Injection molding machine and controller

Abstract

This invention relates to injection molding machines and controllers, providing technology for more appropriately implementing real-time control processing related to the operation of industrial machinery such as injection molding machines. One embodiment of the injection molding machine (1) includes a mold clamping device (100), an injection unit (300), an ejection unit (200), and a controller (700). Specifically, the mold clamping device (100) clamps the mold assembly (10). The injection unit (300) fills the mold assembly (10), which is clamped by the mold clamping device (100), with molding material. The ejection unit (200) removes the molded product from the mold assembly (10) after the molding material filled by the injection unit (300) has cooled and solidified. The controller (700) outputs an interruption request according to a predetermined control cycle and performs control processing related to the operation of the injection molding machine (1) based on the interruption request. Furthermore, the controller (700) outputs an interruption request before the preparation of the data required for the control processing is completed, and begins the control processing after the preparation of the required data is completed.

Description

Technical Field

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

[0002] For example, in industrial machinery such as injection molding machines, various data, such as data output from various sensors, are used to perform control processing related to their actions according to a prescribed control cycle (see Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2006-73027 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In the control device (controller) of industrial machinery, an interrupt request is output according to a specified control cycle, and control processing related to the action of the industrial machinery is executed according to the interrupt request.

[0008] However, the required time for interrupt handling may vary depending on factors such as the overhead of interrupt handling and cache hit status during interrupt handling. Therefore, for example, if this required time is relatively longer, the start time of control processing based on the completion of data preparation required for control processing will be relatively slower, which may affect the real-time performance of control processing.

[0009] Therefore, in view of the above-mentioned issues, the object of the present invention is to provide a technology that enables more appropriate real-time control processing related to the operation of industrial machinery such as injection molding machines.

[0010] Methods for solving problems

[0011] To achieve the above objectives, one embodiment of the present invention provides an injection molding machine comprising:

[0012] Mold closing device, used to close the mold assembly;

[0013] An injection device fills the mold assembly, which is closed by the mold closing device, with molding material.

[0014] An ejector device removes the molded article from the mold assembly after the molding material filled by the injection device has cooled and solidified; and

[0015] The control device outputs interrupt requests at predetermined intervals and performs control processing related to the operation of the injection molding machine based on the interrupt requests.

[0016] The control device outputs the interrupt request before a trigger that serves as the basis for initiating the control process is generated, and begins the control process after the trigger is generated.

[0017] Furthermore, in another embodiment of the present invention, a controller is provided, which comprises:

[0018] The interrupt request output section outputs interrupt requests at a specified period; and

[0019] The control processing unit performs control processing related to the operation of the industrial machinery based on the interruption request.

[0020] The interrupt request output unit outputs the interrupt request before a trigger that serves as the basis for starting the control process is generated.

[0021] The control processing unit begins the control processing after the trigger is generated.

[0022] The effects of the invention

[0023] According to the above implementation method, real-time control processing related to the operation of industrial machinery such as injection molding machines can be more appropriately realized. Attached Figure Description

[0024] 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.

[0025] 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.

[0026] Figure 3 This is a diagram illustrating an example of the hardware structure of the control system of an injection molding machine.

[0027] Figure 4 This is a block diagram illustrating an example of the functional structure of a controller.

[0028] Figure 5 This is a timing diagram representing an example of the controller's actions.

[0029] Figure 6 This is a flowchart that roughly illustrates an example of the configuration process related to an interrupt request.

[0030] Figure 7 This is an example of a setting screen displayed on a display device.

[0031] Figure 8 This is a timing diagram showing the operation of the controller of the injection molding machine involved in the comparative example. Detailed Implementation

[0032] The embodiments will now be described with reference to the accompanying drawings.

[0033] [Overview of Injection Molding Machine Management System]

[0034] First, refer to Figure 1 , Figure 2 An overview of the injection molding machine management system SYS involved in this embodiment will be provided.

[0035] Figure 1 , Figure 2 This diagram illustrates an example of the injection molding machine management system according to this embodiment. Specifically, in Figure 1 The image depicts a side sectional view showing the state of the injection molding machine 1 when the mold opening is complete. Figure 2 The image depicts a side sectional view showing the state of the injection molding machine 1 when the mold is closed. The following is an example... Figure 1 , Figure 2 As shown, 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.

[0036] The injection molding machine management system SYS includes multiple injection molding machines 1 (3 in this example) and management devices 2.

[0037] Alternatively, the injection molding machine 1 included in the injection molding machine management system SYS can also be one machine.

[0038] <Injection Molding Machine>

[0039] Injection molding machine 1 (an example of industrial machinery) performs a series of actions to obtain a molded product.

[0040] Furthermore, the injection molding machine 1 is communicatively connected to the management device 2 via a designated communication line NW. Additionally, the injection molding machine 1 can also be communicatively connected to other injection molding machines 1 via the communication line NW.

[0041] The communication line NW can be, for example, a one-to-one communication line. Furthermore, the communication line NW can include a local area network (LAN) of the facility (factory) where the injection molding machine 1 is located. The LAN can be constructed using wired connections, wireless connections, or a combination of both. The communication line NW can also include a wide area network (WAN) outside the facility (factory) where the injection molding machine 1 is located. The WAN can, for example, include a mobile communication network that uses base stations as terminals. The mobile communication network can, for example, correspond to 4G (4G) including LTE (Long Term Evolution). th Generation: 4th generation), 5G(5 th Generation (5th generation), etc. Furthermore, a wide area network (WAN) may also include, for example, satellite communication networks utilizing communication satellites. Furthermore, a WAN may also include, for example, the Internet. Furthermore, a communication line (NW) may also include, for example, short-range communication lines corresponding to wireless communication standards such as Bluetooth (registered trademark) communication and WiFi communication.

[0042] For example, injection molding machine 1 sends (uploads) data related to its operating status (hereinafter referred to as "operating status data") and data related to its production status (hereinafter referred to as "production status data") to management device 2 via communication line NW. The operating status data may include, for example, measurement data and control data related to the operating status (e.g., position, speed, angular velocity, acceleration, etc.) of the driven parts of injection molding machine 1. Furthermore, the operating status data may include, for example, measurement data and control data related to the operating status (e.g., current, voltage, etc.) of the electric drive parts of injection molding machine 1. Furthermore, the operating status data may include, for example, measurement data and control data related to the operating status (e.g., working oil pressure, etc.) of the hydraulic drive parts. Furthermore, the operating status data may include, for example, data related to the temperature status of specified parts of injection molding machine 1. Thus, management device 2 can automatically or manually monitor the operating status based on input from management personnel or workers, and manage the maintenance schedule and operating plan of injection molding machine 1. Furthermore, the data related to production status includes, for example, data related to the production quantity (number of injections) of molded products from a specified time point. Thus, the management device 2 can monitor the production status of molded products based on the injection molding machine 1.

