JPH06182842A - Method for supporting injection molding technique and device therefor - Google Patents

Abstract

PURPOSE:To more efficiently derive an appropriate countermeasure of a noncon forming state of a molded article. CONSTITUTION:An initial molding condition setting means 103 selects an initial molding condition to an objective molded article by referring to a conforming article molding condition data base 205 and sets it in an injection molding machine 300 through a molding condition output means 110. If s nonconforming molding occurs in a molded article 400 molded by this injection molding machine 300, a plurality of actions to the nonconforming molding are successively derived by a countermeasure inferring means 101. A molding condition related to the countermeasure is set in the injection molding machine 300 through the molding condition output means 110 to make it conduct injection molding. If a molded article 400 mole by the injection molding machine 300 is judged to be nondefective, a molding condition in this shore is stored in the conforming article condition data base 205 as a conforming article molding condition.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and apparatus 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, or the injection molding machine. In addition, since many control parameters such as speed, pressure, and 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. It's a very difficult task.
Of course, it 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. With respect to the selected molding defect, the current setting condition of the molding conditions is checked 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 / analytical approach such as detailed analysis of the cause of the molding failure that usually occurs, and deriving candidate measures based on that analysis,
In many cases, a certain measure is intuitively decided from experience and intuition among a plurality of measures. The defect selected is not always eliminated by the first selected measure, and the optimum molding conditions are searched for by repeating trial and error of repeating the third and fourth terms.

Assuming that countermeasures A to E can be considered for the defects that have occurred during the countermeasure against the defective molding when the molding conditions are set out, an injection molding expert has a plurality of countermeasures, for example, A and B. Are 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 is executed, and if it is deteriorated, 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. It can be seen that the countermeasures are implemented in various patterns such as, and that there is some sort of sequence relation between the plurality of possible countermeasures-countermeasure procedure knowledge.

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, the defect selected by the initially selected measure is rarely eliminated, and knowledge about this measure is largely related to how quickly the optimum molding conditions can be set, and it is important for the expert to have the knowledge. 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 Alternatively, there has been proposed an attempt 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-02-128820.

Among these, the conventional example mainly carries out 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 Multiple countermeasure plans are presented with priorities according to the above, and the operator selects these countermeasure plans. Further, the conventional example mainly sets the initial molding conditions, and the conventional example shows a single measure.

[0016]

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

In the conventional example, the procedure for deriving the countermeasure plan is completely different from that of an expert, and it is difficult to analyze the cause a.

B It is difficult to set the certainty.

C People tend to vary.

D No realistic instruction is given regarding the countermeasure procedure. As a result, the process of deriving the countermeasure plan becomes complicated, the database or knowledge base becomes large in scale, and change, improvement, and maintenance are likely to be difficult.

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 present invention has been made in view of the problems of the above-mentioned prior art, and is an injection molding technique in an injection molding machine for more efficiently deriving an appropriate countermeasure against a defective condition of a molded product. The purpose of the present invention is to provide a support method and a device therefor.

[0024]

The method for supporting the injection molding technique of the present invention is to find the optimum non-defective molding condition corresponding to the target molding product from the non-defective molding condition database in which the molding conditions at the time of molding the non-defective product by the injection molding machine are accumulated. The initial molding condition setting step for extracting the initial molding conditions of the target molded product and the relevant molding condition at the time of setting the initial molding condition or deriving a countermeasure plan for the defective molding countermeasure for the target molded product. A molding condition input step set in the injection molding machine, a trial shooting step in which the injection molding machine having molding conditions set in the molding condition input step performs injection molding, and a molded article molded in the test shooting step If a defective molding is found in the molded product by checking whether or not it is a non-defective product, a defective data input step of determining the defective item and the defective condition, and the molded product is a non-defective product in the defective data input step. In case of disconnection, the molding conditions of the injection molding machine at that time are added to the above-mentioned non-defective product molding condition database as non-defective product molding conditions, and if defective molding is found, it is carried out for each possible defective molding. A plurality of countermeasures to be taken and their selection rules are referred to a pre-recorded molding defect countermeasure matrix, and a countermeasure inference step of deriving a countermeasure against the defective item and defective situation in accordance with the priority order; 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, in the countermeasure inference step, each defective item is There is a case where priorities are set and a measure for each defective item is derived in the order of the priorities.

