JP3662366B2 - Production line automatic operation system - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an automatic startup and / or lowering operation system for a production line using an extrusion molding machine. In particular, the present invention relates to an automatic start-up operation system capable of automatically starting and / or lowering from a stop state to a molding operation state in a production line using an extruder having a raw material supply device.
[0002]
[Prior art]
Currently, in a production line that is generally used, for example, a production line having an extruder, the start-up operation method from a stop state to a molding operation state is performed by a skilled operator, and the operator is always in an operation state. There was a need to monitor. That is, the operator started up gradually until the molding conditions were satisfied while monitoring the load state and pressure. Therefore, the start-up procedure, start-up conditions, start-up time, etc. greatly depend on the skill level of the operator.
[0003]
For example, in order to start up the extruder, each operation such as driving of each motor such as a screw motor or feeder motor, starting of a lubricating oil pump or a temperature controller, opening of a valve of a hopper, charging of a raw material, etc. is performed in a predetermined manner. Must be executed in order and timing. The startup operation by the extruder has various different startup procedures and conditions depending on the performance of the extruder, the size and material of the material, and the like.
[0004]
The same applies to the fall operation.
[0005]
[Problems to be solved by the invention]
As described above, at the time of start-up operation of the extruder, for example, conditions such as drive current, torque, time, etc. of each motor such as a screw motor and a feeder motor, start of a lubricating oil pump, a temperature controller, etc., a hopper, etc. It is very difficult to determine the start-up conditions and start-up procedures for the valve opening, raw material charging sequence and timing.
[0006]
Conventionally, it has been necessary for an operator to be sufficiently skilled in order to complete such an operation accurately, quickly and without trouble. In the start-up operation of the extruder, the start-up procedure and time differ depending on the skill level of the operator, etc. Also, for the beginner operator, the start-up operation of the extruder is complicated, time-consuming and difficult. It was a thing.
[0007]
Further, even when a skilled operator performs a start-up operation, the operation must be monitored for a long time around the extruder.
[0008]
Furthermore, there were similar problems with the operation for falling.
[0009]
In view of the above points, the present invention automatically starts and / or reverses an extruder from a stopped state to a raw material supply and production state by a predetermined procedure in a production line using an extruder having a raw material supply device. It is intended to provide an automatic driving system that can be lowered to
[0010]
In addition, the present invention simplifies the start-up and / or the fall operation by reproducing the same start-up and / or fall-down operation even if not a skilled worker when automatically starting the production line. The purpose is to save labor in startup and / or shutdown operation by shortening the startup and / or shutdown operation time.
[0011]
[Means for Solving the Problems]
An automatic operation system for a production line according to the present invention relates to a production line having an extruder, and is an automatic operation system for a production line for automatically starting and / or reversely lowering the extruder from a stopped state to a production state. A monitoring unit for monitoring the operation of the startup and / or the shutdown operation and measuring desired measurement data when the startup and / or the shutdown operation is executed by an operator; and A first storage means for storing automatic start-up and / or fall-down data based on the detected measurement data as playback data, and automatic start-up and / or turn-down operation processing according to a preset operation pattern Second storage means for storing automatic start-up and / or turn-off data for performing as chart setting data, and automatic start-up and / or turn-off operation A selection means for selecting whether to execute the chart setting method or the playback method; and when the chart setting method is selected by the selection means, the chart setting data is loaded from the second storage means. On the other hand, when the playback method is selected, the playback data is loaded from the first storage means, and automatic startup and / or startup is performed based on the loaded chart setting data or playback data. And a control means for executing the lowering process.
[0012]
The chart setting data or the playback data may include a screw motor current value and a resin pressure value. A plurality of playback data or a plurality of chart setting data may be stored in the first storage unit or the second storage unit. The control means further comprises second selection means for selecting desired chart setting data or desired playback data from the plurality of chart setting data or the plurality of playback data. You may perform automatic starting and / or falling operation based on the chart setting data or playback data selected by the selection means.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail. Here, the startup operation will be described, but the startup operation can be similarly performed.
[0014]
In FIG. 1, the schematic block diagram of the production line using the extrusion molding machine concerning one Embodiment by this invention is shown.
