection molding machine 100 is to receive the control commands 144 that the program component 126 generated via the communication interface 146 educated. The communication interface 146 can be integral part of the controller 102 or a separate automation device. In particular, the communication interfaces 142 and 146 be identical. In the latter case, the controller receives 102 the commandos 144 over the network 140 ,

The ones in the store 110 stored parameter values can be read by a portable computer, such as a laptop computer, personal digital assistant (PDA), smart phone, or other device. The portable computer 148 has a communication interface 150 , From the portable computer 148 can read and / or write to the store 110 be accessed.

For example, those in the memory areas 112 . 114 . 116 . 118 and or 120 stored parameter values and limits, as well as the e-mail addresses are read out, with the relevant data from the communication interface 132 to the communication interface 150 wired or wireless. A user of the portable computer 148 For example, you can manually modify the target parameter values, enter new limits, and / or update the e-mail address. The modified data is then taken from the portable computer 148 via the communication interface 150 to the communication interface 132 transferred and into memory 110 stored.

Furthermore, the portable computer 144 via its communication interface 150 a message 154 from the communication interface 132 receive. The message 154 includes, for example, a warning, error message, or diagnostic information provided by the program component 128 have been generated.

One from the program component 128 generated message 156 with a service request, for example, is sent as an e-mail from a server computer 158 receive a corresponding e-mail program 160 performs. The message 156 will, after coming from the server computer 158 has been received, for example via an intranet 162 to the client computer 164 of a service technician.

Preferably, at least the memory area 116 designed as a non-volatile memory. This allows the processor 122 on the in the memory area 116 stored nominal parameter values as start variables for the continuous adaptation with the aid of the program component 124 to access when the injection molding machine is set.

For the production of injection molded parts, the injection molding tool is first used 104 in the injection molding machine 100 built-in. The electronics module 106 receives from the external sensors 138 the operating parameter values, from the sensors 134 the actual parameter values and from the controller 102 the machine parameter values.

With the in the memory area 116 stored nominal parameter values leads the program component 124 then an adaptation step to adapt the desired parameter values to the current conditions. The program component 126 then generates positioning commands 144 in order to adapt the actual parameter values as quickly as possible to the desired parameter values. The program component 128 continuously analyzes the machine parameter values, if necessary, a message 154 or a message 156 to send.

Preferably, all data in the memory 110 continuously logged, such as all production cycles with the associated spray parameters, the setting speed of the reprint, the temperature times, etc.

The 3 shows a corresponding flow chart. In the step 300 The electronic module records parameters such as operating parameter values, actual parameter values and / or machine parameter values. In the step 302 the target parameter numbers are adapted to the current conditions. For this purpose, a suitable adaptation method is used, which is based, for example, on characteristics, calculation specifications and / or a neural network.

In the step 304 a set-actual comparison of desired parameter values and the associated actual parameter values is performed. For example, if one of the actual parameter values deviates too much from the associated desired parameter value, in step 306 Generates a corresponding Stellkommando for the control of the injection molding machine to readjust the injection molding machine to comply with the desired parameter value.

It is particularly advantageous that the electronic module 106 acts as a master for the control of the injection molding machine. This is particularly advantageous because the injection molding tool can be used with its electronic module for various injection molding machines, which naturally have different characteristics even with the same design due to specimen scatters or different degrees of wear.

The 4 shows a flowchart of an operation of the program component 128 (see. 2 ). In the step 400 a diagnosis of the machine parameters is carried out. The stored limits can be used. If the diagnostic shows that there is an error or service is required (step 402 ), the program component generates a message to the responsible addressee (step 404 ). In the opposite case, the process control goes to the step 400 back.

