WO2024157328A1 - 制御装置及び制御方法 - Google Patents

制御装置及び制御方法 Download PDF

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Publication number
WO2024157328A1
WO2024157328A1 PCT/JP2023/001936 JP2023001936W WO2024157328A1 WO 2024157328 A1 WO2024157328 A1 WO 2024157328A1 JP 2023001936 W JP2023001936 W JP 2023001936W WO 2024157328 A1 WO2024157328 A1 WO 2024157328A1
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Prior art keywords
control device
prime mover
diagnostic
diagnostic operation
preliminary
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PCT/JP2023/001936
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English (en)
French (fr)
Japanese (ja)
Inventor
淳史 堀内
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Fanuc Corp
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Fanuc Corp
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Priority to PCT/JP2023/001936 priority Critical patent/WO2024157328A1/ja
Priority to JP2024572546A priority patent/JPWO2024157328A1/ja
Publication of WO2024157328A1 publication Critical patent/WO2024157328A1/ja
Anticipated expiration legal-status Critical
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/02—Gearings; Transmission mechanisms
    • G01M13/023—Power-transmitting endless elements, e.g. belts or chains

Definitions

  • This disclosure relates to a control device and a control method.
  • the condition of a drive unit equipped in industrial machinery can be diagnosed by analyzing the frequency characteristics (resonance curve).
  • the condition of the drive unit can be diagnosed, for example, for mechanical resonance points, stability, and responsiveness, and the diagnostic results are used for preventive maintenance of the drive unit.
  • the frequency characteristics are measured by a diagnostic operation (frequency sweep operation) that applies a specified input signal to the drive unit to be controlled and observes the output signal.
  • the driving mechanism is driven by a diagnostic operation, and the frictional force is identified from the frequency response of the driving mechanism based on the motor drive current (the frequency characteristics of this application), and the condition of the driving mechanism is diagnosed.
  • the tension value of the belt that transmits the power of industrial machinery is estimated based on the data obtained by the diagnostic operation, and the degree of damage to the belt is diagnosed. In this way, it is publicly known to analyze the frequency characteristics obtained by performing a diagnostic operation and diagnose the condition of the driving device (for example, Patent Documents 1 and 2, etc.).
  • the operating conditions related to the diagnostic operation e.g., operation command values such as motor rotation speed, the configuration of drive parts such as the reducer equipped in the drive unit, the rigidity of the drive unit, the magnitude of the load on the drive unit, etc.
  • the frequency characteristics obtained by the diagnostic operation will give the same analysis results.
  • the operator adjusted the position of the drive unit to the position where the diagnostic operation would be performed and then performed the diagnostic operation, which resulted in differences in the meshing state (e.g., backlash, play, rattle, etc.) of the power transmission parts such as the belt/pulley/gears equipped in the drive unit at the start of the diagnostic operation.
  • the control device for an injection molding machine solves the above problem by positioning the prime mover at one end of a predetermined pre-operating range when analyzing the frequency characteristics of the prime mover that drives the drive unit equipped in the industrial machine, then positioning the prime mover at the other end of the pre-operating range, and then positioning the prime mover at a diagnosis start position to start the diagnostic operation.
  • An aspect of the present disclosure is a control device that includes a vibration signal generation unit that generates a vibration signal that vibrates a prime mover that drives a drive unit of an industrial machine, a control unit that positions the prime mover at a predetermined diagnosis start position and controls a diagnostic operation that diagnoses the frequency characteristics using the vibration signal, a data acquisition unit that acquires at least the vibration signal and feedback data obtained from the diagnostic operation, and a frequency characteristic calculation unit that calculates a resonance curve that indicates frequency characteristics based on the feedback data, and the control unit controls a pre-operation that performs at least one operation of positioning the prime mover at one end of a predetermined pre-operation range and then positioning it at the other end of the pre-operation range before controlling the diagnostic operation, and then positions the prime mover at the diagnosis start position and starts the diagnostic operation.
  • FIG. 2 is a schematic hardware configuration diagram of a control device according to an embodiment of the present disclosure.
  • FIG. 1 is a schematic configuration diagram of an injection molding machine.
  • FIG. 2 is a perspective view of a belt and a pulley which are a power transmission means provided in the injection molding machine.
  • FIG. 2 is a block diagram showing schematic functions of a control device according to the first embodiment.
  • 6 is a graph illustrating a change in position of a servo motor during a diagnostic operation of an injection molding machine.
