JP2021066057A - Injection molding machine management device and injection molding machine - Google Patents

Abstract

To easily determine the degree of mechanical condition data variation of an injection molding machine.SOLUTION: An injection molding machine management device for managing mechanical condition data related to a mechanical condition when an injection molding machine is operated, comprises a storage unit and a control unit. The control unit comprises: a mechanical condition data acquisition section for acquiring mechanical condition data related to a mechanical condition when the injection molding machine is operated; a mechanical condition data recording section for making the mechanical condition data acquired in the mechanical data acquisition section correspond to mold information, associating it with a molding date and time and/or an accumulated number of shots, and periodically recording it in the storage section; a classification section for classifying the mechanical condition data recorded in the storage section by mold; and an output control section for outputting the mechanical condition data of the injection molding machine classified by mold in the classification section.SELECTED DRAWING: Figure 2

Description

The present invention is an injection molding machine management device and an injection molding machine that classifies and manages machine state data related to the state of the machine during operation of the injection molding machine for each mold by associating it with the processing date and time and / or the number of processing shots. Regarding.

In an injection molding machine, it is necessary to monitor whether the molding state is well maintained during the molding operation and whether any abnormality has occurred during the molding operation in order to produce a good molded product. Is important.
For this reason, the injection molding machine acquires data from each sensor and motor installed in the injection molding machine at predetermined sampling times during one cycle, and the maximum value and the time during which the resin is injected are obtained from the data. Is calculated / measured, and the calculated / measured data is used for monitoring the molding state, determining the quality of the molded product, and the like.
For example, for each injection molding machine, the values of various data representing the molding operating state such as molding cycle time, injection time, measuring time, temperature of motor, peak pressure, load factor of motor, etc. are measured for each molding cycle. ing.

For example, Patent Document 1 describes an electric injection molding machine that displays the load status of a drive unit that drives the electric injection molding machine over a plurality of cycles on a display unit, and each time one cycle is executed, the electric injection molding machine is displayed. An electric injection molding machine is disclosed in which a load factor of a drive unit is obtained and a load factor trend indicating a change in the obtained load factor over a plurality of cycles is displayed on the display unit.
Specifically, the injection molding machine 10 moves an injection servomotor 15a that moves the screw 13 provided in the nozzle 12 forward and backward, a metering servomotor 15b that rotates the screw 13 to measure the amount of resin, and an eject pin 14. The ejector servomotor 15c that projects the molded product from the mold 11, the mold clamping servomotor 15d that clamps the mold 11, and the heat generating temperatures of the servomotors 15a to 15d are detected, and information on the detected temperature is obtained. It is provided with sensors 16a to 16d to transmit to the controller 30, and one cycle (molding step, injection step (including forward / backward movement of the nozzle)), weighing step, mold opening step, projecting step, and standby for forming one molded product. The load factor of each servomotor 15a to 15d is calculated each time the step) is executed. The injection molding machine 10 displays the change in the load factor from the servomotors 15a to 15d obtained over a plurality of cycles on the display unit (overload trend display area 42).
By doing so, the electric injection molding machine disclosed in Patent Document 1 can predict the load status by displaying the load status based on the change in the load factor obtained over a plurality of cycles on the display unit. If the user determines from this tendency that seizure (overheating) of the servomotors 15a to 15d may occur, the driving unit is protected from overload by changing the molding conditions, and the molded product is manufactured. It is possible to suppress a decrease in the number of production.

Patent No. 5811035

In an injection molding machine, the time required for one cycle (one shot) is short, and in many cases molding is performed regardless of Saturday and Sunday. Therefore, while using the injection molding machine for a long period of time, it is determined whether or not the injection molding machine is maintained in good condition, and if some deterioration or the like has already occurred in the mechanical part of the injection molding machine, It is important to promptly prevent and maintain the molded product before it becomes defective.
In this regard, the technique disclosed in Patent Document 1 can protect the drive unit from overload by estimating the number of cycles in which the load factor reaches the limit value based on the change in the load factor, but injection It is difficult to determine whether or not some deterioration has already occurred in the mechanical part of the molding machine.

The present invention periodically classifies and manages the machine state data related to the state of the machine during operation of the injection molding machine for each mold in association with the processing date and time and / or the number of processing shots. An object of the present invention is to provide an injection molding machine management device and an injection molding machine that support determination of a change status of machine state data based on the state data and the history of the machine state data so far.

(1) One aspect of the present disclosure is an injection molding machine management device that manages machine state data relating to a machine state during operation of the injection molding machine, and includes a storage unit and a control unit, and the control unit. Corresponds the machine state data acquisition unit that acquires the machine state data related to the state of the machine at the time of operation of the injection molding machine and the machine state data acquired by the machine state data acquisition unit with the information of the mold, and molds. A machine state data recording unit that periodically records the date and time and / or the cumulative number of shots in the storage unit, and a classification unit that classifies the machine state data periodically recorded in the storage unit for each mold. The present invention relates to an injection molding machine management device including an output control unit for outputting machine state data of the injection molding machine classified for each mold by the classification unit.

(2) One aspect of the present disclosure relates to an injection molding machine including the injection molding machine management device according to (1).

According to one aspect, the injection molding is performed by comparing the current machine state data regarding the state of the machine generated during the molding operation of the injection molding machine for each mold with the history of the machine state data so far. The degree of change in the machine state data of the machine can be easily determined.

