JP6619837B2 - 射出成形における射出成形部品質の再現方法及びその方法を行う射出成形ユニット - Google Patents
射出成形における射出成形部品質の再現方法及びその方法を行う射出成形ユニット Download PDFInfo
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- 238000002347 injection Methods 0.000 title claims description 86
- 239000007924 injection Substances 0.000 title claims description 86
- 238000001746 injection moulding Methods 0.000 title claims description 47
- 238000000034 method Methods 0.000 title claims description 40
- 238000004519 manufacturing process Methods 0.000 claims description 132
- 239000000155 melt Substances 0.000 claims description 30
- 238000007789 sealing Methods 0.000 claims description 25
- 238000001816 cooling Methods 0.000 claims description 23
- 238000011156 evaluation Methods 0.000 claims description 20
- 230000000694 effects Effects 0.000 claims description 2
- 230000002950 deficient Effects 0.000 description 6
- 230000003247 decreasing effect Effects 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 238000012545 processing Methods 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/766—Measuring, controlling or regulating the setting or resetting of moulding conditions, e.g. before starting a cycle
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
- B29C2045/776—Measuring, controlling or regulating of velocity or pressure of moulding material determining the switchover point to the holding pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Description
10 基準グラフ
10.M0 現内圧グラフ
10.M1−10.M4 変更した機械パラメータが割り当てられた内圧グラフ
11 インジェクタ
11’ 制御装置
12 溶融物
13 射出成形金型
14 射出成形部品
15 制御部
16 評価部
E 内圧グラフの適合終了
I 射出段階
II 保持圧力段階
III 残留冷却段階
n 比較失敗
p 内圧
pI 射出段階開始時の内圧
pII 充填圧力
pIII 封止点圧力
pmax 最大内圧
t 時間
tI 射出段階の開始
tII 切替点
tIII 封止点
tIV 残留冷却段階の終了
V0〜V4 内圧グラフの比較
M 機械パラメータ
M0 現機械パラメータ
M1〜M4 割当済み機械パラメータ
y 比較成功
Z0〜Z4 製造サイクル
Claims (14)
- 射出成形において射出成形部品質を再現する方法であって、
複数の段階(I〜III)を有する製造サイクル(Z0〜Z4)において射出成形金型(13)により射出成形部品(14)を製造し、射出段階(I)で前記射出成形金型(13)のキャビティ内に溶融物(12)を射出し、保持圧力段階(II)で前記溶融物(12)をキャビティ内で凝固させ、残留冷却段階(III)の最後に、冷まされ続けた前記溶融物(12)が射出成形部品(14)として前記キャビティから取り出され、
前記キャビティの内圧(p)の時間による変化を検出して、内圧グラフ(10、10.M0〜10.M4)として表示し、製造された射出成形部品(14)が少なくとも一つの所定の品質特性を満たす製造サイクルの少なくとも一つの内圧グラフが基準グラフ(10)として用いられ、
比較(V0)により、現製造サイクル(Z0)の内圧グラフ(10.M0)が少なくとも一つの所定の閾値を上回っているかどうかを判断し、現製造サイクル(Z0)の内圧グラフ(10.M0)が前記閾値を上回る場合、後続の製造サイクル(Z1〜Z4)の内圧グラフ(10.M1〜10.M4)が前記基準グラフ(10)に適合するよう少なくとも一つの現機械パラメータ(M0)を変更する、方法であって、前記現機械パラメータ(M0)は、機械パラメータ(M1〜M4)を備え、
前記製造サイクルの各段階(I〜III)に少なくとも一つの機械パラメータ(M1〜M4)が割り当てられ、
前記割り当てられた機械パラメータ(M1〜M4)は、前記製造サイクルのその段階(I〜III)の内圧(p)に与える影響が、割り当てられていない機械パラメータよりも大きく、
複数の製造サイクル(Z1〜Z4)では、前記割り当てられた機械パラメータ(M1〜M4)が所定の順番で変更され、各製造サイクル(Z1〜Z4)ごとに1つの割り当てられた機械パラメータ(M1〜M4)が変更される、