Further, the injection molding support device of the present invention includes a molding condition setting support unit having a database unit for storing the molding conditions at the time of molding a non-defective product of the injection molding machine, and the initial molding conditions for the target molded product in the database. When the injection molding machine is set to perform injection molding with reference to a good product molding condition stored in the section, and a molding failure occurs in the molded product molded by the injection molding machine, a plurality of molding defects are treated. If the countermeasures are sequentially derived, the molding conditions are set in the injection molding machine based on the countermeasures, and if the molded product is determined to be a non-defective product, the molding condition at that time is regarded as the non-defective product molding condition, and the molding condition determination support unit And a molding failure countermeasure expert system section which is stored in the database section of.

The database condition of the molding condition output support unit stores the molding conditions at the time of molding a non-defective product by the injection molding machine, and molding of the target molded product by the countermeasure plan derived by the molding failure countermeasure expert system unit. When the defect is resolved, the molding condition related to the countermeasure plan is stored, the molding defect countermeasure expert system unit, information input means for inputting molding information for setting the molding condition for the target molded product, Based on the molding information input from the information input means, the non-defective molding condition database of the molding condition setting support unit is searched to extract the non-defective molding condition corresponding to the target molded product to obtain the initial molding condition of the target molded product. Derived when the initial molding condition setting means and the initial molding conditions defined by the initial molding condition setting means or a molding defect countermeasure for a molded product A molding defect was found in the molding condition output means for setting the molding condition related to the countermeasure in the injection molding machine and the molded product molded by the injection molding machine according to the molding condition set by the molding condition output means. In this case, if the molded product is a non-defective product, the defective molding input means for determining the defective item and the defective condition, and the molding condition of the injection molding machine at that time is stored in the non-defective product condition database of the molding condition output support unit. When a molding defect is found in the molded product, there is a measure reasoning unit that sequentially derives an optimum countermeasure plan for the defective item and the defective situation. When there are multiple defective items, the general control unit that prioritizes each defective item, and the multiple countermeasures to be taken for each molding defect that may occur. It has a specialized database section in which a molding defect countermeasure matrix in which these selection rules are recorded in advance is stored, and an inference control section for sequentially deriving a countermeasure plan for the defective item with reference to the molding defect countermeasure matrix. In the case, as the molding information, specification data indicating specifications of a mold, a molding material, and an injection molding machine, and molded product data indicating a shape and dimensions of a target molded product are input from the information input means, In the case where a molded product has a defect, the molding condition output support unit records the defective item, the defective situation, a countermeasure plan, and a measured value of the molding condition corresponding to the molding condition set in the injection molding machine. The countermeasure history storage means stored as data is provided, and the molding failure countermeasure expert system section is provided with a molding condition input section for measuring the measured molding condition value. The overall control unit of the countermeasure inference means stores, in the countermeasure history storage means, the defective item and the defective situation determined by the defective molding input means, the countermeasure plan, and the molding condition actual value when the defective molding of the molded product occurs. The inference control unit of the countermeasure inference means derives a countermeasure plan by referring to the molding defect countermeasure matrix based on the countermeasure history data, and the inferior countermeasure expert system unit sets the initial molding condition setting unit to Initial molding condition display means for displaying the extracted non-defective molding conditions and initial molding condition changing means for changing the non-defective molding conditions displayed by the initial molding condition display means are provided. In some cases, the non-defective molding conditions changed by the molding condition changing means are set in the injection molding machine as the initial molding conditions.

[0027]

The function of supporting the injection molding technique of the present invention is that when a molding defect occurs in a molded product molded by an injection molding machine,
Optimum molding conditions for the target molded product while sequentially deriving a plurality of countermeasures for eliminating the molding failure and setting the molding conditions related to the elicited countermeasures in the injection molding machine each time. To explore.

The injection molding support device of the present invention selects the initial molding conditions for the target molded product from the molding conditions at the time of molding a good product and sets it 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 the molded product molded by the injection molding machine is judged to be good, by accumulating the molding conditions at that time as good product molding conditions, the database at the time of setting the initial molding conditions of the target molded product becomes rich, As the initial molding condition, it is possible to set a condition closer to a good product molding condition.

[0029]

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

FIG. 1 shows the configuration of an embodiment of the present invention.