It is a figure which shows the outline of the injection molding machine and the injection molding information management apparatus in the 1st Embodiment of this invention. It is a figure which shows an example which calculates the average value for every 10,000 shots from the machine state data value for each mold. It is a figure which shows the display example which displays the machine state data which shows the possibility of abnormality on the display part when the sign of abnormality is detected in any of the mechanical parts of an injection molding machine. It is a figure which shows the schematic diagram of the injection molding machine management apparatus which manages the machine state data for each one or a plurality of injection molding machines connected by a network.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
(First Embodiment)

Hereinafter, one embodiment of the injection molding machine management device of the present invention will be described with reference to the drawings. FIG. 1 illustrates one embodiment in which the injection molding machine management device 7 is a device different from the injection molding machine 1.
FIG. 1 illustrates a case in which the injection molding machine 1 and the injection molding machine management device 7 are directly connected via an interface, but the present invention is not limited to this. For example, the injection molding machine 1 and the injection molding machine management device 7 may be connected via a network. Further, in FIG. 1, one injection molding machine management device 7 is connected to one injection molding machine 1, but as will be described later, a plurality of N injection molding machines (N ≧ 2) 1 −N (1 ≦ n ≦ N) may be connected to one injection molding machine management device 7.
Further, as will be described later, the injection molding machine 1 may be provided with the injection molding machine management device 7. In this case, the injection molding machine 1-1 provided with the injection molding machine management device 7 also manages another injection molding machine 1-n (2 ≦ n ≦ N) not equipped with the injection molding machine management device 7. It may be.
Before explaining the injection molding machine management device 7, the injection molding machine 1 will be briefly described.

<Injection molding machine>
As shown in FIG. 1, the main body of the injection molding machine 1 is provided with a mold opening / closing and mold clamping mechanism portion (hereinafter, also referred to as “mold clamping portion 10”) and an injection portion 40 on a machine base (not shown). The part is composed. The mold clamping portion 10 is provided with a plurality of movable portions such as a movable platen 13 and an ejector mechanism 50, as will be described later.
Further, the injection molding machine 1 includes a control device 60.

<Molding part>
The mold clamping portion 10 will be described.
In the mold clamping portion 10, the fixed platen 12 and the rear platen 15 are connected by a plurality of tie bars (not shown), and the movable platen 13 is movably arranged along the tie bars between the fixed platen 12 and the rear platen 15. It is installed. Further, the fixed side mold 32 of the mold 30 is attached to the fixed platen 12, and the movable side mold 33 is attached to the movable platen 13.

The movable platen 13 is a servomotor 21 for opening / closing and mold clamping (hereinafter, also referred to as “mold clamping servomotor 21”) attached to the rear platen 15 via a toggle mechanism 20 constituting the mold clamping portion 10. FIG. It can be moved from side to side.
Specifically, by driving the mold clamping servomotor 21, the ball screw (not shown) is driven via a power transmission means such as a pulley or a belt, and the toggle mechanism 20 is moved forward or backward (to the right in FIG. 1 or backward). The toggle mechanism 20 is driven (to the left), and the movable platen 13 is moved forward or backward in the direction of the fixed platen 12 to open / close, clamp, and open the mold 30.
A position / speed detector 21a such as a pulse coder that detects the rotation position / speed of the mold clamping servomotor 21 is attached to the motor shaft of the mold clamping servomotor 21. It is configured to detect the position of the movable platen 13 (movable side mold 33) by the position feedback signal from the position / speed detector 21a.

<Ejector mechanism>
An ejector servomotor 51 that drives the product projecting mechanism portion 50 (hereinafter, also referred to as “ejector mechanism 50”) is attached to the movable platen 13. The ejector mechanism 50 is a mechanism for projecting a molded product from the mold 30 (movable side mold 33) provided on the movable platen 13.
Specifically, the ejector mechanism 50 transmits the rotational force of the ejector servomotor 51 via a power transmission means (not shown) including a pulley and a belt (timing belt), and a ball screw / nut mechanism (not shown). It is transmitted to the eject pin 14, the eject pin 14 is projected into the mold 30 (movable side mold 33), and the molded product is projected from the mold 30 (movable side mold 33).
The ejector servomotor 51 is also equipped with a position / velocity detector 51a for detecting the rotation position / velocity of the ejector servomotor 51 such as a pulse coder. The position of the eject pin 14 is detected by the position feedback signal from the position / velocity detector 51a.

<Injection part>
The injection unit 40 includes a hopper 48, an injection cylinder 41, an injection screw 43, an injection servomotor 46, a weighing servomotor 45, and the like.
A hopper 48 is provided above the injection cylinder 41 in order to supply the resin material into the injection cylinder 41. A nozzle portion 42 is attached to the tip of the injection cylinder 41, and an injection screw 43 is inserted into the injection cylinder 41.
The injection screw 43 is provided with a pressure sensor 47 such as a load cell that detects the pressure applied to the molten resin in the injection cylinder 41 by the pressure applied to the injection screw 43. For example, the detected resin pressure (resin pressure applied to the screw 43) can be measured based on the detection signal of the pressure sensor 47.
The injection screw 43 is rotated forward or reverse by the weighing servomotor 45 via a transmission means 45c composed of a pulley, a timing belt, and the like. The measuring servomotor 45 is equipped with a position / speed detector 45a for detecting the rotation position / speed of the measuring servomotor 45 such as a pulse coder (not shown), and detects the rotation position and the rotation speed of the injection screw 43.
Further, the injection screw 43 is driven by an injection servomotor 46 via a transmission means 46c including a mechanism for converting a rotary motion such as a pulley, a belt, and a ball screw / nut mechanism into a linear motion, and ejects the inside of the injection cylinder 41. It moves in the major axis direction of the cylinder 41. The injection servomotor 46 is equipped with a position / speed detector 46a for detecting the rotation position / speed of the injection servomotor 46 such as a pulse coder, and detects the position and speed of the injection screw 43 in the axial direction.

