Molding auxiliary device for injection molding machine

Abstract

The invention comprises: a temperature control unit (6) for controlling the temperature of a material supply unit (5) for supplying a resin material (R) to the interior of a heating cylinder (4); and a molding machine controller (10) having: a basic data input unit (Fi) for inputting the type of resin; a data processing unit (F) having a temperature control data table (DT) and a temperature setting processing unit (Fcs), wherein the temperature control temperature data table (DT) sets the optimum temperature control temperature (Tr) of the temperature control unit (6) according to the type of resin, and the temperature setting processing unit (Fcs) reads the temperature control temperature (Tr) corresponding to the input type of resin from the temperature control temperature data table (DT) at least when setting molding conditions, after the type of resin is input from the basic data input unit (Fi), and sets the temperature control temperature (Tr) of the temperature control unit (6) as the temperature control temperature (Tr); and an output processing function unit (Fd) for displaying the temperature control temperature (Tr) on a display (7).

Description

Technical Field

[0001] The present invention relates to a molding assisting device of an injection molding machine suitable for use in assisting the injection molding machine which performs molding by injecting and filling a plasticized molten resin into a mold using a screw. Background Art

[0002] Usually, an injection molding machine performs molding by injecting plasticized molten resin into a mold through a screw, so whether the molten resin can be maintained in an appropriate state becomes an important factor in ensuring the desired molding quality. In particular, when excessive plasticization is performed, the resin decomposition rate becomes high, resulting in undesirable conditions such as deterioration of the molten resin (carbonization, etc.) and generation of useless gas. Such undesirable conditions are closely related to the molding conditions and residence time of the molten resin. When the molding conditions are not suitable and the residence time becomes long, there is a risk of increased resin decomposition rate due to excessive plasticization. Therefore, a technology for grasping the state of the molten resin in the heating cylinder and performing necessary countermeasures has also been proposed, for example, by the injection molding machine disclosed in Patent Document 1 and the plasticization simulation device disclosed in Patent Document 2.

[0003] On the other hand, the state of the molten resin in the heating cylinder is also affected by the temperature of the resin material (granular material) itself (resin material temperature) fed into the interior of the heating cylinder. Therefore, a technology has been proposed for stabilizing or adjusting the temperature of a temperature control section of a material supply section attached to the front of the heating cylinder (screw) that controls the temperature of the resin material.

[0004] Conventionally, as such a technology, there are known a hopper flange of an injection molding machine disclosed in Patent Document 3 and a temperature adjustment device of a hopper lower temperature adjustment portion of an injection molding machine disclosed in Patent Document 4. The purpose of the hopper flange disclosed in Patent Document 3 is to rapidly and stably increase the temperature of the hopper flange and to increase the temperature of the lower portion of the hopper, thereby achieving improved plasticizing ability and stable plasticizing of the resin. Specifically, a rod-shaped heater is provided at the front section of the hopper flange, a cooling water pipe is provided at the rear section of the hopper flange, and a thermocouple is provided at the center of the hopper flange, so that the temperature of the hopper flange can be controlled within a range of 70°C to 130°C. In addition, the temperature adjustment device disclosed in Patent Document 4 has a temperature adjustment device body connected to a cooling hole provided in a temperature adjustment portion under the hopper through a pipe, and the temperature adjustment device body has a tank for a cooling medium, a pump, a radiator, and a fan driven by a motor that is opposite to the radiator and delivers cold air. The cooling medium circulates between the temperature adjustment portion under the hopper and the temperature adjustment device body through the drive of the pump, and a temperature sensor is provided in the temperature adjustment portion under the hopper. By controlling the control device of the injection molding machine, when the temperature detected by the temperature sensor is higher than the set temperature, the circulating cooling medium is cooled by the fan, and the temperature of the temperature adjustment portion under the hopper is feedback controlled.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2005-022260

[0008] Patent Document 2: Japanese Patent Application Publication No. 2015-123668

[0009] Patent Document 3: Japanese Patent Application Publication No. 2006-272600

[0010] Patent Document 4: Japanese Patent Application Publication No. 2005-28868 Summary of the invention

[0011] Problems to be solved by the invention

[0012] However, the above-mentioned conventional technology for stabilizing or adjusting the temperature of the temperature regulating section in the material supply section still has the following problems.

[0013] First, the temperature control of the material supply unit (material drop port, hopper) is based on the preheating of the front section when the resin material is supplied to the inside of the heating cylinder, and is performed in consideration of the efficiency or stabilization of the heating cylinder processing in the back section. Therefore, it is basically an independent temperature control for the material supply unit, that is, temperature control from the perspective of stably and correctly maintaining the set target temperature (temperature control temperature), so it cannot be said that the accurate temperature control temperature is necessarily set, and from the perspective of achieving efficiency and stabilization of the heating cylinder processing, there is room for further improvement.

[0014] Second, the setting of the heating temperature in the heating tube is usually performed on each heating section (band heater) attached to the nozzle section, head section, front section, middle section, and rear section, respectively, to obtain a specified temperature distribution in the axial direction of the heating tube. Therefore, if the temperature of the resin material itself supplied from the material supply section that affects the heating tube side, that is, the temperature of the temperature control section attached to the material supply section, is further optimized by associating it with the overall molding conditions, the temperature control on the heating tube side, and the type of resin, the melting state of the resin in the heating tube can also be further optimized. However, in the conventional temperature control section, since there is no such association concept, it is difficult to expand the overall adjustment range of the molding conditions and to achieve detailed adjustment. As a result, the improvement of the height plasticization quality and thus the improvement of the molding quality is limited.

[0015] An object of the present invention is to provide a molding assisting device for an injection molding machine that solves the problems existing in the above-mentioned background art.

[0016] Means for solving problems

[0017] In order to solve the above-mentioned problems, the present invention is characterized in that, when constituting a molding assisting device 1 of an injection molding machine that assists the injection molding machine M in molding by injecting and filling a plasticized molten resin into a mold 2 through a screw 3, the device is configured to include: a temperature regulating unit 6 that regulates the temperature of a material supply unit 5 that supplies a resin material R to the inside of a heating cylinder 4; and a molding machine controller 10, which has: a basic data input unit Fi that can at least input the type of resin; a data processing unit F that has a temperature regulating temperature data table DT and a temperature setting processing unit Fcs, the temperature regulating temperature data table DT setting the optimal temperature regulating temperature Tr of the temperature regulating unit 6 according to the type of resin, the temperature setting processing unit Fcs at least reads out the temperature regulating temperature Tr corresponding to the input type of resin from the temperature regulating temperature data table DT after the type of resin is input from the basic data input unit Fi when setting molding conditions, and sets the temperature regulating temperature Tr as the temperature regulating temperature Tr of the temperature regulating unit 6; and an output processing function unit Fd that displays the temperature regulating temperature Tr on at least a display 7.

[0018] In this case, according to a preferred embodiment of the invention, the material supply unit 5 may include at least one or both of a hopper 5h or a material supply device Prm attached to the heating cylinder 4 and a material drop port 5d of the heating cylinder 4, and the pellet material Rp may be applied to the resin material R. In addition, the upper limit value Tru of the temperature control temperature Tr may be set in the temperature control temperature data table DT, and a temperature control temperature manual input function may be provided in the basic data input unit Fi, which allows manual input of at least the lower limit value Trm of the temperature control temperature Tr. Furthermore, the basic data input unit Fi may input basic data Do including at least molding condition data Dm related to molding conditions and screw data Ds related to the form of the screw 3. On the one hand, in the data processing unit F, solid phase ratio calculation formula data Dc for calculating the solid phase ratio Xc of the molten resin in the heating cylinder 4 based on the basic data Do may be set, and a solid phase ratio calculation processing unit Fcp may be provided, which obtains an estimated solid phase ratio Xcs of the molten resin at the end of metering by calculation processing based on the basic data Do and the solid phase ratio calculation formula data Dc. On the other hand, the screw data Ds may include data related to the type of material of the screw surface 3f, whereby, in the data processing unit F, the decomposition rate calculation formula data Dr for calculating the resin decomposition rate Xr of the screw surface 3f during molding based on the basic data Do may be set, and a decomposition rate calculation processing unit Fcr may be provided, which calculates the estimated resin decomposition rate Xrs by calculation processing based on the basic data Do and the decomposition rate calculation formula data Dr. In addition, a determination processing unit Fcj may be provided in the data processing unit F, which performs determination processing on the degree of the estimated solid phase ratio Xcs and / or the estimated resin decomposition rate Xrs and outputs the result of the determination processing, and a data display unit 8 may be provided in the output processing function unit Fd, and the data display unit 8 includes a determination result display unit 8j for displaying the result of the determination processing output from the determination processing unit Fcj. Furthermore, in the data processing unit F, a temperature rise calculation formula data Dw for calculating an estimated temperature rise ΔTus based on data related to the shear calorific value E used for calculation processing based on the decomposition rate calculation formula data Dr can be set, and a temperature rise calculation processing unit Fct can be provided, which calculates the estimated temperature rise ΔTus by calculation processing based on the temperature rise calculation formula data Dw. Therefore, a temperature rise display unit 8fu for displaying the estimated temperature rise ΔTus calculated by the temperature rise calculation processing unit Fct on the display 7 can be provided in the output processing function unit Fd.On the one hand, in the data processing unit F, resin temperature conversion formula data for converting the temperature adjustment temperature Tr into the resin material temperature Tro based on at least a part of the shape data of the resin material R in the molding condition data and the molding cycle time data can be set, and a resin temperature conversion processing function for obtaining the resin material temperature Tro by conversion processing based on the resin temperature conversion formula data can be provided. Therefore, a resin material temperature display unit 8to for displaying the resin material temperature Tro obtained by the resin temperature conversion processing function on the display 7 can be provided in the output processing function unit Fd.

[0019] Effects of the Invention

[0020] According to the molding assisting device 1 for an injection molding machine of the present invention, the following remarkable effects are achieved.

[0021] (1) Since a temperature control data table DT and a temperature setting processing unit Fcs are provided, the temperature control data table DT sets the optimal temperature control temperature Tr of the temperature control unit 6 according to the type of resin. The temperature control unit 6 controls the temperature of the material supply unit 5 that supplies the resin material R to the interior of the heating tube 4. The temperature setting processing unit Fcs reads the temperature control temperature Tr corresponding to the input type of resin from the temperature control temperature data table DT after inputting the type of resin from the basic data input unit Fi at least when setting the molding conditions, and sets the temperature control temperature Tr of the temperature control unit 6 accordingly. Therefore, it is particularly possible to set the optimal (accurate) temperature control temperature Tr that matches the type of resin, which can further improve the efficiency and stabilization of the overall processing in the heating tube 4.

