Injection molding machine, injection molding machine system, and management device

Abstract

The present application provides a technique capable of automatically collecting data related to an anomaly of an injection molding machine. An injection molding machine (1) according to an embodiment starts collecting data related to the injection molding machine (1) of a predetermined content in a case where an event that can be a cause of an anomaly occurs. The event that can be a cause of an anomaly includes, for example, a change (for example, a change in a control parameter) or an update (for example, an update of software) related to an action of the injection molding machine (1) according to an input from the outside (for example, an input accepted from a user, a signal received from a management device (2), or the like).

Description

Technical Field

[0001] This invention relates to an injection molding machine, etc. Background Technology

[0002] For example, in industrial machinery such as injection molding machines, there is a known technology where, when an abnormality occurs, the user operates according to instructions and collects data for abnormality diagnosis and analysis (see Patent Document 1).

[0003] Previous technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2014-133378 Summary of the Invention

[0006] The technical problem to be solved by the invention

[0007] However, it is desirable to automatically collect data related to anomalies.

[0008] Therefore, in view of the above-mentioned issues, the object of the present invention is to provide a technology that can automatically collect data related to anomalies of injection molding machines.

[0009] means for solving technical problems

[0010] To achieve the above objectives, in one embodiment of the present invention, an injection molding machine is provided, comprising:

[0011] Mold closing device, used to close the mold assembly;

[0012] The injection device fills the mold assembly, which is closed by the mold closing device, with molding material; and

[0013] The ejector device removes the molded article from the mold assembly after the molding material filled by the injection device has cooled and solidified.

[0014] In the event of an event that could be the cause of an anomaly, begin collecting pre-defined data related to the injection molding machine.

[0015] Furthermore, in another embodiment of the present invention, an injection molding machine system is provided, comprising an injection molding machine and a management device capable of communicating with the injection molding machine. Tool It includes: a mold closing device for closing the mold assembly; an injection device for filling the mold assembly, which is closed by the mold closing device, with molding material; and an ejection device for removing the molded article from the mold assembly after the molding material filled by the injection device has cooled and solidified.

[0016] In the event that an event occurs in the injection molding machine that could be a cause of an anomaly, the management device controls the injection molding machine to begin collecting pre-defined data related to the injection molding machine.

[0017] Furthermore, in another embodiment of the present invention, a management device is provided, configured to communicate with an injection molding machine, the injection molding machine comprising: a mold clamping device for clamping a mold assembly; an injection device for filling the mold assembly, which is clamped by the mold clamping device, with molding material; and an ejection device for removing a molded article from the mold assembly after the molding material filled by the injection device has cooled and solidified, and controlling the injection molding machine to begin collecting predetermined data related to the injection molding machine in the event that an event occurs in the injection molding machine that may be the cause of an malfunction.

[0018] Invention Effects

[0019] According to the above embodiments, a technology can be provided that can automatically collect data related to anomalies of injection molding machines. Attached Figure Description

[0020] Figure 1 This is a diagram illustrating an example of the structure of an injection molding machine management system, which includes an injection molding machine.

[0021] Figure 2 This is a diagram illustrating an example of the structure of an injection molding machine management system, which includes an injection molding machine.

[0022] Figure 3 This is a diagram illustrating an example of the structure of the control system of an injection molding machine.

[0023] Figure 4 This is a diagram representing an example of the data conditions for each event in a set of multiple object events and the content of the collected object data.

[0024] Figure 5 This is an example diagram that represents information about specifying multiple object events, the data collection conditions for each of the multiple object events, and the content of the object data to be collected. Detailed Implementation

[0025] The embodiments will now be described with reference to the accompanying drawings.

[0026] [Structure of Injection Molding Machine Management System]

[0027] First, refer to Figure 1 , Figure 2 The structure of the injection molding machine management system SYS involved in this embodiment will be described.

[0028] Figure 1, Figure 2 This diagram illustrates an example of the injection molding machine management system SYS according to this embodiment. Specifically, Figure 1 The image depicts a side sectional view showing the state of injection molding machine 1 when the mold is fully opened. Figure 2 The figure depicts a side sectional view showing the state of the injection molding machine 1 when the mold is closed. Hereinafter, in the figures of this embodiment, the X-axis, Y-axis and Z-axis are perpendicular to each other, the positive and negative directions of the X-axis (hereinafter referred to as "X direction") and the positive and negative directions of the Y-axis (hereinafter referred to as "Y direction") represent the horizontal direction, and the positive and negative directions of the Z-axis (hereinafter referred to as "Z direction") represent the vertical direction.

[0029] The injection molding machine management system SYS (an example of an injection molding machine system) includes multiple (three in this example) injection molding machines 1 and a management device 2.

[0030] In addition, the injection molding machine management system SYS can contain one, two, or more than four injection molding machines.

[0031] <Structure of an Injection Molding Machine>

[0032] Injection molding machine 1 performs a series of actions to obtain a molded product.

[0033] Furthermore, injection molding machine 1 is communicatively connected to management device 2 via a defined communication line NW. Injection molding machine 1 can also be communicatively connected to other injection molding machines 1 via the communication line NW. The communication line NW may include, for example, a local area network (LAN) within the factory where injection molding machine 1 is located. The LAN can be wired, wireless, or a combination of both. The communication line NW may also include, for example, a wide area network (WAN) outside the factory where injection molding machine 1 is located. The WAN may include, for example, a mobile communication network with base stations as terminals. The mobile communication network may be compatible with, for example, 4G (4th Generation) or 5G (5th Generation) technologies, including LTE (Long Term Evolution). The WAN may also include, for example, a satellite communication network utilizing communication satellites. Furthermore, the WAN may also include, for example, the Internet. Furthermore, the communication line NW can also be a short-range wireless communication line corresponding to Bluetooth (registered trademark) communication or WiFi communication.

[0034] For example, injection molding machine 1 sends (uploads) data related to its operating status (hereinafter, "operating status data") to management device 2 via communication line NW. This allows management device 2 (or its manager or operator, etc.) to monitor the operating status and manage the maintenance schedule or operating schedule of injection molding machine 1. Furthermore, based on the operating status data, management device 2 generates control-related data (e.g., molding conditions) for injection molding machine 1 and sends it to injection molding machine 1, thereby enabling external control of injection molding machine 1.

[0035] Furthermore, for example, injection molding machine 1 can also act as a master unit, monitoring or controlling the operations of other injection molding machines 1 (as slave units) via communication line NW. Specifically, injection molding machine 1 (slave unit) can send operating status data to injection molding machine 1 (master unit) via communication line NW. Thus, injection molding machine 1 (master unit) can monitor the operations of other injection molding machines 1 (slave units). Furthermore, injection molding machine 1 (master unit) can also, based on the operating status data, simultaneously monitor the operating status of other injection molding machines 1 (slave units) and send operation-related control commands to them via communication line NW. Thus, injection molding machine 1 (master unit) can control the operations of other injection molding machines 1 (slave units).

[0036] The injection molding machine 1 includes a mold clamping device 100, an ejection device 200, an injection device 300, a moving device 400, and a control device 700.

[0037] <<Mold Closing Device>>

[0038] The mold closing device 100 performs mold closing, mold clamping, and mold opening of the mold device 10. The mold closing device 100 is, for example, horizontal, and the mold opening and closing direction is horizontal. The mold closing device 100 includes a fixed pressure plate 110, a movable pressure plate 120, a toggle seat 130, a connecting rod 140, a toggle mechanism 150, a mold closing motor 160, a motion conversion mechanism 170, and a mold thickness adjustment mechanism 180.

[0039] In the following description of the mold closing device 100, the direction of movement of the movable pressure plate 120 during mold closing will be explained. Figure 1 and Figure 2 The direction of movement of the movable pressure plate 120 during mold opening is set as the front (center right direction). Figure 1 and Figure 2 The left-middle direction is used as the rear direction for explanation.

[0040] The fixed pressure plate 110 is fixed relative to the frame Fr. The fixed mold 11 is installed on the surface of the fixed pressure plate 110 opposite to the movable pressure plate 120.

[0041] The movable pressure plate 120 is configured to move freely relative to the frame Fr in the mold opening and closing direction. A guide member 101 for guiding the movable pressure plate 120 is laid on the frame Fr. A movable mold 12 is mounted on the surface of the movable pressure plate 120 opposite to the fixed pressure plate 110.

[0042] The movable pressure plate 120 moves forward and backward relative to the fixed pressure plate 110 to perform mold closing, mold assembly, and mold opening.

[0043] The mold device 10 is configured to include a fixed mold 11 corresponding to the fixed pressure plate 110 and a movable mold 12 corresponding to the movable pressure plate 120.

[0044] The toggle seat 130 is connected to the fixed pressure plate 110 at a predetermined interval L and is mounted on the frame Fr so as to be freely movable in the mold opening and closing direction. For example, the toggle seat 130 can be configured to be freely movable along a guide laid on the frame Fr. In this case, the guide of the toggle seat 130 can be interchangeable with the guide 101 of the movable pressure plate 120.

[0045] In addition, the fixed pressure plate 110 is fixed relative to the frame Fr, and the toggle seat 130 is configured to move freely relative to the frame Fr in the mold opening and closing direction. Alternatively, the toggle seat 130 can be fixed relative to the frame Fr, and the fixed pressure plate 110 can be configured to move freely relative to the frame Fr in the mold opening and closing direction.

