Adjusting device for injection molding machine and injection molding machine

Abstract

The present invention provides a technology capable of automatically suppressing generation of abnormal noise when abnormal noise is generated due to operation of a mechanical part of an injection molding machine. An adjustment device of an injection molding machine includes: an acquisition unit that acquires working noise generated due to operation of a mechanical part that constitutes the injection molding machine; an analysis unit that acquires a feature of the working noise acquired by the acquisition unit; a storage unit that stores a feature of abnormal noise generated due to operation of the mechanical part; a determination unit that determines the mechanical part that generates abnormal noise based on the feature acquired by the analysis unit and the feature stored by the storage unit; and an adjustment unit that adjusts an instruction for operation of the mechanical part determined by the determination unit.

Description

[0001] This application is a divisional application of the application filed on January 29, 2021, with application number 202110124700.1 and invention title "Adjustment device for injection molding machine and injection molding machine". Technical Field

[0002] This application claims priority based on Japanese Patent Application No. 2020-015496, filed on January 31, 2020. The entire contents of that Japanese application are incorporated herein by reference.

[0003] This invention relates to an adjustment device for an injection molding machine and an injection molding machine. Background Technology

[0004] The monitoring method of the injection molding machine in Patent Document 1 monitors the vibration and working noise of each working part of the injection molding machine according to each step of each molding process using an accelerometer and a microphone. Based on the period of the monitoring signal, it monitors the stable state of the working cycle of the molding process, and based on the abnormal value of each monitoring signal, it monitors the occurrence of abnormalities in each working part.

[0005] Patent Document 1: Japanese Patent Application Publication No. 5-50480

[0006] Previously, if abnormal noises such as vibration or sliding noise were generated due to the movement of mechanical parts in an injection molding machine, the user would contact a skilled maintenance technician. The technician would then identify the mechanical part causing the abnormal noise and adjust the instructions for its movement. Therefore, until a skilled technician arrived, the injection molding machine would either continue operating while generating abnormal noise or be shut down. Summary of the Invention

[0007] One aspect of the present invention provides a technology that can automatically suppress the generation of abnormal noise when abnormal noise is generated due to the movement of mechanical parts of an injection molding machine.

[0008] The adjustment device for an injection molding machine according to one aspect of the present invention includes:

[0009] The acquisition department acquires the operating noise generated by the movement of the mechanical parts that make up the injection molding machine;

[0010] The analysis unit acquires the characteristics of the operating noise obtained by the acquisition unit;

[0011] The storage unit stores the characteristics of abnormal noise generated by the movement of the mechanical parts;

[0012] The determination unit determines the mechanical part that generates abnormal noise based on the features obtained by the analysis unit and the features stored by the storage unit; and

[0013] The adjustment unit adjusts the instructions for the operation of the mechanical part determined by the determination unit.

[0014] Invention Effects

[0015] According to one aspect of the present invention, when abnormal noise is generated due to the movement of mechanical parts of an injection molding machine, the generation of abnormal noise can be automatically suppressed. Attached Figure Description

[0016] Figure 1 This is a diagram showing the state of the injection molding machine at the end of mold opening according to one embodiment.

[0017] Figure 2 This is a diagram showing the state of the injection molding machine during mold closing according to one embodiment.

[0018] Figure 3 This diagram illustrates the components of an adjustment device for an injection molding machine according to one embodiment, using functional blocks.

[0019] Figure 4 middle, Figure 4 (A) is a graph representing the frequency characteristics of the operating noise under normal conditions. Figure 4 (B) is a graph showing the frequency characteristics of the operating noise under abnormal conditions. Figure 4 (C) is a graph representing the frequency characteristics of abnormal noise.

[0020] Figure 5 It is a diagram representing a portion of an instance of a database.

[0021] Figure 6 It means Figure 5 The remaining part of the database is shown in the graph.

[0022] Figure 7 This is a diagram illustrating an example of a notch filter.

[0023] Figure 8 This is an example diagram representing the speed command production department.

[0024] Figure 9 This is a diagram showing an example of a gain correction unit.

[0025] Figure 10 This is a diagram illustrating an example of the proportional gain before and after correction in the filling process.

[0026] Figure 11 This diagram illustrates an example of the speed command before and after correction in the filling process.

[0027] Figure 12This is a diagram showing another example of setting up a calibration unit.

[0028] In the diagram: 10-Injection molding machine, 100-Mold clamping device, 200-Ejection device, 300-Injection device, 400-Moving device, 700-Control device, 710-Adjustment device, 711-Acquisition unit, 712-Analysis unit, 713-Storage unit, 714-Determination unit, 715-Adjustment unit, 716-Notch filter, 717-Switching unit, 718-Gain correction unit, 719-Setting correction unit. Detailed Implementation

[0029] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, in the drawings, the same or corresponding structures are sometimes labeled with the same symbols, and descriptions are omitted.

[0030] Figure 1 This is a diagram showing the state of the injection molding machine at the end of mold opening according to one embodiment. Figure 2 This diagram illustrates the mold-closing state of the injection molding machine according to one embodiment. In this specification, the X-axis, Y-axis, and Z-axis are mutually perpendicular directions. The X-axis and Y-axis represent horizontal directions, and the Z-axis represents vertical directions. When the mold-closing device 100 is horizontal, the X-axis represents the mold opening and closing direction, and the Y-axis represents the width direction of the injection molding machine 10. The negative side of the Y-axis is referred to as the operating side, and the positive side of the Y-axis is referred to as the opposite side of the operating side.

[0031] like Figures 1-2 As shown, the injection molding machine 10 includes a mold clamping device 100 for opening and closing a mold assembly 800, an ejector device 200 for ejecting the molded article formed by the mold assembly 800, an injection device 300 for injecting molding material into the mold assembly 800, a moving device 400 for moving the injection device 300 forward and backward relative to the mold assembly 800, a control device 700 for controlling each component of the injection molding machine 10, and a frame 900 for supporting each component of the injection molding machine 10. The frame 900 includes a mold clamping device frame 910 for supporting the mold clamping device 100 and an injection device frame 920 for supporting the injection device 300. The mold clamping device frame 910 and the injection device frame 920 are respectively mounted on the base plate 2 via horizontal adjusting casters 930. The control device 700 is arranged in the internal space of the injection device frame 920. The components of the injection molding machine 10 will be described below.

[0032] (Mold closing device)

[0033] In the description of the mold closing device 100, the moving direction of the movable pressure plate 120 when the mold is closed (e.g., the positive X-axis direction) is set to forward, and the moving direction of the movable pressure plate 120 when the mold is opened (e.g., the negative X-axis direction) is set to rearward.

[0034] The mold closing device 100 performs mold closing, pressurization, mold closing, depressurization, and mold opening of the mold device 800. The mold device 800 includes a fixed mold 810 and a moving mold 820.

