JPH11268096A - Molding machine and trouble shooting system of molding machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To rapidly and effectively analyze a content of a trouble by providing an external communication controller, and a constitution of transmitting respective operating condition data or the like to an external computer via a telephone channel at the time of a trouble in a molding machine and receiving respective operating condition data formed by the computer. SOLUTION: An external communication controller 14 controls transmission and reception of data to and from an external computer. Here, a microcomputer 4 of an injection molding machine 1 is communicated with an external host computer 20 via a public telephone channel 17 by using a modem 15. When a fault occurs in the machine 1, set operating condition data or the like are transmitted from the microcomputer 4 to the computer 20. At the reception side, the data are analyzed, then trial operation condition values are calculated, and transmitted to the microcomputer 4. The trial operation result is again transmitted to the computer 20 side. Thus, before a service-main goes to a job side, effective information is obtained, and rapid and effective trouble countermeasure can be executed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a microcomputer for controlling an entire machine (hereinafter referred to as a microcomputer).
The present invention relates to a molding machine such as an injection molding machine, a foam molding machine, and a die casting machine, and a trouble diagnosis method for the molding machine.

[0002]

2. Description of the Related Art In the field of a molding machine such as an injection molding machine, a microcomputer for controlling the entire molding machine is built in the machine, and the microcomputer operates according to an automatic molding operation program.
Machines that execute continuous automatic operation with reference to preset operation condition values and measurement information from a sensor group provided in each section of the machine are becoming common.
In such an injection molding machine with a built-in microcomputer, when the microcomputer determines that an abnormality has occurred in the measurement information from the sensor group or the like, the microcomputer refers to data that was previously subjected to a case study to the display device. Is displayed so that the operator of the machine recognizes the occurrence of the abnormality, and when it is determined that the content of the abnormality is equal to or higher than a predetermined level, the machine is urgently stopped.

[0003] When such an alarm message is displayed, the operator of the machine performs a trouble process according to the contents of the alarm message if the content of the abnormality is relatively mild to deal with. If the error cannot be dealt with by the operator or needs to be reported to the manufacturer, or if the error is not resolved even though While stopped, they had to ask the manufacturer's serviceman for troubleshooting.

[0004]

As described above, when a user is notified of a trouble occurrence by telephone or the like as described above, a conventional service person listens to the machine model and the contents of the trouble and predicts the general situation. I was heading to the site. However, in this case, it is difficult for the serviceman to properly prepare replacement parts and the like, because an accurate situation cannot be grasped only by information from a telephone call or the like from the user. If the site is far from the current location of the serviceman, it takes time for the serviceman to arrive, and if the serviceman does not go to the site immediately due to unavoidable circumstances, the response by the serviceman will be delayed, During this time, the user is at a major disadvantage because the machine remains stopped. If you do not have the necessary replacement parts found by a service technician on site,
Since parts are ordered after this point, parts replacement takes time in such a situation. When encountering troubles that are difficult for a serviceman to judge,
In such a situation, it takes time to troubleshoot the problem because a specialist engineer on the manufacturer side is contacted. It was pointed out that there was a problem.

[0005] The present invention has been made in view of the above points,
It is an object of the present invention to realize a trouble diagnosis method capable of quickly and accurately analyzing a trouble content of a molding machine before a service person goes to the site, and a molding machine to be applied thereto.

[0006]

According to the present invention, in order to achieve the above-mentioned object, a microcomputer provided in a molding machine uses a microcomputer provided in each molding machine based on set operating condition data and measurement information from each sensor. An automatic operation control function to drive and control the
It has at least an actual operation condition data (monitor data) storage function for storing actual operation condition data at the time of automatic operation based on the measurement information from each sensor and a self-abnormality diagnosis function, and forms an alarm message when an abnormality occurs. In the trouble diagnosis method for a molding machine, which is displayed on the display device of the machine, a trouble occurs in the molding machine, and the trouble cannot be dealt with by an operator, the trouble needs to be contacted to a maker, or the display is required. In the case where the error is not resolved despite the processing according to the contents of the alarm message displayed on the equipment, the public telephone line is also combed when the manufacturer's request for troubleshooting is made by the molding machine user. Is connected to the manufacturer's host computer via a dedicated network. The set operating condition data, the actual operating condition data recorded by monitoring, and the corresponding alarm information data are taken in from the computer, and the host computer analyzes the causes of the trouble based on the data taken into the host computer. The operating condition command data calculated on the basis of the above is transmitted to the microcomputer of the molding machine via the public telephone line or the dedicated network, and the molding machine executes a test operation for determining or narrowing down the cause of the trouble, and In response to this, the host computer analyzes the test operation result again.

