JP3617354B2 - Injection molding method and apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an injection molding method and apparatus, and more particularly to an injection molding method and apparatus suitable for molding an insert molded product, for example, a small rotor with a built-in magnet.
[0002]
[Prior art]
Generally, a small rotor for a watch is obtained as an injection molded product. The injection molding process for this type of insert product is as follows. First, a magnet material is loaded into a lower mold cavity in a mold opening with respect to a mold in which a plurality of cavities are formed by a lower mold and an upper mold. Thereafter, the mold is clamped and the resin is injected and injected. After a predetermined time, the mold is opened and the product is extruded and taken out. Since the runner resin remains in one mold, the runner is removed from the mold and the next injection process is started. Therefore, a plurality of molded products are obtained at a time by one injection operation, and a multi-cavity of 6 or more is common.
[0003]
[Problems to be solved by the invention]
However, in the conventional injection molding method, since it is intended to increase the work efficiency by taking a large number of pieces at a time, the size of the apparatus is unavoidable, and the mold clamping load increases as the number of picks increases. In other words, there was a problem that a clamping force of about 15 tons was required for 6 pieces. In addition, as described above, until the product is taken out, a series of processes such as loading of the insert part into the cavity, resin injection into the mold-clamped cavity, product taking out, and runner removal must be performed. This cycle time is required to be 10 to 11 seconds in the current injection apparatus, and it takes less than 2 seconds to obtain one product. Therefore, it is desired to further shorten this cycle time. .
[0004]
A rotary type injection molding machine is known as a device for speeding up injection work (Japanese Patent Laid-Open No. 8-281696). This corresponds to two or more lower molds corresponding to one upper mold, and is configured such that a plurality of lower molds are arranged around the rotary table, and mold clamping injection on one lower mold side In accordance with the work, an injection product is taken out on the other lower mold side to shorten the cycle time. However, even with this method, there is a limit to shortening the cycle time.
[0005]
An object of the present invention is to provide an injection molding method and apparatus capable of significantly reducing the molding cycle time of an insert molded product, paying attention to the above-mentioned conventional problems.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, an injection molding method according to the present invention is arranged such that an injection stage, a product recovery stage, an insert member supply stage, and an insert member detection stage are arranged around a rotary table and are simultaneously positioned on each stage. While circulating the lower mold placed on the rotary table, a pair of upper molds corresponding to the lower mold are prepared on the injection stage, and the upper molds are alternately switched for mold clamping and injection molding. In this injection molding time, the product recovery, the supply of the insert member, the presence / absence of the insert member and the float detection work and the runner removal work are performed simultaneously, and this series of work is repeated every intermittent rotation of the rotary table. did. The molding operation using the upper and lower molds may be performed as a single piece.
[0007]
In the injection stage, the pair of upper molds are moved up and down simultaneously, and the runner of the previous injection residue is chucked and removed by the chuck means waiting in a fixed position by using the vertical movement of the standby side upper mold. In the product collection stage, it is desirable that the collected product is counted by a sensor placed in a common product collection passage, and then collected and collected in a collection container provided for each lower mold. In the product recovery stage, it is desirable that the defective insert member be recovered based on the member loading failure signal in the insert member detection stage. In the insert member supply stage, the insert member continuously supplied from the parts feeder is separated from the supply path by being released to the side, and is then sucked and conveyed to the lower mold. At this time, the insert member accommodating portion is formed in the feeding head to be adsorbed, and the opening of the accommodating portion is brought close to the insert member to be sucked and accommodated in the accommodating portion, so that it can be accommodated smoothly. . In the insert member supply stage, the insert member is accommodated inside the contact surface of the feed head that moves to a position where it is joined to the lower mold, and the sleeve around the accommodating portion is retracted and moved when the mold contacts. An insert member is loaded into the mold cavity. In addition, in the insert member detection stage, the sensor head is lowered from directly above the insert member supplied to the lower mold cavity in the insert member supply stage and brought into contact with the mold surface, and the detection provided on the sensor head. A pin is brought into contact with the insert member, and the presence / absence of the insert member and floating detection may be performed by the displacement of the detection pin relative to the mold surface.
[0008]
The injection molding apparatus according to the present invention has a rotary table provided with a plurality of lower molds at the peripheral portion and capable of intermittent rotation, and a mold clamping injection unit, a product recovery unit, and an insert around the rotary table. A member supply unit and an insert member detection unit are arranged, and each mold circulates and moves each unit position while attaching the lower mold provided on the periphery of the rotary table so as to be simultaneously positioned at each unit position. The mold clamping injection unit can be clamped by arranging a pair of upper molds at the injection position and a standby position on the side thereof, and alternately switching the upper mold relative to the lower mold that circulates. An upper mold switching means is provided, and the product recovery unit, the insert member supply unit, and the insert member detection unit are within the injection molding time by the mold clamping injection unit. Tsu up by product recovery, the supply of the insert member, is characterized in that a control means for concurrently work and runner removal operation of presence and floating detection of the insert member.
[0009]
In such an injection molding apparatus, the product recovery unit includes a product pickup means, a recovery passage for the product taken out by the product pickup means, a sensor for counting the recovered product in the product recovery passage, and the product recovery passage. What is necessary is just to comprise and provide the some collection | recovery container arrange | positioned corresponding to each lower metal mold | die, and its distribution means. Further, the insert member supply unit has a separating means for allowing the insert member continuously supplied from the parts feeder to separate from the supply path to the side, and the separated insert member to the lower mold on the rotary table. It is set as the structure provided with the material supply head made to adsorb | suck conveyance. Further, the material supply head has a suction surface of the insert member and a sleeve surrounding the periphery of the insert member to form a storage portion, and is configured to be retractable by joining the sleeve front end surface to the lower mold. It is desirable to expose the insert member so that it can be loaded into the lower mold cavity.