<Measuring instrument>
In the above description, the pressure sensor 47 that detects the pressure applied to the molten resin in the injection cylinder 41 by the pressure applied to the injection screw 43 has been illustrated, but the measuring instrument such as the sensor is not limited to this. For example, temperature sensors for measuring the temperature, cylinder temperature, mold temperature, etc. of the servomotors 45, 46, 21, 51 can be installed at each location. Further, a measuring instrument for measuring the instantaneous current value and the instantaneous voltage value of each of the servomotors 45, 46, 21, and 51 may be installed. In addition, a strain sensor may be installed to measure the mold clamping force.
By measuring the machine state data regarding the state of the machine during the operation of the injection molding machine 1 by these measuring instruments, the injection molding machine 1 (control device 60) can be, for example, the servo motors 45, 46, 21, 51. Load factor and temperature, peak pressure during injection holding process, index of reverse flow rate of resin during injection, mold clamping force during mold clamping process, power transmission unit (for example, the long axis of the injection cylinder 41 inside the injection cylinder 41) Ball screw when moving in the direction, ball screw driven when opening / closing / tightening the mold 30 and opening the mold, driven when the molded product is projected from the mold 30 (movable side mold 33) It is possible to detect the load factor (ball screw, etc.), the temperature of the power transmission unit, the transmission force of the power transmission unit, the transmission work amount of the power transmission unit, the power consumption amount, the injection time, the measurement time, the cycle time, and the like.

More specifically, regarding the load factor of each servomotor, for example, as described in Japanese Patent Application Laid-Open No. 09-262888, the instantaneous power value calculated from the instantaneous current value and the instantaneous voltage value of each servomotor. And the rated value of each servomotor, the instantaneous load factor is calculated, and from the instantaneous load factor, for example, the average load factor per unit time, the average load factor per process, the average load factor per cycle, And the maximum load factor per cycle may be detected. In this embodiment, the maximum load factor of each servomotor may be adopted as the machine state data. The above-mentioned load factor may be adopted as the servomotor load factor.

The peak pressure during the injection holding step may be detected by, for example, a pressure sensor 47 arranged between the injection servomotor 46 and the injection screw 43.

As for the index of the reverse flow rate of the resin at the time of injection, for example, as described in Japanese Patent Application Laid-Open No. 2008-155379, the rotational force from the screw advance start time (injection start time) to the rotational force peak time acting on the screw. The time integral value of, or the value obtained by integrating the rotational force from the screw advance start time (injection start time) to the rotational force peak time with respect to the screw position, is detected as an index showing the reverse flow rate of the resin at the time of injection. May be good.

Regarding the mold clamping force during the mold clamping process, for example, as described in Japanese Patent Application Laid-Open No. 9-178753, a strain sensor for detecting the amount of strain of the constituent members of the mold clamping device is provided, and the strain detected by the strain sensor is provided. The mold clamping force may be detected from the amount.

The load factor of the power transmission unit and the like may be described in, for example, Japanese Patent Application Laid-Open No. 2013-119212. For example, a pressure sensor interposed between the nut part (or ball screw part) of the ball screw and the movable body part that moves in the axial direction by the ball screw, and the rotation of the servomotor provided in the rotation drive part that rotates the ball screw are detected. The operating distance of the ball screw detected from the rotary encoder and the load factor (life consumption) of the ball screw may be detected from.
The measured machine state data is not limited to these. Any measurable data known to those of skill in the art may be detected.

<Control device>
The control device 60 that controls the injection molding machine 1 includes a numerical control unit 61, a programmable logic controller PLC62, a servo control unit 63, and the like.
The PLC 62 includes a PLC CPU 621 that controls the sequence operation of the injection molding machine 1, and a storage unit 622 that is used for temporary storage of a sequence program and arithmetic data. The numerical control unit 61 includes a numerical control CPU 611 that controls the injection molding machine 1 as a whole, and a storage unit 612 used for temporary storage of an automatic operation program and calculation data.

Further, the servo control unit 63 includes a servo control CPU 631 that processes a position loop, a speed loop, and a current loop, and a storage unit 632 that is used for a control program dedicated to servo control and temporary storage of data. Further, the servo control unit 63 advances or reverses the servo amplifier 45b that drives the metering servomotor 45, the servo amplifier 46b that drives the injection servomotor 46 that drives the screw 43 in the axial direction to perform injection, and the toggle mechanism 20. A mold clamping servomotor that drives the toggle mechanism 20 (to the right or left in FIG. 1) and advances or retracts the movable platen 13 in the direction of the fixed platen 12 to open / close / mold / open the mold 30. The mold clamping servo amplifier 21b that drives the 21 and the servo amplifier 51b that drives the ejector servomotor 51 are connected.
Position / velocity detectors 45a, 46a, 21a, 51a are attached to the servomotors 45, 46, 21, 51, respectively, and the outputs from the position / velocity detectors 45a, 46a, 21a, 51a are servos. It is designed to be returned to the control unit 63.
The servo control unit 63 is a movement command to each axis (measurement servo motor 45, injection servo motor 46, mold clamping servo motor 21, ejector servo motor 51) commanded by the numerical control unit 61, and a position / speed detector 45a, The position and speed feedback control is performed based on the detection position and speed fed back from 46a, 21a and 51a, and the drive current feedback control of each servomotor 45, 46, 21 and 51 is executed to execute each servo amplifier. The servomotors 45, 46, 21, 51 are driven and controlled via 45b, 46b, 21b, 51b.
By doing so, for example, a current value register for storing the rotational position of the injection servomotor 46 fed back from the position / velocity detector 46a is provided, and the axial position of the screw 43 ( The injection position) can be detected.
In addition, the movable platen 13 (movable side metal) is based on the position feedback signal from the position / speed detector 21a that detects the rotation position / speed of the mold clamping servomotor 21 such as a pulse coder attached to the motor shaft of the mold clamping servomotor 21. The position of the mold 33) can be detected.
Further, the control device 60 is connected to a display 65 composed of a liquid crystal or a CRT.

