WO2014175167A1 - Système de fonctionnement intelligent pour une ligne de traitement de moulage de plastique - Google Patents

Système de fonctionnement intelligent pour une ligne de traitement de moulage de plastique Download PDF

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Publication number
WO2014175167A1
WO2014175167A1 PCT/JP2014/060953 JP2014060953W WO2014175167A1 WO 2014175167 A1 WO2014175167 A1 WO 2014175167A1 JP 2014060953 W JP2014060953 W JP 2014060953W WO 2014175167 A1 WO2014175167 A1 WO 2014175167A1
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WIPO (PCT)
Prior art keywords
processing line
information
smart
resin material
evaluation information
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PCT/JP2014/060953
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English (en)
Japanese (ja)
Inventor
花岡　一成
稔 春
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株式会社松井製作所
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Publication of WO2014175167A1 publication Critical patent/WO2014175167A1/fr

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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Systems or methods specially adapted for specific business sectors, e.g. utilities or tourism
    • G06Q50/04—Manufacturing
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
    • G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76003—Measured parameter
    • B29C2945/7613—Weight
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76177—Location of measurement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76929—Controlling method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30—Computing systems specially adapted for manufacturing

Definitions

  • the present invention relates to an improvement in an operation system of a plastic molding processing line for producing a molded product using a molding machine.
  • the following patent document proposes a technique for grasping in real time the amount of resin loss in a production line for molded products, reducing the amount of resin loss, and improving the efficiency of the production line.
  • an object of the present invention is to make the molding line smarter by making these wastes visible.
  • a plastic molding processing line smart operation system is a plastic molding processing line manufacturing system that uses a molding machine to manufacture a molded product, and includes a material weighing device installed upstream of the molding machine, and a processing line.
  • Data collection means that collects operation information of each device that constitutes, and the information collected by the data collection means is read and used until the resin material is supplied from the raw material storage unit to the molding machine and molded.
  • calculation processing means for calculating at least one or more of the resin material, power consumption, and operation time as preset processing line smartization evaluation information, and processing line smartization evaluation information calculated by the calculation processing means It is constructed by incorporating a monitoring device for display.
  • the factory in which the plastic molding line is configured in this way is called a smart factory in the present invention.
  • the monitoring device may visualize the processing line operational efficiency by arranging the read processing line smart evaluation information in time series.
  • the system includes storage means for accumulating quality information and processing line smartization evaluation information calculated by the arithmetic processing means, and shot identification information for identifying a molded shot of the molded product for each molded product. And an identification information providing means for assigning.
  • the monitoring device may be configured as a display / operation panel installed adjacent to the processing line.
  • the monitoring device may be configured as a portable terminal that can be connected to the processing line via a communication path including wireless communication.
  • the processing line smart evaluation information regarding time, resin material, and electric power is calculated, visualized as the operation efficiency of the processing line, and displayed on the monitoring means. You can immediately know whether you are within the standards. That is, the standard management of the plastic molding line becomes extremely easy.
  • shot identification information for identifying a shot of the molded product is given to each molded product, even if there is an inquiry about the molded product at a later date, it is printed on the molded product. Since quality information can be answered based on the identification information, the traceability of the molded product is improved.
  • the monitoring device is constituted by a portable terminal, it is highly convenient because the operation information of the device and the operation efficiency of the processing line can be displayed at a desired place in the factory.
  • the plastic molding processing line 1 (hereinafter simply referred to as a processing line) has a line configuration in which a weighing and blending machine 11, a dryer 12, a material weighing device 13, and a molding machine 14 are arranged.
  • a mold temperature controller 15 is connected to the molding machine 14.
  • the metering and blending machine 11 uses raw materials such that unused resin materials, recycled materials obtained by pulverizing sprues, runners, molding defects, etc., and master batches of colorants, etc., have a preset blending ratio. It is a device that weighs and mixes.
  • the dryer 12 is a device that heats and drys the resin material mixed in the metering and blending machine 11 so as to have a predetermined moisture content.
  • the material weighing device 13 is a device for weighing the resin material dried by the dryer 12 one batch at a time and supplying it to the molding machine 14, and the total mass including the loss of the resin material put into the processing line 1. Measure. Such a material measuring device 13 may be provided upstream of the molding machine 14.
  • the molding machine 14 is an apparatus for forming a molded product by heating and melting the resin material transported through the material measuring device 13 and then solidifying it by high-pressure injection (shot) into a cavity of a mold (not shown). .
  • the mold temperature controller 15 is a device for controlling the temperature by passing a heat transport medium (water, oil, etc.) through the mold of the molding machine 14.
  • the arithmetic processing means 16 is configured as a line control device including a data collecting means 16a for collecting operation information from each device constituting the processing line 1 and a control means 16b for controlling these devices in cooperation.
  • the data collection unit 16a may include, as device operation information, a blending notification signal output from the weighing and blending machine 11 (every time the raw materials are metered and blended), a drying chamber temperature signal output from the dryer 12, and a material outage warning signal ( When the remaining amount of the resin material is lower than the standard), a measurement notification signal output from the material weighing device 13 (every time the resin material is measured), a shot signal output from the molding machine 14 (every shot of the molding process), A material out notice signal (when the remaining amount of the resin material stored in the apparatus is below the reference) and the medium temperature signal output by the mold temperature controller 15 are collected.
  • the arithmetic processing means 16 is connected with a storage means 17 constituted by a hard disk or the like and a monitoring device 18 having a display unit (not shown
