JP3020363B2 - Setting method of monitor condition of molding machine - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for setting monitoring conditions in a molding machine such as an injection molding machine.
The present invention relates to a method for setting a condition value of each monitor item used for automatically determining the quality of a molded product.

[0002]

2. Description of the Related Art In recent molding machines such as an injection molding machine, a large number of operating condition values, which are factors for determining the quality of a molded product (product), are finely set in advance, and control of the entire machine (molding machine) is performed. A microcomputer performs a continuous automatic molding operation by referring to measurement information from various sensors and the like based on the operation condition values. By the way, it is inevitable in manufacturing that the operating conditions fluctuate due to sudden fluctuation factors or the like. If a defective product is generated due to such a fluctuation in the operating condition, the defective product of the shot can be automatically eliminated. Is desirable.

Therefore, in addition to the above-mentioned set values of the molding operation conditions, an upper limit value and a lower limit value are set for each monitor item of a large number of operation conditions to be monitored, and each monitor item is set while performing a continuous automatic molding operation. The actual operating condition value was measured to determine how it actually changed.If the measured value was within the above upper and lower limits, it was a good product.If it exceeded the upper or lower limit, it was defective. In the event that a defect is determined, molding machines with a monitor function (automatic inspection function) that take the molded product at that time to the defective product reservoir at the time of ejection and removal have begun to spread recently. I have.

The above-mentioned monitor items are, for example, “position”, “operating time”, “temperature”, “speed”, “pressure”, “rotation speed”, and “inline screw type injection molding machine”. A large number of subdivided items of about 50 to 100 are provided for “total rotation amount”, “back pressure”, and the like. Such a large number of monitor items are generally set by the operator by inputting an upper limit value and a lower limit value by an absolute key value for each item.

[0005]

As described above, conventionally, in order to specify an allowable range of each monitor item, an upper limit value and a lower limit value are input as absolute values to set an allowable range for pass / fail determination. Therefore, if the operating condition set value is changed during continuous automatic molding operation, the allowable range value for pass / fail judgment will deviate from the appropriate value, and the upper limit and lower limit of the monitor item will be changed to the absolute value each time. It was necessary to re-enter and set again. In addition, the operating conditions of the molding machine are often that a plurality of conditions are closely related to each other, and when a certain operating condition set value is changed, a plurality of operating condition values related to this often need to be changed, In such a case, there is a problem in that the operation of resetting the upper limit and the lower limit of the monitor item due to the change of the operation condition setting value takes time and burdens the operator.

Accordingly, a technical problem to be solved by the present invention is to solve the above-mentioned problems of the prior art.
The purpose is to facilitate the setting work of the permissible range for each monitor item for pass / fail judgment. Also, even if the operation condition set value is changed, the permissible range is automatically linked to this. An object of the present invention is to provide an easy-to-use molding machine with a monitor function whose values can be changed and set.

[0007]

SUMMARY OF THE INVENTION It is an object of the present invention to compare a predetermined allowable range value and a measured value for each monitor item in order to determine the quality of a molded product during continuous automatic molding operation. In a molding machine having a function of judging the quality of a molded article based on the comparison result, a setting mode for setting an allowable range value for each monitor item as a ± range value with respect to a reference value , and an allowable range for each monitor item. The value,
Settings that can be entered and set as the upper and lower absolute values
Mode is achieved by making it selectable .

[0008]

[Function] Setting mode (relative value monitor mode) for setting the permissible range value for each monitor item as ± range value relative to the reference value
And a setting mode (absolute value monitor mode) in which an allowable range value for each monitor item can be set as an upper limit absolute value and a lower limit absolute value. When the relative value monitor mode is selected, the monitor is set. A reference value and a ± range value with respect to the reference value are input and set for each item. With this, the microcomputer obtains an allowable range value for each monitor item from the reference value and the ± range value, and compares it with the actually measured value.