[0022] (2) The temperature control temperature Tr of the temperature control unit 6 is at least displayed on the display 7, so the operator confirms the temperature control temperature Tr. From the viewpoint of further improving the plasticization quality, the operator can use the auxiliary functions such as the change of the molding conditions in the molding auxiliary device 1, or can arbitrarily change (adjust) the temperature control temperature Tr manually. That is, since the change of the temperature control temperature Tr can be included in the change of the molding conditions, the adjustment range of the entire molding conditions can be expanded, thereby ensuring a higher molding quality by further improving the plasticization quality.

[0023] (3) According to a preferred embodiment, if the material supply unit 5 includes at least one or both of the hopper 5h or the material supply device Prm attached to the heating cylinder 4 and the material drop port 5d of the heating cylinder 4, these three material supply units can be selected as the temperature adjustment target of the temperature adjustment unit 6, so that the flexibility and ease of implementation can be improved without being restricted by the structure of the injection molding machine M. In particular, it becomes a useful adjustment means (setting change means) when it is difficult to change the heating temperature of the heating cylinder 4, the molding cycle time, etc.

[0024] (4) According to a preferred method, if the granular material Rp is applied to the resin material R, the granular material Rp which is widely popular and has a fixed shape such as a cylindrical shape can be used as the object, so the temperature of the granular material Rp itself to be temperature-controlled can be easily and correctly estimated, and the temperature control temperature Tr can also be accurately set.

[0025] (5) According to a preferred method, if the upper limit value Tru of the temperature control temperature Tr is set in the temperature control temperature data table DT, the temperature control temperature of the higher importance side (upper limit value Tru) when the temperature control temperature Tr is controlled by setting the upper limit value Tru and the lower limit value Trm can be automatically set. Therefore, even when various control methods are adopted, accurate control of the temperature control temperature (target temperature) can be performed.

[0026] (6) According to a preferred embodiment, if a manual temperature input function for manually inputting at least the lower limit value Trm of the temperature control temperature Tr is provided in the basic data input portion Fi, the lower limit value Trm in the case of automatically setting the upper limit value Tru can be arbitrarily set by manual input, and the overall manual setting of the temperature control temperature Tr (upper limit value Tru and lower limit value Trm) can be easily performed as needed.

[0027] (7) According to a preferred embodiment, if the basic data input portion Fi has the function of inputting basic data Do including at least molding condition data Dm related to the molding conditions and screw data Ds related to the shape of the screw 3, sufficient data for grasping the melting state of the molten resin in the heating tube 4 can be collected, thereby reliably obtaining accurate estimated solid phase fraction Xcs, estimated resin decomposition rate Xrs, etc. representing the melting state of the desired resin (molten resin).

[0028] (8) According to a preferred embodiment, if solid phase ratio calculation formula data Dc is set in the data processing unit F to calculate the solid phase ratio Xc of the molten resin in the heating cylinder 4 based on the basic data Do, and a solid phase ratio calculation processing unit Fcp is set to calculate the estimated solid phase ratio Xcs of the molten resin at the end of metering by calculation processing based on the basic data Do and the solid phase ratio calculation formula data Dc, the insufficient plasticization of the resin can be accurately (quantitatively) grasped based on the estimated solid phase ratio Xcs obtained based on the basic data Do, so that appropriate countermeasures can be taken for the insufficient plasticization. In particular, since human judgment such as experience is not required, even a novice operator with little experience can improve the yield and molding quality of the molded product, and can perform more ideal molding (production). Moreover, the physical properties (melting characteristics, etc.) of each type of resin material R can be reflected in the calculation of the estimated solid phase ratio Xcs, so a more accurate (correct) estimated solid phase ratio Xcs can be obtained.

[0029] (9) According to a preferred method, if the screw data Ds includes data related to the type of material of the screw surface 3f, the catalytic effect of the metal material of the screw surface 3f on the molten resin and the degradation factors caused by the ease of bonding can be reflected in the calculation processing, thereby enabling a more accurate (correct) estimation of the molten state.

[0030] (10) According to a preferred embodiment, if the decomposition rate calculation formula data Dr for calculating the resin decomposition rate Xr of the screw surface 3f during molding based on the basic data Do is set in the data processing unit F, and the decomposition rate calculation processing unit Fcr for calculating the estimated resin decomposition rate Xrs by calculation processing based on the basic data Do and the decomposition rate calculation formula data Dr is set, the basic data Do used in the calculation processing of the solid phase rate calculation formula data Dc can also be used in the calculation processing of the decomposition rate calculation formula data Dr, etc., and the estimated resin decomposition rate Xrs can be easily calculated. Moreover, based on the estimated resin decomposition rate Xrs easily obtained by calculation processing, the degradation state of the molten resin can be accurately grasped. As a result, in addition to the boundary point on one side (insufficient plasticization side) of the molten state based on the estimated solid phase rate Xcs, the boundary point on the other side (excessive plasticization side) of the molten state based on the estimated resin decomposition rate Xrs can be used to set the appropriate range of the molten state, and the moldability and molding quality can be stabilized and improved.

[0031] (11) According to a preferred embodiment, if a determination processing unit Fcj is provided in the data processing unit F, and the determination processing unit Fcj performs determination processing on the degree of the estimated solid phase ratio Xcs and / or the estimated resin decomposition ratio Xrs, and outputs the result of the determination processing, the operator can easily grasp the melting state of the molten resin which is difficult to determine, and thus can quickly perform necessary response processing.

[0032] (12) According to a preferred embodiment, if a data display unit 8 including a determination result display unit 8j for displaying the result of the determination processing output from the determination processing unit Fcj is provided in the output processing function unit Fd, the operator can confirm the result of the determination processing by visual means. Therefore, even a novice operator with little experience can easily and reliably confirm whether the melting state of the molten resin is appropriate, and can quickly take necessary measures such as changing the setting of the molding conditions, thereby realizing efficient and high-capacity production of molded products.

[0033] (13) According to a preferred embodiment, if a temperature rise calculation formula data Dw is set in the data processing unit F for calculating the estimated temperature rise ΔTu based on data related to the shear heating value E, and the shear heating value E is used for calculation processing based on the decomposition rate calculation formula data Dr, and a temperature rise calculation processing unit Fct is set for calculating the estimated temperature rise ΔTus by calculation processing based on the temperature rise calculation formula data Dw, then the data related to the shear heating value E used in the calculation processing based on the decomposition rate calculation formula data Dr can also be used in the calculation processing of the temperature rise calculation formula data Dw, so the estimated temperature rise ΔTus can be easily calculated.

[0034] (14) According to a preferred method, if a temperature rise display unit 8fu is provided in the output processing function unit Fd so as to display the estimated temperature rise ΔTus calculated by the temperature rise calculation processing unit Fct on the display 7, then in addition to information related to the estimated solid phase fraction Xcs and / or the estimated resin decomposition rate Xrs, information related to the estimated temperature rise ΔTus can also be confirmed, thereby enabling a more accurate grasp of the melting state of the molten resin.

[0035] (15) According to a preferred method, if in the data processing unit F, resin temperature conversion formula data for converting the temperature control temperature Tr into the resin material temperature Tro is set based on at least a portion of the shape data of the resin material R in the molding condition data and the molding cycle time data, and a resin temperature conversion processing function for calculating the resin material temperature Tro by conversion processing based on the resin temperature conversion formula data is set, then the resin material temperature Tro can be estimated based on the obtained temperature control temperature Tr, thereby accurately understanding the temperature state of the resin material temperature Tro itself and the melting state of the resin based on the temperature state, that is, information related to the relationship with the estimated solid phase fraction Xcs and / or the estimated resin decomposition rate Xrs, the estimated rising temperature ΔTus, etc.

[0036] (16) According to a preferred embodiment, if a resin material temperature display unit 8to is provided in the output processing function unit Fd so as to display the resin material temperature Tro obtained by the resin temperature conversion processing function in the data processing unit F on the display 7, the resin material temperature Tro can be easily confirmed by visual inspection, and the information can be easily confirmed by comparing with other information, i.e., the estimated solid phase fraction Xcs and / or the estimated resin decomposition rate Xrs, the estimated temperature rise ΔTus, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a system block diagram of a processing system (control system) in a molding support device of an injection molding machine according to a preferred embodiment of the present invention.

[0038] Figure 2 This is a block diagram showing the mechanical structure of an injection molding machine equipped with the molding assisting device.

[0039] Figure 3 This is a schematic perspective view of a pellet material as a resin material used in the injection molding machine.

[0040] Figure 4 A schematic diagram of a screw for explaining the calculation function of the solid phase ratio calculation processing unit included in the molding assisting device.

[0041] Figure 5 This is a characteristic diagram of a change in the solid phase ratio with respect to the position of the screw for explaining the calculation function of the solid phase ratio calculation processing unit included in the molding assisting device.

[0042] Figure 6 This is a table showing the degree of adhesion of resins to metals, which is the basis of the resin decomposition rate, by type.

[0043] Figure 7 This is a diagram for explaining the principle of resin degradation which is the basis of the resin decomposition rate calculated by the resin decomposition rate calculation processing unit included in the molding assisting device.

[0044] Figure 8 This is a table showing the decomposition easiness of resins relative to metals, which is the basis of the resin decomposition rate, by type.

[0045] Fig. 9 This is a correlation characteristic diagram showing the relationship between the estimated temperature rise and the actually measured temperature rise in the molding assisting device.

[0046] Fig.10 This is a functional explanatory diagram of a determination processing unit included in the molding assisting device.

[0047] Fig.11 This is a screen image of the data display section in the molding assisting device.

[0048] Fig.12 This is a correlation characteristic diagram showing the relationship between the actually measured resin material temperature and the estimated resin material temperature using the type of resin as a parameter for explaining the effectiveness of the molding assisting device.

[0049] Fig.13 This is a characteristic diagram showing the relationship between the deviation of the resin temperature and the temperature rise of the resin for explaining the effectiveness of the molding assisting device.

[0050] Fig.14 This is a characteristic diagram showing the relationship between the deviation of the resin temperature and the index showing the stability of the resin temperature for explaining the effectiveness of the molding assisting device.

[0051] Fig.15a This is a characteristic diagram showing the relationship between the temperature variation of the resin material and the temperature control temperature, which is the verification result for the resin (PP) based on the temperature control temperature data table provided in the molding assisting device.