  • 11 is a graph illustrating a change in position of a servo motor in a pre-operation related to a diagnostic operation.
  • 13 is a graph illustrating a change in position of a servo motor in a pre-operation related to another diagnostic operation.
  • FIG. 1 is a schematic configuration diagram of an injection molding machine.
  • FIG. 2 is a perspective view of a belt and a pulley which are a power transmission means provided in the injection molding machine.
  • FIG. 2
  • FIG. 2 is a schematic diagram of a toothed belt and a toothed pulley.
  • FIG. 11 is a block diagram showing schematic functions of a control device according to a second embodiment.
  • FIG. 13 is a screen configuration diagram showing an example of a setting screen for a preliminary operation range.
  • FIG. 1 is a schematic hardware configuration diagram showing a main part of a control device according to a first embodiment of the present disclosure.
  • the control device 1 according to this embodiment can be implemented as a control device that controls an industrial machine based on a control program, for example.
  • a control program for example.
  • an example is shown in which the control device 1 is implemented as a control device that controls an injection molding machine 2, which is a type of industrial machine.
  • the CPU 11 provided in the control device 1 is a processor that controls the entire control device 1.
  • the CPU 11 reads the system program stored in the ROM 12 via the bus 22, and controls the entire control device 1 according to the system program.
  • the RAM 13 temporarily stores temporary calculation data, display data, various data input from outside, etc.
  • the non-volatile memory 14 is composed of, for example, a memory backed up by a battery (not shown) or an SSD (Solid State Drive), and the memory state is maintained even when the power supply of the control device 1 is turned off.
  • the non-volatile memory 14 stores programs and data read from the external device 72 via the interface 15, programs and data input via the input device 71, and programs and data acquired from the injection molding machine 2 or other devices via the network 5.
  • the stored data may include, for example, data related to physical quantities such as the motor current, voltage, torque, position, speed, acceleration, injection cylinder temperature, resin pressure, flow rate, flow rate, mold temperature and pressure, mold temperature and pressure, mold temperature regulator temperature and pressure, molded product removal machine position and speed, and vibration and sound generated in each part of the injection molding machine 2 detected by a sensor attached to the injection molding machine 2.
  • the programs and data stored in the non-volatile memory 14 may be expanded into the RAM 13 when executed/used.
  • various system programs such as known analysis programs are written in advance in the ROM 12.
  • the interface 15 is an interface for connecting the CPU 11 of the control device 1 to an external device 72 such as a USB device.
  • an external device 72 such as a USB device.
  • system programs, programs related to the operation of the injection molding machine 2, setting data, etc. are read from the external device 72.
  • programs and setting data created and edited within the control device 1 can be stored in an external storage means via the external device 72.
  • the interface 20 is an interface for connecting the CPU 11 of the control device 1 to a wired or wireless network 5.
  • the network 5 may communicate using technologies such as serial communication such as RS-485, Ethernet (registered trademark), optical communication, wireless LAN, Wi-Fi (registered trademark), Bluetooth (registered trademark), etc.
  • serial communication such as RS-485, Ethernet (registered trademark), optical communication, wireless LAN, Wi-Fi (registered trademark), Bluetooth (registered trademark), etc.
  • At least one injection molding machine 2 to be controlled, at least one other industrial machine 4, a fog computer 6, a cloud server 7, etc. are connected to the network 5, and data is exchanged between the control device 1 and the network 5.
  • the display device 70 displays the various data loaded into the memory, data obtained as a result of executing programs, etc., output via the interface 17.
  • the input device 71 which is comprised of a keyboard, pointing device, etc., passes instructions and data based on operations by the operator to the CPU 11 via the interface 18.
  • FIG. 2 is a schematic diagram of the injection molding machine 2.
  • the injection molding machine 2 is mainly composed of a mold clamping unit 401 and an injection unit 402.
  • the mold clamping unit 401 is equipped with a movable platen 416 and a fixed platen 414.
  • a movable mold 412 is attached to the movable platen 416, and a fixed mold 411 is attached to the fixed platen 414.
  • a servo motor 50 is attached to the mold clamping unit 401 as a prime mover.
  • a ball screw (not shown) is driven via a power transmission means such as a belt 420 and a pulley 422, and the movable platen 416 can be advanced or retreated in the direction of the fixed platen 414.
