JPH05169507A - Supporting method of injection molding technology - Google Patents

Abstract

PURPOSE:To more effectively find proper countermeasure against the non-con forming situation of molded article. CONSTITUTION:By setting initial set values under the condition being selected by an initial. molding condition setting means 103 on reference to a conforming article molding condition data base 205 or providing default rule, when no similar molding conditions are obtained, the initial molding conditions for an object molded article is set through a molding condition outputting means 110 into an injection molder 300. When poor molding develops in the article 400 molded by the injection molder 300, a plurality of countermeasures against the faulty molding are derived from a countermeasure reasoning means 101 in succession so as to set the molding conditions according to the countermeasure through the molding condition outputting means 110 into the injection molder 300 for injection-molding When an article 400 molded by the injection molder 300 is judged as a conforming article, the molding conditions at the time is housed in the conforming article molding condition data base 205 as conforming article molding conditions.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for supporting injection molding technology in an injection molding machine.

[0002]

2. Description of the Related Art The most important work for producing a product in injection molding is to set molding conditions. Generally, the molding conditions vary greatly depending on the shape and size of the molded product, the molding material, and the injection molding machine. Also, since many control parameters such as injection speed, pressure, temperature during molding are complicatedly related to each other, it is a reality that this molding condition finding work depends on the intuition and experience of a so-called skilled engineer. , Very difficult and work. This is almost impossible for beginners as well as those with little specialized knowledge and experience. The fact is that it takes a considerable amount of time and money to train specialists who are familiar with this injection molding machine.

When an injection molding expert sets molding conditions, 1. Set the initial molding conditions that do not break the mold, referring to past data of similar molded products. 2. By actually performing molding, observing the type and degree of molding defects occurring in the molded product, and deciding which defect should be preferentially addressed. 3. For the selected molding failure, the current setting condition of the molding conditions is looked at from the possible measures, and the most effective measure is selected and executed. 4. While confirming the effect of the measures, repeat this work until the defective molding is eliminated. 5. When there are no molding defects, make final fine adjustments in consideration of productivity and stability. The optimum molding conditions are set according to the procedure.
Here, rather than a theoretical and analytical approach, such as detailed analysis of the causes of molding defects that usually occur and deriving candidate measures based on that analysis, experience from multiple measures Intuitively, it is often the case that a certain measure is decided intuitively. The defect selected is not always eliminated by the initially selected measure, and the optimum molding conditions are searched for by performing trial and error by repeating the steps 3 and 4.

Assuming that countermeasures A to E can be considered for the defects that are occurring during the countermeasure against the defective molding when the molding conditions are set out, an injection molding expert may take a plurality of countermeasures, for example, A and B. It will be executed alternately. After executing a certain measure, for example A, another specific measure, such as B, is always executed thereafter. A certain measure, for example A, is executed, and a specific measure is executed according to the result. For example, if it is improved, measure B
If it is worse, measure C is executed. If all other measures, such as A, B, C, and D, are executed and all fail, then the remaining measures E are executed and if the result is improved, then return to A and execute the measures again. Go.

Measures are implemented in various patterns such as, and some sort of order relation among a plurality of possible measures-
It can be seen that they have knowledge of countermeasure procedures.

That is, the expert does not present one measure that seems to be optimal at that time, but derives the order of a plurality of possible measures = countermeasure procedure from past experience.

In general, a defect selected by the initially selected countermeasure is rarely solved, and knowledge of this countermeasure procedure is greatly related to how quickly the optimum molding conditions can be set, and an expert has an important point. It can be called knowledge.

A knowledge engineering approach of constructing an expert system by extracting and arranging the experience and know-how possessed by the above-mentioned injection molding specialists and performing molding condition setting work even if not an expert Or, an attempt has been proposed to support the work of an expert so that molding conditions can be set more efficiently.

Prior arts relating to the same type of system prior to the present invention include JP-A-63-209917, JP-A-63-209918, JP-A-64-24719 and JP-A-2-128820.

Among these, the conventional example mainly performs a detailed analysis of the cause of failure, b derives a plurality of countermeasures according to the analysis, c calculates the certainty of the obtained countermeasures, and d It presents multiple countermeasures with priorities according to e and selects the countermeasures by the operator. Further, the conventional example mainly sets initial molding conditions, and the conventional example shows a single measure.

[0011]

However, the above-mentioned conventional techniques have the following problems.

In the conventional example, the procedure for deriving a countermeasure plan is completely different from that of an expert. A It is difficult to analyze the cause b It is difficult to set the certainty c It is easy for the person to vary d The reality of the countermeasure procedure Therefore, the process of deriving the measure is complicated, the database or knowledge base becomes large in scale, and it is difficult to change, improve, and maintain.

In the conventional example, the specific contents of the diagnostic expert system are not described.

In the conventional example, the process of deriving the countermeasure plan is unclear, and it seems that a fixed table is used.
This method cannot always output appropriate countermeasures for various failure situations.

The following two points are particularly important in determining molding conditions in injection molding, and both of them depend on the experience and intuition of a skilled molding engineer.

Description is made in the conventional example of the computer system that sets the initial molding conditions that match the target molded product and takes appropriate measures against the molding failure situation that has occurred. Regarding the initial molding condition setting, although there are some, there is a method of extracting similar molding conditions from the good product molding condition database and a method of setting by flow analysis.

However, it is not always possible to obtain the optimum similar molding conditions for the target molded product, and conversely there is a possibility that adverse measures will be adversely affected depending on the molding conditions adopted. If the filling balance in the injection and pressure-holding processes is poor due to the setting conditions such as injection speed, pressure-holding switching point, and pressure-holding pressure, etc. It is likely to induce a defect.
Since there is little operational margin, it takes time to deal with defects, and in the worst case, defects may not be resolved.

The present invention has been made in view of the problems of the above-mentioned prior art, and it is possible to more efficiently derive an appropriate countermeasure for the defective condition of a molded product, and yet to have an operating margin. It is an object of the present invention to provide a method for supporting an injection molding technique in an injection molding machine.