  • the monitoring device 18 includes display operation means. For example, it may be configured by a touch panel or the like installed adjacent to the processing line 1 and connected to the arithmetic processing means 16 by wire. Or you may be comprised by the workstation which can communicate with the arithmetic processing means 16 by LAN in a factory. Or you may be comprised by the portable terminals (tablet etc.) which can communicate with the arithmetic processing means 16 by the communication path
  • This communication path may include the Internet, and the monitoring device 18 may be configured as a communication terminal installed in a remote management center.
  • the monitoring device 18 when the monitoring device 18 is constituted by a portable terminal, the operation information of the device, the operation efficiency of the processing line, etc. can be displayed at a desired location in the factory, which is highly convenient.
  • a power meter 21 is provided for each device on the power supply line from the power supply unit 20 to each device. These wattmeters 21 constitute data collection means 16 a, and their measured values are transmitted to the arithmetic processing means 16.
  • the processing line 1 may be provided with identification information giving means 22 for printing identification information such as a serial number on a molded product.
  • the identification information giving means 22 is constituted by an ink printer, a laser printer or the like, and may print (engrave) the identification information represented by a character string, a one-dimensional barcode, or a two-dimensional barcode on a molded product, An electronic tag configured with an electronic tag and filled with identification information may be assembled to a molded product.
  • the process in the processing line 1 is basically the same as the conventional process. That is, to explain only the outline, first, unused resin material, recycled material, etc. are blended by the metering blender 11, the blended resin material is conveyed to the dryer 12 and dried for a predetermined time, The resin material is weighed in batch units by the material weighing device 13, and the weighed resin material is conveyed to the molding machine 14, where it is injection-molded to produce a molded product. The flow of the resin material is indicated by broken-line arrows in the figure.
  • the control means 16b controls the processing line 1 by transmitting a command signal to each device based on such operation information.
  • the arithmetic processing unit 16 supplies resin material from the raw material storage unit to the molding machine 14 based on the operation information of each device collected by the data collecting unit 16a and performs molding processing. It has a function of calculating at least one or more of the power consumption, the mass of the resin material, and the operation time used as the processing line smart evaluation information for each preset evaluation timing.
  • the calculated machining line smart evaluation information is stored in the storage means 17. It is desirable that each processing line smart evaluation information is assembled at the evaluation timing when the information is calculated.
  • the raw material storage part is a part defined as a supply point of the resin material in the calculation of the processing line smartization evaluation information.
  • the dryer 12 that stores and heat-drys the resin material is defined as the material storage unit, and the material metering device 13 is disposed immediately thereafter, but this is only an example.
  • an unused resin material hopper, a recycled material hopper, a masterbatch hopper, etc. (all not shown) provided on the upstream side of the weighing and blending apparatus 11 are defined as a material storage unit. Also good. In that case, since the weighing and blending machine 11 measures the resin material, it is not necessary to separately provide the material weighing device 13.
  • Processing line smartization evaluation information is visualized by a predetermined method and evaluated as the operation efficiency of the processing line 1. Therefore, the monitoring device 18 has a function of accepting the operation of the operator and reading out and visualizing the machining line smart conversion evaluation information calculated by the arithmetic processing means 16 in real time. Specifically, the processing line smart conversion evaluation information may be arranged in a time series to be graphed and displayed on a display unit (not shown). With this configuration and processing, the factory is made smarter.
  • Processing line smart evaluation information is calculated, for example, at each evaluation timing set in advance during the operation period of the processing line.
  • the accumulated amount of each resource (power, resin material, time) supplied to the processing line 1 and the molded product molded in the same period during the period from the start of operation of the processing line 1 to the evaluation timing May be calculated as the average resource consumption corresponding to the molded product.
  • the evaluation timing is periodic, various variations are possible. For example, one shot of a forming process or a predetermined number of shots may be defined as one shot unit in information processing, and the evaluation timing may be set every time the forming process is performed for one shot unit. Alternatively, the evaluation timing may be set every predetermined time, the evaluation timing may be set every time a predetermined amount of resin material is supplied to the processing line, or the evaluation timing is set every time a predetermined number of products are produced. May be.
  • the configuration of the processing line 1 may be changed depending on the product or the raw material, a device that can be replaced to change the configuration of the processing line 1 is registered in advance in the arithmetic processing means 16, When the device is automatically or manually replaced, the arithmetic processing means 16 may detect it and automatically switch the display content of the monitoring device 18.
  • timing at which one molding process is performed is set as the evaluation timing, and the collection of operation information from the apparatus constituting the processing line 1 and the processing line smartization evaluation information
  • the calculation and visualization of the operating efficiency of the processing line 1 will be specifically described.
  • FIGS. 2 (a) to 2 (c) are examples of graphs in which operation information collected from apparatuses constituting a processing line is arranged and arranged in time series (time T1 to time T27).
  • the operation start point of the processing line 1 is set as the starting point of the time axis (horizontal axis).
  • Graph (G1) in FIG. 2 (a) is a graph in which the cumulative number of molding shots from the operation start time of the processing line 1 is arranged in the order of time as a bar B.
  • the first shot appears at time T5, and thereafter, the cumulative number of shots increases as time passes until time T14.
  • the processing line 1 is forcibly stopped (chocolate stop), so the cumulative number of shots is It has not changed. Thereafter, the processing line 1 is restarted, and the cumulative number of shots increases with time from time T20 to time T27.
  • the forced stop of the processing line 1 is caused by, for example, occurrence of a defect, but may be automatically performed or may be manually performed by an operator's operation.
  • the defective molding process is caused, for example, when the molten resin material is injected from the nozzle of the molding machine 14 into the mold and becomes vaporized and adheres to the mold surface and the gap.
  • Specific symptoms include short shots, mold parting burrs, and gas burns.
  • a graph G2 in FIG. 2B is an arrangement in which the cumulative amount of the resin material supplied to the molding machine 14 from the operation start time of the processing line 1 is arranged as the height of the bar B in time order as the bar B.