  • Other examples of the prime mover may be a hydraulic motor, a hydraulic cylinder, a linear motor, or a direct drive motor.
  • FIG. 3 is a perspective view of belt 420 and pulley 422, which are power transmission means provided in the injection molding machine 2 shown in FIG. 2.
  • a toothed belt may be used as belt 420
  • a toothed pulley may be used as pulley 422.
  • a flat belt, a V-belt, a chain, etc. may also be used as belt 420.
  • a linear bush, a ball screw, a spline coupling part, etc. may also be used as power transmission means.
  • a direct drive motor may be used as the direct drive motor.
  • the injection unit 402 is composed of an injection cylinder 426, a hopper 436 that stores the resin material to be supplied to the injection cylinder 426, and a nozzle 440 provided at the tip of the injection cylinder 426.
  • the injection unit 402 can move the injection cylinder 426 forward or backward in the direction of the fixed platen 414 by driving a servo motor (not shown).
  • the mold clamping unit 401 closes and clamps the mold by moving the movable platen 416, and the injection unit 402 presses the nozzle 440 against the fixed mold 411 and then injects a measured amount of resin into the injection cylinder 426 into the mold. These operations are controlled by commands from the control device 1 (not shown).
  • sensors are attached to each part of the injection molding machine 2, and various physical quantities necessary for controlling the molding operation are detected.
  • the detected physical quantities include the motor current, voltage, torque, position, speed, and acceleration of the drive unit, the temperature of the injection cylinder 426, the pressure of the resin in the injection cylinder 426, the flow rate of the resin, the temperature and pressure of the mold, the temperature and pressure of the mold temperature regulator, the position and speed of the molded product removal machine, and vibrations and sounds generated in each part of the injection molding machine 2.
  • the detected physical quantities are sent and output to the control device 1.
  • each detected physical quantity is stored in the RAM 13, non-volatile memory 14, etc.
  • FIG. 4 is a schematic block diagram showing the functions of the control device 1 according to the first embodiment of the present disclosure.
  • Each function of the control device 1 according to this embodiment is realized by the CPU 11 of the control device 1 shown in FIG. 1 executing a system program and controlling the operation of each part of the control device 1.
  • the control device 1 of this embodiment includes a control unit 100, a vibration signal generating unit 110, a data acquiring unit 120, a frequency characteristic calculating unit 130, and an output unit 140.
  • a control program 200 including commands for controlling the injection molding machine 2 is pre-stored in the RAM 13 to the non-volatile memory 14 of the control device 1.
  • the RAM 13 to the non-volatile memory 14 of the control device 1 are pre-stored with a parameter storage unit 210, which is an area in which parameters related to the diagnostic operation of the injection molding machine 2 are pre-stored, and an acquired data storage unit 220, which is an area in which the data acquiring unit 120 stores data acquired from the servo motor 50, sensors, etc., of the injection molding machine 2.
  • the control unit 100 analyzes the blocks of the control program 200 and controls each part of the injection molding machine 2 based on the analysis results. For example, when a block of the control program 200 commands the control unit 100 to drive each axis of the injection molding machine 2, the control unit 100 generates movement command data according to the command from the block and outputs it to the servo motor 50 equipped in the injection molding machine 2. Also, when a block of the control program 200 commands the control unit 100 to operate a peripheral device attached to the injection molding machine 2, the control unit 100 generates and outputs a predetermined signal to operate the peripheral device.
  • control unit 100 can output general commands related to the control of the injection molding machine 2, such as the operation of injecting resin measured in the injection cylinder 426 into a mold, to the injection molding machine 2 according to the command from the block of the control program 200.
  • control unit 100 acquires position feedback, speed feedback, and torque feedback of the servo motor 50 equipped in the injection molding machine 2, as well as detection value data detected by sensors such as a temperature sensor and a humidity sensor, and uses the data to control the injection molding machine 2.
  • the control unit 100 controls the injection molding machine 2 to perform a diagnostic operation (frequency sweep operation) in which the servo motor 50, which drives the belt 420, is driven at a predetermined range of rotation speeds (frequencies) using the excitation signal generated by the excitation signal generation unit 110.
  • the operator or manufacturer determines appropriate values for the parameters required for the diagnostic operation (e.g., the diagnostic operation range of the servo motor 50, the upper limit position of the diagnostic operation range, the lower limit position of the diagnostic operation range, the type of excitation signal, the maximum value, minimum value, and increment value of the excitation frequency, etc.) through experiments in advance and stores them in the parameter storage unit 210.