The configuration of this embodiment is as shown in FIG.
Molding failure countermeasure expert system department (hereinafter referred to as "ES
Part. ) 100 and molding condition setting support unit (hereinafter,
It is called "Support Department". ) 200 and.

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 from 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 is provided with 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 Defect 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 mold-related information, the specification data such as the model of the mold 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 a molding condition example stored in advance 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 operator determines the initial molding condition changing means 105 by using the initial molding condition changing means 105. It is possible to change to 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 symptom, a cause, a countermeasure, etc. relating to the defectiveness and a sample photograph.

The countermeasure inference means 101, as shown in FIG. 2, has 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 uses the 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 that 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 accumulating means 204 is the countermeasure inferring means 101 of the ES section 100.
The non-defective molding conditions transferred from are stored in the non-defective molding condition database 205. As the good measure history data, the E
The actual measurement value of the molding condition transferred from the S section 100, 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 point 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, an outline of the operation of the ES section 100 will be described with reference to the flowchart shown in FIG. Input of molding information (step S100) The molding information necessary for searching the optimum molding conditions for the target molded product is input. Optimum molding for the target molded product from the non-defective molding conditions stored in the non-defective molding condition database 205 according to some key data items in the molding information input in the initial molding condition setting (step S200). Enter the conditions by searching and set as the initial molding conditions. According to the initial molding conditions set in the trial shot (step S300) or the current molding conditions changed in the inference result presentation, the actual molding is performed and the state of the molded product is observed (step S40).
0).

If a non-defective product having no defective molding can be molded, the countermeasure for defective molding is terminated. Molding defect input (step S500) When a defect has occurred in the molded product as a result of the trial firing, the defect item is selected and input. Countermeasure inference (step S600) Occurrence according to a database regarding countermeasures for molding defects in the system based on all data input up to now, that is, molding information, molding condition set values, molding condition actual values, defects, countermeasure history, etc. Infer the optimal countermeasures for eliminating the molding failure. 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, molding information is input (step S100).
Then, the molding information of the seven items described above is input from the information input unit 102.

Next, 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 S201), 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 S202).

If there is a non-defective molding condition corresponding to the molding information, the non-defective molding condition is extracted (step S
203) Use initial molding conditions.

At this time, the setting condition items specific to the target molded product are changed according to the default setting rules (step S204).

On the other hand, if there is no molding condition corresponding to the molding information, a new molding condition is set according to the default setting rule (step S205).

The initial molding conditions set as described above are displayed on the initial molding condition display means 104 (step S206) and confirmed by the operator. At this time, if it is determined by the operator's judgment that the molding conditions need to be changed (step S207), the initial molding condition changing means 105 can be used to change to more suitable initial molding conditions (step S208). ).

Subsequently, the trial shooting (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). The 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 from the defective molding input means 108 to the countermeasure inference means 101, 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) with reference 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 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 transfer" which indicates a correction work for performing the next countermeasure at the same time or "correction" which only corrects the current countermeasure, and "suggestion" or "comment" which notifies the operator of a message.

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

First, in the inference result presentation 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"
Whether there is a message to be displayed as (step S702), and if there is a message (step S703), the target parameter and the correction amount by the "correction" are displayed (step S704), and according to that, 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", then it is 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). Further, in step S705, “correction transfer” of the countermeasure plan
If so, the correction target parameter and the operation amount are displayed (step S706), and it is checked whether or not there is the "comment" in step S707. If there is a "comment" to be displayed, that message is displayed (step S
708), if there is no "comment", then "suggestion"
It is checked whether or not there is a message to be displayed as (step S709). The message displayed as “proposal” is, for example, a message related to a mold or a molding material such as the suggestion message group MSG-10 shown in Table 1. This is mainly due to the countermeasures derived by the countermeasure inference to eliminate defects. This is displayed when it is not possible.

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 determines that the suggestion is displayed as a result of the countermeasure inference, the suggestion message group M is displayed.
The relevant message is extracted by referring to SG-10, transferred to the inference result presenting means 109 and displayed.

[0076]

[Table 1] If there is a message to be displayed as "proposal", that message is displayed (step S710), and then the molding conditions are changed by the "correction shift" in 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).

