JPH11277554A - Digital control system for foam molding machine and digital control type foam molding machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To perform a foam molding work even by an unskilled person by individually storing set conditions in a foam molding step in a memory by digitally setting, calling the conditions from the memory at each time of altering the conditions, and foam molding under the called conditions. SOLUTION: Conditions, setting time and the like are digitally input regarding all steps, and stored in a memory. Thus, all the set conditions of a mold 1 are input. Similarly, all and detailed correcting items of an incorporated mold are input, an environmental setting is finished, and then an actual foaming operation is started. The mold 1 of a foam molding S to be intended to be molded is mounted at a foam molding machine. A mold number of the mold 1 is input to call its data from the memory. When the operation is started, the operation is conducted according to the set conditions. Thus, if the set conditions can be called, the form molding can be executed as set with good reproducibility even by an unskilled worker.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention is to store each setting condition of a foam molding process suitable for each mold or external condition every time the condition is changed, and to optimize the setting every time the mold or external condition is changed. The present invention relates to a digital control method and a digital control type foam molding machine in a foam molding machine capable of performing foam molding in the same manner as a skilled worker by selecting and resetting setting conditions.

[0002]

2. Description of the Related Art In a foam molding operation, it is necessary to equalize the temperature of the entire mold or to perform foam molding by controlling the vapor pressure and the surface pressure in the mold according to set conditions. It is an ideal thing to get. However, conventional foam molding machines are inexpensive foam products themselves, so the foam molding machine itself must be mechanically simple, and only very simple controls and display devices are installed. Had not been.

Accordingly, molding conditions such as a mold temperature, a temperature of a steam chamber, a temperature of a foam molded body, a surface pressure, and a steam pressure in a foam molding process are set in advance, and a foam molding operation is performed in accordance with the set conditions. Such a thing was not performed at this stage at all, and the actual foam molding work relied exclusively on direct operation of the steam valve based on the intuition and experience of skilled workers.

[0004] That is, when one production lot is completed and the next lot is switched, the molds are exchanged according to the next product. In accordance with the mold, seasonal factors such as spring, summer, autumn and winter are used. Skilled workers directly operate the steam valve each time, taking into account changes in the surrounding environment during foam molding work, such as morning and afternoon of the work day, and show the completed state of the foam molded body and the needle of the pressure detection device A trial shot was performed while comparing and examining the values, and the conditions for a new mold were determined each time based on intuition and experience. In particular, since the change in the vapor pressure of the mold during the heating step has a great effect on the foamed molded product, it is very important to determine the conditions.

[0005] As described above, such work requires not only very skillful work but also time-consuming work by a skilled worker, which occupies a large part of the setup work. This has conventionally been required to reduce the time for this part. Further, once the setting is changed, it is difficult to reproduce the vapor pressure, it takes time and effort to determine the conditions, and there is also a problem that an error easily occurs even if the setting is reset.

[0006]

In the present invention, each pattern for determining the conditions of foam molding, which has conventionally depended on the intuition and experience of a skilled worker, is digitally input to a storage device of a machine in advance, and the mold is changed. And the change of the setting conditions due to changes in the surrounding environment can be selected mechanically to simplify the foam molding work, so that complicated and unstable foam molding work can be performed by unskilled people without relying on skilled workers. The task is to make work possible.

[0007]

A digital control method in a foam molding machine according to claim 1 is described as follows: "The setting condition (α) in the foam molding process is individually set by digital setting in a storage device (17).
b), and each time the molding condition (α) changes, the stored setting condition (α) is called from the storage device (17b),
Perform foam molding under the set condition (α) ”.

According to this, since the setting condition (α) in the foam molding process can be individually stored in the storage device (17b) by digital setting, the storage device (17b) changes every time the molding condition (α) changes. It is possible to call the setting condition (α) stored from (17b) and perform foam molding under the setting condition (α) `` for example, with good reproducibility at a valve opening according to the setting condition '', It does not require any conventional skill. Therefore, even an unskilled person can perform the same foam molding work as a skilled person from that time.

When a large number of dies (1) are present, the setting conditions (α) are digitally set for each of the dies (1), and the conditions for a series of processes are all digitally stored. . Further, since the air conditioner is not provided around the foam molding machine, molding conditions such as temperature and humidity vary depending on the season of spring, summer, autumn and winter, or the weather and work time. Therefore, these fluctuation factors are also digitally input as part of the setting condition (α) as needed, and are called up as needed. Examples of the setting condition (α) are as described in claims 2 to 4.