[0035] The mold clamping device 100 is, for example, horizontal, and the mold opening and closing direction is horizontal. The mold clamping device 100 includes a fixed pressure plate 110 for mounting the fixed mold 810, a movable pressure plate 120 for mounting the moving mold 820, an elbow seat 130 spaced apart from the fixed pressure plate 110, a connecting rod 140 connecting the fixed pressure plate 110 and the elbow seat 130, an elbow mechanism 150 for moving the movable pressure plate 120 relative to the elbow seat 130 in the mold opening and closing direction, a mold clamping motor 160 for operating the elbow mechanism 150, a motion conversion mechanism 170 for converting the rotational motion of the mold clamping motor 160 into linear motion, and a mold thickness adjustment mechanism 180 for adjusting the distance between the fixed pressure plate 110 and the elbow seat 130.

[0036] The fixed pressure plate 110 is fixed to the mold closing device frame 910. The fixed mold 810 is installed on the surface of the fixed pressure plate 110 opposite to the movable pressure plate 120.

[0037] The movable pressure plate 120 is configured to move freely relative to the mold closing device frame 910 in the mold opening and closing direction. A guide member 101 for guiding the movable pressure plate 120 is laid on the mold closing device frame 910. A movable mold 820 is mounted on the surface of the movable pressure plate 120 opposite to the fixed pressure plate 110. By moving the movable pressure plate 120 forward and backward relative to the fixed pressure plate 110, the mold device 800 performs mold closing, pressure increase, mold closing, pressure release, and mold opening.

[0038] The toggle seat 130 is spaced apart from the fixed pressure plate 110 and is freely movable on the mold clamping device frame 910 in the mold opening and closing direction. Alternatively, the toggle seat 130 can be configured to move freely along a guide laid on the mold clamping device frame 910. The guide of the toggle seat 130 can also be shared with the guide 101 of the movable pressure plate 120.

[0039] In addition, in this embodiment, the fixed pressure plate 110 is fixed to the mold clamping device frame 910, and the toggle seat 130 can move freely relative to the mold clamping device frame 910 in the mold opening and closing direction. However, it can also be configured such that the toggle seat 130 is fixed to the mold clamping device frame 910, and the fixed pressure plate 110 can move freely relative to the mold clamping device frame 910 in the mold opening and closing direction.

[0040] Connecting rods 140 connect the fixed pressure plate 110 and the toggle seat 130 at intervals L along the mold opening and closing direction. Multiple connecting rods 140 can be used (e.g., four). The multiple connecting rods 140 are configured parallel to the mold opening and closing direction and extend according to the clamping force. At least one connecting rod 140 can be equipped with a connecting rod strain detector 141 to detect the strain of the connecting rod 140. The connecting rod strain detector 141 sends a signal indicating its detection result to the control device 700. The detection result of the connecting rod strain detector 141 is used for detecting the clamping force, etc.

[0041] Furthermore, in this embodiment, a connecting rod strain gauge 141 is used as the clamping force detector for detecting the clamping force, but the present invention is not limited to this. The clamping force detector is not limited to a strain gauge and can be piezoelectric, capacitance, hydraulic, or electromagnetic, etc., and its installation position is not limited to the connecting rod 140.

[0042] 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 has a crosshead 151 that moves in the mold opening and closing direction and a pair of linkages that extend and retract with the movement of the crosshead 151. Each linkage has a first linkage 152 and a second linkage 153 connected by pins or the like, allowing for free extension and retraction. The first linkage 152 is mounted to swing freely relative to the movable pressure plate 120 via pins or the like. The second linkage 153 is mounted to swing freely relative to the toggle seat 130 via pins or the like. The second linkage 153 is mounted to the crosshead 151 via a third linkage 154. When the crosshead 151 moves forward or backward relative to the toggle seat 130, the first linkage 152 and the second linkage 153 extend and retract, and the movable pressure plate 120 moves forward or backward relative to the toggle seat 130.

[0043] 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 also have 4. One end of the third link 154 can also be connected to the node between the first link 152 and the second link 153.

[0044] The clamping motor 160 is mounted on the toggle seat 130 and operates the toggle mechanism 150. The clamping motor 160 causes the first link 152 and the second link 153 to extend and retract relative to the toggle seat 130 by moving the crosshead 151 forward and backward, and also causes the movable pressure plate 120 to move forward and backward relative to the toggle seat 130. The clamping motor 160 is directly connected to the motion conversion mechanism 170, but can also be connected to the motion conversion mechanism 170 via a belt and pulleys.

[0045] The motion conversion mechanism 170 converts the rotary motion of the clamping motor 160 into the linear motion of the crosshead 151. The motion conversion mechanism 170 includes a lead screw shaft and a lead screw nut screwed onto the lead screw shaft. Ball bearings or rollers can be clamped between the lead screw shaft and the lead screw nut.

[0046] Under the control of the control device 700, the mold closing device 100 performs the mold closing process, the pressure raising process, the mold closing process, the pressure release process, and the mold opening process.

[0047] In the mold closing process, the crosshead 151 is advanced to the mold closing end position at a set speed by driving the mold closing motor 160, thereby advancing the movable pressure plate 120 and bringing the moving mold 820 into contact with the fixed mold 810. The position and speed of the crosshead 151 are detected, for example, 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.

[0048] Furthermore, the crosshead position detector for detecting the position of the crosshead 151 and the crosshead movement speed detector for detecting the movement 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 movement speed detector for detecting the movement speed of the movable platen 120 are not limited to the mold clamping motor encoder 161; conventional detectors can be used.

[0049] In the pressurization process, the mold clamping motor 160 is further driven to advance the crosshead 151 from the mold closing end position to the mold closing position, thereby generating a mold clamping force.

[0050] During the mold closing process, the mold closing motor 160 is driven to maintain the position of the crosshead 151 in the mold closing position. During the mold closing process, the mold closing force generated by the pressurization process is maintained. During the mold closing process, a cavity space 801 (see reference) is formed between the moving mold 820 and the fixed mold 810. Figure 2 The injection unit 300 fills the cavity space 801 with liquid molding material. The filled molding material is solidified, thereby obtaining a molded article.

[0051] The number of cavity spaces 801 can be one or more. In the latter case, multiple molded articles can be obtained simultaneously. An insert can be configured in a part of the cavity space 801, and molding material can be filled in another part of the cavity space 801. A molded article in which the insert and the molding material are integrally molded can be obtained.

[0052] During the depressurization process, the mold closing motor 160 is driven to retract the crosshead 151 from the mold closing position to the mold opening start position, thereby causing the movable pressure plate 120 to retract and reduce the mold closing force. The mold opening start position and the mold closing end position can be the same position.

[0053] In the mold opening process, the mold closing motor 160 is driven to cause the crosshead 151 to retract from the mold opening start position to the mold opening end position at a set moving speed, thereby causing the movable pressure plate 120 to retract and the moving mold 820 to separate from the fixed mold 810. Then, the ejector device 200 ejects the molded product from the moving mold 820.

