KR102203378B1 - Method for manufacturing a product using injection molding device - Google Patents

Abstract

The injection molding apparatus monitoring system according to the present invention is installed in the working area of the first injection molding apparatus, connected to the first injection molding apparatus, and collects and displays temperature data and pressure data from the connected first injection molding apparatus, and the When at least one of the collected temperature data and pressure data exceeds the preset upper limit or falls below the lower limit, it is installed in the work area of the first monitoring device and the second injection molding device to light up an alarm, and the second injection molding device and A second connected and connected second injection molding apparatus collects and displays temperature data and pressure data, and turns on an alarm when at least one of the collected temperature data and pressure data exceeds or falls below a preset upper limit. And a monitoring device, and a central management server collecting temperature data and pressure data from the first and second monitoring devices and providing them to a user terminal.

Description

Monitoring device and injection molding device monitoring system including the same {METHOD FOR MANUFACTURING A PRODUCT USING INJECTION MOLDING DEVICE}

The present invention relates to a monitoring device and an injection molding device monitoring system including the same, and more particularly, to a monitoring device and a monitoring system installed at a work site to monitor the injection molding device.

Injection molding is one of the molding methods for processing plastic raw materials, and the process is performed using an injection molding device.

In general, an injection molding apparatus includes a material supply unit for supplying a material, an injection unit for heating and melting the supplied material, and injecting a molten material into a mold, and a mold unit for forming a mold for a molded product.

When the molten material is injected from the injection part to the mold part, the quality of the molded product produced by such an injection molding apparatus varies greatly depending on the injection temperature and injection pressure. Accordingly, it is necessary to monitor injection data such as injection position, injection temperature and injection pressure for product quality control.

A conventional monitoring device collects temperature data in real time from a temperature sensor attached to an injection molding apparatus and displays the collected temperature data in real time. In addition, the conventional injection molding apparatus monitoring system displays an alarm when temperature data received from a temperature sensor exceeds a preset upper limit or falls below a lower limit.

Since such a conventional monitoring device only provides simple functions, there is a problem that it is difficult for an operator to precisely control the injection molding device.

In addition, since the conventional monitoring device only provides real-time data, there is another problem in that it is difficult to analyze the cause even if a problem occurs in product quality, and that it is difficult to manage product quality.

On the other hand, the conventional monitoring device is provided by a company that manufactures the injection molding device while providing the injection molding device. Such a conventional monitoring device has a problem that a manufacturer cannot perform a monitoring function for other injection molding devices. As described above, since the conventional monitoring devices are not compatible with each other for each manufacturer, there is another problem that it is difficult for the manufacturer to integrate and manage the monitoring of a plurality of injection molding devices.

The present invention has been devised to solve the above-described problems, and provides a monitoring device installed at the work site and capable of providing various information necessary for the operator to control the injection molding device, and an injection molding device monitoring system including the same. It is to do.

The present invention is to provide a monitoring device capable of providing real-time data as well as performance data at a work site, and an injection molding device monitoring system including the same.

An object of the present invention is to provide a monitoring device capable of connecting a monitoring device to each of a plurality of injection molding devices and integrating and managing data monitored through a plurality of monitoring devices, and an injection molding device monitoring system including the same.

The present invention is to provide a monitoring device compatible with the manufacturer of the injection molding device and an injection molding device monitoring system including the same.

In order to solve the above problems, the present invention may include the following configuration.

The injection molding apparatus monitoring system according to the present invention is installed in the work area of the first injection molding apparatus, connected to the first injection molding apparatus, and collects and displays temperature data and pressure data from the connected first injection molding apparatus. , When at least one of the collected temperature data and pressure data exceeds or falls below a preset upper limit, the first monitoring device illuminates an alarm, and the second injection molding is installed in the work area of the second injection molding device. It is connected to the device and collects and displays temperature data and pressure data from the connected second injection molding device, and turns on an alarm when at least one of the collected temperature data and pressure data exceeds or falls below a preset upper limit. And a second monitoring device, and a central management server collecting temperature data and pressure data from the first and second monitoring devices and providing them to a user terminal.

According to the present invention, the following effects can be achieved.

The present invention provides not only temperature data, but also data such as pressure, speed, position, and production quantity, so that an operator can control the injection molding apparatus more precisely.

