JP2010052319A - Method of controlling injection molding machine - Google Patents

Method of controlling injection molding machine Download PDF

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JP2010052319A
JP2010052319A JP2008220779A JP2008220779A JP2010052319A JP 2010052319 A JP2010052319 A JP 2010052319A JP 2008220779 A JP2008220779 A JP 2008220779A JP 2008220779 A JP2008220779 A JP 2008220779A JP 2010052319 A JP2010052319 A JP 2010052319A
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mold
injection molding
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molding machine
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JP5248243B2 (en
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Hideya Takenobu
秀也 武信
Toshiyuki Sotoike
俊幸 外池
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Toyo Mach & Metal Co Ltd
東洋機械金属株式会社
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<P>PROBLEM TO BE SOLVED: To control an injection molding machine to keep a molding speed enough not to be stopped and to continue operation, until a next process machine is returned to a normal state from a stopped state. <P>SOLUTION: The injection molding machine is switched to a delay cycle mode, when an abnormal signal from the next process machine is received. In the delay cycle mode, a primary injection time to inject into a mold device from a heating cylinder, a mold opening time of the mold device, a cooling time of molten resin in the mold device, and a measuring time to supply the molten resin to inside the heating cylinder are extended, respectively. A molding cycle of one shot for 3.5-4 s in a normal molding cycle is extended for 1-10 min in the delay cycle mode, and an injection molding machine 1 is controlled to be operated at a minimum speed where the injection molding machine 1 is not stopped. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

この発明は、射出成形機と後工程機とを連動させ、後工程機の異常時において、後工程機が復旧するまで射出成形機の成形サイクルを遅延させるように制御する射出成形機の制御方法に関するものである。   The present invention relates to an injection molding machine control method in which an injection molding machine and a post-processing machine are interlocked, and control is performed to delay the molding cycle of the injection molding machine until the post-processing machine is restored when the post-processing machine is abnormal. It is about.

従来、射出成形機においては、射出装置の加熱筒内において加熱された溶融樹脂を金型装置のキャビティに充填し、冷却固化した成形品を金型装置から取り出す成形サイクルを繰り返すものであって、この種の射出成形機の成形サイクルとして、まず、計量工程が行われ、加熱筒内において樹脂を蓄え、金型装置の型閉めが行われた状態で加熱筒内の溶融樹脂の射出工程が行われる。射出ノズルから射出された樹脂は、金型装置内のキャビティ空間に充填され、次に、キャビティ空間内の樹脂の圧力を保持する保圧工程を経て金型装置を冷却させてキャビティ空間内の樹脂を冷却する冷却工程を行い、キャビティ内の樹脂が固化した成形品を型開工程後、金型装置から成形品が取り出す成形サイクルを繰り返す。   Conventionally, in an injection molding machine, a molten resin heated in a heating cylinder of an injection apparatus is filled in a cavity of a mold apparatus, and a molding cycle for taking out a cooled and solidified molded product from the mold apparatus is repeated. As a molding cycle of this type of injection molding machine, first, the weighing process is performed, the resin is stored in the heating cylinder, and the injection process of the molten resin in the heating cylinder is performed with the mold device closed. Is called. The resin injected from the injection nozzle is filled into the cavity space in the mold apparatus, and then the mold apparatus is cooled through a pressure-holding process for maintaining the pressure of the resin in the cavity space, so that the resin in the cavity space is filled. A cooling process for cooling the resin is performed, and after the mold opening process for the molded product in which the resin in the cavity is solidified, a molding cycle in which the molded product is taken out from the mold apparatus is repeated.

前記射出成形機において、例えば、DVD等のディスク基板を成形する場合、並設した2台の射出成形機を運転してそれぞれディスク基板を成形し、これら各射出成形機と連動して各射出成形機から取り出された2枚のディスク基板を後工程機によって貼り合わせてDVDとして製造する。すなわち、射出成形機と、この射出成形機で成形した製品に対して後加工を行う後工程機とは、互いに同期させて運転させるように制御する必要がある。このため、後工程機が故障などによって異常が発生して一時的に停止した場合、射出成形機も後工程機と連動させて停止させる必要がある。しかし、射出成形機を停止させた場合、金型装置が冷えて再び運転を開始する際に、正常な成形サイクルを行うまで時間がかかり、成型効率が著しく悪くなってしまう。   In the injection molding machine, for example, when molding a disk substrate such as a DVD, the disk substrate is molded by operating two injection molding machines arranged in parallel, and each injection molding is linked with each injection molding machine. Two disk substrates taken out from the machine are bonded together by a post-process machine to produce a DVD. That is, it is necessary to control the injection molding machine and a post-process machine that performs post-processing on a product molded by the injection molding machine so as to be operated in synchronization with each other. For this reason, when the post-process machine is abnormally stopped due to a failure or the like and temporarily stopped, the injection molding machine needs to be stopped in conjunction with the post-process machine. However, when the injection molding machine is stopped, when the mold apparatus cools down and starts operation again, it takes time until a normal molding cycle is performed, and the molding efficiency is remarkably deteriorated.

このため、例えば、特許文献1には、後工程機にトラブルが発生した場合、射出工程の次の冷却工程の時間、あるいはディスク基板の取出しが終了した後、型閉工程が開始されるまでの休止時間を延長することによって、後工程機の異常時において、通常の成形サイクルより長くした射出成形システムの制御方法が開示されている。   For this reason, for example, in Patent Document 1, when a trouble occurs in the post-process machine, the time of the cooling process next to the injection process or after the disk substrate is taken out until the mold closing process is started. A control method for an injection molding system is disclosed in which the downtime is extended so that the time of the post-processing machine is longer than that of a normal molding cycle when the post-processing machine is abnormal.