[0052] Fig.15b This is a characteristic diagram showing the relationship between the temperature variation of the resin material and the temperature control temperature, which is the verification result for the resin (GPPS) which is the basis of the temperature control temperature data table provided in the molding assisting device.

[0053] Fig.15c This is a characteristic diagram showing the relationship between the temperature variation of the resin material and the temperature control temperature, which is the verification result for the resin (ABS) based on the temperature control temperature data table provided in the molding assisting device.

[0054] Fig.15d This is a characteristic diagram showing the relationship between the temperature variation of the resin material and the temperature control temperature, which is the verification result for the resin (POM) based on the temperature control temperature data table provided in the molding assisting device.

[0055] Fig.16 This is a flowchart showing a molding assist processing procedure using the molding assist device.

[0056] Fig.17a This is a display screen diagram showing an example of a determination message displayed by the output processing function unit included in the molding assisting device.

[0057] Fig.17b This is another display screen diagram showing an example of a determination message displayed by the output processing function unit included in the molding support device.

[0058] Fig.17c This is another display screen diagram showing an example of a determination message displayed by the output processing function unit included in the molding support device.

[0059] Fig.17d This is another display screen diagram showing an example of a determination message displayed by the output processing function unit included in the molding support device.

[0060] Description of symbols

[0061] 1: Molding auxiliary device; 2: Mold; 3: Screw; 3f: Screw surface; 4: Heating cylinder; 5: Material supply unit; 5h: Hopper; 5d: Material drop port; 6: Temperature adjustment unit; 6p: Material temperature adjustment unit; 7: Display; 8: Data display unit; 8j: Judgment result display unit; 8fu: Rising temperature display unit; 8to: Resin material temperature display unit; 10: Molding machine controller; M: Injection molding machine; R: Resin material; Rp: Granular material; F: Data processing unit; Fi: Basic data input unit; Fd: Output processing function unit; Fcs: Temperature setting unit Processing unit; Fcp: solid phase ratio calculation processing unit; Fcr: decomposition ratio calculation processing unit; Fcj: judgment processing unit; Fct: rising temperature calculation processing unit; Tr: temperature control temperature; DT: temperature control temperature data table; Dm: molding condition data; Ds: screw data; Do: basic data; Dc: solid phase ratio calculation formula data; Dr: decomposition ratio calculation formula data; Dw: rising temperature calculation formula data; Xc: solid phase ratio; Xr: resin decomposition ratio; Xcs: estimated solid phase ratio; Xrs: estimated resin decomposition ratio; ΔTus: estimated rising temperature; material supply device Prm. DETAILED DESCRIPTION

[0062] Next, the best mode for carrying out the present invention will be listed and described in detail based on the drawings.

[0063] First, in order to easily understand the forming assisting device 1 according to the present embodiment, Figure 2 An overview of an injection molding machine M that can utilize the molding assisting device 1 will be described.

[0064] Figure 2 The figure shows an injection molding machine M, in particular, an injection device Mi in which a mold clamping device is omitted. In the injection device Mi, 4 is a heating cylinder, and a nozzle 4n is installed at the front end of the heating cylinder 4 via a head 4h. The nozzle 4n has a function of injecting the molten resin inside the heating cylinder 4 into the mold 2 represented by the imaginary line. In addition, a hopper 5h is provided at the upper rear end of the heating cylinder 4, and a material drop port 5d penetrating the heating cylinder 4 is formed between the lower end opening of the hopper 5h and the inside of the heating cylinder 4. As a result, the hopper 5h and the inside of the heating cylinder 4 are connected via the material drop port 5d, and the resin material R represented by the imaginary line in the hopper 5h is supplied to the inside of the heating cylinder 4 through the material drop port 5d. In addition, the hopper 5h is illustrated, but it is also possible to use it instead of the hopper 5h. Figure 2 The material supply device Prm shown. When the material supply device Prm is used, Figure 2In the embodiment, the hopper 5h is removed from the hopper mounting portion of the heating cylinder 4, and a material supply device Prm is attached instead. The material supply device Prm has a function of quantitatively feeding the resin material R contained in a separately arranged material tank into the material drop port 5d each time through the feeding adapter. Therefore, the hopper 5h, the material supply device Prm, and the material drop port 5d constitute the material supply unit 5 of this embodiment for supplying the resin material R to the inside of the heating cylinder 4.

[0065] On the other hand, a heater 6h is attached to the outer peripheral surface of the hopper 5h to heat the resin material R contained in the hopper 5h, and a water jacket 6j is formed on the heating cylinder 4 around the material drop port 5d. In addition, the heater 6h is connected to the power supply circuit 6de of the temperature control driver 6d, and the water jacket 6j is connected to the temperature control water circulation circuit 6dw of the temperature control driver 6d. The temperature control water circulation circuit 6dw can control the temperature (heat or cool) of the granular material Rp passing through the material drop port 5d by circulating the temperature-controlled water medium (warm water or cooling water) in the water jacket 6j. In addition, the power supply circuit 6de and the temperature control water circulation circuit 6dw are respectively connected to the controller body 22. Thus, the control instructions for the power supply circuit 6de and the temperature control water circulation circuit 6dw are given from the controller body 22 to the temperature control driver 6d. In addition, the temperature control temperature Tr is detected by a temperature sensor (not shown), and the detection signal is given to the temperature control driver 6d. Therefore, the heater 6 h , the water jacket 6 j , and the temperature control driver 6 d constitute a temperature control unit 6 that controls the temperature of the material supply unit 5 .

[0066] In addition, the material supply device Prm is also provided with a material temperature control unit 6p using a heater or the like, and therefore the material temperature control unit 6p is connected to a power supply circuit 6de of a temperature control driver 6d. Thus, the temperature control of the material temperature control unit 6p can also be performed by a controller main body 22 described later in the injection molding machine M, and in particular, the temperature control can be integrated with the temperature control of the heater 6h and the water jacket 6j.

[0067] Resin material R use Figure 3 If such a granular material Rp is applied, the granular material Rp which is widely used and has a fixed shape such as a cylindrical shape can be used as the object, so the temperature of the granular material Rp itself to be temperature-controlled can be easily and accurately estimated, and the temperature control temperature Tr can also be accurately set.

[0068] In addition, in the present embodiment, the hopper 5h, the material supply device Prm, and the material drop port 5d are used as the material supply unit 5, but any one of the hopper 5h, the material drop port 5d, and the material supply device Prm may be used as the material supply unit 5, or the hopper 5h and the material drop port 5d, or the material supply device Prm and the material drop port 5d may be used as the material supply unit 5. Therefore, the temperature control unit 6 attached to the material supply unit 5 may also use one or both of the hopper 5h, the material supply device Prm, and the material drop port 5d as the temperature control target. For example, the heater 6h and the material temperature control unit 6p may be removed from the illustrated structure or not used, and only the water jacket 6j may be used as the temperature control target of the temperature control unit 6, or only the material temperature control unit 6p and the heater 6h may be used as the temperature control target of the temperature control unit 6 without using the water jacket 6j. Thus, each material supply unit of the hopper 5h, the material supply device Prm, and the material drop port 5d can be selected as the temperature control object of the temperature control unit 6, so it is not limited by the structure of the injection molding machine M, etc., and the flexibility and ease of implementation can be improved. In particular, it becomes a useful adjustment means (setting change means) when it is difficult to change the heating temperature of the heating cylinder 4, the molding cycle time, etc.

[0069] On the other hand, the screw 3 is loaded inside the heating tube 4 so that it can rotate freely and advance and retreat freely. A spiral screw ridge portion 3mp is formed on the outer peripheral surface of the screw 3, and then the screw surface 3f is coated with a prescribed surface material (metal) taking into account durability and the like. The screw 3 has a metering zone Zm, a compression zone Zc, and a feed zone Zf from the front side to the rear side. On the other hand, the rear end of the screw 3 is connected to the screw drive unit 9. The screw drive unit 9 has a screw rotation mechanism 9r for rotating the screw 3 and a screw advance and retreat mechanism 9m for advancing and retreating the screw 3. In addition, the drive method of the screw rotation mechanism 9r and the screw advance and retreat mechanism 9m is shown as an electrical method using an electric motor in the illustrated case, but it can also be a hydraulic method using a hydraulic circuit, and the drive method is not limited. Moreover, the screw rotation mechanism 9r and the screw advance and retreat mechanism 9m are connected to the power supply driver 9d, and the power supply driver 9d is connected to the controller body 22. Thus, control commands for the screw rotating mechanism 9r and the screw advancing and retracting mechanism 9m are given to the power driver 9d from the controller body 22. Physical quantities such as the speed and position of the screw 3 are detected by speed sensors and position sensors (not shown), and the detection signals are given to the power driver 9d.

[0070] Furthermore, the heating tube 4 has a heating tube front portion 4f, a heating tube middle portion 4m, and a heating tube rear portion 4r from the front side to the rear side, and a front heating portion 11f, a middle heating portion 11m, and a rear heating portion 11r are attached to the outer peripheral surface of each portion 4f, 4m, and 4r, respectively. Similarly, a head heating portion 11h is attached to the outer peripheral surface of the head portion 4h, and a nozzle heating portion 11n is attached to the outer peripheral surface of the nozzle 4n. Each of these heating portions 11f, 11m, 11r, 11h, and 11n can be composed of a belt heater or the like. Therefore, the nozzle heating portion 11n, the head heating portion 11h, the front heating portion 11f, the middle heating portion 11m, and the rear heating portion 11r constitute a heating group portion 11. Furthermore, the heating group portion 11 is connected to a heater driver 11d, and the heater driver 11d is connected to a controller main body 22. Thus, the controller body 22 gives control instructions to the heater driver 11d for each heating unit 11f, 11m, 11r, 11h, 11n. In addition, the heating temperature is detected by a temperature sensor (thermocouple, etc.) not shown in the figure, and the detection signal is given to the heater driver 11d.

[0071] on the other hand, Figure 1 1 shows a molding machine controller 10 that is responsible for the overall control of the injection molding machine M. The molding machine controller 10 has a controller body 22 with computer functions that has a built-in CPU and internal memory 10m and other hardware, and a display 7 is connected to the controller body 22. The display 7 can display necessary information and is provided with a touch panel 7t, which can be used to perform various input operations such as input, setting, and selection. In addition, a driver group 24 that drives (starts) various actuators is connected to the controller body 22. The driver group 24 includes Figure 2 The power supply circuit 6de and the temperature control water circulation circuit 6dw shown include a temperature control driver 6d, a power supply driver 9d, and a heater driver 11d.