In addition, the present invention is installed at the work site, and when an abnormality occurs in the injection molding apparatus, the operator can immediately respond.

In addition, since the present invention provides performance data, it is possible to analyze the cause of an abnormality at the work site, and by visually showing the performance data, an operator can more easily find the cause of the abnormality.

In addition, since the present invention directly receives an analog signal from a sensor, it can be installed regardless of the type of controller of the injection molding apparatus.

1 is a schematic diagram of an injection molding apparatus monitoring system according to the present invention.
2 is a view for explaining the configuration of the injection molding apparatus shown in FIG.
3 is a view for explaining the configuration of the monitoring device shown in FIG.
4 is a view of the monitoring device shown in FIG. 1
5A is a diagram illustrating an example of displaying real-time data on a display panel.
5B is a diagram illustrating an example in which performance data is displayed on a display panel in a graph form.

The meaning of the terms described in this specification should be understood as follows.

Singular expressions should be understood as including plural expressions unless clearly defined differently in context, and terms such as “first” and “second” are used to distinguish one element from other elements, The scope of rights should not be limited by these terms.

It is to be understood that terms such as "comprise" or "have" do not preclude the presence or addition of one or more other features or numbers, steps, actions, elements, parts, or combinations thereof.

Hereinafter, embodiments of an injection molding apparatus control system according to the present invention will be described in detail with reference to the accompanying drawings.

1 is a schematic diagram of an injection molding apparatus monitoring system according to the present invention.

Referring to FIG. 1, an injection molding apparatus monitoring system 100 according to the present invention includes an injection molding apparatus 110 and a monitoring apparatus 120.

The injection molding apparatus 110 heats and melts the material, injects the molten material and injects it into a mold for injection molding. The injection molding apparatus 110 is installed at the work site and the operation is controlled under the control of the controller.

The injection molding apparatus 110 according to the present invention includes all of the various types of injection molding apparatuses. For example, the injection molding apparatus 110 is a plunger-type injection molding device that injects molten material into the mold part using a plunger, a screw-type injection molding device that injects molten material into the mold part using a screw, and It may include a plunger-screw type injection molding apparatus for melting the material using a screw and injecting the molten material into the mold using a plunger.

Hereinafter, for convenience of explanation, it is assumed that the injection molding apparatus 110 is a screw type injection molding apparatus.

2 is a view for explaining the configuration of the injection molding apparatus shown in FIG.

Referring to FIG. 2, the injection molding apparatus 110 according to the present invention includes a material supply unit 210, an injection unit 220, a mold unit 230, a sensor 240, and a control unit 250.

When the material is injected into the hopper, the material supply unit 210 supplies the injected material to the injection unit 220. In the material supply unit 210, the amount of material supplied is controlled by the control unit 250.

The injection unit 220 heats and melts the material supplied from the material supply unit 210, and injects the molten material into the mold unit 230.

The injection unit 220 includes a cylinder, a heater for melting the material supplied from the material supply unit 210, a screw for injecting the molten material into the mold unit 230, and a mold for the molten material to be injected. A nozzle leading to the unit 230 may be included.

When the material is supplied from the material supply unit 210 to the cylinder, the injection unit 220 heats the cylinder using a heater and melts the material by moving the screw forward or rotating. At this time, the material supplied from the material supply unit 210 is melted by increasing the temperature due to the heat supplied from the heater and the frictional heat generated when the screw is advanced or rotated. This molten material accumulates on the tip of the screw.

The injection unit 220 advances the screw with a pressure and speed according to the molding conditions when the molten material is accumulated by a specified amount at the tip of the screw. Through this, the injection unit 220 injects the molten material into the mold unit 230 through a nozzle.

The injection unit 220 controls at least one of an injection temperature, an injection pressure, an injection speed, and an injection position by the control unit 250.

The mold unit 230 includes a mold for forming a mold of a product, and cools the material injected into the mold while maintaining a constant pressure. When cooling is completed, the mold unit 230 opens the mold and takes out the product.

The mold unit 230 controls at least one of a temperature inside the mold, a pressure inside the mold, a temperature of a cooling water cooling the mold, and a temperature of a temperature controller that heats the mold by the control unit 250.

