JPH11207750A - Insert molding device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent a defective article from being produced by detecting the installing state of a part before the pouring of a molding material by a method wherein a detecting means for detecting whether the part on a die occupies its installation position or not is provided. SOLUTION: First of all, under the state that dies are opened, a part is inserted in part inserting holes 101 of a movable die 100 until the leg bottom parts 21 of the part strike against abutting surfaces 102. Image data representing the positional relationship of the leg bottom parts 21 of the part to the positions of the abutting surfaces 102 are observed with a video camera 120 so as to transmit that image information to a controlling part 130, in which the image data are image-processed so as to judge whether the positions of the leg bottom parts 21 lies within its allowable value or not. When the observed value lies within the predetermined allowable value, the actuating signal of the opening and closing actuator of a mold is outputted. After a movable die 10 and a fixed mold 50 are clamped together, an actuating signal is outputted from the controlling part 130 to a resin pouring actuator 170 in order to pour melted molding material through a pouring port 52.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an insert molding apparatus, and more particularly to an insert molding apparatus for preventing erroneous molding without loading components in a mold and preventing molding with a component loaded at a shifted position. Related to the device.

[0002]

2. Description of the Related Art Next, a conventional insert molding apparatus will be described. First, an example of a molded product will be described with reference to FIG. 5A and 5B are external views of a molded product, wherein FIG. 5A is a front view, and FIG. The molded product 10 is a coil component for an electronic circuit, in which a metal coil-shaped component 20 exposes a range of a distance D from a leg bottom 21 of the component for the purpose of preventing deformation, and the other components are sealed in a resin portion 30. . Then, for example, due to the automatic mounting of the component by the component mounter, the resin portion bottom surface 3 is formed.
Accuracy of the distance D between the base 1 and the leg bottom 21 is required.

Next, insert molding will be described with reference to FIG. FIG. 6 is a schematic configuration diagram of a conventional molding die, and (a) shows a state in which the mold is opened and a component 20 is loaded.
(B) shows a state where the mold is clamped and the injection material is injected. The molding die includes a steel fixed die 50 fixed to the molding apparatus main body, and a steel iron movable die 400 that moves in the EF direction to close the mold and open the mold. The fixed mold 50 has a cavity 51 having the same shape as the resin part 30 of the molded product.
And an injection port 52 for injecting a resin into the cavity 51. The component 20 is inserted and held in the movable mold 400, and the contact surface 402 is
Two component insertion holes 401 serving as surfaces for determining a zero loading position are provided.

Next, the forming process will be described. First, in a state where the mold is opened, the component 20 is inserted into the component insertion hole 4 of the movable mold 400 by hand or a carrier (not shown).
01, the component leg bottom 21 is inserted until it hits the contact surface 402. Subsequently, after the movable mold 400 and the fixed mold 50 are clamped, the molten molding material is injected from the injection port 52. Then, after the molding material is cured, the mold is opened, and the molded product 10 in which the component 20 and the resin portion 30 are integrally joined is taken out.

[0005]

However, in the above-described insert molding apparatus, the molding material is injected in a state where the component 20 is not loaded due to an operation error of the operator or in a state where the component 20 is not securely inserted to the contact surface 402. In this case, a defective product such as a molded product in which the component 20 is missing or a molded product in which the position of the component 20 is shifted is generated. Therefore, it is desired to detect the loaded state of the component 20 before the molding material is injected to prevent a defective product from being manufactured.

[0006]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems. An insert molding apparatus for molding a target object by injecting a molding material after placing a part in a mold is provided.
A detecting means is provided for detecting that the component is in the loading position in the mold.

[0007] The detecting means may include a transparent member forming a part of the mold so that the position of the component in the mold can be seen, and a loading position of the component through the transparent member. And an optical detecting means for detecting the temperature. Further, the detection means comprises suction means for suctioning the loaded portion of the component in the mold, and pressure detection means for detecting the pressure of the suction space by the suction means. Things.

The detecting means includes a pressurizing means for sucking a gas into a portion of the mold in which the component is loaded, and a pressure for detecting a pressure of a gas suction space by the pressurizing means. And a detecting means. Further, the detecting means comprises a proximity sensor whose output signal changes in a state where the component is loaded at an appropriate loading position of the component in the mold.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described with reference to FIG. FIG. 1 is a schematic configuration diagram of an insert molding apparatus according to a first embodiment of the present invention, where (a) is a configuration diagram (only a mold section is a cross-sectional view).
(B) is an arrow B view of the flange. In this embodiment, the molded article 10 shown in FIG. 5 is also molded.