[0054] The setting conditions in the mold closing process, the pressure raising process, and the mold closing process are set uniformly as a series of setting conditions. For example, the moving speed, position (including the mold closing start position, moving speed switching position, mold closing end position, and mold closing position) and mold closing force of the crosshead 151 in the mold closing process and the pressure raising process are set uniformly as a series of setting conditions. The mold closing start position, moving speed switching position, mold closing end position, and mold closing position are arranged sequentially from back to front, and represent the start and end points of the range for setting the moving speed. The moving speed is set for each range. There can be one or more moving speed switching positions. Alternatively, no moving speed switching position can be set. It is also possible to set only either the mold closing position or the mold closing force.

[0055] The settings for the depressurization and mold opening processes are also set in the same way. For example, the moving speed and position (mold opening start position, moving speed switching position, and mold opening end position) of the crosshead 151 in the depressurization and mold opening processes are set uniformly as a series of settings. The mold opening start position, moving speed switching position, and mold opening end position are arranged sequentially from front to back, and represent the start and end points of the range for setting the moving speed. The moving speed is set for each range. There can be one or more moving speed switching positions. Alternatively, no moving speed switching position can be set. The mold opening start position and the mold closing end position can be the same position. Furthermore, the mold opening end position and the mold closing start position can be the same position.

[0056] In addition, the moving speed and position of the movable pressure plate 120 can be set instead of the moving 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.

[0057] However, the toggle mechanism 150 amplifies the driving force of the clamping motor 160 and transmits it to the movable pressure plate 120. This amplification factor is also known as the toggle ratio. The toggle ratio varies depending on the angle θ (hereinafter also referred to as "link angle θ") 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°.

[0058] When the thickness of the mold assembly 800 changes due to replacement of the mold assembly 800, temperature changes of the mold assembly 800, etc., mold thickness adjustment is performed to obtain the 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 the linkage angle θ of the toggle mechanism 150 is a specified angle at the moment of mold contact between the moving mold 820 and the fixed mold 810.

[0059] The mold clamping device 100 includes a mold thickness adjustment mechanism 180. The mold thickness adjustment mechanism 180 adjusts the mold thickness by adjusting the distance L between the fixed pressure plate 110 and the toggle seat 130. Furthermore, the timing of the mold thickness adjustment is performed, for example, during the period from the end of the molding cycle to the start of the next molding cycle. The mold thickness adjustment mechanism 180 includes, for example, a lead screw shaft 181 formed at the rear end of the connecting rod 140, a lead screw nut 182 that is rotatably and non-retractably held in the toggle seat 130, and a mold thickness adjustment motor 183 that rotates the lead screw nut 182 screwed to the lead screw shaft 181.

[0060] Each connecting rod 140 is provided with a lead screw shaft 181 and a lead screw nut 182. The rotational driving force of the die thickness adjustment motor 183 can be transmitted to multiple lead screw nuts 182 via the rotational driving force transmission unit 185. Multiple lead screw nuts 182 can be rotated synchronously. Alternatively, multiple lead screw nuts 182 can be rotated individually by changing the transmission path of the rotational driving force transmission unit 185.

[0061] The rotary drive force transmission unit 185 is, for example, composed of gears. In this case, a driven gear is formed on the outer periphery of each lead screw nut 182, a drive gear is mounted 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 rotatably held at the center of the toggle seat 130. Alternatively, the rotary drive force transmission unit 185 may be composed of belts and pulleys instead of gears.

[0062] The operation of the die thickness adjustment mechanism 180 is controlled by the control device 700. The control device 700 drives the die thickness adjustment motor 183, causing the lead screw nut 182 to rotate. As a result, the position of the toggle seat 130 relative to the connecting rod 140 is adjusted, and the distance L between the fixed pressure plate 110 and the toggle seat 130 is adjusted. Alternatively, multiple die thickness adjustment mechanisms can be used in combination.

[0063] The interval L is detected using a die thickness adjustment motor encoder 184. 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 the 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 of the toggle seat 130 and the interval L. However, 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; conventional detectors can be used.

[0064] 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.

[0065] 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.

[0066] (Ejection device)

[0067] In the description of the ejector device 200, similar to the description of the mold closing device 100, the moving direction of the movable pressure plate 120 when the mold is closed (e.g., the positive X-axis direction) is set to forward, and the moving direction of the movable pressure plate 120 when the mold is opened (e.g., the negative X-axis direction) is set to rearward.

[0068] Ejection device 200 is mounted on movable pressure plate 120 and moves forward and backward together with movable pressure plate 120. Ejection device 200 has ejection rod 210 for ejecting molded article from mold device 800 and drive mechanism 220 for moving ejection rod 210 along the moving direction (X-axis direction) of movable pressure plate 120.

[0069] Ejector rod 210 is configured to move freely in and out of the through hole in movable pressure plate 120. The front end of ejector rod 210 contacts movable component 830 which is freely disposed inside moving mold 820. The front end of ejector rod 210 may or may not be connected to movable component 830.

[0070] The drive mechanism 220 includes, for example, an ejector motor and a motion conversion mechanism that converts the rotational motion of the ejector motor into the linear motion of the ejector rod 210. The motion conversion mechanism includes a lead screw shaft and a lead screw nut screwed to the lead screw shaft. Ball bearings or rollers may be clamped between the lead screw shaft and the lead screw nut.

[0071] The ejector device 200 performs the ejection process under the control of the control device 700. In the ejection process, the ejector rod 210 is moved forward from the standby position to the ejection position at a set speed, thereby causing the movable part 830 to move forward and eject the molded part. Then, the ejector motor is driven to move the ejector rod 210 backward at a set speed, causing the movable part 830 to return to the original standby position.

[0072] The position and movement speed of the ejector rod 210 can be detected, for example, using an ejector motor encoder. The ejector motor encoder detects the rotation of the ejector motor and sends a signal indicating its detection result to the control device 700. Furthermore, the ejector rod position detector for detecting the position of the ejector rod 210 and the ejector rod movement speed detector for detecting the movement speed of the ejector rod 210 are not limited to the ejector motor encoder; conventional detectors can be used.

[0073] (Injection device)

[0074] In the description of the injection device 300, unlike the description of the mold clamping device 100 and the description of the ejection device 200, the direction of movement of the screw 330 during filling (e.g., the negative X-axis direction) is set to forward, and the direction of movement of the screw 330 during metering (e.g., the positive X-axis direction) is set to rearward.

[0075] An injection unit 300 is mounted on a sliding base 301, which is configured to move freely forward and backward relative to an injection unit frame 920. The injection unit 300 is also configured to move freely forward and backward relative to a mold assembly 800. The injection unit 300 contacts the mold assembly 800 and fills the cavity space 801 within the mold assembly 800 with molding material. The injection unit 300 includes, for example, a cylinder 310 for heating the molding material, a nozzle 320 disposed at the front end of the cylinder 310, a screw 330 configured to move freely forward and backward and rotate freely within the cylinder 310, a metering motor 340 for rotating the screw 330, an injection motor 350 for moving the screw 330 forward and backward, and a pressure detector 360 for detecting the force transmitted between the injection motor 350 and the screw 330.