[0043] Furthermore, for example, injection molding machine 1 can act as the main machine to monitor or control the operation of other injection molding machines 1 (auxiliary machines) via communication line NW. Specifically, injection molding machine 1 (auxiliary machine) can send operating status data to injection molding machine 1 (main machine) via communication line NW. Thus, injection molding machine 1 (main machine) can monitor the operation of other injection molding machines 1 (auxiliary machines). Furthermore, injection molding machine 1 (main machine) can, based on the operating status data, simultaneously monitor the operating status of other injection molding machines 1 (auxiliary machines) and send operation-related control commands to them via communication line NW. Thus, injection molding machine 1 (main machine) can control the operation of other injection molding machines 1 (auxiliary machines).

[0044] <Management Device>

[0045] The management device 2 is communicatively connected to the injection molding machine 1 via the communication line NW, and manages the operating status and application status of the injection molding machine 1. The management device 2 can manage the operating status and application status of the injection molding machine 1 according to prescribed rules or autonomously. Furthermore, the management device 2 can manage the operating status and application status of the injection molding machine 1 based on various inputs received from users of the injection molding machine 1, such as managers and staff. In other words, the management device 2 can also support the management of the operating status and application status of the injection molding machine 1 by users such as managers and staff.

[0046] The functions of management device 2 are implemented through any hardware or any combination of hardware and software. For example, management device 2 is an information processing device including a CPU (Central Processing Unit), a memory device such as RAM (Random Access Memory), a non-volatile auxiliary storage device such as ROM (Read Only Memory), and an input / output interface device for communication with external devices. Furthermore, management device 2 can implement various functions by loading a program installed on the auxiliary storage device onto the memory device and executing it on the CPU. Management device 2 can, for example, obtain the program installed on 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, and USB (Universal Serial Bus) memory. Moreover, management device 2 can, for example, obtain (download) the program installed on the auxiliary storage device from an external computer via the interface device.

[0047] The management device 2 can be, for example, a cloud server or internal server located in a remote location such as a management center outside the factory where the injection molding machine 1 is located. Alternatively, the management device 2 can also be an edge server located inside the factory where the injection molding machine 1 is located, in a location relatively close to the factory (e.g., a wireless base station or base station room near the factory). Furthermore, the management device 2 can also be a terminal device (user terminal) used by users of the injection molding machine 1, such as managers or staff. The user terminal can be a management terminal device within the factory where the injection molding machine 1 is located, or a terminal device (user terminal) used by users of the injection molding machine 1. The management terminal device and user terminal can be, for example, a fixed terminal device such as a desktop PC (Personal Computer). Alternatively, the management terminal device and user terminal can also be portable (mobile) terminal devices that can be carried by users such as managers or staff of the injection molding machine 1. Portable terminal devices can include, for example, smartphones, tablets, and laptops.

[0048] For example, the management device 2 can grasp the operating status of the injection molding machine 1 based on the operating status 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 also perform various diagnoses, such as abnormality diagnosis of the injection molding machine 1, based on the operating status data it has grasped.

[0049] Furthermore, the management device 2 can, for example, manage the production status of the injection molding machine 1 based on the production status data sent (uploaded) from the injection molding machine 1.

[0050] Furthermore, for example, the management device 2 can also transmit control signals, including control information for the injection molding machine 1 (e.g., information related to various setting conditions), via the communication line NW. Thus, the management device 2 can control the operation of the injection molding machine 1.

[0051] [Structure of an Injection Molding Machine]

[0052] Next, continue to refer to Figure 1 , Figure 2 The structure of the injection molding machine is described.

[0053] like Figure 1 , Figure 2 As shown, 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 controller 700.

[0054] <<Mold Closing Device>>

[0055] 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.

[0056] 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 to the right). Figure 1 and Figure 2 The left-middle direction is used as the rear direction for explanation.

[0057] 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.

[0058] The movable pressure plate 120 can be configured to move freely relative to the frame Fr along the mold opening and closing direction. A guide member 101 is laid on the frame Fr to guide the movable pressure plate 120. The moving mold 12 is installed on the surface of the movable pressure plate 120 opposite to the fixed pressure plate 110.

[0059] 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.

[0060] 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.

[0061] The toggle seat 130 is connected to the fixed pressure plate 110 at a predetermined interval L and is movably mounted on the frame Fr in the mold opening and closing direction. The toggle seat 130 can be configured to move freely along a guide laid on the frame Fr, for example. In this case, the guide of the toggle seat 130 can also be interchangeable with the guide 101 of the movable pressure plate 120.

[0062] Alternatively, the fixed pressure plate 110 can be fixed relative to the frame Fr, and the toggle seat 130 can move freely relative to the frame Fr in the mold opening and closing direction.

[0063] 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 for detecting the strain of the connecting rod 140 can be installed on at least one 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 controller 700. The detection result of the connecting rod strain detector 141 is used, for example, for detecting the clamping force.

[0064] Alternatively, or in addition to the connecting rod strain detector 141, any clamping force detector suitable for detecting clamping force can be used. For example, the clamping force detector is not limited to a strain gauge, but can also be piezoelectric, capacitive, hydraulic, or electromagnetic, and its installation position is not limited to the connecting rod 140.

[0065] 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 linkage 152 and a second linkage 153 connected by pins to be freely flexible. The first linkage 152 is mounted to be freely oscillating relative to the movable pressure plate 120 via pins, and the second linkage 153 is mounted to be freely oscillating relative to the toggle seat 130 via pins. 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 flex and extend, causing the movable pressure plate 120 to move forward or backward relative to the toggle seat 130.

[0066] 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 node where one end of the third link 154 is connected to the first link 152 and the second link 153.

[0067] 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, causing the first link 152 and the second link 153 to extend and retract, thereby moving 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.

[0068] 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 171 and a lead screw nut 172 screwed to the lead screw shaft 171. Balls or rollers may be located between the lead screw shaft 171 and the lead screw nut 172.

[0069] Under the control of the controller 700, the mold closing device 100 performs the mold closing process, the mold closing process, and the mold opening process.

[0070] In the mold closing process, the mold closing motor 160 is driven to advance the crosshead 151 at a set speed to the mold closing completion position, causing the movable pressure plate 120 to advance so that the moving 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 controller 700.

[0071] 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.

[0072] In the mold closing process, the mold closing motor 160 is further driven to advance the crosshead 151 from the mold closing completion position to the mold closing position, thereby generating a mold closing force. During mold closing, a cavity space 14 is formed between the moving 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 cured to obtain a molded product. There can be multiple cavity spaces 14, in which case multiple molded products can be obtained simultaneously.