When this countermeasure plan is displayed, all the molding conditions can be displayed in order to confirm the setting status 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 in step S716. On the other hand, when the selected countermeasure plan is adopted, the operation amount can be arbitrarily changed, so it is checked whether or not it is necessary to change it (step S71).
3), if there is no need to change, set molding conditions in step S716 according to the selected countermeasure,
If it is necessary to change the manipulated variable, after inputting the manipulated variable (step S715), the molding conditions are similarly set in step S716. When the result of the countermeasure inference is "correction" described above, the target parameter and the correction amount are displayed, but 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. 7 is a flow chart showing in detail the matrix processing (step S602) of FIG.

Here, as the molding defect countermeasure matrix stored in the specialized database section 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, and C) that may occur are generated. ...) A plurality of countermeasure plans (A, B, C, ...) are recorded for each of the countermeasure numbers corresponding to the determined priorities. 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 the molding condition corresponding to, and thereafter, for the defects that have occurred similarly, the corresponding countermeasure plan is selected in the order of the countermeasure numbers.

[0083]

[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. In the countermeasure result matrix of this embodiment, as shown in Table 3, for example, five items are considered as changes in the molded product: improvement of defects, no effect, appearance of other defects, existence of other defects, and elimination of other defects. In Table 2,
For example, if the defective measure is improved as a result of executing the measure corresponding to the measure No. 2, the measure corresponding to the measure No. 2 is continuously executed until the molded product becomes a good product. Also,
If there is no effect, execute "B-3". This "B-
"3" indicates "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. Further, as a result of executing the countermeasure plan corresponding to the countermeasure number 2, when another defect occurs in the molded product (another defect appears), "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).

[0085]

[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.

[0086]

[Table 4]

[0087]

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

[0088]

[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
The same applies to.

[0089]

[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 executing the measure proposed derived from the result of the measure inference. For example, in the matrix MTL-7 shown in Table 8, if the injection speed is changed in sequence, the injection speed does not exceed the set allowable range, or the injection speed is changed. At, the countermeasure plan corresponding to the countermeasure number 7, 8 or 9 is selected depending on whether or not the elapsed time related to the injection process exceeds the allowable range.

[0090]

[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 condition 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 under way, the countermeasure plan is derived by referring to the basic matrix as the initial setting at the time of starting the defect countermeasure. Therefore, the countermeasure number corresponding to the countermeasure plan is initialized ( Countermeasure 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 "focused basic matrix").

[0093]

[Table 9] As countermeasure measures for the defective item of interest shown in Table 9, nine countermeasure plans A to H corresponding to the countermeasure numbers 2 to 9 are considered, and in the case of the countermeasure number 1, the process check shown in Table 4 is performed. Reference to matrix MIK-1 is shown, and in the case of countermeasure number 10, the proposed message group MSG- in Table 1 above is shown.
10 references are shown.

When the initialization of the countermeasure number is completed, the countermeasure number 1 of the noted basic matrix shown in Table 9 is referred to (step S803), and it is checked whether or not the countermeasure number 1 indicates the countermeasure plan (step S803). S804). Here, the measure number 1 is the process check matrix MIK-1.
Since it indicates that the message does not indicate a countermeasure plan, it is then checked whether or not there is a message to be displayed as a "suggestion" or "comment" (step S8).
12). In this case, there is no message to display, so
Next, it is checked whether or not it is a reference to another matrix (step S
814). Here, since the countermeasure number 1 indicates the reference of the process check matrix as described above, the process check matrix MIK-1 is referred to, and the IVS mode setting status and whether the process is injection or pressure holding is defective. A countermeasure plan is selected depending on whether the problem has occurred (step S
815). 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, in any case, since the countermeasure number indicating the countermeasure plan is recorded, the matrix to be referred to. Then, it is determined whether or not to shift to a “procedure” such as a subroutine indicating another process (step S816). In this case as well, since 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), based on the updated countermeasure number,
The attention basic matrix is referred to (step S80).
3). 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, the IVS mode is "H".
If the defect occurrence process is the injection process, the countermeasure number 2 is selected, and as a result of referring to the attention basic matrix, the countermeasure plan A is selected (step S80).
4) It is output to the inference result presenting means 109 (step S8).
05), if there is no change, it is set in the injection molding machine 300 by the molding condition output means 110.