[0009] The reference value of the monitor item may be directly inputted by the operator as a numerical value, or the operation condition set value of the operation condition item corresponding to each monitor item may be automatically taken in, or the continuous automatic molding. It is set by automatically taking in the actual measurement data of each monitor item of the latest shot during operation.

Alternatively, a reference value of a monitor item and a ± range value with respect to the reference value are automatically set based on a result of statistical calculation processing of an actual measurement value of a predetermined number of shots during a continuous automatic molding operation.

If the relative value monitor mode is selected in this manner,
It is only necessary to set the reference value of the monitor item and the ± range value with respect to the reference value. The setting work of the permissible range for each monitor item is simple and easy. Further, even when the operating condition set value is changed, the allowable range value is automatically changed only by changing the reference value of the monitor item, so that the resetting operation becomes extremely easy. In particular, if the reference value of the monitor item is set by automatically importing the operating condition set value and actual measurement data, even if the operating condition set value is changed, it will automatically be linked to this. The reference value of the monitor item can be changed, and the allowable range value can be automatically reset.

Further, if the reference value of the monitor item and the ± range value relative to the reference value are automatically set based on the result of the statistical calculation processing of the actually measured value of the predetermined number of shots, the setting of the monitor condition can be entirely performed. Be automated.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS. FIG. 1 is a simplified block diagram of a control system of the injection molding machine according to the present embodiment.

In FIG. 1, reference numeral 1 denotes a machine (injection molding machine)
A microcomputer (microcomputer), which is a system controller that controls overall operation control, display output control, print output control, data management processing, determination processing, etc., 2 is a sensor group including a large number of sensors provided in each part of the machine, 3 is a driver group composed of a large number of driver circuits for driving and controlling a large number of driving sources arranged in each part of the machine. 4 is a key input device arranged in a front part of the machine.
Reference numeral 5 denotes a display device such as a color CRT display and a color LCD disposed near the key input device, and reference numeral 6 denotes a printer connected to the machine as necessary.

The microcomputer 1 controls the entire molding process such as plasticization / metering operation, injection operation, mold opening / closing operation, eject operation, operation of a product unloader, calculation / storage processing of measured data, non-defective / defective products. Calculation / determination processing such as (good / defective shot) determination processing, output control processing to the display device 5 and the printer 6, and the like are executed. This microcomputer 1
Actually means various I / O interfaces, ROM, R
Although it is configured with an AM, a CPU, and the like, and executes various processes by various programs created in advance, in the present embodiment, a molding condition setting storage unit 11, an actual measurement value storage unit 12, a molding process control unit 13 , A monitor condition setting storage unit 14, a statistical calculation processing unit 15, a good / bad determination unit 16, and the like will be described below.

The molding condition setting storage section 11 stores various operating condition setting values in a rewritable form. For example, an operator interacts with various setting screens on the display device 5. The key input device 4 according to the format
The operating condition setting values over a large number of molding condition items are stored by the input from. The molding conditions stored in the molding condition setting storage unit 11 include, for example,
The relationship between the screw position and screw rotation speed and back pressure during the weighing process (charge process), suckback control conditions,
Speed and pressure conditions along the position axis or time axis during the injection stroke (primary injection stroke and dwelling stroke), heater temperature of each part,
Mold closing (mold closing) stroke and speed control conditions, mold clamping force, mold opening stroke and speed control conditions, eject control conditions, product unloader control conditions, and the like.

The measured value storage unit 12 stores all measured data (measured values x) of a large number of monitor items which are prerequisites for executing a monitor operation (automatic inspection operation) during a continuous automatic molding operation. Is captured over a predetermined number of consecutive shots. The monitoring items to be taken are roughly classified into position monitoring items, operation time monitoring items, temperature monitoring items, speed monitoring items, pressure monitoring items, rotation speed monitoring items, power monitoring items, and the like. A considerable part overlaps with this,
For example, about 50 to 100 monitor items are preset so as to cover factors closely related to the quality of the molded article.