[0015]
The production line includes an extruder 10, a pelletizer unit 20, a control unit 30 that controls these, and the like.
[0016]
Examples of the extruder 10 include a single-screw extruder, a twin-screw or multi-screw extruder, and a special extruder, which can be appropriately applied to a desired extruder. In the extruder 10, as a structure for supplying raw materials, for example, a hopper 101, a feeder motor 102, a raw material feeder 110, and the like are provided. Moreover, as a structure for extruding a plastic etc., the barrel part 105, the screw 104, the screw motor 103, the head part 109, etc. are provided, for example. Moreover, a measuring instrument for detecting various data necessary for performing control and the like is provided. For example, the screw motor 103 includes a screw motor ammeter 112 and a screw motor speed meter 113, and the feeder motor 102 includes various measuring instruments such as a feeder motor ammeter 114 and a feeder motor speed meter 115. .
[0017]
The head unit 109 has a structure that can be automatically opened and closed by air or hydraulic pressure in order to automate the opening and closing of the head clamp. Further, the head portion 109 is provided with a resin pressure gauge 111.
[0018]
For the heating / cooling function, a heater 107 such as a barrel unit 105 and a head unit 109, a barrel cooling pump 108, and the like are provided. In addition, a lubricating oil pump 106, a vent vacuum device for vacuum exhaust, a gear box, and the like are provided.
[0019]
The pelletizer unit 20 includes a cooling water tank 121, a pelletizer 120, and the like. A cooling water tank 121 is provided at the rear stage of the head portion, and cools the extruded molten material. Further, a pelletizer 120 and a cutter motor 122 are provided at the subsequent stage of the cooling water tank 121 in order to manufacture pellets. Also, a pressure-feed turbo blower 123, a suction pressure-feed blower 124, and the like are provided for conveyance.
[0020]
Further, the control unit 30 is provided with a control panel 130 for performing various controls, and the overall control of the production line can collectively control the temperature, drive, sequence, and the like by using a process controller.
[0021]
Next, the operation | movement outline | summary of the extrusion machine used for such a production line is demonstrated. In FIG. 2, the schematic for demonstrating operation | movement of an extruder is shown.
The general sequence of startup operations in the extruder is as follows (1) to (5). That is,
(1) A plastic raw material is supplied from the hopper 101.
(2) The temperature rise is completed by heating the barrel portion 105 and the head portion 109 with the heater 107.
(3) Start the barrel cooling pump 108 and the lubricating oil pump 106.
(4) The screw motor 103 is started.
(5) Start the feeder motor 102.
(6) When the resin is discharged from the head unit 109, the cutter motor 122 is activated and the pelletizer 120 is operated.
(7) After the resin is cut by the pelletizer 120, it is conveyed to the next line.
[0022]
The production line operates as described below through the sequence of startup operations. First, in the extruder 10, the supplied raw material is sent from the feeder motor 102 to the barrel unit 105. In the barrel portion 105, the screw 104 is driven by the screw motor 103 to transport the raw material forward, and the raw material is gradually heated and melted by the heater 107 or the like. Next, the melted resin is extruded through the head portion 109. The pressure of the extruded resin is measured by a resin pressure gauge 111.
[0023]
Next, in the pelletizer unit 20, the extruded resin is cooled through the cooling water tank 121 and input to the pelletizer 120. The pelletizer 120 is pelletized to a predetermined size and is conveyed by a conveyance line.
[0024]
Then, it is sent to the production line as appropriate and commercialized.
[0025]
In FIG. 3, the block diagram regarding the control part 30 of the automatic starting operation system which concerns on this invention is shown.
[0026]
The control unit 30 according to the present invention includes a control panel 130, a process controller 131, a storage device 132, and an external storage drive device 134.
[0027]
The process controller 131 is connected to the extruder 10 (for example, a twin screw extruder) and the pelletizer unit 20. The process controller 131 performs various controls such as automatic start-up operation processing, temperature control, drive control, sequence control, and data input / output.
[0028]
Regarding control of the extruder 10, for example, desired automatic startup data stored in the control storage device 132 is selected by the control panel 130 or the like. Next, the process controller 131 loads the selected automatic startup data from the storage device 132, and executes control of the extruder by the automatic startup program based on the loaded automatic startup data.