A second aspect of the present invention relates to a digital control method for a foam molding machine according to the first aspect, wherein "the molding condition (α) is:
It is the reference pressure in the mold ”.

A third aspect of the present invention relates to a digital control method for a foam molding machine according to the first aspect, wherein "the molding condition (α) is
Cavity component (1a) of the mold (1) in the foam molding process
1) At least one of the reference temperature of (1b1), the reference temperature of the steam chamber, and the reference temperature of the foamed molded article (S) ”.

A fourth aspect of the present invention is a digital control method for a foam molding machine according to the first aspect, wherein "the molding condition (α) is:
This is the reference position for the moving mold (1a) in the foam molding process. "
It is characterized by things.

Claims 2 to 4 define the types of the molding conditions (α). By storing these molding conditions (α) in advance, even an unskilled person can use the same method as an expert. The foam molding operation becomes possible.

According to a fifth aspect of the present invention, there is provided a digital control method for a foam molding machine according to the first aspect, wherein "the temperature of the cavity components (1a1) and (1b1) of the mold (1) in the foam molding process, the temperature in the steam chamber, The temperature of the molded body, or at least one of the pressure in the mold or the position of the moving mold is detected and stored as digital measurement data (β), and each reference data of the molding condition (α) is stored. And measurement data (β)
And the deviation (△ t) is calculated, the deviation (△ t) is stored, and the deviation (△ t) or the reference data (α) is stored.
Alternatively, at least one of the measurement data (β) is called at any time to perform a visual display ”.

According to this method, at least any one of the deviation (Δt), the reference data (α), and the measurement data (β) can be called out at any time and can be visually displayed. Since the state of the molding operation can be seen, it is easy to grasp the operation state.

According to a sixth aspect of the present invention, there is provided a digital control method for a foam molding machine according to the fifth aspect, characterized in that "visual display is performed by making a graph." As a means of comparison, plotting the measured data in chronological order and graphing it is the easiest way to compare the data.In this way, even unskilled people are required to change the mold. Defect measures can now be easily taken.

Here, the deviation between the detected data and the set data
By visualizing (△ t), the degree of deviation from the setting data can be clearly understood, and this is an effective means for quickly detecting and correcting abnormalities. As a method of visualizing the divergence, as shown in FIG. 15, the setting data (α) is linearly displayed, and the detection data (β) is displayed vertically above and below the center to visualize the deviation (△ t). And as shown in FIG. 16, through each step (die heating, one-side heating, reverse one-side heating, each step of double-sided heating) or a graph of the setting data for each of the above steps, superimposing the detection data on this, and deviating its deviation. There is a way to visualize (△ t).

In any case, when the comparison and display are performed on the same scale, the difference is difficult to see. If the deviation (△ t) is too small, an integer value near the maximum value of the deviation (△ t) is displayed in full scale. The difference emphasizes the difference and makes it easier to see. In addition, the detection data at the time of non-defective products or an average value curve of data obtained by measuring and accumulating the data several times continuously may be used as the reference setting data (α).

A seventh aspect of the present invention relates to a digital control method in the foam molding step according to the first to fifth aspects, wherein "measurement data
If (β) exceeds the permissible range, an alarm is issued, and if it exceeds the permissible limit, the operation is stopped. ”

As a result, not only can the occurrence of an abnormality be quickly known and a countermeasure against the defect can be taken promptly, but also, when the allowable limit is exceeded, the emergency stop is performed and the production of the defective product is immediately stopped. This is very favorable in terms of yield management. As will be described later, the allowable width and allowable limit (〇〇 upper limit, △△ lower limit on the screen)
Is set for various measurement data (β) such as the temperature, surface pressure, and mold pressure of the foamed molded product.

The digitally controlled foam molding machine according to the present invention is characterized in that an input device (23) for digitally setting the setting condition (α) in the foam molding process, and a molding condition (α) from the input device (23). And the measurement data (β) in the molding process and the deviation of both (△
storage device that individually stores at least one of
b) and a CPU (17f) that performs a feedback control by comparing and calculating the stored molding conditions (α) and the measured data (β).
And molding conditions (α) and measurement data (β) or both (α) (β)
And a display device (24) for calling at least one of the deviations (Δt) at any time to perform a visual display ”.