[0010]
The insert member detection unit has a sensor head that can be moved up and down toward the lower mold cavity and can be stopped by contacting the mold surface. The sensor head is in contact with the supplied insert member. It is only necessary to provide a detection pin that can be made and detect the presence or absence of the insert member and the float by displacement of the detection pin with respect to the mold surface.
[0011]
By configuring in this way, during one injection operation, product collection, supply of insert members, presence / absence of insert members and float detection are performed at the same time, and especially by taking a single mold. As a result, the molding cycle time can be shortened to more than half that of the prior art, and the production efficiency can be greatly improved.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, specific embodiments of an injection molding method and apparatus according to the present invention will be described in detail with reference to the drawings.
[0013]
1 to 3 show an overall perspective view, a front view, and a side view of an injection molding apparatus. As shown in these drawings, in the injection molding apparatus, a rotary table 12 is arranged at a substantially central position of a base 10, and a lower molding die 14 is formed at four positions on the peripheral edge of the rotary table 12. At an equiangular position of 90 degrees. The details of the rotary table 12 equipped with the molding lower die 14 are shown in FIGS. 4 to 5, and a roller gear mounted on the base 10 using a motor 16 attached to the lower part of the base 10 as a drive source. It is attached to the cam unit 18 and supported so as to rotate intermittently by 90 degrees in one direction. A slit cam photo sensor 20 is attached to the roller gear cam unit 18 so that the rotation stop position can be accurately detected. As shown in FIG. 5, the lower mold 14 disposed at four locations around the rotary table 12 is fixed to a mold base 24 that is guided up and down by a lift guide 22 fixed to the rotary table 12. The mold base 24 is lifted from the turntable 12 by raising the mold base 24 and is matched with a molding upper mold 26 described later.
[0014]
As shown in FIG. 6, a mold clamping injection stage 28A for discharging resin to the clamped upper and lower molds is provided around the outer periphery of the rotary table 12 provided with four such lower molds 14. ((1) in the figure), a product recovery stage 28B (2 in the figure) for taking out the molded product from the mold, and an insert member supply stage 28C (FIG. 2) for loading the magnet material as an insert member into the lower mold 14 There are four stages, middle (3)) and a detection stage 28D ((4) in the figure) for detecting whether the insert member is raised from the lower mold 14 or loaded. The rotary table 12 is rotationally driven and controlled so that each of the mounted lower molds 14 is rotated at intervals of 90 degrees corresponding to these four stages and stopped. Accordingly, the lower molds 14 mounted on the four positions of the rotary table 12 are simultaneously positioned on the respective stages 28A to 28D, and circulate and move through the respective stages 28A to 28D by rotation. Work, material supply work, presence / absence detection of magnet material can be performed. By such a rotary system, the injection molding of the insert member can be performed efficiently.
[0015]
Incidentally, a pair of upper molds 26A and 26B are disposed on the mold clamping injection stage 28A corresponding to the lower mold 14 that has been moved to the injection stage 28A by the rotary table 12. The pair of upper molds 26A and 26B are supported so as to be able to reciprocate laterally so that the mold clamping position and the retracting position can be alternately moved, and are supported so as to be able to move up and down for mold clamping. That is, as shown in FIGS. 2 and 7 to 8, the frame 30 erected on the base 10 can be pushed up by a mold clamping pin 60 described later, and can be lowered by the elevating cylinder 32. An up-and-down movable plate 34 is provided, and a slider 36 that is reciprocally movable is attached to the upper side of the up-and-down movable plate 34 to the side. A pair of upper molds 26A, 26B are fixed to the front surface of the slider 36, and one upper mold 26A (26B) corresponds to the lower mold 14 that has moved to the injection stage 28A and the position where the mold can be clamped, The other upper mold 26B (26A) corresponds to the side mold clamping standby position. Thus, the upper molds 26A and 26B can be moved alternately between the mold clamping position and the retracted position by driving the slider 36. And the runner chuck | zipper means 38 (38A, 38B) which removes the runner produced by the last injection from an upper metal mold | die is provided in the stand-by position set on both sides of the mold clamping position.
[0016]
A specific configuration of the runner chuck means 38 is shown in FIGS. A support plate 40 that can be moved up and down by a lifting cylinder 39 is arranged in parallel with the transverse movement line of the upper mold 26 (26A, 26B), and is directed to the standby position of the upper mold 26 at both left and right ends of the support plate 40. Arm 42 (42A, 42B) is provided. A chuck 46 capable of holding a runner 44 protruding from the upper surface of the upper mold 26 that has reached the standby position is provided at the lower end of the tip of the arms 42A, 42B, and a sensor 48 for detecting the presence or absence of the runner 44. Is attached. Such runner chuck means 38A, 38B are arranged such that when one upper mold 26A (or 26B) enters the mold clamping operation with respect to the lower mold 14 located on the mold clamping injection stage 28A, The runner 44 of the mold 26B (or 26A) is gripped, and the runner 44 is removed from the upper mold 26 by using an operation in which the lower mold 14 is lowered for the mold release operation. In the embodiment, the support plate 40 is simultaneously lifted when the lower die 14 is lowered, and the runner 44 is forcibly pulled up. Below these runner chuck means, runner chutes 50 (50A, 50B) are arranged (see FIGS. 7 and 8), and the upper mold 26 with the runner 44 removed is moved to the injection position, and there are no obstacles below. Sometimes, the chuck 46 is opened, and the runner is discarded due to natural fall.