[0073] In the mold opening process, the crosshead 151 is retracted to the mold opening completion position at a set speed by driving the mold closing motor 160, which causes the movable pressure plate 120 to retract, so that the moving mold 12 separates from the fixed mold 11. Then, the ejector device 200 ejects the molded product from the moving mold 12.

[0074] The setting conditions in the mold closing and mold closing processes are set uniformly 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) and mold closing force of the crosshead 151 in the mold closing and mold closing processes are set uniformly 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 speed setting interval. The speed is set for each interval. There can be one or more speed switching positions. Alternatively, no speed switching position can be set. Only the mold closing position and mold closing force can be set.

[0075] 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 set speed interval. The speed is set for each interval. There can be one or more speed switching positions. Alternatively, no speed switching position can be set. 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.

[0076] 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.

[0077] The toggle mechanism 150 amplifies the driving force of the clamping motor 160 and transmits it to the movable pressure plate 120. Its amplification ratio is also known as the toggle ratio. The toggle ratio varies depending on the angle θ (hereinafter referred to as the "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°.

[0078] 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 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 at the point when the moving mold 12 contacts the fixed mold 11, the connecting rod angle θ of the toggle mechanism 150 becomes the specified angle.

[0079] The mold clamping device 100 has a mold thickness adjustment mechanism 180, which adjusts the gap L between the fixed pressure plate 110 and the toggle seat 130, thereby adjusting the mold thickness. 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.

[0080] Each connecting rod 140 is equipped with a lead screw shaft 181 and a lead screw nut 182. 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.

[0081] In addition, by changing the transmission path of the rotation transmission unit 185, multiple lead screw nuts 182 can be rotated individually.

[0082] 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.

[0083] Alternatively, instead of gears, the rotation transmission unit 185 can also be composed of belts, pulleys, etc.

[0084] The action of the die thickness adjustment mechanism 180 is controlled by the controller 700. The controller 700 drives the die thickness adjustment motor 183 to rotate the lead screw nut 182, adjusts the position of the toggle seat 130 of the lead screw nut 182 relative to the fixed pressure plate 110, and adjusts the distance L between the fixed pressure plate 110 and the toggle seat 130.

[0085] 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 controller 700. The detection result of the die thickness adjustment motor encoder 184 is used for monitoring and controlling the position and interval L of the toggle seat 130.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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 has a linear motor for mold opening and closing, and may also have an electromagnet for mold clamping.

[0090] <<Ejection Device>>

[0091] After the molding material filled into the mold assembly 10 by the injection device 300 cools and solidifies, the ejector device 200 ejects the molded article from the mold assembly 10. The ejector device 200 includes an ejector motor 210, a motion conversion mechanism 220, and an ejector rod 230, etc.

[0092] 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 to the right). Figure 1 and Figure 2 (The middle direction is to the left) is used to explain the rear direction.

[0093] 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.

[0094] 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. Balls or rollers may be located between the lead screw shaft and the lead screw nut.

[0095] The ejector rod 230 moves freely in and out of the through hole of the movable pressure plate 120. The front end of the ejector rod 230 contacts the movable part 15, which is freely disposed inside the moving mold 12. The front end of the ejector rod 230 may or may not be connected to the movable part 15.

[0096] The ejection device 200 performs the ejection process under the control of the controller 700.

[0097] In the ejection process, the ejector motor 210 is driven to advance the ejector rod 230 from the standby position to the ejection position at a set speed, thereby advancing the movable part 15 and ejecting 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 controller 700.

[0098] In addition, the ejector rod position detector for detecting the position of the ejector rod 230 and the ejector rod movement 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.

[0099] <<Injection Device>>

[0100] The injection unit 300 is mounted on a sliding base 301 that moves freely forward and backward relative to the frame Fr, and also moves 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.

[0101] 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-hand direction is set to the front, which will separate the injection device 300 from the mold device 10. Figure 1 and Figure 2 (The middle direction is to the right) is used to explain the rear direction.

[0102] 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.

[0103] Cylinder block 310 along the axial direction of cylinder block 310 ( Figure 1 and Figure 2 The space is divided into multiple zones (from left to right). A heater 313 and a temperature detector 314 are installed in each zone. The controller 700 controls the heater 313 for each zone so that the temperature detected by the temperature detector 314 becomes the set temperature.

[0104] 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 arranged on the outer periphery of the nozzle 320. The controller 700 controls the heater 313 so that the detected temperature of the nozzle 320 becomes the set temperature.

[0105] 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.

[0106] A 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] Pressure detector 360 detects the pressure transmitted between injection motor 350 and screw 330. Pressure detector 360 is disposed in the force transmission path between injection motor 350 and screw 330, and detects the pressure acting on pressure detector 360.

[0114] The pressure detector 360 sends a signal indicating its detection result to the controller 700. The detection result of the pressure detector 360 is used for the control and monitoring of the pressure exerted by the screw 330 on the molding material, the back pressure relative to the screw 330, and the pressure exerted by the screw 330 on the molding material.

[0115] Under the control of the controller 700, the injection device 300 performs metering, filling, and pressure holding processes.

[0116] 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. As a result, 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, a metering motor encoder 341 is used to detect 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 controller 700.

[0117] 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.

[0118] In the metering process, to limit the rapid retraction of the screw 330, a predetermined back pressure can be applied to the screw 330 by driving the injection motor 350. 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 controller 700. The metering process is complete when the screw 330 retracts to the metering completion position and a predetermined amount of molding material accumulates in front of the screw 330.

[0119] 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, an injection motor encoder 351 is used to detect the position and speed of the screw 330. The injection motor encoder 351 detects the rotation of the injection motor 350 and sends a signal indicating its detection result to the controller 700. If the screw 330 reaches the 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.

[0120] Furthermore, during the filling process, after the screw 330 reaches the set position, it can be paused at that position before V / P switching. Alternatively, instead of stopping the screw 330, it can be moved forward or backward at a slight speed 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.

[0121] 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, a pressure detector 360 is used to detect the holding pressure. The pressure detector 360 sends a signal indicating its detection result to the controller 700. The set value of the holding pressure can be changed according to the elapsed time since the start of the holding pressure process.

[0122] 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 also be performed during the cooling process.

[0123] 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.

[0124] 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.

[0125] <<Mobile Devices>>

[0126] 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.

[0127] 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-hand direction is set to the front, which will separate the injection device 300 from the mold device 10. Figure 1 and Figure 2 (The middle direction is to the right) is used to explain the rear direction.

[0128] In addition, Figure 1 , 2 In this device, the moving device 400 is disposed on one side of the cylinder 310 of the injection device 300, but it can be disposed on both sides of the cylinder 310, or it can be disposed symmetrically with the cylinder 310 as the center.

[0129] 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.