[0019]

The method for supporting the injection molding technique of the present invention is to provide an optimum non-defective molding condition corresponding to a target molded product from a non-defective molding condition database in which molding conditions at the time of molding a non-defective product by an injection molding machine are accumulated. Or if similar molding conditions cannot be obtained, set a default setting rule to set the initial setting value, fill only by injection, and then hold pressure to almost fill the initial molding condition. As the initial molding condition setting step for setting the initial molding condition of the target molded product as described above, and when deriving a measure for setting the initial molding condition or deriving a countermeasure plan for countermeasures against molding defects, the applicable molding condition is set to the injection molding. The molding condition input step set in the machine, the test shot step in which the injection molding machine in which the molding condition is set in the molding condition input step performs injection molding, and the molding step performed in the test shot step If a molded product is found to be non-defective and a molding defect is found in the molded product, a defective data input step of determining the defective item and the defective situation, and the molded product is a non-defective product in the defective data input step. If it is judged that the molding conditions of the injection molding machine at that time are added as good product molding conditions to the good product molding condition database, and if molding defects are found, it is carried out for each possible molding defect. A plurality of countermeasures to be taken, and a countermeasure inference step of deriving a countermeasure against the defective item and defective situation according to the priority by referring to a molding defect countermeasure matrix in which the selection rules thereof are recorded in advance. If there is an inference result presentation step for displaying the countermeasure plan derived in the countermeasure inference step, and if there are multiple defective items determined in the defective data input step. At measures inference process, it sets a priority to each of the defective item, and a case of deriving the countermeasures for each failure item in the order of their priority.

[0020]

[Function] The initial molding condition for the target molded product is selected from the molding conditions at the time of molding the non-defective product, or the initial filling adjustment is carried out based on the initial setting value according to the default setting rule, and the result is set in the injection molding machine. .. When a molding failure occurs in a molded product molded according to the initial molding conditions, a plurality of countermeasures for eliminating the molding failure are sequentially derived, and the derived measures are taken for each case. The molding conditions related to the plan are set in the injection molding machine.

When a molded product molded by the injection molding is judged to be a non-defective product, the molding conditions at that time are accumulated as non-defective product molding conditions, so that a database for setting the initial molding condition of the target molded product is abundant. As a result, the initial molding conditions can be set to conditions closer to the good product molding conditions.

[0022]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is an explanatory view showing the structure of an injection molding support device used for carrying out the present invention.

As shown in FIG. 1, a molding failure countermeasure expert system section (hereinafter referred to as "ES section") 100
And molding condition setting support section (hereinafter referred to as "support section") 2
00 and 00.

The ES section 100 is a section in the injection molding machine 300 that eliminates defects while sequentially proposing optimal countermeasures for molding defects that mainly occur.
00 is for database management provided to the ES unit 100, and E
This is a part for processing various data output by the S section 100.

The ES section 100 includes a countermeasure inference means 101, an information input means 102, an initial molding condition setting means 103, an initial molding condition display means 104, and an initial molding condition changing means 105.
It comprises a molding condition input means 106, a countermeasure history recording means 107, a molding failure input means 108, an inference result presentation means 109, and a molding condition output means 110.

The information input means 102 is for searching the optimum molding conditions for the target molded product such as the shape and size of the molded product, the mold, the molding material, the specifications of the injection molding machine 300 and the working environment. It is an input unit for the molding information necessary for, and has an input keyboard and a display means for displaying information. The input molding information is the countermeasure inference means 10
1 and the initial molding condition setting means 103.

In this embodiment, the following seven items are sequentially input as the molding information.

Molded product registration information Molding work related information Molded product related information Molding material related information Injection molding machine related information Mold related information Failure priority information The molded product registration information is data for molded product management,
Predetermined identification information is input from the keyboard.

As the molding work-related information, a work environment (temperature, humidity, etc.) and a work time zone are input from the keyboard.

When inputting the molding material-related information, the resin name, manufacturer name, and grade of a plurality of molding materials registered in advance in the material database 201 of the support unit 200, which will be described later, are displayed. Select the relevant information from the information provided.

When inputting the information related to the injection molding machine,
Since the models and screw diameters of a plurality of injection molding machines registered in advance in the injection machine database 202 of the support unit 200 are displayed, similarly, the corresponding one is selected from the displayed information.

As the die-related information, specification data such as the die type to be used and the gate diameter are input from the keyboard.

The defect priority information designates a countermeasure priority order that determines which of the molding defects gives priority to the countermeasure when a plurality of molding defects occur.

The initial molding condition setting means 103, based on the molding information input from the information input means 102, is an example of molding conditions prestored in the non-defective molding condition database 205 of the support unit 200, or a non-defective molding by the user. From the non-defective molding conditions accumulated in the condition database 205, the optimum molding conditions for the target molded product are extracted,
With respect to the molding condition items specific to the molded product, the setting is automatically changed according to the default setting rule, and the molding condition output unit 1 uses the changed molding condition as the initial molding condition.
The injection molding machine 300 is set via 10 and the initial molding conditions are transferred to the countermeasure inference means 101.

When the molding conditions are extracted by the initial molding condition setting means 103, the molding conditions are displayed on the initial molding condition display means 104. At this time, the initial molding condition changing means 105 is used according to the operator's judgment. It is possible to change to more suitable molding conditions.

The molding condition input means 106 obtains an actual measurement value (molding condition actual measurement value) corresponding to the molding condition when the injection molding machine 300 performs injection molding according to the set molding condition, and If it is a non-defective product, the molding conditions at that time are fetched and transferred to the countermeasure inference means 101.

When the molding condition input means 106 transfers the measured molding condition value to the countermeasure inference means 101, the countermeasure history recording means 107 generates the measured molding condition value as an initial molding condition or a countermeasure plan. The support unit 20 stores the countermeasure history data together with the molding defect and its status.
It is stored in the countermeasure history storage unit 208 of 0.