The sensor 240 is installed in at least one of the material supply unit 210, the injection unit 220, and the mold unit 230 to detect a specific physical quantity. The sensor 240 includes at least one of a temperature sensor that detects temperature, a pressure sensor that detects pressure, a speed sensor that detects a speed, and a position sensor that detects a position.

The sensor 240 provides the detected value to the controller 250 or the monitoring device 120. More specifically, the sensor 240 may detect at least one of speed, temperature, pressure, and position, and may output the detected sensor data to the controller 250 or the monitoring device 120 as an analog signal.

The controller 250 receives sensor data from the plurality of sensors 240 and controls the operation of at least one of the material supply unit 210, the injection unit 220, and the mold unit 230 based on the received sensor data. do.

The control unit 250 may output a process signal to the monitoring device 120. Here, the process signal corresponds to a process start signal indicating the start of one process cycle or a process end signal indicating the end of one process cycle.

The process cycle for producing a product using the injection molding apparatus 110 consists of a weighing and plasticizing process, an injection process, a holding pressure and a cooling process. The metering and plasticizing process corresponds to a process in which a material is supplied from the material supply unit 210 to the injection unit 220, and the supplied material is heated to make it a molten state. The injection process corresponds to a process of injecting a molten material into the mold unit 230. The holding pressure and cooling process corresponds to a process of cooling the molten material filled in the mold unit 230 while maintaining a constant pressure.

When the weighing and plasticizing process starts, the control unit 250 may generate a process start signal and output a digital signal to the monitoring device 120. When the cooling process is finished, the controller 250 may generate a process termination signal and output the digital signal to the monitoring device 120.

Also, the control unit 250 may output a material shortage signal to the monitoring device 120. When the amount of material to be supplied to the material supply unit 210 is less than a certain amount, the control unit 250 may generate a material shortage signal and output a digital signal to the monitoring device 120.

Referring back to FIG. 1, the monitoring device 120 is installed at the work site to receive sensor data from the injection molding device 110, and monitors the injection molding device 110 based on the received sensor data.

Hereinafter, the monitoring device 120 will be described in more detail with reference to FIG. 3.

3 is a diagram for explaining a configuration of the monitoring device shown in FIG. 1.

3, the monitoring device 120 according to the present invention includes a digital signal input unit 310, a production quantity calculation unit 320, an analog signal input unit 330, a data collection unit 340, a memory 350, A monitoring unit 360, a setting unit 370, an alarm unit 380, and a display unit 390 are included.

The setting unit 370 sets a signal input to the digital signal input unit 310 and a plurality of analog signal input units 330. More specifically, the setting unit 370 sets a digital signal input through the digital signal input unit 310. For example, the setting unit 370 may set the digital signal input unit 310 to input a process signal output from the control unit 250.

The setting unit 370 sets an analog signal input to each of the plurality of analog signal input units 330. For example, the setting unit 370 may set the analog signal of the first sensor data output from the first sensor 240a to be input to the first analog signal input unit 330a. The setting unit 370 may set the analog signal of the second sensor data output from the second sensor 240b to be input to the second analog signal input unit 330b.

Also, the setting unit 370 sets an upper limit or a lower limit of sensor data corresponding to an analog signal input to any one of the plurality of analog signal input units 330. Here, the sensor data includes at least one of temperature data detected by a temperature sensor, pressure data detected by a pressure sensor, speed data detected by a speed sensor, and position data detected by a position sensor.

For example, the setting unit 370 may set an upper limit or a lower limit of temperature data input to any one of the plurality of analog signal input units 330. In addition, the setting unit 370 may set an upper limit or a lower limit of the pressure data input to any one of the plurality of analog signal input units 330.

In addition, the setting unit 370 may set the production target quantity for the product.

The digital signal input unit 310 receives a digital signal set by the setting unit 370. More specifically, the digital signal input unit 310 may receive a digital signal from the control unit 250. In this case, the input digital signal may include at least one of a process signal and a material shortage signal.

Although only one digital signal input unit 310 is shown in FIG. 3, a plurality of digital signal input units 310 may be provided. The first digital signal input unit 310 may receive a process signal as a digital signal. In addition, the second digital signal input unit 310 may receive a material shortage signal as a digital signal.