Reference numeral 50 denotes a steel fixed mold fixed to the main body of the insert molding apparatus. The fixed mold 50 is provided with a cavity 51 having the same shape as the resin part 30 of the molded product, and an injection port 52 for injecting a resin (corresponding to a molding material) into the cavity. Reference numeral 100 denotes a steel movable mold that moves in the EF direction with respect to the fixed mold 50 to clamp and open the mold. The movable mold 100 is provided with two component insertion holes 101 in which the component 20 is inserted and held, and a contact surface 102 of the component is a surface for determining a loading position of the component 20. Then, at least one of the component insertion holes 10
1 is provided with a through hole 103 that penetrates from the outer surface of the movable mold 100 and allows the vicinity of the contact surface 102 of the component insertion hole 101 to be observed. The through hole 103 is formed in a stepped cylindrical shape with the small-diameter cylindrical hole 104 on the component insertion hole 101 side. A nest 105 made of a transparent member such as heat-resistant glass is fitted in the through hole 103. Reference numeral 106 denotes a flange for fixing the insert 105, which is fastened to the movable mold 100 with a plurality of screws 108 so as to cover the through hole 103. This flange 106 is a metal annular plate, and has a central observation window hole 107 and a screw 1.
A plurality of holes (not shown) into which the holes 08 are inserted are formed.

Reference numeral 120 denotes a video camera for photographing the gap between the component leg bottom 21 and the contact surface 102 through the nest 105. Reference numeral 140 denotes a speaker that alerts the user of the abnormality by voice when the component 20 is abnormally loaded. Reference numeral 150 denotes a lamp that alerts the user by displaying an abnormality when the loading of the component 20 is abnormal.
Reference numeral 160 denotes a mold opening / closing actuator for opening and closing the mold, and is a drive mechanism including an electric motor or a hydraulic cylinder mechanism. Reference numeral 170 denotes a resin injection actuator for injecting a molten resin into the cavity 51 in response to a signal associated with the closing and opening of the mold, and is constituted by a screw type or plunger type mechanism. 130 is the video camera 12
This is a control unit that inputs video information from 0 and outputs control signals to the speaker 140, the lamp 150, the mold opening / closing actuator 160, and the resin injection actuator 170 according to the loaded state of the component 20, and is configured by a microcomputer. .

Next, the processing steps will be described. First, in a state where the mold is opened, the component 20 is inserted into the component insertion hole 101 of the movable mold 100 by hand or a carrier (not shown).
Then, the component leg bottom 21 is inserted until it hits the contact surface 102. Image data in the vicinity of the contact surface 102, that is, image data indicating the positional relationship of the leg bottom 21 of the component with respect to the position of the contact surface 102 is observed by the video camera 120, and the image information is transmitted to the control unit 130. The control unit 130 performs image processing on the image data to determine whether the position of the component leg bottom 21 is within the allowable value, and when it is determined that the position is outside the allowable value, the control unit 130 interrupts the process and outputs the signal from the speaker 140. An alarm is issued to the operator by sound emission, lighting of the lamp 150, or the like. If the observed value is within the predetermined allowable value, an operation signal is output to the opening / closing actuator 160 of the molding die. After the movable mold 100 is clamped to the fixed mold 50, the control unit 130 outputs an operation signal to the resin injection actuator 170, and injects the molten molding material from the injection port 52. The completion of the mold clamping refers to a point in time when the pressing of the movable mold 100 against the fixed mold 50 reaches a predetermined pressure. Then, after the molding material is hardened by being left in a mold-clamped state for a predetermined time, the control unit 130 outputs a signal for opening the mold to the mold opening / closing actuator 160 to open the mold. Then, the molded product 10 in which the component 20 and the resin portion 30 are integrally joined is taken out by hand or a transport device.

Next, a second embodiment of the present invention will be described with reference to FIG. FIG. 2 is a schematic configuration diagram of an insert molding apparatus according to a second embodiment of the present invention, in which only a mold portion is shown in a sectional view. In this embodiment, the molded article 10 shown in FIG. 5 is also molded. Reference numeral 50 denotes a fixed iron metal mold fixed to the insert molding apparatus main body. The fixed mold 50 is provided with a cavity 51 having the same shape as the resin portion 30 of the molded product, and an injection port 52 for injecting resin into the cavity. 200
Is moved in the EF direction with respect to the fixed mold 50 to clamp the mold,
This is a steel moving mold that opens the mold. The movable mold 200 is provided with two parts insertion holes 201 in which the parts 20 are inserted and held, and the contact surface 202 is a plane for determining the loading position of the parts 20. A vent hole 203 penetrating from the outer surface of the mold is provided on the contact surface 202 of the hole 201. When the component leg bottom 21 abuts on the contact surface 202 at the joint surface between the vent hole 203 and the contact surface 202, the flow of air between the vent hole 203 and the part of the component insertion hole 201 (that is, the outside air pressure region) is shut off. The area of the vent hole 203 is
02 (the cross-sectional area of the component leg bottom 21). Reference numeral 250 denotes the vent hole 2 coupled to the vent hole 203.
It is a pump that sucks the air in the inside 03. Reference numeral 210 denotes an air pressure sensor that detects the air pressure in the vent hole 203.