The molding process control section 13 is provided with sensors provided in each section of the machine based on a molding process control program created in advance and operating condition setting values stored in the molding condition setting storage section 11. The driver group 3 (motor driver, electromagnetic control of hydraulic system) is referred to by referring to the data from the actual measurement value storage unit 12 and the time measurement information from the clock means built in the microcomputer 1 to fetch the measurement information from the group 2 in real time. A corresponding drive source is driven and controlled via a valve driver, a heater driver, etc.) to execute a series of molding steps.

The monitor condition setting storage section 14 stores rewritable allowable range values respectively corresponding to the above-mentioned many monitor items. In the present embodiment, a setting mode (“relative value monitor” mode) in which an allowable range value for each monitor item is set as a ± range value with respect to a reference value, and an allowable range value for each monitor item is set to an upper limit absolute value and A setting mode (“absolute value monitor” mode) in which an input can be set as the lower limit absolute value can be selected. When the “relative value monitor” mode is selected, a reference value and a ± range value with respect to the reference value are stored in the monitor condition setting storage unit 14 for each monitor item,
Also, when the “absolute value monitor” mode is selected,
The upper limit value and the lower limit value for each monitor item input as the absolute value are stored in the monitor condition setting storage unit 14. For example, in the case of setting the monitor condition relating to “Heater 1” as a monitor item, in the “relative value monitor” mode, a reference value = 200 ° C., ± range value = 10 ° C. (5%) is input, and the monitor condition The setting storage unit 14 stores the reference value and ±
The range value is stored. In the “absolute value monitor” mode, the lower limit value is 190 ° C. and the upper limit value is 21 as the absolute value.
When 0 ° C. is input, the monitor condition setting storage unit 14 stores the upper limit value and the lower limit value.

The above-described setting of the monitor condition is performed, for example, in an interactive manner with a plurality of monitor condition setting screens called on the display device 5 in accordance with the “relative value monitor” mode or the “absolute value monitor” mode. The operator operates the key input device 4.

In this embodiment, when the "relative value monitor" mode is selected, the "relative value monitor"
On the setting screen for the predetermined monitor condition corresponding to the mode, the operator directly inputs the reference value of the monitor item as a numerical value (“setting” mode) or the operation condition setting of the operation condition item corresponding to each monitor item as the reference value A mode that automatically captures values (“set value linked” mode) or a mode that automatically captures the actual measurement data of each monitor item of the latest shot during continuous automatic molding operation as a reference value (“monitor value transfer” mode) The three modes can be alternatively selected. When the “setting” mode is selected, the reference value numerical data input by the operator using the key input device 4 is sequentially taken into the monitor condition setting storage unit 14 as the reference value of each monitor item. When the “set value interlocking” mode is selected, the operating condition set value of each operating condition item stored in the molding condition setting storage unit 11 is stored in the monitor condition setting storage unit 14 as the reference value of each monitor item. When the “monitor value transfer” mode is selected, the measured data of each monitor item of the latest shot stored in the measured value storage unit 12 is stored in the monitor condition setting storage unit. 14 collectively takes in as reference values of each monitor item. In addition,
The “set value interlocking” mode is applied only to the operation condition item corresponding to the monitor item. If the operation condition item corresponding to the monitor item does not exist, the “setting” mode or “ Monitor value transfer mode,
Alternatively, it is input and set in a “monitor statistics correction” mode described later.