When a process signal is input to the digital signal input unit 310, the production quantity calculation unit 320 calculates the current production quantity of the product produced by the injection molding apparatus 110. More specifically, when a process signal is input, the production quantity calculation unit 320 calculates the current production quantity by summing the number of cavities in the mold with the previous production quantity.

Each of the plurality of analog signal input units 330a, 330b, ..., 330n is connected to any one of the plurality of sensors 240a, 240b, ..., 240n to receive sensor data as an analog signal from the connected sensor 240 .

The first analog signal input unit 330a may be connected to the first sensor 240a installed in the mold unit 230 to receive temperature data obtained by detecting the temperature inside the mold from the first sensor 240a as an analog signal.

The second analog signal input unit 330b may be connected to the second sensor 240b installed in the mold unit 230 to receive pressure data that detects the pressure inside the mold from the second sensor 240b as an analog signal.

The third analog signal input unit 330c may be connected to the third sensor 240c installed in the injection unit 220 to receive velocity data that detects the injection speed from the third sensor 240c as an analog signal.

The fourth analog signal input unit 330d may be connected to the fourth sensor 240d installed in the injection unit 220 to receive position data, which detects the injection position from the fourth sensor 240d, as an analog signal.

The fifth analog signal input unit 330e may be connected to the fifth sensor 240e installed in the injection unit 220 to receive pressure data that detects the injection pressure from the fifth sensor 240e as an analog signal.

The data collection unit 340 collects sensor data from the plurality of analog signal input units 330a, 330b, ..., 330n in real time, and stores the collected sensor data in the memory 350. In addition, the data collection unit 340 may also collect the current production quantity of the product calculated by the production quantity calculation unit 320.

The monitoring unit 360 monitors the sensor data collected by the data collection unit 340. More specifically, the monitoring unit 360 checks whether the sensor data collected in real time by the data collection unit 340 exceeds the upper limit set by the setting unit 370. If it exceeds, the monitoring unit 360 generates an event exceeding the upper limit and notifies the alarm unit 380.

The monitoring unit 360 checks whether the sensor data collected in real time by the data collection unit 340 is less than the lower limit set by the setting unit 370. If it is not reached, the monitoring unit 360 generates an event that is less than the lower limit and notifies the alarm unit 380.

The monitoring unit 360 compares the current production quantity of the product collected by the data collection unit 340 with the target quantity set by the setting unit 370. If the current production quantity is greater than or equal to the target quantity, the monitoring unit 360 generates a production completion event and notifies the alarm unit 380.

In FIG. 3, the monitoring unit 360 is shown as receiving the current production quantity of the product from the data collection unit 340, but in another embodiment, the monitoring unit 360 is provided from the production quantity calculation unit 320. You may be provided with the current production quantity of the product. The monitoring unit 360 may compare the current production quantity of the product calculated by the production quantity calculation unit 320 with the target quantity set by the setting unit 370.

In addition, the monitoring unit 360 monitors real-time data or performance data of monitoring the injection molding apparatus 110, and provides the monitored real-time data or performance data to an operator through the display unit 390.

More specifically, when real-time data is requested from an operator through the display unit 390, the monitoring unit 360 displays real-time data collected by the data collection unit 340 on the display unit 390.

In addition, the monitoring unit 360 displays the performance data stored in the memory 350 on the display unit 390 when the performance data is requested from the operator through the display unit 390. In this case, the monitoring unit 360 may display the performance data on the display unit 390 in a graph form, and display the upper and lower limits of the performance data on the display unit 390 together.

The alarm unit 380 notifies the operator when any one of an upper limit exceeded event, a lower limit lower event, and a production completion event occurs.

More specifically, the alarm unit 380 includes an alarm, and turns on the alarm when any one of an upper limit exceeded event, a lower limit lower event, and a production completion event occurs. In this case, the alarm unit 380 may display the alarm in different colors according to the event.

For example, the alarm unit 380 may light an alarm in red for an event exceeding an upper limit or an event below the lower limit. In addition, the alarm unit 380 may light an alarm in yellow in the event of completion of production.

In one embodiment, the alarm unit 380 may generate an alarm message and transmit the generated alarm message to the user terminal 140 when any one of an upper limit exceeding event, a lower limit undertaking event, and a production completion event occurs. have.