  • the control unit 100 commands the excitation signal generation unit 110 to generate an excitation signal based on the parameters read from the parameter storage unit 210, and the resulting excitation signal is used for the diagnostic operation of the injection molding machine 2.
  • the vibration signal generating unit 110 generates a vibration signal that vibrates the servo motor 50 of the injection molding machine 2 when performing a diagnostic operation of the injection molding machine 2.
  • the vibration signal may be, for example, a sine wave signal, a square wave signal, a rectangular wave signal, a triangular wave signal, a sawtooth wave signal, or the like.
  • FIG. 5 is a graph illustrating a change in the position of the servo motor 50 during the diagnostic operation of the injection molding machine 2.
  • the diagnostic operation of the injection molding machine 2 is controlled by using a sine wave signal as the excitation signal.
  • the frequency of a sine wave signal with a predetermined amplitude is swept and input to the servo motor 50 as a control signal.
  • the amplitude of the sine wave signal input to the servo motor 50 is kept constant, and the frequency of the sine wave is changed as time passes, such as increasing the frequency of the sine wave in a range from 1 Hz to 1 kHz in 10 Hz increments.
  • the control unit 100 drives the servo motor 50 to reciprocate within a predetermined diagnostic operation range determined by the signal shape and amplitude.
  • the position of the servo motor 50 fluctuates between the upper limit position xd1 of the diagnostic operation and the lower limit position xd2 of the diagnostic operation, with the central position xd0 of the diagnostic operation as the center.
  • the control unit 100 controls the injection molding machine 2 to perform a pre-operation related to the diagnostic operation before controlling the diagnostic operation of the injection molding machine 2.
  • the pre-operation related to the diagnostic operation moves the servo motor 50 within a predetermined pre-operation range. This pre-operation may be performed by moving the servo motor 50 through all positions in the pre-operation range. For example, the servo motor 50 may be positioned at one end of the pre-operation range and then moved to the other end of the pre-operation range. It is more preferable that the pre-operation range is set to include the diagnostic operation range in which the servo motor 50 of the injection molding machine 2 is driven during the diagnostic operation, but it may be a range narrower than the diagnostic operation range.
  • the pre-operation may be performed at least once, or may be performed by reciprocating between one end and the other end of the pre-operation range a predetermined number of times. It is desirable that the pre-operation related to the diagnostic operation performed for the same injection molding machine 2 is always the same operation. For example, if the end that is first positioned in the pre-operation for the diagnostic operation of a certain injection molding machine 2 is set to the upper limit position of the pre-operation range, it is desirable that the end that is first positioned in the pre-operation range should always be set to the upper limit position of the pre-operation range in the subsequent pre-operations as well. Also, if positioning is performed once from one end to the other end, it is desirable that subsequent pre-operations also be performed once from one end to the other end.
  • FIG. 6 is a graph illustrating the position change of the servo motor 50 in the preliminary operation related to the diagnostic operation.
  • the servo motor 50 is moved from one end to the other end of the preliminary operation range (the range of the upper limit position xp 1 of the preliminary operation to the lower limit position xp 2 of the preliminary operation), which is a range including the diagnostic operation range (the range of the upper limit position xd 1 of the diagnostic operation to the lower limit position xd 2 of the diagnostic operation) in which the servo motor 50 is driven in the diagnostic operation.
  • the diagnostic operation range the range of the upper limit position xd 1 of the diagnostic operation to the lower limit position xd 2 of the diagnostic operation
  • the position of the servo motor 50 is positioned from the start position xp 0 of the preliminary operation to the upper limit position xp 1 (>the upper limit position xd 1 of the diagnostic operation), which is one end of the preliminary operation range, and then to the lower limit position xp 2 ( ⁇ the lower limit position xd 2 of the diagnostic operation), which is the other end of the preliminary operation range.
  • the servo motor 50 is positioned at the diagnosis start position of the diagnostic operation (the center position xd 0 of the diagnostic operation) and then the diagnostic operation is started.
  • FIG. 7 is a graph illustrating a position change of the servo motor 50 in a pre-operation related to another diagnostic operation.
  • the operation of positioning the servo motor 50 at the lower limit position xp 2 , which is one end of the pre-operation range, and then positioning at the upper limit position xp 1, which is the other end, is repeated twice.