[0130] Motor 420 operates hydraulic pump 410. Motor 420 drives hydraulic pump 410 by means of rotational direction and torque corresponding to control signals from controller 700. Motor 420 can be an electric motor or an electric servo motor.

[0131] 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 is a first chamber, and a rear chamber 436, which is a second chamber. The piston rod 433 is fixed relative to the fixed pressure plate 110.

[0132] 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 propelling the injection device 300 forward. As the injection device 300 advances, the nozzle 320 is pressed 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.

[0133] 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.

[0134] 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.

[0135] <<Controller>>

[0136] The controller 700 (an example of a control device) directly sends control signals to the mold clamping device 100, the ejection device 200, the injection device 300, and the moving device 400, and performs various controls related to the injection molding machine 1.

[0137] The controller 700 can be implemented using any hardware or any combination of hardware and software. For example, the controller 700 is configured around a computer having a CPU 701, a memory device 702, an auxiliary storage device 703, and an input / output interface device 704 for communication with external devices. The controller 700 performs various controls by loading a program installed in the auxiliary storage device 703 into the memory device 702 and executing it with the CPU 701. Furthermore, the controller 700 receives external signals or outputs signals to external devices via the interface device 704. For example, the controller 700 can communicatively connect to the management device 2 via a communication line NW according to the interface device 704. Furthermore, the controller 700 can communicatively connect to other injection molding machines 1 (and their controllers 700) via the communication line NW according to the interface device 704. Furthermore, the controller 700 can obtain the program installed in itself (auxiliary storage device 703) from a specified recording medium via the interface device 704. The specified recording media include, for example, floppy disks, CDs (Compact Discs), DVDs (Digital Versatile Discs), BDs (Blu-ray Discs), SD memory cards, and USB (Universal Serial Bus) storage devices. Furthermore, the controller 700 can also acquire (download) programs from an external computer (e.g., management device 2) via the interface device 704.

[0138] The functions of controller 700 can be implemented by a single controller 700, as described later, or they can be shared by multiple controllers (e.g., upper controller 700A and lower controller 700B, etc.) (see reference). Figure 2 ).

[0139] The controller 700 repeatedly manufactures molded products by causing the injection molding machine 1 to repeatedly perform mold closing, mold closing, and mold opening processes. Furthermore, during the mold closing process, the controller 700 causes the injection unit 300 to perform metering, filling, and pressure holding processes.

[0140] The series of actions used to obtain a molded article, such as the actions from the start of a metering process performed by the injection unit 300 to the start of the next metering process performed by the 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".

[0141] A single molding cycle may consist of, for example, a metering process, a mold closing process, a mold clamping process, a filling process, a pressure holding process, a cooling process, a mold opening process, and an ejection process. This sequence is the order in which each process begins. Furthermore, the filling process, the pressure holding process, and the cooling process are performed from the start of the mold clamping process to the end of the mold clamping process. Moreover, the end of the mold clamping process coincides with the start of the mold opening process.

[0142] 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; in this case, 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. Moreover, when an opening / closing valve is provided to open and close the flow path of the nozzle 320 of the injection device 300, the mold opening process can begin during the metering process. This is because even if the mold opening process begins during the metering process, as long as the opening / closing valve closes the flow path of the nozzle 320, the molding material will not leak from the nozzle 320.

[0143] The controller 700 is connected to the operating device 750 and the display device 760, etc.

[0144] The operating device 750 (an example of an input device) receives user-related inputs to the injection molding machine 1 and outputs a signal corresponding to the input to the controller 700. Thus, the user can perform operations related to the injection molding machine 1.

[0145] Furthermore, the injection molding machine 1 (controller 700) can be configured to receive input from a user via an external device. Thus, the user can, for example, remotely operate the injection molding machine 1. At this time, image data from a camera capable of capturing the operating status of the injection molding machine 1 can be sent to the external device. Therefore, the operation can be performed while simultaneously monitoring the operating status of the remotely controlled injection molding machine 1 on the external device.

[0146] For example, the controller 700 can receive user input from the management device 2 and other injection molding machines 1 via the communication line NW. Furthermore, the controller 700 can receive user input from a terminal device via the communication line NW. The terminal device can be a fixed terminal device such as a desktop PC, or a portable terminal device such as a smartphone, tablet, or laptop PC.

[0147] The display device 760 displays various images under the control of the controller 700.

[0148] The display device 760 displays, for example, an operation screen related to the injection molding machine 1 that corresponds to the operation input in the operation device 750.

[0149] The operation screen displayed on the display device 760 is used for settings related to the injection molding machine 1. These settings include, for example, setting the molding conditions related to the injection molding machine 1 (specifically, inputting setting values). Furthermore, these settings include, for example, selecting the types of detection values ​​from various sensors related to the injection molding machine 1 that are recorded as stored data during the molding operation. These settings also include, for example, setting the display specifications (e.g., the type of actual value displayed, display method, etc.) 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 provided and can be switched on and overlaid on the display device 760. The user can operate the operation device 750 while observing the operation screen displayed on the display device 760, thereby enabling settings related to the injection molding machine 1 (including inputting setting values).

[0150] Furthermore, under the control of the controller 700, the display device 760 displays information screens that provide various information to the user corresponding to the operations on the operation screen. Multiple information screens are provided, and they are switched on the display device 760 or displayed in overlapping layers. 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 actual operation of the injection molding machine 1).

[0151] The operating device 750 and the display device 760 are, for example, composed of a touch panel display and can be integrated.

[0152] In this embodiment, the operating device 750 and the display device 760 are integrated, but they can also be installed independently. Furthermore, multiple operating devices 750 can also be installed.

[0153] [Hardware structure of the control system of an injection molding machine]

[0154] Next, refer to Figure 3 The hardware structure of the control system of injection molding machine 1 is described.

[0155] Figure 3 This is a diagram illustrating an example of the hardware structure of the control system of injection molding machine 1.

[0156] like Figure 3 As shown, the control system of injection molding machine 1 includes a controller 700, a driver 710, and a sensor 720.

[0157] The controller 700 includes a CPU 701 and an FPGA (Field Programmable Gate Array) 705.

[0158] CPU 701 (an example of a control processing unit) performs control processing related to the operation of injection molding machine 1 (hereinafter referred to as "motion control processing") based on data acquired from driver 710 and sensor 720 via FPGA 705. The motion control processing includes servo control processing of the electric motor. Specifically, CPU 701 initiates control functions related to the operation of injection molding machine 1 (functions of control unit 7001 described later) based on periodically output interrupt requests (hereinafter simply referred to as "interrupt requests") from FPGA 705, and executes control processing related to the operation of injection molding machine 1. Then, CPU 701 outputs data equivalent to control commands to driver 710, etc., via FPGA 705.