  • ⁇ M in the figure indicates a weighing unit (one batch mass) of the material weighing device 13. Comparing with the graph of FIG. 2A, it can be seen that the resin material of only ⁇ M is additionally supplied every time the molding machine 14 performs three shots. However, this is only an example, and for how many shots of molding process the resin material is supplied once more is the resin mass unit of molding process (resin mass required for one shot) and material metering. Depends on the unit of measure of the device 13.
  • the resin material is continuously supplied at times T3 and T4, which is to store a certain resin material in the molding machine 14 in advance. Also, the resin material is continuously supplied at times T18 and T19. This is because the resin material remaining in the molding machine 14 is purged (time T17) as the processing line 1 is forcibly stopped and restarted. Therefore, to make up for it.
  • the graph G3 in FIG. 2C is an arrangement in which the accumulated amount of power supplied to the processing line 1 from the operation start time of the processing line 1 is arranged in the order of time as a bar B.
  • the cumulative amount of power is basically proportional to the cumulative number of shots.
  • a large amount of electric power is used for preheating the dryer 12 and the mold temperature controller 15.
  • the accumulated amount of power does not change.
  • considerable electric power is used for reheating the mold temperature controller 15 and the like.
  • 3 (a) to 3 (c) are graphs of the machining line smartization evaluation information calculated based on the operation information shown in FIGS. 2 (a) to 2 (c).
  • the horizontal axis of the graphs G4 to G6 is not the time axis, but the cumulative number of molding shots.
  • the 10th scale on the horizontal axis means the 10th shot.
  • the graph G4 in FIG. 3A is obtained by arranging the values of the processing line smartization evaluation information (time evaluation information) related to time as a bar B in the order of shots.
  • Each value of the time evaluation information is calculated from the length of the period from the start of operation of the processing line 1 to the time of each evaluation timing and the cumulative number of shots in that period.
  • the value of the sixth shot is obtained by dividing the value T in FIG.
  • each value of the time evaluation information is an average value of the time required for each shot at each evaluation timing. If the time evaluation information is graphed as shown in FIG. 3A, the transition of the time efficiency of the processing line 1 can be grasped at a glance.
  • the broken line in the graph G4 is a reference value for time efficiency, and may be set to 110% of the ideal value determined by the performance of the molding machine 14.
  • Graph G5 in FIG. 3 (b) is obtained by arranging the values of the processing line smartization evaluation information (material use evaluation information) related to the resin material in the order of shots as a bar B.
  • Each value of the material use evaluation information was calculated from the cumulative amount of the resin material supplied to the processing line 1 from the start of operation of the processing line 1 to the time of each evaluation timing, and the cumulative number of shots in that period. Is.
  • the value of the sixth shot is obtained by dividing the value M in FIG. 2B by the value X in FIG.
  • each value of the material use evaluation information is an average value of the resin material used per shot at each evaluation timing. If the material use evaluation information is graphed as shown in FIG. 3B, the transition of the material use efficiency of the processing line 1 can be grasped at a glance.
  • the broken line in the graph G5 is a reference value for material use efficiency, and may be set to 110% of the resin mass unit of the molding process.
  • the graph G6 in FIG. 3C is obtained by arranging the values of the processing line smart evaluation information (electric power usage evaluation information) related to electric power in the order of shots as a bar B.
  • Each value of the power usage evaluation information is calculated from the cumulative amount of power supplied to the processing line 1 from the time when the processing line 1 is started to the time of each evaluation timing, and the cumulative number of shots in that period. It is.
  • the value of the sixth shot is obtained by dividing the value P in FIG. 2C by the value X in FIG.
  • each value of the power usage evaluation information is an average value of power used per shot at each evaluation timing.
  • the broken line in the graph G6 is a reference value of power usage efficiency, and may be set to 110% of the ideal value determined by the average power consumption when the processing line 1 is stably operating.
  • the process line smart evaluation information on time, resin material, and electric power is quantitatively visualized and evaluated, the time change of the operation efficiency and the operation efficiency can be reduced. You can immediately know if you are within the standards. That is, it is possible to easily perform standard management during system operation.
  • the reference value may be set based on the specifications of each device and the data accumulated in the mass production preparation stage. That is, the reference value includes not only the data at the time of stable operation, but also the amount of the discarded resin material and the influence of the forced stop of the processing line 1.
  • the efficiency of the processing line has been discussed based on the specifications (champion data) of each device, and it has been difficult to evaluate the actual efficiency of the processing line.
  • the actual efficiency of the processing line 1 can be evaluated by visualizing the processing line smartization evaluation information as described above, the inefficiency immediately after the start of the operation of the processing line 1 and the processing line 1 The magnitude of impact, etc. when forced to stop is clarified. Therefore, it helps to optimize the number of products in the lot, and the ability of the device can be evaluated. For example, in the case of a large molding machine, 10 products can be obtained in one shot of molding, but it is understood that the amount of resin material to be discarded is too large to be suitable for a small lot.
  • the arithmetic processing means 16 performs one shot of molding processing.
  • the value of the processing line smartization information may be normalized by using the mass of the resin material used in the above, or a predetermined mass such as 10 kg as a resin material mass unit.
  • the smart evaluation information regarding the supply of resin materials and electric power is standardized in this way, it becomes possible to compare the processing line smart evaluation information between processing lines with different types of molded products.
  • the value of the processing line smartization information may be standardized by a product unit amount such as one dozen.
  • the arithmetic processing means 16 may store the quality information (drying time, drying temperature, mold temperature set value, measurement value, etc.) collected by the data collecting means 16a in the storage means 17 together with the processing line smartization evaluation information. .
  • the identification information providing unit 22 may include information for specifying the evaluation timing at the time when the molded product is molded into the identification information provided for each molded product. For example, information for specifying a shot in which the molded product is made may be included as identification information.
  • the quality assurance system can be explained at the client's inspection, and when there is an inquiry about the molded product at a later date, the quality information etc. is answered based on the identification information printed on the molded product. This improves traceability. It should be noted that the monitoring device 18 may be able to appropriately browse the quality information stored in the storage unit 17.