ことを特徴とする方法。 - 前記射出段階(I)には、前記所定の順番の第1機械パラメータ(M1)として射出速度が割り当てられ、第1後続製造サイクル(Z1)では前記射出速度が変更され、切替点からの所定の偏差が第1閾値として用いられることを特徴とする請求項1に記載の方法。
- 前記現製造サイクル(Z0)の内圧グラフ(10.M0)の切替点が前記基準グラフ(10)の切替点よりも早い場合、前記射出速度を低下させることにより変更し、第1比較(V1)により、前記低下した射出速度により検出された第1後続製造サイクル(Z1)の内圧グラフ(10.M1)が前記第1閾値を上回っているかどうかを判断することを特徴とする請求項2に記載の方法。
- 前記現製造サイクル(Z0)の内圧グラフ(10.M0)の切替点が前記基準グラフ(10)の切替点よりも後に生じる場合、前記射出速度を上昇させることにより変更し、第1比較(V1)により、前記上昇した射出速度で検出された第1後続製造サイクル(Z1)の内圧グラフ(10.M1)が前記第1閾値を上回っているかどうかを判断することを特徴とする請求項2に記載の方法。
- 前記保持圧力段階(II)には、前記所定の順番の第2機械パラメータ(M2)として保持圧力レベルが割り当てられ、第2後続製造サイクル(Z2)では前記保持圧力レベルが変更され、最大内圧からの所定の偏差が第2閾値として用いられることを特徴とする請求項1〜請求項4のいずれかに記載の方法。
- 前記第1後続製造サイクル(Z1)の内圧グラフ(10.M1)の最大内圧が前記基準グラフ(10)の最大内圧よりも高い場合、前記保持圧力レベルを低下させることにより変更し、第2比較(V2)により、前記低下した保持圧力レベルで検出された第2後続製造サイクル(Z2)の内圧グラフ(10.M2)が前記第2閾値を上回っているかどうかを判断することを特徴とする請求項5に記載の方法。
- 前記第1後続製造サイクル(Z1)の内圧グラフ(10.M1)の最大内圧が前記基準グラフ(10)の最大内圧よりも低い場合、前記保持圧力レベルを上昇させることにより変更し、第2比較(V2)により、前記上昇した保持圧力レベルで検出された第2後続製造サイクル(Z2)の内圧グラフ(10.M2)が前記第2閾値を上回っているかどうかを判断することを特徴とする請求項5に記載の方法。
- 前記保持圧力段階(II)と残留冷却段階(III)には、前記所定の順番の第3機械パラメータ(M3)として金型温度が割り当てられ、第3後続製造サイクル(Z3)では前記金型温度が変更され、前記保持圧力段階(II)と残留冷却段階(III)における前記基準グラフ(10)の所定の内圧(p)からの所定の偏差が第3閾値として用いられることを特徴とする請求項1〜7のいずれか一項に記載の方法。
- 前記基準グラフ(10)の封止点(tIII)において、第2後続製造サイクル(Z2)の内圧グラフ(10.M2)の内圧(p)が、前記基準グラフ(10)の封止点圧力(pIII)よりも高い場合、前記金型温度を低下させることにより変更し、第3比較(V3)により、低下した金型温度で検出された第3後続製造サイクル(Z3)の内圧グラフ(10.M3)が第3閾値を上回っているかどうかを判断することを特徴とする請求項8に記載の方法。
- 前記基準グラフ(10)の封止点(tIII)において、第2後続製造サイクル(Z2)の内圧グラフ(10.M2)の内圧(p)が、前記基準グラフ(10)の封止点圧力(pIII)よりも低い場合、前記金型温度を上昇させることにより変更し、第3比較(V3)により、上昇した金型温度で検出された第3後続製造サイクル(Z3)の内圧グラフ(10.M3)が第3閾値を上回っているかどうかを判断することを特徴とする請求項8に記載の方法。
- 前記残留冷却段階(III)には、前記所定の順番の第4機械パラメータ(M4)として保持圧力時間が割り当てられ、この保持圧力時間が第4後続製造サイクル(Z4)で変更され、封止点への到達が第4閾値として用いられることを特徴とする請求項1〜請求項10のいずれか一項に記載の方法。
- 前記保持圧力時間を上昇させることにより変更し、第4比較(V4)により、前記上昇した保持圧力時間で検出された第4後続製造サイクル(Z4)の内圧グラフ(10.M4)が前記第4閾値を上回っているかどうかを判断することを特徴とする請求項11に記載の方法。
- 前記第4比較(V4)が成功で、前記上昇した保持圧力時間で検出された第4後続製造サイクル(Z4)の内圧グラフ(10.M4)が前記第4閾値を上回っていない場合、前記基準グラフ(10)に対する後続製造サイクル(Z1〜Z4)の内圧グラフ(10.M1〜10.M4)の調整が完了し、前記第4比較(V4)が失敗で、前記上昇した保持圧力時間で検出された第4後続製造サイクル(Z4)の内圧グラフ(10.M4)が前記第4閾値を上回っている場合、前記所定の順番の第1機械パラメータ(M1)がさらなる第1後続製造サイクル(Z1)で変更されることを特徴とする請求項12に記載の方法。
- 請求項1〜13のいずれか一項に記載の方法を行う射出成形ユニット(1)であって、
現製造サイクル(Z0)の少なくとも一つの現機械パラメータ(M0)を前記射出成形ユニット(1)の入力部を介して入力可能であり、前記射出成形ユニット(1)は、電子データメモリ、出力部、プロセッサを有する評価部(16)を備え、前記基準グラフ(10)は、前記電子データメモリに保存可能であり、一つの割り当てられた機械パラメータ(M1〜M4)を所定の順番で変更することにより、前記基準グラフ(10)に対する後続製造サイクル(Z1〜Z4)の内圧グラフ(10.M1〜10.M4)の調整を行う評価プログラムを前記プロセッサにロード可能であり、内圧グラフ(10、10.M0〜10.M4)を前記出力部に表示することを特徴とする射出成形ユニット。
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