[0046] Connecting rods 140 connect the fixed pressure plate 110 and the toggle seat 130 at a distance L in the mold opening and closing direction. Multiple connecting rods 140 can be used (e.g., four). Each connecting rod 140 is parallel to the mold opening and closing direction and extends according to the clamping force. A connecting rod strain detector 141 is provided on at least one connecting rod 140 to detect the strain of the connecting rod 140. The connecting rod strain detector 141 is, for example, a strain gauge. The connecting rod strain detector 141 sends a signal indicating its detection result to the control device 700. For example, the detection result of the connecting rod strain detector 141 is used for detecting the clamping force, etc.

[0047] Alternatively, the connecting rod strain gauge 141 can be used instead, or any clamping force detector capable of detecting clamping force can be used. For example, the clamping force detector is not limited to a strain gauge and can be piezoelectric, capacitive, hydraulic, or electromagnetic, etc., and its installation position is not limited to the connecting rod 140.

[0048] A toggle mechanism 150 is disposed between a movable pressure plate 120 and a toggle seat 130, and allows the movable pressure plate 120 to move relative to the toggle seat 130 in the mold opening and closing direction. The toggle mechanism 150 consists of a crosshead 151 and a pair of linkages. Each linkage has a first link 152 and a second link 153 that are flexibly connected by a pin or the like. The first link 152 is oscillatingly mounted on the movable pressure plate 120 by a pin or the like, and the second link 153 is oscillatingly mounted on the toggle seat 130 by a pin or the like. The second link 153 is mounted on the crosshead 151 via a third link 154. When the crosshead 151 moves forward or backward relative to the toggle seat 130, the first link 152 and the second link 153 flex and extend, causing the movable pressure plate 120 to move forward or backward relative to the toggle seat 130.

[0049] Furthermore, the structure of the toggle mechanism 150 is not limited to... Figure 1 and Figure 2 The structure shown. For example, in Figure 1 and Figure 2 In this configuration, each link group has 5 nodes, but it can be 4, or it can be the combination of one end of the 3rd link 154 and the nodes of the 1st link 152 and the 2nd link 153.

[0050] The clamping motor 160 is mounted on the toggle seat 130 and operates the toggle mechanism 150. The clamping motor 160 moves the crosshead 151 forward and backward relative to the toggle seat 130, thereby extending and retracting the first link 152 and the second link 153, which in turn moves the movable pressure plate 120 forward and backward relative to the toggle seat 130. The clamping motor 160 is directly connected to the motion conversion mechanism 170, but it can also be connected to the motion conversion mechanism 170 via a belt, pulley, etc.

[0051] The motion conversion mechanism 170 converts the rotary motion of the mold clamping motor 160 into the linear motion of the crosshead 151. The motion conversion mechanism 170 includes a lead screw shaft 171 and a lead screw nut 172 screwed to the lead screw shaft 171. Ball bearings or rollers can be clamped between the lead screw shaft 171 and the lead screw nut 172.

[0052] The mold closing device 100 performs mold closing, mold closing, and mold opening processes under the control of the control device 700.

[0053] In the mold closing process, the crosshead 151 is advanced to the mold closing completion position by driving the mold closing motor 160, thereby causing the movable pressure plate 120 to advance so that the movable mold 12 contacts the fixed mold 11. For example, the position and speed of the crosshead 151 are detected using a mold closing motor encoder 161. The mold closing motor encoder 161 detects the rotation of the mold closing motor 160 and sends a signal indicating its detection result to the control device 700.

[0054] Furthermore, the crosshead position detector for detecting the position of the crosshead 151 and the crosshead speed detector for detecting the speed of the crosshead 151 are not limited to the mold clamping motor encoder 161; conventional detectors can be used. Similarly, the movable platen position detector for detecting the position of the movable platen 120 and the movable platen speed detector for detecting the speed of the movable platen 120 are not limited to the mold clamping motor encoder 161; conventional detectors can be used.

[0055] In the mold closing process, the mold closing motor 160 is further driven to advance the crosshead 151 from the completed mold closing position to the mold closing position, thereby generating a mold closing force. During mold closing, a cavity space 14 is formed between the movable mold 12 and the fixed mold 11, and the injection device 300 fills the cavity space 14 with liquid molding material. The filled molding material is solidified, thereby obtaining a molded product. There can be multiple cavity spaces 14, in which case multiple molded products can be obtained simultaneously.

[0056] In the mold opening process, the crosshead 151 is retracted to the mold opening position at a set speed by driving the mold closing motor 160, thereby causing the movable pressure plate 120 to retract so that the movable mold 12 separates from the fixed mold 11. Then, the ejector device 200 ejects the molded product from the movable mold 12.

[0057] The settings for the mold closing and mold closing processes are uniformly set as a series of settings. For example, the speed, position (including the mold closing start position, speed switching position, mold closing completion position, and mold closing position) or mold closing force of the crosshead 151 in the mold closing and mold closing processes are uniformly set as a series of settings. The mold closing start position, speed switching position, mold closing completion position, and mold closing position are arranged sequentially from back to front, and represent the start and end points of the intervals where speeds are set. The speed is set for each interval. There can be one or more speed switching positions. Speed ​​switching positions can be omitted. Only the mold closing position and mold closing force can be set.

[0058] Furthermore, the setting conditions in the mold opening process are also set in the same way. For example, the speed and position (including the mold opening start position, speed switching position, and mold opening completion position) of the crosshead 151 in the mold opening process are set uniformly as a series of setting conditions. The mold opening start position, speed switching position, and mold opening completion position are arranged sequentially from front to back, and represent the start and end points of the interval where the speed is set. The speed is set for each interval. There can be one or more speed switching positions. Speed ​​switching positions can be omitted. The mold opening start position and the mold closing position can be the same position. Furthermore, the mold opening completion position and the mold closing start position can be the same position.

[0059] In addition, the speed and position of the movable pressure plate 120 can be set instead of the speed and position of the crosshead 151. Furthermore, the clamping force can be set instead of the position of the crosshead (e.g., the mold closing position) and the position of the movable pressure plate.

[0060] The toggle mechanism 150 amplifies the driving force of the mold clamping motor 160 and transmits it to the movable pressure plate 120. Its amplification ratio is also referred to as the toggle ratio. The toggle ratio varies depending on the angle θ (hereinafter, "link angle") formed by the first link 152 and the second link 153. The link angle θ is determined by the position of the crosshead 151. The toggle ratio reaches its maximum when the link angle θ is 180°.

[0061] When the thickness of the mold assembly 10 changes due to replacement of the mold assembly 10, temperature changes of the mold assembly 10, etc., mold thickness adjustment is performed to obtain a specified mold closing force during mold closing. In mold thickness adjustment, for example, the distance L between the fixed pressure plate 110 and the toggle seat 130 is adjusted so that at the moment of mold contact between the movable mold 12 and the fixed mold 11, the connecting rod angle θ of the toggle mechanism 150 becomes a specified angle.

[0062] The mold clamping device 100 has a mold thickness adjustment mechanism 180, which adjusts the mold thickness by adjusting the gap L between the fixed pressure plate 110 and the toggle seat 130. The mold thickness adjustment mechanism 180 includes: a lead screw shaft 181 formed at the rear end of the connecting rod 140; a lead screw nut 182 held in the toggle seat 130 for free rotation; and a mold thickness adjustment motor 183 that rotates the lead screw nut 182 screwed to the lead screw shaft 181.

[0063] Lead screw shaft 181 and lead screw nut 182 are mounted on each connecting rod 140. The rotation of the die thickness adjustment motor 183 can be transmitted to multiple lead screw nuts 182 via the rotation transmission unit 185. Multiple lead screw nuts 182 can be rotated synchronously.

[0064] In addition, by changing the transmission path of the rotation transmission unit 185, it is also possible to make multiple lead screw nuts 182 rotate individually.

[0065] The rotation transmission unit 185 is composed of, for example, gears. At this time, a driven gear is formed on the outer periphery of each lead screw nut 182, a drive gear is installed on the output shaft of the die thickness adjustment motor 183, and an intermediate gear that meshes with multiple driven gears and drive gears is kept in the center of the toggle seat 130 so as to rotate freely.

[0066] Alternatively, instead of gears, the rotation transmission unit 185 can also be composed of belts, pulleys, etc.

[0067] The action of the die thickness adjustment mechanism 180 is controlled by the control device 700. The control device 700 adjusts the position of the toggle seat 130 of the lead screw nut 182 relative to the fixed pressure plate 110 by driving the die thickness adjustment motor 183 to rotate the lead screw nut 182, thereby adjusting the distance L between the fixed pressure plate 110 and the toggle seat 130.

[0068] The die thickness adjustment motor encoder 184 is used to detect the interval L. The die thickness adjustment motor encoder 184 detects the rotation amount and direction of the die thickness adjustment motor 183, and sends a signal indicating its detection result to the control device 700. The detection result of the die thickness adjustment motor encoder 184 is used to monitor and control the position and interval L of the toggle seat 130.

[0069] In addition, the toggle seat position detector for detecting the position of the toggle seat 130 and the interval detector for detecting the interval L are not limited to the die thickness adjustment motor encoder 184, and conventional detectors can be used.

[0070] The die thickness adjustment mechanism 180 adjusts the interval L by rotating one of the screw shaft 181 and screw nut 182 that are screwed together. Multiple die thickness adjustment mechanisms 180 or multiple die thickness adjustment motors 183 can be used.

[0071] In addition, the mold closing device 100 in this embodiment is a horizontal type with the mold opening and closing direction in the horizontal direction, but it can also be a vertical type with the mold opening and closing direction in the vertical direction.