Further, the molding machine is provided with an external communication control unit for transmitting and receiving data to and from an external computer. When a trouble occurs in the molding machine, a modem is connected to the external communication control unit. Data can be transmitted and received to and from an external computer via a telephone line, the molding machine transmits the set operating condition data, the actual operating condition data, alarm information by the self-abnormality diagnosis function to an external computer, , To receive each operation condition data for a test run created by the external computer.

[0008] When the user notifies the manufacturer of the trouble handling request, the operator of the host computer of the manufacturer returns a call to the person in charge of the user to return the telephone to the communication of the microcomputer of the molding machine in which the trouble has occurred. A request is made to connect the input / output end to a telephone set, for example, via a modem. Then, after the microcomputer is connected to the telephone, the operator of the manufacturer's host computer calls the user's telephone via the public line, and connects the host computer and the microcomputer of the molding machine so that transmission and reception are possible. From the side, the set operation condition data, actual operation condition data, and the alarm information data stored in the microcomputer are taken in.

The data taken into the host computer is, for example, a trouble (abnormality) diagnosis program incorporated in the host computer (this is a much lower level than the self-abnormality diagnosis program provided in the microcomputer of the molding machine). The diagnostic function program above is backed up and constructed by a huge amount of case study data and inference calculation methods) and the rich knowledge and experience of the technical staff who is the operator of the host computer. Is analyzed, and trouble factors that are likely to be predicted are listed. The result of this analysis is
It has accuracy comparable to or better than the judgment results of servicemen with rich experience and knowledge. In addition, this index
A test operation condition value for eliminating the inferred trouble factor or for more accurately determining or narrowing down the trouble factor is calculated.

[0010] Next, the operator of the host computer informs a person in charge of the user that a trial operation is to be performed by telephone on another line for accurate analysis of the cause of the trouble, and / or a communication with the host computer. The transmission to the microcomputer (of the molding machine) connected via the public line causes the display device of the molding machine to display a message indicating that a trial run is to be performed for accurate analysis of the cause of the trouble. Thereby, the person in charge on the user side (the molding machine operator) confirms whether or not the molding machine is operable at the required test operation location, and if "OK", inputs a key to that effect. Send to host computer by operation. This confirmation operation is for confirming safety, and a person in charge on the user side (operator of the molding machine) confirms, for example, whether there is a person or an unnecessary object in the mold opening space. After confirming the above communication from the operator of the molding machine (user side), the operator of the host computer (manufacturer side) transmits the test operation condition value determined from the analysis result to the microcomputer of the molding machine, and A test run based on the operation from the host computer is performed. At the time of this test operation, it is desirable that a machine operator on the user side be attached to the molding machine to confirm the event.

The results of the trial operation are taken into the host computer by transmission from the microcomputer of the molding machine, and analyzed again, whereby the cause of the trouble (abnormality or failure) is fixed or narrowed down to a large extent. In the case of a simple failure, for example, a message is sent from the host computer to the microcomputer, and a message is sent to the display device of the molding machine on the troubleshooting method, and the operator of the molding machine (user side) takes action based on the message. By doing so, the trouble is eliminated. In addition, if a service technician of the manufacturer goes to the site and determines that it is necessary to take action, the analysis result is notified to the nearest service technician, and if it is determined that parts replacement is necessary, The replacement part to be replaced is also notified.

[0012] Therefore, the serviceman can obtain accurate information before going to the site, can accurately prepare a replacement part to be predicted, and can quickly and accurately take measures against the problem at the site. .

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to an embodiment shown in FIGS. FIG. 1 is a block diagram schematically showing an overall configuration to which a trouble diagnosis system according to the present invention is applied. In FIG. 1, an injection molding machine generally indicated by reference numeral 1 includes a known mechanism such as a mold opening / closing device 2 and an injection device 3 and a microcomputer 4 for controlling the entire machine. Each of the drive units of the mechanism system is referred to through a driver group 6 by referring to an operation condition value set in advance and measurement information from a sensor group 5 disposed in each part of the machine by an automatic molding operation program. The source is driven and controlled. Reference numeral 7 denotes a key input device serving as input operation means for the microcomputer 4, and reference numeral 8 denotes a display device comprising a color CRT display for displaying the results of processing by the microcomputer 4, and the like.