[0072] Therefore, the molding machine controller 10 includes an HMI control system and a PLC control system, and stores a PLC program and an HMI program in an internal memory 10m. The PLC program is used to execute the sequence actions of various processes in the injection molding machine M, the monitoring of the injection molding machine M, etc., and the HMI program is used to execute the setting and display of the action parameters of the injection molding machine M, the display of the action monitoring data of the injection molding machine M, etc.

[0073] Next, refer to Figures 1 to 16 The structure of the molding assisting device 1 according to the present embodiment that can be used in such an injection molding machine M will be described.

[0074] The forming assisting device 1 according to this embodiment comprises Figure 1The molding machine controller 10 and the peripheral actuators shown are configured as follows. Therefore, an assist program Ps based on an application program for making the molding assist device 1 function is stored in the internal memory 10m of the molding machine controller 10.

[0075] The molding assisting device 1 basically has a basic function of maintaining the molten state of the resin in the heating cylinder 4 in an optimal state. In addition, in the present embodiment, by optimizing the temperature control temperature Tr of the temperature control unit 6 for controlling the temperature of the pellet material Rp supplied to the heating cylinder 4, the molding assisting device 1 is constructed to further optimize the basic function.

[0076] Therefore, in order to facilitate understanding of the molding assisting device 1 according to the present embodiment, the basic functions of the molding assisting device 1 will be described first.

[0077] like Figure 1 As shown in FIG. 1 , the molding assisting device 1 having basic functions includes a basic data input portion Fi for inputting basic data Do, and the basic data Do includes at least molding condition data Dm related to molding conditions and screw data Ds related to the form of the screw 3. The basic data input portion Fi can use a touch panel 7t attached to the display 7. That is, an input screen (not shown) is displayed on the display 7, so that necessary numerical values ​​can be input, selected, etc. through the touch panel 7t.

[0078] At this time, the molding condition data Dm includes various data related to the molding conditions for molding by the injection molding machine M, specifically, basic data related to various physical quantities such as melt flow rate, screw speed, metering time, back pressure, metering position, front temperature, middle temperature, rear 1 temperature, rear 2 temperature, and molding cycle time, and a plurality of various data related to the molding conditions such as data related to various resin materials R... used, that is, various granular materials Rp... In addition, the data related to each granular material Rp... includes various physical properties of each granular material Rp... such as melting characteristics. In this way, if the molding condition data Dm includes data related to the granular material Rp... (resin material R...) used, the physical properties (melting characteristics, etc.) of each granular material Rp... can be reflected in the calculation of the estimated solid phase ratio Xcs described later, so that a more accurate (correct) estimated solid phase ratio Xcs can be obtained.

[0079] In addition, the screw data Ds includes various data related to the shape of the screw 3, specifically, data related to various dimensions such as the screw outer diameter, screw flight width, friction coefficient between the solid and the screw, screw groove depth, screw width direction length, screw lead, flight coefficient, helix angle of the screw flight, number of pitches, and data related to the type of material of the screw surface 3f, etc. In particular, if the data related to the type of material of the screw surface 3f is included, the catalytic effect of the metal material of the screw surface 3f on the molten resin and the deterioration factor caused by the ease of adhesion can be reflected in the calculation process, so that the melting state can be estimated more accurately (correctly).

[0080] In this way, if the basic data input part Fi has the function of inputting basic data Do including at least molding condition data Dm related to the molding conditions and screw data Ds related to the shape of the screw 3, sufficient data for grasping the melting state of the molten resin in the heating tube 4 can be collected, so that accurate estimated solid phase ratio Xcs, estimated resin decomposition rate Xrs, etc. representing the melting state of the desired resin (molten resin) can be reliably obtained.

[0081] On the other hand, the molding assisting device 1 includes a data processing unit F. The data processing unit F includes an arithmetic formula data setting unit Fs using an internal memory 10m, in which solid phase ratio arithmetic formula data Dc, decomposition ratio arithmetic formula data Dr, and rising temperature arithmetic formula data Dw are set. The solid phase ratio arithmetic formula data Dc is data related to arithmetic formula for calculating the solid phase ratio Xc of the molten resin in the heating cylinder 4 based on the aforementioned basic data Do, the decomposition ratio arithmetic formula data Dr is data related to arithmetic formula for calculating the resin decomposition ratio Xr on the screw surface 3f during molding based on the aforementioned basic data Do, and the rising temperature arithmetic formula data Dw is data related to arithmetic formula for calculating the rising temperature ΔTu based on data related to the shear calorific value E used for the calculation processing based on the decomposition ratio arithmetic formula data Dr.

[0082] Next, the solid phase ratio calculation formula for calculating the solid phase ratio Xc as the basis of the solid phase ratio calculation formula data Dc, the decomposition rate calculation formula for calculating the resin decomposition rate Xr as the basis of the decomposition rate calculation formula data Dr, and the rising temperature calculation formula for calculating the rising temperature ΔTu as the basis of the rising temperature calculation formula data Dw are described in detail.

[0083] First, the solid phase ratio calculation formula will be described. Figure 4 A schematic diagram of the screw 3 for explaining the calculation function of the solid phase ratio Xc is shown. Figure 4, 3 represents the screw, 4 represents the heating cylinder, 31 represents the screw groove bottom, 32 represents the screw thread, 33 represents the melt film, 34 represents the solid bed, and 35 represents the melt pool. In addition, Cx represents the width of the solid at the current position, and Cw represents the length obtained by subtracting the thread width from the pitch width.

[0084] An example of a solid phase ratio calculation formula used in this embodiment is shown in [Formula 101].

[0085] Solid phase ratio Xc=Cx / Cw

[0086] =(Cx′ / Cw)·(1-ka·Φi)…[Formula 101]

[0087] Where, Φi=f(Tq, Tc)·Φe

[0088] As shown in [Formula 101], the solid phase ratio Xc can basically be calculated by Cx / Cw. In [Formula 101], Cx′ represents the width of the solid before 1 pitch, ka represents the adjustment coefficient, Φi represents the melting speed during injection, Φe represents the melting speed during extrusion, Tq represents the metering time, and Tc represents the molding cycle time.

[0089] Generally, in a melting mechanism including a continuously operated heating cylinder such as an extruder, a known model formula proposed by Tadmor in 1978 is widely used as a theoretical formula for predicting the plasticization state.

[0090] On the other hand, in the injection molding machine M, since intermittent operation (injection → metering → standby) is performed, injection conditions such as injection position and screw stop time are included, which are different from those of the extrusion molding machine. Therefore, the known model formula cannot be directly applied to the injection molding machine M. Therefore, the solid phase ratio calculation formula used in the present embodiment is a model formula that can be applied to the extrusion molding machine. The formula is converted into a model formula that can be applied to the injection molding machine M, that is, the model formula that can be applied to the extrusion molding machine is converted into a model formula that can be applied to the injection molding machine M, that is, the model formula that can be applied to the extrusion molding machine is multiplied by the function formula including the metering time Tq and the cycle time Tc by the melting speed Φe (a quantity that indicates the melting speed, and the unit is dimensionless) of the resin material, and the Φi obtained is used for the solid phase ratio calculation formula.

[0091] Thus, if the calculation formula shown in [Formula 101] is used, the model formula applicable to the extrusion molding machine is converted into the model formula applicable to the injection molding machine M, so that the solid phase ratio Xc representing the melting ratio (melting degree) of the molten resin in the heating cylinder 4 containing the screw 3 can be obtained. Therefore, the solid phase ratio Xc obtained by the solid phase ratio calculation formula can be used as the estimated solid phase ratio Xc obtained based on the input basic data Do, that is, the estimated solid phase ratio Xcs.

[0092] Furthermore, it is preferred to verify whether the estimated solid phase ratio Xcs is consistent with the solid phase ratio of the actually obtained molten resin, that is, the measured solid phase ratio, and after adjustment, set the substantially consistent solid phase ratio calculation formula as the solid phase ratio calculation formula data Dc in this embodiment.

[0093] In addition, the closer the term (1-ka·Φi) in [Formula 101] is to 0, that is, the faster the speed Φi is, the closer the solid phase ratio Xc is to 0, suggesting that the molten resin in the heating tube 4 is completely melted. In the embodiment, the amount of unmelted solid remaining is further calculated based on the solid phase ratio Xc, and the correlation with the fluctuation mode of the resin temperature during molding is examined. The thickness of the molten film 33 is generally used to calculate shear heat generation, but the measured value and the calculated value deviate greatly. Therefore, in this embodiment, the solid phase ratio (adjusted value) when completely melted is specified and separated into solid phase and liquid phase to calculate the value of shear heat generation only in the liquid phase. As a result, it can be confirmed that it is roughly consistent with the measured value.

[0094] Figure 5 The solid phase ratio Xc obtained from the solid phase ratio calculation formula shows the change with respect to the position of the screw 3. Figure 5 The horizontal axis represents the screw pitch number, and the larger the number, the closer to the nozzle side. In addition, the vertical axis represents the solid phase ratio Xc. The closer the solid phase ratio Xc is to 0, the closer it is to a completely molten state. When the solid phase ratio Xc is 0, it becomes a completely molten state. Figure 5 In FIG. 1 , the solid phase ratio Xc at the position indicated by Xcs is regarded as the estimated solid phase ratio Xcs of the molten resin at the end of metering.

[0095] The estimated solid phase ratio Xcs does not necessarily have to be 0 in practical applications. The judgment criterion is preferably selected as "0.06", and this value can be confirmed to be an appropriate value based on experimental results. Therefore, when the estimated solid phase ratio Xcs is "Xcs≤0.06", it can be judged to be in a good melting state, and in the case of "Xcs>0.06", it can be judged that the melting is insufficient (insufficient plasticization). In this way, the size of the estimated solid phase ratio Xcs becomes an indicator of the melting state such as insufficient plasticization of the molten resin. In addition, the estimated solid phase ratio Xcs represents the melting level of the molten resin, so the unmelted polymer fraction can also be used.

[0096] In this way, if the solid phase ratio calculation formula data Dc for calculating the solid phase ratio Xc of the molten resin in the heating cylinder 4 based on the basic data Do is set in the calculation formula data setting unit Fs, the estimated solid phase ratio Xcs of the molten resin at the end of metering can be obtained by the solid phase ratio calculation processing unit Fcp described later, through the calculation processing based on the basic data Do and the solid phase ratio calculation formula data Dc, so that the obtained estimated solid phase ratio Xcs can be used to accurately (quantitatively) grasp the insufficient plasticization of the resin, thereby, it is possible to take appropriate countermeasures for the insufficient plasticization. In particular, since human judgment such as experience is not required, even a beginner operator with little experience can improve the yield and molding quality of the molded product, and can perform more ideal molding (production). Moreover, the physical properties (melting characteristics, etc.) of each type of granular material Rp... can be reflected in the calculation of the estimated solid phase ratio Xcs, so a more accurate (correct) estimated solid phase ratio Xcs can be obtained.