  • This allows a lubricant such as grease to permeate the power transmission means driven by the servo motor 50, and allows the meshing of the power transmission means such as a belt/pulley/gear to become familiar.
  • a lubricant such as grease
  • the operation of the servo motor 50 is made to wait for a predetermined waiting time tw 1.
  • the timing for starting the diagnostic operation after the end of the pre-operation may be set to a predetermined time tw 2. This makes it possible to reduce a shock related to the servo motor 50 when transitioning from the pre-operation to the diagnostic operation.
  • the values of the predetermined waiting time tw1 and the predetermined time tw2 may be selected, for example, by repeatedly conducting an experiment in which the rotation direction of the servo motor 50 is reversed and shocks are observed.
  • the upper limit position xp 1 and the lower limit position xp 2 of the preliminary operation may be determined according to the structure of the power transmission means. For example, when a toothed belt and a toothed pulley as illustrated in FIG. 8 are used as the power transmission means, the upper limit position xp 1 and the lower limit position xp 2 of the preliminary operation may be determined to be a distance from the center position xd 0 of the diagnostic operation multiplied by a predetermined coefficient ⁇ ( ⁇ is 1.0 or more) to the pitch p of the toothed belt or the toothed pulley.
  • the upper limit position xp 1 and the lower limit position xp 2 of the preliminary operation may be determined based on the respective pitches.
  • the upper limit position xp 1 of the preliminary operation may be a position obtained by adding a predetermined margin value ⁇ 1 ( ⁇ 1 is 0.0 or more) to the upper limit position xd 1 of the diagnostic operation.
  • the lower limit position xp 2 of the preliminary operation may be a position obtained by subtracting a predetermined margin value ⁇ 2 ( ⁇ 2 is 0.0 or more) from the lower limit position xd 2 of the diagnostic operation.
  • the preliminary operation range may be determined to have a width obtained by multiplying the diagnostic operation range by a predetermined coefficient ⁇ ( ⁇ is 1.0 or more).
  • the upper limit position xp 1 and the lower limit position xp 2 of the preliminary operation may be determined at a position away from the center position in the amplitude direction of the sine wave by a predetermined coefficient ⁇ that is predetermined for the amplitude of the sine wave.
  • the preliminary operation range includes the diagnostic operation range, and the lubrication state of the lubricant (grease) related to the drive part in the diagnostic operation range at the start of the diagnostic operation is always in the same state. Therefore, it is possible to expect stable analysis results of diagnostic operations.
  • the upper limit position xp 1 and the lower limit position xp 2 of the preliminary operation determined by the above method are outside the movable range of the servo motor 50, they may be clamped so as to be within the movable range of the servo motor 50.
  • the control unit 100 may set a predetermined torque limit value for the torque of the servo motor 50 when controlling the positioning of the preliminary operation. It is desirable that this torque limit value is a value smaller than the torque limit value during normal operation when the injection molding machine 2 manufactures molded products.
  • the torque limit value may be a value smaller than the torque limit value during normal operation and diagnostic operation of the injection molding machine 2.
  • a predetermined speed limit value may be set for the speed of the servo motor 50. It is desirable that this speed limit value is a value smaller than the speed limit value during normal operation of the injection molding machine 2.
  • the speed limit value may be a value smaller than the speed limit value during normal operation and diagnostic operation of the injection molding machine 2. In this way, by limiting the movement during positioning of the preliminary operation to a low torque or low speed compared to normal operation, it is possible to safely position the diagnosis start position.
  • the control unit 100 may be configured to stop the pre-operation and diagnostic operation if the time elapsed from the start of the pre-operation to its end exceeds a predetermined time limit. In such a case, a warning may be output, such as by displaying an alarm message on the display device 70 or sounding a buzzer. If the pre-operation is taking longer than expected, there is a high possibility that some kind of trouble has occurred in the drive unit. If a diagnostic operation is started in such a state, not only will an accurate diagnosis not be possible, but there is also a possibility that serious damage will be caused to the drive unit of the injection molding machine 2. Detecting such a situation makes it possible to prevent problems from occurring in advance.
  • Parameters related to the pre-operation can be determined in advance by an operator or manufacturer based on experiments and stored in the parameter storage unit 210.
  • the data acquisition unit 120 acquires feedback data such as position feedback, speed feedback, and torque feedback acquired from the servo motor 50 of the injection molding machine 2 during the diagnostic operation of the injection molding machine 2, and detection value data detected by sensors of the injection molding machine 2, and stores the acquired data in the acquired data storage unit 220.