Abstract

Selon la présente invention, dans une ligne de traitement de moulage de plastique, la ligne de traitement (1) est configurée de sorte à incorporer : un dispositif de pesage de matériau (13) installé côté amont d'une machine de moulage (14) ; un moyen de collecte de données (16a) qui collecte des informations de fonctionnement pour chaque dispositif ; et un moyen de traitement de calcul (16) qui lit les informations collectées par le moyen de collecte de donnes (16a) et, comme informations d'évaluation intelligente prédéterminées pour la ligne de traitement, calcule la masse du matériau de résine et/ou la consommation d'énergie et/ou le temps de fonctionnement utilisé jusqu'à ce que le matériau de résine soit fourni par une unité de stockage de matériau de départ à la machine de moulage et soit moulé/traité ; et un dispositif de surveillance (18) qui affiche les informations d'évaluation intelligente pour la ligne de traitement calculées par le moyen de traitement de calcul (16).
PCT/JP2014/060953 2013-04-22 2014-04-17 Système de fonctionnement intelligent pour une ligne de traitement de moulage de plastique WO2014175167A1 (fr)

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JP2013-089719 2013-04-22
JP2013089719A JP2014215636A (ja) 2013-04-22 2013-04-22 プラスチック成型加工ラインのスマート化稼働システム

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WO2023198798A1 (fr) * 2022-04-14 2023-10-19 Motan Holding Gmbh Structure de système de traitement de particules de plastique

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Publication number Priority date Publication date Assignee Title
WO2023198798A1 (fr) * 2022-04-14 2023-10-19 Motan Holding Gmbh Structure de système de traitement de particules de plastique

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