[0072] Furthermore, the mold clamping device 100 of this embodiment has a mold clamping motor 160 as a drive source, but a hydraulic cylinder may be used instead of the mold clamping motor 160. Also, the mold clamping device 100 may have a linear motor for mold opening and closing, or it may have an electromagnet for mold clamping.

[0073] <<Ejection Device>>

[0074] After the molding material filled into the mold assembly 10 by the injection device 300 cools and solidifies, the ejection device 200 ejects the molded article from the mold assembly 10. The ejection device 200 includes an ejection motor 210, a motion conversion mechanism 220, and an ejection rod 230, etc.

[0075] In the following description of the ejector device 200, similarly to the description of the mold closing device 100, the direction of movement of the movable pressure plate 120 during mold closing will be described. Figure 1 and Figure 2 The direction of movement of the movable pressure plate 120 during mold opening is set as the front (center right direction). Figure 1 and Figure 2 The left-middle direction is used as the rear direction for explanation.

[0076] The ejector motor 210 is mounted on the movable pressure plate 120. The ejector motor 210 is directly connected to the motion conversion mechanism 220, but it can also be connected to the motion conversion mechanism 220 via a belt, pulley, etc.

[0077] The motion conversion mechanism 220 converts the rotary motion of the ejector motor 210 into the linear motion of the ejector rod 230. The motion conversion mechanism 220 includes a lead screw shaft and a lead screw nut screwed to the lead screw shaft. Ball bearings or rollers can be clamped between the lead screw shaft and the lead screw nut.

[0078] The ejector rod 230 is configured to move freely in and out of the through hole in the movable pressure plate 120. The front end of the ejector rod 230 contacts the movable component 15, which is configured to move freely in and out of the movable mold 12. The front end of the ejector rod 230 may or may not be connected to the movable component 15.

[0079] The ejection device 200 performs the ejection process under the control of the control device 700.

[0080] In the ejection process, the ejector rod 230 is advanced from the standby position to the ejection position at a set speed by driving the ejector motor 210, thereby advancing the movable part 15 to eject the molded part. Then, the ejector motor 210 is driven to retract the ejector rod 230 at a set speed, causing the movable part 15 to retract to its original standby position. For example, the position and speed of the ejector rod 230 are detected using an ejector motor encoder 211. The ejector motor encoder 211 detects the rotation of the ejector motor 210 and sends a signal indicating its detection result to the control device 700.

[0081] In addition, the ejector rod position detector for detecting the position of the ejector rod 230 and the ejector rod speed detector for detecting the speed of the ejector rod 230 are not limited to the ejector motor encoder 211, and conventional detectors can be used.

[0082] <<Injection Device>>

[0083] The injection unit 300 is mounted on a sliding base 301 that moves freely forward and backward relative to the frame Fr, and is configured to move freely forward and backward relative to the mold assembly 10. The injection unit 300 contacts the mold assembly 10 and fills the cavity space 14 within the mold assembly 10 with molding material. The injection unit 300 includes, for example, a cylinder 310, a nozzle 320, a screw 330, a metering motor 340, an injection motor 350, and a pressure detector 360.

[0084] In the following description of the injection device 300, the direction in which the injection device 300 approaches the mold assembly 10 will be described. Figure 1 and Figure 2 The left-center direction is set to the front, which will separate the injection device 300 from the mold device 10. Figure 1 and Figure 2 The right-center direction is used as the rear direction for explanation.

[0085] The cylinder body 310 heats the molding material supplied to it from the supply port 311. The molding material includes, for example, resin. The molding material is formed in granular form and supplied to the supply port 311 in a solid state. The supply port 311 is formed at the rear of the cylinder body 310. A cooler 312, such as a water-cooled cylinder, is provided on the outer periphery of the rear of the cylinder body 310. A heater 313, such as a belt heater, and a temperature detector 314 are provided on the outer periphery of the cylinder body 310, further forward than the cooler 312.

[0086] Cylinder block 310 along the axial direction of cylinder block 310 ( Figure 1 and Figure 2 The system is divided into multiple zones (left and right). A heater 313 and a temperature detector 314 are installed in each zone. For each zone, the control device 700 controls the heater 313 so that the temperature detected by the temperature detector 314 becomes the set temperature.

[0087] The nozzle 320 is located at the front end of the cylinder 310 and presses against the mold assembly 10. A heater 313 and a temperature detector 314 are provided on the outer periphery of the nozzle 320. The control device 700 controls the heater 313 so that the detected temperature of the nozzle 320 becomes the set temperature.

[0088] The screw 330 is configured to rotate freely and move forward and backward within the cylinder 310. When the screw 330 is rotated, the molding material is conveyed forward along the spiral grooves of the screw 330. As the molding material is conveyed forward, it is gradually melted by heat from the cylinder 310. As the liquid molding material is conveyed forward of the screw 330 and accumulates at the front of the cylinder 310, the screw 330 is retracted. Then, when the screw 330 is moved forward, the liquid molding material accumulated at the front of the screw 330 is injected from the nozzle 320 and fills the mold assembly 10.

[0089] The check ring 331 is installed at the front of the screw 330 so that it can move freely forward and backward. The check ring 331 acts as a check valve to prevent the molding material from flowing backward from the front of the screw 330 when the screw 330 is pushed forward.

[0090] When the screw 330 is advanced, the check ring 331 is pushed backward by the pressure of the molding material in front of the screw 330, and retracts relative to the screw 330 to a closed position that blocks the flow path of the molding material (see reference). Figure 2 This prevents the molding material accumulated in front of the screw 330 from flowing backward.

[0091] On the other hand, when the screw 330 is rotated, the check ring 331 is pushed forward by the pressure of the molding material being conveyed forward along the spiral groove of the screw 330, and advances relative to the screw 330 to the open position where the flow path of the molding material is opened (see reference). Figure 1 Thus, the molding material is conveyed to the front of the screw 330.

[0092] The check ring 331 can be either a cotransformer that rotates with the screw 330 or a non-cotransformer that does not rotate with the screw 330.

[0093] Additionally, the injection device 300 may have a drive source that moves the check ring 331 back and forth relative to the screw 330 between an open position and a closed position.

[0094] The metering motor 340 rotates the screw 330. The drive source for rotating the screw 330 is not limited to the metering motor 340; for example, it could be a hydraulic pump.

[0095] The injection motor 350 moves the screw 330 forward and backward. A motion conversion mechanism is provided between the injection motor 350 and the screw 330 to convert the rotational motion of the injection motor 350 into the linear motion of the screw 330. This motion conversion mechanism may include, for example, a lead screw shaft and a lead screw nut screwed to the lead screw shaft. Ball bearings, rollers, etc., may be provided between the lead screw shaft and the lead screw nut. The drive source for moving the screw 330 forward and backward is not limited to the injection motor 350; for example, it may be a hydraulic cylinder.

[0096] Pressure detector 360 detects the pressure transmitted between injection motor 350 and screw 330. Pressure detector 360 is located in the force transmission path between injection motor 350 and screw 330, and detects the pressure acting on pressure detector 360.

[0097] The pressure detector 360 sends a signal indicating its detection result to the control device 700. The detection result of the pressure detector 360 is used to control and monitor the pressure exerted on the screw 330 from the molding material, the back pressure relative to the screw 330, and the pressure exerted on the molding material from the screw 330.

[0098] The injection device 300 performs metering, filling, and pressure holding processes under the control of the control device 700.

[0099] In the metering process, the metering motor 340 drives the screw 330 to rotate at a set speed, conveying the molding material forward along the spiral grooves of the screw 330. Simultaneously, the molding material is gradually melted. As the molten molding material is conveyed forward of the screw 330 and accumulates at the front of the cylinder 310, the screw 330 retracts. For example, the metering motor encoder 341 detects the rotational speed of the screw 330. The metering motor encoder 341 detects the rotation of the metering motor 340 and sends a signal indicating its detection result to the control device 700.

[0100] In addition, the screw speed detector for detecting the rotational speed of the screw 330 is not limited to the metering motor encoder 341, and conventional detectors can be used.

[0101] In the metering process, to prevent the screw 330 from retracting too rapidly, the injection motor 350 can be driven to apply a set back pressure to the screw 330. For example, a pressure detector 360 is used to detect the back pressure on the screw 330. The pressure detector 360 sends a signal indicating its detection result to the control device 700. If the screw 330 retracts to the metering completion position and a predetermined amount of molding material accumulates in front of the screw 330, the metering process is complete.

[0102] In the filling process, the injection motor 350 is driven to advance the screw 330 at a set speed, filling the cavity space 14 within the mold assembly 10 with the liquid molding material accumulated in front of the screw 330. For example, the position and speed of the screw 330 are detected using an injection motor encoder 351. The injection motor encoder 351 detects the rotation of the injection motor 350 and sends a signal indicating its detection result to the control device 700. If the screw 330 reaches a set position, a switch is made from the filling process to the holding pressure process (so-called V / P switching). The position where V / P switching occurs is also called the V / P switching position. The set speed of the screw 330 can be changed according to the position of the screw 330, time, etc.

[0103] Furthermore, during the filling process, after the screw 330 reaches the set position, it can be paused at that position before V / P switching. Instead of stopping the screw 330, it can also be moved forward or backward at a slight speed just before V / P switching. Moreover, the screw position detector for detecting the position of the screw 330 and the screw speed detector for detecting the speed of the screw 330 are not limited to the injection motor encoder 351; conventional detectors can be used.