In this embodiment, a mode for automatically setting a reference value of a monitor item and a ± range value with respect to the reference value based on a result of statistical calculation processing of an actual measurement value of a predetermined number of shots during a continuous automatic molding operation (see FIG. 1). "Monitor statistics correction" mode) is provided. Statistical calculation processing unit 1
Reference numeral 5 has a function of calculating a reference value of each monitor item and a ± range value with respect to the reference value when the “monitor statistics correction” mode is selected, and a predetermined number of shots stored in the measured value storage unit 12. Is statistically processed using the actual measurement data of each monitor item, and an average value x _AVE = Σx / n (n is the number of shots) of the actual measurement value x and the actual measurement value x
Range R = x _MAX −x _MIN and standard deviation σ = √
[{X ² − ({x) ² / n} / (n−1)] ”is calculated first. Then, according to the selection command of the ± range value (depending on whether to use the variation range R or the standard deviation σ), when the variation range R is selected, ± range value = R × ( (Constant) / 2, and when the standard deviation σ is selected, arithmetic processing is performed as ± range value = 3σ × (constant) / 2. The average value x _AVE of the actually measured values x obtained by the statistical operation processing unit 15 is transferred and stored in the monitor condition setting storage unit 14 as the reference value of the monitor item, and the ± range value obtained by the statistical operation Is also transferred to the monitor condition setting storage unit 14 and stored in the storage area corresponding to the reference value.

In the "monitor statistics correction" mode, the "relative value monitor" mode and the "absolute value monitor" mode can be selected, and the "relative value monitor" mode is selected. When the "absolute value monitor" mode is selected, the monitor condition setting storage unit 14 stores the reference value and the ± range value transferred from the statistical operation processing unit 15. The upper and lower limit values calculated by the monitor condition setting storage unit 14 itself from the data transferred from the statistical operation processing unit 15 or the upper and lower limit values calculated by the statistical operation processing unit 15 are stored in the unit 14.

The pass / fail judgment section 16 compares the data stored in the monitor condition setting storage section 14 with the actual measurement data of the latest shot (the latest actual measurement data transferred from the actual measurement value storage section 12). It is determined whether or not the measured value is within a preset allowable range. That is, (reference value−
It is determined whether or not the actually measured value is included in the (range) and (reference value + range), and whether or not the actually measured value is between the lower limit and the upper limit is determined. If the measured value deviates from the allowable range, this is indicated to the molding process controller 13.
By controlling the product unloader by the molding process control unit 13 (or operating the reversing chute), the molded product by the latest shot is transported as a defective product to a predetermined defective product storage. When a failure occurs, an alarm message screen of the display device 5 is displayed as necessary, and the failure monitor item is visually recognized by an operator, or the occurrence of an abnormality is recognized by a horn or a warning lamp (not shown). It is made to let. Further, when a failure occurs, the alarm history storage unit (not shown) stores the fact so that the alarm (failure) history and the like can be printed out by the printer 6 later.

Next, the operation based on the above configuration will be described. When setting monitoring conditions, the key input device 4
By operating the predetermined key, the "statistical mode alarm history" setting mode screen as shown in FIG. 2 is first called on the display screen 5a of the display device 5. The setting mode screen shown in FIG. 2 is a basic mode screen for setting monitor conditions. On this screen, the user can select one of the "relative value monitor" mode and the "absolute value monitor" mode. It is possible to select whether to turn on or off the "monitor statistics correction" mode. That is, in the basic setting mode screen of FIG.
Move the cursor to the “absolute value monitor” display field 21 of the “monitor processing mode” and select the “absolute value monitor” mode. Similarly, move the cursor to the “relative value monitor” display field 22 to display the “relative value monitor”. Mode ". In the basic setting mode screen shown in FIG. 2, the cursor is moved to the "monitor correction" display column 23 of "statistical processing", the "monitor statistics correction" mode is selected, and the cursor is moved to the "OFF" display column 24. To turn off the "monitor statistics correction" mode (in this embodiment, the other simple statistical calculation modes are also turned off).

Now, after selecting the "relative value monitor" mode on the basic setting mode screen of FIG. 2 and appropriately calling the monitor setting mode screen by key operation, a "monitor 1" setting mode screen as shown in FIG. Is displayed.
In the setting mode screen shown in FIG. 3, one of the three modes of the "setting" mode, the "set value interlocking" mode, and the "monitor value transfer" mode is selected as the reference value capturing mode. The user can select one of them. On the setting mode screen shown in FIG. 3, the user moves the cursor to the "setting mode" display field 31 of "reference value mode" and selects the above "setting mode", and selects "linked with setting value". The cursor is moved to the display column 32 to select the above-mentioned "set value interlocking" mode, and the cursor is moved to the "monitor value transfer" display column 33 to select the above-mentioned "monitor value transfer" mode.