With the above configuration, the PLC control unit 62 controls the sequence operation of the entire injection molding machine, and the numerical control unit 61 distributes movement commands to the servomotors of each axis based on the operation program, molding conditions, and the like. The servo control unit 63 includes movement commands distributed to each axis (measurement servomotor 45, injection servomotor 46, mold clamping servomotor 21, ejector servomotor 51), and position / speed detectors 45a, 46a, 21a. Based on the position and speed feedback signals detected in 51a, servo control such as position loop control, speed loop control, and current loop control (torque control) is performed, and so-called digital servo processing is executed.

For example, when a mold closing command is input, the servo control unit 63 obtains a position deviation amount based on the movement command and a feedback signal from the position / speed detector 21a, and multiplies this position deviation amount by the position gain. The speed command is obtained, the current speed of the mold clamping servomotor 21 detected by the position / speed detector 21a is subtracted from the speed command to obtain the speed deviation, and the speed loop processing is performed to the mold clamping servomotor 21. The current command value as the torque command of is obtained, the current loop processing is performed by the difference between this current command value and the current drive current value of the mold clamping servo motor 21, and the current loop processing is performed and output to the mold clamping servo amplifier 21b to output the mold clamping servo. The motor 21 is driven and controlled. The control of other servomotors is the same, and the configuration of the control device 60 and the configuration of the mechanical portion of the injection molding machine 1 are the same as those of the conventional injection molding machine.
The injection molding machine 1 has been described above. The configuration of the injection molding machine 1, its function, and the like are techniques known to those skilled in the art, and detailed description thereof will be omitted.
Next, the injection molding machine management device 7 will be described.

<Injection molding machine management device>
The injection molding machine management device 7 (hereinafter, also referred to as “management device 7” for short) is directly connected to the injection molding machine 1 via an interface. The management device 7 includes, for example, a control unit 71, a storage unit 72, a display unit 75 composed of a CRT, a liquid crystal, etc., and an input unit 76 for inputting data and commands such as a keyboard and a mouse, which are composed of a computer such as a PC. Be prepared. The management device 7 acquires various measurement data from the injection molding machine 1 for each molding cycle, for example. The control unit 71 of the management device 7 includes a CPU, a memory, and the like provided in a normal computer (not shown).
As described above, the management device 7 not only periodically stores a large amount of machine state data generated in the injection molding machine 1, but also links it to the number of processed shots and / or the molding date and time for each mold. By classifying and managing, it is required to support the judgment of the change status of the machine state data over the long term.
Therefore, the management device 7 includes a functional unit described below.

FIG. 1 shows the functional configuration of the control unit 71 of the management device 7. As shown in FIG. 1, the control unit 71 includes a machine state data acquisition unit 711, a machine state data recording unit 712, a classification unit 713, an output control unit 714, an abnormality detection unit 715, and an average value calculation unit 716. And a change amount calculation unit 717.

<Machine status data acquisition unit 711>
The machine state data acquisition unit 711 acquires machine state data regarding the state of the machine during the molding operation of the injection molding machine 1. Specifically, the machine state data acquisition unit 711 monitors, for example, the molding cycle start signal generated by the numerical control unit 61 of the injection molding machine 1, and completes the previous molding cycle with the detection of the signal to start the next cycle. It may be considered that the machine state data in the previous molding cycle is acquired based on the completion of the previous molding cycle.
In addition to the acquisition of the machine state data, the machine state data acquisition unit 711 refers to the machine state data with the identification information of the mold used at the time of the molding operation and the cumulative number of shots related to the molding operation (the relevant). The shots related to the molding operation correspond to which cumulative number of shots by the injection molding machine 1) and / or the molding date and time of the molding operation (for example, a time stamp indicating the end of the molding cycle) are linked and acquired. To do.
Here, the mechanical state data is the molding data value in each step (mold closing step, mold clamping step, filling step, pressure holding step, cooling step (measuring step), mold opening step, projecting step) constituting the molding cycle. is there.
In the present embodiment, the machine state data acquired by the machine state data acquisition unit 711 includes the motor load factor and motor temperature of each of the servomotors 45, 46, 21, and 51, the peak pressure during the injection holding process, and the resin during injection. Index of reverse flow rate, mold clamping force during mold clamping process, ball screw when moving the inside of the injection cylinder 41 in the major axis direction of the injection cylinder 41, opening / closing / mold clamping of the mold 30 , The load factor of the ball screw driven when opening the mold, the ball screw driven when the molded product is projected from the mold 30 (movable side mold 33), the temperature of each power transmission unit, each power It shall include, but is not limited to, at least one of the transmission force of the transmission unit, the transmission work amount of each power transmission unit, the power consumption amount, the measurement time, and the cycle time. As described above, the measuring instrument may include arbitrary machine state data obtained by measuring the machine state data regarding the state of the machine during the operation of the injection molding machine 1.