[0029]
On the other hand, regarding the start-up data input of the extruder 10, the start-up data when an operator such as a skilled worker actually drives and controls the extruder 10 is stored in the history storage unit 132 b in the storage unit 132. As this data, a time-series screw motor current value, feeder motor current value, resin pressure, and the like can be appropriately provided as necessary. These various data are detected by various measuring instruments such as a screw motor ammeter 112 and a resin pressure gauge 111 provided in the extruder 10 or the pelletizer unit 20.
[0030]
The storage device 132 is connected to the external storage drive device 134. The external storage drive unit 134 reads automatic startup data stored in an external storage medium such as a floppy disk or MO, or vice versa, and stores predetermined data in the external storage medium.
[0031]
The storage unit 132 includes a setting storage unit 132a and a history storage unit 132b. The setting storage unit 132a stores automatic startup data (chart setting data) set in advance for general purposes. On the other hand, the history storage unit 132b stores startup data (playback data) when a startup operation is performed by a skilled worker or the like. As such automatic start-up data, a desired plurality of files (for example, 10 files) can be stored.
[0032]
Next, the operation of the automatic start-up operation system according to the present invention will be described. FIG. 4 shows a flowchart of the automatic startup operation according to the present invention.
[0033]
In the automatic startup operation of the production system, first, a startup button provided on the control panel 130 or the like is pressed (S401), and the process controller 131 starts an automatic startup program. Next, the control panel 130 or the like is selected by which method the automatic startup operation is performed (S403).
[0034]
If “A. Chart setting method” is selected, the process proceeds to step S405. When there are a plurality of preset automatic startup files, a desired file is selected (S405). Such a selection operation can be selected at the same time when the drive method is selected in step S403. The “A. chart setting method” is for determining operation patterns in advance and performing operation control. As an operation pattern, for example, there is one that is set to a maximum of 6 steps and controlled so as to gradually increase the current value of each motor. Next, the process controller 131 loads desired automatic startup data (chart setting data) stored in the setting storage unit 132a (S407).
[0035]
On the other hand, if “B. Playback method” is selected in step S403, the process proceeds to step S409. The “B. playback method” is to reproduce the operation pattern of the start-up operation of a skilled worker and control the extruder 10 and the pelletizer unit 20 by the automatic start-up operation. In the history storage unit 132b, data such as each measuring instrument related to the startup operation pattern by a skilled worker is stored in advance as playback data. Here, when there are a plurality of preset automatic startup files, a desired file is selected (S409). Next, the process controller 131 loads desired startup data (playback data) stored in the history storage unit 132b (S411).
[0036]
Next, the process controller 131 executes an automatic startup program based on the loaded automatic startup data, and automatically starts up the extruder 10 and the pelletizer 20 (S413).
[0037]
The operation of the automatic startup program by the process controller 131 will be described below.
[0038]
FIG. 5 shows a schematic diagram of an operation chart of a production line in a general normal mode.
[0039]
First, in the setup chart in the preparation stage, when the power is turned on, program operation data is set. Next, when the temperature start is operated, the temperature raising step is executed automatically and / or manually. When the temperature reaches a certain temperature (temperature increase is completed), the auxiliary motor A is operated, and the barrel cooling pump 108 and the lubricating oil pump 106 are operated.
[0040]
The start chart for the next stage is a chart for starting up the variable speed motor in a maximum of 6 steps in order to automatically start up the variable speed motor. Here, when a drive start operation is performed, for example, an auxiliary motor B such as a vent stuffer (not shown) provided in the barrel unit 105 is operated, and the screw motor 103, the feeder motor 102, and the pelletizer 120 are cut as described above. Each motor such as the motor 122 is sequentially driven.
[0041]
Next, in the main chart, the plastic raw material is pelletized through the above-described processes such as temperature control and process control. Further, an operation chart for smoothly changing the setting of the variable speed motor at the time of changing the conditions is included in the main chart.
[0042]
The stop chart at the next stage is a chart for lowering in a maximum of 6 steps in order to automatically stop the variable speed motor. When the drive stop is operated, the motors are sequentially stopped, and the auxiliary motor B is also stopped.
