Molding optimization method and device of injection molding machine

Abstract

The basic molding conditions for the initial resin materials (Cro, Cgo) used at the initial stage of producing a predetermined molded article, and the basic melting characteristics (Pro. Pgo) relating to the molten state of the initial resin materials (Cro, Cgo) based on the basic molding conditions are obtained, and when an additional resin material (Crs.Cgs) switched by the initial resin materials (Cro, Cgo) for producing the molded article is used, the additional resin material (Crs.Cgs) is added to the initial resin materials (Cro, Cgo) for producing the molded article, and the additional resin material (Crs.Cgs) is added to the initial resin materials (Cro, Cgo). Second molding conditions for the additional resin material (Crs.Cgs) and second melting characteristics (Prs, Pgs) relating to the molten state of the additional resin material (Crs.Cgs) on the basis of the second molding conditions are obtained, and the additional resin material (Crs.Cgs) is molded so that the second melting characteristics (Prs, Pgs) approximate the basic melting characteristics (Pro. Pgo). A conversion process including at least the set temperature is performed on the second molding condition by a predetermined conversion means.

Description

Technical Field

[0001] The present invention relates to a molding optimization method and device for an injection molding machine suitable for use in producing molded products by injecting and filling plasticized molten resin into a mold using a screw. Background Art

[0002] In general, an injection molding machine uses a screw to inject plasticized molten resin into a mold to produce a molded product. Therefore, whether the molding conditions for the resin material used can be optimized and the optimized molding conditions can be properly maintained is an important factor in ensuring the desired molding quality. Therefore, various means (methods) for optimizing molding conditions have been proposed.

[0003] Conventionally, as such means (methods), a molding assisting device for an injection molding machine described in Patent Document 1 and a molding condition optimizing method for an injection molding machine described in Patent Document 2 are known. The purpose of the molding auxiliary device disclosed in the document 1 is to be able to set the best (accurate) temperature control temperature matching the type of resin, improve the efficiency and stability of the heating tube, and expand the overall adjustment range of the molding conditions to ensure the improvement of plasticization quality and high molding quality. Specifically, it is composed of: a temperature control unit, which controls the temperature of a material supply unit that supplies resin material to the interior of the heating tube; and a molding machine controller, the molding machine controller having: a basic data input unit capable of inputting the type of resin; a data processing unit having a temperature control temperature data table and a temperature setting processing unit; and an output processing function unit, wherein the temperature control temperature data table sets the best temperature control temperature based on the temperature control unit for each type of resin, in the temperature setting processing unit, after the type of resin is input from the basic data input unit when setting the molding conditions, the temperature control temperature corresponding to the input resin type is read from the temperature control temperature data table, thereby setting it as the temperature control temperature of the temperature control unit, and the output processing function unit displays the temperature control temperature on the display.

[0004] In addition, the purpose of the molding condition optimization method disclosed in Document 2 is to provide a method for quickly and easily setting the optimal molding conditions of an injection molding machine. Specifically, through a trial molding test, while changing the molding conditions, the molding conditions of qualified products composed of an injection curve and a holding pressure curve are set, and the trial molding test is implemented again based on the conditions, and the main molding variables are measured and monitored to obtain the variation range of the main molding variables caused by the environmental changes in the molding state during molding. Based on the new combination of the main molding variables obtained by the experimental design method in consideration of the variation range, multiple updated molding tests are implemented under the updated molding conditions. For each molded product obtained as a result of the molding test, the appearance quality is judged by the operator's visual inspection. In the case of defective items, the above-mentioned updated molding conditions are corrected using a correction program and the updated molding test is repeatedly performed. In the case of no defective items at all, the final updated molding conditions are used as the optimal molding conditions.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2020-1183

[0008] Patent Document 2: Japanese Patent Application Laid-Open No. 10-272663 Summary of the invention

[0009] Problems to be solved by the invention

[0010] However, the conventional means (methods) for optimizing the above-mentioned molding conditions still have the following problems to be solved.

[0011] That is, the existing means (methods) mainly focus on optimizing the condition values ​​from the perspective of absolute values ​​for molding conditions. In other words, they mainly focus on how to accurately and precisely set the real-time molding conditions related to the molding conditions. Therefore, from the perspective of relative optimization, it is not necessarily done in reality. In this case, for changes caused by interference such as external air temperature, countermeasures such as correction processing are taken, but there are issues that may not be fully addressed for changes in manufacturing batches and changes in grades of resin materials.