<Machine state data recording unit 712>
The machine state data recording unit 712 associates the machine state data acquired by the machine state data acquisition unit 711 with the mold information, and periodically records it in the storage unit 72 in association with the cumulative number of shots and / or the molding date and time. To do.
Specifically, the machine state data recording unit 712 is a machine related to the mold, which is calculated over a plurality of preset cycles based on the machine state data acquired for each molding cycle of each mold. The average value of the state data (that is, for each item data included in the machine state data) may be stored in the storage unit 72 in association with the mold. By doing so, it is possible to grasp the tendency of the machine state data when injection molding is performed using the same mold as the number of shots increases, and reduce the storage capacity for storing the machine state data. can do.
Regarding the number of shots in one cycle when the machine state data recording unit 712 periodically (for each of a plurality of molding cycles) calculates the average value and stores it in the storage unit 72, for example, one shot of an injection molding machine. It may be set as appropriate according to the processing time required for the above. Further, the number of shots per cycle may be set for each mold.

<Classification unit 713>
The classification unit 713 classifies the machine state data periodically recorded in the storage unit 72 by the machine state data recording unit 712 for each mold.
The classification unit 713 collects machine state data from the first shot recorded in the storage unit 72 by the machine state data recording unit 712 to the latest cumulative number of shots for each mold (that is, mold A, mold B, etc.). And mold C).
By doing so, it is possible to grasp the tendency of each mold as the number of shots of the machine state data at the time of molding by the injection molding machine increases.

<Output control unit 714>
The output control unit 714 outputs the machine state data of the injection molding machine classified for each mold by the classification unit 713. Specifically, the output control unit 714 may display the classified machine state data on the display unit 75. Further, the output control unit 714 may output the classified machine state data as a file.

<Anomaly detection unit 715>
The abnormality detection unit 715 is based on the current machine state data of the injection molding machine 1 and the past machine state data stored in the storage unit 72 corresponding to the mold corresponding to the current machine state data. The possibility of abnormality of the injection molding machine 1 is detected.
Here, two detection methods will be described.
The first detection method is calculated by the average value calculation unit 716 described later from the latest data of the machine state data of the injection molding machine 1 classified for each mold and the history data of the machine state data belonging to the same classification as the latest data. This is a method of detecting an abnormality in the injection molding machine 1 based on a comparison with the average value obtained.
The second detection method is based on the molding date and / or the change amount with the cumulative number of shots of the machine state data of the injection molding machine 1 classified for each mold, which is calculated by the change amount calculation unit 717 described later. , This is a method of detecting an abnormality in the injection molding machine 1.

First, the first detection method will be described. Before explaining the first detection method, the average value calculation unit 716 will be described.
<Average value calculation unit 716>
The average value calculation unit 716 is used when the abnormality detection unit 715 detects an abnormality in the injection molding machine 1 based on the first detection method.
The average value calculation unit 716 stores the historical data of the machine state data belonging to the same classification for each machine state data of the injection molding machine 1 classified for each mold, which is the detection target of the abnormality detection unit 715, in the storage unit 72. Input from, and calculate the average value for each cumulative number of shots specified in advance.
FIG. 2 is a diagram showing an example in which the average value of the machine state data value for each mold is calculated for each cumulative number of shots specified in advance.
Specifically, in FIG. 2, the average value calculation unit 716 has a cumulative number of 10,000 shots by the injection molding machine with respect to the injection motor load factor, the injection motor temperature, and the injection ball screw load factor for each mold. An example of calculating the average value for each is shown.
As shown in FIG. 2, in the molding operation by the injection molding machine, molding from the first shot to 10,000 shots is performed by the mold C, and then molding from 10,001 shots to 20,000 shots is performed by the mold A. , 30,001 shots to 60,000 shots are molded by the mold B.
In this example, the cumulative number of shots for calculating the average value is 10,000, and the average values of the injection motor load factor, the injection motor temperature, and the injection ball screw load factor are calculated. The cumulative number of shots to calculate is not limited to 10,000. For example, it may be appropriately set for each mold according to the processing time required for one shot of the injection molding machine.