[0043]
Finally, in the end chart, when the temperature stop operation is performed, the production line is stopped after the auxiliary motor A is stopped.
[0044]
Next, the automatic startup operation operation in the fully automatic mode in such a production line will be described.
FIG. 6 shows a detailed operation chart of the fully automatic auto mode operation. In addition, the order (1) to (7) of the startup operation in the upper stage in the figure corresponds to the order (1) to (7) of the startup operation shown in FIG.
[0045]
Here, the chart of FIG. 6A shows the overall temperature of the extruder, and the chart of FIG. 6B shows the drive (current value, rotational speed, etc.) of the screw motor 103. FIGS. 6C to 6F show the auto mode state, the drive control state of the screw motor 103, the temperature control state, and the start-up button state, respectively.
[0046]
Start-up operation in fully automatic auto mode is as follows.
(1) First, the mode changeover switch is set to the “fully automatic mode” (see FIG. 6C).
(2) Next, the startup button is set to “ON” (see FIG. 6F). Then, the lamp of the start-up button blinks and the barrel temperature starts to be raised.
(3) When the barrel temperature reaches a predetermined value, the temperature rise is completed (see FIGS. 6A and 6E).
(4) When the temperature rise is completed, the screw temperature adjustment pump and the lubricating oil pump are started. Further, the entire temperature is set to a constant temperature during a certain period T1 after completion of the temperature increase (see FIGS. 6A and 6E).
(5) The drive is started after a predetermined time T1, and at this time, the single-axis feeder is activated (see FIG. 6 (d)). That is, in the start chart, the screw motor rotation speed is increased by, for example, six steps and reaches a desired value. In addition, a change chart can also be implemented after a start chart (refer FIG.6 (b)). Drive control of the screw motor 103, the feeder motor 102, etc. is executed based on the automatic startup data.
(6) Further, in the production chart, the production is performed while maintaining the desired value (see FIG. 6B). In the production chart, for example, the lamp of the start-up button can be identified from the start chart to the production chart by switching from the blinking state to the lighting state.
[0047]
In addition, hydraulic pumps, such as lubricating oil, can also be driven by manual operation etc.
[0048]
The automatic startup operation using the automatic startup data used in “A. Chart setting method” and “B. Playback method” will be described below.
(1) A. Chart setting method
The automatic startup operation of the extruder is started by a start-up button. When the start-up button is pressed, the screw motor 103 and the feeder motor 102 are controlled in a preset manner.
[0049]
Chart setting data stored in the setting storage unit 132a of the storage device 132 is used for the starting procedure, conditions, time, and the like.
[0050]
At this time, generally, in the normal mode, the operation conditions differ depending on whether the inside of the barrel is empty or the raw material is mixed. The fluidity of the raw material varies depending on the state of the raw material. Therefore, when the operator operates, for example, it is necessary to monitor the current of the screw motor 103, the current of the feeder motor 102, the resin pressure gauge 111, and the like. However, in the fully automatic auto mode, it is possible to automatically make the same judgment as the operator by monitoring the change in these states with the controller.
[0051]
The process controller 131 executes an automatic startup program based on the chart setting data.
(2) B. About playback method
Here, a description will be given below with particular attention paid to the screw motor 103 which is a variable speed motor for driving the extruder and the feeder motor 102 which is a variable speed motor of the raw material supply apparatus.
[0052]
FIG. 7 shows a typical operation chart when a skilled operator starts up to a production chart.
[0053]
First, in the present invention, the procedure and the like when a skilled operator performs start-up operation are edited and stored. At this time, for example, drive data of the screw motor 103, the feeder motor 102, and the like are stored in the history storage unit 132b of the storage device 132 by the process controller 131 as time-sequential automatic startup data (playback data). Here, as an example, the automatic startup data includes the current values of the screw motor 103 and the feeder motor 102 and the resin pressure value 111 as an example. Each of these data is data detected by a predetermined measuring instrument.