[0097] Next, the decomposition rate calculation formula is described. [Formula 102] shows an example of the decomposition rate calculation formula used in this embodiment.

[0098] Resin decomposition rate Xr = E·Wa·kb…[Formula 102]

[0099] Among them, E=f(W, L, σ, γ, ζ)

[0100] Wa∝f(Φm,Φc,Qs)

[0101] [Formula 102] is a formula basically based on Tadmor's model formula, and is a calculation formula for obtaining the resin decomposition rate Xr in the injection molding machine M. In [Formula 102], E is the shear heat value [MJ] calculated based on Tadmor's model formula, and is the total shear heat value obtained by integrating the shear heat value from the complete melting position to the front end of the screw 3. Wa represents the bonding work between the molten resin and the metal [MJ / square meter], and kb represents the adjustment coefficient considering the catalytic effect of the metal.

[0102] In addition, in the calculation of the shear heat value E, W represents the length obtained by subtracting the thread width from the pitch width, L represents the screw helix length, σ represents the shear stress, γ represents the shear velocity, ζ represents the dimensionless depth, and in the calculation of the bonding work Wa, Φm represents the work function of the base metal, Φc represents the work function of the metal coated on the base metal, and Qs represents the amount of oxygen attached to the outermost metal. In addition, the oxygen amount Qs can be measured using an X-ray analyzer (EDX device). This bonding work Wa represents the ease of bonding between the molten resin and the metal. Figure 6 In FIG. 1 , the degree of adhesion of the molten resin to the metal on the screw surface 3 f is shown by type.

[0103] In addition, the catalytic effect (oxidation induction time) of the metal becomes a factor of degradation of the molten resin, so the catalytic effect is reflected in the coefficient kb. Generally, it is known that when a polymer (resin) is heated, it becomes a polymer free radical active species by depriving hydrogen. In the case of a polymer free radical active species, the molecular weight of the polymer is not reduced in this state, but when it comes into contact with a metal, it combines with oxygen and free radicals in the air by generating a catalytic effect, resulting in a phenomenon of promoting the decomposition of the molten resin. Figure 7 (a) to (c) schematically illustrate this phenomenon. Figure 7 (a) shows a state where the polymer 45 is activated (thermally decomposed) by heat. In this state, when catalytic activation is performed using a metal species, as shown in FIG. Figure 7 As shown in (b), an oxidation phenomenon occurs in which oxygen 46 is combined with the activated polymer 45. Furthermore, in the case of further development, as Figure 7 As shown in (c), the phenomenon of polymer 45 being reduced in molecular weight due to oxidative decomposition occurs. Figure 8 This is a diagram showing the ease of decomposition of molten resin with respect to metal on the screw surface 3f by type.

[0104] In the calculation result of the resin decomposition rate Xr based on the decomposition rate calculation formula [Formula 102], the residence time of the molten resin, the bonding work, the oxidation induction time, the screw shape, etc. are taken into consideration, so the resin decomposition rate Xr obtained by the decomposition rate calculation formula can be used as the estimated resin decomposition rate Xr obtained based on the input basic data Do, that is, the estimated resin decomposition rate Xrs. If such a decomposition rate calculation formula data Dr is set, the basic data Do used in the calculation processing of the above-mentioned solid phase ratio calculation formula data Dc can also be used in the calculation processing of the decomposition rate calculation formula data Dr, etc., and the estimated resin decomposition rate Xrs can be easily calculated.

[0105] In addition, the experimental (confirmed) results confirmed that as long as the estimated resin decomposition rate Xrs can be maintained at 0.00, no degradation will occur. Therefore, in the case of a value greater than 0.00, it can be understood that the molten resin is in a degraded state (including a case where the risk of transitioning to a degraded state is high). That is, in the case where the estimated resin decomposition rate Xrs is "Xrs = 0.00", it can be judged that it is in a good molten state without degradation, and in the case of "Xrs>0.00", it can be judged that it is in a degraded state or has a high risk of transitioning to a degraded state. In this way, the size of the estimated resin decomposition rate Xrs can be used as an indicator of the degraded state of the molten resin caused by excessive plasticization.

[0106] In this way, if the decomposition rate calculation data Dr for calculating the resin decomposition rate Xr of the screw surface 3f during molding based on the basic data Do is set in the calculation data setting unit Fs, the decomposition rate calculation processing unit Fcr described later can perform calculation processing based on the basic data Do and the decomposition rate calculation data Dr, thereby calculating the estimated resin decomposition rate Xrs. Therefore, the basic data Do used in the calculation processing of the solid phase ratio calculation data Dc can also be used in the calculation processing of the decomposition rate calculation data Dr, and the estimated resin decomposition rate Xrs can be easily calculated.

[0107] Moreover, the estimated resin decomposition rate Xrs that can be easily obtained by calculation processing can accurately grasp the degradation state of the molten resin. Therefore, in addition to the boundary point on one side (insufficient plasticization side) of the molten state based on the estimated solid phase ratio Xcs, the appropriate range of the molten state can be set by using the boundary point on the other side (excessive plasticization side) of the molten state based on the estimated resin decomposition rate Xrs. This can achieve stabilization and improvement of moldability and molding quality.

[0108] Next, the temperature rise calculation formula is described. [Formula 103] shows an example of the temperature rise calculation formula that is the basis of the temperature rise calculation formula data Dw.

[0109] Rising temperature ΔTu=E / (Q·Cm)…[Formula 103]

[0110] In [Formula 103], E〔MJ〕 can utilize the shear calorific value E in [Formula 102] for calculating the resin decomposition rate Xr. In addition, Q represents plasticizing ability, and Cm represents melt specific heat (resin specific heat).

[0111] In this way, in order to obtain the temperature rise ΔTu, the data related to the above-mentioned shear calorific value E can be used, so the estimated temperature rise ΔTus can be easily obtained. That is, in order to obtain the estimated temperature rise ΔTus, the shear calorific value E from the complete melting position to the screw tip can be divided by the plasticizing capacity Q and the resin specific heat Cm. In addition, the molten resin is not treated as a Newtonian fluid like water, but as an exponential law fluid like syrup.

[0112] The above-mentioned solid phase ratio Xc and resin decomposition rate Xr are also closely related to the temperature rise ΔTu of the resin. Therefore, in addition to the information related to the estimated solid phase ratio Xcs and / or the estimated resin decomposition rate Xrs, if the estimated temperature rise ΔTus is displayed as information related to the estimated solid phase ratio Xcs and the estimated resin decomposition rate Xrs as information related to the melting state of the molten resin, the information related to the estimated temperature rise ΔTus can also be confirmed, so the operator (user) can more accurately grasp the melting state.

[0113] Fig. 9 The correlation characteristics between the estimated temperature rise ΔTus and the measured temperature rise are shown. In this characteristic, ABS resin is used as the resin, and all the estimated temperature rise ΔTus are lower than the critical value p=0.01, and sufficient correlation can be confirmed.

[0114] On the other hand, the data processing unit F includes a calculation processing function unit Fc using the molding machine controller 10 (controller body 22 and internal memory 10m). The calculation processing function unit Fc can perform calculation processing using the above-mentioned solid phase ratio calculation formula data Dc, decomposition rate calculation formula data Dr, and temperature rise calculation formula data Dw.

[0115] Therefore, the calculation and processing functional unit Fc includes at least: a solid phase ratio calculation and processing unit Fcp, which is used to calculate the solid phase ratio Xc of the molten resin at the end of metering, that is, the estimated solid phase ratio Xcs, through calculation and processing based on the basic data Do and the solid phase ratio calculation formula data Dc; a decomposition rate calculation and processing unit Fcr, which is used to calculate the resin decomposition ratio Xr of the molten resin, that is, the estimated resin decomposition ratio Xrs, through calculation and processing based on the basic data Do and the decomposition rate calculation formula data Dr; and a rising temperature calculation and processing unit Fct, which is used to calculate the estimated rising temperature ΔTus through calculation and processing based on the rising temperature calculation formula data Dw.

[0116] Furthermore, the calculation processing function unit Fc includes a determination processing unit Fcj that performs determination processing on the degree of the estimated solid phase ratio Xcs and / or the estimated resin decomposition rate Xrs, and outputs auxiliary message data Dh corresponding to the result of the determination processing. In this case, it is preferable to perform determination processing on the degree of both the estimated solid phase ratio Xcs and the estimated resin decomposition rate Xrs, but it is also possible to perform determination processing on only the degree of one of the estimated solid phase ratio Xcs and the estimated resin decomposition rate Xrs as needed.

[0117] Fig.10 Indicates the criteria used for determination processing. Fig.10, the judgment result "01" is the case of "Xcs≤0.06" and "Xrs=0.00". In this case, the molten state is in a sufficient state and is not in a degraded state, so it can be judged to be in a good molding environment. The judgment result "02" is the case of "Xcs≤0.06" and "Xrs>0.00". In this case, it can be judged that the molten state is in a sufficient state, but it may become a degraded state. The judgment result "03" is the case of "Xcs>0.06" and "Xrs=0.00". In this case, it can be judged that insufficient plasticization may occur, but it will not become a degraded state. The judgment result "04" is the case of "Xcs>0.06" and "Xrs>0.00". In this case, it can be judged that insufficient plasticization may occur and it may become a degraded state.

[0118] Furthermore, the determination processing unit Fcj has a function of outputting auxiliary message data Dh corresponding to the determination results "01" to "04". Specifically, when the determination result is "01", the auxiliary message mr is output, when the determination result is "02", the auxiliary message m1 is output, when the determination result is "03", the auxiliary message m2 is output, and when the determination result is "04", the auxiliary message m3 is output. In addition, the specific contents of the auxiliary message will be described in the molding assisting method using the molding assisting device 1 described later.