[0159] In this example, the interrupt request used is a so-called hardware interrupt request output from external hardware (FPGA705 in this example) to the CPU701. Similar to actuator motion control processing or servo control processing implemented as motion control processing, the CPU701, for example, implements relatively low-priority processing (hereinafter referred to as "low-priority processing") in the background of processing with relatively high priority (hereinafter referred to as "high-priority processing"). If an interrupt request for high-priority processing is input from the FPGA705 while low-priority processing is being implemented, the CPU701 invokes the interrupt processing corresponding to the interrupt request. Then, the CPU701 starts the high-priority processing corresponding to the interrupt request based on the interrupt processing. Thus, the CPU701 can appropriately implement periodically executed high-priority processing according to a predetermined control cycle (an example of a predetermined cycle) while implementing low-priority processing.

[0160] The FPGA 705 (an example of a request output unit) functions as an input / output interface between the controller 700 and the outside world. That is, the interface device 704 includes the FPGA 705.

[0161] FPGA705 receives data related to the control of the actuator (hereinafter referred to as "control data") from driver 710, or sends data equivalent to control instructions to driver 710 upon request from CPU 701.

[0162] Furthermore, the FPGA705 receives measurement data related to the state of the injection molding machine 1 from the sensor 720, or sends data equivalent to control commands related to the measurement actions of the sensor 720 according to a request from the CPU701.

[0163] Furthermore, the FPGA705 periodically outputs interrupt requests to the CPU701 to initiate control functions related to the operation of the injection molding machine 1. Specifically, the FPGA705 can repeatedly set the end timer according to a predetermined control cycle and output an interrupt request when the timer ends.

[0164] The driver 710 drives the actuator according to control commands from the controller 30. The actuator is, for example, an electric motor, and the driver 710 outputs drive current to the electric motor according to the control commands from the controller 30. Thus, the controller 700 (CPU 701) controls the electric motor through the driver 710, thereby enabling the injection molding machine 1 to perform the desired actions. The electric motor includes, for example, a clamping motor 160, a mold thickness adjustment motor 183, an ejector motor 210, a metering motor 340, an injection motor 350, and a motor 420.

[0165] Sensor 720 outputs measurement data related to the state of injection molding machine 1. Sensor 720 includes, for example, an encoder capable of measuring the rotational position of the electric motor. Encoders include, for example, a clamping motor encoder 161, a mold thickness adjustment motor encoder 184, an ejector motor encoder 211, a metering motor encoder 341, and an injection motor encoder 351. Furthermore, sensor 720 includes a current sensor and a voltage sensor that detect the voltage and current of the electrical system, including the current and voltage of the electric motor. Additionally, sensor 720 includes various sensors (e.g., a connecting rod strain gauge 141, a temperature sensor 314, and a pressure sensor 360, etc.) capable of measuring forces, temperatures, and pressures acting on specified parts of injection molding machine 1.

[0166] [Functional Structure of the Controller]

[0167] Next, refer to Figure 4 The functional structure of controller 700 is described.

[0168] Figure 4 This is a block diagram illustrating an example of the functional structure of the controller 700.

[0169] like Figure 4 As shown, the controller 700 includes a control unit 7001, a display processing unit 7002, a storage unit 7003, a setting unit 7004, and a storage unit 7005. The functions of the control unit 7001, display processing unit 7002, and setting unit 7004 are implemented, for example, by loading a program installed in the auxiliary storage device 703 into the storage device 702 and executing it on the CPU 701. Furthermore, the functions of the storage units 7003, 7005, etc., are implemented, for example, by using a storage area defined in the auxiliary storage device 703 of the controller 700.

[0170] The control unit 7001 performs control related to the operation of the injection molding machine 1 based on data input from the driver 710 and the sensor 720. As described above, the function of the control unit 7001 is initiated and executed based on periodic interrupt requests output from the FPGA 705.

[0171] The display processing unit 7002 displays an information screen on the display device 760 based on input received from the user via the operation device 750. Specifically, the display processing unit 7002 displays a screen (hereinafter referred to as a "setting screen") for the user to make settings related to the aforementioned interrupt request using the operation device 750.

[0172] The settings related to the interrupt request include settings related to the output timing of the interrupt request from the FPGA705 (e.g., the setting of the correction time T1 described later). Furthermore, the settings related to the interrupt request include settings related to the start timing of the motion control processing based on the interrupt request (e.g., the setting of the waiting time T2 described later).

[0173] The storage unit 7003 stores (registers) the settings related to the above-mentioned interruption request (for example, the setting values ​​of correction time T1 and waiting time T2, which will be described later).

[0174] The setting unit 7004 performs settings related to the aforementioned interruption request. For example, the setting unit 7004 automatically performs settings related to the interruption request when triggered by a specified input from the user received via the operating device 750 or a condition other than the specified input. Conditions other than the specified input (hereinafter referred to as "automatic setting start conditions") may include, for example, the initial start (power on) during the pre-shipment inspection process of the injection molding machine 1 and the initial start after the initialization of the controller 700 of the injection molding machine 1. Furthermore, the automatic setting start conditions may include the initial start after changes (updates) to specified hardware such as the actuator of the injection molding machine 1 and specified software such as the program related to motion control processing. Moreover, for example, the setting unit 7004 may also perform settings related to the interruption request based on user input received via the operating device 750, which is equivalent to the user's desired setting content. That is, settings related to the interruption request can be performed manually.

[0175] Furthermore, the setting unit 7004 can also restrict the function of automatically or manually making settings related to interruption requests based on user input. This prevents situations where the settings related to interruption requests are unnecessarily changed, adversely affecting the operation of the injection molding machine 1.

[0176] For example, the setting unit 7004 identifies the user operating the injection molding machine 1 and determines whether or not to allow settings related to interruption requests based on input from the operating device 750, according to the user's decision. This, for example, can prevent situations where a user lacking knowledge of interruption requests mistakenly changes settings related to interruption requests. Specifically, a registration information database can be constructed that associates allowed or disallowed settings related to interruption requests with identification information (hereinafter referred to as "user identification information") specified for each user (e.g., each user's ID, facial recognition image data, etc.). Therefore, the setting unit 7004 can identify the user using the operating device 750 based on the ID input from the operating device 750 and the image data obtained during facial recognition.

[0177] Furthermore, for example, when input from a user is received via an external device of the injection molding machine 1, the setting unit 7004 can also restrict the function of setting related to interruption requests. Specifically, the function of setting related to interruption requests based on some or all of the input from the external device can be disabled. This is because, for example, if the settings related to interruption requests are changed based on user input from an external device in a situation where the operation of the injection molding machine 1 is relatively difficult to control, the corresponding measures may be delayed if the operation of the injection molding machine 1 is adversely affected as a result. Furthermore, this is because, for example, if the settings related to interruption requests can be changed based on input from an external device, problems may arise from a safety perspective.