特許第3589598号公報Japanese Patent No. 3589598

しかしながら、前記特許文献1のように冷却工程の時間あるいは型閉じが開始されるまでの休止時間を遅延させたとして射出成形機が遅延できる時間には限度がある。すなわち、この種のDVDなどのディスク基板を成形する1ショットの成形サイクルの時間は3.5〜4秒であるのに対し、冷却工程の時間あるいは型閉じが開始されるまでの休止時間を遅延させたとしても1ショットの成形サイクルの時間は16秒程度である。このため、後工程機が復旧するまでの時間が長くなると、射出成形機の運転が困難となり、射出成形機を停止せざるを得ず、生産性の低下を招く、という課題を有していた。   However, there is a limit to the time that the injection molding machine can delay if the cooling process time or the pause time until the mold closing is started is delayed as in Patent Document 1. That is, the time of one shot molding cycle for molding a disk substrate such as this type of DVD is 3.5 to 4 seconds, while the cooling process time or the pause time until the mold closing is started is delayed. Even if it makes it, the time of the molding cycle of 1 shot is about 16 seconds. For this reason, when the time until the post-process machine is restored becomes longer, the operation of the injection molding machine becomes difficult, and the injection molding machine has to be stopped, resulting in a decrease in productivity. .

本発明は、前記従来の射出成形機の課題を解決して、後工程機にトラブルが発生している状態において射出成形機が停止しない速度で運転を維持して射出成形機の1ショットの成形サイクルの時間をできるだけ延長することが可能な射出成形機の制御方法を提供することを目的とする。   The present invention solves the problems of the conventional injection molding machine, and maintains the operation at a speed at which the injection molding machine does not stop in a state where trouble occurs in the post-processing machine, and molding one shot of the injection molding machine. It is an object of the present invention to provide a method for controlling an injection molding machine capable of extending the cycle time as much as possible.

請求項1記載の射出成形機の制御方法は、加熱筒内で加熱された溶融樹脂を金型装置のキャビティに射出し、キャビティ内で冷却固化した成形品を取り出す射出成形機と、この射出成形機と連動して該射出成形機から取り出した成形品に対して加工を行う後工程機と、この後工程機からの異常信号に基づいて前記射出成形機を通常サイクルモードから遅延サイクルモードに切り換える制御手段を備え、前記遅延サイクルモードでは前記制御手段により、1ショットの成形サイクルを1〜10分に延長する成形条件に設定するように制御したことを特徴とする。   The method of controlling an injection molding machine according to claim 1 includes: an injection molding machine for injecting molten resin heated in a heating cylinder into a cavity of a mold apparatus and taking out a molded product cooled and solidified in the cavity; A post-process machine that processes the molded product taken out from the injection molding machine in conjunction with the machine, and switches the injection molding machine from the normal cycle mode to the delay cycle mode based on an abnormal signal from the post-process machine In the delay cycle mode, the control means controls the molding conditions so that one shot molding cycle is extended to 1 to 10 minutes.

請求項1記載の射出成形機の制御方法によれば、制御手段により、1ショットの成形サイクルを1〜10分に延長する成形条件に設定することにより、長い冷却時間においても安定連続成形を可能とし、1ショットの成形サイクルにかかる成形時間を延長する。   According to the control method of the injection molding machine according to claim 1, stable continuous molding is possible even in a long cooling time by setting the molding condition to extend the molding cycle of one shot to 1 to 10 minutes by the control means. And extending the molding time for a one-shot molding cycle.

請求項2記載の射出成形機の制御方法は、前記遅延サイクルモードでは、金型装置の型閉時間、加熱筒から金型装置に射出する一次射出時間、金型装置の型開時間の変更及び計量動作後のノズルバック動作、サックバック遅延の追加により、金型装置内での溶融樹脂の冷却時間を延長することを特徴とする。   The method for controlling an injection molding machine according to claim 2, wherein in the delay cycle mode, the mold closing time of the mold apparatus, the primary injection time of injection from the heating cylinder to the mold apparatus, the change of the mold opening time of the mold apparatus, and The cooling time of the molten resin in the mold apparatus is extended by adding a nozzle back operation and a suck back delay after the metering operation.

請求項2記載の射出成形機の制御方法によれば、射出成形機は、成形が開始すると、金型装置の型閉工程、射出ノズルが前進して加熱筒から金型装置に射出する一次射出工程、金型装置内での溶融樹脂の冷却時間、金型装置の型開工程、成形品の取出という一連の射出成形機の作動が開始するが、遅延サイクルモードでは冷却時間を延ばし、一連の射出成形機の作動を遅延させて射出成形機が停止しない速度まで減速させて、1ショットの成形サイクルにかかる成形時間を延長する。   According to the method for controlling an injection molding machine according to claim 2, when the molding starts, the injection molding machine performs a mold closing process of the mold apparatus, a primary injection in which the injection nozzle advances and is injected from the heating cylinder to the mold apparatus. A series of injection molding machine operations such as processes, cooling time of the molten resin in the mold apparatus, mold opening process of the mold apparatus, and removal of the molded product are started. In the delay cycle mode, the cooling time is extended, The operation of the injection molding machine is delayed to slow down to a speed at which the injection molding machine does not stop, thereby extending the molding time for one shot molding cycle.

請求項3の射出成形機の制御方法は、前記遅延サイクルモードでは、金型装置の型開速度を減速させて型開するように制御した特徴とする。   The control method of the injection molding machine according to claim 3 is characterized in that in the delay cycle mode, the mold opening speed of the mold apparatus is controlled to be reduced to open the mold.