  • the feedback data such as position feedback, speed feedback, and torque feedback acquired by the data acquisition unit 120 is time-series data.
  • the detection value data acquired by the data acquisition unit 120 may be data values acquired at a predetermined timing. For example, the room temperature at the timing when the diagnostic operation is started may be acquired as the detection value data.
  • the data acquisition unit 120 may acquire data detected by the industrial machine 4 from another industrial machine 4 via the network 5.
  • the data may also be acquired as data input by the operator from the input device 71 or data input via the external device 72.
  • the frequency characteristic calculation unit 130 calculates frequency response data (hereinafter referred to as a resonance curve) indicating the frequency characteristics of feedback data such as position feedback, speed feedback, and torque feedback acquired by the data acquisition unit 120 during diagnostic operation of the injection molding machine 2.
  • the resonance curve calculated by the frequency characteristic calculation unit 130 may be, for example, a gain curve, which is curve data indicating frequency-gain characteristics, or a phase curve, which is curve data indicating frequency-phase characteristics.
  • Such data can be calculated by performing known frequency analysis such as fast Fourier transform on the feedback data, which is time-series data.
  • the output unit 140 displays and outputs to the display device 70 a resonance curve indicating the frequency characteristics of the feedback data during the diagnostic operation calculated by the frequency characteristic calculation unit 130.
  • the output unit 140 may transmit and output the determination result of the resonance curve to the injection molding machine 2 via the network 5. It may also be configured to transmit and output to a higher-level computer such as the fog computer 6 or cloud server 7. Furthermore, it may be output to a log recording area previously provided on the non-volatile memory 14 or the like.
  • the resonance curve indicating the output frequency characteristics is used to analyze the resonance point, stability, responsiveness, etc. of the drive unit of the injection molding machine 2 driven by the servo motor 50, and to understand the operating characteristics.
  • the control device 1 moves the drive unit within a predetermined pre-operation range (the range between the upper limit position of the pre-operation and the lower limit position of the pre-operation) before performing a diagnostic operation.
  • a predetermined pre-operation range the range between the upper limit position of the pre-operation and the lower limit position of the pre-operation
  • the motor rotation direction when positioning the motor at the position at the start of the diagnosis and the movement direction of the movable parts of the drive unit are always moved and positioned in the same direction. Therefore, the meshing state (backlash, gap, play, rattle) of the power transmission parts such as the belt/pulley/gear of the drive unit is always in the same state when the diagnostic operation is started. As a result, the diagnostic operation is performed in the same state, so the reproducibility of the diagnostic operation is realized.
  • the reproducibility of the analysis results of the frequency characteristics obtained by the diagnostic operation is also improved.
  • the reproducibility, analysis accuracy, and reliability of the analysis results such as the graph shape of the resonance curve obtained by analyzing the frequency characteristics and the resonance point (resonance frequency) obtained by analyzing the resonance curve are improved.
  • the lubricating condition of the lubricant (grease) on the moving parts of the drive unit becomes familiar, and the frictional force on the moving parts of the drive unit during diagnostic operation will be in the same state when the diagnostic operation is performed. This achieves reproducibility of the diagnostic operation.
  • control device 1 according to the second embodiment differs from the control device 1 according to the first embodiment in that the control device 1 according to the second embodiment has a function of supporting parameter setting for a preliminary operation.
  • the control device 1 according to the second embodiment has a hardware configuration similar to that of the control device according to the first embodiment.
  • FIG. 9 is a schematic block diagram showing the functions of the control device 1 according to the second embodiment.
  • Each function of the control device 1 according to this embodiment is realized by the CPU 11 of the control device 1 shown in FIG. 1 executing a system program and controlling the operation of each part of the control device 1.
  • the control device 1 of this embodiment further includes a parameter setting unit 150 in addition to the control unit 100, the excitation signal generating unit 110, the data acquiring unit 120, the frequency characteristic calculating unit 130, and the output unit 140.
  • a control program 200 including commands for controlling the injection molding machine 2 is pre-stored in the RAM 13 to the non-volatile memory 14 of the control device 1.
  • the RAM 13 to the non-volatile memory 14 of the control device 1 further include a parameter storage unit 210, which is an area in which parameters related to the diagnostic operation of the injection molding machine 2 are pre-stored, and an acquired data storage unit 220, which is an area in which the data acquiring unit 120 stores data acquired from the servo motor 50, sensors, etc., of the injection molding machine 2.