[0178] The storage unit 7005 stores various types of data for use by the setting unit 7004. For example, the aforementioned registration information database can be constructed in the storage unit 7005.

[0179] [Specific examples of controller actions]

[0180] Next, refer to Figure 5 A specific example of the operation of controller 700 will be explained.

[0181] Figure 5 This is a timing diagram illustrating an example of the operation of controller 700. Specifically, Figure 5 It is a timing diagram representing the various states of "data output", "data preparation", "interrupt timer", "interrupt handling" and "motion control processing" in the controller.

[0182] "Data output" refers to the output status of data (e.g., control data to the driver 710) that is the result of motion control processing performed by the controller 700 (control unit 7001).

[0183] "Data preparation" refers to the preparation status of data (e.g., data received from driver 710, sensor 720, output data of motion control processing in the previous control cycle, etc.) used in motion control processing by controller 700 (control unit 7001). The data used in motion control processing is stored in the internal memory of FPGA 705, and CPU 701 can access the internal memory of FPGA 705 to use this data and execute motion control processing.

[0184] "Interrupt Timer" refers to the operating state of the timer set to enable the FPGA705 to output an interrupt request. In the diagram, the rising end of the timer's operating state indicates the start of the timer, and the falling end indicates the end of the timer. Moreover, the interrupt request is output triggered by the end of the timer.

[0185] "Interrupt handling" refers to the implementation status (whether or not) of preprocessing (interrupt handling) used to interrupt low-priority processing and perform action control processing according to the interrupt request output from FPGA705.

[0186] "Motion control processing" indicates the implementation status (whether or not) of motion control processing executed by CPU701.

[0187] In this example, as a setting related to the interrupt request, the output time of the interrupt request changes from the initial state, i.e., the defined reference state. The reference state refers to the state where the time of the interrupt request coincides with the reference time that triggers the start of motion control processing. In this example, the reference state refers to the state where the time of the interrupt request coincides with the assumed time when the preparation of the data used in the motion control processing is complete.

[0188] Specifically, provided that the output cycle of the interrupt request, i.e., the control cycle of the action control processing, remains unchanged, the timing of the interrupt request is advanced by a time T1 from the reference state. More specifically, the end time of the timer for the interrupt request of the FPGA705 is advanced by a time T1 from the reference state.

[0189] Therefore, as Figure 5 As shown, when the timer ends before the data preparation is complete, the FPGA705 outputs an interrupt request to the CPU701 (time t11).

[0190] Additionally, if an interrupt request is output, the FPGA705 starts the next timer (around time t12).

[0191] CPU701 starts interrupt handling based on the interrupt request output from FPGA705 (time t12).

[0192] In this example, as a setting related to the interrupt request, the start time of the motion control processing based on the interrupt request is changed from the initial state. The initial state is, for example, a state where the start time of motion control coincides with the completion time of the interrupt processing. That is, in the initial state, if the interrupt processing is completed, motion control processing begins immediately.

[0193] Specifically, the start time of motion control processing is changed to the later of the time when the interrupt processing is completed and the time when the waiting time T2 has elapsed since the start of the interrupt processing.

[0194] This interrupt handling requires a relatively long time, and the elapsed time T2 is approximately the same as the time the interrupt is accepted (time t13). Therefore, CPU701 begins action control processing at this time.

[0195] Furthermore, in this example, the waiting time T2 is set such that the start time of the motion control processing is approximately simultaneous with (e.g., immediately after) the completion of data preparation for the motion control processing in the FPGA 705. Therefore, the motion control processing begins immediately after the data preparation is complete. Consequently, the CPU 701 can begin motion control processing after the latest data preparation is complete. Therefore, the CPU 701 can appropriately control the operation of the injection molding machine 1. Moreover, since motion control begins immediately after the completion of data preparation for the motion control processing, the controller 700 can easily ensure real-time performance related to the motion control processing.

[0196] Furthermore, the waiting time T2 can be set arbitrarily, as long as the motion control processing starts after the preparation of the data used in the assumed motion control processing is complete.

[0197] If the motion control processing in this control cycle is completed, the CPU 701 will then output data related to the execution result of the motion control processing in this control cycle (time t14). The output data is stored (written) in the internal memory of the FPGA 705, for example.

[0198] After the CPU701 completes its data output, if the timer that started after the last interrupt request output ends, the FPGA705 will output an interrupt request to the CPU701 (time t15).

[0199] CPU701 starts interrupt handling based on the interrupt request output from FPGA705 (time t16).

[0200] This interrupt handling is completed in a relatively short time (time t17). Therefore, after the interrupt handling is completed, CPU 701 waits for a waiting time T2 from the start of the interrupt handling before starting motion control processing (time t18). Thus, even if the interrupt handling ends relatively early, by appropriately setting the waiting time T2, CPU 701 can start motion control processing after the data used in motion control processing has been prepared.

[0201] If the action control processing in this control cycle is completed, then CPU701 will output data related to the execution result of the action control processing in this control cycle (time t19).

[0202] In both the previous and current control cycles, motion control processing begins after a waiting time T2 elapsed since the interrupt handling started. Therefore, controller 700 can ensure that the output time (data output time T0) of data related to the execution result of motion control processing, based on the completion of data preparation used in the motion control processing, is approximately the same. Thus, controller 700 can more appropriately ensure real-time performance related to motion control processing.

[0203] Alternatively, instead of setting a waiting time T2, the FPGA 705 can output a notification to the CPU 701 indicating that the data preparation for the motion control processing is complete. In this case, the start time of the motion control processing is changed to the later of the interrupt processing completion time and the data preparation completion time. Thus, the controller 700 can begin motion control processing in response to the completion of data preparation.

[0204] [Configuration handling related to interrupt requests]

[0205] Next, refer to Figure 6 The configuration processing related to interrupt requests performed by controller 700 is explained.

[0206] Figure 6 This is a flowchart that roughly illustrates an example of the setting process related to an interrupt request performed by the controller 700. This flowchart can be executed, for example, when a specified input from the user is received via an operating device 750, etc. Furthermore, this flowchart can be executed, for example, when the aforementioned automatic setting start condition is met.

[0207] like Figure 6 As shown, in step S102, the setting unit 7004 determines whether the function of automatically performing settings related to the interrupt request (hereinafter referred to as "automatic setting function") is effective.

[0208] The automatic setting function can be selected by the user via operating device 750, for example. Furthermore, when the aforementioned automatic setting start condition is met, the automatic setting start condition can be set as an initial state and be valid, or it can be set as an initial state or invalid state according to the specifications of each purchaser of injection molding machine 1.

