JP2014215636A - Smart operation system for plastic molding process line - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a plastic molding process line in which waste in electric power, resin material, production time and the like is visualized to be smarter than a conventional one.SOLUTION: A processing line 1 is constructed by integrating: a material weighing device 13 which is arranged in the upstream side of a molding machine 14; data collection means 16a which collects operational information of each device; data processing means 16 which reads information collected by the data collection means 16a, and calculates at least one of resin material amount, power consumption, and operation time consumed while the resin material is supplied from a raw material storage to a molding machine and used for a molding process, as smart processing line evaluation information set in advance; and a monitoring device 18 which displays the smart processing line evaluation information calculated by the data processing means 16.

Description

  The present invention relates to an improvement in an operation system of a plastic molding processing line for producing a molded product using a molding machine.

  Conventionally, in the molding line as described above, it has been a problem to improve the operation efficiency. For example, the following patent document proposes a technique for grasping in real time the amount of resin loss in a production line for molded products, reducing the amount of resin loss, and improving the efficiency of the production line.

JP2003-131722

  However, at present, the molding processing line as described above is operated in a state where it is difficult to see waste of power, waste of resin material, waste of production time, and the like. Therefore, an object of the present invention is to make the molding line smarter by making these wastes visible.

  According to the present invention, a plastic molding line production system is a smart molding system that uses a molding machine to manufacture a molded product. The plastic molding line operation system includes a material metering device installed upstream of the molding machine, and a processing line. Data collection means that collects operation information of each device that constitutes, and the information collected by the data collection means is read and used until the resin material is supplied from the raw material storage unit to the molding machine and processed. In addition, calculation processing means for calculating at least one or more of the resin material, power consumption, and operation time as preset processing line smart evaluation information, and processing line smart evaluation information calculated by the calculation processing means It is constructed by incorporating a monitoring device for displaying. The factory in which the plastic molding line is configured in this way is called a smart factory in the present invention.

  The monitoring device may visualize the processing line operational efficiency by arranging the read processing line smart evaluation information in time series.

  The system includes storage means for accumulating quality information and processing line smartization evaluation information calculated by the arithmetic processing means, and shot identification information for specifying a molded shot of the molded product for each molded product. And an identification information providing means for assigning may be further incorporated.

  The monitoring device may be configured as a display / operation panel installed adjacent to the processing line.

  The monitoring device may be configured as a portable terminal that can be connected to the processing line via a communication path including wireless communication.

  According to the present invention, the processing line smart evaluation information regarding time, resin material, and electric power is calculated, visualized as the operation efficiency of the processing line, and displayed on the monitoring means. You can immediately know whether you are within the standards. That is, the standard management of the plastic molding line becomes extremely easy.

    In addition, if shot identification information for identifying the shot of the molded product is given to each molded product, even if there is an inquiry about the molded product at a later date, it will be printed on the molded product. Since quality information can be answered based on the identification information, the traceability of the molded product is improved.

  In particular, when the monitoring device is configured by a portable terminal, the operation information of the device, the operation efficiency of the processing line, and the like can be displayed at a desired location in the factory, which is highly convenient.

It is a system configuration figure showing an example of an embodiment of the present invention. It is an example of the graph which showed the operation information of the plastic molding processing line about (a) time, (b) resin material, and (c) electric power. It is a graph of the processing line smart evaluation information regarding (a) time, (b) resin material, and (c) electric power calculated based on the operation information shown in FIG. 2 (a) to FIG. 2 (c).

  In the system configuration diagram of FIG. 1, it is assumed that the plastic molding line is configured by a minimum apparatus for the sake of simplicity.

  The plastic molding processing line 1 (hereinafter simply referred to as a processing line) has a line configuration in which a weighing and blending machine 11, a dryer 12, a material weighing device 13, and a molding machine 14 are arranged. A mold temperature controller 15 is connected to the molding machine 14.

  The metering and blending machine 11 uses raw materials such that unused resin materials, recycled materials obtained by pulverizing sprues, runners, molding defects, etc., and master batches of colorants, etc., have a preset blending ratio. It is a device that weighs and mixes.