According to this, not only the molding condition (α) but also
Since at least one of the measurement data (β) or the deviation (Δt) between the molding condition (α) and the measurement data (β) is stored, these can be called up at any time and displayed visually. It is very easy to grasp the work situation.

According to a ninth aspect of the present invention, there is provided a digital control type foam molding machine according to the eighth aspect, wherein an alarm is issued when the measured data (β) exceeds an allowable range, and the operation is performed when the measured data (β) exceeds an allowable limit. It is equipped with an alarm mechanism to stop it. "

Thus, according to the apparatus of the present invention, not only the occurrence of an abnormality can be quickly detected, and a countermeasure for a defect can be taken promptly, but also, when the allowable limit is exceeded, an emergency stop is performed to produce a defective product. It can be stopped immediately, which is very favorable in terms of yield management. As will be described later, the allowable width and the allowable limit are set with respect to various measurement data such as the temperature, surface pressure, and mold pressure of the foam molded article.

[0025]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The outline of the main parts of a foam molding machine according to the present invention will be described below. FIG. 1 shows an embodiment of the present invention, in which a mold (1) for foam molding is divided into a male mold (1a) and a female mold (1b).
Each is provided with a steam chamber (2a) (2b), and a drain pipe (20a) (20b), a cooling pipe (22a) (22b), an air pipe (not shown), and other necessary members are installed.

A steam pipe (3a) (3b) extends from the steam source (10) and is connected to the male and female molds (1a) (1b). Control valves (5a) (5b) for these steam pipes (3a) (3b)
Is installed. The control valves (5a) and (5b) reduce the pressure of the steam discharged from the high-pressure steam source (10) to a required pressure and control the flow rate so that the pressure in the steam chambers (2a) and (2b) becomes a predetermined value. In this embodiment, the piston valve is used as a control valve because the same operation can be obtained by controlling the opening degree of the piston valve.

The steam pipes (3a) and (3b) are steam-side hoses.
They are connected to the steam side bases (13a) (13b) provided on the male and female molds (1a) (1b) via (14a) (14b). The drain side is a drain base (12a) that is led out from the bottom of the male and female molds (1a) and (1b).
Drain hoses (7a) and (7b) are detachably connected to (12b), and drain valves (8a) are connected to piping sections (9a) and (9b) provided downstream of the drain hoses (7a) and (7b). ) (8b) is connected,
These constitute the drain pipes (20a) (20b).

The measuring devices installed in this device include a pressure detecting device (4a) (4b), a surface pressure detector (33), a temperature measuring device (m), and a position detector such as an encoder or a potentiometer. (34), etc., and the pressure detection devices (4a) (4b) are connected to the drain hoses (7a) (7b) via the pilot pipes (11a) (11b).
The pipe section (9a) (9b) between the drain valve (8a) (8b) or the drain valve (8a) (8b) itself upstream of the valve body, and the steam chamber (2a) (2b Drain valve (8
a) The pressure on the upstream side of the valve element of (8b) is detected, and an analog signal is sent to an analog input interface (17d) of a control circuit (17) to be described later instead of the analog signal. Of course, the connection positions of the pilot pipes (11a) and (11b) are not limited to the positions described above, and the direct
(2a) and (2b) may be connected.

The surface pressure detector (33) is installed in at least one of the molds (1a) (1b) (in the embodiment of the present invention, set on the female mold (1b) side), and its detection end is Exposed in cavity (16). The surface pressure detector (33) detects a change in surface pressure during the foam molding process (heating and cooling process) of the foam molded product (S) in the cavity (16), and an analog input interface (17d) described later. To output a surface pressure analog signal.

The temperature measuring device (m) is mounted on the mold (1). In the present embodiment, the temperature measuring device (m) is disposed so that the detection portions are exposed in the cavities (2a) and (2b) of the mold (1). And the foam molded body in the cavities (2a) and (2b)
(S2) (M2) (mb)
2) (ma4) (mb4), or a mold temperature measuring device (ma3) (mb3) that measures the temperature of the cavity components (1a1) (1b1) of the mold (1), or a steam chamber (2a) (2b ) For measuring the temperature of steam room (ma1) (mb1) (ma5) (mb5).