[0119] In addition, the forming auxiliary device 1 has Figure 1 The output processing function unit Fd is shown. The output processing function unit Fd can be said to be a processing function for utilizing the output of the determination result, and has a display function for displaying the above-mentioned auxiliary messages mr, m1, m2, ... on the display 7. The auxiliary messages mr, m1, m2, m3 include determination messages mrj, m1j, m2j, m3j indicating the results of the determination processing and countermeasure messages m1p, m2p, m3p for executing countermeasures corresponding to the determination messages m1j, m2j, m3j (see Figure 17a to Figure 17d ). Therefore, the auxiliary message data Dh corresponding to the auxiliary messages mr, m1, m2, and m3 are stored in the internal memory 10m.

[0120] In addition, as other processing functions using the judgment results, although omitted in the figure, data related to the estimated solid phase ratio Xcs and data related to the estimated resin decomposition ratio Xrs can also be used as correction data corresponding to the countermeasure messages m1p, m2p..., and utilized for automatic correction processing to automatically correct the corresponding molding conditions.

[0121] Furthermore, the output processing function unit Fd has Fig.11The data display unit 8 shown in FIG. 1 is provided with a temperature control temperature display unit 8t, a resin state display unit 8f, and a judgment result display unit 8j. In this case, the temperature control temperature display unit 8t is further provided with a hopper temperature display unit (or a material temperature control unit temperature display unit) 8th, a material drop port temperature display unit 8tr, and a resin material temperature display unit 8to, and the resin state display unit 8f is provided with an estimated resin decomposition rate display unit 8fp, an estimated solid phase rate display unit 8fc, and an estimated rising temperature display unit 8fu. In each of these display units, each physical quantity is numerically displayed. In addition, a message display unit 8jm is provided in the judgment result display unit 8j.

[0122] The above is the basic function of the molding assisting device 1. This basic function is to maintain the melting state of the resin in the heating cylinder 4 in an optimal state. On the other hand, the state (temperature adjustment state) of the granular material Rp supplied to the heating cylinder 4 is also closely related to the melting state of the resin in the heating cylinder 4.

[0123] Therefore, in the molding assisting device 1 of the present embodiment, from the viewpoint of further optimizing such basic functions, the temperature control state of the pellets Rp is optimized as the configuration of the main portion. Hereinafter, the configuration of the main portion will be specifically described.

[0124] First, if Figure 1 As shown, in the molding condition data Dm inputted through the basic data input part Fi, data Dmc related to the molding cycle time Tc is included as the data of interest. In addition, a resin selection part (selection list) Dms is provided to input the type of the granular material Rp... (resin material R...), and a temperature control temperature input part Dmt is provided to input the temperature (temperature control temperature) of the temperature control part 6. In this case, the temperature control temperature input part Dmt is assumed to be manually inputted. In the present embodiment, if the resin is selected through the above-mentioned resin selection part Dms, the temperature control temperature Tr is automatically set, but it is considered that it can be arbitrarily inputted even by manual operation. In particular, when controlling the temperature control temperature Tr, in the case of setting the upper limit value Tru and the lower limit value Trm for control, the upper limit value Tru can be automatically set according to the type of the granular material Rp... (resin material R...) selected by the resin selection part (selection list) Dms, and the lower limit value Trm can be set manually. In addition, in this case, both the upper limit value Tru and the lower limit value Trm can be set manually. Therefore, the basic data input unit Fi includes a temperature adjustment temperature manual input function that allows manual input of the lower limit value Trm (including the upper limit value Tru as necessary) of the temperature adjustment temperature Tr.

[0125] In addition, a temperature control temperature data table DT is provided in the internal memory 10m, and a temperature setting processing unit Fcs is provided as the calculation processing function unit Fc. The temperature control temperature data table DT is a table in which the optimum temperature control temperature Tr of the temperature control unit 6 described above is set according to the type of resin. In this case, the temperature control temperature Tr itself can be directly set as the temperature control temperature Tr, or as described above, an upper limit value Tru and a lower limit value Tru of the control range of the temperature control temperature Tr can be selected, and the upper limit value Tru can be set in the temperature control temperature data table DT, and the lower limit value Trm can be set by the temperature control temperature manual input function of the basic data input unit Fi described above.

[0126] In this way, if the upper limit value Tru of the temperature control temperature Tr is set in the temperature control temperature data table DT, the temperature control temperature of the higher importance side (upper limit value Tru) in the case of controlling the temperature control temperature Tr by setting the upper limit value Tru and the lower limit value Trm can be automatically set. Therefore, even when various control methods are adopted, accurate control of the temperature control temperature (target temperature) can be performed, and if a temperature control temperature manual input function that can manually input at least the lower limit value Trm of the temperature control temperature Tr is set in the basic data input part Fi, the lower limit value Trm in the case of automatically setting the upper limit value Tru can be arbitrarily set by manual input, and the overall manual setting of the temperature control temperature Tr (upper limit value Tru and lower limit value Trm) can be easily performed as needed.

[0127] Furthermore, the temperature setting processing unit Fcs has a function of reading out the temperature control temperature Tr (or the upper limit value Tru) corresponding to the input type of resin from the temperature control temperature data table DT when setting the molding conditions described later, and setting the temperature control temperature Tr of the temperature control unit 6. As described above, the temperature control temperature Tr is a concept including at least one or both of the temperature control temperature Trh of the heater 6h attached to the hopper 5h, the temperature control temperature of the material temperature control unit 6p of the material supply device Prm, and the temperature control temperature Trd of the water jacket 6j attached to the material drop port 5d.

[0128] Next, refer to Figure 1 to Figure 3 and Fig.12 , Figure 15a to Figure 15d The temperature adjustment temperature data table DT and the temperature setting processing unit Fcs will be described in detail.

[0129] In the known model formula proposed by Tadmor mentioned above, as shown in [Formula 104], there is a term related to the resin material temperature Tro of the resin material R, that is, the generally widely used granular material Rp.

[0130] [Mathematical formula 1]

[0131]

[0132] Here, δ is the melt film thickness, km is the thermal conductivity of the melt, Tb is the heating cylinder temperature, Tmo is the melting point, Tro is the resin material temperature, Va and Vb are coefficients indicating the melting rate, X is the solid bed width, Vbx is the cylinder circumferential speed component in the screw width direction, Cs is the solid specific heat, ρm is the liquid density, and λ is the latent heat of melting.

[0133] Therefore, if information on the temperature control of the temperature control unit 6 in the injection molding machine M can be reflected in the model formula for predicting the plasticization state in the injection molding machine M, a melting state closer to reality can be simulated.

[0134] Therefore, in this embodiment, first, it is verified Figure 2 The correlation between the measured value of the temperature of the granular material Rp (resin material temperature Tro) at the center of the material drop port 5d and the estimated value of the temperature in the middle of the granular material Rp is shown. In this case, regarding the measured value, a thermocouple is arranged at the center of the material drop port 5d to measure the temperature. On the other hand, the estimated value is estimated using the calculation formula [Formula 105].

[0135] Tro(x,t)=f(Trx,Try,X,α,Tc)

[0136] …[Formula 105]

[0137] Here, Tro(x, t) is the temperature of the pellet material Rp taking into account the molding cycle time Tc, that is, the estimated resin material temperature, which is equivalent to Tro in [Equation 104]. In addition, Trx is Figure 3 The temperature of one side surface of the cylindrical granular material Rp shown is in contact with the boundary position of the material drop port 5d and the hopper 5h (or the material supply device Prm), Try is the temperature of the opposite side surface when it contacts the heating cylinder 4 near the inlet 3i of the screw 3 for the molding cycle time Tc, and α is the inherent value of the resin material obtained by dividing the thermal conductivity kn of the granular material Rp by the heat capacity.

[0138] Then, according to the type of resin, the test conditions (molding conditions) are changed to obtain the estimated value of the resin material temperature Tro obtained by [Formula 105], and the above-mentioned measured conditions, i.e. Figure 2 The measured value of the temperature of the granular material Rp at the central position of the material drop port 5d is shown in FIG. Fig.12 In the embodiment, four types of resins are used: PP (polypropylene), GPPS (general purpose polystyrene), POM (polyacetal), and ABS (acrylonitrile butadiene).

[0139] Depend on Fig.12 It can be seen that the estimated resin material temperature Tros and the measured resin material temperature Trom near 80°C have a significant dispersion compared to other temperatures, but the overall correlation coefficient between the measured value and the estimated value is 0.98. That is, a graph roughly showing a 1:1 rise to the right can confirm the validity of [Formula 105]. Therefore, the temperature of the granular material Rp can be estimated by the temperature control temperature Trd of the material drop port 5d and the temperature control temperature Trh of the hopper 5h (or the temperature control temperature of the material supply device Prm), and further by [Formula 105] which depends on the molding conditions and the physical properties of the resin.

[0140] Furthermore, the temperature stability of the resin accompanying the temperature change of the pellet Rp was evaluated. Fig.13 This is a graph showing the deviation (%) of the resin temperature relative to the temperature rise ΔTu (°C) of the resin in the heating cylinder 4. Fig.13 It can be seen that a V-shaped graph is obtained in which the deviation of the resin temperature decreases as the temperature rise ΔTu approaches 0. In addition, the following results are obtained: as the temperature rise ΔTu increases on the negative side, the unmelted resin increases, and as the temperature rise ΔTu increases on the positive side, the carbide increases.

[0141] Therefore, it can be seen that as the unstable factors increase, the deviation of the resin temperature becomes larger. Therefore, in order to further reduce the deviation, the condition for obtaining the best melting state is that the unmelted resin, carbide, and the temperature rise ΔTu of the resin are close to 0. That is, the estimated solid phase ratio Xcs, the estimated resin decomposition rate Xrs, and the estimated temperature rise ΔTus can be obtained by estimation. Therefore, as an index representing the stability of the resin temperature based on the calculation, a dimensionless function f(Xcs, Xrs, ΔTus) was prepared, and the correlation with the deviation of the resin temperature [%] (measured value) was examined.

[0142] Fig.14 A correlation diagram showing the deviation between f(Xcs, Xrs, ΔTus) and resin temperature. Fig.14 In the correlation diagram shown, the correlation coefficient between the value calculated from f(Xcs, Xrs, ΔTus) and the variation in resin temperature is 0.67 (p=2.37E-24). Therefore, it is estimated that the variation in resin temperature can be predicted by calculation.

[0143] Therefore, the temperature of the hopper 5h (or material supply device Prm) and the material drop port 5d, that is, the temperature control temperature Trh and / or Trd, is set as the molding condition, and the temperature control temperature (Trh, Trd) is changed to 40〔℃〕, 60〔℃〕, and 80〔℃〕, thereby actually measuring the deviation of the resin temperature, and for f(Xcs, Xrs, ΔTus), the temperature control temperature (Trh, Trd) of the hopper 5h (or material supply device Prm) and the material drop port 5d is input as the molding condition, thereby calculating the deviation of the resin temperature.