  The dryer 12 is a device that heats and drys the resin material mixed in the metering and blending machine 11 so as to have a predetermined moisture content.

  The material weighing device 13 is a device for weighing the resin material dried by the dryer 12 one batch at a time and supplying it to the molding machine 14, and the total mass including the loss of the resin material put into the processing line 1. Measure. Such a material measuring device 13 may be provided upstream of the molding machine 14.

  The molding machine 14 is an apparatus for forming a molded product by heating and melting the resin material transported through the material measuring device 13 and then solidifying it by high-pressure injection (shot) into a cavity of a mold (not shown). .

  The mold temperature controller 15 is a device that controls the temperature by passing a heat transport medium (water, oil, etc.) through the mold of the molding machine 14.

  The arithmetic processing means 16 is configured as a line control device including a data collecting means 16a for collecting operation information from each device constituting the processing line 1 and a control means 16b for controlling these devices in cooperation. For example, the data collection unit 16a may include, as operation information of the apparatus, a blending notification signal output from the weighing and blending machine 1 (every time the raw materials are metered and blended), a drying chamber temperature signal output from the dryer 12, and a material outage warning signal ( When the remaining amount of the resin material is lower than the standard), a measurement notification signal output from the material weighing device 13 (every time the resin material is measured), a shot signal output from the molding machine 14 (every shot of the molding process), A material out notice signal (when the remaining amount of the resin material stored in the apparatus is below the reference) and the medium temperature signal output by the mold temperature controller 15 are collected. The arithmetic processing means 16 is connected with a storage means 17 constituted by a hard disk or the like and a monitoring device 18 having a display unit (not shown).

  The monitoring device 18 includes display operation means. For example, it may be configured by a touch panel or the like installed adjacent to the processing line 1 and connected to the arithmetic processing means 16 by wire. Or you may be comprised by the workstation which can communicate with the arithmetic processing means 16 by LAN in a factory. Or you may be comprised by the portable terminals (tablet etc.) which can communicate with the arithmetic processing means 16 by the communication path | route including wireless communication, such as the WiFi router 19 connected to the LAN line. This communication path may include the Internet, and the monitoring device 18 may be configured as a communication terminal installed in a remote management center.

  In particular, when the monitoring device 18 is configured by a portable terminal, the operation information of the device, the operation efficiency of the processing line, and the like can be displayed at a desired location in the factory, which is highly convenient.

  A wattmeter 21 is provided for each device on the power supply line from the power supply unit 20 to each device. These wattmeters 21 constitute data collection means 16 a, and their measured values are transmitted to the arithmetic processing means 16.

  The processing line 1 may be provided with identification information giving means 22 for printing identification information such as a serial number on the molded product. The identification information giving means 22 is constituted by an ink printer, a laser printer or the like, and may print (engrave) the identification information represented by a character string, a one-dimensional barcode, or a two-dimensional barcode on a molded product, An electronic tag configured with an electronic tag and filled with identification information may be assembled to a molded product.

  The process in the processing line 1 is basically the same as the conventional process. That is, to explain only the outline, first, unused resin material, recycled material, etc. are blended by the metering blender 11, the blended resin material is conveyed to the dryer 12 and dried for a predetermined time, and the dried The resin material is weighed in batch units by the material weighing device 13, and the weighed resin material is conveyed to the molding machine 14, where it is injection-molded to produce a molded product. The flow of the resin material is indicated by broken-line arrows in the figure.

  Since all of the metering and blending machine 11, the dryer 12, the material metering device 13, and the molding machine 14 perform continuous operation, the resin material transported from the previous device is temporarily stored and stored. Minutes are withdrawn for each process (measuring, injection molding), so if the stored amount falls below the standard, a material out warning signal is output. The control means 16b controls the processing line 1 by transmitting a command signal to each device based on such operation information.

  In addition to such basic operations, the arithmetic processing unit 16 supplies resin material from the raw material storage unit to the molding machine 14 based on the operation information of each device collected by the data collecting unit 16a and performs molding processing. It has a function of calculating at least one or more of the power consumption, the mass of the resin material, and the operation time used as the processing line smart evaluation information for each preset evaluation timing. The calculated machining line smart evaluation information is stored in the storage means 17. It is desirable that each processing line smart evaluation information is assembled at the evaluation timing when the information is calculated.