The microcomputer 4 actually has various I / Os.
An interface, a ROM for storing main control programs and various fixed data, a RAM for reading and writing various flags and measurement data, a CPU (Central Processor Unit) for overall control, etc. In this embodiment, the molding condition setting storage unit 9, the molding process control unit 10, and the actual measurement value storage unit 1
1, assuming that it has functional units such as an abnormality determination data storage unit 12, an abnormality diagnosis unit 13, and an external communication control unit 14,
The following is described.

The molding condition setting storage unit 9 stores various molding condition values input by the key input means 7 or other appropriate input means in a form which can be rewritten after being processed as necessary. . The molding conditions include, for example, the relationship between the screw position, the screw rotation speed, and the back pressure during the charge stroke, suckback control conditions, and subdivision of the (primary injection stroke) from the injection start position to the pressure holding switching point (position). Injection speed conditions, subdivided secondary injection pressure (holding pressure) conditions from the holding pressure switching time to the holding pressure end time,
Examples include the band heater temperature, mold closing stroke and speed, mold clamping force, mold opening stroke and speed, eject control conditions, and the like.

The molding process control section 10 measures measurement information (actual measurement value storage) from the sensor group 5 based on a molding process control program created in advance and setting condition values stored in a molding condition setting storage section 9. While referring to the latest data stored in the unit 11 and time measurement information from a clock built in the microcomputer 4, the corresponding drive sources are driven and controlled via the driver group 6 to execute a series of molding steps. .

The actual measured value storage unit 11 is configured to capture and store all actual measured values of preset monitor items during continuous automatic operation over a predetermined number of consecutive shots. . The monitoring items to be taken are roughly classified into time monitoring items, position monitoring items, rotation speed monitoring items, speed monitoring items, pressure monitoring items, temperature monitoring items, and power monitoring items. A considerable portion overlaps with this, and factors that will be related to the quality of the molded article and the abnormality determination are preset as monitor items.

The abnormality determination data storage section 12 stores an abnormal event, an abnormal numerical value, etc., which have been subjected to a case study in advance. Then, the abnormality diagnosis unit 13 takes in the data of the molding condition setting storage unit 9 and the data of the actually measured value storage unit 11 and refers to the contents of the abnormality determination data storage unit 12,
It is determined whether an abnormality has occurred.

When the abnormality diagnosing unit 13 recognizes the occurrence of an abnormal situation, it generates an alarm, for example, and extracts the message information of the corresponding abnormal item from an alarm message storage unit (not shown). Is forcibly displayed. Further, when it is determined that the content of the abnormality is equal to or higher than the predetermined level, a signal indicating this is output to the molding process control unit 10, and the molding process control unit 10 is configured to stop the machine in an emergency.

The external communication control unit 14 controls the transmission and reception of data to and from an external computer. For example, the external communication control unit 14 uses a modem (modulator / demodulator) 15 and a telephone 16 to communicate with the external computer via a public telephone line 17. So-called computer communication is made possible (it goes without saying that communication is possible through a dedicated computer communication network line).

FIG. 2 shows a display device 8 of the injection molding machine.
2 shows a part of a list of alarm message contents displayed in FIG.
For the abnormalities that can be dealt with by the operator of the molding machine as indicated by the above, the trouble can be solved by performing the processing according to this message (closing the "purge cover"). Further, when the content of the abnormality is something that cannot be dealt with by the operator or needs to be contacted by the manufacturer (for example, the content shown by the message content M2 in FIG. 2), the processing according to the instruction content of the alarm message is performed. If the abnormality is not resolved even though the operation has been performed, the manufacturer will be contacted with the machine stopped.

In FIG. 1, a host computer generally indicated by reference numeral 20 is installed in a place where a technical staff of a manufacturer and sales maker of an injection molding machine is resident. Modem 18,
The user's telephone 16 and modem 15 can communicate with the microcomputer 4 of the injection molding machine 1 through a telephone 19 and a public telephone line 17. 21, 2
Reference numerals 2 and 23 denote key input means connected to the host computer 20, a display device including a color CRT, and an external storage device including a disk recording device.