As shown in the figure, all of these temperature measuring devices (m) may be provided, but only one of them may be used, or a combination of and / or may be used. Further, the temperature measuring devices (m) may be provided one by one, or a plurality of the temperature measuring devices (m) may be provided, and a plurality of temperature measuring devices (m) may be measured at different locations of the mold (1). When installed vertically, the temperature distribution above and below the mold (1) or the foamed article (S) can be understood. Depending on the installation location, the temperature measuring device (m) has (a) the temperature of the foamed molded product (S) in the cavity (16), (b) the cavity component (1a1) of the mold (1).
The temperature of (1b1), (c) or the temperature of the steam chamber (2a) (2b) is measured, and a temperature measurement analog signal is output to the analog input interface (17d).

The position detector (34) is, for example, an encoder or a potentiometer, and is provided at an appropriate position of the movable die (1b) or an appropriate position of the main body portion, and the position of the movable die (1b) is instantaneously determined. As a result, as shown in FIG. 11, the parting surface of the fixed mold (1a) is used as a reference position to start the cracking position, the eject position, the mold opening completion position, and the mold closing speed toward the cracking position. In various mold movement control, such as a position to decelerate, a start point and an end point of an area where the moving speed of the moving mold (1b) is reduced before and after the eject position, and a position to reduce the mold opening speed just before the mold opening completion position. It can detect important points.

The main control unit comprises an input device (23) and a display device (2
4), screen copy device (24a), alarm mechanism (25), control circuit (17), analog input interface (17d), analog output interface (17i), A / D converter (17e), D /
A control section (17h) and control drive sections (19a, 19b) such as an electropneumatic proportional valve, and a control valve drive pneumatic pressure source (18) passes through a control valve drive pipe (18a). Connected to the control drive units (19a) (19b). The compressed air for pilot controlled by the control drive units (19a) (19b) flows out of the control drive units (19a) (19b), the pilot pipes (11a ') (11b'), and the switching valves (6a) (6b). The control valves (5a) and (5b) are supplied to the control units (5a) and (5a) of the control valves (5a) and (5b) to control the valve opening of the control valves (5a) and (5b).

The control circuit (17) receives the setting condition (α) from the input device (23) (pressure setting data such as vapor pressure and surface pressure, reference temperature data, and setting position data of the moving mold (1b). The CPU (17f) itself may take in data of the non-defective stage and automatically calculate and set the various data without inputting by the operator in advance. >>) CPU (17f) connected to the circuit (17a), the input device (23), the display device (24), the external data storage device (17j), the storage device (17b), and the data conversion unit (17c) and performing any data processing. ), Setting condition (α) input to the key input setting circuit (17a)
Also, a storage device (17b) that stores the detection data (β) and a deviation (偏差 t) between them, a sequence of the entire device, a pressure detection device (4a) (4b), and a surface pressure detector (33) , Temperature measurement device (m), detection data (β) from various sensors such as position detector (34) and data read from the storage circuit (17b)
(α) and a data conversion circuit (17c) that performs data conversion so as to correspond to each other,

[0035] Pressure detecting device (4a) (4b) and temperature measuring device
(m), a surface pressure detector (33), or an analog input interface (17d) that receives analog signals from various sensors such as a position detector (34) such as an encoder, and an output value from the analog input interface (17d). Are converted into digital data, respectively, and the data conversion unit (17c)
A / D data conversion circuit (17e) for outputting to

A D / A data conversion circuit (17h) for converting an output value of the data conversion circuit (17c) from a digital value to an analog value, and a value from the D / A data conversion circuit (17h) is used as a control driver (19a ) (19b), analog output interface (17i), external input consisting of 10 switches
(17l) and an I / O unit (17k) connected to an external output (17m) composed of valves and the like.

Next, a method of inputting the setting condition (α) and its operation will be described. FIG. 3 shows a touch panel type display device (2
Various menus are shown on the basic screen shown in 4). When the maintenance is touched in the menu, the screen is switched, and the maintenance screen submenu shown in FIG. 4 is displayed. This shows the contents of the maintenance menu,
If another menu is selected, the submenu set for each menu will be displayed on the display device (24).

When the user touches the menu of the screen configuration of the maintenance screen submenu, the screen configuration screen of FIG. 5 appears, and a submenu group connected to the main menu is displayed as a tree. Thus, the entire menu configuration can be understood at a glance.