[0209] When the automatic setting function is active, the setting unit 7004 proceeds to step S104; when the automatic setting function is not active, the flowchart ends.

[0210] In step S104, the setting unit 7004 causes the control unit 7001 to actually operate, and in the initial state of the correction time T1 and the waiting time T2, it measures the time required from the output (generation) of the interrupt request to the start of the action control processing. That is, the setting unit 7004 measures the time required from the output of the interrupt request to the completion of the interrupt processing.

[0211] If step S104 is completed, the controller 700 proceeds to step S106.

[0212] In step S106, the setting unit 7004 determines whether the number of measurements of the time required from the output (generation) of the interrupt request to the start of the motion control process is greater than or equal to a set number Nth (an integer greater than or equal to 1). If the number of measurements is not greater than or equal to the set number Nth, the setting unit 7004 returns to step S104 and repeats the processing of steps S104 and S106 in the next control cycle of the motion control process. On the other hand, if the number of measurements is greater than or equal to the set number Nth, the setting unit 7004 stops the actual operation of the function of the control unit 7001 and proceeds to step S108.

[0213] Alternatively, during normal operation of the injection molding machine 1, the time required from the output of the interrupt request to the completion of the interrupt processing can be appropriately measured as background processing, and the measurement result can be used. In this case, steps S104 and S106 can be omitted.

[0214] In step S108, the setting unit 7004 sets the calibration time T1 and the waiting time T2 based on the measurement results of the set number Nth.

[0215] For example, the setting unit 7004 can set the correction time T1 based on the maximum value among the measurement results of the set number Nth. Specifically, the setting unit 7004 can set the correction time T1 as the maximum value or higher among the measurement results of the set number Nth. This allows the interruption process to be completed before the time when the data intended for use in the motion control processing is ready. Therefore, by appropriately setting the waiting time T2, the controller 700 can start the motion control processing corresponding to the completion of data preparation. Specifically, the setting unit 7004 can set the time intended from the output of the interrupt request to the start of the interrupt processing to a value greater than or equal to the determined correction time T1.

[0216] Furthermore, for example, the setting unit 7004 can also set the correction time T1 and the waiting time T2 based on the average value of the measurement results of the set number Nth.

[0217] If step S108 is completed, the controller 700 ends the processing of this flowchart.

[0218] Thus, in this example, the controller 700 can set the correction time T1 and the waiting time T2 according to the actual time required from the output of the interrupt request to the completion of the interrupt processing.

[0219] [Specific examples of screen settings]

[0220] Next, refer to Figure 7 This section explains the settings screen used for making settings related to interrupt requests.

[0221] Figure 7 This is an example of a setting screen (setting screen 70) displayed on the display device 760.

[0222] Alternatively, the same settings screen can also be displayed on the management device 2 or the aforementioned terminal device, which are external to the injection molding machine 1 and can be communicatively connected via the communication line NW. Thus, users of the injection molding machine 1, such as managers and staff, can view or perform settings related to interruption requests through the management device 2 or the aforementioned terminal device.

[0223] like Figure 7 As shown, the setting screen 70 includes a processing content display unit 71, a calibration time display unit 72, a waiting time display unit 73, and icons 74 to 77.

[0224] The processing content display unit 71 uses a timing diagram to depict the processing flow from the output of the interrupt request to the start of the motion control processing, and displays the time intervals corresponding to the correction time T1 and the waiting time T2. Thus, the user can understand the processing flow from the output of the interrupt request to the start of the motion control processing, and specifically confirm the time intervals corresponding to the correction time T1 and the waiting time T2 within that flow.

[0225] The current setting value of the calibration time T1 is displayed on the calibration time display unit 72.

[0226] The current setting value of the waiting time T2 is displayed on the waiting time display unit 73.

[0227] Icon 74 indicates whether the automatic setting function is enabled or disabled, that is, whether the settings related to interrupt requests can be performed automatically or manually. In this example, it shows that the automatic calibration function is enabled.

[0228] Icon 75 is the operation object used to start setting the correction time T1 and waiting time T2 based on the automatic setting function. The user operates icon 75 via operating device 750, thereby enabling the user to perform the operation according to the above... Figure 6 The flowchart enables the controller 700 to automatically set the calibration time T1 and the waiting time T2.

[0229] Icon 76 is an operation object used to manually switch to a control state where settings related to interrupt requests can be made. This can be achieved by operating icon 76 via operation device 750, etc., to input values ​​into the input boxes for correction time T1 and waiting time T2 in the correction time display unit 72 and waiting time display unit 73.

[0230] Furthermore, as described above, when the settings related to the interrupt request corresponding to user input received via the operating device 750, etc., are restricted (disabled), icons 75 and 76 can be displayed in an inoperable state (e.g., an unselectable state). Moreover, the values ​​that can be input during the correction time T1 and the waiting time T2 can, of course, be pre-limited to a range that will not adversely affect the motion control processing.

[0231] Icon 77 is the operation object used to return to a specified screen (e.g., the home screen).

[0232] Thus, the user can confirm the settings related to the interrupt request (the settings for correction time T1 and waiting time T2) through the setting screen 70. Furthermore, the user can use the automatic setting function through the setting screen 70 or manually change the settings related to the interrupt request by controlling the controller 700.

[0233] [effect]

[0234] Next, refer to Figure 8 The function of the injection molding machine 1 (controller 700) involved in this embodiment will be explained.

[0235] Figure 8 This is a timing diagram showing the operation of the controller of the injection molding machine involved in the comparative example. Hereinafter, structures identical to the controller 700 in the comparative example will be described using the same names without any symbols.

[0236] In this example, the timer is set to end when the data preparation for the motion control processing in the FPGA is complete.

[0237] like Figure 8 As shown, the FPGA outputs an interrupt request (time t21) corresponding to the end of the timer.

[0238] Additionally, if an interrupt request is output, the FPGA starts the next timer (around time t22).

[0239] The CPU begins interrupt handling based on the interrupt request output from the FPGA (time t22).

[0240] If the interrupt request is completed, the CPU begins action control processing (time t23). During this control cycle, the interrupt processing ends in a relatively short time.

[0241] The CPU outputs data related to the execution result of the motion control processing in this control cycle (time t24). The output data is stored (written) in the FPGA's internal memory, for example.

[0242] After the CPU-based data output is completed, if the timer that started after the output of the last interrupt request ends, then, as before, the FPGA will output an interrupt request to the CPU (time t25) corresponding to the completion of the preparation of the data used in the motion control processing.

[0243] CPU701 begins interrupt handling based on the interrupt request output from the FPGA (time t26).

[0244] If the interrupt handling is complete, CPU701 begins action control processing (time t27). In this control cycle, the interrupt handling takes a relatively longer time compared to the previous control cycle (the dotted line in the diagram). This is because the required time for interrupt handling can sometimes vary depending on factors such as the overhead of interrupt handling and cache hit status.