The host computer 20 is actually composed of a CPU, a ROM, a RAM, an I / O interface, a bus and the like, and executes desired processing by various processing programs created in advance. In the embodiment, for convenience of explanation, it is assumed that the apparatus includes functional units such as an abnormality learning data storage unit 24, a reception data storage unit 25, an abnormality determination unit 26, a test operation setting data calculation unit 27, and an external communication control unit 28. Will be described.

The abnormal learning data storage unit 24 stores a large number of abnormal event items, abnormal numerical values, and the like, which are previously subjected to case studies, and factor items closely related to or possibly related thereto. Actually, the data drawn and transferred from the external storage device 23 is rewritten and stored as needed because of the limitation of the memory capacity.

The received data storage unit 25 stores data transmitted from an external computer (here, the microcomputer 4 of the injection molding machine 1) via the external communication control unit 28. In the present embodiment, the reception data storage unit 25 stores the setting operation condition data, the actual operation condition data (monitor) from the molding condition setting storage unit 9, the actual measurement value storage unit 11, and the abnormality diagnosis unit 13 of the microcomputer 4. Item measured value) and the corresponding alarm code.

The abnormality determination unit 26 refers to the data group stored in the abnormality learning data storage unit 24 and the reception data storage unit 25 and determines the cause of the abnormal phenomenon by an abnormality diagnosis program using an inference operation method or the like. A search is performed and output to the display device 22 or the like. Further, the operator of the host computer 20 is assigned a technical person having rich knowledge and experience about the injection molding machine. With reference to the processing result of the abnormality determination unit 26, the contents of the abnormality (trouble) are accurately analyzed, and the trouble factors to be predicted are listed with high accuracy.

The test operation setting data calculation section 27 is provided to solve the trouble factors which have been identified and inferred as described above by an operation data table (not shown) and a case instruction input by an operator (technical engineer) which have been subjected to case study in advance. Alternatively, a test operation condition value for determining or narrowing down the trouble factor more accurately is calculated.

The external communication control unit 28 controls the transmission and reception of data to and from an external computer, similarly to the external communication control unit 14 on the microcomputer 4 side.

In the above configuration, if a trouble occurs in the injection molding machine 1 and the user cannot cope with the trouble, the user informs the manufacturer of a trouble coping request. In response, the operator (technical staff) of the host computer 20 on the manufacturer side returns a call to the person in charge of the user side, and the communication input / output end of the microcomputer 4 of the injection molding machine 1 in which the trouble has occurred. ,
A request is made to connect to telephone 16 via modem 15. After the microcomputer 4 is connected to the user's telephone 16, the operator of the maker's host computer 20 calls the user's telephone 16 from the manufacturer's modem 18 and telephone 19 via the public telephone line 17. Then, the host computer 20 and the microcomputer 4 are connected so as to be able to transmit and receive. Thereafter, by the operation from the host computer 20 side, as described above, the set operation condition data, the actual operation condition data, and the alarm information data stored in the microcomputer 4 are stored in the reception data storage unit 25 of the host computer 20. It is taken in.

As described above, the data taken into the host computer 20 is analyzed by the trouble (abnormal) diagnosis program and the rich knowledge and experience of the technical staff, and the trouble phenomenon is analyzed and the trouble is highly likely to be predicted. The factors are listed. This analysis result has an accuracy comparable to or higher than the judgment result at the site of a service person with rich experience and knowledge. Further, a test operation condition value is calculated to eliminate the determined and inferred trouble factor or to more accurately determine or narrow down the trouble factor.

Thereafter, the operator of the host computer 20 notifies the person in charge of the user on the telephone of another line that a trial operation is to be performed for accurate analysis of the cause of the trouble, and / or The transmission to the microcomputer 4 connected to the microcomputer 20 via the public telephone line 17 causes the display device 8 on the molding machine to display an indication that a trial run is to be performed for accurate analysis of the cause of the trouble. Thereby, the person in charge on the user side (the operator of the molding machine) checks whether or not the molding machine can be operated at the required test operation location. The data is transmitted to the host computer 20 by the operation of the input means 7. This confirmation should be done to confirm safety.

After confirming the above communication from the operator of the molding machine (user side), the operator of the host computer 20 transmits the test operation condition value determined from the analysis result to the microcomputer 4 of the injection molding machine 1. Then, the injection molding machine 1 is caused to execute a test operation based on this by an operation from the host computer 20 side. At the time of this test operation, it is desirable that the injection molding machine 1 be provided with a machine operator on the user side for the sake of safety and accurate confirmation of the event at the site.