In order to input the setting condition (α) for a certain mold (1), first, touch the timer and input setting on the basic screen in FIG. 3 to call the timer and input setting screen in FIG. .
In this screen, the process column is provided as a blank at the left end,
"Mold closing process" in order from No.1 blank or at appropriate intervals
"Bead filling process""Mold heating process""One-side heating process"
"Necessary reverse heating process", "double-side heating process", "cooling process", "drainage process", "cooling process", "mold release process", "mold opening process", and other necessary processes are performed as required.

A set time input column for inputting a set time is provided next to the process column, and a standard set time for each process is input. A condition column is provided for each blank column next to the set time input column so that conditions such as "AND" and "OR" can be input.

On the right side of the table, "input names" such as "mould open", "mould open throw", etc. are arranged, and the "input name" of each process that intersects the "input name" used in each process. A blank circle is written in the blank field. For example, in "type closing", "cracking" is performed, so write "black circle" in the "cracking" part, write "and" in the "condition column", and write "10 seconds" in the "setting time column". When filling in, in the mold closing step, when the position detector (34) detecting the moving amount of the moving mold (1b) reaches the "cracking" position and the set time of 10 seconds has elapsed, the next " To the bead filling process.

Conversely, if "OR" is written in the "condition column", the earlier of the "set time" of "10 seconds" before reaching the "cracking" position,
Even if the "cracking" has not been reached, the process moves to the next "bead filling process", and a signal indicating that the "cracking" position has been reached by the elapse of 10 seconds of the "set time" is input. Before the "set time" elapses, the process moves to the "bead filling process".

In this way, "condition", "set time" and "black circle" are entered for all the steps, and this menu is completed. In some processes, time setting is not performed and only position detection is performed. In such a case, the setting time may be set to 0 and the setting condition may be input as “and”. Similarly, when control is performed only by setting the time, no entry is made in the “black circle” or the “condition field”, and the field is left blank. In addition, although only 10 items are displayed in the “process No. column”, it is possible to input more than 10 items by scrolling. Further, if the process reading portion on the screen is touched, it is called every ten items.

After completing the entry on the "timer, input setting" screen of FIG. 7, the screen returns to the basic screen of FIG. 3 and touches the "load setting" to call the "load setting screen" of FIG. On this screen, a "process name entry field" where the process name is entered on the left vertical is a "load name entry column" where the load name is entered on the upper side.
Is provided, and "black circle" can be entered in the blank space at the intersection of both. In the “process name entry field”, the processes such as “mold closing”, “bead filling process”, etc. are entered in order or at appropriate intervals as described above, and in the “load name entry field”, the control valve of the entire device is entered. Fill in the name, and put "black circle" in the place of the control valve used for each process. For example, in the "mold closing step", since "mold closing valve" is used, "black circle" is entered in a blank space where both of them intersect. Next, in the “bead filling process”, “filling valve”, “filler valve”, and “hopper shutter valve” are used.
Fill in. In this way, "black circles" are entered for each load used in all processes.

When the load setting is completed, the screen returns to the basic screen shown in FIG. 3 and touches "condition setting" to call the condition setting submenu shown in FIG. Further, by touching the “Temperature setting” portion in FIG. 6, the “Temperature setting screen” in FIG. 9 is called,
"Mold temperature upper limit""Product temperature lower limit""Product temperature lower limit"
Digital input of "product temperature upper limit" and other set temperature and upper / lower limit value of temperature. This data is input to the storage device (17b) via the CPU (17f).

When the temperature setting is completed, the display returns to the condition setting submenu in FIG. 6, and touches the "Pressure setting (1)" to call up the "Pressure setting screen" in FIG. "Mold fixed pressure" which is the internal pressure of the steam chamber (2a) of the mold
Or "Mold moving pressure" which is the internal pressure of the steam chamber (2b) of the moving mold
... Digital input of various set values or upper / lower limit values related to various pressures and surface pressures used in this apparatus.

When the pressure setting is completed, the display returns to the basic screen shown in FIG. 3 and touches the "change mold" section to call up the "change mold screen" shown in FIG. 11, and the parting of the fixed mold (1a) is performed. Digitally input "cracking position", "eject position", "mould open position", etc. based on the surface. FIG. 12 shows an input device (23), which is a touch panel screen of ten keys appearing on each menu screen.

The setting condition of the mold (1) as described above
When the input is completed for all of (α), the screen returns to the basic screen of FIG.
"Molding condition list screen" is called. On the “molding condition list screen”, the setting condition (α) of the mold (1) is displayed as a list, and the setting condition (α) can be checked at a glance.