[0012] Therefore, for example, when a predetermined molded product is produced, the remaining amount of the resin material in use decreases, and when new resin material is added (supplemented), there are many cases where defective molded products increase due to differences in the manufacturing batches of the resin material. In this case, it is caused by the subtle differences in the physical property values ​​of the resin materials, and it is not easy to understand what physical property values ​​are different to what extent and how they affect the whole.

[0013] As a result, operators are forced to re-set molding conditions, which is a major cause of reduced production efficiency. Moreover, as long as the same molded product can be ensured by re-setting the molding conditions, there will be a lot of influence on the deviation of the molded product, so there is a problem that the quality and homogeneity of the molded product cannot be fully ensured.

[0014] An object of the present invention is to provide a molding optimization method and apparatus for an injection molding machine that solves the problems existing in the background art.

[0015] Means for solving problems

[0016] In order to solve the above-mentioned problems, the molding optimization method of the injection molding machine M of the present invention optimizes the molding conditions when the plasticized molten resin is injected into the mold 2 by the screw 3 to produce the molded product. The molding optimization method of the injection molding machine M is characterized in that the basic molding conditions as the basic molding conditions for the initial resin material Cro, Cgo used in the initial stage of producing the specified molded product and the basic melting characteristics Pro.Pgo related to the melting state of the initial resin material Cro, Cgo based on the basic molding conditions are pre-calculated, and when the additional resin material Crs.Cgs switched from the initial resin material Cro, Cgo for producing the molded product is used, the second molding conditions for the additional resin material Crs.Cgs and the second melting characteristics Prs, Pgs related to the melting state of the additional resin material Crs.Cgs based on the second molding conditions are calculated, and the second molding conditions are converted by a specified conversion unit in a manner that the second melting characteristics Prs, Pgs are close to the basic melting characteristics Pro.Pgo.

[0017] In addition, in order to solve the above-mentioned problems, the molding optimization device 1 of the injection molding machine of the present invention optimizes the molding conditions when the plasticized molten resin is injected into the mold 2 by the screw 3 to produce the molded product. The molding optimization device of the injection molding machine M is characterized in that it has a molding machine controller 4 provided with an optimization processing unit 5, and the optimization processing unit 5 has: a basic molding condition setting function unit Ff, which sets the basic molding conditions for the initial resin materials Cro, Cgo used in the initial stage of producing the specified molded product; a basic melting characteristic calculation function unit Fp, which calculates the melting state of the initial resin materials Cro, Cgo based on the basic molding conditions. and basic melting characteristics Pro.Pgo; a second molding condition setting function unit Fs, which sets the second molding condition for the additional resin material Crs.Cgs switched from the initial resin material Cro, Cgo for producing the molded product; a second melting characteristic calculation function unit Fq, which calculates the second melting characteristics Prs, Pgs related to the melting state of the additional resin material Crs.Cgs based on the second molding condition; and a molding condition conversion processing function unit Fc, which performs conversion processing on the second molding condition including at least a set temperature through a prescribed conversion unit in such a way that the second melting characteristics Prs, Pgs approximate the basic melting characteristics Pro.Pgo.