[0104] During the holding pressure process, the injection motor 350 pushes the screw 330 forward, maintaining the pressure of the molding material at the front end of the screw 330 (hereinafter also referred to as "holding pressure") at a set pressure, and pushing the remaining molding material in the cylinder 310 towards the mold assembly 10. This replenishes any insufficient molding material in the mold assembly 10 due to cooling shrinkage. For example, the holding pressure is detected using a pressure detector 360. The pressure detector 360 sends a signal indicating its detection result to the control device 700. The set value of the holding pressure can be changed according to the elapsed time since the start of the holding pressure process.

[0105] During the holding pressure process, the molding material in the cavity space 14 within the mold assembly 10 is gradually cooled. Upon completion of the holding pressure process, the inlet of the cavity space 14 is blocked by the solidified molding material. This state is called gate sealing, which prevents the backflow of molding material from the cavity space 14. After the holding pressure process, a cooling process begins. During the cooling process, the molding material within the cavity space 14 solidifies. To shorten the molding cycle time, a metering process can be performed during the cooling process.

[0106] Furthermore, the injection device 300 in this embodiment is a coaxial screw type, but it can also be a pre-plasticizing type, etc. In a pre-plasticizing type injection device, the molding material molten in the plasticizing cylinder is supplied to the injection cylinder, and the molding material is injected from the injection cylinder into the mold device. In the plasticizing cylinder, the screw is configured to rotate freely or rotate freely and retract freely, and in the injection cylinder, the plunger is configured to retract freely.

[0107] Furthermore, the injection device 300 in this embodiment is horizontal with the cylinder 310's axis in the horizontal direction, but it can also be vertical with the cylinder 310's axis in the vertical direction. The mold clamping device combined with the vertical injection device 300 can be either vertical or horizontal. Similarly, the mold clamping device combined with the horizontal injection device 300 can be either horizontal or vertical.

[0108] <<Mobile Devices>>

[0109] The moving device 400 moves the injection device 300 forward and backward relative to the mold assembly 10. Furthermore, the moving device 400 presses the nozzle 320 relative to the mold assembly 10 to generate nozzle contact pressure. The moving device 400 includes a hydraulic pump 410, a motor 420 as a drive source, and a hydraulic cylinder 430 as a hydraulic actuator.

[0110] In the following description of the moving device 400, similarly to the description of the injection device 300, the direction in which the injection device 300 approaches the mold device 10 will be described. Figure 1 and Figure 2 The left-center direction is set to the front, which will separate the injection device 300 from the mold device 10. Figure 1 and Figure 2 The right-center direction is used as the rear direction for explanation.

[0111] In addition, mobile device 400 in Figure 1 , Figure 2 It can be arranged on one side of the cylinder 310 of the injection device 300, but it can be arranged on both sides of the cylinder 310, or it can be arranged symmetrically with the cylinder 310 as the center.

[0112] The hydraulic pump 410 has a first port 411 and a second port 412. The hydraulic pump 410 is a bidirectional rotating pump, generating hydraulic pressure by switching the rotation direction of the motor 420, drawing in working fluid (e.g., oil) from either the first port 411 or the second port 412 and discharging it from the other port. Furthermore, the hydraulic pump 410 can also draw working fluid from a tank and discharge working fluid from either the first port 411 or the second port 412.

[0113] Motor 420 operates hydraulic pump 410. Motor 420 drives hydraulic pump 410 by means of rotational direction and rotational torque corresponding to control signals from control device 700. Motor 420 can be an electric motor or an electric servo motor.

[0114] The hydraulic cylinder 430 has a cylinder body 431, a piston 432, and a piston rod 433. The cylinder body 431 is fixed relative to the injection device 300. The piston 432 divides the interior of the cylinder body 431 into a front chamber 435, which serves as a first chamber, and a rear chamber 436, which serves as a second chamber. The piston rod 433 is fixed relative to the fixed pressure plate 110.

[0115] The front chamber 435 of the hydraulic cylinder 430 is connected to the first port 411 of the hydraulic pump 410 via a first flow path 401. Working fluid discharged from the first port 411 is supplied to the front chamber 435 via the first flow path 401, thereby propelling the injection device 300 forward. The injection device 300 advances, pressing the nozzle 320 against the fixed mold 11. The front chamber 435 functions as a pressure chamber, generating the nozzle contact pressure of the nozzle 320 through the pressure of the working fluid supplied from the hydraulic pump 410.

[0116] On the other hand, the rear chamber 436 of the hydraulic cylinder 430 is connected to the second port 412 of the hydraulic pump 410 via the second flow path 402. The working fluid ejected from the second port 412 is supplied to the rear chamber 436 of the hydraulic cylinder 430 via the second flow path 402, thereby pushing the injection device 300 backward. The injection device 300 retracts and the nozzle 320 separates from the fixed mold 11.

[0117] Furthermore, the moving device 400 is not limited to a structure including a hydraulic cylinder 430. For example, instead of a hydraulic cylinder 430, an electric motor and a motion conversion mechanism that converts the rotational motion of the electric motor into the linear motion of the injection device 300 may also be used.

[0118] <<Control Device>>

[0119] The control device 700 directly sends control signals to the mold clamping device 100, the ejection device 200, the injection device 300, and the moving device 400 to perform various controls related to the injection molding machine 1.

[0120] The control device 700 can be implemented using any hardware or any combination of hardware and software. For example, the control device 700 is configured around a computer, which includes a CPU (Central Processing Unit) 701, a memory device 702, an auxiliary storage device 703, and an input / output interface device 704. The control device 700 performs various controls by having the CPU 701 execute programs installed in the auxiliary storage device 703. Furthermore, the control device 700 receives external signals or outputs signals to external devices via the interface device 704. For example, the control device 700 can communicatively connect to the management device 2 via a communication line NW through the interface device 704. The control device 700 can also communicatively connect to other injection molding machines 1 (control devices 700) via the communication line NW through the interface device 704. Furthermore, the control device 700 can also acquire programs from a specified recording medium through the interface device 704. The specified recording media include, for example, floppy disks, CDs (CompactDiscs), DVDs (Digital Versatile Discs), BDs (Blu-ray Discs), SD memory cards, and USB (Universal Serial Bus) storage devices. Furthermore, the control device 700 can also acquire (download) programs from an external computer (e.g., management device 2) via the interface device 704.

[0121] The functions of the control device 700 may be implemented by a single controller, or they may be shared by multiple controllers as described later.

[0122] The control device 700 repeatedly manufactures molded products by repeatedly causing the injection molding machine 1 to perform mold closing, mold closing, and mold opening processes. Furthermore, during the mold closing process, the control device 700 causes the injection unit 300 to perform metering, filling, and pressure holding processes.

[0123] The series of actions used to obtain a molded article, such as the actions from the start of a metering process based on injection unit 300 to the start of the next metering process based on injection unit 300, are also referred to as "injection" or "molding cycle". Furthermore, the time required for one injection is also referred to as "molding cycle time".

[0124] A single molding cycle may consist, for example, in the following order: metering, mold closing, mold clamping, filling, pressure holding, cooling, mold opening, and ejection. This sequence represents the order in which each process begins. Furthermore, the filling, pressure holding, and cooling processes occur from the start to the end of the mold clamping process. The end of the mold clamping process coincides with the start of the mold opening process.

[0125] Furthermore, to shorten the molding cycle time, multiple processes can be performed simultaneously. For example, the metering process can be performed during the cooling process of the previous molding cycle, and the mold closing process can also be performed at the beginning of the molding cycle. The filling process can begin during the mold closing process. The ejection process can begin during the mold opening process. Furthermore, if an on / off valve is provided to open and close the flow path of the nozzle 320 of the injection unit 300, the mold opening process can also begin during the metering process. This is because even if the mold opening process begins during the metering process, as long as the on / off valve closes the flow path of the nozzle 320, the molding material will not leak from the nozzle 320.

[0126] The control device 700 is connected to the operation device 750 and the display device 760, etc.

[0127] The operating device 750 (an example of an input unit) accepts the user's operation input related to the injection molding machine 1 and outputs the signal corresponding to the operation input to the control device 700.

[0128] The display device 760 displays various images under the control of the control device 700.

[0129] The display device 760 displays, for example, an operation screen related to the injection molding machine 1 corresponding to the operation input in the operation device 750.

[0130] The operation screen displayed on the display device 760 is used for settings related to the injection molding machine 1. Settings related to the injection molding machine 1 include, for example, setting the molding conditions related to the injection molding machine 1 (specifically, inputting setting values). This setting also includes, for example, settings related to selecting the types of detection values ​​from various sensors related to the injection molding machine 1 that are stored as data records during the molding operation. Furthermore, this setting includes, for example, setting the display specifications (e.g., the type of actual value displayed or the display method) of the detection values ​​(actual values) from various sensors related to the injection molding machine 1 during the molding operation on the display device 760. Multiple operation screens are prepared and switched between displaying on the display device 760, or displayed in overlapping layers. The user can perform settings related to the injection molding machine 1 (including inputting setting values) by observing the operation screen displayed on the display device 760 and operating the operation device 750.

[0131] Furthermore, under the control of the control device 700, the display device 760 displays information screens that provide the user with various information corresponding to the operations on the operation screen. Multiple information screens can be prepared and switched to be displayed on the display device 760, or displayed in an overlapping manner. For example, the display device 760 displays settings related to the injection molding machine 1 (e.g., settings related to the molding conditions of the injection molding machine 1). Also, for example, the display device 760 displays management information (e.g., information related to the operating performance of the injection molding machine 1, etc.).