In the setting mode screen shown in FIG. 3, for example, when a "setting" mode is selected as a mode for taking in a reference value, a mode in which an operator directly inputs a reference value of each monitor item is set. By the operation, the reference value and the ± range value are sequentially input and set for each monitor item. Then, when the setting on the "monitor 1" setting mode screen of FIG. 3 is completed, the "monitor 2" setting mode screen (not shown) is called up by operating the next screen call key or the like, and the same input setting is performed. This is repeated in the same manner as described below to set all the monitor items.

It is premised that operating condition set values have been set. However, when the "set value interlocking" mode is selected as a reference value capturing mode on the setting mode screen of FIG. In this mode, the operating condition set value is automatically taken in as the reference value of the item corresponding to the condition item. Therefore, the operator sequentially inputs and sets the above-mentioned ± range values for each monitor item by operating the cursor movement keys and the numerical keys, and directly inputs the reference value by key operation or the like for monitor items not included in the operation condition items. I will go. The number of monitor items not included in the operation condition items is relatively small. In this case as well, it goes without saying that all the setting mode screens are called and the input setting is performed to the end.

It is premised that the automatic molding operation is in a continuous automatic molding operation state in which it is guaranteed that non-defective products are molded. On the setting mode screen of FIG. When the mode is selected, the actual measurement data of each monitor item of the latest shot during the continuous automatic molding operation is automatically taken in as the reference value of each monitor item. Therefore, the operator only needs to sequentially input and set only the ± range value for each monitor item by operating the cursor movement key and the numerical key. In this case as well, it goes without saying that all the setting mode screens are called and the input setting of the ± range value is performed until the end.

After the setting of the reference value and the ± range value of each monitor item is completed by selecting the “relative value monitor” mode as described above, the operating condition set value must be changed for some reason. Then, there is a possibility that the monitor setting condition for the pass / fail judgment is out of the appropriate range. However, in the “relative value monitor” mode, only the reference value needs to be changed after the setting of the ± range value is completed, so that it is extremely easy to modify the monitor setting conditions. In particular,
If a "set value interlocking" mode or a "monitor value transfer" mode is used as the reference value capturing mode, the reference value itself is also automatically corrected, so that the usability is improved without much trouble.

After selecting the "absolute value monitor" mode on the basic setting mode screen shown in FIG. 2, the monitor setting mode screen is called by appropriate key operation. Monitor setting mode screen is displayed. In the monitor setting mode screen for the "absolute value monitor" mode, a column for inputting an upper limit value and a lower limit value is displayed for each monitor item, and each monitor item is operated by operating the cursor movement keys and numerical keys. The upper limit value and the lower limit value are sequentially input and set.

On the basic setting mode screen shown in FIG. 2 (for example, when the “relative monitor” mode is selected), the “monitor statistical correction” mode is selected, and “R” on the basic setting mode screen shown in FIG. 2 is selected. When the above-described variation range R of the actual measurement value x is selected in the display column 25, the actual measurement value x for each monitor item is statistically processed using the actual measurement data of a predetermined number of shots, and the average value x _AVE of the actual measurement value x is obtained. And the range R of the variation x of the actually measured value x and the ± range value = R × (constant) / 2 are calculated, and the average value x _AVE of the actually measured value x is used as the reference value, and R
× (constant) / 2 are automatically taken in as ± range values. On the other hand, select the "monitor statistics correction" mode,
When the above-mentioned standard deviation σ is selected in the “3σ” display field 26 on the basic setting mode screen of FIG. 2, the actual measurement value x for each monitor item is statistically calculated using the actual measurement data of a predetermined number of shots. The average value x _{AVE of the} value x, the standard deviation σ,
± Range value = 3σ × (constant) / 2 to calculate actual measurement value x
The average value x _AVE is automatically taken as a reference value and 3σ × (constant) / 2 is automatically taken as a ± range value.