[0018] On the other hand, according to a preferred embodiment of the invention, the present invention can make the basic melting characteristics Pro.Pgo include at least the basic solid phase ratio characteristics as the basic screw position, and make the second melting characteristics Prs, Pgs include at least the second solid phase ratio characteristics for the screw position. Therefore, the optimization processing unit 5 can be provided with: a basic melting characteristic calculation function unit Fp, which obtains at least the basic solid phase ratio characteristics for the screw position as the basic melting characteristics Pro.Pgo; and a second melting characteristic calculation function unit Fq, which obtains at least the second solid phase ratio characteristics for the screw position as the second melting characteristics Prs, Pgs. At this time, the basic solid phase ratio characteristics can use the estimated solid phase ratio of the molten resin corresponding to the screw position obtained by calculation processing based on the physical property value data Dc involved in the initial resin material Cro, Cgo and the solid phase ratio calculation formula data Dm, and the second solid phase ratio characteristics can use the estimated solid phase ratio of the molten resin corresponding to the screw position obtained by calculation processing based on the physical property value data Dc involved in the additional resin material Crs.Cgs and the solid phase ratio calculation formula data Dm. Therefore, a solid phase ratio calculation processing unit Fx can be provided in the molding machine controller 4. The solid phase ratio calculation processing unit Fx calculates the estimated solid phase ratio as the basic solid phase ratio characteristic of the molten resin corresponding to the screw position by calculating the physical property value data Dc related to the initial resin material Cro, Cgo and the solid phase ratio calculation formula data Dm, and calculates the estimated solid phase ratio as the second solid phase ratio characteristic of the molten resin corresponding to the screw position by calculating the physical property value data Dc related to the additional resin material Crs.Cgs and the solid phase ratio calculation formula data Dm. In addition, a display 4d can be provided in the molding machine controller 4. The display 4d has a graphic display unit Vsg for graphically displaying the basic melting characteristic Pro.Pgo and the second melting characteristic Prs, Pgs. In addition to the basic solid phase ratio characteristic, the basic melting characteristic Pro.Pgo can also include one or more of the screw speed, back pressure, and cycle time for which the limiting conditions are set respectively, and in addition to the second solid phase ratio characteristic, the second melting characteristic Prs, Pgs can also include one or more of the screw speed, back pressure, and cycle time for which the limiting conditions are set respectively. It should be noted that the conditions for switching from the initial resin material Cro, Cgo to the additional resin material Crs.Cgs can include changes in the manufacturing batch of the resin material and / or changes in the grade of the resin material.

[0019] Effects of the Invention

[0020] According to the molding optimization method and device 1 of the injection molding machine M of the present invention, the following remarkable effects are achieved.

[0021] (1) When implementing the molding optimization method, basic molding conditions for an initial resin material Cro, Cgo used at the initial stage of producing a predetermined molded product and basic melting characteristics Pro.Pgo related to the melting state of the initial resin material Cro, Cgo based on the basic molding conditions are obtained in advance. When using an additional resin material Crs.Cgs switched from the initial resin material Cro, Cgo for producing the molded product, second molding conditions for the additional resin material Crs.Cgs and second melting characteristics Prs, Pgs related to the melting state of the additional resin material Crs.Cgs based on the second molding conditions are obtained, and the second melting characteristics Prs ,Pgs approximates the basic melting characteristic Pro.Pgo in a manner, and the second molding condition is converted to at least the set temperature through a prescribed conversion unit. Therefore, for example, when a prescribed molded product is produced, when a new resin material with a different manufacturing batch is added, the operator does not need to set the molding conditions again when, for example, the cause cannot be fully determined. This improves production efficiency and reduces defective products. Even when there is a change in the resin material, the homogeneity and quality can be improved by ensuring the same molded product. This allows accurate optimization from a relative point of view, that is, optimization of changes in manufacturing batches and grades involving resin materials.

[0022] (2) The molding optimization device 1 has a molding machine controller 4 provided with an optimization processing unit 5, wherein the optimization processing unit 5 has a basic molding condition setting function unit Ff, a basic melting characteristic calculation function unit Fp, a second molding condition setting function unit Fs and a second melting characteristic calculation function unit Fq, and has a molding condition conversion processing function unit Fc, which performs conversion processing on the second molding condition including at least a set temperature through a prescribed conversion unit in such a way that the second melting characteristic Prs, Pgs approximates the basic melting characteristic Pro.Pgo, thereby being able to easily and accurately implement the molding optimization method in the injection molding machine M.

[0023] (3) According to a preferred method, if the basic melting characteristic Pro.Pgo includes at least a basic solid phase ratio characteristic for the screw position, and the second melting characteristic Prs,Pgs includes at least a second solid phase ratio characteristic for the screw position, the melting state of the resin material, especially the solid phase ratio directly related to the viscosity, can be utilized, thereby obtaining more accurate information on the melting state.

[0024] (4) According to a preferred method, if the optimization processing unit 5 is respectively provided with: a basic melting characteristic calculation function unit Fp, in which at least a basic solid phase ratio characteristic for the screw position is calculated as a basic melting characteristic Pro.Pgo; and a second melting characteristic calculation function unit Fq, in which at least a second solid phase ratio characteristic for the screw position is calculated as a second melting characteristic Prs, Pgs, then the information (data) related to the melting state of the resin material can be easily obtained using the molding machine controller 4.