請求項3の射出成形機の制御方法によれば、金型装置の型開速度を落すことによって冷却時間を延長しても安定した連続成形が可能となるように制御し、金型装置の型開時間を延長することができるとともに、型開速度が緩やかとなり、型開する際、キャビティ空間の内周面に貼り付いた基板の取出しが容易になる。   According to the control method of the injection molding machine of claim 3, the mold is controlled so that stable continuous molding is possible even if the cooling time is extended by reducing the mold opening speed of the mold apparatus. While the opening time can be extended, the mold opening speed becomes slow, and when the mold is opened, the substrate attached to the inner peripheral surface of the cavity space can be easily taken out.

請求項4の射出成形機の制御方法は、前記後工程機からの復旧信号を受けると通常成形モードより長く、遅延サイクルモードより短い調整サイクルを予め設定されたショット数繰り返してから通常成形モードに復帰するように構成したことを特徴とする。   According to the control method of the injection molding machine of claim 4, when the recovery signal from the post-process machine is received, the adjustment cycle longer than the normal molding mode and shorter than the delay cycle mode is repeated for a preset number of shots, and then the normal molding mode is entered. It is configured to return.

請求項5の射出成形機の制御方法によれば、後工程機が復旧すると、通常成形モードより長く、遅延サイクルモードより短い成形時間に設定された調整モードを予め設定されたショット数の成形を行った後、通常成形モードに復帰する。   According to the control method of the injection molding machine of claim 5, when the post-process machine is restored, the adjustment mode set to the molding time longer than the normal molding mode and shorter than the delay cycle mode is molded with a preset number of shots. After that, the normal molding mode is restored.

請求項1記載の射出成形機の制御方法によれば、加熱筒内で加熱された溶融樹脂を金型装置のキャビティに射出し、キャビティ内で冷却固化した成形品を取り出す射出成形機と、この射出成形機と連動して該射出成形機から取り出した成形品に対して加工を行う後工程機と、この後工程機からの異常信号に基づいて前記射出成形機を通常サイクルモードから遅延サイクルモードに切り換える制御手段を備え、前記遅延サイクルモードでは前記制御手段により、1ショットの成形サイクルを1〜10分に延長する成形条件に設定するように制御したものであるから、冷却時間を延長し、射出成形機が停止しない速度まで減速させて、後工程機が復旧まで可及的に射出成形機の1ショットの成形サイクルにかかる成形時間を可及的に延長することができ、後工程機が復旧するまで射出成形機の運転を維持することで後工程機が復旧した時点で通常の成形モードへと短時間で復帰できるため、生産性を高めることができる。   According to the method for controlling an injection molding machine according to claim 1, an injection molding machine for injecting molten resin heated in a heating cylinder into a cavity of a mold apparatus and taking out a molded product cooled and solidified in the cavity, A post-process machine that processes the molded product taken out from the injection molding machine in conjunction with the injection molding machine, and the injection molding machine is changed from the normal cycle mode to the delay cycle mode based on an abnormal signal from the post-process machine. Control means to switch to, in the delay cycle mode, the control means is controlled to set the molding conditions to extend the molding cycle of one shot to 1 to 10 minutes, so the cooling time is extended, Decrease the injection molding machine to a speed that does not stop, and extend the molding time required for one injection molding machine cycle as much as possible until the post-processing machine recovers. Come, since the post-process machine can return in a short time to normal molding mode when the post-process machine is restored by maintaining the operation of the injection molding machine to be restored, it is possible to enhance the productivity.

請求項2記載の射出成形機の制御方法によれば、前記遅延サイクルモードでは、金型装置の型閉時間、加熱筒から金型装置に射出する一次射出時間、金型装置の型開時間の変更及び計量動作後のノズルバック動作、サックバック遅延の追加により金型装置内での溶融樹脂の冷却時間を延長することにより、射出成形機が停止しない速度まで減速させて、後工程機が復旧まで可及的に射出成形機の1ショットの成形サイクルを延長するように制御することができる。   According to the control method of the injection molding machine according to claim 2, in the delay cycle mode, the mold closing time of the mold apparatus, the primary injection time of injection from the heating cylinder to the mold apparatus, the mold opening time of the mold apparatus By changing the nozzle back operation after the change and metering operations and adding a sack back delay, the molten resin cooling time in the mold unit is extended to reduce the speed until the injection molding machine does not stop, and the post-process machine is restored. It can be controlled to extend the one-shot molding cycle of the injection molding machine as much as possible.

請求項3の射出成形機の制御方法によれば、前記遅延サイクルモードでは、金型装置の型開速度を減速させて型開するように制御したことによってキャビティ空間の内周面に貼り付いた基板の離型安定性を高めることができる。   According to the method for controlling an injection molding machine according to claim 3, in the delay cycle mode, the mold opening speed of the mold apparatus is controlled to be reduced so that the mold is opened, and the die is stuck to the inner peripheral surface of the cavity space. The mold release stability of the substrate can be improved.

請求項4の射出成形機の制御方法によれば、前記後工程機からの復旧信号を受けると通常成形モードより長く、遅延サイクルモードより短い調整サイクルを予め設定されたショット数繰り返してから通常成形モードに復帰したものであるから、予め設定されたショット数、調整モードで成形を繰り返すことで金型装置を正常な温度まで戻し、その後の通常成形サイクルへの変更が円滑に行うことができる。   According to the method for controlling an injection molding machine of claim 4, when a recovery signal is received from the post-processing machine, normal molding is performed after repeating a preset number of shots that are longer than the normal molding mode and shorter than the delay cycle mode. Since it has returned to the mode, the mold apparatus can be returned to a normal temperature by repeating molding in the preset number of shots and adjustment mode, and then the change to the normal molding cycle can be performed smoothly.