[0076] 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.

[0077] The cylinder block 310 is divided into multiple regions along its axial direction (e.g., the X-axis direction). A heater 313 and a temperature detector 314 are respectively installed in each of the multiple regions. A set temperature is set for each of the multiple regions, and the control device 700 controls the heater 313 so that the temperature detected by the temperature detector 314 becomes the set temperature.

[0078] A nozzle 320 is located at the front end of the cylinder 310 and presses against the mold device 800. 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.

[0079] 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 molten molding material is conveyed forward of the screw 330 and accumulates at the front of the cylinder 310, the screw 330 retracts. Then, when the screw 330 is moved forward, the molten molding material accumulated at the front of the screw 330 is injected from the nozzle 320 and fills the mold assembly 800.

[0080] A check ring 331 is installed at the front of the screw 330 as a check valve, which prevents the molding material from flowing backward from the front of the screw 330 when the screw 330 is pressed forward.

[0081] When the screw 330 is advanced, the check ring 331 is pressed 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.

[0082] On the other hand, when the screw 330 is rotated, the check ring 331 is pressed 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] Pressure detector 360 detects the force transmitted between injection motor 350 and screw 330. The detected force is converted into pressure by control device 700. Pressure detector 360 is located in the force transmission path between injection motor 350 and screw 330, and detects the force acting on pressure detector 360.

[0088] 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.

[0089] The injection unit 300 performs metering, filling, and pressure holding processes under the control of the control unit 700. The filling and pressure holding processes can be collectively referred to as the injection process.

[0090] In the metering process, the metering motor 340 is driven to rotate the screw 330 at a set speed, and the molding material is conveyed forward along the spiral groove 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. The rotational speed of the screw 330 is detected, for example, using a metering motor encoder 341. 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. Alternatively, the screw speed detector for detecting the rotational speed of the screw 330 is not limited to the metering motor encoder 341; conventional detectors can be used.

[0091] 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. The back pressure on the screw 330 is detected, for example, using a pressure detector 360. The pressure detector 360 sends a signal indicating its detection result to the control device 700. The metering process ends when the screw 330 retracts to the metering end position and a predetermined amount of molding material accumulates in front of the screw 330.

[0092] The position and speed of the screw 330 in the metering process are uniformly set as a series of preset conditions. For example, the metering start position, speed switching position, and metering end position are set. These positions are arranged sequentially from front to back and represent the start and end points of the set speed interval. The speed is set for each interval. There can be one or more speed switching positions, or no speed switching position can be set. Furthermore, the back pressure is set for each interval.

[0093] In the filling process, the injection motor 350 is driven to advance the screw 330 at a set speed, filling the cavity space 801 within the mold assembly 800 with the liquid molding material accumulated in front of the screw 330. The position and speed of the screw 330 are detected, for example, 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 the 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.

[0094] The position and moving speed of the screw 330 in the filling process are uniformly set as a series of preset conditions. For example, the filling start position (also called the "injection start position"), the moving speed switching position, and the V / P switching position are set. These positions are arranged sequentially from back to front and represent the start and end points of the set moving speed interval. The moving speed is set for each interval. There can be one or more moving speed switching positions. Alternatively, no moving speed switching position may be set.

[0095] The upper limit of the pressure of the screw 330 is set for each range of the screw 330's travel speed. The pressure of the screw 330 is detected by a pressure detector 360. When the detected value of the pressure detector 360 is below the set pressure, the screw 330 advances at the set travel speed. On the other hand, when the detected value of the pressure detector 360 exceeds the set pressure, in order to protect the mold, the screw 330 advances at a slower travel speed than the set travel speed, so that the detected value of the pressure detector 360 falls below the set pressure.

[0096] Furthermore, during the filling process, after the screw 330 reaches the V / P switching position, it can be paused at the V / P switching position before the V / P switch is performed. Alternatively, the screw 330 can be moved forward or backward at a slight speed instead of stopping before the V / P switch is about to occur. Moreover, the screw position detector for detecting the position of the screw 330 and the screw speed detector for detecting the movement speed of the screw 330 are not limited to the injection motor encoder 351; conventional detectors can be used.

[0097] In the holding pressure process, the injection motor 350 is driven to press 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 800. This replenishes the amount of molding material in the mold assembly 800 that is insufficient due to cooling shrinkage. The holding pressure is detected, for example, 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. The holding pressure and the holding time of the holding pressure can be set separately for multiple holding pressure processes, or they can be set uniformly as a series of setting conditions.

[0098] During the holding pressure process, the molding material in the cavity space 801 within the mold assembly 800 is gradually cooled. At the end of the holding pressure process, the inlet of the cavity space 801 is blocked by the solidified molding material. This state is called gate sealing, which prevents the backflow of molding material from the cavity space 801. After the holding pressure process, the cooling process begins. During the cooling process, the molding material within the cavity space 801 solidifies. To shorten the molding cycle time, a metering process can be performed during the cooling process.

[0099] 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, molten molding material in a 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 but not retract, or the screw is configured to rotate freely and retract freely. On the other hand, in the injection cylinder, the plunger is configured to retract freely.

[0100] 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.

[0101] (Mobile device)

[0102] In the description of the moving device 400, similar to the description of the injection device 300, the direction of movement of the screw 330 during filling (e.g., the negative X-axis direction) is set to forward, and the direction of movement of the screw 330 during metering (e.g., the positive X-axis direction) is set to rearward.

[0103] The moving device 400 moves the injection device 300 forward and backward relative to the mold device 800. Furthermore, the moving device 400 presses the nozzle 320 against the mold device 800, generating 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.

[0104] 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. Alternatively, 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.

[0105] 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.

[0106] The hydraulic cylinder 430 has a cylinder body 431, a piston 432, and a piston rod 433. The cylinder body 431 is fixed 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 to a fixed pressure plate 110.

[0107] 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 ejected from the first port 411 is supplied to the front chamber 435 via the first flow path 401, thereby pressing the injection device 300 forward. As the injection device 300 advances, the nozzle 320 is pressed against the fixed mold 810. The front chamber 435 functions as a pressure chamber, which generates the nozzle contact pressure of the nozzle 320 through the pressure of the working fluid supplied from the hydraulic pump 410.

[0108] 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 pressing the injection device 300 backward. The injection device 300 retracts and the nozzle 320 separates from the fixed mold 810.

[0109] In addition, in this embodiment, the moving device 400 includes a hydraulic cylinder 430, but the present invention is not limited thereto. For example, 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 be used instead of the hydraulic cylinder 430.

[0110] (Control device)

[0111] The control device 700 is, for example, composed of a computer, such as Figures 1-2 As shown, the device includes a CPU (Central Processing Unit) 701, a storage medium 702 such as a memory, an input interface 703, and an output interface 704. The control device 700 causes the CPU 701 to execute a program stored in the storage medium 702, thereby performing various controls. Furthermore, the control device 700 receives signals from the outside through the input interface 703 and sends signals to the outside through the output interface 704.

