JP5138926B2 - Injection molding machine - Google Patents

Description

  The present invention relates to a molding machine such as an injection molding machine or a die casting machine, and in particular, includes a display device capable of displaying images of various display modes under the control of a controller that controls the entire machine (molding machine). It relates to a molding machine.

  Recent molding machines such as injection molding machines have a display device such as a color liquid crystal display, and various operation condition setting mode images for setting or confirming the operation conditions for automatic operation by this display device. Various measurement data display mode images for displaying the actual measurement data of many measurement items during automatic operation, periodic inspection mode images for automatically displaying the inspection items at the periodic inspection period and urging regular inspections, occurrence of abnormalities Sometimes an alarm mode image for recognizing this is displayed.

  Among the above-described actual measurement data display mode images, there is a one-cycle actual measurement graph image that graphically displays the actual measurement data of one molding cycle (molding operation cycle). By using this one-cycle actual measurement graph image, one molding is performed. The operation of each part of the machine during the cycle is visible on one screen.

  In addition, if any abnormality occurs during the operation of the machine, the operation of the machine is automatically stopped, the alarm mode image is displayed with priority, and the machine operator is notified that the abnormality has occurred. . When an abnormality occurs in the machine, the measured data up to the time of occurrence of the abnormality is displayed in a graph in the one-cycle actual measurement graph image.

  As described above, conventionally, when an abnormality occurs in the machine, the actual measurement data up to the time of occurrence of the abnormality is displayed in a graph in the one-cycle actual measurement graph image. It was pointed out that even if the graph image is displayed, the operating status of the machine after the occurrence of the abnormality cannot be confirmed, which is inconvenient for analyzing the cause of the abnormality. In addition, it was pointed out that when an abnormality occurred, it was not possible to confirm that the machine had automatically stopped automatically in response to the abnormality.

  The present invention has been made in view of the above points, and an object of the present invention is to be able to display a measured data graph image that is significant for analyzing an abnormality occurrence factor when an abnormality occurs.

In order to achieve the above-described object, the present invention includes a controller that drives and controls each part of the machine based on each set operating condition value and measurement information from each sensor, and the controller includes a predetermined molding operation. In a molding machine that executes a series of molding operation steps according to a program, captures and stores measured data of each operating condition during operation , and displays images of various display modes on a display device based on instructions from the operator, In the actual measurement data graph image display mode in which the actual measurement data is displayed in a graph on the display device, the controller completely stops the molding machine from the occurrence of abnormality when the molding machine operation is abnormal and the molding machine is automatically stopped. The actual measurement data until this is displayed in a graph on the display device .

  In the present invention, in the actual data graph image display mode in which the actual measurement data of the molding operation cycle is displayed in a graph, when an abnormality occurs in the operation of the molding machine, the actual measurement data after the occurrence of the abnormality is also displayed in a graph. Therefore, it becomes easy to analyze the cause of the abnormality that the machine has stopped from the actual measurement data after the occurrence of the abnormality. In addition, when an abnormality occurs, it can also be confirmed whether or not the machine has automatically stopped automatically in response to the abnormality.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 5 relate to an inline screw type injection molding machine according to an embodiment of the present invention (hereinafter referred to as the present embodiment), and FIG. 1 is a simplified control system of the injection molding machine according to the embodiment. FIG.

  In FIG. 1, reference numeral 1 denotes a system controller that controls operation control and display control of the entire machine (injection molding machine). This system controller 1 includes hardware resources such as arithmetic functional elements and memories, and various types of resources that are held in advance. In cooperation with software resources such as application software, various processing such as various arithmetic processing, data writing / calling processing, display control processing, and command output processing are executed. The functions of the function blocks shown in the system controller 1 will be described later. Each function block is realized by the hardware resource and the software resource. Further, 2 is a sensor group composed of a large number of sensors provided in each part of the machine, and 3 is composed of a large number of driver circuits for driving and controlling a large number of drive sources arranged in each part of the machine. A driver group 4 is a key input device disposed on the front portion of the machine, and 5 is a display device (color liquid crystal display device with a touch panel) with a touch panel input portion 5a disposed on the front portion of the machine. The key input device 4 and the touch panel input unit 5a constitute a user input interface.