以下、本発明の実施の形態について図面を参照しながら詳述する。なお、本実施例では成形品としてDVDなどの記憶媒体として用いるディスク基板を成形する射出成形機を例として説明する。   Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In this embodiment, an injection molding machine for forming a disk substrate used as a storage medium such as a DVD as a molded product will be described as an example.

図1は本実施例における射出成形機の概念図、図2は射出成形機の動作を示すフローチャート、図3は射出成形機の成形サイクルを示すタイムチャート、図4は設定画面を示す説明図である。   1 is a conceptual diagram of an injection molding machine in the present embodiment, FIG. 2 is a flowchart showing the operation of the injection molding machine, FIG. 3 is a time chart showing a molding cycle of the injection molding machine, and FIG. 4 is an explanatory diagram showing a setting screen. is there.

図1において、1は射出成形機であり、図示しない成形用金型のキャビティに溶融樹脂を充填するための射出装置2と、フロントプレート3とリヤプレート4との間に連結したタイバー5と、加熱筒6の内部に軸方向に進退自在にかつ周方向に回転自在に挿入されるスクリュ7と、前記スクリュ7の基端部が回転自在に支持されるプッシャープレート8と、前記リヤプレート4に回転自在に支持されたボールねじ軸9と、このボールねじ軸9と螺合するように前記リヤプレート4に固定されたボールナット10と、ベルト11とプーリ12を介して前記ボールねじ軸9を回転させることによって前記スクリュ7を軸方向に進退移動させる射出用サーボモータ13と、ベルト14とプーリ15を介して前記スクリュ7を回転させる計量用サーボモータ16、溶融樹脂の圧力を検出するロードセル18と、前記スクリュ7の回転によって前記加熱筒6の先端部に供給される溶融樹脂の圧力により後退する前記スクリュ7の後退速度を検出するエンコーダ19と、演算装置としての図示されないCPUから成り、各種のデータに基づいて射出成形機1を制御する制御手段20などによって構成されている。また、本実施例では成形するディスク基板に穴開加工するカットパンチ(図示しない)と、成形品を取り出すエジェクタピン(図示しない)が進退可能に設けられており、成形サイクル開始信号が出力されると、型閉、ノズル前進、型閉、射出、冷却、型開、取出という一連の成形作動を開始する。   In FIG. 1, 1 is an injection molding machine, an injection device 2 for filling a cavity of a molding die (not shown) with a molten resin, a tie bar 5 connected between a front plate 3 and a rear plate 4; A screw 7 is inserted into the heating cylinder 6 so as to be movable back and forth in the axial direction and rotatably in the circumferential direction, a pusher plate 8 on which the base end portion of the screw 7 is rotatably supported, and the rear plate 4. A ball screw shaft 9 supported rotatably, a ball nut 10 fixed to the rear plate 4 so as to be screwed with the ball screw shaft 9, and the ball screw shaft 9 via a belt 11 and a pulley 12. An injection servo motor 13 that moves the screw 7 in the axial direction by rotating it, and a metering servo that rotates the screw 7 via a belt 14 and a pulley 15. And a load cell 18 that detects the pressure of the molten resin, and an encoder 19 that detects the retreating speed of the screw 7 that retreats due to the pressure of the molten resin supplied to the tip of the heating cylinder 6 by the rotation of the screw 7. And a control means 20 that controls the injection molding machine 1 based on various data. In this embodiment, a cut punch (not shown) for punching a disk substrate to be molded and an ejector pin (not shown) for taking out a molded product are provided so as to be able to advance and retreat, and a molding cycle start signal is output. Then, a series of molding operations such as mold closing, nozzle advance, mold closing, injection, cooling, mold opening, and removal are started.

次に、図2のフローチャートを参照して射出成形機1の制御について説明する。本実施例における射出成形機1は、該射出成形機1から取り出した成形品に対して後加工を行う図示しない後工程機(図示しない)を備え、後工程機からの信号に基づいて射出成形機1を制御する。まず、射出成形機1を自動運転する際(ステップS1)、後工程機が停止状態にある時(ステップS2)、後工程機からの後工程機準備完了信号がOFFでサイクル遅延信号がOFFの場合(ステップS3)、所定ショット数、射出成形機1の自動運転を継続し(ステップS4)、所定ショット数に達する前に後工程機準備完了信号がONとなった場合(ステップS5)、射出成形機1を通常サイクルで自動運転する(ステップS6)。   Next, the control of the injection molding machine 1 will be described with reference to the flowchart of FIG. The injection molding machine 1 in this embodiment is provided with a non-illustrated post-process machine (not shown) that performs post-processing on a molded product taken out from the injection molding machine 1, and injection molding based on a signal from the post-process machine. The machine 1 is controlled. First, when the injection molding machine 1 is automatically operated (step S1), when the post-process machine is in a stopped state (step S2), the post-process machine preparation completion signal from the post-process machine is OFF and the cycle delay signal is OFF. In the case (step S3), the automatic operation of the injection molding machine 1 is continued for a predetermined number of shots (step S4), and the post-process machine preparation completion signal is turned ON before reaching the predetermined number of shots (step S5). The molding machine 1 is automatically operated in a normal cycle (step S6).