The defective molding input means 108 is used for the injection molding machine 3.
If a defect has occurred in the molded product 400 molded by No. 00, the defective item and the defective status are discriminated and transferred to the countermeasure inference means 101. If the molded product 400 is a non-defective product, the countermeasure reasoning is performed to that effect. Notify the means 101.
Further, the defective molding input means 108 is provided with a display means for displaying a description of symptoms, causes, countermeasures, etc. relating to the defectiveness and a sample photograph.

As shown in FIG. 2, the countermeasure inference means 101 includes an overall control unit 1011 and a specialized database unit 1012.
And an inference control unit 1013.

When there are a plurality of defective items input from the defective molding input means 108, the overall control unit 1011 determines a defective item to be preferentially dealt with (hereinafter referred to as "notable defect"). This defective defect is basically determined based on the priority order defined by the defect priority information input as the molding information, but the priority order may be changed each time according to the situation of the defect that has occurred. You can When the molded product 400 is a non-defective product, the overall control unit 1011 sets the molding condition transferred from the molding condition input unit 106 at that time as the non-defective product molding condition.
00 to the non-defective molding condition accumulating means 204, and the molded product 4
When a molding failure occurs in 00, the measured molding condition value, the initial molding condition or the countermeasure plan, the molding failure that has occurred and the situation thereof are transferred to the countermeasure history recording unit 107.

The specialized database unit 1012 stores a molding defect countermeasure matrix composed of a plurality of matrices, which will be described later, for deriving an optimum countermeasure plan according to a defective item.

The inference control unit 1013 derives an optimum countermeasure plan for a defective item with reference to the molding defect countermeasure matrix. Further, when the inference control unit 1013 derives a measure and changes the molding condition, the changed molding condition is set in the injection molding machine 300 via the molding condition output unit 110.

The inference result presenting means 109 displays the countermeasure plan derived by the countermeasure inferring means 101. At this time, the operator confirms the countermeasure plan so that the forming condition based on the countermeasure plan is displayed. Be changed.

The support unit 200 has a material database 2
01 and injection machine database 202, non-defective molding condition printing means 203, non-defective molding condition storage means 204, non-defective molding condition database 205, and countermeasure history display means 2
06, countermeasure history printing means 207, countermeasure history saving means 20
8 and countermeasure history selection means 211, molding condition examination interruption processing means 209, molding condition examination restart continuation means 210, and molding condition examination returning means 212.

As described above, the material database 201 stores molding material-related information which is molding information. Similarly, the injection machine database 202 also stores injection molding machine-related information that is molding information.

The non-defective molding condition storage means 204 uses the ES
The non-defective molding conditions transferred from the countermeasure inference means 101 of the unit 100 are stored in the non-defective molding condition database 205. The non-defective item molding condition database 205 can also store non-defective item molding conditions by the operator.

The non-defective molding condition printing means 203, the countermeasure history display means 206, the countermeasure history printing means 207, and the countermeasure history storage means 208 are transferred from the ES section 100 as the printing of the non-defective article molding conditions and the countermeasure history data, respectively. The actual measurement value of the molding condition, the initial molding condition or the countermeasure, and the molding defect and the situation thereof which have occurred are displayed, printed and stored.

The molding condition examination interruption processing means 209 sets the interruption processing mode so that the ES section 100 holds the current molding conditions, defective items and history data.
Also, the operation of the support unit 200 can be stopped.
The interruption processing mode set by the molding condition examination interruption processing means 209 is ended by an instruction from the molding condition examination restart continuation means 210, and at that time, the operation is performed in a state based on each data held when the interruption processing mode is set. It will be restarted.

The countermeasure history selection means 211 selects a molding condition at an arbitrary time from the countermeasure history data stored in the countermeasure history storage means 208.

The returning means 212 for examining the molding conditions takes a countermeasure against defects by using the molding condition selected by the countermeasure history selecting means 211 as a countermeasure plan.

Next, the outline of the operation of the ES section 100 will be described with reference to the flowchart of FIG. 3 showing the outline of all the steps of the first embodiment.

Input of molding information (step S100) The data of the molding information necessary for searching the optimum molding conditions for the target molded product is input.

Initial molding condition setting (step S20
0), a database search to be described later is performed according to some key data items in the molding information, and the optimum molding for the target molding product is selected from the non-defective molding conditions stored in the non-defective molding condition database 205. Enter the conditions by searching and set them as the initial molding conditions. If the optimum molding conditions cannot be obtained, the initial filling adjustment is performed according to the default setting rule described later.

Under the initial molding conditions set in the trial shot (step S300) or the current molding conditions changed by the inference result presentation described later, actual molding is performed and the state of the molded product is observed (step S400).

If a non-defective product having no defective molding can be molded, the defective molding countermeasure is terminated.

Molding defect input (step S500) If a molded product has a defect as a result of test firing, the defect item is selected and input.

Countermeasure inference (step S600) Based on all the data input up to now, that is, the molding information, the molding condition set value, the molding condition actual value, the defect, the countermeasure history, etc., the database regarding the molding defect countermeasure in the system is created. Therefore, we infer the optimal countermeasure for eliminating the molding failure that has occurred.

The countermeasure plan derived by the inference result presentation (step S700) is displayed. The molding conditions are automatically changed upon confirmation by the operator.

Next, the details of each step will be described.

First, input molding information (step S100)
Then, the molding information of the seven items described above is input from the information input unit 102.

Next, the initial molding condition setting (step S20)
0) will be described with reference to the flowchart shown in FIG.

First, the initial molding condition setting means 103 searches the non-defective molding condition database 205 based on some key data items of the molding information input in the molding information input (step S100). Step S210), in the non-defective molding condition database 205,
It is checked whether or not there is an optimum non-defective molding condition corresponding to the molding information (step S211).