[0025] (5) According to a preferred method, if the estimated solid phase fraction of the molten resin corresponding to the screw position obtained by calculation processing based on the physical property value data Dc involved in the initial resin material Cro, Cgo and the solid phase fraction calculation formula data Dm is used in the basic solid phase fraction characteristics, and the estimated solid phase fraction of the molten resin corresponding to the screw position obtained by calculation processing based on the physical property value data Dc involved in the additional resin material Crs.Cgs and the solid phase fraction calculation formula data Dm is used in the second solid phase fraction characteristics, then it can be reliably implemented by utilizing the proposed molding assist device (Japanese Patent Gazette No. 2020-1183) and the like, and accurate information (data) on the melting state of the resin material can be obtained in a numerical manner.

[0026] (6) According to a preferred method, if a solid phase ratio calculation processing unit Fx is set in the molding machine controller 4, the solid phase ratio calculation processing unit Fx calculates the estimated solid phase ratio as the basic solid phase ratio characteristic of the molten resin corresponding to the screw position by calculating the physical property value data Dc involved in the initial resin material Cro, Cgo and the solid phase ratio calculation formula data Dm, and calculates the estimated solid phase ratio as the second solid phase ratio characteristic of the molten resin corresponding to the screw position by calculating the physical property value data Dc involved in the additional resin material Crs.Cgs and the solid phase ratio calculation formula data Dm. Then, the proposed molding auxiliary device, etc. can be utilized, and therefore it can be easily and reliably implemented using the molding machine controller 4.

[0027] (7) According to a preferred embodiment, if a display 4d is provided in the molding machine controller 4, and the display 4d has a graphic display portion Vsg for graphically displaying the basic melting characteristics Pro.Pgo and the second melting characteristics Prs, Pgs, the operator can accurately confirm the different states of the resin material through the graphic display, thereby improving the ease and accuracy of implementation from the perspective of achieving optimization.

[0028] (8) According to a preferred method, if the basic melting characteristics Pro, Pgo include, in addition to the basic solid phase ratio characteristics, one or more of the screw speed, back pressure, and cycle time for which restrictive conditions are set respectively, and if the second melting characteristics Prs, Pgs include, in addition to the second solid phase ratio characteristics, one or more of the screw speed, back pressure, and cycle time for which restrictive conditions are set respectively, then from the perspective of equalizing the molding conditions, high-precision equalization can be achieved, and the effect can be further improved.

[0029] (9) According to a preferred method, if the conditions for switching from the initial resin material Cro, Cgo to the additional resin material Crs.Cgs include a change in the manufacturing batch of the resin material and / or a change in the grade of the resin material, all issues arising during actual production can be roughly covered. Therefore, from the perspective of solving the issues, the molding optimization method (molding optimization device 1) of the present invention can be most effectively utilized. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a diagram of a setting screen of a display in a molding optimization device according to a preferred embodiment of the present invention.

[0031] Figure 2 This is a structural diagram showing the mechanical structure of an injection molding machine equipped with the molding optimization device.

[0032] Figure 3 It is a block diagram of the processing system (control system) in the molding optimization device.

[0033] Figure 4 It is a flowchart showing the processing steps of the molding optimization method according to the preferred embodiment of the present invention.

[0034] Figure 5 It specifically shows Figure 4 A flow chart of the steps of a portion of a flow chart is shown.

[0035] Figure 6 This is a table showing the physical property values ​​of resin materials produced in different batches used in the implementation of the molding optimization method.

[0036] Figure 7 This is a table showing set temperatures for different resin materials of production batches used in the implementation of the molding optimization method.

[0037] Figure 8 This is a characteristic diagram (graphic display diagram) of changes in the estimated solid phase ratio with respect to the screw position used in the implementation of the molding optimization method.

[0038] Fig. 9This is a graph showing the relationship between the length of the strip flow and the number of shots, for illustrating the effect of implementing the molding optimization method.

[0039] Fig.10 This is a table showing the physical property values ​​of resin materials of different grades used in implementing the molding optimization method.

[0040] Fig.11a This is a table showing the set temperatures for resin materials of different grades used in implementing the molding optimization method.