一方、所定ショット数に達しても後工程機準備完了信号がOFFの場合(ステップS7)、射出成形機1を自動停止する(ステップS8)。そして、後工程機が復旧した場合、すなわち、後工程機から後工程機準備完了信号がON、サイクル遅延信号のOFFの場合、射出成形機1を手動操作に切り換え(ステップS9)、自動運転を再開する(ステップS10)。   On the other hand, if the post-process machine preparation completion signal is OFF even if the predetermined number of shots is reached (step S7), the injection molding machine 1 is automatically stopped (step S8). When the post-process machine is restored, that is, when the post-process machine preparation completion signal is ON and the cycle delay signal is OFF, the injection molding machine 1 is switched to manual operation (step S9), and automatic operation is performed. Resume (step S10).

また、後工程機準備完了信号がOFF、サイクル遅延信号のONの場合(ステップS11)、射出成形機1を所定時間、例えば1〜3分、遅延サイクルモードで運転し(ステップS12)、この間に後工程機が復旧してサイクル遅延信号のOFFとなったら(ステップS13)、所定ショット、例えば15ショット成形した後、自動運転を再開する(ステップS14)。所定時間、例えば10〜15分経過してもサイクル遅延信号のOFFのままの場合(ステップS15)、遅延サイクルモードを所定時間、例えば5〜10分、延長する(ステップS16)。この時間内に後工程機が復旧し、後工程機から後工程機準備完了信号がON、サイクル遅延信号のOFFとなった場合(ステップS17)、所定ショット、例えば15ショット成形した後、射出成形機1の自動運転を再開する(ステップS18)。しかし、ステップS16で遅延サイクルモードの延長時間を経過し(ステップS19)、それでもサイクル遅延信号のONがない場合、射出成形機1を自動停止する(ステップS20)。その後、手動操作に切り換え(ステップS21)、後工程機が復旧した場合、すなわち、後工程機から後工程機準備完了信号がON、サイクル遅延信号がOFFとなった場合、射出成形機1を自動運転する(ステップS22)。   When the post-process machine preparation completion signal is OFF and the cycle delay signal is ON (step S11), the injection molding machine 1 is operated in the delay cycle mode for a predetermined time, for example, 1 to 3 minutes (step S12). When the post-process machine is restored and the cycle delay signal is turned off (step S13), a predetermined shot, for example, 15 shots, is formed, and then automatic operation is resumed (step S14). If the cycle delay signal remains OFF after a predetermined time, for example, 10 to 15 minutes (step S15), the delay cycle mode is extended by a predetermined time, for example, 5 to 10 minutes (step S16). If the post-process machine recovers within this time, and the post-process machine ready signal is turned on and the cycle delay signal is turned off from the post-process machine (step S17), after molding a predetermined shot, for example, 15 shots, injection molding The automatic operation of the machine 1 is resumed (step S18). However, if the extended time of the delay cycle mode has elapsed in step S16 (step S19) and the cycle delay signal is still not ON, the injection molding machine 1 is automatically stopped (step S20). Thereafter, switching to manual operation (step S21), when the post-process machine is restored, that is, when the post-process machine preparation completion signal is turned ON and the cycle delay signal is turned OFF from the post-process machine, the injection molding machine 1 is automatically Operate (step S22).

次に図3を参照して遅延サイクルモードでの射出成形機1の制御について説明する。遅延サイクルモードでは、制御手段20によって、加熱筒6内のスクリュ7を前進して加熱筒6から金型装置に射出する一次射出時間、金型装置の型開時間、金型装置内の溶融樹脂の冷却時間、加熱筒6の内部へ溶融樹脂を供給する計量時間を延長して射出成形機1が安定連続成形できる長いサイクルで運転する。   Next, the control of the injection molding machine 1 in the delay cycle mode will be described with reference to FIG. In the delay cycle mode, the control means 20 advances the screw 7 in the heating cylinder 6 and injects it from the heating cylinder 6 to the mold apparatus, the primary injection time, the mold opening time of the mold apparatus, and the molten resin in the mold apparatus. The injection molding machine 1 is operated in a long cycle that allows stable continuous molding by extending the cooling time and the metering time for supplying the molten resin into the heating cylinder 6.

まず、タイミングt0で型閉工程が開始され、型閉工程が終了したタイミングt1で加熱筒6内のスクリュ7を前進させて加熱筒6から金型装置に溶融樹脂を射出(一次射出)する射出工程が開始されるが、遅延サイクルモードでは制御手段20によってスクリュ7を駆動する射出用サーボモータ13の回転を通常サイクルモードの50%の速度に減速して低速回転させることによって射出時間を延長する。金型装置内に射出された溶融樹脂を所定時間、保圧し、保圧が完了したタイミングt3で金型装置を冷却して金型装置に射出された溶融樹脂を可塑化する。遅延サイクルモードでは、通常成形サイクルで設定された冷却時間に達したタイミングt4で60.0秒、冷却時間を延長する。   First, at the timing t0, the mold closing process is started, and at the timing t1 when the mold closing process is completed, the screw 7 in the heating cylinder 6 is advanced to inject the molten resin from the heating cylinder 6 to the mold apparatus (primary injection). In the delay cycle mode, the injection time is extended by reducing the rotation of the injection servo motor 13 that drives the screw 7 by the control means 20 to 50% of the normal cycle mode and rotating it at a low speed. . The molten resin injected into the mold apparatus is held for a predetermined time, and the mold apparatus is cooled at timing t3 when the holding is completed to plasticize the molten resin injected into the mold apparatus. In the delay cycle mode, the cooling time is extended by 60.0 seconds at the timing t4 when the cooling time set in the normal molding cycle is reached.