[0054]
In FIG. 7, the solid line indicates the drive chart of the screw motor 103, and the wavy line indicates the drive chart of the feeder motor 102. For example, in the first step, the number of rotations of the screw motor 103 increases during the first one minute, and a constant value is maintained between one and two minutes thereafter. While the screw motor 103 is at a constant value, the rotational speed of the feeder motor 102 is gradually increased. Next, in the second step, the number of rotations of the screw motor 103 is increased between 2 minutes and 3 minutes in the first half, while the number of rotations of the feeder motor 102 is kept constant. In the latter half of 3 to 4 minutes, the rotational speed of the screw motor 103 becomes a constant value, and the feeder motor 102 increases the rotational speed. Similarly, the rotational speeds of the screw motor 103 and the feeder motor 102 are increased stepwise until the fifth step.
[0055]
Such a start-up operation chart is stored in the history storage unit 132b as playback data.
[0056]
FIG. 8 shows an operation chart in the case where the process controller performs the automatic startup operation by the playback method based on the automatic startup data edited and stored as described above.
[0057]
In this case, as an example, the playback data stored in the history storage unit 132b is provided with a fixed state of five stages as shown in the startup operation chart shown in FIG. It is assumed that the driving chart is realized. The process controller 131 loads this playback data and executes an automatic startup program based on this data.
[0058]
That is, during the first step of 3 minutes to 5 minutes, the number of rotations of the screw motor 103 is increased between 3 minutes and 4 minutes. Then, between 4 and 5 minutes, the number of rotations of the screw motor 103 is kept constant, while the number of rotations of the feeder motor 102 is increased. Next, between 5 minutes and 7 minutes, which is the second step, between 5 minutes and 6 minutes, the rotation speed of the feeder motor 102 is kept constant, while the rotation speed of the screw motor 103 is increased. Then, between 6 minutes and 7 minutes, the screw motor 103 rotational speed is kept constant, while the feeder motor 102 rotational speed is increased. Similarly, in the third step to the fifth step, the rotation charts of the screw motor 103 and the feeder motor 102 are alternately provided with a period in which the rotation speed is maintained in a constant state and a period in which the number of rotations tends to increase. To migrate. In this way, both motors are finally driven at a predetermined current value (or rotational speed and torque).
[0059]
In this way, the start-up operation by a skilled operator is reproduced.
[0060]
Next, FIG. 9 shows a flowchart of the motor drive control function according to the present invention.
[0061]
First, when the execution of the program is started in the start chart, in the first step, the screw motor 103 and the feeder motor 102 are activated (S901, S903). Then, the rotational speed of the screw motor 103 is gradually increased based on preset automatic startup data or the like. Here, the step value n is set to “2”.
[0062]
Next, in the second step, the rotational speed of the feeder motor 102 is gradually increased (S907). In this state, when the load of the screw motor 103 exceeds a specified current value (for example, 50% of the rated current value) by the screw motor ammeter 112 (S909), the rotation speed of the feeder motor 102 is temporarily set to the specified rotation speed. (S911). Then, this state is maintained for a predetermined time T2 seconds until the load decreases and the current value of the screw motor 103 decreases and stabilizes (S911). After T2 seconds, if the load of the screw motor 103 is lower than the specified current value, the process proceeds to the next step.
[0063]
Further, during the acceleration of the screw motor 103 (S907), when the resin pressure suddenly increases and reaches the specified pressure (S913), the time T3 until the acceleration of the screw motor 103 is interrupted and the resin pressure is stabilized. The rotation speed of the screw motor 103 is held for a second (S915). If the pressure falls below the specified pressure after T3 seconds, the screw motor 103 is increased again.
[0064]
In this manner, the operation of the second step is repeated so as to maintain the operation of the second step for a certain period of time by a timer or the like in the state of the predetermined screw motor current and resin pressure (S917).
[0065]
After a certain time, the number of steps is increased (S919), and the process proceeds to the next third step. Similarly to the second step state, the third step state is controlled by the screw motor current, the resin pressure, and the like, and the preset state is maintained for a certain period of time.
[0066]
Similarly, when automatic control is performed until a predetermined number of steps, for example, the fifth step state is reached (S921), the automatic startup operation is terminated.