When there is a non-defective molding condition corresponding to the molding information, the non-defective molding condition is extracted and the corresponding data is input (step S221) to be the initial molding condition.

At this time, the unique condition items unique to the target molded product are changed according to the default setting rule to set the unique condition items (step S2).
22).

On the other hand, if similar molding conditions are not obtained as a result of the non-defective molding condition database search (step S210), initial setting values are set (default setting) according to default setting rules (step S231), and initial filling adjustment is performed. Is performed (step S232). This initial filling adjustment is executed according to the flowchart shown in FIG.

First, the holding pressure is set to 0 (step S91).
0), trial shooting is performed (step S920).

Then, the presence / absence of burrs is checked, and if they have occurred, the highest priority is given to countermeasures against burrs (step S9).
31) Then, perform the trial shot again.

If there is no burr, the presence / absence of the remaining amount is checked. If the predetermined amount of remaining amount is not secured, a measure to secure the remaining amount is taken (step S932), and the trial firing is performed again. If there is no burr and the remaining amount is secured, the filling amount is input, and a countermeasure is taken according to the input (step S93
3, S934), the trial shot is performed again.

As a countermeasure for insufficient filling, for example, a method of gradually increasing the filling amount while adjusting the measured value and the holding pressure switching point can be considered. However, in reality, there are cases in which filling cannot be performed without adjusting the injection speed, and in some cases it may be necessary to adjust the temperature conditions.

When the complete filling by the injection process is confirmed by such measures, the default holding pressure is reset (step S935) and the trial firing is performed again to confirm the state of the final filling.

At this stage, if there is no burr and a predetermined remaining amount is secured, and if it is not overfilling, the initial filling adjustment is finished, and the process proceeds to the molding condition display (step S240) and thereafter.

The initial molding conditions set as described above are displayed on the initial molding condition display means 104 (step S240) and confirmed by the operator. At this time, if it is determined by the operator's judgment that the molding condition needs to be changed (step S241), the initial molding condition changing means 105 can be used to change and input the condition to a more suitable initial molding condition ( Step S250).

Next, the trial inference (step S300) to the countermeasure inference (step S600) will be described with reference to the flowchart shown in FIG.

The initial molding conditions set by the initial molding condition setting means 103 are set in the injection molding machine 300 through the molding condition output means 110 (step S30).
1). When the initial molding conditions are set, the injection molding machine 300 performs molding according to the initial molding conditions (step S302), and at that time, the actual measurement values of the molding conditions corresponding to the initial molding conditions are measured. After the completion, the measured actual molding condition values are input to the countermeasure inference means 101 by the molding condition input means 106 (step S30).
3). The measured value of the molding condition is used as the countermeasure history recording means 107.
By this, it is stored in the countermeasure history storage unit 208 of the support unit 200 as a part of the history data of the defect countermeasure when the molding failure occurs (step S304).

After that, the defective molding input means 108 checks whether or not there is a defective molded product 400 molded by the injection molding machine 300 (step S400). Since the countermeasure plan for the defect countermeasure defines the parameters of the molding conditions and the manipulated variables thereof (fixed value and variable value), the condition of the molded product after the actual setting change is observed.
If no defect has occurred in the molded product 400 and it is determined that the molded product 400 is a good product, it is not necessary to derive a countermeasure for the defective molding, and therefore the countermeasure for defective molding of the molded product 400 ends.

On the other hand, if a defect has occurred in the molded product 400, in order to determine the defect that has occurred, an explanation of symptoms, causes, countermeasures, etc. relating to the defect and a sample photograph are displayed (step S501). A defective item occurring in the molded product 400 is selected from the displayed sample photograph or the like (step S502).

When the defective item is determined, the defective item is input to the countermeasure inference means 101 from the molding defect input means 108, and the defective portion of interest is determined by the overall control unit 1011 of the countermeasure inference means 101 (step S601). As described above, the defect of interest is determined based on the defect priority information input as the molding information. However, depending on the condition of the defect that has occurred, the operator changes the priority to determine the defect of interest. can do. Then, in order to deal with the defect of interest, the inference control unit 1013 in the countermeasure inference means 101 derives a countermeasure plan (countermeasure inference) by referring to the molding defect countermeasure matrix in the specialized database unit 1012 (step S602).

As a result of this countermeasure inference, when the normal countermeasure plan defined in the above-mentioned molding defect countermeasure matrix is selected and when the countermeasure plan is transferred during the defect countermeasure implementation, the current countermeasure is corrected. There are “correction migration” indicating a correction work for performing the next countermeasure at the same time, “correction” for only correcting the current countermeasure, and “suggestion” or “comment” for notifying the operator of a message.

Next, inference result presentation (step S700)
This will be described with reference to the flowchart shown in FIG.

First, in the inference result presenting means 109,
It is checked whether or not the result of the measure inference by the measure inference means 101 is "correction" of the measure (step S701). Here, in the case of "correction" of the countermeasure plan, then "comment"
It is checked whether or not there is a message to be displayed as (step S702), and if there is a message, it is displayed (step S703), and then the target parameter and the correction amount by the "correction" are displayed (step S704), and according to it. The molding conditions of the injection molding machine 300 are changed (step S716). The message displayed as the above-mentioned "comment" has a caution during operation (for example, test firing or measurement is performed after molding conditions such as temperature are stable with respect to a set value).

On the other hand, if it is determined in step S701 that the countermeasure plan is not "correction", it is then checked whether or not the countermeasure plan is "correction shift" (step S705). It is checked whether there is a message to be displayed as "comment" (step S707).

In step S705, if the measure is "correction shift", the parameter to be corrected and the manipulated variable are displayed (step S706), and the step S7 is executed.
It is checked whether or not there is 07 "comment". Then, if there is a "comment" to be displayed, that message is displayed (step S708), and if there is no "comment", then it is checked whether or not there is a message to be displayed as a "suggestion" (step S709).