As described above, when the average value calculation unit 716 calculates the average value for each cumulative number of shots specified in advance from the historical data of the machine state data of the injection molding machine 1 classified for each mold, The abnormality detection unit 715 detects an abnormality in the injection molding machine 1 based on a comparison between the latest data of the machine state data of the injection molding machine 1 classified for each mold and the average value calculated by the average value calculation unit 716. To detect.
Specifically, for example, the difference between the latest data of the machine state data (for example, the average value calculated over a plurality of preset cycles) and the average value calculated by the average value calculation unit 716 is in advance. If it exceeds the set upper limit value, it may be detected as a sign of abnormality.
FIG. 3 is a diagram showing an example of comparing the machine state data value for each mold with the average value calculated for each cumulative number of shots specified in advance and the latest data of the machine state data. Here, the average value for every 10,000 shots is calculated for the machine state data (injection servomotor load factor, injection servomotor temperature, and injection ball screw load factor), and the value and average of the latest data of the machine state data. By monitoring whether or not the difference from the value exceeds a predetermined upper limit value, a sign of abnormality in any of the mechanical parts of the injection molding machine 1 is detected.
With reference to FIG. 3, the abnormality detection unit 715 can detect an abnormality in the injection servomotor load factor and the injection servomotor temperature in molding using the mold A.
In addition, the output control unit 714 records the machine state data (injection servomotor load factor, injection servomotor temperature, and injection) in the latest data from a total of 500,001 shots to 510,000 shots using the mold data of the mold A. The display unit 75 may be displayed so that the user can easily confirm that the value of (ball screw load factor) may be abnormal.
By displaying the possibility of abnormal values for the injection servomotor load factor and the injection servomotor temperature by the output control unit 714, the user can use the components constituting the injection unit 40, which causes the load of the injection servomotor to increase, for example. It is possible to grasp the possibility of signs of abnormality.
The mechanical state data indicating the possibility of a sign of abnormality is not limited to the injection servomotor load factor and the injection servomotor temperature. For example, to the metering servomotor load factor (and / or metering servomotor temperature), mold clamping servomotor load factor (and / or mold clamping servomotor temperature), or ejector servomotor load factor (and / or ejector servomotor temperature). When there is a possibility of an abnormal value, it is possible to grasp the possibility of a sign of an abnormality in the parts constituting each mechanical part that causes the load of the weighing servo motor, the mold clamping servo motor, or the ejector servo motor to increase. ..
Further, when there is a possibility that the load factor of the power transmission unit (ball screw) has an abnormal value, it is possible to grasp the possibility of a sign of deterioration of the power transmission unit (ball screw).
Further, when there is a possibility of an abnormal value in the peak pressure during the injection holding process, the index of the reverse flow rate of the resin during injection, and the measurement time, the possibility of screw wear or the like can be grasped.
Further, when there is a possibility of an abnormal value in the mold clamping force during the mold clamping process, for example, it is possible to grasp the necessity of adjusting the mold thickness and the like.
In addition, since the abnormal value of the power consumption is likely to occur in conjunction with, for example, the abnormal value of each motor load factor and / or the motor temperature, it can be judged that there is a high possibility of a sign of the abnormality. it can.

Next, the second detection method will be described. Before explaining the second detection method, the change amount calculation unit 717 will be described.
The change amount calculation unit 717 is used when the abnormality detection unit 715 detects an abnormality in the injection molding machine 1 based on the second detection method.
The change amount calculation unit 717 is designated in advance from the historical data of the machine state data belonging to the same classification for each machine state data of the injection molding machine 1 classified for each mold, which is the detection target of the abnormality detection unit 715. Calculate the amount of change due to the date and time of molding and / or the cumulative number of shots.
The abnormality detection unit 715 increases the upper limit increase rate from the normal value for each mold and each item included in the machine state data based on the amount of change from the past machine state data stored in the storage unit 72. And / or the lower limit reduction rate is set in advance, and when the machine state data value is increased from the normal value for the mold corresponding to the current machine state data of the injection molding machine 1, the increase rate is set in advance. If the set upper limit increase rate is exceeded or exceeds the upper limit increase rate, or if the machine state data value is decreasing from the normal value, it is below the preset lower limit decrease rate or the lower limit decrease rate. When the following occurs, it may be detected that there is a possibility of abnormality in the injection molding machine 1.

As described above, when the abnormality detection unit 715 determines that there is a possibility of an abnormality in any of the mechanical parts of the injection molding machine 1, the output display unit 714 displays the abnormality on the display unit 75. The current machine state data determined to be a possible abnormal value may be alerted to the user by, for example, changing the display color scheme. The display method for calling attention is not limited to changing the display color scheme. The display format of the current machine state data determined to be an abnormal value that may be abnormal may be different from the display format of the normal value so that the user can easily distinguish it.
Even if an abnormality cannot be detected by monitoring the molded product generated during molding and determining the quality of the molded product, or even if an abnormality in the mold cannot be detected, the abnormality detection unit 715 currently uses the abnormality detection unit 715. It is preferable that the operation is performed so as to confirm the change status of the machine state data and detect the possibility of abnormality based on the machine state data of the above and the history of the machine state data so far. By doing so, one of the injection molding machines 1 is based on the machine state data for each mold, which is periodically recorded in the injection molding machine 1 before the abnormality of the molded product or the abnormality of the mold occurs. It is possible to detect signs of abnormality in the mechanical part of the above and enable preventive maintenance.
The embodiment of the injection molding machine management device has been described above.

Each component included in the injection molding machine management device 7 can be realized by hardware (including an electronic circuit or the like), software, or a combination thereof. When realized by software, the programs constituting this software are installed in the computer (numerical control device 1). In addition, these programs may be recorded on removable media and distributed to users, or may be distributed by being downloaded to a user's computer via a network. Further, when configured by hardware, a part or all of the functions of each component included in the control unit 71 are, for example, an ASIC (Application Specific Integrated Circuit), a gate array, an FPGA (Field Programmable Gate Array), a CPLD ( It can be configured by an integrated circuit (IC) such as a Complex ProgramLogic Device).

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments. Further, the effects described in the present embodiment merely list the most preferable effects arising from the present invention, and the effects according to the present invention are not limited to those described in the present embodiment.