  The system controller 1 includes a plasticizing operation, a suck back operation, a mold opening / closing operation (a mold opening operation and a mold closing operation (a mold closing / clamping operation)), an ejecting operation (an eject ejecting operation and an eject returning operation), an injection operation (1 Control of the entire molding process such as the next injection operation and pressure holding operation), calculation / storage processing of measured data, calculation / determination processing such as non-defective / defective product determination processing, abnormality determination processing, or output of the display device 5 Various processes such as an image display control process are executed. In the system controller 1, 11 is a molding condition setting storage unit, 12 is a molding process control unit, 13 is an actual measurement value storage unit, and 14 is a display processing unit. Further, in the display processing unit 14, 15 is a data conversion processing unit, 16 is a graph scale generation unit, 17 is a fixed data storage unit for display, and 18 is a display image data generation unit.

  In the molding condition setting storage unit 11, various operating condition values input by the touch panel input unit 5 a or the key input device 4 or transferred from various storage media and input are stored in a rewritable form. Yes. The operating condition value includes, for example, the electric power value, the relationship between the screw position and screw rotation speed during the plasticizing process, the screw retraction speed, and the back pressure, the suck back control condition, and the holding pressure switching from the injection start point (position). Injection speed condition to point (position) and injection pressure condition, secondary injection pressure (holding pressure) condition from holding pressure switching time to holding pressure end time, mold closing (clamping) stroke and speed / pressure control conditions, Examples include mold clamping force, mold opening stroke and speed / pressure control conditions, eject control conditions, temperature control conditions for each part, control conditions for an automatic product take-out machine, and the like.

  The molding process control unit 12 is based on a previously created molding process control program and set condition values stored in the molding condition setting storage unit 11, and includes sensor groups 2 (position sensors, pressure sensors) disposed in each part of the machine. The corresponding drive source is driven via the driver group 3 (motor driver, heater driver, etc.) while referring to the measurement information from the sensor, rotation speed sensor, temperature sensor, etc.) and the timekeeping information from the built-in clock. Control and execute a series of molding steps.

  In the actual measurement value storage unit 13, all the actual measurement data of the monitor items set in advance during the continuous automatic operation are captured over a predetermined number of consecutive shots. Examples of monitor items to be captured include time monitoring items, position monitoring items, rotational speed monitoring items, speed monitoring items, pressure monitoring items, temperature monitoring items, power monitoring items, and the like. Further, when the machine is stopped (automatically stopped) due to the occurrence of an abnormality, all actually measured data of the monitor items from the occurrence of the abnormality until the machine is completely stopped is captured and stored.

  The display processing unit 14 displays a display image in a designated display mode based on a display image creation / control program created in advance in response to an instruction for calling a display image in a mode desired by the operator using the touch panel input unit 5a or the key input device 4. Create data.

  That is, when a call instruction for a predetermined display image by the operator arrives, the data conversion processing unit 15 of the display processing unit 14 displays the display from the information stored in the molding condition setting storage unit 11 or the actual measurement value storage unit 13 as necessary. Data for use in displaying the mode image is extracted and converted into a form corresponding to the display form of the designated display mode image. For example, if the specified display mode is a graphic image of a certain process or cycle, the extracted data is converted into image data that has been drawn, or the specified display mode is the operating state of a certain process. If it is a setting image, the extracted data is converted into numerical image data. When the designated display mode is a graphic image, the graph scale generation unit 16 generates a graph scale (graph scale) created in advance based on the contents of the data conversion processing unit 15 or the operator's scale instruction. Graph scale grid image data and scale numerical image data with a predetermined magnification are generated by the program.

  The generation processing data of the data conversion processing unit 15 and the graph scale generation unit 16 is taken into the display image data generation unit 18 and is enlarged / reduced according to the graph scale at a predetermined position on the graph scale grid image data at a predetermined magnification. The graphic image data captured by the conversion processing into the rate is overwritten and combined. Further, data to be used for displaying the display mode image from a large number of characters, symbols, graphic figures, ruled line data, and the like, which are fixed data for the mode image created and stored in advance in the display fixed data storage unit 17. Is extracted and taken into the display image data generation unit 18 and is also synthesized as image data for display.

  As a result, the display image data generation unit 18 arranges and synthesizes the specified graphic scale for the graphic display image, scale numbers, line drawing graph, mode display characters, unit symbols, item display characters, etc. Image data to which information or the like is added is created, and is held so as to be rewritable.