[0132] The operating device 750 and the display device 760 can be configured as a touch panel type display and can be integrated.

[0133] Furthermore, while the operation device 750 and display device 760 are integrated in this embodiment, they can also be provided independently. Multiple operation devices 750 can also be provided. Alternatively, other input devices that accept input other than user operation input can be provided instead of the operation device 750. These other input devices may include, for example, a voice input device that accepts user voice input, or a gesture input device that accepts user gesture input. Voice input devices may include, for example, a microphone. Gesture input devices may include, for example, a camera (video recording device).

[0134] <Structure of the Management Device>

[0135] As described above, the management device 2 is communicatively connected to the injection molding machine 1 via the communication line NW.

[0136] The functions of management device 2 can be implemented by any hardware or any combination of hardware and software. For example, management device 2 may be centered around a computer, which includes a CPU, RAM and other memory devices, ROM and other non-volatile auxiliary storage devices, and an input / output interface device for external communication. Furthermore, management device 2 can implement various functions by loading programs installed in the auxiliary storage device into the memory device and executing them on the CPU. Management device 2 can, for example, obtain programs installed in the auxiliary storage device from a specified recording medium via the interface device. Specified recording media include, for example, floppy disks, CDs (Compact Discs), DVDs (Digital Versatile Discs), BDs (Blu-ray Discs), SD memory cards, USB (Universal Serial Bus) memory, etc. Furthermore, management device 2 can also, for example, obtain (download) programs installed in the auxiliary storage device from an external computer via the interface device.

[0137] The management device 2 is, for example, a server. The server may include, for example, a cloud server or a local server located in a remote location such as a management center outside the factory where the injection molding machine 1 is located. Furthermore, the server may also include, for example, an edge server located inside the factory where the injection molding machine 1 is located or in a location relatively close to the factory (e.g., a wireless base station or office near the factory). The management device 2 is also, for example, a terminal device (user terminal) used by users or managers of the injection molding machine 1. The user terminal may include, for example, a fixed terminal device (e.g., a desktop computer terminal) within the factory where the injection molding machine 1 is located. The user terminal may also include a mobile terminal (e.g., a smartphone, tablet, or laptop computer terminal) that is movable by users or managers of the injection molding machine 1.

[0138] The management device 2 can, for example, monitor the operating status of the injection molding machine 1 based on data sent (uploaded) from the injection molding machine 1, and manage the operating status of the injection molding machine 1. Furthermore, the management device 2 can perform various diagnostics, such as diagnosing abnormalities in the injection molding machine 1, based on the monitored operating status.

[0139] Furthermore, the management device 2 can, for example, provide information related to the operating status of the injection molding machine 1 to the user or manager of the injection molding machine 1 based on data sent from the injection molding machine 1. Specifically, the management device 2 can provide information related to the operating status of the injection molding machine 1 through a display device (e.g., a liquid crystal display, an organic EL (electroluminescence) display) or a sound output device (e.g., a speaker) included in the device.

[0140] Furthermore, the management device 2 can, for example, receive input related to the operation or settings of the injection molding machine 1 from the user or administrator of the injection molding machine 1 via an input device provided in this device. Thus, the user of the management device 2 can perform operations or settings related to the injection molding machine 1 from outside the injection molding machine 1.

[0141] Furthermore, the management device 2 can also transmit control data (e.g., data related to various setting conditions such as molding conditions) to the injection molding machine 1 via the communication line NW. Thus, the management device 2 can control the operation of the injection molding machine 1.

[0142] [Data Collection Function]

[0143] Next, refer to Figures 3-5 The details of the data collection function of injection molding machine 1 are explained.

[0144] <An example of data collection functionality>

[0145] Figure 3 This is a diagram illustrating an example of the structure related to the data collection function of injection molding machine 1.

[0146] like Figure 3 As shown, the injection molding machine 1, as a structure related to the data collection function, includes a control device 700, a driver 710, an encoder 720, an operating device 750, and a display device 760.

[0147] The control device 700 includes controllers 700A and 700B.

[0148] The controller 700A controls one or more controllers 700B, centrally controlling the entire injection molding machine 1. The controller 700A includes a data collection unit 7001, a data collection specified information storage unit 7002, a data collection data storage unit 7003, a screen display processing unit 7004, and a specified information setting unit 7005. The functions of the data collection unit 7001, the screen display processing unit 7004, and the specified information setting unit 7005 are implemented, for example, by loading various programs installed in the auxiliary storage device 703 of the controller 700A into the memory device 702 and executing them on the CPU 701. Furthermore, the functions of the data collection specified information storage unit 7002 and the data collection data storage unit 7003 are implemented, for example, by using a storage area defined in the auxiliary storage device 703 of the controller 700A.

[0149] The controller 700B controls the motion of various electric actuators (hereinafter referred to as "electric actuators") that enable the injection molding machine 1 to operate. The controller 700B is, for example, a motion controller. The actuators to be controlled include, for example, the clamping motor 160, the mold thickness adjustment motor 183, the ejector motor 210, the metering motor 340, the injection motor 350, and the motor 420 described above. The controller 700B generates control data related to the electric actuators to be controlled and outputs (sends) the control data to the driver 710. Furthermore, the controller 700B can also generate control data related to the encoder 720 (e.g., data related to setting conditions such as the acquisition cycle of detection data) and send it to the encoder 720.

[0150] In this example, the controller 700B is connected to the driver 710, and the driver 710 is connected to the encoder 720 via physical communication cables, forming a logical network (field network) that enables communication between the controller 700B and each of the driver 710 and encoder 720.

[0151] Alternatively, instead of building a field network, physical communication cables can be connected between the controller 700B and each of the drive 710 and encoder 720.

[0152] The driver 710 drives the electric actuator. The electric actuator may include, for example, the aforementioned clamping motor 160, mold thickness adjustment motor 183, ejector motor 210, metering motor 340, injection motor 350, and motor 420. The driver 710 outputs a drive current to the electric actuator based on control data received from the controller 700B. Thus, the controller 700B can control the operation of the electric actuator, which is the controlled object, via the driver 710. Furthermore, the driver 710 can send data related to the actual operating status of the driver 710 (this device) to the controller 700B (e.g., commanded value and actual value of the drive current).

[0153] Encoder 720 acquires detection data related to the mechanical position of the electric actuator. Encoder 720 may include, for example, the aforementioned clamping motor encoder 161, mold thickness adjustment motor encoder 184, ejector motor encoder 211, metering motor encoder 341, injection motor encoder 351, etc. Encoder 720 outputs (sends) the detection data to controller 700B. Therefore, controller 700B can control the electric actuator by simultaneously monitoring its position and operating state (e.g., speed, acceleration) based on the detection data related to its position.

[0154] The data collection unit 7001 collects data related to the injection molding machine 1. Specifically, the data collection unit 7001 collects data by sending a signal to a device capable of acquiring data of the target object at once, requesting that the device send the data of the target object. For example, the data collection unit 7001 can request the controller 700B, driver 710, encoder 720, etc., to send the data of the target object, and collect the data of the target object from them. Furthermore, as described later, when data collection conditions such as timing are specified, the data collection unit 7001 can send the data of the target object according to the data collection conditions by requesting the target device to send data according to the data collection conditions.

[0155] In addition, the controller 700B, driver 710, and encoder 720 are examples of data output devices that output various data to the controller 700A. The controller 700A can collect various data from other devices mentioned above. Other devices may include, for example, devices that measure the temperature state related to the injection molding machine 1 (e.g., temperature detector 314), devices that measure the pressure state related to the injection molding machine 1 (e.g., pressure detector 360), etc.

[0156] For example, in the event that may cause an abnormality in the injection molding machine 1, the data collection unit 7001 begins collecting pre-defined data related to the injection molding machine 1 according to prescribed data collection conditions. There may be multiple events as objects (hereinafter, "object events"). For each of the multiple object events, the content of the data to be collected based on the occurrence of the object event (hereinafter, "collected object data") is pre-defined. The data collected based on the occurrence of the object event may contain information needed for cause analysis of abnormalities that may occur due to the object event. Therefore, it is possible to start collecting data needed for cause analysis of abnormalities in advance, triggered by the occurrence of the object event. Thus, if an abnormality actually occurs due to the object event, it is possible to use the already collected data for cause analysis of the abnormality.

[0157] Data collection conditions may include, for example, the timing of data collection (hereinafter, "collection timing"). The collection timing may include, for example, a data collection period in addition to a specific timing. Furthermore, the data collection conditions may include, for example, the period from the start of data collection to the end of collection (hereinafter, "collection period"). Therefore, since the data collection period is limited, the processing load of the controller 700A caused by data collection can decrease as time elapses from the start of data collection, thus controlling the increase in the processing load of the controller 700A. The collection period may, for example, be predetermined to a value larger than the maximum value of the period from the occurrence of an object event to the occurrence of an anomaly due to the object event.