The result of the test operation is taken in the host computer 20 in real time by the transmission from the microcomputer 4, and analyzed again, whereby the cause of the trouble (abnormality or failure) is fixed or narrowed down. For example, in the case of a simple failure, transmission from the host computer 20 to the microcomputer 4
A message is sent to the display device 8 of the molding machine about a troubleshooting method, and the user operator takes measures based on the message to resolve the problem. In addition, if a service technician of the manufacturer goes to the site and determines that it is necessary to take action, the analysis result is notified to the nearest service technician, and if it is determined that parts replacement is necessary, The replacement part to be replaced is also notified.

Therefore, the serviceman can obtain accurate information before going to the site, and can accurately prepare a predicted replacement part, and can take quick and accurate troubleshooting on the site. .

[0035]

As described above, according to the present invention, a trouble diagnosis method for a molding machine, which enables a quick and accurate analysis of the trouble contents of the molding machine before a service person goes to the site, and a molding machine applied to the method. And its value is enormous.

[Brief description of the drawings]

FIG. 1 is a block diagram schematically showing an overall configuration to which a trouble diagnosis system according to the present invention is applied.

FIG. 2 is an explanatory view showing a partial list of alarm message contents displayed on a display device of the injection molding machine.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Injection molding machine 2 Die opening and closing device 3 Injection device 4 Microcomputer (microcomputer) 5 Sensor group 6 Driver group 7 Key input means 8 Display device 9 Molding condition setting storage unit 10 Molding process control unit 11 Measured value storage unit 12 Abnormality judgment data Storage unit 13 abnormality diagnosis unit 14 external communication control unit 15, 18 modem 16, 19 telephone set 17 public telephone line 20 host computer 21 key input means 22 display device 23 external storage device 24 abnormality learning data storage unit 25 reception data storage unit 26 abnormality Judgment unit 27 Test run setting data calculation unit 28 External communication control unit

Claims (4)

[Claims] An automatic operation control function for controlling a drive of each section of the molding machine based on each set operation condition data and measurement information from each sensor, and a microcomputer provided in the molding machine; A real operation condition data (monitor data) storage function for storing actual operation condition data at the time of automatic operation based on the measurement information and the like, and a self-abnormality diagnosis function. An external communication control unit for transmitting and receiving data between the external communication control unit and a modem connected to the external communication control unit when a trouble occurs in the molding machine, and transmitting and receiving data to and from the external computer via a telephone line. The molding machine transmits the set operating condition data, the actual operating condition data, and alarm information by the self-abnormality diagnosis function to a previous state. A molding machine that transmits the data to an external computer and receives each operating condition data for a test run created by the external computer. 2. The molding machine according to claim 1, wherein a computer communication network is connected to the external communication control unit, and data is transmitted to and received from an external computer via the computer communication network. 3. An automatic operation control function for driving and controlling each part of the molding machine based on each set operation condition data and measurement information from each sensor, and a microcomputer provided in the molding machine; At least an actual operation condition data (monitor data) storage function for storing actual operation condition data at the time of automatic operation based on the measurement information and the like, and a self-abnormality diagnosis function. In the trouble diagnosis method for the molding machine, which is displayed on the display, a trouble has occurred in the molding machine, and the contents of the abnormality cannot be dealt with by the operator, need to contact the manufacturer, or are displayed on the display device. If the error is not resolved even though the processing according to the instruction content of the alarm message When a user of the molding machine requests the manufacturer to deal with a problem, the set operating condition data is monitored and monitored from the microcomputer of the molding machine to the manufacturer's host computer via a public telephone line or a dedicated network. The actual operating condition data recorded and the corresponding alarm information data are fetched, and the host computer analyzes the cause of the trouble based on the data fetched into the host computer, and the operating condition command data calculated based on the analysis result is obtained. The public telephone line or a dedicated network is transmitted to the microcomputer of the molding machine to make the molding machine execute a test operation for determining or narrowing down the cause of the trouble. The feature is that the side analyzes it Trouble diagnosis method for molding machines. 4. The molding machine according to claim 3, wherein a signal indicating that it is confirmed that the test operation can be started is transmitted from the operator of the molding machine to the host computer before the start of the test operation in accordance with a command from the host computer. After that, the host computer executes a test run of the molding machine, and this test run is characterized in that the operator of the molding machine is present at the test run for accurate confirmation of the event at the site. Trouble diagnosis method for molding machines.