  • control unit 100, the excitation signal generating unit 110, the data acquiring unit 120, the frequency characteristic calculating unit 130, and the output unit 140 of the control device 1 according to this embodiment have the same functions as the control unit 100, the excitation signal generating unit 110, the data acquiring unit 120, the frequency characteristic calculating unit 130, and the output unit 140 of the control device 1 according to the first embodiment.
  • the parameter setting unit 150 provides a user interface for an operator to set parameters related to the preliminary operation range.
  • FIG. 10 is a screen configuration diagram showing an example of a setting screen for the preliminary operation range.
  • a user interface is provided for calculating the upper limit position and the lower limit position of the preliminary operation based on the configuration of the power transmission means and the parameters of the diagnosis operation range.
  • the configuration of the power transmission means (pitch value, etc.) may be set in advance in the control device 1 as a parameter related to the configuration of the injection molding machine 2.
  • the parameters related to the diagnosis operation range may be read and used based on the values of the parameters set in the parameter storage unit 210.
  • the setting screen for the preliminary operation range may display a graph related to the position change related to the diagnosis operation on the screen based on the values of the parameters set in the parameter storage unit 210.
  • the operator may input the upper limit position and the lower limit position of the preliminary operation while referring to the screen.
  • the upper limit position and the lower limit position of the preliminary operation may be calculated according to the configuration of the power transmission means by inputting a coefficient ⁇ related to the toothed belt provided in the power transmission means.
  • the upper limit position and the lower limit position of the preliminary operation may be a value obtained by multiplying the pitch of the toothed belt by the coefficient ⁇ .
  • the upper limit position and the lower limit position of the pre-action may be calculated according to the diagnostic operation range by inputting coefficients ⁇ 1 , ⁇ 2 , ⁇ , etc. related to the diagnostic operation range.
  • the upper limit position of the pre-action may be a value obtained by adding the coefficient ⁇ 1 to the upper limit position of the diagnostic operation range.
  • the setting screen for the pre-action range may display a graph related to the position change related to the pre-action on the screen based on the input upper limit position and lower limit position of the pre-action and the value of the parameter related to the pre-action set in the parameter storage unit 210.
  • the control device 1 which has the above configuration, can appropriately determine the upper and lower limit positions of the pre-operation, eliminating the need for the operator to resort to trial and error.
  • the control device 1 so far performs a pre-operation before performing a diagnostic operation, so that the meshing state (backlash, gap, play, rattle) of the power transmission parts such as the belt/pulley/gear of the drive unit is always in the same state when the diagnostic operation is started.
  • the diagnostic operation is performed in the same state, so the reproducibility of the diagnostic operation is achieved, and the reproducibility of the analysis results (frequency characteristics) obtained from the diagnostic operation is also good.
  • each of the above-mentioned embodiments of the present disclosure describes the operation of the control device 1 by taking an injection molding machine 2 as an example of a type of industrial machine.
  • the control device 1 according to the present disclosure can be applied to various other industrial machines.
  • it can be suitably used when diagnosing the operation of industrial machines equipped with a specific prime mover and power transmission means, such as extrusion molding machines, blow molding machines, electric discharge machines, robots, machine tools, mining machines, etc.
  • prime movers equipped in industrial machines include servo motors, hydraulic motors, hydraulic cylinders, linear motors, and direct drive motors.
  • examples of power transmission means equipped in industrial machines include drive units equipped with any of belts, pulleys, linear bushings, ball screws, spline coupling parts, etc.
  • a control device (1) includes an excitation signal generating unit (110) that generates an excitation signal for vibrating a prime mover (50) that drives a drive unit provided in an industrial machine (4); a control unit (100) that controls a diagnostic operation of positioning the prime mover (50) at a predetermined diagnosis start position and diagnosing frequency characteristics using the excitation signal; a data acquiring unit (120) that acquires at least the excitation signal and feedback data obtained from the diagnostic operation; and a frequency characteristic calculating unit (130) that calculates a resonance curve indicating frequency characteristics based on the feedback data, and the control unit (100) controls a pre-operation that performs at least one operation of positioning the prime mover (50) at one end of a predetermined pre-operation range and then positioning it at the other end of the pre-operation range before controlling the diagnostic operation, and then positions the prime mover (50) at the diagnosis start position and starts the diagnostic operation.