[0158] Furthermore, alternative methods can be used, such as setting a collection period or, based on this, to reduce the processing load of the controller 700A related to data collection based on the elapsed time since the start of data collection. For example, data collection conditions can be specified such that the amount of data to be collected decreases based on the elapsed time since the start of data collection. Specifically, data collection conditions can be specified such that the number of data types included in the data collected for each object event decreases based on the elapsed time since the start of data collection. For example, if the data collected for an object event includes both command values ​​and actual values ​​of specified parameters, the data collection conditions can be specified such that the command values ​​are deleted from the data collected after a specified time has elapsed since the start of data collection, leaving only the actual values ​​as the data collected. Furthermore, if the data collected for an object event includes data related to the position and speed of the electric actuator of the controlled object, the data collection conditions can be specified such that speed-related data is deleted from the data collected after a specified time has elapsed since the start of data collection, leaving only position-related data as the data collected. This is because speed-related data can be calculated based on position-related data. Furthermore, data collection conditions can be specified, for example, by extending the interval (cycle) of data collection from the current data collection to the next data collection based on the time elapsed since the start of data collection.

[0159] For example, Figure 4 This is a diagram illustrating the data collection conditions for each event in a set of multiple object events and the content of the collected object data.

[0160] like Figure 4 As shown, multiple object events that trigger the start of data collection (collection start trigger) include, for example, software updates of the controller 700B and driver 710. This is because, for example, if the software update ends in an incomplete state or the software itself has defects (bugs), the software cannot operate normally, and the injection molding machine 1 may malfunction. Software updates can be performed manually, for example, by a service personnel or other user of the injection molding machine 1 (hereinafter, "molding machine user"). In this case, an external device used by the molding machine user (e.g., a laptop computer terminal) can be connected to the control device 700 via a specified communication cable. Furthermore, software update data can be installed in the controller 700B and driver 710 based on commands input from the external device based on the molding machine user's operation. Additionally, software updates can also be automatically performed by distributing software update data from a management device 2 or similar device to the injection molding machine 1, based on instructions input from a higher-level device such as the management device 2 (an example of an external device) or the controller 700A.

[0161] Software updates that trigger data collection include, for example, updates to the software related to the interface for sending and receiving commands (command interface). In this example, the data collection conditions for updates to the software related to the command interface are as follows: the collection period is one week, and the collection timing is specified when commands are sent and received. Furthermore, in this example, the content (type) of the data collected for updates to the software related to the command interface is specified as command logs.

[0162] Furthermore, software updates that trigger data collection include, for example, updates to software related to the motion control of the electric actuator. In this example, regarding the data collection conditions for updates to the motion control-related software, the collection period is one week, and the data collection cycle, which is the timing of the collection, is defined as the control cycle (motion cycle) of the motion control. Also, in this example, the content (type) of the data collected for updates to the motion control-related software is defined as the speed command value, position command value, actual speed value, and actual position value of the electric actuator of the controlled object.

[0163] Furthermore, software updates triggered by data collection include, for example, updates to the software related to the speed control of the electric actuator. In this example, regarding the data collection conditions for updates to the speed control-related software, the collection period is one week, and the data collection cycle, which is the collection timing, is defined as the control cycle (servo cycle) of the electric actuator's servo control. Also, in this example, the content (type) of the data collected for updates to the speed control-related software is defined as the speed command value, actual speed value, and torque command value of the controlled electric actuator.

[0164] Furthermore, software updates triggered by data collection include, for example, updates to the software related to the current control (torque control) of the electric actuator. In this example, the data collection conditions for the update of the software related to current control are as follows: the collection period is one week, and the data collection cycle, which is the collection timing, is defined as the servo cycle. Moreover, in this example, the content (types) of the data collected for the update of the software related to current control includes the current command value, actual current value, actual voltage value, and PWM (Pulse Width Modulation) command value of the controlled electric actuator.

[0165] Furthermore, multiple object events that trigger the start of data collection (collection start trigger) include, for example, changes to control parameters in the controller 700B and the driver 710. This is because, for example, if the control parameters are not set to appropriate values, the control of the electric actuator cannot be performed properly, and as a result, the operation of the injection molding machine 1 may malfunction. The control parameters can be changed, for example, according to the specified operation input from the molding machine user received through the operating device 750. At this time, the control parameters can be changed directly according to the specified operation input from the molding machine user, or indirectly according to molding conditions, etc., which are changed according to the specified operation input from the molding machine user. Furthermore, the control parameters can also be changed automatically according to instructions input from upper-level devices such as the management device 2 and the controller 700A.

[0166] Changes in control parameters that trigger data collection include, for example, changes in control parameters related to the acceleration or deceleration of the electric actuator of the controlled object (acceleration / deceleration parameter changes). In this example, regarding the data collection conditions for acceleration / deceleration parameter changes, the collection period is one month, and the data collection cycle, which is the collection timing, is defined as the motion cycle. Furthermore, in this example, the content (type) of the collected object data for acceleration / deceleration parameter changes is defined as the speed command value, position command value, actual speed value, and actual position value of the electric actuator of the controlled object.

[0167] Furthermore, changes to control parameters that trigger data collection include, for example, changes to control parameters related to the control of pressure generated by the operation of the electric actuator of the controlled object (pressure control parameter changes). In this case, the electric actuator of the controlled object is, for example, an injection motor 350, which, as described above, is controlled to maintain the holding pressure in the pressure holding process at a set pressure. In this example, regarding the data collection conditions for changes to pressure control parameters, the collection period is one month, and the data collection cycle, as the collection timing, is defined as the control cycle related to pressure control (pressure control cycle). Furthermore, in this example, the content (type) of the collected object data for changes to pressure control parameters is defined as the command value of the pressure of the controlled object (pressure command value), the actual value of the pressure (actual pressure value), the speed command value of the electric actuator of the controlled object, and the actual speed value.

[0168] Furthermore, changes to control parameters that trigger data collection include, for example, changes to control parameters related to the speed servo control of the electric actuator of the controlled object (speed servo control parameter changes). In this example, regarding the data collection conditions for speed servo control parameter changes, the collection period is one month, and the data collection cycle, which is the collection timing, is defined as the servo cycle. Also, in this example, the content (type) of the data collected for speed servo control parameter changes is defined as the speed command value, actual speed value, and torque command value of the electric actuator of the controlled object.

[0169] Furthermore, changes to control parameters that trigger data collection include, for example, changes to control parameters related to the current servo control of the controlled object's electric actuator (current servo control parameter changes). In this example, regarding the data collection conditions for changes to current servo control parameters, the collection period is one month, and the data collection cycle, which is the collection timing, is defined as the servo cycle. Moreover, in this example, the data collected for changes to current servo control parameters is defined as the current command value, actual current value, actual voltage value, and PWM command value of the controlled object's electric actuator.

[0170] Return to Figure 3 The data collection specification information storage unit 7002 (an example of a storage unit) stores information such as multiple object events that are specified as triggers for data collection, the data collection conditions for each of the multiple object events, and the content of the object data to be collected (hereinafter, "data collection specification information").

[0171] The data collection specification information may include, for example, information specifying multiple object events (hereinafter, "object event specification information"). Furthermore, the data collection specification information may include, for example, information specifying (defining) the data collection conditions for each of the multiple object events and the content of the object data to be collected (hereinafter, "collection condition / content specification information").

[0172] For example, in each predetermined control cycle, the data collection unit 7001 refers to the object event specification information to determine whether any of the specified multiple object events has occurred. If any of the object events specified in the object event specification information has occurred, the data collection unit 7001 refers, for example, to the collection condition / content specification information corresponding to the occurred object event. Then, the data collection unit 7001 begins collecting the specified content of the object data according to the specified data collection conditions.

[0173] For example, Figure 5 This is a diagram representing an example of data collection specified information (data collection specified information 5000).

[0174] like Figure 5As shown, the data collection specification information 5000 includes object event specification information 5100 and collection condition / content specification information 5200.

[0175] like Figure 5 As shown, the object event specification information 5100 is provided as table information representing a list of the contents of multiple object events. In the object event specification information 5100, as object events, changes in current gain (“current gain change”) as control parameters in the controller 700B and updates to software related to the command interface (“command I / F update”) are specified.

[0176] Collection condition / content specification information 5200 is provided as table information representing a list of data collection conditions and the content of the collected object data (“data type list”) for each of the multiple events specified in object event specification information 5100. Collection condition / content specification information 5200 includes collection condition / content specification information 5210 and 5220.

[0177] The collection condition / content specification information 5210 corresponds to the change in current gain specified by the object event specification information 5100. In the data collection conditions of the collection condition / content specification information 5210, the collection period is a period of 20 injection volumes, and the data collection period is specified as 100 μsec (microseconds). Furthermore, in the content of the collected object data in the collection condition / content specification information 5210, the torque command value and actual torque value of the electric actuator of the controlled object are specified.

[0178] The collection condition / content specification information 5220 corresponds to the software changes related to the command interface specified by the object event specification information 5100. In the data collection conditions of the collection condition / content specification information 5220, the collection period is one month, and the collection timing is specified for each communication with the upper controller 700A and the lower driver 710 of the controller 700B. Furthermore, in the content of the collected object data in the collection condition / content specification information 5220, command data sent to the upper controller 700A, command data received from the controller 700A, command data sent to the lower driver 710, and command data received from the driver 710 are specified.

[0179] The data collection unit 7001 determines in each specified control cycle whether any of the multiple object events specified in the object event specification information 5100 has occurred.

[0180] When a change in current gain related to the control of a specified electric actuator of the controlled object by the controller 700B is determined, the data collection unit 7001 refers to the collection condition / content specification information 5210 corresponding to the change in current gain. Furthermore, the data collection unit 7001 begins collecting specified target data according to the data collection conditions specified by the collection condition / content specification information 5210. Specifically, when a change in current gain is determined, the data collection unit 7001 begins collecting the torque command value and actual torque value of the target electric actuator at a period of 100 microseconds. And, when a period of 20 injection volumes has elapsed since the start of data collection, the data collection unit 7001 terminates data collection.