If this "monitor statistics correction" mode is used, it is premised that a continuous automatic molding operation is performed in which a non-defective product is guaranteed to be molded. (That is, all the monitor conditions of each monitor item) are automatically taken in and set, so that the monitor condition setting operation is a simple operation that can be performed by almost no burden.

[0034]

As described above, according to the present invention, it is easy to set an allowable range for each monitor item for quality judgment, and even when the operation condition set value is changed,
In conjunction with this, the allowable range value can be changed and set automatically,
An easy-to-use molding machine with a monitor function can be provided, and its value is enormous. In addition, the tolerance for each monitor item
Setting mode for setting the ambient value as a ± range value relative to the reference value
And the allowable range value for each monitor item,
The setting mode that can be set and input as the lower limit absolute value is selected.
Users can use one or the other as needed.
Setting mode can be selected, and setting to be set with ± range value
Selecting a mode makes it easier to set the range.
You can select the setting mode to set the absolute value and the lower absolute value.
If the upper and lower limits for the reference value are different,
Fine settings are possible, and this is also convenient
It becomes

[Brief description of the drawings]

FIG. 1 is a simplified block diagram of a control system of an injection molding machine according to one embodiment of the present invention.

FIG. 2 is an explanatory diagram showing an example of a setting mode screen according to an embodiment of the present invention.

FIG. 3 is an explanatory diagram showing an example of a setting mode screen according to an embodiment of the present invention.

[Explanation of symbols]

 Reference Signs List 1 microcomputer 2 sensor group 3 driver group 4 key input device 5 display device 6 printer 11 molding condition setting storage unit 12 actual measurement value storage unit 13 molding process control unit 14 monitoring condition setting storage unit 15 statistical calculation processing unit 16 good / bad judgment unit

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 45/76 B22D 17/32 G07C 3/14 G06F 15/46

Claims (6)

(57) [Claims] In order to determine the quality of a molded product during a continuous automatic molding operation, a predetermined allowable range value for each monitor item is compared with an actually measured value, and the quality of the molded product is determined based on the comparison result. In a molding machine having a function of determining, a permissible range value for each of the monitor items is set to ±
Setting mode to set with range value and each monitor item
Enter the allowable range value as the upper limit absolute value and lower limit absolute value
A monitor setting method for a molding machine , wherein a settable setting mode is selectable . 2. The method according to claim 1, wherein the reference value setting mode of the reference value of the monitor item is set to off.
Direct input mode in which the operator inputs the reference value directly by numerical value
Monitor setting for molding machines characterized by the provision of
Method. 3. The monitor according to claim 1, wherein the reference value setting mode of the reference value of the monitor item is
Operating condition setting value of operating condition item corresponding to monitor item
Is automatically set as the reference value.
Condition setting of the molding machine characterized by the
Fixed method. 4. The system according to claim 1, wherein the reference value setting mode of the reference value of the monitor item is a continuous value.
Each monitor item of the latest shot during automatic molding operation
Automatically captures the actual measurement data as the reference value.
A molding machine provided with a data transfer mode.
Monitor condition setting method. 5. The method according to claim 1, wherein an actual measurement value of a predetermined number of shots during a continuous automatic molding operation is obtained.
Based on the result of the statistical calculation processing, the standard of the monitor item
Automatic setting of the value and the ± range value for the reference value
Monitor for molding machines characterized by a unique mode
Condition setting method. 6. The criterion according to claim 5, wherein the criterion is determined based on a result of the statistical operation processing.
The value is the average value of the actually measured values, and is the result of the statistical calculation processing.
The ± range value of the reference value determined based on the results is the measured value.
Calculated the variation range or standard deviation of
Molding machine, characterized in that it is a shall be determined from the results
Monitor condition setting method.