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 S809) are sequentially examined. However, none of them correspond, so the countermeasure number is referred to as the countermeasure result matrix. Update the countermeasure number 3 selected from (Step S81
1) The reference basic matrix is referred to based on the countermeasure number (step S803). In this case, the countermeasure plan B corresponding to the countermeasure number 3 is selected from the noted basic matrix (step S804), and the countermeasure plan B is similarly output to the inference result presentation means 109 (step S805). If another defect appears as a result of implementing the measure A in step S806 (another defect appears), "correction" (R-2) of the measure A corresponding to the measure number 2 in the measure result matrix. Do. When this "correction" measure is taken, it is confirmed whether or not another defect that has appeared due to the implementation of the measure A is eliminated, and if it is eliminated (other defect elimination), By referring to the molding condition setting status matrix MTC-4 (see Table 6) (steps S807 and S808), the next countermeasure plan is selected. In the molding condition setting matrix MTC-4, "procedure" is selected. When the CMP-4 indicating the is selected, the corresponding “procedure” is referred to (steps S809 and S81).
0), and update to the countermeasure number determined by the "procedure" (step S818).

In addition, in the step S806, if the countermeasure defect A is found to be "improved" as a result of implementing the countermeasure plan A, the countermeasure plan A will be 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, along with the countermeasure numbers recorded in the noticed basic matrix, the countermeasure plan for the noticed defective item is derived with reference to the defect countermeasure matrix in order. 2-9
If the above noted defects are not resolved even after implementing all the measures derived from, that is, there is a fatal problem with the mold, molding material, injection molding machine, etc. that cannot be resolved by changing the setting of molding conditions. If judged, the reference of the proposal message group MSG-10 is instructed in the noted basic matrix (steps S804, S812), and the corresponding message is transferred to the inference result presentation means 109 as a proposal 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 check 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.

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.

[0102]

As described above, according to the present invention, the following effects can be obtained. (1) Optimal molding conditions are set by a simple data input operation such as molding information, so the time required to set the molding conditions is shortened, and the labor or material
Energy loss can be greatly reduced. (2) Even beginners with little experience can set optimal molding conditions, preventing variations in molding condition settings.
It is possible to always obtain stable and high-quality molded products. (3) Since the database of non-defective molding conditions and molding failure countermeasure matrix used for deriving the molding conditions is stored in a database, the size of the knowledge base for deriving the optimum molding conditions can be made compact, and the knowledge base can be changed or improved. Easy to maintain. (4) By creating a database of the knowledge base for deriving the molding conditions, it becomes possible to systematically manage various information, and the technology can be accumulated more efficiently.

[Brief description of drawings]

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

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

FIG. 3 is a flowchart showing an example of the operation of the injection molding support device of the present invention.

FIG. 4 is a flowchart showing an example of an initial molding condition setting step of an injection molding technique support method of the present invention.

FIG. 5 is a flowchart showing an example of a molding condition inputting process, a trial shooting process, a defect data inputting process, and a countermeasure inference process of the injection molding technology support method of the present invention.

FIG. 6 is a flow chart showing an example of an inference result presentation step of the injection molding technology support method of the present invention.

FIG. 7 is a flowchart showing an example of matrix processing of a countermeasure inference process.

[Explanation of symbols]

100 Molding Defect 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 Defect Input Means 109 Inference Result display 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 storage 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 backtracking means 300 Injection molding machine 400 Molded product 1011 All The control unit 1012 professional database section 1013 inference control unit S100, S200~S208, S300~S304,
S400, S500 to S502, S600 to S602,
S700-S716, S801-S818 steps

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Esaka Gen 1-6-1, Funakoshi Minami, Aki-ku, Hiroshima City, Hiroshima Prefecture Japan Steel Works Hiroshima Works

Claims (9)