  When the designated display mode is not a graphic image, the image data for the designated display image is similarly displayed according to the contents of the data conversion processing unit 15 and the fixed display data storage unit 17. 18 is generated and held.

  The image data of the display image data generation unit 18 is transferred to a frame buffer (not shown) and temporarily stored, and the output of the frame buffer is sent to the display device 5 in response to a command from the display processing unit 14. Image data in a predetermined mode is displayed on the screen.

  FIG. 2 shows an actual measurement of one cycle displayed when the operator touches the “one cycle graph” button 21 in the display image in a state where image data of a predetermined mode is displayed on the display screen of the display device 5. A graph image (actual measurement graph image of a molding operation cycle) is shown, and is a one-cycle actual measurement graph image when the machine is operating normally. In the one-cycle actual measurement graph image (measurement graph image of the molding operation cycle) shown in FIG. 2 and FIGS. 3 to 5 described later, the starting point of the graph drawing of the one-cycle actual measurement graph image is the start of the plasticizing process. Yes. Further, when the machine is operating normally, the end point of the graph drawing of the one-cycle actual measurement graph image (the actual measurement graph image of the molding operation cycle) is the end of the injection process (primary injection process and pressure holding process). It has become. In FIG. 2, 31 is a plasticizing screw rotation speed, 32 is a plasticizing back pressure, 33 is a plasticizing screw retracting speed, 34 is a suck back speed (suck back screw retracting speed), 35 is a mold opening speed, 36 is an eject ejection speed, 37 is an eject return speed, 38 is a mold closing speed, 39 is a mold clamping speed, 40 is an injection speed (injection screw speed), and 41 is an injection pressure (injection resin pressure).

  FIG. 3 shows a first example of a one-cycle actual measurement graph image (measurement graph image of the molding operation cycle) displayed on the display screen of the display device 5 when an abnormality occurs. In FIG. 3, the actual measurement data for two molding cycles (two shots) are drawn by overwriting, the solid line indicates the actual measurement data of the latest molding cycle, and the broken line indicates the molding cycle immediately before the latest molding cycle. Actual measurement data is shown, and reference numerals 31 to 41 denote the same speed and pressure as in FIG. In the example shown in FIG. 3, the solid line and the broken line are substantially overlapped from the plasticizing process to the end of the mold closing process, and the operation of the latest molding cycle is normal until the low speed / low pressure mold closing before the mold closing process. Although performed, the low speed / low pressure mold closing was not performed normally, so the low speed mold opening speed 42 indicates that the low speed mold opening was performed after the low speed / low pressure mold closing failure. Therefore, it is possible to reliably confirm the abnormal operation of the low-speed / low-pressure mold closing in the mold closing process based on the measured data after the low-speed / low-pressure mold closing, and the machine is safe in response to the occurrence of the abnormality. It can also be confirmed that it has been automatically stopped.

  FIG. 4 shows a second example of the one-cycle actual measurement graph image (the actual measurement graph image of the molding operation cycle) displayed on the display screen of the display device 5 when an abnormality occurs. In FIG. 4 as well, actual measurement data for two molding cycles (two shots) are drawn by overwriting, the solid line indicates the actual measurement data of the latest molding cycle, and the broken line indicates the molding cycle one before the latest molding cycle. Actual measurement data is shown, and reference numerals 31 to 42 denote the same speed and pressure as in FIG. In the example shown in FIG. 4, the solid line and the broken line are substantially overlapped from the plasticizing process to the initial stage of the injection process, and the operation of the latest molding cycle was normally performed until the initial stage of the primary injection in the injection process. After that, it can be clearly confirmed from the comparison between the injection speed 40 and injection pressure 41 indicated by the solid line and the injection speed 40 and injection pressure 41 indicated by the broken line that the primary injection has not been performed normally. In the example shown in FIG. 4, the abnormality in the injection pressure 41 is a failure factor of the primary injection. Knowing the pressure value of the abnormal injection pressure 41 and the duration of the abnormality helps to analyze the cause of the injection pressure abnormality. be able to. In addition, after the occurrence of an abnormality, it can be visually recognized by the low-speed mold opening speed 42 that the low-speed mold opening has been performed, and it can also be confirmed that the machine has been safely and automatically stopped in response to the occurrence of the abnormality.