The message displayed as "proposal" is, for example, a message related to a mold or a molding material such as the proposal message group MSG-10 shown in Table 1. This is mainly due to the countermeasure plan derived by the countermeasure inference. Displayed when the defect cannot be resolved.

This suggestion message group MSG-10 is stored in the specialized database section 1012 of the countermeasure inference means 101, and when the inference control section 1013 judges that it is a proposal display as a result of the countermeasure inference, the suggestion message group M is displayed.
The corresponding message is extracted by referring to GS-10, transferred to the inference result presentation means 109 and displayed.

[0086]

[Table 1] If there is a message to be displayed as "proposal", that message is displayed (step S710), and then the molding condition is changed by the "correction shift" in the molding condition change (step S716). If there is no message to be displayed, the result of the above-mentioned countermeasure inference means that "correction transfer" of the countermeasure plan or selection of a normal countermeasure plan, so the countermeasure plan after the shift or the selected countermeasure plan is displayed (step S711).

At the time of displaying the countermeasure plan, all the molding conditions can be displayed in order to confirm the setting condition of the molding conditions related to the countermeasure plan. It is also possible to take a manual countermeasure by the operator without adopting the selected countermeasure plan, and the judgment is made in step S712.

In the case of implementing the manual countermeasure, after setting the manual input mode (step S714), the molding condition for the defect is set by the manual operation by changing the molding condition (step S716). On the other hand, when the selected measure is adopted, the operation amount can be arbitrarily changed. Therefore, it is checked whether or not the change is necessary (step S713). Therefore, if it is necessary to set the molding conditions in the molding condition change (step S716) and change the manipulated variable, after changing and inputting the manipulated variable (step S715), the molding condition is similarly changed (step S7).
In 16), the molding conditions are set.

When the countermeasure inference result is "correction", the target parameter and the correction amount are displayed.
The molding conditions cannot be changed.

When the setting of the molding conditions according to the measure against the defect is completed as described above, the trial shot (step S300) is executed in FIG.

Here, the process of countermeasure inference by the inference control unit 1013 of the countermeasure inference means 101 will be described with reference to the flowchart shown in FIG.

FIG. 8 is a flowchart showing in detail the matrix processing (step S602) of FIG.

Here, as the molding defect countermeasure matrix stored in the specialized database unit 1012 of the countermeasure inference means 101, (1) basic molding defect countermeasure matrix (2) countermeasure result matrix (3) process check matrix (4) molding Consider the six types of condition setting status matrix (5) Countermeasure history check matrix (6) Limit check matrix.

As shown in Table 2, the basic matrix of countermeasures against defective molding (hereinafter referred to as "basic matrix") is registered in advance and a plurality of defective moldings (A, B, C, ...) A plurality of countermeasure plans (A, B, C, ...) Are recorded for each of the countermeasures corresponding to each of them, with priorities determined. For example, when the defect A occurs, first, the countermeasure plan “A” corresponding to the countermeasure number 1 is given.
Molding is performed by setting molding conditions corresponding to, and thereafter, for the defects that have occurred similarly, corresponding countermeasure plans are selected in the order of the countermeasure numbers.

[0095]

[Table 2] The countermeasure result matrix is for deriving a countermeasure plan to be executed next according to the change of the molded product as a result of executing the countermeasure plan for the defective molding.

The countermeasure result matrix of this embodiment is, for example, as shown in Table 3, as a change of the molded product, improvement of defects,
We are considering 5 items: no effect, appearance of other defects, existence of other defects, and elimination of other defects. In Table 2, for example, when the defective measure is improved as a result of executing the measure plan corresponding to the measure number 2, the measure plan corresponding to the measure number 2 is continuously executed until the molded product becomes a good product. If there is no effect, "B
-3 ”is executed. This "B-3" indicates a "correction shift" of the countermeasure plan, and the countermeasure plan corresponding to the countermeasure number 3 is executed by returning the molding condition setting value to the previous setting value. Furthermore, as a result of executing the countermeasure plan corresponding to the countermeasure number 2,
When other defects occur in the molded product (other defects appear), "R-
2 ”is executed.

This "R-2" indicates "correction" of the countermeasure plan, and the countermeasure opposite to the countermeasure plan corresponding to the countermeasure number 2 is taken. For example, if the countermeasure plan corresponding to the countermeasure number 2 is a measure for increasing the injection speed, a countermeasure for decreasing the injection speed is implemented by "R-2". When the other defect is resolved (other defect is resolved), the next countermeasure plan is derived with reference to another matrix (MTC-4).

[0098]

[Table 3] The process check matrix is for deriving a countermeasure plan from a process in which a molding defect has occurred. In this embodiment, Tables 4 and 5 are used.
As shown in, a matrix MIK- that shows a countermeasure plan for each switching mode (IVS mode) from the injection process to the pressure holding process.
1 and MKC-5 and MKC-6 which show countermeasures for the injection and pressure-holding steps.

[0099]

[Table 4]

[0100]

[Table 5] The molding condition setting status matrix is for checking the setting status of molding conditions and deriving the next countermeasure plan,
In this embodiment, as shown in Table 6, the matrix MTC-4 relating to the temperature conditions 1 and 2 indicating the temperatures of the molten resin, the mold and the like is considered as the molding conditions. In Table 6, CMP
-4 is a procedure such as another subroutine, X is a set value,
Y is a recommended value.

[0101]

[Table 6] The measure history check matrix determines the measure to be implemented next based on the history of the measures already taken. For example, in the matrix MRC-5 shown in Table 7, the measure corresponding to the measure number 6 is executed. After that, if the countermeasure plan corresponding to the countermeasure number 5 is carried out (6 → 5), the countermeasure plan to be carried out next corresponds to the countermeasure number 7, and in other cases ( 6 → 5 ), the countermeasure is taken. Implement countermeasures corresponding to number 6. The matrix MRC-6 in Table 7 is considered in the same manner.