  • the torque limit value when the control unit (100) executes the preliminary operation is smaller than either the torque limit value when the industrial machine (4) is operated normally or the torque limit value when controlling the diagnostic operation.
  • the speed limit value when the control unit (100) executes the preliminary operation is smaller than either the speed limit value when the industrial machine (4) is operated normally or the speed limit value when controlling the diagnostic operation.
  • the pre-operation range includes the diagnostic operation range.
  • the power transmission means of the drive unit includes at least one of a toothed belt and a gear, and the pre-operating range is determined based on either the pitch of adjacent teeth of the toothed belt or the pitch of adjacent teeth of the gear.
  • the control device (1) according to another aspect of the present disclosure further includes a parameter setting unit (150) that provides a user interface for an operator to specify the preliminary operating range.
  • control unit (100) waits for a predetermined waiting time when the prime mover (50) is positioned at at least one end or the other end of the preliminary operation.
  • pre-operation performs an operation of positioning the prime mover to one end of the pre-operation range and then to the other end of the pre-operation range two or more times.
  • control unit (100) clamps the pre-operating range to the movable range of the prime mover (50) when the pre-operating range is outside the movable range of the prime mover (50).
  • control unit (100) stops starting the diagnostic operation when the elapsed time required for the preliminary operation exceeds a predetermined time limit.
  • the control device (1) according to another aspect of the present disclosure further includes a display device (70), and outputs and displays the results of the diagnostic operation on the display device (70).
  • a control method includes a control device (1) executing the following steps: a vibration signal generation step of generating a vibration signal for vibrating a prime mover (50) that drives a drive unit equipped in an industrial machine (4); a pre-operation step of controlling a pre-operation that performs at least one operation of positioning the prime mover (50) at one end of a predetermined pre-operation range and then positioning it at the other end of the pre-operation range; a diagnostic operation step of positioning the prime mover (50) at a predetermined diagnosis start position and controlling a diagnostic operation that diagnoses frequency characteristics using the vibration signal; a data acquisition step of acquiring at least the vibration signal and feedback data obtained from the diagnostic operation; and a frequency characteristic calculation step of calculating a resonance curve indicating frequency characteristics based on the feedback data.
  • Control device 2 Injection molding machine 4 Industrial machine 5 Network 6
  • Network 6 Injection molding machine 5
  • Network 6 Injection molding machine 5
  • Network 6 Injection molding machine 5
  • Network 6 Injection molding machine 5
  • Network 6 Injection molding machine 5
  • Network 6 Injection molding machine 5
  • Network 6 Injection computer 7
  • Cloud server 11 CPU 12 ROM 13 RAM 14
  • Non-volatile memory 15, 17, 18, 20 Interface 22
  • Bus 50 Servo motor 70
  • Display device 71
  • Input device 72 External device 100
  • Control unit 110 Excitation signal generation unit 120
  • Data acquisition unit 130 Frequency characteristic calculation unit 140
  • Output unit 150 Parameter setting unit 200
  • Control program 210 Parameter storage unit 220 Acquired data storage unit 420
  • Belt 422 Pulley Pulley

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
PCT/JP2023/001936 2023-01-23 2023-01-23 制御装置及び制御方法 Ceased WO2024157328A1 (ja)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2018017689A (ja) * 2016-07-29 2018-02-01 オークマ株式会社 送り軸の異常判定方法
JP2019007772A (ja) * 2017-06-21 2019-01-17 バンドー化学株式会社 ベルト走行試験装置及びそれを用いたクラック発生時間特定方法
JP2020038173A (ja) * 2018-09-05 2020-03-12 富士電機株式会社 機械診断装置及び機械診断プログラム
JP2021060313A (ja) * 2019-10-08 2021-04-15 ファナック株式会社 診断装置及び機械学習装置

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2018017689A (ja) * 2016-07-29 2018-02-01 オークマ株式会社 送り軸の異常判定方法
JP2019007772A (ja) * 2017-06-21 2019-01-17 バンドー化学株式会社 ベルト走行試験装置及びそれを用いたクラック発生時間特定方法
JP2020038173A (ja) * 2018-09-05 2020-03-12 富士電機株式会社 機械診断装置及び機械診断プログラム
JP2021060313A (ja) * 2019-10-08 2021-04-15 ファナック株式会社 診断装置及び機械学習装置

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