金型装置内の樹脂の冷却工程と並行してノズルを後退させるノズルバックを行うが、金型装置からノズルを離した後、ノズルから溶融樹脂が漏れる所謂、鼻たれが起こりやすくなるため鼻たれを防止するサックバックを行う。遅延サイクルモードは冷却工程を延長することから、遅延サイクルモードでは可塑化後のタイミングt5から40.00秒遅らせたタイミングt6からサックルバックを開始するとともに、ノズルバックは35.00秒遅らせてタイミングt7から開始する。すなわち、ノズルバックが完了して5秒経過したタイミングt6からサックバックを開始する。なお、遅延サイクルモードにおいてサックバック幅は6.00mm、ノズルバックのストロークは10.0mmに設定している。サックバックが完了したタイミングt8で加熱筒6内の樹脂の圧力を調整して加熱筒6に所定量の樹脂を供給する計量工程を行う。   In parallel with the resin cooling process in the mold apparatus, the nozzle back is retracted, but after the nozzle is released from the mold apparatus, the molten resin leaks from the nozzle, so the sore sag is likely to occur. To prevent back-up. Since the delay cycle mode extends the cooling process, in the delay cycle mode, the buckle start is started from the timing t6 delayed by 40.00 seconds from the post-plasticization timing t5, and the nozzle back is delayed by 35.00 seconds to the timing t7. Start with That is, suck back is started from timing t6 when 5 seconds have elapsed after nozzle back is completed. In the delay cycle mode, the suck back width is set to 6.00 mm and the nozzle back stroke is set to 10.0 mm. At the timing t8 when the suck back is completed, a measuring step of adjusting the pressure of the resin in the heating cylinder 6 and supplying a predetermined amount of resin to the heating cylinder 6 is performed.

冷却工程が完了したタイミングt9で型開が開始されるが、冷却工程が長くなると、金型装置及び樹脂の温度が安定せず、通常成形サイクルの同じ速度で金型装置を高速で型開すると、キャビティ空間の内周面に固化した樹脂が貼り付きやすくなるため型開を開始するタイミングt9で50%減速させて金型装置の型開速度を落とした状態で型開し、所定時間が経過したタイミングt10で速度を戻して型開きする。また、本実施例では成形するディスク基板に対してパンチ(図示せず)による穴明加工を行う。この穴明工程は、冷却工程と並行して行われるが、前述したように、遅延サイクルモードでは、冷却工程を延長することから、冷却工程を延長に伴ってパンチの前進位置での停止時間も所定時間遅延させる。そして、パンチの前進が終わって穴開工程が終了した後、タイミングt9で金型装置の型開が開始されるとともに、パンチを後退させるが、金型装置の型開速度を減速するのに伴ってパンチの後退するタイミングも遅延する。そして、金型装置の型開が完了したタイミングt12でエジェクトピンを前進させてキャビティ内の樹脂を取り出した後、エジェクトピンを後退させる。このエジェクトピンの後退が完了したタイミングt13で1ショットの成形サイクルが終了する。この後、エジェクトピンの後退が完了したタイミングt13で型閉するとともにノズルを前進させて金型装置に接触させるノズルタッチと加熱筒6内のスクリュ7を前進させて加熱筒6から金型装置に溶融樹脂を射出する射出工程とを開始するが射出工程は、0.60秒遅らせたタイミングt14で開始し、以後、同様な成形サイクルを繰り返す。   The mold opening is started at timing t9 when the cooling process is completed. However, if the cooling process becomes longer, the temperature of the mold apparatus and the resin is not stabilized, and the mold apparatus is opened at a high speed at the same speed of the normal molding cycle. Since the solidified resin easily adheres to the inner peripheral surface of the cavity space, the mold is opened with the mold opening speed reduced by 50% at the timing t9 when the mold opening is started, and the predetermined time has elapsed. The mold is opened by returning the speed at the timing t10. Further, in this embodiment, drilling is performed on a disk substrate to be formed by a punch (not shown). This drilling process is performed in parallel with the cooling process. However, as described above, in the delay cycle mode, the cooling process is extended, so the stop time at the forward position of the punch is increased along with the extension of the cooling process. Delay for a predetermined time. After the advancement of the punch is completed and the hole opening process is completed, the mold opening of the mold apparatus is started at timing t9 and the punch is moved backward, but the mold opening speed of the mold apparatus is reduced. As a result, the timing at which the punch moves backward is also delayed. Then, at the timing t12 when the mold opening of the mold apparatus is completed, the eject pin is advanced to take out the resin in the cavity, and then the eject pin is retracted. The one-shot molding cycle is completed at timing t13 when the ejection of the eject pin is completed. Thereafter, the mold is closed at the timing t13 when the retraction of the eject pin is completed, and the nozzle is moved forward to come into contact with the mold apparatus, and the screw 7 in the heating cylinder 6 is advanced to move the heating cylinder 6 to the mold apparatus. The injection process of injecting the molten resin is started, but the injection process starts at a timing t14 delayed by 0.60 seconds, and thereafter the same molding cycle is repeated.