[0017]
Here, the mold clamping mechanism for performing the injection operation is configured as follows. As shown in FIG. 2 to FIG. 3 and FIG. 11, an AC servo motor 52 is arranged at the lower part of the base 10, and a pair of left and right ball screws 56 are wound around the motor 52 by a conductive belt 54. It protrudes upward. In the upper part of the base 10, an elevating base 58 is disposed on the lower surface side of the rotary table 12, and the elevating base 58 is screwed to the ball screw 56. Therefore, the lift base 58 can be moved up and down by the operation of the servo motor 52. A mold clamping pin 60 protrudes from an intermediate portion of the lifting base 58 sandwiched between the screwed portion with the ball screw 56, and the pin position is set so that this coincides with the injection center of the mold clamping injection stage 28A. . The mold clamping pin 60 pushes up the mold base 24 of the rotary table 12 described above, causes the lower mold 14 to be aligned with the upper mold 26 that is waiting at the mold clamping center position, and then further raised. Thus, the mold is clamped by coming into contact with the injection unit 62 disposed above the upper mold 26. Therefore, by operating the mold clamping pin 60 by the servo motor 52 of the lower drive source, as shown in FIG. 5, from the mold opening position ((1) in the same figure), the lower mold 14 and the upper mold 26 are used. After the mold matching operation, the mold clamping operation (1) of the mold clamping pin 60 is performed by pressing the molds 14 and 26 thus matched together against the injection unit 62 to obtain a clamping force. It is continuously performed by stroke operation.
[0018]
In order to clamp the mold, the injection unit 62 is attached to an injection unit fixing frame 64 that is overhanging directly above the mold clamping injection stage 28A (see FIGS. 2 and 3). In order to receive the clamping force. That is, the unit mounting base 66 is horizontally disposed on the fixed frame 64, and is suspended from the mounting base 66 so that the nozzle center of the injection unit 62 coincides with the mold clamping center. As a result, when the mold clamping pin 60 is pushed up to perform the mold clamping operation, the mold clamping pin 60 pushes up the lower mold 14 so as to be aligned with the upper mold 26A, and further rises to continue the injection unit 62. The mold is clamped by pressing against the nozzle, and the mold clamping force is received by the nozzle.
[0019]
As shown in FIG. 12, the working mode after the lower mold 14 reaches the mold clamping injection stage 28A is that the mold clamping pin 60 is in the lower position and one upper mold 26A is positioned at the mold clamping center. The other upper mold 26B is in a standby position on the right side in the figure (A in the figure). The standby position is located on the left and right of the mold clamping position, but the runner chuck means 38A removes the runner 44 removed from the upper mold 26A at the left standby position in the drawing. From this state, the mold clamping pin 60 is pushed up to enter a mold clamping operation (FIG. B). The mold clamping pin 60 pushes up the lower mold 14 to align with the upper mold 26 </ b> A, and further rises and presses against the nozzle of the injection unit 62 to perform mold clamping. At this time, the upper die 26A and the other upper die 26B adjacent to the upper die 26A are attached to a common slider 36, and the slider 36 enters the ascending mode by the vertical movable plate 34 by the operation of the elevating cylinder 32. Then, the runner 44 attached to the upper mold 26B at the standby position can be gripped by the runner chuck means 38B. Then, the runner chuck means 38B clamps the runner 44 remaining in the upper mold 26B on the right side by the previous injection (FIG. 3C). During this time, injection is performed, and the resin formed in the cavity formed between the lower mold 14 and the upper mold 26A is filled.
[0020]
After the injection operation and the runner 44 are clamped, the mold clamping pin 60 is lowered and the mold is opened (D in the figure). The upper mold 26A is lowered to the initial height position by this mold opening operation, and the runner 44 is removed from the nozzle by moving away from the injection nozzle. At this time, since the upper mold 26B in the standby position is also lowered simultaneously, the runner 44 held by the runner chuck means 38B is removed from the standby mold 26B. By this operation, the upper mold 26B in the standby position becomes ready for molding, and the runner 44 remains in the upper mold 26A subjected to injection molding, so that the pair of upper molds 26A and 26B is moved to the slider 36. As a result, the whole moves to the left (Fig. E), and the upper die 26 is replaced. Then, the runner chuck means 38 is lowered and the presence or absence of the runner 44 of the upper mold 26A moved to the standby position is detected by the sensor 48, and the chucking posture is entered (F in FIG. 5).
[0021]
Thereafter, the state is the same as that shown in FIG. 12A, the rotary table 12 is rotated 90 degrees, the next lower mold 14 is moved to the mold clamping injection stage 28A, and is gripped by the runner chuck means 38B. The runner 44 is released and discarded through the runner chute 50. Thereafter, the same mode is repeated with the lower mold 14 replaced and the upper mold 26B replaced. And by rotation of the turntable 12, in each stage 28A-28D, injection | emission, product taking-out, loading of the magnetic material which is an insert member, the presence or absence of a magnetic material, and a float detection are performed.
[0022]
FIG. 13 is a time chart of the above-described operation, and the operation mode of each element described above can be understood from the same drawing.
[0023]
Next, a product recovery unit 68 is installed in the product recovery stage 28B adjacent to the mold clamping injection stage 28A, and details thereof are shown in FIGS. The product collection unit 68 includes an air slide table 72 installed on a gantry 70. The slide direction of the air slide table 72 coincides with a straight line passing over the lower mold 14 positioned on the product recovery stage 28B, and a suction negative pressure is introduced to the lower surface of the slide arm 72A of the slide table 72. A product suction head 74 and an NG product suction head 76 are provided, and these suction / suction heads 74 and 76 are positioned immediately above the lower mold 14 of the product recovery stage 28B in accordance with a control command. In the embodiment, as shown in FIG. 14, the NG product suction head 76 is always disposed on the lower mold 14, and the product suction head 74 is positioned on the lower mold 14 when the slide arm 72 </ b> A is extended. It is set to be located at.
[0024]
Further, as shown in FIG. 15, an ejector push-up cylinder 78 is disposed at a lower position on the product collection stage 28 </ b> B with the rotary table 12 interposed therebetween. The cylinder 78 has a push-up pin 78A inserted into the mold base 24 when the lower mold 14 moved from the mold clamping injection stage 28A reaches the product recovery stage 28B and stops. The product 14 or the NG product in the lower die 14 is pushed up to bring the suction head 74 or the suction head 76 into proximity.