[0181] Furthermore, when it is determined that a change has been made to the software related to the command interface in the controller 700B, the data collection unit 7001 refers to the collection condition / content specification information 5220 corresponding to the change in the software related to the command interface. The data collection unit 7001 then begins collecting data from the specified collection targets according to the data collection conditions specified by the collection condition / content specification information 5220. Specifically, when it is determined that a change has been made to the software related to the command interface in the controller 700B, the data collection unit 7001 begins collecting transmitted command data or received command data between the controller 700A and the driver 710 of the controller 700B for each communication. The data collection unit 7001 terminates data collection after one month from the start of data collection.

[0182] Alternatively, data collection conditions can be specified uniformly for each event across multiple object events. In this case, the information related to the data collection conditions does not need to be managed for each individual event across multiple object events; the data collection specification information can only specify the content of the data collected for each event across multiple object events.

[0183] Return to Figure 3The data collected by the data collection unit 7001 is stored in the data collection and data storage unit 7003 in an accumulation manner. Specifically, similar to the software updates described above, the data in the data collection and data storage unit 7003 can be retrieved from an external device operated by the molding machine user via a communication cable connected to the control device 700. Furthermore, the data in the data collection and data storage unit 7003 can also be sent (uploaded) to the management device 2 upon request or automatically. Therefore, in cases such as when an anomaly occurs due to an object event, the cause of the anomaly can be analyzed based on the data accumulated in the data collection and data storage unit 7003. Moreover, the data accumulated in the data collection and data storage unit 7003 can be automatically cleared after a predetermined period since it was stored in the data collection and data storage unit 7003. This is because, after a certain period, it is possible to determine whether the data has been retrieved externally or is no longer needed due to no anomaly.

[0184] The display processing unit 7004 enables the display device 760 to display various information screens.

[0185] The screen display processing unit 7004 displays, for example, a confirmation screen (hereinafter, "designated information confirmation screen") on the display device 760 for the molding machine user to confirm the content of the data collection designated information storage unit 7002. Furthermore, the screen display processing unit 7004 may also display, for example, a setting screen (hereinafter, "designated information setting screen") on the display device 760 for setting (adding or changing) the content of the data collection designated information storage unit 7002. Thus, the molding machine user can operate the designated information setting screen via the operation device 750 to set the content of the data collection designated information. The designated information confirmation screen and the designated information setting screen may contain the same content. The following explanation assumes that the designated information confirmation screen and the designated information setting screen contain the same content.

[0186] The designated information setting unit 7005 (an example of a setting unit) sets (changes) the content of designated information for data collection based on the prescribed operation input received from the molding machine user via the operating device 750. For example, the designated information setting unit 7005 sets or changes the data collection conditions and the (content) of the collected object data for each object event based on the prescribed operation input received from the molding machine user via the operating device 750. Furthermore, the designated information setting unit 7005 can also, for example, add new object events and set the corresponding data collection conditions and the content (type) of the collected object data based on the prescribed operation input received from the molding machine user via the operating device 750, or set the deletion of object events.

[0187] Specifically, the designated information setting unit 7005 can set the content of the designated information to be collected based on the operation content of the designated information setting screen received through the operation device 750.

[0188] In the specified information setting screen, for example, as described above. Figure 4 As shown, a table can be displayed, including a list of object events and data collection conditions and the content of the collected object data for each object event. This allows the molding machine user to confirm the content of the specified information for the current data collection.

[0189] Furthermore, the data collection conditions and the content of the target data displayed on the specified information setting screen can be changed by the user via the operating device 750. Moreover, when the changed content is displayed, and a confirmation operation is performed via the operating device 750, the specified information setting unit 7005 can set the changed data collection specified information and update the data collection specified information in the data collection specified information storage unit 7002. Thus, the molding machine user can change the data collection conditions and the content of the target data via the specified information setting screen.

[0190] Furthermore, based on the prescribed input received through the operation device 750, a row corresponding to a new object event can be added to the table information on the designated information setting screen. In the newly added row of the table information, the content of the new object event, data collection conditions, and the content (type) of the object data to be collected can be input according to the prescribed input received through the operation device 750. Furthermore, when a confirmation operation is performed through the operation device 750 while the new input content is displayed, the designated information setting unit 7005 can add and set the new object event, the corresponding data collection conditions, and the content (type) of the object data to be collected to the data collection designated information, updating the data collection designated information storage unit 7002's data collection designated information. Similarly, based on the prescribed input received through the operation device 750, a row corresponding to a specific object event can be deleted from the table information on the designated information setting screen. Furthermore, when a row corresponding to a specific object event has been deleted, and a confirmation operation is performed via the operation device 750, the specified information setting unit 7005 can delete the specific object event for data collection specified information, along with the corresponding data collection conditions and the content (type) of the collected object data, and update the data collection specified information in the data collection specified information storage unit 7002. Thus, the molding machine user can add new object events or delete unwanted object events through the specified information setting screen.

[0191] Furthermore, the specified information setting screen can also be displayed on a display device installed in the management device 2 (e.g., a server, a fixed terminal device, a mobile terminal, etc.). That is, the functions of the data collection specified information storage unit 7002, the screen display processing unit 7004, and the specified information setting unit 7005 can also be provided in the management device 2. Therefore, the user of the management device 2 (e.g., the operator or manager of the injection molding machine 1) can confirm the data collection specified information from outside the injection molding machine 1, or set (change) the data collection specified information through the input device installed in the management device 2. At this time, the management device 2 sends the data collection specified information set (changed) according to the user's input to the injection molding machine 1, and it is reflected in the data collection specified information on the injection molding machine 1 side. Furthermore, it is also possible for data collected by the injection molding machine 1 to be sent to the management device 2, essentially making the management device 2 collect data related to the injection molding machine 1. In this case, the data collected by the injection molding machine 1 can be sent to the management device 2 according to a request (instruction) from the management device 2, or it can be sent to the management device 2 automatically. In the latter case, for example, the data collected by the injection molding machine 1 can be sent to the management device 2 after a predetermined time interval, or the data collected by the injection molding machine 1 can be sent to the management device 2 in real time.

[0192] <Another example of data collection functionality>

[0193] Part of the functionality of the data collection unit 7001 can also be transferred to the management unit 2.

[0194] Specifically, the management device 2 can also determine the occurrence of a target event based on the operating status data uploaded from the injection molding machine 1 and information related to various changes or updates to the injection molding machine 1 managed by this device, and control the injection molding machine 1 to start collecting data corresponding to the target event. At this time, the functions of the data collection designated information storage unit 7002, the screen display processing unit 7004, and the designated information setting unit 7005 are transferred to the management device 2. Furthermore, the data collection unit 7001 of the controller 700A can collect data of the content specified by the instruction according to the pre-defined or instruction-specified data collection conditions, based on the instructions from the management device 2, and record it in the data collection data storage unit 7003.

[0195] Furthermore, similar to the case described above, the data collected by the injection molding machine 1 can be sent to the management device 2, and the management device 2 can essentially collect data related to the injection molding machine 1.

[0196] [effect]

[0197] Next, the function of the injection molding machine management system SYS (injection molding machine 1, management device 2) involved in this embodiment will be explained.

[0198] In this embodiment, when an object event occurs that may be the cause of an anomaly, the injection molding machine 1 (controller 700A) begins to collect data related to the injection molding machine 1 with pre-defined content.

[0199] For example, in situations where data is needed for cause analysis after an anomaly occurs, the user needs to operate the injection molding machine 1 to reproduce the anomaly and collect specific data. Therefore, data collection for cause analysis can potentially involve a relatively large workload. Furthermore, understanding the content of the data required for cause analysis is already necessary. Thus, operations by specialized service personnel or by the molding machine user following instructions from service personnel are considered, raising concerns about the increasing complexity and sophistication of data collection-related tasks.

[0200] On the other hand, in order to deal with anomalies, the necessary data can be collected continuously, but this may increase the processing load on the control device 700 and affect the original operation of the injection molding machine 1. Furthermore, since the capacity of the non-volatile storage medium (e.g., auxiliary storage device 703, etc.) within the control device 700 is limited, it may be impractical to collect the necessary data continuously.

[0201] Furthermore, empirical observations and statistical verification indicate that events that alter the injection molding machine 1 (e.g., component replacement, control parameter changes, software updates, etc.) are highly likely to trigger malfunctions or other problems in the machine. Therefore, even if the injection molding machine 1 has been in use for a certain period after leaving the factory, there may be situations where the probability of malfunctions is low, and the necessity for data collection is low. Conversely, even in cases of short usage periods, there may be situations where the probability of malfunctions is high, and the necessity for data collection is high. Therefore, it is desirable to collect data in conjunction with situations where the probability of malfunctions is high.

[0202] In contrast, in this embodiment, without any warning signs of an anomaly, data collection for anomaly cause analysis can begin in advance, triggered by the occurrence of an object event that could potentially cause the anomaly. Therefore, if an actual anomaly occurs after the object event, the required data is already acquired, allowing the collected data to be directly used for anomaly cause analysis. In other words, the injection molding machine 1 can automatically collect the necessary data related to anomalies. Furthermore, since data collection is limited to situations where an object event that could potentially cause an anomaly has occurred, the increased processing load on the control device 700 (controller 700A) can be suppressed. Moreover, it is not necessary to collect data continuously, nor is it necessary to precisely collect data in conjunction with the occurrence of an anomaly or its warning signs; data collection can be performed automatically in situations where the probability of an anomaly is high based on experience or statistics. Therefore, the injection molding machine 1 (controller 700) can effectively and easily collect data for anomaly cause analysis.