[0102]

[Table 7] The limit check matrix is a measure to be implemented next, depending on whether or not the set value of a specific parameter in the molding conditions exceeds the allowable range by implementing the measure proposed as a result of the measure inference. For example, in the matrix MTL-7 shown in Table 8, if the injection speed is changed in the order of the injection speed, the injection speed does not exceed the set allowable range, or the injection speed is changed. The countermeasure plan corresponding to the countermeasure number 7, 8 or 9 is selected depending on whether or not the elapsed time relating to the injection process exceeds the allowable range.

[0103]

[Table 8] In the overall control unit 1011 of the countermeasure inference means 101, when the defective item of interest for the defective molding is determined (see FIG.
Step S601), the inference control unit 1013 of the countermeasure inference means 101 checks whether or not a countermeasure against a molding defect of the molded product 400 is currently being performed (step S801).

In this case, if the injection molding machine 300 is the first molding for the target molded article according to the initial molding conditions set by the initial molding condition setting means 103, it means that the countermeasure against the molding failure is not under way.

In step S801, if the defect countermeasure is not underway, in order to derive the countermeasure plan by referring to the basic matrix as the initial setting at the time of starting the defect countermeasure,
Initialization of the measure number corresponding to the measure plan (measure number = 1)
Is performed (step S802).

Table 9 shows an example of a portion of the basic matrix corresponding to a defective item of interest (hereinafter referred to as "attention basic matrix").

[0107]

[Table 9] As countermeasures for the defective item of interest shown in Table 9, nine countermeasures A to H corresponding to the countermeasures Nos. 2 to 9 are considered, and in the case of the countermeasure No. 1, the process check shown in Table 4 is performed. Reference to the matrix MIK-1 is shown, and in the case of the countermeasure number 10, the proposed message group MSG-1 in Table 1 above is shown.
0 reference is shown.

When the initialization of the countermeasure number is completed, the countermeasure number 1 of the noted basic matrix shown in Table 9 above is referred to (step S803), and it is checked whether or not the countermeasure number 1 indicates the countermeasure plan (step S803). S804).

Here, since the countermeasure number 1 indicates the reference of the process check matrix MIK-1, it is judged that it does not indicate a countermeasure plan, and subsequently, it should be displayed as "proposal" or "comment". It is checked whether there is a message (step S812). In this case as well, there is no message to be displayed, so it is next checked whether it is a reference to another matrix (step S814).

Since the countermeasure number 1 indicates the reference of the process check matrix as described above, the IVS is referred to by referring to the process check matrix MIK-1 described above.
A countermeasure plan is selected depending on the mode setting status and in which process of injection or pressure holding the defect has occurred (step S815).

As a result, it is checked whether or not there is a matrix to be further referred to (step S814). In the case of the process check matrix MIK-1, the measure number indicating the measure is recorded in any case. It is judged that there is no matrix to be processed, and then it is checked whether or not the transition to the "procedure" such as a subroutine showing another process is performed (step S818). In this case also, the transition to the "procedure" is not performed. After updating the countermeasure number to the countermeasure number selected from the process check matrix MIK-1 (step S818), the noted basic matrix is referred to based on the updated countermeasure number (step S8).
03). In step S816, if the procedure is to be changed to the “procedure”, the procedure is referred to (step S817), and the countermeasure number determined by the “procedure” is updated (step S818).

In the process check matrix MIK-1, if the IVS mode is "H" and the defect occurrence process is the injection process, the measure number 2 is selected. As a result of referring to the noted basic matrix, the measure is taken. Option A
Is selected (step S804) and output to the inference result presenting means 109 (step S805). If there is no change, the molding condition output means 110 sets it in the injection molding machine 300.

If there is a molding defect in the molded product 400 molded by the injection molding machine 300 according to the countermeasure A, the defective product countermeasure is in progress in step 801.
Based on the change of 0, the countermeasure result matrix (see Table 3) is referred to (step S806).

As a result, when the countermeasure plan A determines that there is "no effect" for the defective item of interest, "correction shift" (B-3) to the countermeasure number 3 is selected. After that, whether or not there is a matrix to be referred to (step S807) and whether or not there is a “procedure” to be referred to (step S80).
9) are examined in order, but if none of them apply, the measure number is the measure number 3 selected from the measure result matrix.
(Step S811), and the basic matrix of interest is referred to based on the countermeasure number (step S80).
3).

In this case, the countermeasure plan B corresponding to the countermeasure number 3 is selected from the attention basic matrix (step S80).
4) Similarly, the countermeasure plan B is output to the inference result presentation unit 109 (step S805). In addition, the step S
In 806, if another defect appears as a result of implementing the measure A (other defect appearance), “correct” (S-2) of the measure A corresponding to the measure number 2 is performed in the measure result matrix.

When this "correction" measure is taken, it is confirmed whether or not other defects that have appeared due to the implementation of the measure A are eliminated, and if it is eliminated (other defects are eliminated). In this case, the molding condition setting status matrix MTC-4 (see Table 6) is referred to (step S80).
7, S808), the next measure will be selected,
"Procedure" in the molding condition setting matrix MTC-4
When the CMP-4 indicating the is selected, the corresponding "procedure" is referred to (steps S809 and S810), and the countermeasure number determined by the "procedure" is updated (step S818).

In addition, in the step S806, when the countermeasure plan A is found to be "improved" as a result of implementing the countermeasure plan A, the countermeasure plan A is repeated,
At that time, the molding condition is set while changing the operation amount of the parameter related to the “improvement” of the defective item of interest.

As described above, the countermeasure plan for the defective item of interest is derived by sequentially referring to the defect countermeasure matrix along the countermeasure number recorded in the noticed basic matrix. 2-9
If all of the countermeasures derived from the above do not solve the noted defect, that is, there is a fatal problem with the mold, molding material, injection molding machine, etc. that cannot be solved by changing the setting of molding conditions. If determined, the reference of the suggestion message group MSG-10 is instructed in the attention basic matrix (steps S804 and S812), and the corresponding message is transferred to the inference result presenting means 109 as a suggestion message. Displayed (step S81
3).