[0025]
The NG product suction head 76 is provided on the front end portion side of the slide arm 72A, and is disposed and set so as to be positioned immediately above the mold 14 at the retreat limit position. The product suction head 74 is located at the advance limit position of the slide arm 72A. The arrangement is set so as to be located immediately above the lower mold 14 described above. Therefore, when the lower mold 14 for which the NG signal is detected by the insert member detection stage 28D described later reaches the product recovery stage 28B, the slide arm 72A is held at the rear end limit position, and the suction head 76 is moved to the lower mold. 14 is on standby. A suction tube 80 is connected to the suction head 76, which is in communication with an NG product collection container 82 provided in the gantry 70, and the magnet material as the NG product is collected here. On the other hand, when the lower mold 14 holding the normally molded product in the cavity reaches the product collection stage 28B, the slide arm 72A is extended and the suction head 74 is positioned immediately above the lower mold 14. The lower mold 14 is lifted by the push-up pin 78A. As a result, the molded product is adsorbed on the surface of the adsorption head 74 to which the suction negative pressure is introduced. After this suction, the slide arm 72A moves backward, but a product recovery passage 84 is formed in the pedestal 70 directly below the suction head 74 at the retracted limit position, and the product is dropped by throwing in the suction negative pressure. . These series of operations are performed during the injection operation time in the mold clamping injection stage 28A described above.
[0026]
A single counting sensor 86 is installed in the product collection passage 84, and after counting the collected products, each molded product is distributed to a plurality of product collection containers provided corresponding to the plurality of lower molds 14, respectively. It has come to be collected. The distribution mechanism is shown in FIG. A receiving table in which product receiving ports 90 (90A, 90B, 90C, 90D) of molded products corresponding to the four lower molds 14 and idle shot receiving ports 92 (92A, 92B, 92C, 92D) are opened. 94 is disposed on the lower surface portion of the product recovery passageway 84. These receiving ports 90 and 92 individually correspond to the plurality of lower molds 14, and are driven and controlled so that the same receiving ports 90 and 92 correspond to the same lower mold 14. That is, the receiving table 94 is moved in a plane by the horizontal cylinder mechanism 96 and the lower vertical cylinder mechanism 98 for each incoming lower die 14 at the outlet portion of the product collection passage 84. The product receiving ports 90A, 90B, 90C, 90D arranged in a rectangular shape are moved in pitch vertically and horizontally, so that the product collection passage 84 is switched and communicated cyclically. Switching to the group of idle shot receiving ports 92 having the same arrangement configuration adjacent to the group of product receiving ports 90 is performed by the receiving port group switching cylinder mechanism 100 arranged at the lower part of the vertical cylinder mechanism 98. Done by actuation. After the receiving port group is switched from the product receiving side to the empty shot receiving port side, the receiving ports 92A, 92B, 92C, and 92D corresponding to the lower molds 14 are similarly moved by the plane moving mechanisms 96 and 98 to the product. Switch to the recovery passageway 84 for connection.
[0027]
A discharge tube 102 is attached to each of the product receiving port 90 and the blank shot receiving port 92, and the product is collected through the tube 102 by a collection stocker unit 104 installed at the lower part of the apparatus. The collection stocker unit 104 includes four product collection containers 106 (106A, 106B, 106C, 106D) arranged in a row and four spare product collection containers 108 (108A, 108B, 108C, 108D) arranged in a row. The movable base 110 is placed, and the movable base 110 is mounted in the casing frame 112. A traverse cylinder 113 is connected to the movable base 110, and when the amount collected by the product collection container 106 reaches a predetermined amount, it is automatically switched to the spare side by moving the base. In the top plate portion of the casing frame 112 in which the product collection containers 106 are arranged, the discharge tube 102 from the above-described distribution mechanism, in particular, the tubes 102A to 102D connected to the product receiving port 90 are connected and opened. The opening faces the openings of the product collection containers 106A, 106B, 106C, 106D. On the other hand, empty shot product storage boxes 114 (114a, 114b, 114c, 114d) are arranged on the upper surface of the casing frame 112. These are connected to the discharge tubes 102a to 102d connected to the blank shot receiving port 92. As a result, the blank shot product and the molded product discharged corresponding to each lower mold 14 are introduced into the common product collection passage 84 through the product suction head 74, and the number of shots is counted, and the passage exit side With this sorting mechanism, the shots and molded products are sorted and sorted for each individual lower die 14 and collected in a predetermined container.
[0028]
FIG. 18 shows a product recovery work mode in the product recovery stage 28B configured as described above. When the lower mold 14 on which the molded product is mounted by the rotary table 12 reaches the stage 28B, the slide arm 72A moves forward, and moves the product suction head 74 to a position directly above the lower mold 14 (A in the figure). Next, the ejector push-up cylinder 78 waiting in the downward direction is actuated to push up the push-up pin 78A, lift the molded product from the lower mold 14 and suck it onto the suction head 74 to which negative pressure is introduced (B in the figure). ). Then, when the ejector push-up cylinder 78 is lowered, the push-up pin 78A is separated from the product and enters a conveying state (FIG. C). In response to the lowering of the push-up pin 78A, the slide arm 72A moves backward, and the suction head 74 is positioned directly above the product recovery passageway 84 (D in the figure). Thereafter, the product is dropped by breaking the vacuum, and is counted by the counting sensor 86 when passing through the passage (FIG. E). This series of operations is performed every time the lower mold 14 reaches the product collection stage 28B. The time chart of these operations is as shown in FIG. 19, and is controlled by the sequencer of the control panel. When the NG product arrives, the slide arm 72 </ b> A causes the suction head 76 to stand by above the lower mold 14 and collects the NG product into the collection container 82 through the suction head 76 by operating the push-up cylinder 78.