[0067]
As described above, in the embodiment of the present invention, the start-up operation system for the production line using the extruder has been described. Similarly, the motor operation control function can be provided for the stand-down operation system. That is, when the screw motor rotational speed is decreased stepwise, the process controller performs an automatic falling operation by the playback method based on the screw motor current value and the resin pressure value.
[0068]
The extruder can be applied to an oblique axis extruder, a single axis or a twin axis extruder, and the like. Further, the present invention is not limited to extrusion molding machines, and can be applied to all molding machines such as injection molding machines, blow molding machines, and compression molding machines. Furthermore, it can be applied not only to molding machines but also to general production lines.
[0069]
In the embodiment of the present invention, only the screw motor current value and the resin pressure value are used. However, the present invention is not limited to this, and the rotation speed or torque of each motor such as a feeder motor current value, screw motor, feeder motor, etc. Desired data can be used as automatic startup data. By using such various data, it is possible to precisely reproduce the startup operation pattern of a skilled worker or the like.
[0070]
【The invention's effect】
As described above, the start-up and / or down operation in a production line using an extruder having a raw material supply device has conventionally been different in start-up procedure and time depending on the operator, and is troublesome for beginners. Although it was difficult, according to the present invention, the extruder can be automatically started up from a stopped state to a raw material supply and production state according to a predetermined procedure.
[0071]
In addition, according to the present invention, when the production line is automatically started up and / or lowered, it is possible to start up and / or bring down by reproducing the same start up and / or down operation without being a skilled worker. The operation can be simplified, and the startup and / or the shutdown operation time can be shortened to save the startup and / or the shutdown operation.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram of a production line using an extruder according to an embodiment of the present invention.
FIG. 2 is a schematic diagram for explaining the operation of the extruder.
FIG. 3 is a configuration diagram relating to a control unit 30 of the automatic start-up operation system according to the present invention.
FIG. 4 is a flowchart of automatic startup operation according to the present invention.
FIG. 5 is a schematic diagram of an operation chart of a production line in a general normal mode.
FIG. 6 is a detailed operation chart of full automatic mode operation.
FIG. 7 is a typical operation chart when a skilled operator starts up to a production chart.
FIG. 8 is an operation chart when the process controller performs an automatic startup operation by a playback method.
FIG. 9 is a flowchart for a motor drive control function according to the present invention.
[Explanation of symbols]
10 Extruder
20 Pelletizer
30 Control unit
102 Feeder motor
103 screw motor
105 Barrel
109 Head
111 Resin pressure gauge
112 Screw motor ammeter
114 Feeder motor ammeter
120 pelletizer
130 Control Panel
131 Process controller
132 Storage device
132a Setting storage unit
132b History storage unit

Claims (4)

A production line having an extruder, an automatic operation system for a production line for automatically raising and / or lowering the extruder from a stopped state to a production state,
Monitoring means for monitoring the operation of the start-up and / or the fall operation and measuring desired measurement data when the start-up and / or the fall operation are executed by an operator;
First storage means for storing automatic rise and / or fall data based on the measurement data detected by the monitoring means as playback data;
A second storage means for storing automatic startup and / or falling data for executing automatic startup and / or falling operation processing in accordance with a preset operation pattern as chart setting data;
A selection means for selecting whether the automatic start-up and / or the fall-down operation is executed by the chart setting method or the playback method;
When the chart setting method is selected by the selection unit, the chart setting data is loaded from the second storage unit. On the other hand, when the playback method is selected, the play setting is selected from the first storage unit. Control means for loading back data and executing automatic startup and / or lowering processing based on the loaded chart setting data or the playback data;
A production line automatic operation system characterized by comprising:   The automatic operation system for a production line according to claim 1, wherein the chart setting data or the playback data includes a screw motor current value and a resin pressure value.   The automatic operation system for a production line according to claim 1 or 2, wherein a plurality of playback data or a plurality of chart setting data are stored in the first storage means or the second storage means. . A second selection means for selecting desired chart setting data or desired playback data from the plurality of chart setting data or the plurality of playback data;
The control means performs automatic start-up and / or fall-down operation based on the chart setting data or playback data selected by the second selection means;
The production line automatic operation system according to claim 3.

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