The process check matrices MKC-5, MKC-6, which are not referred to in the above-mentioned countermeasure inference process,
The countermeasure history check matrices MRC-5 and MRC-6 and the limit check matrix MTL-7 can be considered in the same manner as the process check matrix MIK-1 and the molding condition setting status matrix MTC-4.

For example, the process check matrix MKC-
5 and MKC-6, as a result of implementing the countermeasure plan corresponding to the countermeasure numbers 5 and 6 in the countermeasure result matrix,
It is referred to when the noticed defect is improved, and the limit check matrix MTL-7 is referred to when the noticed defect is improved as a result of implementing the countermeasure plan corresponding to the countermeasure number 7. In addition, the countermeasure history check matrix MRC-5, M
RC-6 is the process chuck matrix MK.
When referring to C-5 and MKC-6, it is referred to when the defect occurrence process is the pressure holding process.

By sequentially referencing the “molding failure countermeasure matrix” described as the multidimensional structure matrix in this way, each time point according to the defective status of the molded product or the operating status of the injection molding machine is actually checked. In this way, it is possible to take countermeasures against molding defects while proposing the optimum countermeasure plan in, and finally obtain the optimum non-defective molding conditions for the target molded product.

Further, during the countermeasure inference of the ES section 100,
By operating the support unit 200, a wider range of defect countermeasures and data management can be performed. For example, the non-defective molding condition printing means 203 and the countermeasure history printing means 207 can print out and confirm any non-defective molding conditions or countermeasure history, and the countermeasure history can be displayed by using the countermeasure history display means 106. Is. With respect to the display of the countermeasure history, it becomes easy to confirm the countermeasure plan (molding condition) in the case of returning to an arbitrary time and taking a defect countermeasure by using the returning means 212 after examining the molding condition.

Next, the second embodiment will be described.

In this embodiment, the countermeasure inference means 10 shown in FIG. 2 is used.
By additionally registering the initial filling countermeasure unit in the first specialized database unit 1012, it is possible to perform the initial filling adjustment while using the inference structure common to the defective molding countermeasure of the first embodiment.

FIG. 9 is a flow chart showing the outline of all the steps of the second embodiment.

The differences between this embodiment and the first embodiment are as follows, and the other points are the same as those in the first embodiment.
Only the differences will be described below.

Initial molding condition setting (step S200
A) The in-adjustment flag check is performed immediately before the molding defect input (step S500A), and if the adjustment is in progress, the molding defect input (step S500A) is not performed and the countermeasure inference (step S600A) is performed. It is checked whether or not the filling process is completed, and if not completed, the same process as in the first embodiment is performed. However, the above-mentioned difference in which the process at the end is different will be described with reference to the flowchart shown in FIG.

Similar to the first embodiment, the non-defective molding condition database 205 is searched (step S210A), and the optimum non-defective molding condition corresponding to the molding information exists in the non-defective molding condition database 205. It is checked whether or not (step S211A).

If there is a non-defective molding condition corresponding to the molding information, the non-defective molding condition is extracted (step S
221A) Initial molding conditions.

At this time, the unique condition items unique to the target molded product are changed according to the default setting rule (step S222A).

The difference between this embodiment and the first embodiment is that
Non-defective molding condition database search (step S210A)
As a result, if the similar molding conditions are not obtained, the initial setting value is set according to the default setting rule (step S231A), the holding pressure is set to 0, and the flag indicating the initial filling adjustment is set ( Step S232
A).

Next, the difference will be described with reference to the flowchart shown in FIG.

Molding condition setting (step S301A), molding (step S302A), molding condition actual measurement value input (step 303A), countermeasure history addition / update (step S30)
4A) is sequentially executed to check whether or not a defect has occurred in the molded product 400 (step S400A), and when it is determined that the product is non-defective, the defective molding countermeasure is ended in steps S301 to S400. Is the same as.

If the molded product 400 is defective,
The in-adjustment flag is checked immediately before the defect input process (step S410A), and if the adjustment is in progress, the molding defect input (step S500A) is not performed and the process immediately proceeds to the countermeasure inference process (see FIG. 9).

On the other hand, the adjustment flag is checked (step S410A). If the adjustment is not in progress, the defective item is displayed (step S501A) and the defective item is selected (step S502A). After that, the adjustment flag is checked again (step S603A), and if the adjustment is in progress, the defective defect is regarded as the initial filling adjustment (step S604A), and the matrix process is performed (step S602A).

If the adjustment flag is checked (step S603A) and the adjustment is not in progress, a defect of interest is determined (step S601A) and matrix processing is executed (step S602A).

Here, the defective item display (step S50)
1A) and defective item selection (step S502A) are performed in the same manner as steps S501 and S502 of the first embodiment.

Further, the defect of interest is determined (step S601).
Similar to the first embodiment, the countermeasure plan is derived (countermeasure inference) with reference to A) and the molding defect countermeasure matrix (step S602A).

FIG. 11 shows a flow chart of the initial filling adjustment process which is started when the initial filling adjustment is set as the defect of interest in step S603A.

The presence or absence of burrs is checked, and if any burrs have occurred, the highest priority countermeasure against burrs is taken (step S101
1).

If there is no burr, the presence / absence of the remaining amount is checked, and if the predetermined amount of remaining amount is not secured, the remaining amount securing measure is taken (step S1012).

If there is no burr and the remaining amount is secured, a countermeasure for the filling amount is taken (step S1013, step S10).
1014).

As a countermeasure against insufficient filling, for example, a method of gradually increasing the filling amount while adjusting the measured value and the holding pressure switching point can be considered. However, in reality, there are cases where filling cannot be performed without adjusting the injection speed, and in some cases it is also necessary to adjust the temperature conditions.

When complete filling is confirmed by the injection process by the above measures, the default holding pressure is reset (step S1015).