[0245] If the action control processing in this control cycle is completed, then the CPU701 will output data related to the execution result of the action control processing in this control cycle (time t28).

[0246] In the comparative example, as described above, an interrupt request is output corresponding to the completion of data preparation used in the motion control process. Therefore, the output time of data related to the execution result of the motion control process (data output time T0c) based on the completion of data preparation used in the motion control process depends on the length of the interrupt processing time. That is, if the interrupt processing time is relatively longer, the start time of the motion control process based on the completion of data preparation will be relatively later, which may affect the real-time performance of the motion control process.

[0247] In contrast, in this embodiment, the controller 700 outputs an interrupt request before a trigger (hereinafter referred to as "start trigger") that serves as the basis for starting motion control processing is generated, and starts control processing after the trigger is generated. Specifically, the start trigger may be the completion of preparation of data required for motion control processing.

[0248] Therefore, the controller 700 can perform interrupt processing before the start of triggering. This suppresses the impact of deviations in the required time of interrupt processing on the start time of motion control processing. Furthermore, even if the interrupt processing ends relatively early, motion control processing begins after the start of triggering, thus preventing it from being performed before the start of triggering. Therefore, the controller 700 can more appropriately achieve real-time control processing related to its motion in the injection molding machine 1.

[0249] Furthermore, in injection molding machine 1, the same technique can be used for other control processes besides motion control processing. In this case, the output time of the interruption request (correction time T1) and the time to start other control processes (waiting time T2) can be appropriately set according to the trigger that serves as the basis for starting other control processes.

[0250] Furthermore, in this embodiment, when the start preparation for the motion control process is completed after the output interrupt request and before the trigger generation begins, the controller 700 can wait for the trigger generation before starting the motion control process.

[0251] Therefore, the controller 700 can initiate motion control processing in response to the generation of the start trigger. Thus, in the injection molding machine 1, the controller 700 can more appropriately achieve real-time performance related to its motion.

[0252] Furthermore, in this embodiment, the controller 700 can start action control processing after a predetermined time (waiting time T2) has elapsed since the interrupt processing based on the interrupt request began.

[0253] Therefore, by appropriately setting the waiting time T2, the controller 700 can begin motion control processing after the initial trigger is generated.

[0254] Furthermore, in this embodiment, the controller 700 can measure the time required from the output of the interrupt request to the completion of the interrupt processing multiple times, and set the output time of the interrupt request (correction time T1) and the waiting time T2 according to the measurement results.

[0255] Therefore, the controller 700 can take into account the actual deviation of the time required from the output of the interrupt request to the completion of the interrupt processing, and set the output time of the interrupt request (correction time T1) and the waiting time T2 more appropriately.

[0256] Alternatively, only the output time of the interrupt request (correction time T1) and the waiting time T2 can be set. This is because, as mentioned above, when the FPGA705 outputs a notification that data preparation is complete to the CPU701, the action control processing can begin accordingly. Furthermore, this is because when no notification of data preparation completion is output, the correction time T1 is set to a relatively small value, thereby ensuring that the completion time of the interrupt processing is always after the start of triggering (data preparation completion).

[0257] Furthermore, in this embodiment, when a specified input is received by the operation device 750, the display device 760 can display settings related to the start of motion control processing based on the output of the interrupt request, including the output time of the interrupt request.

[0258] Thus, the injection molding machine 1 enables the user to confirm settings related to the start of motion control processing based on the interrupt request output (e.g., settings for correction time T1 and waiting time T2).

[0259] [Transformation, alteration]

[0260] The above describes the implementation of the injection molding machine management system SYS, etc. However, the present invention is not limited to the above implementation, etc., and various modifications and alterations can be made within the scope of the subject matter described in the technical solution.

[0261] For example, the information regarding the timing of the output interruption request and the start time of control processing based on the interruption request in the above-described embodiment can also be used in controls related to the actions of other controlled machinery. Other machinery includes, for example, industrial machinery used in factories and industrial robots.

[0262] Finally, this application claims priority based on Japanese Patent Application No. 2021-060659, filed on March 31, 2021, the entire contents of which are incorporated herein by reference.

[0263] Explanation of symbols

[0264] 1-Injection molding machine (industrial machinery), 2-Management device, 100-Mold clamping device, 200-Ejection device, 300-Injection device, 400-Moving device, 700-Controller (control device), 701-CPU (control processing unit), 702-Memory device, 703-Auxiliary storage device, 704-Interface device, 705-FPGA (Request Output Unit), 710-Driver, 720-Sensor, 750-Operating device (input device), 760-Display device, 7001-Control unit, 7002-Display processing unit, 7003-Storage unit, 7004-Setting unit, 7005-Storage unit, SYS-Injection molding machine management system.

Claims

1. An injection molding machine, comprising: Mold closing device, used to close the mold assembly; An injection device fills the mold assembly, which is closed by the mold closing device, with molding material. An ejector device removes the molded article from the mold assembly after the molding material filled by the injection device has cooled and solidified; and The control device outputs interrupt requests at predetermined intervals and performs control processing related to the operation of the injection molding machine based on the interrupt requests. The control device outputs the interrupt request before the trigger occurs, and begins the control process after the trigger occurs. The trigger becomes the basis for initiating the control process. The trigger signifies the completion of the preparation of the data required for the control process.

2. The injection molding machine according to claim 1, wherein, After the interrupt request is output and before the start preparation for the control process is completed, the control device waits for the trigger to be generated before starting the control process.

3. The injection molding machine according to claim 1 or 2, wherein, The control device begins the control process after a predetermined time has elapsed since the interruption process based on the interruption request started.

4. The injection molding machine according to claim 1 or 2, wherein, The control device repeatedly measures the time required from the output of the interrupt request to the completion of the interrupt processing based on the interrupt request, and sets the output time of the interrupt request based on the measurement results.

5. The injection molding machine according to claim 3, wherein, The control device repeatedly measures the time required from the output of the interrupt request to the completion of the interrupt processing based on the interrupt request, and sets the output time of the interrupt request and the specified time according to the measurement results.

6. The injection molding machine according to claim 1 or 2, comprising: Input device, for receiving user input; and When the display device receives a specified input through the input device, it displays settings including the output time of the interrupt request and related to the start of the control process based on the output of the interrupt request.

7. A controller comprising: The interrupt request output section outputs interrupt requests at a specified period; and The control processing unit performs control processing related to the operation of the industrial machinery based on the interruption request. The interrupt request output unit outputs the interrupt request before a trigger occurs. The control processing unit begins the control processing after the trigger is generated. The trigger becomes the basis for initiating the control process. The trigger signifies the completion of the preparation of the data required for the control process.

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