[0041] Fig.11b This is a table showing molding conditions for resin materials of different grades used in implementing the molding optimization method.

[0042] Fig.12 This is a characteristic diagram of specific heat relative to temperature of resin materials of different grades used in the implementation of the molding optimization method.

[0043] Fig.13 It is used for illustration purposes Fig.12 A graph showing the relationship between the strip flow length and the number of shots of the resin material when the molding optimization method is implemented.

[0044] Explanation of symbols

[0045] 1: Molding optimization device, 2: Mold, 3: Screw, 4: Molding machine controller, 4d: Display, 5: Optimization processing unit, M: Injection molding machine, Cro: Initial resin material, Cgo: Initial resin material, Crs: Additional resin material, Cgs: Additional resin material, Dc: Physical property value data, Dm: Solid phase ratio calculation formula data, Ff: Basic molding condition setting function unit, Fp: Basic melting characteristic calculation function unit, Fs: Second molding condition setting function unit, Fq: Second melting characteristic calculation function unit, Fc: Molding condition conversion processing function unit, Fx: Solid phase ratio calculation processing unit, Pro: Basic melting characteristic, Pgo: Basic melting characteristic, Prs: Second melting characteristic, Pgs: Second melting characteristic, Vsg: Graphic display unit DETAILED DESCRIPTION

[0046] Next, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0047] First, in order to easily understand the molding optimization device 1 of this embodiment, refer to Figure 2 and Figure 3 An overview of an injection molding machine M that can utilize the apparatus 1 will be described.

[0048] Figure 2An injection molding machine M is shown, in particular, an injection device Mi in which a mold clamping device is omitted. In the injection device Mi, 11 is a heating cylinder, and a nozzle 11n is installed at the front end of the heating cylinder 11 via a head 11h. The nozzle 11n has a function of injecting the molten resin inside the heating cylinder 11 into the mold 2 shown by the imaginary line. In addition, a hopper 11s is provided at the upper rear end of the heating cylinder 11, and a material drop port 11d penetrating the heating cylinder 11 is formed between the lower end opening of the hopper 11s and the inside of the heating cylinder 11. As a result, the hopper 11s is connected to the inside of the heating cylinder 11 via the material drop port 11d, and the resin material C represented by the imaginary line in the hopper 11s is supplied to the inside of the heating cylinder 11 through the material drop port 11d.

[0049] On the other hand, a heater 12s for heating the resin material C contained in the hopper 11s is attached to the outer peripheral surface of the hopper 11s, and a water jacket 12j is formed on the heating cylinder 11 around the material drop port 11d. In addition, the heater 12s is connected to the power supply circuit 12e in the temperature control driver 12d, and the water jacket 12j is connected to the temperature control water circulation circuit 12w in the temperature control driver 12d. The temperature control water circulation circuit 12w can control the temperature (heat or cool) of the resin material C passing through the material drop port 11d by circulating the temperature-controlled water medium (warm water or cooling water) in the water jacket 12j. In addition, the power supply circuit 12e and the temperature control water circulation circuit 12w are respectively connected to the controller body 22. Thus, the control command for the power supply circuit 12e and the temperature control water circulation circuit 12w is given to the temperature control driver 12d from the controller body 22. In addition, the temperature control temperature is detected by the temperature sensor, and the detection signal is given to the temperature control driver 12d.

[0050] In addition, the screw 3 is loaded inside the heating tube 11 so that it can rotate freely and advance and retreat freely. It should be noted that the surface of the screw is subjected to a coating treatment using a prescribed surface raw material (metal) in consideration of durability, etc. The screw 3 has a metering area Zm, a compression area Zc, and a feed area Zf from the front side to the rear side. On the other hand, the rear end of the screw 3 is connected to the screw drive unit 13. The screw drive unit 13 has a screw rotation mechanism 13r for rotating the screw 3 and a screw advance and retreat mechanism 13m for advancing and retreating the screw 3. In the illustrated case, the driving method of the screw rotation mechanism 13r and the screw advance and retreat mechanism 13m shows an electrical method using an electric motor, but it can also be a hydraulic method using a hydraulic circuit, and there is no restriction on the driving method. In addition, the screw rotation mechanism 13r and the screw advance and retreat mechanism 13m are connected to the power supply driver 13d, and the power supply driver 13d is connected to the controller body 22. Thus, control commands for the screw rotating mechanism 13r and the screw advancing and retracting mechanism 13m are given to the power driver 13d from the controller body 22. Physical quantities such as the speed and position of the screw 3 are detected by speed sensors and position sensors (not shown), and the detection signals are given to the power driver 13d.