FIG. 14 shows a "memory card screen". In this embodiment, blanks 1 to 30 are provided, and a series of setting conditions (α) can be stored in each blank. Therefore, “1. When the user touches the mold number 0001, the storage device (17b) reads "1.
The data of the mold number 0001 is called, and the CPU (17
It is read in f), and all control of this device is performed under this data. Therefore, if the data selection corresponding to the mold (1) to be used is not mistaken, the control suitable for the mold (1) is performed with good reproducibility, and a skilled worker is not required.

The "memory card screen" can store up to 30 setting conditions (α), but if more memory is required, the external data The memory may be expanded using the storage device (17j).

In this way, all the holding molds (1) to (n) and the detailed correction items are input, the environment setting is completed, and the actual foaming operation is started. Attach the mold (1) of the foam molded article (S) to be molded to the foam molding machine, input the mold number (for example, 0001) of the mold (1), and transfer the data from the storage device (17b). call.

When the foam molding operation is started, the movable mold (1b) is closed according to the set conditions, decelerates from the set position, and cracks at the set position. When the cracking is completed, the cavity (16) is filled with a predetermined amount of the pre-expanded beads (15) through a filler (not shown). When the filling of the pre-expanded beads (15) is completed, the male and female molds (1a) (1
Open the drain valves (8a) and (8b) and the control valves (5a) and (5b) in b), and let the steam from the steam source (10) elapse for a set time for the male and female molds (1a) and (1b).
The male and female molds (1a) and (1b) are heated to the set temperature by flowing into the steam chambers (2a) and (2b).

At this time, since the prefoamed beads 15 in the cavity 16 are hardly heated, the temperature of the foamed molded body is measured by the temperature measuring devices (ma2), (mb2), (ma4), and (mb4). The rise is small. However, the cavity components (1a1) (1b
Since the temperature of 1) and the temperature of the steam chambers (2a) and (2b) have risen, the mold temperature measuring device (ma3) (mb3) and the steam room temperature measuring device
(ma1) (mb1) (ma5) (mb5) detects the temperature rise. At this time,
If a plurality of temperature measuring devices (m) are set up and down or left and right, the temperature at each location can be detected, and the temperature distribution can be known.

When the heating of the male and female molds (1a) and (1b) is completed,
Switch to << One-side heating process >> to heat the filled beads (15), discharge air and drain between beads (15),
(15) Uniform expansion is achieved. Here is a male (1a) drain valve
Open (8a), close the male (1a) control valve (5a), close the female (1b) drain valve (8b) and open the female (1b) control valve (5b). Steam flows from the female (1b) steam chamber (2b) through the cavity (16) at the steam pressure according to the set pressure controlled by the flow rate or feedback control, and heats the pre-expanded beads (15) in the cavity (16). Later, the male (1a) steam chamber (2
Enters a) and flows out of the male (1a) drain valve (8a).

During this time, the pressure in the steam chamber (2b) is detected by the pressure detector (4b) connected to the drain valve (8b). On the other hand, as the heating proceeds, the pre-expanded beads (1
5) swells and the flow of steam becomes worse. In other words, the steam room
The pressure of (2b) gradually increases and is detected, and one-side heating is performed as set by the above-described feedback control.
At the same time, the temperature of the foamed product (S) is detected.

The mold temperature measuring devices (ma3) (mb3) and the steam room temperature measuring devices (ma1) (mb1) (ma5) (mb5) also detect the rising temperature by the same operation as described above. At this time, if a plurality of temperature measuring devices (m) are set up and down or left and right, the temperature at each location can be detected, and the temperature distribution can be known. Then, these are stored in the storage device (17b). The temperature and vapor pressure are displayed on the display device (24) in a switchable manner as needed.

On the other hand, when the heating step is completed, << reverse one-side heating >> is performed as necessary (in other words, the reverse one-side heating may not be performed). In this step, the flow direction is reversed with respect to the flow direction of the one side heating, and the heating of the beads (15) and the discharge of air and drain between the beads (15) are performed as described above, and the further beads (15) are formed. Inflate. Close the male (1a) drain valve (8a), open the male (1a) control valve (5a), and open the female (1b) drain valve (8b) to control the female (1b) When the valve (5b) is closed, steam flows from the steam chamber (2a) of the male mold (1a) through the cavity (16), and the cavity (1
After heating the pre-foamed beads (15) in the 6) from the opposite direction as set, they enter the steam chamber (2b) of the female mold (1b) and flow out of the drain valve (8b) of the female mold (1b). go.