以上のように、遅延サイクルモードでは、1ショットの成形サイクルの時間をできるだけ延ばして後工程機が復旧するまで遅延サイクルモードを繰り返すことによって、後工程機が復旧した後に成形機が通常成形へ復帰するまでの時間を大幅に短くすることが可能である。すなわち、DVDなどのディスク基板を成形する射出成形機1においては、通常成形サイクルでは1ショットの成形サイクルが2〜3秒であるに対し、遅延サイクルモードでは加熱筒6内のスクリュ7を前進して加熱筒6から金型装置に射出する一次射出時間、金型装置の型開時間、金型装置内の溶融樹脂の冷却時間、加熱筒6の内部へ溶融樹脂を供給する計量時間のそれぞれを延長することによって、1ショットの成形サイクルの時間を1〜10分まで延長することが可能である。このように、射出成形機1が安定連続成形可能な延長サイクル、すなわち、1ショットの成形サイクルの時間を1〜10分まで遅延させることにより、後工程機が復旧するまで射出成形機1を極めて遅い速度で運転を維持することができる。なお、1ショットの成形サイクルの時間が10分を超えると、加熱筒6内において樹脂焼けが発生し、加熱筒6の内壁に炭化した樹脂膜が貼り付く、あるいは炭化した樹脂粉が金型装置内に混入するなど、射出成形機1の故障を引き起こすから、成形サイクルの延長時間は最長で10分に設定する。換言すれば10分以内であれば、射出成形機1に悪影響を与えないで1ショットの成形サイクルの時間を最大限、延長することができる。また、後工程機が復旧した場合、後工程機が復旧した時点から通常サイクルモードに移行するまで予め設定されたショット数、調整サイクルモードで成形動作を行う。調整サイクルモードでは、加熱筒6内のスクリュ7を前進させて加熱筒6から金型装置に溶融樹脂を射出(一次射出)する射出工程から保圧、可塑化、サックバックを経て加熱筒6内のスクリュ7を後退させて加熱筒6内に所定の溶融樹脂を供給する計量工程までの時間を通常形成サイクルよりやや長くなるように設定し、その調整サイクルモードを予め設定されたショット数、繰り返すことによって、正常な通常成形モードへと安定して移行できる。すなわち、遅延サイクルモードでは、冷却工程が長く、金型装置の温度が必要以上に低下してしまうが、予め設定されたショット数、調整モードで成形を繰り返すことで金型装置を正常な温度まで戻すことができで、通常成形サイクルへの変更が円滑に行うことができる。   As described above, in the delay cycle mode, the molding machine returns to normal molding after the post-process machine is restored by repeating the delay cycle mode until the post-process machine is restored by extending the time of the molding cycle of one shot as much as possible. It is possible to greatly shorten the time to do. That is, in the injection molding machine 1 that molds a disk substrate such as a DVD, the molding cycle of one shot is 2 to 3 seconds in the normal molding cycle, whereas the screw 7 in the heating cylinder 6 is advanced in the delay cycle mode. The primary injection time for injecting from the heating cylinder 6 to the mold apparatus, the mold opening time of the mold apparatus, the cooling time for the molten resin in the mold apparatus, and the metering time for supplying the molten resin to the inside of the heating cylinder 6 respectively. By extending, it is possible to extend the time of the molding cycle of 1 shot to 1 to 10 minutes. In this way, the injection molding machine 1 can be made extremely stable until the post-processing machine is restored by delaying the time of the extended cycle in which the injection molding machine 1 can be stably continuously molded, that is, the molding cycle time of one shot to 1 to 10 minutes. You can keep driving at a slow speed. In addition, when the time of the molding cycle of one shot exceeds 10 minutes, resin burning occurs in the heating cylinder 6, and the carbonized resin film sticks to the inner wall of the heating cylinder 6, or the carbonized resin powder is in the mold apparatus. In order to cause a failure of the injection molding machine 1 such as being mixed in, the extended time of the molding cycle is set to 10 minutes at the longest. In other words, within 10 minutes, the time of one shot molding cycle can be extended to the maximum without adversely affecting the injection molding machine 1. When the post-process machine is restored, the molding operation is performed in the preset number of shots and the adjustment cycle mode from the time when the post-process machine is restored to the transition to the normal cycle mode. In the adjustment cycle mode, the screw 7 in the heating cylinder 6 is advanced to inject the molten resin from the heating cylinder 6 into the mold apparatus (primary injection), and then the pressure in the heating cylinder 6 is passed through pressure holding, plasticization, and suck back. The time until the metering step of retracting the screw 7 and supplying the predetermined molten resin into the heating cylinder 6 is set to be slightly longer than the normal forming cycle, and the adjustment cycle mode is repeated for a preset number of shots. Therefore, it is possible to stably shift to the normal normal molding mode. In other words, in the delay cycle mode, the cooling process is long and the temperature of the mold apparatus decreases more than necessary, but the mold apparatus is brought to a normal temperature by repeating molding in a preset number of shots and adjustment modes. The normal molding cycle can be changed smoothly.

以上のように、本実施例では、遅延サイクルモードにおいて射出成形機1が停止しない程度の成形条件で運転するように制御して1ショットの成形サイクル時間をできるだけ延長する。すなわち、この種のDVDなどのディスク基板を成形する射出成形機1において、射出成形機1が安定連続成形可能な延長サイクルに必要な成形条件で運転される遅延サイクルモードでは、金型装置から取り出される成形品は不良品となるものの、後工程機が復旧するまで射出成形機1が停止しない程度の極めて長い成形時間を掛けて射出成形機1を運転することができ、通常成形モードへと移行する時間を短縮化でき、生産性を高めることができる。また、後工程機が復旧すると、後工程機から復旧信号が送られ、通常成形モードに戻るが、予め設定されたショット数の成形を行う調整モードを経て通常成形モードに復帰する。調整モードでは通常成形モードより長く、遅延サイクルモードより短くなるように設定する。このように、予め設定されたショット数、調整モードで成形を繰り返すことによって、正常な通常成形モードへと安定して移行できる。すなわち、遅延サイクルモードでは、冷却工程が長く、金型装置の温度が必要以上に低下してしまうが、予め設定されたショット数、調整モードで成形を繰り返すことで金型装置を正常な温度まで戻し、その後の通常成形サイクルへの変更が円滑に行うことができる。   As described above, in this embodiment, control is performed so that the injection molding machine 1 is operated under the molding conditions that do not stop in the delay cycle mode, thereby extending the molding cycle time of one shot as much as possible. That is, in the injection molding machine 1 that molds a disc substrate such as this type of DVD, the injection molding machine 1 is taken out from the mold apparatus in the delay cycle mode in which the molding machine 1 is operated under the molding conditions necessary for the extension cycle capable of stable continuous molding. Although the molded product is defective, the injection molding machine 1 can be operated for a very long molding time so that the injection molding machine 1 does not stop until the post-processing machine is restored, and the normal molding mode is entered. Time can be shortened and productivity can be increased. Further, when the post-process machine is restored, a restoration signal is sent from the post-process machine and the normal molding mode is resumed, but the normal molding mode is restored through an adjustment mode in which molding is performed for a preset number of shots. The adjustment mode is set to be longer than the normal molding mode and shorter than the delay cycle mode. As described above, by repeating the molding in the preset number of shots and the adjustment mode, it is possible to stably shift to the normal normal molding mode. In other words, in the delay cycle mode, the cooling process is long and the temperature of the mold apparatus decreases more than necessary, but the mold apparatus is brought to a normal temperature by repeating molding in a preset number of shots and adjustment modes. The change to the normal molding cycle after the return can be performed smoothly.