[0144] Figure 15a to Figure 15d The results obtained according to the type of each granular material Rp... are shown. Fig.15a This indicates that "PP" is used as the pellet material Rp, and the temperature is changed under the condition that the temperature control temperature Trd of the material drop port 5d is the same as the temperature control temperature Trh of the hopper 5h (or the material supply device Prm). Fig.15b This shows the case where "GPPS" is used as the pellet material Rp, and the temperature is changed under the condition that the temperature control temperature Trd of the material drop port 5d is the same as the temperature control temperature Trh of the hopper 5h (or the material supply device Prm). Fig.15c This shows the case where "ABS" is used as the pellet material Rp, and the temperature control temperature Trd of the material drop port 5d is changed so that the temperature control temperature trh of the hopper 5h (or the material supply device Prm) is fixed at 80〔℃〕. Fig.15d The case where "POM" is used as the pellet material Rp and the temperature control temperature Trd of the material drop port 5d is changed so that the temperature control temperature Trh of the hopper 5h (or the material supply device Prm) is fixed at 80 [°C] is shown.

[0145] Depend on Figure 15a to Figure 15d It can be seen that in "PP", if the temperature control temperature Tr (Trd, Trh) in the material drop port 5d and the hopper 5h (or the material supply device Prm) becomes higher, the deviation of the resin temperature becomes larger, but in the calculation, the deviation of the resin temperature at 60〔℃〕 is the largest. Regarding "GPPS", "ABS", and "POM", the calculated values ​​are roughly consistent with the measured values. Therefore, it can be confirmed that the temperature control temperature Tr (Trd, Trh) can be calculated, and the appropriate temperature control temperature Tr (Trd, Trh) and the combination of the temperature control temperatures Trd and Trh of the material drop port 5d and the hopper 5h (or the material supply device Prm) can be made according to the type of resin.

[0146] In the molding assisting device 1 of the present embodiment, appropriate temperature control temperatures Trd and Trh are set according to the type of resin through the temperature control temperature data table DT. If the type of resin is selected (input), the temperature setting processing unit Fcs can be used to automatically set the appropriate temperature control temperatures Trd and Trh of the material drop port 5d and the hopper 5h (or the material supply device Prm).

[0147] Furthermore, the output processing function unit Fd is provided with a function of displaying at least the temperature adjustment temperature Tr (Trd, Trh) on the display 7 . Fig.11 8t based on this function is shown in FIG. In addition, in the data processing unit F, resin temperature calculation formula data for converting the temperature adjustment temperature Tr (Trd, Trh) into the temperature of the pellet material Rp (resin material temperature Tro) based on at least a part of the shape data Dmp of the resin material R in the molding condition data Dm and the molding cycle time data Dmc is set, and a resin temperature calculation processing function for obtaining the resin material temperature Tro by calculation processing based on the resin temperature calculation formula data is set. As a result, the resin material temperature Tro can be estimated based on the obtained temperature adjustment temperature Tr, so that the temperature state of the resin material temperature Tro itself and the melting state of the resin based on the temperature state, that is, information related to the relationship with the estimated solid phase ratio Xcs and / or the estimated resin decomposition rate Xrs, the estimated rising temperature ΔTus, etc. can be accurately grasped.

[0148] Furthermore, the output processing function section Fd is provided with a resin material temperature display section 8to for displaying the resin material temperature Tro obtained by the resin temperature conversion processing function of the data processing section F on the display 7, and the resin material temperature Tro obtained by the resin material temperature display section 8to is displayed. Thus, the resin material temperature Tro can be easily confirmed by visual observation, and the information can be easily confirmed by comparing with other information, that is, the estimated solid phase ratio Xcs and / or the estimated resin decomposition rate Xrs, the estimated temperature rise ΔTus, etc.

[0149] Next, refer to the figures and Fig.16 The flowchart shown in the figure explains a molding assisting method using the molding assisting device 1 of the present embodiment.

[0150] The molding assisting device 1 can be used basically when setting molding conditions before starting production. Note that the operations related to the molding assisting process are executed by the assisting program Ps stored in the internal memory 10m.

[0151] First, the operator performs a setting process (step S1) of the molding conditions in the injection molding machine M according to a normal setting procedure. In this case, in the setting process of the molding conditions, information related to normal molding conditions, that is, normal various information (conditions) for operating the injection molding machine M is set.

[0152] On the other hand, when the molding condition setting process is completed and the molding assisting device 1 according to the present embodiment is used, if a predetermined assisting start key (not shown) is turned on and the molding assisting device 1 is started, the assisting program Ps is executed (step S2). As a result, an input screen (not shown) is displayed on the display 7 (step S3).

[0153] Then, using the touch panel 7t (basic data input unit Fi) corresponding to the displayed input screen, the above-mentioned basic data Do including the molding condition data Dm related to the pre-set molding conditions and the screw data Ds related to the shape of the screw 3 is input (step S4). Specifically, it can be performed by direct numerical input or selection input selected from the window display. In addition, the type of resin used in particular in association with the present embodiment is selected from the resin list of the resin selection unit Dms (step S5). Thus, the temperature control temperatures Trd and Trh corresponding to the selected resin are read from the temperature control temperature data table DT, and are set in the temperature setting processing unit Fcs as the temperature control temperature Tr (Trd, Trh) of the temperature control unit 6 (step S6). Furthermore, the temperature control temperature displayed on Fig.11 The temperature adjustment temperature display unit 8t is shown (step S7). In this case, if the data related to the molding conditions, screw, etc. have already been registered, the input at this time is not necessary. Then, if the input processing of the basic data Do is completed, it is confirmed whether there is any erroneous input of data, input omission, etc., and the confirmation key (not shown) is turned on.

[0154] Thus, in the solid phase ratio calculation processing unit Fcp, calculation processing based on the input basic data Do and the solid phase ratio calculation formula data Dc is performed (step S8). Through this calculation processing, the estimated solid phase ratio Xcs based on the basic data Do is calculated, so the obtained estimated solid phase ratio Xcs is at least temporarily registered in the internal memory 10m. In addition, in the decomposition rate calculation processing unit Fcr, calculation processing based on the input basic data Do and the decomposition rate calculation formula data Dr is performed (step S9). Through this calculation processing, the estimated resin decomposition rate Xrs based on the basic data Do is calculated, so the obtained estimated resin decomposition rate Xrs is at least temporarily registered in the internal memory 10m. And, in the temperature rise calculation processing unit Fct, calculation processing based on the temperature rise calculation formula data Dw is performed (step S10). Through this calculation processing, the estimated temperature rise ΔTus is calculated, so the obtained estimated temperature rise ΔTus is at least temporarily registered in the internal memory 10m. Then, the obtained estimated solid phase ratio Xcs, estimated resin decomposition rate Xrs, and estimated temperature rise ΔTus are displayed on Fig.11 The resin state display unit 8f shown in step S11 is displayed. In this way, in addition to the information related to the estimated solid phase ratio Xcs and the estimated resin decomposition rate Xrs, the information related to the estimated temperature rise ΔTus is also displayed, so the information related to the estimated temperature rise ΔTus can also be confirmed. Therefore, the operator can more accurately grasp the melting state of the resin.

[0155] Furthermore, when the estimated solid phase ratio Xcs and the estimated resin decomposition ratio Xrs are obtained, the determination processing unit Fcj performs the following operations according to the following conditions: Fig.10 The judgment criteria shown in the figure are used to judge the degree of the estimated solid phase ratio Xcs and the estimated resin decomposition rate Xrs (step S12). Then, based on the result of the judgment process, the corresponding Fig.10 The auxiliary messages mr, m1, m2, m3 shown in the figure are selected, and the auxiliary message data Dh corresponding to the selected auxiliary message mr... is outputted. Thus, in the output processing function part Fd, the auxiliary message data Dh selected based on the auxiliary message data Dh outputted from the determination processing part Fcj is outputted. Figure 17a to Figure 17d The auxiliary message mr, m1, m2 or m3 shown is displayed on the message display section 8j (step S13).

[0156] Figure 17a to Figure 17d An example of auxiliary messages mr, m1, m2... in the message display unit 8j is shown. In the example, as required, determination messages m1j, m2j... indicating the results of determination processing are displayed in the upper section, and countermeasure messages m1p, m2p... for executing countermeasures corresponding to the determination messages m1j, m2j... are displayed in the lower section.

[0157] Specifically, in the case of an auxiliary message mr, if Fig.17a As shown in FIG. 1 , for example, a text “is within an appropriate range” is displayed as a judgment message mrj. In the illustrated case, the countermeasure message is not displayed, but as required, a required countermeasure message, that is, a message for further improvement through modification, etc. may be displayed even within an appropriate range. In addition, in the case of an auxiliary message m1, as shown in FIG. Fig.17b As shown in FIG. 1 , as the judgment message m1j, for example, a text "The resin may be carbonized" is displayed, and as the countermeasure message m1p, for example, a text "Please reduce Tm, Tr, Pr, Rm or shorten Tc" (Tm: set temperature for heating, Tr: temperature control temperature, Pr: back pressure, Rm: rotation speed, Tc: molding cycle time) is displayed. Similarly, in the case of the auxiliary message m2, such as Fig.17c As shown in FIG. 1 , as the judgment message m2j, for example, a text “unmelted resin may be generated” is displayed, and as the countermeasure message m2p, for example, a text “please increase Tm, Tr, Pr, Rm or extend Tc” is displayed. Furthermore, in the case of the auxiliary message m3, as shown in FIG. Fig.17d As shown, as the countermeasure message m3p, for example, "Please re-evaluate the molding conditions" is displayed to urge a so-called comprehensive resetting of the molding conditions. In the illustrated case, the determination message is not displayed separately, but the determination message is substantially included in the countermeasure message m3p.

[0158] In this way, if a judgment processing unit Fcj is set in the calculation processing function unit Fc, and the judgment processing unit Fcj performs judgment processing on the degree of the estimated solid phase ratio Xcs and / or the estimated resin decomposition ratio Xrs, and outputs auxiliary message data Dh corresponding to the result of the judgment processing, and a message display unit 8j is set in the output processing function unit Fd to display the auxiliary messages mr, m1, m2... based on the auxiliary message data Dh output from the judgment processing unit Fcj on the display 7, the operator can easily grasp the melting state of the resin that is difficult to judge, and can quickly perform necessary response processing.