[Claims] 1. An initial molding condition for an optimum molding product by extracting an optimum molding condition for a molding product from a database for molding a molding product in which molding conditions for molding a molding product by an injection molding machine are accumulated. A molding condition setting step, a molding condition input step of setting the corresponding molding condition in the injection molding machine when setting an initial molding condition or deriving a countermeasure plan for a defective molding countermeasure for the target molded article; A test injection process in which an injection molding machine with molding conditions set in the condition input process performs injection molding, and whether or not the molded product molded in the test shooting process is a good product is found, and a molding defect is found in the molded product. If the defective product is judged to be a good product in the defective data input step and the defective data input step, the molding condition of the injection molding machine at that time is determined. Add to the non-defective molding condition database as goods molding conditions,
If a molding defect is found, the defect item is referred to by referring to the 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 possible molding defects. And a countermeasure inference step of deriving a countermeasure plan for a defect situation in accordance with the priority order. 2. The injection molding technology support method according to claim 1, further comprising an inference result presentation 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 in the countermeasure inference step, and a countermeasure plan for each defective item is derived in the order of the priority. The method for supporting injection molding technology according to claim 1 or 2, characterized in that. 4. A molding condition output assisting unit having a database unit for storing a molding condition at the time of molding a good product of an injection molding machine, and a database unit of the molding condition issuing assisting unit stores an initial molding condition for a target molded product. When a molding failure occurs in a molded product molded by the injection molding machine by referring to the molding conditions of the non-defective product, the plurality of measures for the molding failure are sequentially derived, and the countermeasures are taken. If it is determined that the molded product is a good product by setting the molding condition in the injection molding machine based on the plan and performing the injection molding, the molding condition at that time is regarded as the good product molding condition and the database unit of the molding condition determination support unit. An injection molding support device having a molding failure countermeasure expert system section that is stored in. 5. The database condition of the molding condition issuing support unit stores molding conditions at the time of molding a non-defective product by an injection molding machine, and the molded product of the target molded product is determined by the countermeasure plan derived by the molding failure countermeasure expert system unit. When the molding failure is resolved, the molding conditions related to the countermeasure plan are stored, and the molding failure countermeasure expert system unit is an information input unit for inputting molding information for setting the molding condition for the target molded product. Based on the molding information input from the information input means, the non-defective molding condition database of the molding condition setting support unit is searched to extract the non-defective molding condition corresponding to the target molded product to perform the initial molding of the target molded product. Initial molding condition setting means as a condition, and initial molding conditions defined by the initial molding condition setting means or derived when a molding defect countermeasure for a molded product is taken When a molding defect is found in the molded product molded by the injection molding machine according to the molding condition output means for setting the molding condition relating to the countermeasure plan in the injection molding machine and the molding condition set by the molding condition output means. A molding defect input means for determining the defective item and the defective situation, and if the molded product is a non-defective product, the molding condition of the injection molding machine at that time is stored in the non-defective product molding condition database of the molding condition output support unit, The injection molding support apparatus according to claim 4, further comprising: a countermeasure inference unit that sequentially derives an optimal countermeasure plan for the defective item and defective situation when a defective molding is found in the molded product. 6. When there are a plurality of defective items, the countermeasure inference means of the molding defect countermeasure expert system unit should be implemented for the overall control unit that sets the priority for each defective item and for each molding defect that may occur. A specialized database section that stores a molding defect countermeasure matrix in which a plurality of countermeasure plans and their selection rules are recorded in advance, and inference control that sequentially derives a countermeasure plan for the defective item with reference to the molding defect countermeasure matrix. The injection molding support device according to claim 5, further comprising: 7. As molding information, specification data indicating specifications of a mold, a molding material, and an injection molding machine, and molding product data indicating a shape and dimensions of a target molding product are inputted from the information input means. The injection molding support device according to claim 5 or 6, characterized in that. 8. The molding condition determination assisting unit, when a molding defect occurs in a molded product, measures the defective condition and the defective condition, the countermeasure plan, and the molding condition measurement corresponding to the molding condition set in the injection molding machine. The value and the measure history storing means for storing as measure history data, the molding failure countermeasure expert system unit, the molding condition input unit for measuring the molding condition actual measurement value,
The overall control unit of the countermeasure inference means stores, in the countermeasure history storage means, the defective item and the defective situation determined by the defective molding input means, the countermeasure plan, and the measured molding condition value when the defective molding occurs in the molded product, The injection molding support apparatus according to claim 6 or 7, wherein the inference control section of the countermeasure inference means derives a countermeasure plan by referring to a molding defect countermeasure matrix based on the countermeasure history data. 9. The molding failure countermeasure expert system section changes the initial molding condition display means for displaying the non-defective molding conditions extracted by the initial molding condition setting means, and the non-defective molding conditions displayed by the initial molding condition display means. 6. The molding condition output means sets the non-defective molding conditions changed by the initial molding condition changing means to the injection molding machine as initial molding conditions. The injection molding support device according to 6, 7 or 8.