[0051] In addition, the heating tube 11 has a heating tube front part 11f, a heating tube middle part 11m, and a heating tube rear part 11r from the front side to the rear side, and the outer peripheral surfaces of each part 11f, 11m, and 11r are respectively attached with a front heating part 14f, a middle heating part 14m, and a rear heating part 14r. Similarly, a head heating part 14h is attached to the outer peripheral surface of the head 11h, and a nozzle heating part 14n is attached to the outer peripheral surface of the nozzle 11n. These heating parts 14f, 14m, 14r, 14h, and 14n can be composed of a belt heater or the like. Therefore, the nozzle heating part 14n, the head heating part 14h, the front heating part 14f, the middle heating part 14m, and the rear heating part 14r constitute the heating group part 14. Moreover, the heating group part 14 is connected to the heater driver 14d, and the heater driver 14d is connected to the controller body 22. Thus, control instructions for each heating unit 14f, 14m, 14r, 14h, and 14n are given from the controller body 22 to the heater driver 14d. In addition, the heating temperature is detected by a temperature sensor (thermocouple, etc.) not shown in the figure, and the detection signal is given to the heater driver 14d.

[0052] on the other hand, Figure 3The molding machine controller 4 responsible for the overall control of the injection molding machine M is shown in the figure. The molding machine controller 4 has the above-mentioned controller body 22 with computer functions, which has hardware such as a CPU and an internal memory 4m built in, and a display 4d is connected to the controller body 22. The display 4d can display necessary information, and is attached with a touch panel 4dt, which can be used to perform various input operations such as input, setting, and selection. In addition, the controller body 22 is connected to a driver group 24 that drives (operates) various actuators. The driver group 24 includes Figure 2 The temperature control driver 12d, the power supply driver 13d and the heater driver 14d are shown to include the power supply circuit 12e and the temperature control water circulation circuit 12w.

[0053] Therefore, the molding machine controller 4 includes an HMI control system and a PLC control system, and stores the PLC program and the HMI program in the internal memory 4m. The PLC program is used to execute the sequential operation of various processes in the injection molding machine M or the monitoring of the injection molding machine M, and the HMI program is used to execute the setting and display of the action parameters of the injection molding machine M and the display of the action monitoring data of the injection molding machine M.

[0054] Next, refer to Figure 1-Figure 3 and Figure 6-Figure 9 The configuration of the molding optimization device 1 according to the present embodiment that can be used in such an injection molding machine M will be described.

[0055] The molding optimization device 1 of this embodiment comprises Figure 3 The molding machine controller 4 and the peripheral actuators of the display 4d shown in the figure are constituted. Therefore, the internal memory 4m of the molding machine controller 4 stores an optimization processing program Ps based on an application program for making the molding optimization device 1 function.

[0056] The molding optimization device 1 basically includes an optimization processing unit 5 that functions through the computer function of the molding machine controller 4, that is, the execution of the optimization processing program Ps, and can optimize molding conditions when a predetermined molded product is produced by the injection molding machine M.

[0057] That is, when producing a predetermined molded product, the remaining amount of the resin material C in use decreases. When a new resin material C is added to the hopper 11s, the viscosity and the like change due to the different manufacturing batches (manufacturing periods) of the resin material C, and there are many cases where defective products increase. In this case, there are many cases where the physical property values ​​of the resin material C are subtly different, but it is not easy to understand what kind of physical property values ​​are different to what extent and how they affect the whole. Therefore, through the molding optimization device 1, when adding such a resin material C with a different manufacturing batch, even beginners can easily reset and optimize the molding conditions.