[0029]
The insert member supply stage 28C adjacent to the product recovery stage 28B described above supplies magnetic material as an insert member for the next product into the cavity of the lower mold 14 emptied by product recovery. . In the insert member supply stage 28 </ b> C, the magnet material continuously supplied from the parts feeder is separated from the supply path by being released to the side, and then is attracted and conveyed to the lower mold 14. A magnet material supply unit 116 installed on the stage 28C is shown in FIG. A parts ball feeder 118 into which a large number of magnet materials are charged is provided, and a linear feeder 122 extending in the tangential direction from the outer peripheral edge of the drum is extended toward the rotary table 12. By rotating the parts ball feeder 118, the magnet materials are continuously supplied to the linear feeder 122 in an aligned state, and can be taken out one by one from the end of the passage. In this embodiment, the parts ball feeder 118 is not continuously rotated but intermittently rotated to prevent generation of wear powder.
[0030]
An escape mechanism 124 is provided at the tip of the linear feeder 122 to separate the magnetic material from the supply path to the side. The details are shown in FIG. The front end portion of the linear feeder 122 is connected to a horizontal slider mechanism 128 mounted on a pedestal 126. The horizontal slider mechanism 126 is equipped with an escape base 128A that can move laterally with a stroke S (see FIG. 21A), and the linear feeder 122 is opened in the escape base 128A. As shown in FIG. 21 (3), a receiving groove 132 that can receive only one magnet material 130 supplied in a row is formed on the part of the escape table 128A facing the linear feeder 122. After receiving the magnetic material 130, it is moved by the stroke S in the lateral direction and separated from the linear feeder 122 so that the magnetic material 130 is always supplied in a correct posture.
[0031]
The magnet material 130 waiting by being offset from the feed path by the distance S is transferred to the lower mold 14 by the magnet material picking device 134 shown in FIG. 22 and loaded into the cavity. . The picking device 134 includes a feeding head 136 for delivering the magnet material 130, and the feeding head 136 is moved up and down for reception from the feeding unit 116 and loading into the lower mold 14. It is supported by a mechanism 138 and is supported by a horizontal slide mechanism 140 that transfers between the material supply unit 116 and the lower mold 14 on the rotary table 12.
[0032]
As shown in detail in FIG. 23, the feeding head 136 has a receiving hole 142 for the magnet material 130 inside the head front end surface, and the magnet material 130 received in the receiving hole 142 is exposed to the outside. It is configured so that it can be delivered without being exposed. A core pin 146 having a tip facing the center of the tip opening of the head main body 144 is inserted, and a negative pressure introduction hole 148 is formed in the core pin 146 so that the magnet material 130 can be adsorbed to the pin tip surface. The attracting surface side of the core pin 146 is set to the same size as the magnet material 130. Further, the front end surface of the head main body 144 and the front end surface of the core pin 146 are set on the same plane. A sleeve 150 is mounted on the outer periphery of the core pin 146 so as to be slidable in the axial direction, and a tip portion of the sleeve 150 protrudes from between the core pin 146 and the opening of the head main body 144 and is pulled into the head main body 144. Can be done. The outer sleeve 150 is elastically biased by a spring 151 inserted in the head main body 144, and the front end of the sleeve 150 protrudes from the front end surface of the head main body 144 and the core pin 146. The above-described magnet material accommodation hole 142 is formed at the tip of the core pin 146 by the protrusion of the sleeve 150.
[0033]
The operation of the material supply head 136 is as follows. As shown in FIG. 23 (2) a, the magnetic material 130 is received from the escape table 128A by being sucked and introduced into the accommodation hole 142 with the tip of the sleeve 150 in the protruding state being close to the escape table 128A. Like to do. This may be set so that the lowering limit of the feed head 136 is restricted by a stopper (not shown) and the tip of the protruding sleeve 150 is not pushed by the escape base 128A. By doing so, it is based on the fact that it was confirmed that the magnet material 130 could be smoothly introduced into the accommodation hole 142.
[0034]
Next, when the material supply head 136 is raised, the magnet material is moved upward in a state where it is accommodated in the accommodation hole 142, and then it is laterally moved and conveyed to the upper position of the lower mold 14. This state is the state shown in FIG. Then, the feeding head 136 is moved downward and is loaded into the lower mold 14. In this loading operation state, the material supply head 136 is moved down as shown in FIG. 23 (2) c until the head main body 144 comes into contact with the lower mold 14. With the joining operation to the lower mold 14, the sleeve 150 is pushed into the head main body 144, and the magnet material 130 is loaded into the cavity in an accurate positioning state while maintaining the attracted state. As a result, the magnet material 130 to be attracted is attracted and loaded in a correct posture until the feeding operation is completed. In particular, when loaded into the cavity of the lower mold 14, the magnet material 130 is loaded in a state of floating from the cavity. Can be effectively prevented.
[0035]
FIG. 24 is a schematic diagram showing an operation process for loading the magnet material 130 into the lower mold 14. In a state where the lower die 14 has reached the insert member supply stage 28C, only one magnet material 130 is separated from the linear feeder 122 by the escape base 128A and is on standby (FIG. A). From this state, the feed head 136 descends toward the escape base 128A, and the tip of the sleeve 150 is brought into a substantially joined state, and is sucked into the accommodation hole 142 by negative pressure (FIG. B). This state is as shown in FIG. 23 (2) (a). When the feeding head 136 is raised from this state, the magnet material 130 is completely accommodated in the accommodation hole 142 (FIG. 24C). This state is as shown in FIGS. 23 (2) and 23 (b). Then, at the same time as the material supply head 136 is moved directly above the lower mold 14, the escape table 128A is moved to the receiving position of the next magnet material 130 (FIG. 24D). At this time, the next magnet material 130 is taken into the escape table 128A. Next, the feed head 136 descends and the sleeve 150 is pushed into the head as the sleeve 150 comes into contact with the lower mold 14, and the head main body 144 is finally lowered while the magnet material 130 is adsorbed. 14 (FIG. 23 (2) (c)). The delivery of the magnet material 130 is performed by stopping the negative pressure suction, whereby the magnet material 130 is loaded into the cavity (FIG. 24E), and then the feeding head 136 is raised (FIG. 24F). The time chart of such work is as shown in FIG.