以上、本発明の前記実施について詳述したが、本発明は前記実施例にお限定されることなく、本発明の要旨の範囲内で種々の変形実施が可能である、例えば、前記実施例ではDVDなどのディスク基板を成形した例を示したが、成形品としてはディスク基板に限定されるものではなく、各種の成形品を成形する射出成形機に適用可能であって、射出成形機の基本的構成も適宜選定すればよい。   As mentioned above, although the said implementation of this invention was explained in full detail, this invention is not limited to the said Example, In the range of the summary of this invention, various deformation | transformation implementation is possible, For example, in the said Example, Although an example of molding a disk substrate such as a DVD has been shown, the molded product is not limited to a disk substrate, and can be applied to an injection molding machine that molds various molded products. The appropriate configuration may be selected as appropriate.

本発明の実施の形態における射出成形機の概念図である。It is a conceptual diagram of the injection molding machine in embodiment of this invention. 本発明の実施の形態における射出成形機の動作を示すフローチャートである。It is a flowchart which shows operation | movement of the injection molding machine in embodiment of this invention. 本発明の実施の形態における射出成形機の成形サイクルを示すタイムチャートである。It is a time chart which shows the molding cycle of the injection molding machine in embodiment of this invention. 本発明の実施の形態における設定画面を示す説明図である。It is explanatory drawing which shows the setting screen in embodiment of this invention.

符号の説明Explanation of symbols

1 射出装置
6 加熱筒
20 制御手段
1 Injection device 6 Heating cylinder 20 Control means

Claims (4)

加熱筒内で加熱された溶融樹脂を金型装置のキャビティに射出し、キャビティ内で冷却固化した成形品を取り出す射出成形機と、この射出成形機と連動して該射出成形機から取り出した成形品に対して加工を行う後工程機と、この後工程機からの異常信号に基づいて前記射出成形機を通常サイクルモードから遅延サイクルモードに切り換える制御手段を備え、前記遅延サイクルモードでは前記制御手段により、1ショットの成形サイクルを1〜10分に延長する成形条件に設定するように制御したことを特徴とする射出成形機の制御方法。   An injection molding machine that injects molten resin heated in a heating cylinder into a cavity of a mold apparatus and takes out a molded product cooled and solidified in the cavity, and a molding that is taken out from the injection molding machine in conjunction with the injection molding machine A post-process machine for processing the product, and control means for switching the injection molding machine from the normal cycle mode to the delay cycle mode based on an abnormal signal from the post-process machine, and in the delay cycle mode, the control means Thus, the control method for the injection molding machine is controlled so as to set the molding condition for extending the one-shot molding cycle to 1 to 10 minutes. 前記遅延サイクルモードでは、金型装置の型閉時間、加熱筒から金型装置に射出する一次射出時間、金型装置の型開時間の変更及び計量動作後のノズルバック動作、サックバック遅延の追加により、金型装置内での溶融樹脂の冷却時間を延長することを特徴とする請求項1記載の射出成形機の制御方法。   In the delay cycle mode, the mold closing time of the mold apparatus, the primary injection time for injecting from the heating cylinder to the mold apparatus, the mold opening time of the mold apparatus, the nozzle back operation after the weighing operation, and the addition of the suck back delay The method for controlling an injection molding machine according to claim 1, wherein the cooling time of the molten resin in the mold apparatus is extended. 前記遅延サイクルモードでは、金型装置の型開速度を減速させて型開するように制御した特徴とする請求項2記載の射出成形機の制御方法。   3. The method of controlling an injection molding machine according to claim 2, wherein in the delay cycle mode, control is performed so that the mold opening speed of the mold apparatus is reduced to open the mold. 前記後工程機からの復旧信号を受けると通常成形モードより長く、遅延サイクルモードより短い調整サイクルを予め設定されたショット数繰り返してから通常成形モードに復帰するように構成したことを特徴とする請求項1〜3の何れか1項に記載の射出成形機の制御方法。   When the recovery signal is received from the post-process machine, the adjustment cycle longer than the normal molding mode and shorter than the delay cycle mode is repeated for a preset number of shots and then returned to the normal molding mode. Item 4. The method for controlling an injection molding machine according to any one of Items 1 to 3.
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JP2001129863A (en) * 1999-11-01 2001-05-15 Meiki Co Ltd Controlling method for injection molding system
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