  The raw material storage part is a part defined as the supply point of the resin material in the calculation of the processing line smartization evaluation information. In this embodiment, a configuration is shown in which the dryer 12 that stores and heat-drys the resin material is defined as the material storage unit, and the material weighing device 13 is disposed immediately thereafter, but this is merely an example. For example, as a modification, an unused resin material hopper, a recycled material hopper, a masterbatch hopper, etc. (all not shown) provided on the upstream side of the weighing and blending apparatus 11 are defined as a material storage unit. Also good. In that case, since the weighing and blending machine 11 measures the resin material, it is not necessary to separately provide the material weighing device 13.

  The processing line smart conversion evaluation information is visualized by a predetermined method and evaluated as the operation efficiency of the processing line 1. Therefore, the monitoring device 18 has a function of accepting the operation of the operator and reading out and visualizing the machining line smart conversion evaluation information calculated by the arithmetic processing means 16 in real time. Specifically, the processing line smart conversion evaluation information may be arranged in a time series to be graphed and displayed on a display unit (not shown). With this configuration and processing, the factory is made smarter.

  The processing line smart conversion evaluation information is calculated, for example, at each evaluation timing set in advance within the operation period of the processing line. The accumulated amount of each resource (power, resin material, time) supplied to the processing line 1 and the molded product molded in the same period during the period from the start of operation of the processing line 1 to the evaluation timing May be calculated as the average resource consumption corresponding to the molded product. Although the evaluation timing is periodic, various variations are possible. For example, one shot of a forming process or a predetermined number of shots may be defined as one shot unit in information processing, and the evaluation timing may be set every time the forming process is performed for one shot unit. Alternatively, the evaluation timing may be set every predetermined time, the evaluation timing may be set every time a predetermined amount of resin material is supplied to the processing line, or the evaluation timing is set every time a predetermined number of products are produced. May be.

  In addition, since the configuration of the processing line 1 may be changed depending on the product or the raw material, a device that can be replaced to change the configuration of the processing line 1 is registered in advance in the arithmetic processing means 16, When the device is automatically or manually replaced, the arithmetic processing means 16 may detect it and automatically switch the display content of the monitoring device 18.

  In the following, for the sake of simplicity, it is assumed that the timing at which one molding process is performed is set as the evaluation timing, and the collection of operation information from the apparatus constituting the processing line 1 and the processing line smartization evaluation information The calculation and visualization of the operating efficiency of the processing line 1 will be specifically described.

  FIG. 2A to FIG. 2C are examples of graphs in which operation information collected from apparatuses constituting the processing line is arranged and arranged in time series (time T1 to time T27). In any of the graphs G1 to G3, the operation start point of the processing line 1 is the starting point of the time axis (horizontal axis).

  The graph G1 in FIG. 2A is a graph in which the cumulative number of molding shots from the operation start time of the processing line 1 is arranged in the order of time as a bar B. The first shot appears at time T5, and thereafter, the cumulative number of shots increases as time elapses until time T14. However, from time T15 to time T19, the processing line 1 is forcibly stopped (choco stop). It has not changed. Thereafter, the processing line 1 is restarted, and the cumulative number of shots increases with time from time T20 to time T27. The forced stop of the processing line 1 is caused by, for example, occurrence of a defect, but may be automatically performed or may be manually performed by an operator's operation.

  The defective molding process occurs, for example, when the molten resin material is injected from the nozzle of the molding machine 14 into the mold and becomes vaporized and adheres to the mold surface and the gap. Specific symptoms include short shots, mold parting burrs, and gas burns.