[0112] The control device 700 repeatedly manufactures molded products by performing metering, mold closing, pressurization, mold closing, filling, pressure holding, cooling, depressurization, mold opening, and ejection processes. The series of actions used to obtain the molded product, such as the action from the start of the metering process to the start of the next metering process, is also called "material injection" or "molding cycle." Furthermore, the time required for one material injection is also called "molding cycle time" or "cycle time."

[0113] A typical molding cycle may include, for example, the following steps in sequence: metering, mold closing, pressure increase, mold closing, filling, pressure holding, cooling, pressure release, mold opening, and ejection. This sequence refers to the order in which each step begins. The filling, pressure holding, and cooling steps occur during the mold closing step. Alternatively, the start of the mold closing step can be set to coincide with the start of the filling step. The end of the pressure release step coincides with the start of the mold opening step.

[0114] 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, or during the mold closing process. In this case, the mold closing process can also be set to be performed at the beginning of the molding cycle. Furthermore, the filling process can begin during the mold closing process. Furthermore, the ejection process can begin during the mold opening process. When an on / off valve is provided for the flow path of the nozzle 320, the mold opening process can begin during the metering process. 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.

[0115] In addition, a single molding cycle can include processes other than metering, mold closing, pressurization, mold closing, filling, pressure holding, cooling, depressurization, mold opening, and ejection.

[0116] For example, a pre-metering suction process can be performed after the pressure holding process and before the metering process begins, to retract the screw 330 to a pre-set metering start position. This reduces the pressure of the molding material accumulated in front of the screw 330 before the metering process begins, preventing the screw 330 from retracting abruptly when the metering process begins.

[0117] Furthermore, a post-metering back suction process can be performed after the metering process ends and before the filling process begins, retracting the screw 330 to a pre-set filling start position (also known as the "injection start position"). This reduces the pressure of the molding material accumulated in front of the screw 330 before the filling process begins, preventing leakage of the molding material from the nozzle 320 before the filling process begins.

[0118] The control device 700 is connected to the operation device 750, which receives user input, and the display device 760, which displays a screen. The operation device 750 and the display device 760 can be integrated, for example, using a touch panel. The touch panel, as the display device 760, displays a screen under the control of the control device 700. Information such as the settings of the injection molding machine 10 and the current status of the injection molding machine 10 can be displayed on the touch panel's screen. Furthermore, input operation sections such as buttons and input fields for receiving user input can be displayed on the touch panel's screen. The touch panel, as the operation device 750, detects user input on the screen and outputs a signal corresponding to the input operation to the control device 700. Thus, for example, the user can simultaneously check the information displayed on the screen and operate the input operation section on the screen to set the injection molding machine 10 (including inputting setting values). Furthermore, by operating the input operation section on the screen, the user can activate the injection molding machine 10 corresponding to the input operation section. Furthermore, the operation of the injection molding machine 10 can be, for example, the operation (including stopping) of the mold clamping device 100, the ejection device 200, the injection device 300, and the moving device 400. Also, the operation of the injection molding machine 10 can be the switching of a display screen shown on the touch panel of the display device 760.

[0119] Furthermore, while the operation device 750 and display device 760 of this embodiment are integrated as a single touch panel, they can be installed independently. Additionally, multiple operation devices 750 can be installed. The operation device 750 and display device 760 are located on the operation side (negative Y-axis direction) of the mold clamping device 100 (more specifically, the fixed pressure plate 110).

[0120] (Adjustment device for injection molding machine)

[0121] Figure 3 This diagram illustrates the components of an adjustment device for an injection molding machine according to one embodiment, using functional blocks. Figure 3 The functional blocks illustrated are conceptual and do not necessarily need to be physically arranged as shown. All or part of these functional blocks can be functionally or physically distributed and integrated in any unit. Regarding the processing functions performed by each functional block, all or any part of them can be implemented by a program executed by the CPU or by hardware based on wiring logic. (Further details will follow.) Figure 7-9 The same applies to 12.

[0122] The adjustment device 710 analyzes the characteristics of the operating noise generated by the movement of the mechanical parts constituting the injection molding machine 10, identifies the mechanical parts generating abnormal noise, and then adjusts the instructions for the movement of the identified mechanical parts. Therefore, when abnormal noise occurs, its generation can be automatically suppressed. As in the past, it is unnecessary to continue operating the injection molding machine 10 while abnormal noise is occurring, or to interrupt the operation of the injection molding machine 10 until a skilled technician, such as a maintenance worker, arrives. Furthermore, it eliminates the need for repeatedly testing parameters to identify the mechanical parts generating abnormal noise or to suppress its generation. Therefore, the time required to restart the injection molding machine 10 can be shortened. Moreover, since skilled technicians store their acquired techniques in the adjustment device 710, there is no concern about the loss of technical expertise.

[0123] The adjustment device 710 sends and receives information from the mold clamping device 100, ejection device 200, injection device 300, and moving device 400. The information sent by the adjustment device 710 to the mold clamping device 100 is, for example, a command to operate mechanical parts such as a motor. Furthermore, the information received by the adjustment device 710 from the mold clamping device 100 is a data set. This data set is detected by various detectors. The detectors detect position, speed, rotational speed, temperature, or pressure, etc.

[0124] The adjustment device 710 is provided as part of the injection molding machine 10, for example, in the control device 700. Because the adjustment device 710 is part of the injection molding machine 10, the commands for the operation of the mechanical parts of the injection molding machine 10 can be adjusted at a location within the injection molding machine 10. Compared to a case where the adjustment device 710 is located remotely away from the injection molding machine 10, it can more quickly suppress the generation of abnormal noise.

[0125] Alternatively, the adjustment device 710 can be installed separately from the injection molding machine 10, or it can be configured to send and receive information to the control device 700 of the injection molding machine 10 via a network such as the Internet. In this case, the adjustment device 710 sends and receives information to the mold clamping device 100, the ejection device 200, the injection device 300, and the moving device 400 via the control device 700.

[0126] like Figure 3As shown, the adjustment device 710 includes an acquisition unit 711 that acquires operating noise via a microphone 500. The microphone 500 converts the operating noise into an electrical signal and sends the converted electrical signal to the acquisition unit 711. The acquisition unit 711 can also store the operating noise of the mechanical parts of the injection molding machine 10 in a corresponding association with the operation of the injection molding machine 10, such as the process of the molding cycle. By storing the process in a corresponding association with the operating noise, the process that generates abnormal noise can be determined. Mechanical parts that do not operate in the determined process can be excluded from the candidates of abnormal noise sources, thereby enabling the determination of the source of abnormal noise with high accuracy.

[0127] Furthermore, the actions stored to establish a corresponding association with operating noise are not limited to processes; they can also include the rotational speed or velocity of mechanical parts. Details will be discussed later, but the frequency of abnormal noise can be a constant value inherent to the mechanical part, such as a resonant frequency, or it can be a variable value that changes according to the rotational speed or velocity of the mechanical part. Even in the latter case, by storing the rotational speed or velocity of the mechanical part, the mechanical part generating the abnormal noise can be identified.