[0203] Furthermore, in this embodiment, the object event may include changes or updates related to the operation of the injection molding machine 1 based on input from an external source. Specifically, changes related to the operation of the injection molding machine 1 triggered by data collection may include changes to the control parameters of the injection molding machine 1. And updates related to the operation of the injection molding machine 1 triggered by data collection may include software updates.

[0204] This is because if changes or updates are made to the operation of injection molding machine 1, then the changes or updates may trigger anomalies related to the operation of injection molding machine 1.

[0205] Furthermore, changes related to the operation of the injection molding machine 1 that trigger data collection can replace changes to the control parameters of the injection molding machine 1, or, in addition, include other changes related to the operation of the injection molding machine 1. Other changes related to the operation of the injection molding machine 1 include, for example, changes (replacements) to field devices such as the driver 710 and encoder 720, or to the controller 700B. In this case, when the field device or controller 700B is changed, a reconfiguration related to the communication (network structure) between the controller 700A and the changed device is performed manually or automatically. Therefore, for example, the controller 700A can determine the change (replacement) of these devices based on the communication-related reconfiguration and identify the occurrence of the data collection trigger (object event). Moreover, updates related to the operation of the injection molding machine 1 that trigger data collection can replace software updates, or, in addition, include other updates related to the operation of the injection molding machine 1 (e.g., updates to data used in control other than software).

[0206] Furthermore, in this embodiment, the data collection specification information storage unit 7002 stores information (data collection specification information) about the content of the collection object data for each of the specified multiple object events. Moreover, when an object event occurs, the injection molding machine 1 (controller 700A) can begin collecting collection object data with content pre-specified by the data collection specification information for that event.

[0207] Therefore, injection molding machine 1 can collect object data corresponding to the content of each of multiple object events.

[0208] Furthermore, in this embodiment, the data collection specification information specifies not only the data content of the object to be collected for each of the multiple object events, but also the data collection conditions. Moreover, when an object event occurs, the injection molding machine 1 (controller 700A) can begin collecting data containing the content specified in the data collection specification information, according to the data collection conditions specified in the data collection specification information, for the event that occurred.

[0209] Thus, injection molding machine 1 can collect data for each of multiple object events, with conditions corresponding to the object event.

[0210] Furthermore, in this embodiment, the operating device 750 accepts input from the user. Also, the designated information setting unit 7005 can, based on the specified input received by the operating device 750, set or change at least one of the data collection conditions and the content of the data of the collected object for each of the multiple object events specified by the data collection designated information.

[0211] Therefore, the molding machine user can change the data collection conditions and the content of the collected object data for each object event in the injection molding machine 1.

[0212] Furthermore, in this embodiment, the injection molding machine 1 can collect data in a manner that reduces the processing load related to data collection, based on the elapsed time since the start of data collection.

[0213] Therefore, injection molding machine 1 can suppress the overall processing load caused by data collection.

[0214] Furthermore, in this embodiment, the data collection period is predetermined, and the injection molding machine 1 (controller 700A) can end the data collection when the collection period has elapsed since the start of the data collection.

[0215] Therefore, specifically, injection molding machine 1 can suppress the overall processing load caused by data collection.

[0216] Furthermore, in this embodiment, the injection molding machine 1 (controller 700A) can reduce the amount of data collected based on the elapsed time since the start of data collection.

[0217] Therefore, specifically, injection molding machine 1 can suppress the overall processing load caused by data collection.

[0218] Furthermore, in this embodiment, the injection molding machine 1 (controller 700A) can extend the data collection cycle based on the elapsed time since the start of data collection.

[0219] Therefore, specifically, injection molding machine 1 can suppress the overall processing load caused by data collection.

[0220] Furthermore, in this embodiment, the management device 2 is configured to communicate with the injection molding machine 1, and in the event that an object event that may be the cause of an anomaly occurs in the injection molding machine 1, it can also control the injection molding machine 1 by starting to collect data related to the injection molding machine 1 with pre-defined content.

[0221] Thus, the injection molding machine management system SYS can, for example, uniformly manage the processing related to data collection for each of the multiple injection molding machines 1 on the management device 2 side.

[0222] [Transformation, Modification]

[0223] The embodiments have been described in detail above, but the present invention is not limited to the specific embodiments described therein, and various modifications and alterations can be made within the scope of the spirit described in the technical solution.

[0224] For example, in the above embodiment, the data collection method was described using injection molding machine 1 as an example, but the same method can be applied to any machine (e.g., other industrial machinery) or device (e.g., household appliances). Other industrial machinery includes, for example, machine tools, industrial robots, and stationary machinery fixed in a factory. Furthermore, other industrial machinery includes, for example, mobile construction machinery. Mobile construction machinery includes, for example, excavators, bulldozers, and other construction machinery; combine harvesters, and other agricultural machinery; and mobile cranes, and other transportation machinery.

[0225] Finally, this application claims priority based on Japanese Patent Application No. 2020-065109, filed on March 31, 2020, the entire contents of which are incorporated herein by reference.

[0226] Symbol Explanation

[0227] 1-Injection molding machine, 2-Management device, 100-Mold clamping device, 200-Ejection device, 300-Injection device, 400-Moving device, 700-Control device, 701-CPU, 702-Memory device, 703-Auxiliary storage device, 704-Interface device, 710-Driver, 720-Encoder, 750-Operating device (input unit), 760-Display device, 7001-Data collection unit, 7002-Data collection specified information storage unit (storage unit), 7003-Collected data storage unit, 7004-Screen display processing unit, 7005-Specified information setting unit (setting unit), SYS-Injection molding machine management system (injection molding machine system).

Claims

1. A control device for an injection molding machine, comprising a first storage unit, The injection molding machine is controlled such that when an event that could cause an malfunction occurs in the injection molding machine, pre-defined data related to the injection molding machine is collected, data is collected repeatedly, and data collection ends when a collection period pre-registered in the first storage unit has elapsed. The events include multiple events, including event 1 and event 2. The collection period differs depending on whether the first event occurs or the second event occurs.

2. A control device for an injection molding machine, comprising a first storage unit, The injection molding machine is controlled such that when an event that could be the cause of an malfunction occurs in the injection molding machine, pre-defined data related to the injection molding machine is started to be collected, data is collected multiple times consecutively, and data is collected in a manner that reduces the processing load related to data collection based on the elapsed time since the start of data collection, and data collection ends as a condition for the elapsed collection period pre-registered in the first storage unit.

3. A control device for an injection molding machine, comprising a first storage unit, The injection molding machine is controlled such that when an event that could cause an malfunction occurs in the injection molding machine, pre-defined data related to the injection molding machine is collected, data is collected repeatedly, and data collection ends when a collection period pre-registered in the first storage unit has elapsed. The events include multiple events, including event 1 and event 2. The types of data collected from the objects differ depending on whether the first event occurs or the second event occurs.

4. An injection molding machine comprising a first storage unit, When an event that could be the cause of an anomaly occurs, the system begins collecting pre-defined data related to the injection molding machine. This data collection is repeated multiple times, and ends when the collection period pre-registered in the first storage unit has elapsed. The events include multiple events, including event 1 and event 2. The collection period differs depending on whether the first event occurs or the second event occurs.

5. An injection molding machine comprising a first storage unit, When an event that could be the cause of an anomaly occurs, data related to the injection molding machine with pre-defined content is collected. Data is collected multiple times consecutively, and the data is collected in a manner that reduces the processing load related to data collection based on the elapsed time since the start of data collection. Data collection ends when the collection period pre-registered in the first storage unit has elapsed.

6. An injection molding machine comprising a first storage unit, When an event that could be the cause of an anomaly occurs, the system begins collecting pre-defined data related to the injection molding machine. This data collection is repeated multiple times, and ends when the collection period pre-registered in the first storage unit has elapsed. The events include multiple events, including event 1 and event 2. The types of data collected from the objects differ depending on whether the first event occurs or the second event occurs.

7. A system for an injection molding machine, comprising a first storage unit, The injection molding machine is controlled such that when an event that could cause an malfunction occurs in the injection molding machine, pre-defined data related to the injection molding machine is collected, data is collected repeatedly, and data collection ends when a collection period pre-registered in the first storage unit has elapsed. The events include multiple events, including event 1 and event 2. The collection period differs depending on whether the first event occurs or the second event occurs.

8. A system for an injection molding machine, comprising a first storage unit, The injection molding machine is controlled such that when an event that could be the cause of an malfunction occurs in the injection molding machine, pre-defined data related to the injection molding machine is started to be collected, data is collected multiple times consecutively, and data is collected in a manner that reduces the processing load related to data collection based on the elapsed time since the start of data collection, and data collection ends as a condition for the elapsed collection period pre-registered in the first storage unit.

9. A system for an injection molding machine, comprising a first storage unit, The injection molding machine is controlled such that when an event that could cause an malfunction occurs in the injection molding machine, pre-defined data related to the injection molding machine is collected, data is collected repeatedly, and data collection ends when a collection period pre-registered in the first storage unit has elapsed. The events include multiple events, including event 1 and event 2. The types of data collected from the objects differ depending on whether the first event occurs or the second event occurs.

Images