The display unit 390 displays real-time data and performance data of monitoring the injection molding apparatus 110. The display unit 390 is implemented as a touch panel, and displays data on the panel to show real-time data and performance data to an operator, and may receive a touch input from the operator.

3 shows that the display unit 390 performs both a display function and an input function, but in another embodiment, a separate input unit may be further included.

The injection molding apparatus monitoring system 100 as described above includes a plurality of injection molding apparatus 110 and monitoring apparatus 120, respectively, as shown in FIG. 1, and may be connected one-to-one. That is, the first monitoring device 120a is installed in the work area of the first injection molding device 110a to monitor the first injection molding device 110a, and the second monitoring device 120b is the second injection molding device ( It is installed in the working area of 110b) to monitor the second injection molding apparatus 110b.

In addition, in the injection molding apparatus monitoring system 100, a plurality of monitoring devices 120a, 120b, ..., 120n may be connected to the central management server 130. The central management server 130 collects and manages data by monitoring a plurality of injection molding devices 110a, 110b, ..., 110n from a plurality of monitoring devices 120a, 120b, ..., 120n installed at the work site can do.

The central management server 130 may be connected to the user terminal 140 to provide integrated data to the user terminal 140. In addition, when an alarm event occurs in at least one of the plurality of monitoring devices 120a, 120b, ..., 120n, the central management server 130 may generate an alarm message and transmit it to the user terminal 140.

4 is a perspective view showing a monitoring device.

Referring to FIG. 4, the monitoring device 120 according to the present invention includes a housing 410, a touch panel 420, an alarm light 430, a programmable logic controller (PLC), a memory (not shown), and a plurality of It includes input devices (not shown). In one embodiment, the monitoring device 120 may further include a temperature card, a circuit breaker and a power supply.

A plurality of input devices (not shown) are connected to the injection molding apparatus 110 to receive a digital signal or an analog signal. More specifically, the plurality of input devices (not shown) includes a digital signal input device and an analog signal input device.

The digital signal input device is connected to the control unit 250 of the injection molding apparatus 110 and receives a process signal from the control unit 250 as a digital signal.

The analog signal input device is connected to the sensor 240 of the injection molding apparatus 110 and receives sensor data as an analog signal from the connected sensor 240. In this case, a plurality of analog signal input devices may be configured, and may be connected to the sensor 240 in a one-to-one manner.

The first analog signal input device may be connected to the first sensor 240a installed in the mold unit 230 to receive temperature data obtained by detecting the temperature inside the mold from the first sensor 240a as an analog signal.

The second analog signal input device may be connected to the second sensor 240b installed in the mold unit 230 to receive pressure data that detects pressure inside the mold from the second sensor 240b as an analog signal.

The third analog signal input device may be connected to the third sensor 240c installed in the injection unit 220 to receive speed data that detects the injection speed from the third sensor 240c as an analog signal.

The fourth analog signal input device may be connected to the fourth sensor 240d installed in the injection unit 220 to receive position data that detects the injection position from the fourth sensor 240d as an analog signal.

The fifth analog signal input device is connected to the fifth sensor 240e installed in the injection unit 220 to receive pressure data that detects injection pressure from the fifth sensor 240e as an analog signal.

The PLC (not shown) monitors the injection molding apparatus 110 based on data input to a plurality of input devices (not shown).

More specifically, the PLC (not shown) displays sensor data input to one of a plurality of input devices (not shown) on the touch panel 420. 5A shows an example of displaying sensor data collected in real time on the touch panel 420.

Then, the PCL (not shown) determines whether the sensor data exceeds a preset upper limit. When the upper limit is exceeded, the PLC (not shown) generates an event exceeding the upper limit and turns on the alarm lamp 430. The PLC (not shown) determines whether the sensor data is less than a preset lower limit. If the lower limit is less than, the PLC (not shown) generates an event of less than the lower limit and turns on the alarm lamp 430.

Meanwhile, the PCL (not shown) stores sensor data input in real time to any one of a plurality of input devices (not shown) in a memory (not shown).

When a request for performance data is input through the touch panel 420, the PLC (not shown) displays performance data for a predetermined period of data stored in the memory 350 on the touch panel 420. At this time, the PLC (not shown) may display the performance data in a graph form so that the operator can more easily recognize the change in the performance data. 5B shows an example of displaying performance data for a predetermined period on the touch panel 420.