[0036]
The lower die 14 loaded with the magnetic material 130 in the insert member supply stage 28C moves to the next insert member detection stage 28D. A detection unit 152 is installed on the stage 28D, and the sensor head 154 is lowered from the upper part of the magnet material 130 loaded in the lower mold cavity and brought into contact with the surface of the lower mold 14 to detect the sensor head 154. The pin 156 is brought into contact with the magnet material 130, and the presence or absence of the magnet member 130 and the floating detection are performed by the displacement of the detection pin 156 with respect to the mold surface.
[0037]
The overall configuration of the magnet material detection unit 152 is shown in FIG. As shown in the figure, the detection unit 152 has a lifting / lowering slide cylinder 160 attached to a gantry frame 158, and a horizontal mounting plate 162 extending to the upper part of the rotary table 12 is fixed to the upper end of the lifting / lowering slide cylinder 160. A sensor head 154 directed to the rotary table 12 is attached to the horizontal mounting plate 162, which is directed to the lower mold 14 stopped by the detection stage 28D. The sensor head 154 can be lowered by the operation of the elevating slide cylinder 160 until the front end surface comes into contact with the lower mold 14.
[0038]
A specific structure of the sensor head 154 is shown in FIG. As shown in the figure, a support sleeve 164 is fixed to the horizontal mounting plate 162. A sensor body 166 is slidably attached to the support sleeve 164. The sensor body 166 has a lower limit set with the upper end surface of the sleeve 164 as a stopper, and is elastically biased downward by a compression spring 168 mounted between the lower end surface of the sleeve 164. A cone head 170 is attached to the lower end of the sensor main body 166, and as shown in FIG. 27 (2), this end surface is in contact with the surface of the lower mold 14 outside the outer edge of the cavity of the lower mold 14. It is configured as follows. A detection pin 156 is inserted in the center of the sensor body 166 so as to be slidable with respect to the sensor body 166, and the tip of the pin protrudes from the cone head 170 and is urged by a predetermined force. The biasing force of the detection pin 156 is set smaller than the compression coil spring 168.
[0039]
Thus, when the sensor head 154 is lowered toward the lower mold 14, when the magnet material 130 is in the mold cavity, the detection pin 156 is pushed upward as shown in FIG. When the magnet material 130 is raised from the cavity, the detection pin 156 is further pushed in from the tip surface of the cone head 170, and the float of the magnet material 130 can be detected by the amount of pushing. In addition, when the magnet material 130 is not present in the cavity, as shown in FIG. 27 (2) b, no pressing force is generated in the detection pin 156, and therefore the detection pin 156 does not move. Thereby, the presence or absence of the magnet material 130 can be detected.
[0040]
FIG. 28 shows an operation mode by such a magnet material detection unit 152. While the lower mold 14 loaded with the magnetic material 130 is rotated by the rotary table 12 toward the insert member detection stage 28D, the sensor head 154 is waiting at a position above the rotary table 12 (FIG. 28A). ). When the lower mold 14 reaches the insert member detection stage 28D, the elevating slide cylinder 160 is actuated to lower the sensor head 154 and press the head end against the lower mold 14 (B in the same figure). The sensor head 154 senses the amount of expansion / contraction of the detection pin 156 using the surface of the lower mold 14 as a reference plane, and detects whether the magnet material 130 is lifted from the cavity or loaded with the magnet material 130. When in the correct loading state, the sensor head 154 is raised (FIG. 5C), and the lower mold 14 is transferred to the next mold clamping injection stage 28A as it is. When the floating of the magnet material 130 is detected or when the magnet material 130 is not loaded in the cavity, the NG mode is set, and this NG signal is sent to the product collection unit 68 in the product collection stage 28B described above. When the mold 14 reaches the product collection stage 28B, the NG product is separated into the NG product collection container 82 through the NG product suction head 76 as an NG product. That is, the NG product suction head 76 of the slide arm 72A of the product recovery unit 68 is put on standby above the lower mold 14 (a in the figure), and the ejector push-up cylinder 78 is operated to lift the NG product. The product collection container 82 is sucked and discharged (FIG. 5B). In the NG mode, the magnet material 130 can be reused by sending it directly to the product recovery stage 28B without injection into the lower mold. FIG. 29 shows an operation time chart of the magnet material detection unit 152, and FIG. 30 shows an operation time chart of the product recovery unit 68 in the NG mode.
[0041]
Thus, in this embodiment, the injection stage 28A, the product collection stage 28B, the insert member supply stage 28C, and the insert member detection stage 28D are arranged around the rotary table, and the rotary table 12 is positioned at the same time on each stage. While circulating the plurality of arranged lower molds 14, a pair of upper molds corresponding to the lower molds are prepared on the injection stage, and the upper molds are alternately switched and used for mold clamping and injection molding. In this injection molding time, control is performed by a control means such as a sequencer mounted on a control panel (not shown) so that product recovery, insert member supply, insert member detection work and runner removal work can be performed simultaneously. Since these operations are repeated every intermittent rotation of the turntable 14, the cycle time of injection molding can be greatly shortened. That.
[0042]
In the mold clamping injection stage 28A, when a pair of upper molds 26 are arranged with respect to the lower mold 14 that is sequentially moved by the rotary table 12, one of the molds is in a mold clamping operation for injection. Then, the runner 44 is removed from the other upper mold 26. Therefore, it is possible to perform clamping to the lower mold 14 that arrives one after another in a short cycle time. In the mold-clamping injection stage 28A, the runner 44 that needs to be taken out before entering the injection is removed by using the mold-clamping operation. Therefore, the rotary injection device can be operated in a shorter cycle. .