[0128] In this embodiment, the number of microphones 500 is one, but it can also be multiple. When there are multiple microphones 500, each microphone 500 also sends an identification signal indicating its location to the acquisition unit 711. The acquisition unit 711 stores the operating noise of the mechanical parts of the injection molding machine 10 for each microphone 500. By storing the operating noise in a corresponding association with the location of the microphone 500, the location where abnormal noise is generated can be determined. Mechanical parts located in locations other than the determined location can be excluded from the candidate sources of abnormal noise, thereby enabling the source of abnormal noise to be determined with high accuracy.

[0129] like Figure 3 As shown, the adjustment device 710 includes an analysis unit 712 that acquires the characteristics of the operating noise obtained by the acquisition unit 711. The analysis unit 712 acquires the frequency characteristics of the operating noise, for example, through Fourier transform. The frequency characteristics of the operating noise include the frequency of the peak value, the intensity of the peak value, and the full width at half maximum (FWHM) of the peak value.

[0130] Figure 4 (A) is a graph representing the frequency characteristics of the operating noise under normal conditions. Figure 4 (B) is a graph showing the frequency characteristics of the operating noise under abnormal conditions. Figure 4 (C) is a graph representing the frequency characteristics of abnormal noise. By comparing the frequency characteristics of the operating noise under normal conditions with those under abnormal conditions, the frequency of the abnormal noise can be determined.

[0131] The analysis unit 712 can also filter the frequency characteristics obtained through Fourier transform and extract only peak values ​​above a predetermined intensity. This removes noise, thus enabling the determination of abnormal noise frequencies with high accuracy. Furthermore, the filtering process can be performed before the Fourier transform process.

[0132] The analysis unit 712 can also store the frequency characteristics of the operating noise of the injection molding machine 10 in a corresponding relationship with the operation of the injection molding machine 10, such as the process of the molding cycle. It can identify the process that generates abnormal noise. It can exclude mechanical parts that do not move in the identified process from the candidates of abnormal noise sources, thereby enabling the identification of the source of abnormal noise with high accuracy.

[0133] Furthermore, the analysis unit 712 can also store the frequency characteristics of the operating noise of the injection molding machine 10 in a corresponding relationship with the location of the microphone 500. This allows for the identification of the location generating abnormal noise. Mechanical parts located in locations other than the identified location can be excluded from the pool of candidates for abnormal noise sources, thereby enabling the identification of the abnormal noise source with high accuracy.

[0134] like Figure 3 As shown, the adjustment device 710 has a storage unit 713 that stores characteristics of abnormal noises generated by the operation of mechanical parts. When there are multiple mechanical parts, the storage unit 713 stores the mechanical parts in a corresponding association with the characteristics of the abnormal noises generated by the operation of the mechanical parts. An example of the database stored in the storage unit 713 is shown below. Figure 5 and Figure 6 middle.

[0135] exist Figure 5 and Figure 6 In this context, "injection shaft" refers to the mechanical part that drives the injection motor 350. Injection shafts may include, for example, the injection motor 350, a ball screw that converts the rotary motion of the injection motor 350 into the linear motion of the screw 330, and the screw 330 itself.

[0136] "Metering shaft" refers to the mechanical parts that move when driving the metering motor 340. Metering shafts include, for example, the metering motor 340, the belt that transmits the rotational motion of the metering motor 340, and the screw 330.

[0137] "Moving shaft" refers to a mechanical part that moves when driving motor 420. Examples of moving shafts include hydraulic pump 410 and hydraulic cylinder 430. Hydraulic cylinder 430 includes piston rod 433, etc.

[0138] "Mold clamping shaft" refers to the mechanical part that moves when driving the mold clamping motor 160. The mold clamping shaft includes, for example, the mold clamping motor 160, a ball screw that converts the rotational motion of the mold clamping motor 160 into the linear motion of the crosshead 151, a toggle mechanism 150 including the crosshead 151, and a movable pressure plate 120 that moves through the toggle mechanism 150.

[0139] "Ejector shaft" refers to the mechanical part that moves when driving the ejector motor. An ejector shaft may include, for example, the ejector motor, a motion conversion mechanism that converts the rotational motion of the ejector motor into the linear motion of the ejector rod 210, and the ejector rod 210 itself. The motion conversion mechanism may include, for example, a belt and a ball screw.

[0140] "Die thickness adjustment shaft" refers to the mechanical part that moves when driving the die thickness adjustment motor 183. The die thickness adjustment shaft includes, for example, a rotary drive force transmission unit 185 and a toggle seat 130. As described above, the rotary drive force transmission unit 185 is composed of gears and the like, and includes a speed reducer.

[0141] Storage unit 713 stores, for example, the frequency of abnormal noise generated by the movement of mechanical parts. The frequency of the abnormal noise is, for example, the resonant frequency of the mechanical parts. The resonant frequency is an inherent frequency of the mechanical parts and is a constant value. The resonant frequency does not depend on the rotational speed or velocity of the mechanical parts. Not only the resonant frequency of each mechanical part, but also the resonant frequencies of groups of multiple mechanical parts moving simultaneously can be registered in the database. Figure 5 and Figure 6 In the equation, H1~H5, H7~H8, H10~H11, H13~H16, H18~H20, H22 and H23 are resonant frequencies, which are constant values.

[0142] The storage unit 713 can also store the frequency of abnormal noise generated by the movement of mechanical parts as a function of the rotational speed or velocity of the mechanical parts. The frequency of abnormal noise sometimes changes depending on the rotational speed or velocity of the mechanical parts. In this case, it is also possible to identify the mechanical part generating the abnormal noise. The frequency of the abnormal noise is, for example, proportional to the rotational speed or velocity of the mechanical parts. In this case, the proportionality constant is recorded in the database. Figure 5 and Figure 6 In the equation, H6, H9, H12, H17, H21, and H24 are functions of the rotational speed of the mechanical parts.

[0143] exist Figure 5 and Figure 6 In the text, "X" indicates a process in which various mechanical parts may generate abnormal noise. For example, the mold clamping motor 160 may generate abnormal noise during mold closing, pressurization, mold closing, depressurization, mold opening, and mold opening limit. In addition, "mold opening limit" refers to the process in which the mold clamping motor 160 is driven in order to maintain the position of the crosshead 151 at the mold opening end position.

[0144] like Figure 5 and Figure 6 As shown, the storage unit 713 can also store the frequency of abnormal noise generated by the movement of mechanical parts in a corresponding relationship with the operation of the injection molding machine 10, such as a process. The process that generates abnormal noise can be determined. Mechanical parts that do not move in the determined process can be excluded from the candidates of abnormal noise sources, thereby enabling the determination of the abnormal noise source with high accuracy.