During this time, as described above, the pressure chamber (2a) is connected to the steam chamber (2a) by the pressure detector (4a) connected to the drain valve (8a).
The vapor pressure of the steam chamber (2a) flowing to the mold is detected and feedback-controlled by the above-described method, and the reverse one-side heating is performed by the optimal vapor pressure set in the reverse one-side heating step in the mold (1). Will be. On the other hand, at the end of the heating step, the beads (15) in the cavity are sufficiently foamed and the foamed molded product (S)
There is almost no steam flow. Then, the process is switched to the next double-sided heating step. During this time, the temperature is simultaneously detected and stored in the storage device (17b). A display device in which the temperature and vapor pressure can be switched as required.
Displayed in (24).

The << double-sided heating step >> is a step mainly aimed at fusing the surface portion of the foamed molded article (S) by increasing the heating temperature by increasing the steam pressure. Male and female mold (1a) (1b) drain valve (8
a) Close (8b) and control valve (5a) for male and female molds (1a) (1b)
(5b) is opened, and steam is supplied to the steam chambers (2a) (2b) of the male and female molds (1a) (1b). In this case, the steam does not flow through the cavity (16), and the foam molding (S) is heated on both sides to sufficiently expand the foam molding.
The beads (15) on the surface of (S) are fused together. At this time, steam does not flow to both drain pipes (20a) (20b), but the pressure detectors (4a) (4b) are connected to the drain valves (8a) (8b) and the steam chambers (2a) (2b) The feedback control of the vapor pressure in the double-sided heating step is performed by the above-described method, and the double-sided heating is performed under the optimum condition.

During this time, the temperature and surface pressure of the foamed molded product (S) are detected at the same time, whether or not the surface pressure and temperature are as set is detected, and the data is stored in the storage device (17b). The above-described feedback control of the vapor pressure is performed together with the pressure detection. Said temperature and vapor pressure,
Various data such as surface pressure are displayed on the display device (24) in a switchable manner as needed.

When the two-sided heating is completed, the process is switched to the << cooling step >>, and the foam molded body in the cavity (16) is cooled to a predetermined temperature by an appropriate means such as vacuum cooling or water cooling. It is in this cooling step that temperature detection is most effective. That is, when the foamed molded article (S) is opened while the temperature of the foamed molded article (S) is high at the time of cooling and the foamed molded article (S) is taken out, the deformation after the takeout is large and the mold collapses, resulting in a defective product.

On the other hand, if the temperature is cooled down sufficiently,
Although there is no such problem, there are problems that the cooling time becomes too long and the machine cycle becomes longer, and that the consumption of cooling water increases accordingly. It is necessary to remove the foam molded body (S) with a foam molded body temperature measuring device (ma2) (mb2) (ma4) (mb4). The cooling process such as cooling and water cooling is completed, and the process can be moved to the next process.

Alternatively, the mold temperature may be measured by a mold temperature measuring device (ma3) (mb3), and when a predetermined temperature is reached, a cooling step such as vacuum cooling or water cooling may be terminated.

Generally, when the temperature reaches a predetermined value, the mold release treatment is performed, and then the mold is opened to take out the foamed molded product (S) and finish the molding. Such a cycle is repeated to form the foamed molded product (S). The die is exchanged before the lot is completed and changed to the next lot. At this time, the mold number of the replaced mold is input as described above, new data is called out, and then the foam molding operation is started.

[0065]

As described above, according to the present invention, the setting conditions in the foam molding process are individually stored in a storage device by digital setting, and the setting conditions stored in the storage device are recalled each time the molding conditions change. Since foam molding is performed under the set conditions, even if the set conditions are called, even unskilled workers can perform foam molding as set with good reproducibility, and conventionally, it is necessary to rely on the intuition and experience of skilled workers. It became very easy to determine the conditions for foam molding. Also, if at least one of the deviation or the reference data or the measurement data can be called at any time and displayed visually, even an unskilled person can see the state of the foam molding work, so that the work state can be understood. Easy to grasp. In particular, if the visualization is graphed, it can be understood at a glance, and even an unskilled person can easily determine the conditions at the time of mold replacement and take measures against a defect. If the measured data exceeds the permissible range, an alarm is issued, and if the measured data exceeds the permissible limit, the operation is stopped. Not only can it be done, but if it exceeds the allowable limit, it can be stopped immediately and the production of defective products can be stopped immediately,
This is also very favorable in terms of yield management.