[0159] In particular, if the auxiliary messages mr, m1, m2... include judgment messages mrj, m1j, m2j... indicating the results of the judgment processing and countermeasure messages m1p, m2p... for executing countermeasures corresponding to the judgment messages m1j, m2j..., the results of the judgment processing can be confirmed by visual means. Therefore, even a novice operator with little experience can easily and reliably confirm whether the melting state of the resin is appropriate, and can quickly take necessary countermeasures such as changing the settings of the molding conditions, thereby realizing efficient and high-capacity production of molded products.

[0160] As a result, if an auxiliary message m1, m2 or m3 other than the appropriate message mr is displayed in the message display section 8j, the molding condition change process is performed (steps S14, S15) according to the displayed auxiliary message m1, m2 or m3, that is, the judgment message m1j ... and the countermeasure message m1p ... For example, if the auxiliary message m2 (judgment message m2j, countermeasure message m2p) is displayed, according to "unmelted resin may be generated" (judgment message m2j) and "Please increase Tm, Tr, Pr, Rm or extend Tc" (countermeasure message m2p), the setting change for increasing one or more of the set temperature Tm, back pressure Pr, and rotation speed Rm, and the setting change for extending the molding cycle time Tc may be performed.

[0161] In this case, the degree of change can be determined by the operator. At this time, as described above, if the estimated solid phase ratio Xcs and the estimated resin decomposition rate Xrs are visually displayed by numerical display or graphical display, the operator can confirm the degree of deviation from the appropriate range, and can judge the degree of change of the molding conditions accordingly.

[0162] In particular, the change of molding conditions may also include the temperature adjustment temperature Tr (Trd, Trh). Therefore, in the case where it is difficult to change the heating temperature of the heating cylinder 4, the molding cycle time, etc. due to the molding environment, various conditions, etc., the temperature adjustment temperature Tr (Trd, Trh) can be changed. The change in this case can be made using Figure 1 The temperature control temperature input section Dmt in the basic data input section Fi shown in the figure can be arbitrarily input by manual operation. In addition, the change in this case is reflected in the display of the temperature control temperature display section 8t. And the degree of change can be confirmed by checking the display of the resin state display section 8f and the determination result display section 8j.

[0163] As described above, in the present embodiment, since the temperature adjustment temperature Tr (Trd, Trh) can be changed, it becomes a useful adjustment means (setting change means) when it is difficult to change the heating temperature of the heating cylinder 4, the molding cycle time, etc.

[0164] Then, when the molding condition change process is completed, a reprocess key (not shown) is turned on to recalculate the estimated solid phase ratio Xcs and the estimated resin decomposition rate Xrs, and perform a re-determination process (steps S16, S8, ...).

[0165] On the other hand, in step S14, if the appropriate message mr is displayed in the message display unit 8j, the molten state is sufficient and not degraded, so it can be confirmed that it is in a good molding environment. Therefore, in order to transfer to the next stage, the end key (not shown) is turned on to end the execution of the auxiliary program Ps (steps S14, S17). That is, the use of the molding auxiliary device 1 can be ended.

[0166] Thus, according to the molding assisting device according to the present embodiment, since the temperature control temperature data table DT sets the optimum temperature control temperature Tr of the temperature control unit 6 according to the type of resin and the temperature setting processing unit Fcs are provided, the temperature control temperature data table DT sets the optimum temperature control temperature Tr of the temperature control unit 6 for controlling the temperature of the material supply unit 5 for supplying the resin material R to the inside of the heating cylinder 4, and the temperature setting processing unit Fcs reads the temperature control temperature Tr corresponding to the input type of resin from the temperature control temperature data table DT after the type of resin is input from the basic data input unit Fi at least when setting the molding conditions, and sets the temperature control temperature Tr of the temperature control unit 6 accordingly, it is possible to set the optimum (accurate) temperature control temperature Tr matching the type of resin, and it is possible to further improve the efficiency and stability of the overall processing in the heating cylinder 4. In addition, since the temperature control temperature Tr of the temperature control unit 6 is at least displayed on the display 7, the operator can confirm the temperature control temperature Tr, and from the viewpoint of further improving the plasticization quality, it is possible to arbitrarily change (adjust) the temperature control temperature Tr by using the auxiliary function such as the change of the molding conditions in the molding assisting device 1 or manually. That is, since the change of the temperature control temperature Tr can be included in the change of the molding conditions, the adjustment range of the entire molding conditions can be expanded, thereby ensuring higher molding quality by further improving the plasticization quality.

[0167] The best embodiment has been described in detail above, but the present invention is not limited to such an embodiment, and the structure, shape, material, quantity, numerical value, method, etc. of the details can be arbitrarily changed, added, or deleted without departing from the scope of the present invention.

[0168] For example, for the resin material R, an example of applying the granular material Rp is given, but it can also be a resin material similar to the granular material Rp, etc., and is not limited to the granular material Rp. In addition, as the basic data Do, the molding condition data Dm and the screw data Ds are exemplified, but other data can also be included, and it can also be a part of the exemplified data. Furthermore, as the basic data input part Fi, the touch panel 7t of the display 7 is exemplified, but in the case of transmitting the data of the external memory storing the basic data Do or sending it through the communication unit, in the case of pre-registering all the data in the internal memory 10m and selecting the basic data Do from the all the data, etc., various input units can be applied as the basic data input part Fi. On the other hand, the solid phase ratio calculation formula data Dc and the decomposition ratio calculation formula data Dr are examples, and other calculation formula data that can be used to calculate the solid phase ratio Xc and the resin decomposition ratio Xr are not excluded.

[0169] Industrial Applicability

[0170] The molding assisting device according to the present invention can be used in various injection molding machines that perform molding by injecting and filling a plasticized molten resin into a mold using a screw.

Claims

1. A molding assisting device for an injection molding machine, which assists the injection molding machine in molding by injecting plasticized molten resin into a mold through a screw, characterized in that: have: A temperature control unit that controls the temperature of a material supply unit that supplies a resin material to the interior of the heating cylinder; and A molding machine controller, comprising: a basic data input unit, which has the function of inputting basic data including at least molding condition data related to molding conditions and screw data related to the shape of the screw, and is capable of inputting the type of resin material, wherein the screw data includes data related to the type of material on the surface of the screw; a data processing unit, which has a temperature control temperature data table and a temperature setting processing unit, wherein the temperature control temperature data table sets the optimal temperature control temperature of the temperature control unit according to the type of resin material, and the temperature setting processing unit reads the temperature control temperature corresponding to the type of resin material input from the temperature control temperature data table after the type of resin material is input from the basic data input unit at least when setting the molding conditions, and sets the temperature control temperature as the temperature control temperature of the temperature control unit; and an output processing function unit, which displays the temperature control temperature at least on a display.

2. The molding auxiliary device of the injection molding machine according to claim 1, characterized in that: The material supply unit is a hopper attached to the heating cylinder.

3. The molding auxiliary device of the injection molding machine according to claim 1, characterized in that: The material supply unit is a material supply device attached to the heating cylinder.

4. The molding auxiliary device of the injection molding machine according to claim 1, characterized in that: The material supply portion is a material drop port of the heating cylinder.

5. The molding auxiliary device of the injection molding machine according to claim 1, characterized in that: The resin material is a granular material.

6. The molding auxiliary device of the injection molding machine according to claim 1, characterized in that: The upper limit value of the temperature adjustment temperature is set in the temperature adjustment temperature data table.

7. The molding auxiliary device of the injection molding machine according to claim 6, characterized in that: The basic data input unit includes a temperature adjustment temperature manual input function capable of manually inputting at least a lower limit value of the temperature adjustment temperature.

8. The molding auxiliary device of the injection molding machine according to claim 1, characterized in that: The data processing unit includes: an arithmetic formula data setting unit, which sets solid phase ratio arithmetic formula data for calculating the solid phase ratio of the molten resin in the heating tube based on the basic data; and an arithmetic processing function unit, which has a solid phase ratio arithmetic processing unit, which calculates the estimated solid phase ratio of the molten resin at the end of metering through arithmetic processing based on the basic data and the solid phase ratio arithmetic formula data.

9. The molding auxiliary device of the injection molding machine according to claim 8, characterized in that: In the calculation formula data setting unit, decomposition rate calculation formula data for calculating the resin decomposition rate on the screw surface during molding based on the basic data is set, and in the calculation processing function unit, there is a decomposition rate calculation processing unit, which calculates the estimated resin decomposition rate through calculation processing based on the basic data and the decomposition rate calculation formula data.

10. The molding auxiliary device of the injection molding machine according to claim 9, characterized in that: In the calculation formula data setting unit, rising temperature calculation formula data for calculating the estimated rising temperature based on data related to the shear calorific value is set. The shear calorific value is used for calculation processing based on the decomposition rate calculation formula data, and the calculation processing function unit is provided with a rising temperature calculation processing unit. The rising temperature calculation processing unit calculates the estimated rising temperature through calculation processing based on the rising temperature calculation formula data.

11. The molding auxiliary device of the injection molding machine according to claim 10, characterized in that: The output processing function unit includes a temperature rise display unit that displays the estimated temperature rise obtained by the temperature rise calculation processing unit on the display.

12. The molding auxiliary device of the injection molding machine according to claim 1, characterized in that: In the data processing unit, resin temperature conversion formula data is set for converting the temperature control temperature into the resin material temperature based on at least a portion of the shape data of the resin material in the molding condition data and the molding cycle time data, and a resin temperature conversion processing function is provided for calculating the resin material temperature through conversion processing based on the resin temperature conversion formula data.

13. The molding auxiliary device of the injection molding machine according to claim 12, characterized in that: The output processing function section includes a resin material temperature display section for displaying the resin material temperature obtained by the resin temperature conversion processing function on the display.

14. The molding auxiliary device of the injection molding machine according to claim 9, characterized in that: The calculation processing function unit includes a determination processing unit that performs determination processing on the degree of the estimated solid phase ratio and outputs a result of the determination processing.

15. The molding auxiliary device of the injection molding machine according to claim 9, characterized in that: The calculation processing function unit includes a determination processing unit that performs determination processing on the degree of the estimated resin decomposition rate and outputs a result of the determination processing.

16. The molding auxiliary device of the injection molding machine according to claim 9, characterized in that: The calculation processing function unit includes a determination processing unit that performs determination processing on the degree of the estimated solid phase ratio and the estimated resin decomposition ratio and outputs the result of the determination processing.

17. The molding auxiliary device of the injection molding machine according to claim 14, 15 or 16, characterized in that: The output processing function section includes a determination result display section that displays a result of the determination processing output from the determination processing section.

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