[0145] like Figure 3 As shown, the adjustment device 710 includes a determination unit 714, which determines the mechanical part that generates abnormal noise based on features acquired by the analysis unit 712 and features stored by the storage unit 713. For example, the determination unit 714 compares the frequency characteristics acquired by the analysis unit 712 with the frequency of the abnormal noise stored by the storage unit 713 to determine the mechanical part that generates abnormal noise.

[0146] Determining part 714, for example, comparison Figure 4 (A) shows the frequency characteristics of the normal operating noise and Figure 4 (B) shows the frequency characteristics of the operating noise during the abnormal condition, and determines... Figure 4 (C) shows the frequency of the peak value of the abnormal noise. Next, the determining unit 714 determines the frequency of the peak value of the abnormal noise and... Figure 5 and Figure 6 The database shown identifies the mechanical parts that are causing the abnormal noise.

[0147] The determination unit 714 can also determine the mechanical part generating the abnormal noise by considering not only the frequency characteristics obtained by the analysis unit 712 and the frequency of the abnormal noise stored by the storage unit 713, but also the rotational speed or velocity of the mechanical part. Even when the frequency of the abnormal noise changes according to the rotational speed or velocity of the mechanical part, the mechanical part generating the abnormal noise can still be determined.

[0148] The determination unit 714 can also determine the mechanical part that generates abnormal noise based on the features obtained by the analysis unit 712, the features stored by the storage unit 713, and the process that generates abnormal noise. If the process that generates abnormal noise is determined, mechanical parts that do not operate in the determined process can be excluded from the candidates of abnormal noise sources, thereby enabling the determination of the source of abnormal noise with high accuracy.

[0149] like Figure 3As shown, the adjustment device 710 includes an adjustment unit 715 that adjusts the instructions for the operation of the mechanical parts determined by the determination unit 714. Therefore, when abnormal noise is generated, the generation of abnormal noise can be automatically suppressed. Therefore, it is not necessary to continue operating the injection molding machine 10 or interrupt the operation of the injection molding machine 10 when abnormal noise is generated, as was the case previously.

[0150] like Figure 7 As shown, the adjustment unit 715 may include a notch filter 716, which corrects the instructions for the operation of the mechanical part determined by the determination unit 714 in order to remove frequency components of abnormal noise from the instructions. The notch filter 716 will be described below, but before that, regarding the instructions for the operation of the mechanical part, please refer to... Figure 7 Please provide an explanation.

[0151] The control device 700, for feedback control, includes a position command generation unit 721, a subtractor 722, a speed command generation unit 723, a torque command generation unit 724, and a current command generation unit 725. The position command generation unit 721 generates a position command θr for the mechanical part, the object of position control. The subtractor 722 calculates the deviation Δθ between the position command θr and the actual position θm. The actual position θm is detected by a position detector D. The position detector D is, for example, an encoder for a motor M. The motor M is, for example, a mold clamping motor 160, an ejector motor, a metering motor 340, an injection motor 350, or a motor 420. The speed command generation unit 723 generates a speed command Vr in a manner that makes the position command θr consistent with the actual position θm, i.e., the deviation Δθ becomes zero. The torque command generation unit 724 generates a torque command Tr in a manner that makes the speed command Vr consistent with the actual speed. The current command generation unit 725 generates a current command Ir in a manner that makes the torque command Tr consistent with the actual torque. Current is supplied to motor M in such a way that the current command Ir matches the actual current, thereby driving motor M.

[0152] The position command generation unit 721 generates a position command θr according to the settings of the input operation unit input on the display screen. For example... Figure 8 As shown, the speed command generation unit 723 generates the speed command Vr through PID calculations, etc. Figure 8 In this context, Kp represents the proportional gain, Ki represents the integral gain, Kd represents the derivative gain, and s is a complex number. Furthermore, the speed command generation unit 723 can also generate commands via PI calculations instead of PID calculations. Similar to the speed command generation unit 723, the torque command generation unit 724 generates the torque command Tr via PID calculations or PI calculations. And, similar to the speed command generation unit 723, the current command generation unit 725 generates the current command Ir via PID calculations or PI calculations. For each type of command, the control gains, such as the proportional gain Kp, integral gain Ki, and derivative gain Kd, are set.

[0153] Next, refer to Figure 7 The notch filter 716 will be described. As described above, the notch filter 716 corrects the command for the operation of the mechanical part determined by the determination unit 714, so as to remove the frequency components of abnormal noise from the command. For example, the notch filter 716 corrects the torque command Tr, so as to remove the frequency components of abnormal noise from the torque command Tr. The target of removal, i.e., the frequency components of abnormal noise, is the frequency of the operating noise of the mechanical part determined by the determination unit 714. The current command generation unit 725 generates the current command Ir in a manner that makes the corrected torque command Tr, corrected by the notch filter 716, consistent with the actual torque.

[0154] The notch filter 716 is used, for example, in the mold closing or opening process when the mold clamping shaft resonates, and corrects the torque command Tr of the mold clamping motor 160 to remove the resonant frequency components of the mold clamping shaft. Furthermore, the command corrected by the notch filter 716 is not limited to the torque command Tr.

[0155] The adjustment unit 715 may further include a switching unit 717 that switches whether to pass the correction command via the notch filter 716. The switching unit 717 passes the correction command via the notch filter 716 only when abnormal noise is generated, and does not pass the correction command via the notch filter 716 when no abnormal noise is generated. When no abnormal noise is generated, unnecessary calculations can be omitted, and the command can be output quickly.

[0156] Next, refer to Figure 9 The gain correction section will be explained. For example... Figure 9 As shown, the adjustment unit 715 includes a gain correction unit 718, which corrects the control gain used in the calculation of the command to reduce the magnitude of abnormal noise of the mechanical parts determined by the determination unit 714. The control gain is, for example, a proportional gain Kp, an integral gain Ki, or a derivative gain Kd.

[0157] For example, during the filling process, when a short-lived but high-volume abnormal noise is generated, the acceleration and deceleration of mechanical parts are too frequent. In this case, the gain correction unit 718 corrects the proportional gain Kp of the speed command generation unit 723 to slow down the operation of the injection motor 350. Furthermore, the volume depends on the frequency of the sound; the higher the frequency, the higher the volume.

[0158] Figure 10 This is a graph showing an example of the proportional gain before and after correction. In Figure 10 In the diagram, the dashed line represents the proportional gain before correction, and the solid line represents the proportional gain after correction. During the filling process, when abnormal noise with a short duration and high volume is generated, the gain correction unit 718 will... Figure 10The proportional gain Kp of the speed command generation unit 723 shown is suppressed to a relatively small value.

[0159] Figure 11 This diagram illustrates an example of the speed command before and after correction. Figure 11 In the diagram, the dashed line represents the speed command before correction, and the solid line represents the speed command after correction. (This is followed by a continuation of the previous sentence, which is not directly related to the previous paragraph.) Figure 10 The correction of the proportional gain Kp shown enables Figure 11 The speed command rises gradually. This reduces the magnitude of short-duration, high-volume abnormal noise during the filling process. Furthermore, the gain correction unit 718 can correct the proportional gain Kp to make the end of the speed command smoother.