100

injection molding machine

102

control

104

injection mold

106

electronic module

108

insulation layer

110

Storage

112

storage area

114

storage area

116

storage area

118

storage area

120

storage area

122

processor

124

program component

126

program component

128

program component

130

program component

132

Communication interface

134

sensor

136

Mold cavity

138

sensor

140

network

142

Communication interface

144

adjusting command

146

Communication interface

148

computer

150

Communication interface

152

parameter values

154

message

156

message

158

Server computers

160

Email client

162

network

164

Client computer

Claims (23)

Injection molding tool with - means ( 110 ) for storing parameters, means ( 122 ) for the evaluation of the parameters, - means ( 126 ; 128 ) for generating a message ( 144 . 154 . 156 ) depending on the evaluation of the parameters, - means ( 130 . 132 ) for transmitting the message, and - means for receiving at least one operating parameter from an external sensor ( 138 ). Injection molding tool according to claim 1, with at least one sensor ( 134 ) for measuring a tool parameter. An injection molding tool according to claim 2, wherein the sensor is for measuring a pressure of plasticized plastic in a mold cavity (10). 136 ), for measuring a temperature of the plasticized plastic in the mold cavity ( 136 ), for measuring a property of the plasticized plastic material and / or for measuring the color of the plasticized plastic in the mold cavity ( 136 ) is trained. Injection molding tool according to claim 3, wherein it is at the operating parameter around the humidity and / or humidity of the plastic granules is. Injection molding tool according to one of the preceding claims, with means ( 132 ) for receiving at least one machine parameter of an injection molding machine. Injection molding tool according to claim 5, wherein it is at the machine parameter by a number of screw revolutions and / or around an opening degree a flow rate adjustment valve. Injection molding tool according to one of the preceding claims, having a memory ( 110 . 116 ) for storing desired parameters, wherein the means for evaluating the processing of the detected parameters and the desired parameters are formed. Injection molding tool according to claim 7, comprising means ( 124 ) for the adaptation of the setpoint parameters. Injection molding tool according to one of the preceding claims, with means ( 128 ) for detecting a warning, error and / or a service condition. Injection molding tool according to claim 9, wherein the means for recognition for access to the at least one machine parameter are formed. Injection molding tool according to claim 9 or 10, wherein the means for detecting to access at least one threshold for the Machine parameters are formed. Injection molding tool according to claim 9, 10 or 11, wherein the means for generating a message ( 154 . 156 ), which reports the warning, error state and / or the service state are formed. Injection molding tool according to claim 12, with at least an e-mail address stored in the memory for transmission the message. Injection molding tool according to claim 12 or 13, with a memory ( 120 ) for storing warning, error and / or service states associated with address data. Injection molding tool according to claim 14, wherein it is at the address data E-mail addresses, SMS addresses, telephone numbers, fax numbers or another electronic address is. Injection molding tool according to one of the preceding claims, having a communication interface ( 132 ) for transmitting parameters to a portable device ( 148 ). Injection molding tool according to one of the preceding claims, wherein the message is an adjusting command ( 144 ) for a controller ( 102 ) of the injection molding machine ( 100 ). Injection molding tool according to one of the preceding Claims, wherein the means for transmitting the message for wireless transmission the message are formed. Electronic module for an injection molding tool with - means ( 110 ) for storing parameters, means ( 122 ) for the evaluation of the parameters, - means ( 126 ; 128 ) for generating a message ( 144 . 154 . 156 ) depending on the evaluation of the parameters, - means ( 130 . 132 ) for sending the message, and - a communication interface ( 132 ) for receiving operating parameters from external sensors ( 138 ). The electronic module of claim 19, wherein the message is an adjunct command ( 144 ) for a controller ( 102 ) an injection molding machine ( 100 ). An electronic module according to claim 19 or 20, wherein the message a warning, error and / or service information includes. Electronic module according to claim 19, 20 or 21, with a microprocessor ( 122 ) for executing an evaluation program ( 124 . 126 . 128 ) and an electronic memory ( 110 ) for storing the parameters. Electronic module according to one of the preceding claims 19 to 22, wherein the communication interface is wireless.