[Modification 1]
The above-described embodiment illustrates a configuration in which the injection molding machine management device 7 is a separate device from the injection molding machine 1. In this case, as described above, the injection molding machine management device 7 may be directly connected to the injection molding machine 1 via an interface unit (not shown).
Further, as shown in FIG. 4, it may be a server (injection molding machine management server) that is communicated and connected to the injection molding machine 1 via the network 4. In this case, by connecting to a plurality of injection molding machines 1-n (1 ≦ n ≦ N; where N is an integer of 2 or more), the injection molding machine management server as the injection molding machine management device 7 injects. The machine state data may be managed for each molding machine 1-n.
FIG. 4 is a diagram showing a schematic view of an injection molding machine management device that manages machine state data for each one or a plurality of injection molding machines connected by the network 4.
For example, the injection molding machine management device 7 may be an edge server that is communicably connected to the injection molding machine (edge). Further, the injection molding machine management device 7 may be realized as a virtual server on the cloud. Further, the functional unit of the injection molding machine management device 7 may be provided as a function on the cloud.

[Modification 2]
Further, the injection molding machine 1 may include the injection molding machine management device 7. In this case, the functional blocks (machine state data acquisition unit 711, machine state data recording unit 712, classification unit 713, output control unit 714, and abnormality detection unit 715) provided in the control unit 71 of the injection molding machine management device 7 are injection molded. The control device 60 included in the machine 1 may be provided. For example, it may be a function provided by the numerical control unit 61. The display 65 may be applied as the display unit 75.
Alternatively, some functional units related to the management functions (machine state data acquisition unit 711, machine state data recording unit 712, classification unit 713, output control unit 714, and abnormality detection unit 715) provided in the injection molding machine management device 7 may be used. The configuration may be such that the control device 60 (for example, the numerical control unit 61) included in the injection molding machine 1 is provided. In this case, the injection molding machine 1 and the injection molding machine management device 7 including the remaining functional parts may be directly connected via an interface part (not shown) as described above. Further, it may be connected so as to be communicable via a network.

<Effect of this embodiment>
According to this embodiment, for example, the following effects can be obtained.

(1) An injection molding machine management device 7 that manages machine state data relating to a machine state during operation of the injection molding machine 1, including a storage unit 72 and a control unit 71, and the control unit 71 ejects. The machine state data acquisition unit 711 that acquires the machine state data related to the machine state during the operation of the molding machine 1 and the machine state data acquired by the machine state data acquisition unit 711 correspond to the mold information, and the molding date and time and / Or a machine state data recording unit 712 that periodically records in the storage unit 72 in association with the cumulative number of shots, and a classification unit 713 that classifies the machine state data periodically recorded in the storage unit 72 for each mold. , An output control unit 714 that outputs machine state data of the injection molding machine 1 classified for each mold by the classification unit 713.
Thereby, for example, by comparing the current machine state data regarding the state of the machine generated during the molding operation of the injection molding machine 1 for each mold with the history of the machine state data so far, the injection molding is performed. The degree of change in the machine state data of the machine 1 can be easily determined.

(2) In the injection molding machine management device 7 according to (1), the current machine state data of the injection molding machine 1 and the mold corresponding to the current machine state data are stored in the storage unit 72. It may have an abnormality detection unit 715 that detects an abnormality of the injection molding machine 1 based on the past machine state data.
As a result, it is possible to detect a sign of an abnormality in any of the mechanical parts of the injection molding machine 1 based on the machine state data of the injection molding machine 1 before an abnormality of the molded product or an abnormality of the mold occurs. ..

(3) The injection molding machine management device 7 according to (2) has an average value calculation unit 716 that calculates an average value of the machine state data of the injection molding machine 1 classified for each mold within the same classification. , The abnormality detection unit 715 is an average calculated by the average value calculation unit 716 from the latest data of the machine state data of the injection molding machine 1 classified for each mold and the history data of the machine state data belonging to the same classification as the latest data. The abnormality of the injection molding machine 1 may be detected based on the comparison with the value.
As a result, one of the mechanisms of the injection molding machine 1 is based on the average value of the machine state data values of the injection molding machine 1 for each mold at the normal time before the abnormality of the molded product or the abnormality of the mold occurs. It is possible to detect signs of abnormality in the part.

(4) The injection molding machine management device 7 according to (2) calculates the change amount according to the molding date and / or the cumulative number of shots of the machine state data of the injection molding machine 1 classified for each mold. It has a calculation unit 717, and the abnormality detection unit 715 may detect an abnormality in the injection molding machine 1 based on the amount of change in the machine state data calculated by the change amount calculation unit 717.
As a result, before an abnormality of the molded product or an abnormality of the mold occurs, an abnormality in any of the mechanical parts of the injection molding machine 1 is made based on the amount of change in the machine state data value of the injection molding machine 1 for each mold. Signs can be detected.

(5) In the injection molding machine management device 7 according to any one of (1) to (4), the machine state data includes the motor load factor related to the servomotor provided for each mechanical unit of the injection molding machine 1 and the injection molding machine. Motor temperature related to the servo motor provided for each mechanical part of 1, load factor of power transmission part of injection molding machine 1, temperature of power transmission part, transmission force of power transmission part, transmission work amount of power transmission part, mold clamping force , The peak pressure at the time of injection, the index of the reverse flow rate of the resin at the time of injection, the measurement time, the cycle time, and the power consumption may be included at least one of them.
Thereby, for example, by comparing the current machine state data in each mechanical part during the operation of the injection molding machine 1 with the history of the machine state data so far, in each mechanical part of the injection molding machine 1. The degree of change in machine state data can be easily determined.