[0043]
Further, in the adjacent product collection stage 28B, when the molded product is individually distributed for each lower mold 14, the common product collection passage 84 is passed, and the number of products is counted by the counting sensor 86 in this passage. It is not necessary to attach a separate sensor for each lower mold 14. The product can be collected only by moving the slide table 72 back and forth, and the product is lifted to the suction position by the push-up cylinder 78, so that the operation can be efficiently performed and the installation space above the rotary table 12 can be reduced. Can greatly contribute to downsizing. When the floating of the magnetic material 130 is detected, the magnetic material 130 can be collected as an NG product at the stage 28B, so that the yield is improved. For product recovery, a plurality of product recovery containers 106 and spare product recovery containers 108 provided in the mold unit are provided, and the cup can be automatically replaced by operating the movable base 110 according to the product count. Is possible. Therefore, the work efficiency is improved. Further, since the initial discharged products generated by the blanking operation necessary for injection molding are separately collected, the disposal process is facilitated.
[0044]
Further, in the insert member supply stage 28C, the magnetic material 130 continuously supplied by the parts ball feeder 118 is separated one by one at the tip portion. This is because in the embodiment, the mold has a single piece configuration, so that many conventional materials are used. It is possible to feed the material with higher accuracy compared to the single piece. That is, when adsorbing a plurality of magnet materials at the same time, adsorption failure is likely to occur, and floating or adsorption separation in the cavity is likely to occur. However, in this embodiment, since each one is reliably adsorbed and loaded, accuracy is improved. It is extremely expensive. Further, since the magnetic material supply head 136 is formed by the external sleeve 150 into which the accommodation hole 142 can be pulled, the magnetic material 130 at the time of adsorption or loading is gripped in a correct posture and accurately loaded into the cavity. be able to. As a result, the floating occurrence rate of the magnet material 130 can be greatly reduced.
[0045]
In addition, in the insert member detection stage 28D, the detection reference surface is the surface of the lower mold 14 itself, and the detection pin 156 is brought into contact with the magnet material 130 loaded in the cavity to detect the presence / absence and floating. , Detection accuracy is greatly improved. Conventionally, since a method of detecting by a laser sensor attached to an apparatus frame has been generally used, the vertical height accuracy of the rotating lower mold 14 is not reliable. Since it is detected in 14 units, the incidence of defective products is reduced and the product accuracy is increased.
[0046]
In such an embodiment, therefore, the plurality of lower molds 14 provided on the periphery of the turntable 12 are simultaneously operated on the stages 28A to 28D arranged in the periphery while performing the operations necessary for molding. As a result, the product manufacturing cycle time can be substantially halved compared to the conventional rotary injection device. In particular, in the case of the embodiment, a manufacturing cycle for obtaining one product can be realized in one second while a single cavity is formed by upper and lower molds.
[0047]
【The invention's effect】
As described above, according to the present invention, the injection stage, the product recovery stage, the insert member supply stage, and the insert member detection stage are arranged around the rotary table, and are arranged on the rotary table so as to be simultaneously positioned on each stage. While the lower mold is circulated, a pair of upper molds corresponding to the lower mold are prepared on the injection stage, and the upper molds are alternately switched and used for mold clamping to perform injection molding. It is configured to repeat the product recovery, insert member supply, insert member detection work and runner removal work at the same time every intermittent rotation of the rotary table, greatly increasing the molding cycle time of insert molded products. An excellent effect of being able to be shortened is obtained.
[Brief description of the drawings]
FIG. 1 is an overall perspective view of an injection molding apparatus according to an embodiment.
FIG. 2 is a front view of the injection molding apparatus according to the embodiment.
FIG. 3 is a side view of the injection molding apparatus according to the embodiment.
FIG. 4 is a plan view and a side view of a rotary table portion.
FIG. 5 is a cross-sectional view showing a mold open state and a mold clamp state of a mold.
FIG. 6 is an explanatory schematic diagram of a stage around a rotary table.
FIG. 7 is a side view of the apparatus showing the lifting mechanism portion of the upper mold.
FIG. 8 is a front view of FIG. 7;
FIG. 9 is a plan view and a front view of a runner chuck means.
FIG. 10 is a side view of the runner chuck means.
FIG. 11 is a plan view of a drive portion of a mold clamping pin.
FIG. 12 is an explanatory diagram of a mold operation in an injection stage.
FIG. 13 is a time chart showing the operation of each element in the injection stage.
FIG. 14 is a plan view of a product recovery unit.
FIG. 15 is a side view of the product recovery unit.
FIG. 16 is a plan view and a side view of the product distribution means.
FIG. 17 is a plan view and a side view of a product collection container.
FIG. 18 is an explanatory diagram of a product collection operation.
FIG. 19 is an operation time chart of the product recovery unit.
FIG. 20 is a plan view and a side view of a magnet material supply unit.
FIG. 21 is a plan view, a side view, and an enlarged plan view of a magnet material separation mechanism.
FIG. 22 is a side view of the drive mechanism unit of the magnet material supply head.
FIG. 23 is an enlarged cross-sectional view of a magnetic material supply head and an explanatory view of a supply operation.
FIG. 24 is an explanatory diagram of the operation of the magnetic material supply head.
FIG. 25 is an operation time chart of the magnet material supply unit.
FIG. 26 is a plan view and a side sectional view of a magnet material detection unit.
FIG. 27 is a cross-sectional side view of the detection head and an explanatory view of the operating state.
FIG. 28 is an operation explanatory diagram of the magnet material detection unit.
FIG. 29 is an operation time chart of the magnet material detection unit.
FIG. 30 is a time chart of the magnetic material recovery operation in the product recovery unit.