  A graph G2 in FIG. 2B is an arrangement in which the cumulative amount of the resin material supplied to the molding machine 14 from the operation start time of the processing line 1 is arranged as the height of the bar B in time order as the bar B. ΔM in the figure indicates a weighing unit (one batch mass) of the material weighing device 13. Comparing with the graph of FIG. 2A, it can be seen that the resin material of only ΔM is additionally supplied every time the molding machine 14 performs three shots. However, this is only an example, and for how many shots of molding process the resin material is supplied once more is the resin mass unit of molding process (resin mass required for one shot) and material metering. Depends on the unit of measure of the device 13. The resin material is continuously supplied at times T3 and T4, which is to store a certain resin material in the molding machine 14 in advance. Also, the resin material is continuously supplied at times T18 and T19. This is because the resin material remaining in the molding machine 14 is purged (time T17) as the processing line 1 is forcibly stopped and restarted. Therefore, to make up for it.

  A graph G3 in FIG. 2C is a graph in which the accumulated amount of power supplied to the processing line 1 from the operation start time of the processing line 1 is arranged as a bar B in time order. The cumulative amount of power is basically proportional to the cumulative number of shots. At times T1 and T2, a large amount of electric power is used for preheating the dryer 12 and the mold temperature controller 15. At times T15 and T16, since the power supply is stopped by the forced stop of the processing line 1, the accumulated amount of power does not change. At times T17 and T18, considerable electric power is used for reheating the mold temperature controller 15 and the like.

  FIG. 3A to FIG. 3C are graphs of the machining line smart evaluation information calculated based on the operation information shown in FIG. 2A to FIG. The horizontal axis of the graphs G4 to G6 is not the time axis, but the cumulative number of molding shots. For example, the 10th scale on the horizontal axis means the 10th shot.

  A graph G4 in FIG. 3A is obtained by arranging the values of the processing line smartization evaluation information (time evaluation information) related to time as a bar B in the order of shots. Each value of the time evaluation information is calculated from the length of the period from the start of operation of the processing line 1 to the time of each evaluation timing and the cumulative number of shots in that period. For example, the value of the sixth shot (shaded portion in the figure) is obtained by dividing the value T in FIG. At this time, each value of the time evaluation information is an average value of the time required for each shot at each evaluation timing. If the time evaluation information is graphed as shown in FIG. 3A, the transition of the time efficiency of the processing line 1 can be grasped at a glance. The broken line in the graph G4 is a reference value for time efficiency, and may be set to 110% of the ideal value determined by the performance of the molding machine 14.

  A graph G5 in FIG. 3B is obtained by arranging the values of the processing line smartization evaluation information (material use evaluation information) regarding the resin material as a bar B in the order of shots. Each value of the material use evaluation information was calculated from the cumulative amount of the resin material supplied to the processing line 1 from the start of operation of the processing line 1 to the time of each evaluation timing, and the cumulative number of shots in that period. Is. For example, the value of the sixth shot (shaded portion in the figure) is obtained by dividing the value M in FIG. 2B by the value X in FIG. At this time, each value of the material use evaluation information is an average value of the resin material used per shot at each evaluation timing. If the material use evaluation information is graphed as shown in FIG. 3B, the transition of the material use efficiency of the processing line 1 can be grasped at a glance. The broken line in the graph G5 is a reference value for material use efficiency, and may be set to 110% of the resin mass unit of the molding process.

  A graph G6 in FIG. 3C is obtained by arranging the values of the processing line smartization evaluation information (power usage evaluation information) related to power as a bar B in the order of shots. Each value of the power usage evaluation information is calculated from the cumulative amount of power supplied to the processing line 1 from the time when the processing line 1 is started to the time of each evaluation timing, and the cumulative number of shots in that period. It is. For example, the value of the sixth shot (shaded area in the figure) is obtained by dividing the value P in FIG. 2C by the value X in FIG. At this time, each value of the power usage evaluation information is an average value of power used per shot at each evaluation timing. If the power usage evaluation information is graphed in this way, the transition of the power usage efficiency of the processing line 1 can be grasped at a glance. Note that the broken line in the graph G6 is a reference value of power usage efficiency, and may be set to 110% of the ideal value determined by the average power consumption when the processing line 1 is stably operating.