[0058] Therefore, if Figure 3 As shown, in the optimization processing unit 5 constituting the main part of the molding optimization device 1, as a basic structure, it is equipped with: a basic molding condition setting function unit Ff, which sets the basic molding condition for the initial resin material Cro used in the initial stage of producing a specified molded product; a basic melting characteristic calculation function unit Fp, which calculates the basic melting characteristic Pro of the melting state of the initial resin material Cro based on the basic molding condition; a second molding condition setting function unit Fs, which sets the second molding condition for the additional resin material Crs switched from the initial resin material Cro for producing the molded product; a second melting characteristic calculation function unit Fq, which calculates the second melting characteristic Prs of the melting state of the additional resin material Crs based on the second molding condition; and a molding condition conversion processing function unit Fc, which performs conversion processing on the second molding condition including at least the set temperature through a specified conversion unit in a manner that the second melting characteristic Prs is close to (including the same case) the basic melting characteristic Pro, and a solid phase ratio calculation processing unit Fx is provided in the molding machine controller 4.

[0059] In this case, the basic melting characteristics Pro of the molten state of the initial resin material Cro can include at least the basic solid phase ratio characteristics for the screw position (hereinafter referred to as the basic solid phase ratio characteristics), and the second melting characteristics Prs of the molten state of the additional resin material Crs can include at least the second solid phase ratio characteristics for the screw position (hereinafter referred to as the second solid phase ratio characteristics). In this way, if the basic melting characteristics Pro include the basic solid phase ratio characteristics, and the second melting characteristics Prs include the second solid phase ratio characteristics, the melting state of the resin material, especially the solid phase ratio directly related to the viscosity, can be used, so that the information of the melting state can be obtained more accurately.

[0060] Therefore, the basic melting characteristic calculation function unit Fp in the above-mentioned optimization processing unit 5 includes the following function, as the basic melting characteristic Pro, at least the basic solid phase ratio characteristic for the screw position is obtained, and the second melting characteristic calculation function unit Fq includes the following function, as the second melting characteristic Prs, at least the second solid phase ratio characteristic for the screw position is obtained. If such basic solid phase ratio characteristic and second solid phase ratio characteristic are used, information (data) related to the melting state of the resin material can be easily obtained by using the molding machine controller 4.

[0061] In particular, the molding optimization device 1 of the present embodiment is provided with a solid phase ratio calculation processing unit Fx. Therefore, the molding auxiliary device proposed by the applicant (refer to Japanese Patent Gazette No. 2020-1183), that is, the estimated solid phase ratio that can be obtained by the estimation unit, can be easily and reliably implemented through the molding machine controller 4, and accurate information (data) on the melting state of the resin material can be obtained in a numerical form.

[0062] Therefore, through the solid phase ratio calculation processing unit Fx, it is possible to obtain the basic solid phase ratio characteristics Pro using the estimated solid phase ratio of the molten resin corresponding to the screw position obtained by calculation processing based on the physical property value data Dc related to the initial resin material Cro and the solid phase ratio calculation formula data Dm, and it is possible to obtain the second solid phase ratio characteristics Prs using the estimated solid phase ratio of the molten resin corresponding to the screw position obtained by calculation processing based on the physical property value data Dc related to the additional resin material Crs and the solid phase ratio calculation formula data Dm. In this way, by using the proposed molding auxiliary device, etc., accurate information (data) on the melting state of the resin material can be obtained in a numerical manner, and it can be implemented reliably.

[0063] on the other hand, Figure 1 The setting screen Vs used in the molding optimization device 1 displayed on the display 4d connected to the controller main body 22 in the molding machine controller 4 is shown.

[0064] The setting screen Vs has the following screen composition: Figure 1 In the figure, a molding machine and resin setting column 31 is arranged at the upper left side, a resin property value setting column 32 is arranged at the upper center, a viscosity setting column 33 is arranged at the upper right side, a condition setting column 34 is arranged at the lower left side, a temperature setting column 35 is arranged from the lower center to the lower right side, and a "flow analysis start" key 36 and a "molded product homogenization" key 37 are arranged below the temperature setting column 35. In this case, the molding machine and resin setting column 31 has a molding machine type setting unit 31a, a screw type setting unit 31b, a resin type setting unit 31c, and a reinforcing fiber type setting unit 31d, respectively, and the resin property value setting column 32 has an input unit for various detailed property values ​​such as specific heat, thermal conductivity, density, melting point, decomposition temperature, melting temperature, and water absorption. In addition, the condition setting column 34 has a condition setting unit including restrictive conditions related to screw speed, back pressure, cycle time, etc., and the display can be switched by switching arrow keys 34c.