  FIG. 5 shows a third example of the one-cycle actual measurement graph image (the actual measurement graph image of the molding operation cycle) displayed on the display screen of the display device 5 when an abnormality occurs. In FIG. 5, the actual measurement data for seven molding cycles (7 shots) are drawn by overwriting, the solid line indicates the actual measurement data for the latest molding cycle, and the broken line indicates the actual measurement data for the past six molding cycles. Reference numerals 31, 33 to 42 denote the same speed and pressure as in FIGS. In the example shown in FIG. 5, in the past six molding cycles, the solid line and the broken line substantially overlap from the mold opening process to the injection process (for convenience of illustration, measured data from the mold opening process to the injection process in the past six molding cycles). Is shown by one broken line), the injection process was normally performed from the mold opening process of the past 6 molding cycles, but the broken lines of the plasticizing process and suck-back process for the past 6 molding cycles showed variation. ing. In the example shown in FIG. 5, in the plasticizing process of the latest molding cycle, as indicated by the solid screw rotation speed 31, the screw retraction speed indicated by the solid line is kept rotating for a long period of time. Therefore, it is clear that the screw rotation is stopped because the screw retraction speed 33 does not reach the expected value even if the screw rotates for a predetermined period. Can be confirmed. In the example shown in FIG. 5, the supply speed of the resin material (resin pellets) is increased by the variation in the broken line in the plasticizing process and the suck back process for the past six molding cycles and the solid line in the plasticizing process in the latest molding cycle. It gradually falls and it can be surely known that the resin material to be supplied is exhausted in the latest molding cycle. In addition, after the occurrence of an abnormality, it can be visually recognized by the low-speed mold opening speed 42 that the low-speed mold opening has been performed, and it can also be confirmed that the machine has automatically and safely stopped in response to the occurrence of the abnormality.

  As described above, in the present embodiment, the actual measurement data after the occurrence of the abnormality is displayed in a graph, so that it is easy to analyze the cause of the abnormality that caused the machine to stop from the actual measurement data after the occurrence of the abnormality. . In addition, when an abnormality occurs, it can also be confirmed whether or not the machine has automatically stopped automatically in response to the abnormality.

It is the block diagram which simplified the control system in the in-line screw type injection molding machine which concerns on one Embodiment of this invention. In the in-line screw type injection molding machine according to the embodiment of the present invention, an explanation showing an example of a one-cycle actual measurement graph image (measurement graph image of a molding operation cycle) during normal operation displayed on the display device during normal operation. FIG. The inline screw type injection molding machine concerning one embodiment of the present invention shows the 1st example of 1 cycle actual measurement graph image (actual measurement graph image of molding operation cycle) displayed on a display device, when abnormality occurs. It is explanatory drawing. The inline screw type injection molding machine concerning one embodiment of the present invention shows the 2nd example of 1 cycle actual measurement graph image (actual measurement graph image of molding operation cycle) displayed on a display device, when abnormality occurs. It is explanatory drawing. The inline screw type injection molding machine concerning one embodiment of the present invention shows the 3rd example of 1 cycle actual measurement graph image (actual measurement cycle image of molding operation cycle) displayed on a display device, when abnormality occurs. It is explanatory drawing.

Explanation of symbols

1 system controller 2 sensor group 3 driver group 4 key input device 5 display device (color liquid crystal display device with touch panel)
5a Touch panel input unit 11 Molding condition setting storage unit 12 Molding process control unit 13 Actual measurement value storage unit 14 Display processing unit 15 Data conversion processing unit 16 Graph scale generation unit 17 Fixed data storage unit for display 18 Display image data generation unit

Claims (1)

It comprises a controller that drives and controls each part of the machine based on each set operating condition value and measurement information from each sensor, and the controller executes a series of molding operation steps according to a predetermined molding operation program , And in the molding machine that captures and stores the actual measurement data of each operating condition during operation, and displays images of various display modes on the display device based on instructions from the operator,
In the actual measurement data graph image display mode in which the actual measurement data is displayed in a graph on the display device, the controller completely stops the molding machine from the occurrence of abnormality when the molding machine operation is abnormal and the molding machine is automatically stopped. the measured data of up to the molding machine, wherein the benzalkonium be graphically displayed on the display device.

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