At this stage, if there is no burr and a predetermined remaining amount is secured, and the holding pressure is set without excess or deficiency of filling, the adjustment is finished (step S1020).

Differences will be described with reference to the flowchart of FIG.

It is checked whether the initial filling adjustment process is completed,
If not completed, steps S701A to S71
5A is executed, which is step S70 of the first embodiment.
1 to step S715.

On the other hand, in the case of termination, the in-adjustment flag is cleared (step S721A), a comment indicating the meaning is displayed (step S722A), and the initial molding conditions are finely adjusted before starting the subsequent molding defect countermeasures. Input mode (step S723).

[0149]

As described above, the present invention has the following effects.

(1) Since the optimum molding conditions are set by a simple data input operation such as molding information, the time required for setting the molding conditions is shortened, and the labor or material / energy loss associated with the setting work is reduced. Can be greatly reduced.

(2) If similar molding conditions cannot be obtained,
According to the procedure actually performed by a skilled person, the initial filling adjustment is performed and the initial molding conditions are derived and set in the injection machine. Therefore, the initial molding conditions in which the filling is balanced by the injection and the holding pressure can be obtained. . As a result, it is possible to secure an operating margin of the set value in the subsequent countermeasure against defective molding, and more efficiently obtain good product molding conditions.

(3) Since even an inexperienced beginner can set the optimum molding conditions, variations in the setting of the molding conditions can be prevented, and consistently high quality molded products can be obtained.

(4) Since a good product molding condition and a molding defect countermeasure matrix used for deriving the molding condition are stored in a database, the size of the knowledge base for deriving the optimum molding condition can be made compact, and the knowledge base can be changed.・ Easy to improve and maintain.

(5) By forming a knowledge base for deriving the molding conditions into a database, it becomes possible to systematically manage various information and more efficiently accumulate the technology.

[Brief description of drawings]

FIG. 1 is a block diagram showing a configuration of an injection molding support device used for implementing the present invention.

FIG. 2 is a block diagram showing a configuration of a countermeasure inference means shown in FIG.

FIG. 3 is a flowchart showing an outline of all steps of the first embodiment of the present invention.

FIG. 4 is a flowchart showing an initial molding condition setting step of the first embodiment of the present invention.

FIG. 5 is a flowchart showing an initial filling adjustment process of the first embodiment of the present invention.

FIG. 6 is a flowchart showing a molding condition inputting process, a trial shooting process, a defect data inputting process, and a countermeasure inferring process according to the first embodiment of the present invention.

FIG. 7 is a flowchart showing an inference result presentation step of the first example of the present invention.

FIG. 8 is a flowchart showing an example of matrix processing of a countermeasure inference step of the first example of the present invention.

FIG. 9 is a flowchart showing an outline of all steps in the second embodiment of the present invention.

FIG. 10 is a flowchart showing an initial molding condition setting step of the second embodiment of the present invention.

FIG. 11 is a flowchart showing an initial filling adjustment process in a countermeasure inference process of the second embodiment of the present invention.

FIG. 12 is a molding condition input step of the second embodiment of the present invention,
It is a flow chart which shows a trial shooting process, a defective data input process, and a countermeasure inference process.

FIG. 13 is a flowchart showing an inference result presentation step according to the second embodiment of the present invention.

[Explanation of symbols]

 100 Molding Failure Countermeasure Expert System Unit 101 Countermeasure Inference Means 102 Information Input Means 103 Initial Molding Condition Setting Means 104 Initial Molding Condition Display Means 105 Initial Molding Condition Changing Means 106 Molding Condition Input Means 107 Countermeasure History Recording Means 108 Molding Failure Input Means 109 Inference Result presenting means 110 Molding condition output means 200 Molding condition output support section 201 Material database 202 Injection machine database 203 Good product molding condition printing means 204 Good product molding condition accumulating means 205 Good product molding condition database 206 Measure history display means 207 Measure history printing means 208 Measures History storage means 209 Molding condition examination interruption processing means 210 Molding condition examination restart continuation means 211 Countermeasure history selection means 212 Molding condition examination returning means 300 Injection molding machine 400 Molded product 1011 All The control unit 1012 professional database section 1013 inference control unit

Front page continuation (72) Inventor Masaaki Kosaka 142, 4102, Miyanodai, Miyadera, Iruma-shi, Saitama Japan Steel Works, Ltd.

Claims (3)

[Claims] 1. When an optimum non-defective molding condition corresponding to a target molded product is extracted from a non-defective product molding condition database in which molding conditions at the time of molding a non-defective product by an injection molding machine are extracted or similar molding conditions cannot be obtained. Is a default setting rule, sets an initial setting value, fills only by injection, and then applies a holding pressure to almost fill the initial molding condition to be the initial molding condition of the target molded product. A setting step, a molding condition input step of setting the corresponding molding conditions in the injection molding machine when setting initial molding conditions for the target molded product or deriving a countermeasure plan for countermeasures against molding defects; A test injection process in which an injection molding machine with molding conditions set in the process performs injection molding, and whether the molded product molded in the test shooting process is a good product or not If found, the defective data input step of determining the defective item and the defective situation, and if the molded product is judged to be a good product in the defective data input step, the molding condition of the injection molding machine at that time is set to a good product. Add to the good product molding condition database as molding conditions,
Further, when a molding defect is found, the defect item is referred to by referring to a molding defect countermeasure matrix in which a plurality of countermeasures to be taken and their selection rules are recorded in advance for each of the molding defects that may occur. And a countermeasure inference process for deriving a countermeasure plan for a defect situation according to a priority order. 2. The injection molding technique support method according to claim 1, further comprising an inference result presenting step of displaying the countermeasure plan derived in the countermeasure inference step. 3. When there are a plurality of defective items determined in the defective data input step, a priority is set for each of the defective items and a countermeasure plan for each defective item is derived in the order of priority in the countermeasure inference step. The method for supporting the injection molding technique according to claim 1 or 2, wherein.