[0160] Additionally, if the filling process is complete, then as follows: Figure 10 As shown, the gain correction unit 718 can also restore the proportional gain Kp of the speed command generation unit 723 to its original value. This is because after the filling process, other processes such as the pressure holding process are performed. After the pressure holding process, the next metering process is performed. The proportional gain Kp before correction can also be used in the pressure holding process or the metering process.

[0161] The gain correction unit 718 can also be applied to processes other than the filling process. For example, in the mold closing process, when a low-volume abnormal noise, such as a booming sound, is generated, the current of the mold closing motor 160 fluctuates and becomes unstable as it attempts to output greater torque. In this case, the gain correction unit 718 corrects the proportional gain Kp of the speed command generation unit 723 to a smaller value, thereby slowing down the operation of the mold closing motor 160. As a result, the magnitude of the low-volume abnormal noise, such as a booming sound, can be reduced.

[0162] Furthermore, the gain correction unit 718 can also be applied to pressure control processes, such as pressure holding or metering processes. In the pressure holding process, the injection motor 350 is driven to press the screw 330 forward, maintaining the pressure of the molding material in the front end of the screw 330 at a set pressure. In the metering process, to prevent the screw 330 from retracting too rapidly, the injection motor 350 is driven to apply a set back pressure to the screw 330.

[0163] In addition, in this embodiment, the gain correction unit 718 corrects the control gain of the speed command generation unit 723, but it can also correct the control gain of other command generation units. For example, the gain correction unit 718 can correct the control gain of the torque command generation unit 724, and it can also correct the control gain of the current command generation unit 725.

[0164] Next, refer to Figure 12 The setting and calibration section will be explained. For example... Figure 12As shown, the adjustment unit 715 may include a setting correction unit 719, which corrects pre-input settings to reduce the magnitude of abnormal noise from mechanical parts determined by the determination unit 714. As described above, the settings are input into the control device 700 and stored by operating the input operation unit set on the display screen.

[0165] For example, as mentioned above, during the filling process, when a short-lived but high-volume abnormal noise is generated, the mechanical parts accelerate or decelerate too abruptly. At this time, if... Figure 11 As shown, the calibration position setting of the calibration unit 719 can be used to make the rise of the speed command smoother. By setting the calibration unit 719, the same effect as the gain calibration unit 718 can be obtained. In addition, the calibration unit 719 can also be set to adjust the position to make the end of the speed command smoother.

[0166] The adjustment device 710 may include a display unit 731 that displays the content determined by the determination unit 714 on the display device 760. The content displayed on the display device 760 via the display unit 731 may include, for example, mechanical parts that generate abnormal noise, characteristics such as the frequency of the abnormal noise, and settings that need to be changed to reduce the magnitude of the abnormal noise. By displaying the content determined by the determination unit 714, the user of the injection molding machine 10 can be alerted. The user can change settings by operating the input operation unit provided on the display screen while observing the screen displayed via the display unit 731.

[0167] And, as Figure 3 As shown, the adjustment device 710 may include a learning unit 732, which acquires the characteristics of the operating noise when the mechanical part generating abnormal noise has been identified through the analysis unit 712, and updates the database stored in the storage unit 713. By updating the database through the learning unit 732, the accuracy of identifying the mechanical part generating abnormal noise can be improved.

[0168] And, as Figure 3 As shown, the adjustment device 710 may include a judgment unit 733, which, after receiving an adjustment command from the adjustment unit 715, determines whether the magnitude of the abnormal noise can be reduced. At this time, after receiving the adjustment command from the adjustment unit 715, the acquisition unit 711 acquires the operating noise, and the analysis unit 712 acquires the characteristics of the operating noise acquired by the acquisition unit 711. Based on these characteristics, the judgment unit 733 determines whether the magnitude of the abnormal noise can be reduced.

[0169] For example, when the peak intensity of the abnormal noise is less than a threshold, the determination unit 733 determines that the magnitude of the abnormal noise can be reduced. Conversely, when the peak intensity of the abnormal noise is greater than or equal to the threshold, the determination unit 733 determines that the magnitude of the abnormal noise cannot be reduced. The threshold can be preset, or the peak intensity of the abnormal noise obtained before the instruction is adjusted.

[0170] When the determination unit 733 determines that the abnormal noise level can be reduced, the injection molding machine 10 continues to operate. On the other hand, when the determination unit 733 determines that the abnormal noise level cannot be reduced, the adjustment unit 715 readjusts the command. The adjustment unit 715 repeats the adjustment command until the determination unit 733 determines that the abnormal noise level can be reduced.

[0171] When the judgment unit 733 determines that the abnormal noise cannot be reduced even if the adjustment unit 715 performs the adjustment command a predetermined number of times, the operation of the injection molding machine 10 is stopped. Alternatively, when the judgment unit 733 determines that the abnormal noise cannot be reduced even if the adjustment unit 715 performs the adjustment command once, the operation of the injection molding machine 10 may also be stopped.

[0172] However, sometimes the adjustment unit 715, by adjusting the command to reduce the magnitude of one abnormal noise, may produce another abnormal noise. In this case, the operation of the injection molding machine 10 can be stopped, or the adjustment unit 715 can be adjusted to reduce the magnitude of the other abnormal noise.

[0173] The history of adjustments based on the instructions from the adjustment unit 715 can also be stored in the storage unit 713. The storage unit 713 can also store the history of adjustments based on the instructions in a corresponding association with the injection process. This is because the adjustments based on the instructions from the adjustment unit 715 may be the reason for classifying the quality of the molded product into qualified and unqualified products, or the cause of other abnormalities.

[0174] The adjustment device for the injection molding machine and the embodiments of the injection molding machine involved in this invention have been described above, but this invention is not limited to the above embodiments. Various changes, modifications, substitutions, additions, deletions, and combinations can be made within the scope described in the technical solution. These, of course, also fall within the technical scope of this invention.

Claims

1. An adjustment device for an injection molding machine, comprising: The acquisition department acquires the operating noise generated by the movement of the mechanical parts that make up the injection molding machine; The analysis unit acquires the characteristics of the operating noise obtained by the acquisition unit; The storage unit stores the characteristics of abnormal noise generated by the movement of the mechanical parts; The determination unit determines the mechanical part that generates abnormal noise based on the features obtained by the analysis unit and the features stored by the storage unit. and The adjustment unit adjusts the instructions for the movement of the mechanical part as determined by the determination unit. The adjustment unit includes a gain correction unit that corrects the control gain used in the calculation of the command in order to reduce the magnitude of the abnormal noise of the mechanical part determined by the determination unit.

2. An injection molding machine, comprising: Mold closing device; mold opening and closing device; An ejector device ejects the molded article formed by the mold device; An injection device is used to inject molding material into the mold device; A moving device that allows the injection device to move forward or backward relative to the mold device; and The control device controls the mold clamping device, the ejection device, the injection device, and the moving device. The control device includes the adjustment device as described in claim 1.

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