Reference numeral 140 denotes a speaker that alerts the user of the abnormality by voice when the component 20 is abnormally loaded. 150 is the part 20
Is a lamp that gives an alarm by displaying an abnormality when the loading is abnormal. Reference numeral 160 denotes a mold opening / closing actuator for opening and closing the mold, and is a drive mechanism including an electric motor or a hydraulic cylinder mechanism. Reference numeral 170 denotes a resin injection actuator for injecting molten resin into the cavity 51 in response to a signal associated with the closing and opening of the mold, which is a screw-type or plunger-type mechanism. A signal 230 corresponding to the pressure of the air in the air hole 203 from the air pressure sensor 210 is input, the loaded state of the component 20 is determined, and the speaker 1
A control unit that outputs control signals to the lamp 40, the lamp 150, the mold opening / closing actuator 160, and the resin injection actuator 170, and is configured by a microcomputer.

Next, the processing steps will be described. First, in a state where the mold is opened, the component 20 is manually or manually transferred (not shown) into the component insertion hole 201 of the movable mold 200.
Is inserted until the component leg bottom portion 21 hits the contact surface 202. As the component leg bottom 21 approaches the contact surface 202, the air resistance through which air flows increases near the contact surface 202, and the air pressure in the vent hole 203 is reduced by suction by the pump 250. The control unit 230 analyzes the data of the air pressure of the vent hole 203 and determines whether the position of the component leg bottom 21 with respect to the contact surface 202 is within an allowable value. If it is determined that the atmospheric pressure data is out of the allowable range, the control unit 230 interrupts the process and alerts the operator of the abnormality by the speaker 140 or the lamp 150. If the observed value is within the predetermined allowable value, an operation signal is output to the opening / closing actuator 160 of the molding die. And the movable mold 200 is fixed mold 5
After the mold is clamped by being combined with 0, an operation signal is output to the resin injection actuator 170, and the molten molding material is injected from the injection port 52. Then, after the molding material is hardened by being left in the mold-clamped state for a predetermined time, the control unit 230 outputs a signal for opening the mold to the mold opening / closing actuator 160 to open the mold. Then, the molded product 10 is taken out by hand or by a conveyor.

In this embodiment, the loaded state of the component 20 is determined by sucking the air in the air hole 203 and reducing the pressure. However, the air is sucked into the air hole 203 and pressurized. It is also possible to determine the loaded state of the component 20 by measuring the pressure (atmospheric pressure) in the 203. Next, a third embodiment of the present invention will be described with reference to FIG.
FIG. 3 is a schematic configuration diagram of an insert molding apparatus according to a third embodiment of the present invention, showing only a mold portion in a cross-sectional view. In this embodiment, the molded article 10 shown in FIG. 5 is also molded.

Numeral 50 is a fixed iron metal mold fixed to the main body of the insert molding apparatus. The fixed mold 50 is provided with a cavity 51 having the same shape as that of the resin portion 30 of the molded product, and an injection port 52 for injecting the resin into the cavity. Reference numeral 300 denotes a steel movable mold that moves in the EF direction with respect to the fixed mold 50, clamps the mold, and opens the mold. The movable mold 300 is provided with two component insertion holes 301 in which the component 20 is inserted and held, and the contact surface 302 is a surface that determines the loading position of the component 20. Reference numeral 310 denotes a proximity sensor whose output signal changes when the component 20 is at an appropriate mounting position (a position within an allowable range). In this embodiment, since the component leg bottom 21 is made of metal, a magnetic sensor that detects a change in the magnetic field can be used. However, a switch having mechanical contacts, a sensor that detects a change in capacitance, or the like can also be used. is there. The proximity sensor detects the contact between the contact surface 302 and the component 2 so as to detect that the component leg bottom 21 is in contact with the contact surface.
It is buried in the mold at an appropriate position so as to face 0.