  As shown in FIGS. 3 (a) to 3 (c), if the processing line smart evaluation information regarding time, resin material, and electric power is quantitatively visualized and evaluated, the time change of the operation efficiency and the operation efficiency can be reduced. You can immediately know if you are within the standards. That is, it is possible to easily perform standard management during system operation. Here, the reference value may be set based on the specifications of each device and the data accumulated in the mass production preparation stage. That is, the reference value includes not only the data at the time of stable operation, but also the amount of the discarded resin material and the influence of the forced stop of the processing line 1.

  Conventionally, the efficiency of the processing line has been discussed based on the specifications (champion data) of each device, and it has been difficult to evaluate the actual efficiency of the processing line. However, in the present invention, since the actual efficiency of the processing line 1 can be evaluated by visualizing the processing line smartization evaluation information as described above, the inefficiency immediately after the start of the operation of the processing line 1 and the processing line 1 The magnitude of impact, etc. when forced to stop is clarified. Therefore, it helps to optimize the number of products in the lot, and the ability of the device can be evaluated. For example, in the case of a large molding machine, 10 products can be obtained in one shot of molding, but it is understood that the amount of resin material to be discarded is too large to be suitable for a small lot.

  In addition, when operating efficiency is compared between multiple lines, abnormalities that are usually difficult to notice, such as a short-time forced stop (choco stop) on one line, can be easily found. That is, comparison management between processing lines is facilitated.

  In order to prevent the processing line smart evaluation information from being affected by the size of the molded product for each type, that is, the difference in the mass of resin contained in one molded product, the arithmetic processing means 16 performs one shot of molding processing. The value of the processing line smartization information may be normalized by using the mass of the resin material used in the above, or a predetermined mass such as 10 kg as a resin material mass unit. In particular, if the smart evaluation information regarding the supply of resin materials and electric power is standardized in this way, it becomes possible to compare the processing line smart evaluation information between processing lines with different types of molded products. Alternatively, the value of the processing line smartization information may be standardized by a product unit amount such as one dozen.

  The arithmetic processing means 16 may store the quality information (drying time, drying temperature, mold temperature set value, measurement value, etc.) collected by the data collecting means 16a in the storage means 17 together with the processing line smartization evaluation information. .

  At this time, the identification information providing means 22 may include information for specifying the evaluation timing at the time when the molded product is molded in the identification information provided for each molded product. For example, information for specifying a shot in which the molded product is made may be included as identification information.

  In this way, the quality assurance system can be explained at the client's inspection, and when there is an inquiry about the molded product at a later date, the quality information etc. is answered based on the identification information printed on the molded product. This improves traceability. It should be noted that the monitoring device 18 may be able to appropriately browse the quality information stored in the storage unit 17.

DESCRIPTION OF SYMBOLS 1 Plastic molding process line 13 Material measuring device 14 Molding machine 16 Arithmetic processing means 16a Data collection means 17 Storage means 18 Monitoring apparatus 22 Identification information provision means

Claims (5)

In an operating system of a plastic molding processing line that manufactures molded products using a molding machine,
A material weighing device installed upstream of the molding machine;
Data collection means for collecting operation information of each device constituting the processing line;
The information collected by the data collection means is read out, and at least one of the resin material, power consumption, and operation time used until the resin material is supplied from the raw material storage unit to the molding machine and processed. An arithmetic processing means for calculating the above as preset processing line smart evaluation information,
A plastic molding processing line smarting operation system configured to incorporate a monitoring device that displays processing line smarting evaluation information calculated by the arithmetic processing means. In claim 1,
The monitoring apparatus visualizes the processing line operating efficiency by arranging the read processing line smart evaluation information in a time series, and a plastic molding processing line smart operation system. In claim 1 or 2,
Storage means for accumulating quality information and processing line smartization evaluation information calculated by the arithmetic processing means;
A smart molding operation system for a plastic molding processing line, further comprising identification information adding means for adding shot identification information for specifying a shot of the molded product to each molded product. In any one of Claims 1-3.
The monitoring device is a smart operation system for a plastic molding processing line configured as a display / operation panel installed adjacent to the processing line. In any one of Claims 1-3.
The monitoring apparatus is a smart operation system for a plastic molding processing line configured as a portable terminal that can be connected to the processing line through a communication path including wireless communication.

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