[Brief description of the drawings]

FIG. 1 is a piping diagram including a control circuit according to the present invention.

FIG. 2 is a block circuit diagram of a main part of a control circuit according to the present invention.

FIG. 3 is a main menu screen of the present invention.

FIG. 4 is a maintenance screen submenu screen of the present invention.

FIG. 5 is a screen configuration menu screen of the present invention.

FIG. 6 is a condition setting screen submenu screen of the present invention.

FIG. 7 is a timer and input setting screen of the present invention.

FIG. 8 is a load setting screen of the present invention.

FIG. 9 is a temperature setting screen of the present invention.

FIG. 10 is a pressure setting screen of the present invention.

FIG. 11 is a mold exchange screen of the present invention.

FIG. 12 is a touch screen type key screen displayed on each screen of the present invention.

FIG. 13 is a molding condition list screen of the present invention.

FIG. 14 is a memory card screen of the present invention.

FIG. 15 is a graph in which the deviation between the set data of the vapor pressure or the surface pressure and the detected vapor pressure or the surface pressure data in the present invention is graphed based on the reference temperature data.

FIG. 16 is a diagram in which a set data graph of the vapor pressure or the surface pressure and a measured data graph of the vapor pressure or the surface pressure in the present invention are superimposed and displayed.

[Explanation of symbols]

 (1)… Die (1a)… Male (1b)… Female (1a1) (1b1)… Cavity component (2a) (2b)… Steam chamber (3a) (3b)… Steam piping (4a) ( 4b) Pressure detector (5a) (5b) Control valve (6a) (6b) Switching valve (7a) (7b) Drain hose (8a) (8b) Drain valve (9a) (9b) Drain Piping from hose to drain valve (10)… Steam source (11a) (11b) (11a ') (11b')… Bilot piping (17b)… Storage device (20a) (20b)… Drain piping (17)… Control circuit (m)… Temperature detector (33)… Surface pressure detector (34)… Position detector

Claims (9)

[Claims] 1. The setting conditions in a foam molding process are individually stored in a storage device by digital setting, and each time the molding conditions are changed, the stored setting conditions are called from the storage device, and the setting conditions are stored under the setting conditions. A digital control method in a foam molding machine, which comprises performing foam molding. 2. The digital control method for a foam molding machine according to claim 1, wherein the molding condition is a reference pressure in a mold. 3. The molding condition according to claim 1, wherein the molding condition is at least one of a reference temperature of a cavity constituting portion of a mold in a foam molding step, a reference temperature of a steam chamber, and a reference temperature of a foam molded article. Digital control method in a foam molding machine. 4. The digital control method for a foam molding machine according to claim 1, wherein the molding condition is a reference position of a moving mold in a foam molding step. 5. A method for detecting at least one of a temperature of a cavity constituting part of a mold, a temperature of a steam chamber, a temperature of a foam molded body, a pressure in a mold, and a position of a moving mold in a foam molding step. And comparing the reference data of the molding conditions with the measurement data to calculate the deviation, and storing the deviation, and storing at least one of the deviation or the reference data or the measurement data. 2. The digital control method for a foam molding machine according to claim 1, wherein the visual display is performed by calling the number 1 at any time. 6. The digital control method in a foam molding machine according to claim 5, wherein visual display is performed by making a graph. 7. The digital control in the foam molding process according to claim 1, wherein an alarm is issued when the measured data exceeds an allowable range, and the operation is stopped when the measured data exceeds an allowable limit. Method. 8. An input device for digitally setting setting conditions in a foam molding process, a storage device for storing at least one of molding conditions, measurement data in the molding process, or a deviation between the two from the input device. It is composed of a control circuit for performing a feedback control by comparing and calculating the molding conditions and the measured data, and a display device for calling at least one of the molding conditions and the measured data or a deviation between the two at any time to provide a visual display. Digital control type foam molding machine. 9. An apparatus according to claim 8, further comprising an alarm mechanism for issuing an alarm when the measured data exceeds an allowable range, and for stopping operation when the measured data exceeds an allowable limit. A digitally controlled foam molding machine as described in the above.