Reference numeral 140 denotes a speaker which alerts the user of a failure in the loading of the component 20 by voice. 150 is the part 20
Is a lamp that gives an alarm by displaying an abnormality when the loading is abnormal. Reference numeral 160 denotes a mold opening / closing actuator for opening and closing the mold, and is a drive mechanism including an electric motor or a hydraulic cylinder mechanism. Reference numeral 170 denotes a resin injection actuator for injecting the molten resin into the cavity 51 in response to a signal accompanying the closing and opening of the mold, which is a screw type or plunger type mechanism. A control unit 330 receives an electric signal from the proximity sensor 301, determines the loaded state of the component 20, and outputs a control signal to the speaker 140, the lamp 150, the mold opening / closing actuator 160, and the resin injection actuator 170. It consists of a microcomputer.

As shown in FIG. 4, the proximity sensor 310 may have a structure for detecting the position of the component leg bottom 21 from the side. In this case, the annular magnetic sensor 311 and the contact surface 302 of the component insertion hole 301 are used. An optical sensor or the like that detects a light blocking state in the vicinity can be used. Next, the processing steps will be described. First, in a state where the mold is opened, the component 20 is placed in the component insertion hole 301 of the movable mold 300 by hand or a carrier, and the component leg bottom 21 is brought into contact with the contact surface 302.
Until it hits. Proximity sensor 310 outputs a signal according to the loaded state of component 20 to control unit 330. The control unit 330 analyzes the output signal of the proximity sensor 310 and determines whether the position of the component leg bottom 21 with respect to the contact surface 302 is within an allowable value. If it is determined that the position is outside the allowable value, the control unit 330 executes the process. At the same time, the operator is alerted by the speaker 140 or the lamp 150 of the abnormality. If the observed value is within the predetermined allowable value, an operation signal is output to the opening / closing actuator 160 of the molding die. After the movable mold 300 is combined with the fixed mold 50 and clamped, an operation signal is output to the resin injection actuator 170, and the molten molding material is injected from the injection port 52. Then, after the molding material is left for a predetermined time in the state of being clamped and the molding material is cured, the control unit 330 outputs a signal for opening the mold to the mold opening / closing actuator, and opens the mold. Then, the molded product 10 is taken out by hand.

[0020]

According to the present invention, since the loaded state of a component can be detected until the molding material is injected after the component is loaded, it is possible to prevent the component from being missing or being molded with the loaded position shifted.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram of an insert molding apparatus according to a first embodiment of the present invention, in which (a) is a configuration diagram, and (b) is a view of a flange viewed from an arrow B.

FIG. 2 is a schematic configuration diagram of an insert molding apparatus according to a second embodiment of the present invention.

FIG. 3 is a schematic configuration diagram of an insert molding apparatus according to a third embodiment of the present invention.

FIG. 4 is a schematic configuration diagram of an insert molding apparatus in which a sensor unit according to a third embodiment of the present invention is modified.

5A and 5B are external views of a molded product, wherein FIG. 5A is a front view, and FIG.

6A and 6B are schematic configuration diagrams of a conventional molding die, in which FIG. 6A is a diagram illustrating a state where the mold is opened and components 20 are loaded, and FIG. 6B is a diagram illustrating a state where the mold is clamped and an injection material is injected.

[Description of Signs] 10 ··· Molded product 20 ··· Parts 50 ··· Fixed mold 100, 200, 300, 400 ··· Moving mold 102, 202, 302, 402 ··· Contact surface 105 ···・ Nesting 120 ・ ・ ・ video camera 130, 230, 330 ・ ・ control unit 210 ・ ・ ・ barometric pressure sensor 250 ・ ・ ・ pump 310 ・ ・ ・ proximity sensor 311 ・ ・ ・ annular magnetic sensor

Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI // B29K 105: 22

Claims (5)

[Claims] 1. An insert molding apparatus for molding a target object by injecting a molding material after a part is put into a mold, wherein a detecting means for detecting that the part in the mold is at a loading position is provided. An insert molding device characterized by being provided. 2. The method according to claim 1, wherein the detecting unit includes: a transparent member forming a part of the mold so that a position of the component in the mold can be seen; and a loading position of the component through the transparent member. 2. An insert molding apparatus according to claim 1, further comprising an optical detecting means for detecting the temperature of said insert. 3. The apparatus according to claim 1, wherein the detecting unit includes: a suction unit configured to perform suction on a part where the component is loaded in the mold; and a pressure detection unit configured to detect a pressure in a suction space by the suction unit. The insert molding apparatus according to claim 1, wherein 4. The detecting means comprises: a pressurizing means for sucking a gas into a part of the mold where the component is loaded; and a pressure detecting means for detecting a pressure of a gas suction space by the pressurizing means. The insert molding apparatus according to claim 1, wherein: 5. The apparatus according to claim 1, wherein the detecting means comprises a proximity sensor whose output signal changes when the component is loaded at an appropriate loading position of the component in the mold. Insert molding equipment.