(6) In the injection molding machine management device 7 according to any one of (1) to (5), the machine state data recording unit calculates the machine state data over a plurality of preset cycles, and is an average value. As a result, it may be recorded in the storage unit 72.
As a result, it is possible to grasp the tendency of the machine state data when injection molding is performed using the same mold as the number of shots increases, and also to reduce the storage capacity.

(7) The injection molding machine management device 7 according to any one of (1) to (6) includes a display unit 75, and the output control unit 714 is an injection molding machine classified for each mold by the classification unit 713. The machine state data of 1 may be output to the display unit 75 and displayed.
As a result, the user can easily confirm that the value of the machine state data may be abnormal.

(8) In the injection molding machine management device 7 according to any one of (1) to (7), the output control unit 714 inputs the machine state data of the injection molding machine 1 classified for each mold by the classification unit 713. You may output to a file.
As a result, the same effect as in (7) can be obtained.

(9) The injection molding machine management device 7 according to any one of (1) to (8) is communicably connected to one or a plurality of injection molding machines 1 and is connected to each one or a plurality of injection molding machines 1. The machine state data may be managed periodically.
Thereby, the machine state data at the time of the molding operation of the injection molding machine 1 can be centrally managed.

(10) The injection molding machine 1 includes the injection molding machine management device 7 according to any one of (1) to (9).
As a result, the same effect as in (1) can be obtained.

1 Injection molding machine 10 Mold clamping part 12 Fixed platen 13 Movable platen 14 Eject pin 15 Rear platen 20 Toggle mechanism 21 Mold clamping servo motor 21a Position / speed detector 21b Mold clamping servo amplifier 21b
30 Mold 32 Fixed side mold 33 Movable side mold 36 Bus 40 Injection part 41 Injection cylinder 42 Nozzle part 43 Injection screw 45 Weighing servo motor 45a Position / speed detector 45b Weighing servo amplifier 46 Injection servo motor 46a Position / speed detection Instrument 46b Injection servo amplifier 47 Pressure sensor 48 Hopper 50 Ejector mechanism 51 Ejector servo motor 51a Position / speed detector 51b Ejector servo amplifier 60 Control device 61 Numerical control unit 611 Numerical control CPU
612 Storage unit 62 PLC
621 PLCCPU
622 Storage unit 63 Servo control unit 631 Servo control CPU
632 Storage unit 65 Display 7 Injection molding machine management device 71 Control unit 711 Machine state data acquisition unit 712 Machine state data recording unit 713 Classification unit 714 Output control unit 715 Abnormality detection unit 716 Average value calculation unit 717 Change amount calculation unit 72 Storage Section 75 Display section 76 Input section

Claims (10)

An injection molding machine management device that manages machine state data related to the state of the machine during operation of the injection molding machine.
Memory and
With a control unit
The control unit
A machine state data acquisition unit that acquires machine state data related to the state of the machine during operation of the injection molding machine,
A machine state data recording unit that associates the machine state data acquired by the machine state data acquisition unit with mold information and periodically records the machine state data in the storage unit in association with the molding date and / or the cumulative number of shots. ,
A classification unit that classifies machine state data periodically recorded in the storage unit for each mold,
It includes an output control unit that outputs machine state data of the injection molding machine classified for each mold by the classification unit.
Injection molding machine management device. Based on the current machine state data of the injection molding machine and the past machine state data stored in the storage unit corresponding to the mold corresponding to the current machine state data, the injection molding machine The injection molding machine management device according to claim 1, further comprising an abnormality detection unit for detecting an abnormality. It has an average value calculation unit that calculates the average value of the machine state data of the injection molding machine classified for each mold within the same classification.
The abnormality detection unit
For comparison between the latest data of the machine state data of the injection molding machine classified for each mold and the average value calculated by the average value calculation unit from the history data of the machine state data belonging to the same classification as the latest data. The injection molding machine management device according to claim 2, which detects an abnormality of the injection molding machine based on the above. It has a change amount calculation unit that calculates the change amount with the molding date and / or the cumulative number of shots of the machine state data of the injection molding machine classified for each mold.
The abnormality detection unit
The injection molding machine management device according to claim 2, wherein an abnormality of the injection molding machine is detected based on the amount of change in the calculated machine state data. The mechanical state data includes a motor load factor related to a servomotor provided for each mechanical part of the injection molding machine, a motor temperature related to a servomotor provided for each mechanical part of the injection molding machine, and a power transmission unit of the injection molding machine. Load factor, temperature of power transmission part, transmission force of power transmission part, transmission work amount of power transmission part, mold clamping force, peak pressure at injection, index of reverse flow rate of resin at injection, weighing time, cycle time, The injection molding machine management device according to any one of claims 1 to 4, which comprises at least one of the power consumption. The machine status data recording unit
The injection molding machine management device according to any one of claims 1 to 5, which records the machine state data in the storage unit as an average value calculated over a plurality of preset cycles. Equipped with a display
The invention according to any one of claims 1 to 6, wherein the output control unit outputs and displays the machine state data of the injection molding machine classified for each mold by the classification unit on the display unit. Injection molding machine management equipment. The injection molding machine management device according to any one of claims 1 to 7, wherein the output control unit outputs the machine state data of the injection molding machine classified for each mold by the classification unit as a file. .. Communicatably connected to one or more injection molding machines,
The injection molding machine management device according to any one of claims 1 to 8, wherein the machine state data is periodically managed for each of the one or more injection molding machines. An injection molding machine including the injection molding machine management device according to any one of claims 1 to 9.

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