When a process signal is input to any one of a plurality of input devices (not shown), the PLC (not shown) calculates the production quantity of the product and displays the calculated production quantity on the touch panel 420. For example, a PLC (not shown) displays the quantity of products produced by the injection molding apparatus 110 on the touch panel 420 as shown in FIG. 5A so that the operator can easily recognize the production progress. At this time, the PLC (not shown) may also display a target quantity to be produced by the injection molding apparatus 110 on the touch panel 420 as shown in FIG. 5A.

Then, the PLC (not shown) determines whether the production quantity of the product reaches a target quantity set in advance. When the production quantity reaches the target quantity, the PLC (not shown) generates a production completion event and turns on the alarm lamp 430.

The housing 410 accommodates a plurality of input devices (not shown), a PLC (not shown), and a memory (not shown).

The touch panel 420 is mounted on the housing 410 and displays data of monitoring the injection molding apparatus 110 according to a touch input from an operator. At this time, the data includes sensor data collected in real time, performance data collected for a predetermined period, and production quantity of products.

The alarm light 430 lights up according to PLC (not shown) control. More specifically, the alarm lamp 430 lights up according to PLC (not shown) control when any one of an upper limit exceeding event, a lower limit undertaking event, and a production completion event occurs.

The present invention described above is not limited to the above-described embodiments and the accompanying drawings, and various substitutions, modifications, and changes are possible within the scope of the technical spirit of the present invention. It will be obvious to those who have the knowledge of.

100: injection molding device monitoring system
110: injection molding device 120: monitoring device
310: digital signal input unit 320: analog signal input unit
330: production quantity calculation unit 340: data collection unit
350: memory 360: monitoring unit
370: setting unit 380: alarm unit
390: display

Claims (6)

It is installed in the work area of the first injection molding apparatus, connected to the first injection molding apparatus, collects and displays temperature data and pressure data from the connected first injection molding apparatus, and displays at least one of the collected temperature data and pressure data. If one exceeds the preset upper limit or falls below the lower limit, the alarm lights up, displays the production quantity of the product produced by the first injection molding device, and if the production quantity of the product is more than the preset target quantity, A first monitoring device that turns on the alarm light;
Installed in the working area of the second injection molding apparatus, connected to the second injection molding apparatus, collects and displays temperature data and pressure data from the connected second injection molding apparatus, and displays at least one of the collected temperature data and pressure data. If one exceeds the preset upper limit or falls below the lower limit, the alarm lights up, displays the production quantity of the product produced by the second injection molding device, and if the production quantity of the product is more than the preset target quantity, A second monitoring device that turns on the alarm light; And
A central management server that collects temperature data and pressure data from the first and second monitoring devices and provides them to a user terminal,
Each of the first and second monitoring devices,
A plurality of analog signal input units receiving the temperature data and pressure data as analog signals from the connected injection molding apparatus;
A digital signal input unit for receiving a process signal indicating the start or end of a process cycle as a digital signal from the connected injection molding apparatus;
PLC that monitors the connected injection molding apparatus based on the temperature data and pressure data, and when the process signal is input, calculates the current production quantity of the product by summing the number of cavities of the connected injection molding apparatus with the previous production quantity ( Programmable Logic Controller);
A memory for storing the input temperature data and pressure data;
A housing accommodating the plurality of input devices, the PLC, and the memory;
A display panel mounted on the housing and displaying data of monitoring the connected injection molding apparatus; And
When at least one of the temperature data and pressure data exceeds the preset upper limit or falls below the lower limit, it is lit in a first color according to the control of the PLC, and when the current production quantity of the product is more than the preset target quantity, the second Injection molding apparatus monitoring system including the alarm light that is lit in color. The method of claim 1, wherein the plurality of analog signal input units,
A first analog signal input unit receiving the temperature data as an analog signal from a first sensor of the connected injection molding apparatus; And
And a second analog signal input unit receiving the pressure data as an analog signal from a second sensor of the connected injection molding device. The method of claim 1, wherein the first and second monitoring devices,
When a performance data request is input through the display panel, temperature data or pressure data for a predetermined period of data stored in the memory are displayed on the display panel. delete delete delete

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