[Explanation of symbols]
10 base
12 Rotary table
14 Lower mold for molding
16 motor
18 Roller gear cam unit
20 Slit cam photo sensor
22 Lifting guide
24 Mold base
26 Upper mold for molding
28A mold clamping injection stage
28B Product recovery stage
28C Insert member supply stage
28D detection stage
30 frames
32 Lifting cylinder
34 Vertical movable plate
36 slider
38A, 38B Runner chuck means
39 Lifting cylinder
40 Support plate
42 arms
44 Lanna
46 Chuck
48 Runner sensor
50 runner shoot
52 AC servo motor
54 Wrapping Conductive Belt
56 ball screw
58 Lifting base
60 type clamping pin
62 Injection unit
64 Injection unit fixed frame
66 Mounting base
68 Product recovery unit
70 frame
72 slide table
72A slide arm
74 Product suction head
76 NG product suction head
78 Ejector push-up cylinder
78A Push-up pin
80 suction tube
82 NG product collection container
84 Product collection passage
86 Counting sensor
90 Product receptacle
92 Empty shot receiving port
94 Reception table
96 Horizontal cylinder mechanism
98 Vertical cylinder mechanism
100 Receptor group switching cylinder mechanism
102 discharge tube
104 Collection stocker section
106 Product collection container
108 Spare product collection container
110 Movable base
112 Casing frame
113 Traverse cylinder
114 Empty shot storage box
116 Magnetic material supply unit
118 Parts Ball Feeder
122 linear feeder
124 Escape mechanism
126 pedestal
128 Horizontal slider mechanism
128A Escape stand
130 Magnet material
132 Magnet material receiving groove
134 Magnetic material picking device
136 Feeding head
138 Elevating slide mechanism
140 Horizontal slide mechanism
142 Magnet material receiving hole
144 Head body
146 Core Pin
148 Negative pressure introduction hole
150 External sleeve
151 Spring
152 Magnet Material Detection Unit
154 Sensor head
156 Detection pin
158 Mounting frame
160 Elevating slide cylinder
162 Horizontal mounting plate
164 Support sleeve
166 Sensor body
168 Compression spring
170 cone head

Claims (13)

An injection stage, a product collection stage, an insert member supply stage, and an insert member detection stage are arranged around the rotary table, and the lower mold placed on the rotary table is circulated and moved while being simultaneously positioned on each stage. A pair of upper molds corresponding to the lower mold is prepared on the stage, and the upper molds are alternately switched and used for mold clamping to perform injection molding, and in this injection molding time, product recovery, supply of insert members, insert members The injection molding method is characterized in that the detection operation and the runner removal operation are performed simultaneously, and this series of operations is repeated every intermittent rotation of the rotary table. The injection molding method according to claim 1, wherein the molding operation by the upper and lower molds is performed as a single piece. In the injection stage, the pair of upper molds are lifted and lowered at the same time, and the runner of the previous injection residue is chucked and removed by the chuck means waiting in a fixed position by using the vertical movement of the standby upper mold. The injection molding method according to claim 1. In the product collection stage, the collected products are counted by a sensor placed in a common product collection passage, and then sorted and collected in a plurality of collection containers provided corresponding to the respective lower molds. Item 2. The injection molding method according to Item 1. 2. The injection molding method according to claim 1, wherein in the product recovery stage, the defective insert member is recovered based on a member loading failure signal in the insert member detection stage. 2. The injection according to claim 1, wherein the insert member supply stage sucks and conveys the insert member continuously supplied from the parts feeder to the lower mold after allowing the insert member to escape from the supply path to the side and being separated. Molding method. In the insert member supply stage, the insert member is accommodated in the contact surface of the feed head that moves to a position where it is joined to the lower mold, and the sleeve around the accommodating portion is retracted and moved when the mold comes into contact. The injection molding method according to claim 1, wherein an insert member is loaded into the mold. In the insert member detection stage, the sensor head is lowered from the upper part of the insert member loaded in the lower mold cavity at the insert member supply stage and brought into contact with the mold surface, and the detection pin provided on the sensor head is used as the insert member. 2. The injection molding method according to claim 1, wherein the insert member is detected by the displacement of the detection pin with respect to the mold surface as a reference. A rotary table with a plurality of lower molds provided at the periphery and capable of intermittent rotation, and a mold clamping injection unit, a product recovery unit, an insert member supply unit, and an insert member detection unit are arranged around the rotary table The lower mold provided on the peripheral edge of the rotary table is mounted so as to be simultaneously positioned at each unit position, and the respective molds are arranged to circulate through the respective unit positions, and the mold clamping injection unit is injected. An upper mold switching means is provided that enables a mold to be clamped by alternately switching the upper mold with respect to a lower mold that circulates and moves a pair of upper molds at a position and a standby position on the side thereof. Product recovery and insert part by the product recovery unit, insert member supply unit, and insert member detection unit in the injection molding time by tightening injection unit Supply, an injection molding apparatus characterized in that a control means for concurrently work and runner removal operation of presence or absence floating detection of the insert member. The product recovery unit is disposed on the outlet side of the product recovery passage, the product pickup means, the recovery passage of the product taken out by the product pickup means, the sensor for counting the recovered product in the product recovery passage, The injection molding apparatus according to claim 9, wherein the injection molding apparatus is configured to include a plurality of collection containers provided corresponding to the molds and a distribution unit thereof. The insert member supply unit separates the insert member continuously supplied from the parts feeder by separating the insert member laterally from the supply path, and sucks and conveys the separated insert member to the lower mold on the rotary table. The injection molding apparatus according to claim 9, further comprising a feeding head to be moved. The feed head has a suction surface of an insert member and a sleeve surrounding the periphery thereof, forms a storage portion, and is configured to be retractable by joining the sleeve front end surface to a lower mold. The injection molding apparatus according to claim 11, wherein the lower mold cavity is exposed and can be loaded into the lower mold cavity. The insert member detection unit has a sensor head that can move up and down toward the lower mold cavity and can stop by contacting the mold surface, and the sensor head can contact the inserted insert member. The injection molding apparatus according to claim 9, further comprising: a detection pin configured to detect the presence or absence of an insert member and a float by displacement of the detection pin relative to a mold surface.

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