[0065] Next, refer to the figures and follow the instructions included. Figure 5 The steps in the flowchart are shown in Figure 4 The flowchart shown explains the molding optimization method of this embodiment including the functions of the molding optimization device 1.

[0066] First, since the validation for confirming the effectiveness of the molding optimization method of this embodiment is carried out, first refer to Figure 6-Figure 9 The verification result will be described.

[0067] In the verification test, a pellet material of polystyrene resin (GPPS) was used as resin material C, an initial resin material used initially was sample Cro, and an additional resin material used additionally was sample Crs. Therefore, the initial resin material Cro and the additional resin material Crs were the same resin material but produced in different batches.

[0068] During the validation test, by using Figure 1 The setting screen Vs shown in the figure performs necessary settings related to the initial resin material Cro and the additional resin material Crs. In this case, in association with the molding optimization method of this embodiment, the resin property value setting column 32 is input (set) Figure 6 The figure shows the physical properties of the initial resin material Cro and the additional resin material Crs. The physical property values ​​are the measured values ​​of the decomposition temperature TG [Cel], the melting point Tm [Cel], and the melting latent heat λ [J / kg]. In addition, Figure 6 The viscosity (calculated value) based on this is shown in . As can be seen from the figure, the viscosity of the initial resin material Cro is 4.4 [g / 10min], and the viscosity of the additional resin material Crs is 5.2 [g / 10min], depending on the production batch. It can be confirmed that the additional resin material Crs has high fluidity.

[0069] In addition, the temperature setting column 35 is used to Figure 7 In this case, the initial resin material Cro is set to a temperature according to the setting rules of the normal molding conditions, and the additional resin material Crs is set to the initial resin material Cro as it is, that is, without correction.

[0070] On the other hand, when the above input processing on the setting screen Vs is completed, the "flow analysis start" key 36 in the setting screen Vs is turned on. Figure 8 The estimated solid phase ratio is shown in FIG. 1 , which shows the variation characteristics of the estimated solid phase ratio relative to the screw position (pitch number). As described above, the "estimated solid phase ratio" at the screw position is calculated by the estimation unit disclosed in the molding assisting device described in Japanese Patent Publication No. 2020-1183, that is, the solid phase ratio calculation processing unit Fx of this embodiment. Figure 8 It can be confirmed that the estimated solid phase ratio of the additional resin material Crs is slightly smaller than the estimated solid phase ratio of the initial resin material Cro.

[0071] The estimated solid phase fraction quantitatively represents the melting state (melting mode) of the resin material. Therefore, if the molding conditions such as the set temperature can be corrected so that the changing characteristics of the estimated solid phase fraction of the additional resin material Crs corresponding to the second melting characteristic Prs and the changing characteristics of the estimated solid phase fraction of the initial resin material Cro corresponding to the basic melting characteristic Pro are consistent (homogenized), the viscosity of the above-mentioned resin materials can be made the same.

[0072] This conversion process is performed by the molding condition conversion process function unit Fc. That is, the second molding condition is converted at least including the set temperature by a predetermined conversion unit in such a manner that the second melting characteristic Prs related to the melting state of the additional resin material Crs obtained by the second melting characteristic calculation function unit Fq is close to (including the same as) the basic melting characteristic Pro related to the melting state of the initial resin material Cro obtained by the basic melting characteristic calculation function unit Fp.

[0073] The conversion processing method uses a mathematical method to perform calculation processing on the set temperature, screw speed, back pressure, cycle time, etc. Among the mathematical methods, various methods such as experimental planning method, Lagrange indefinite multiplier method, Gauss-Jordan method, Newton method, and linear interpolation method can be used, but in this embodiment, the Lagrange indefinite multiplier method is used for conversion processing.

[0074] A specific conversion method is described below: First, the difference between the estimated solid phase ratio of the initial resin material Cro and the estimated solid phase ratio of the additional resin material Crs calculated under the constraint condition is defined as fα, and a polynomial is calculated by applying [Equation 1].

[0075] [Number 1]

[0076]

[0077] In the approximate formula of the quadratic polynomial in [Formula 1], it is determined by [Formula 2].

[0078] [Number 2]

[0079]

[0080] To do this, it is necessary to make the partial differentials of a, b, and c 0. Therefore, the partial differential of a is [Equation 3].

[0081] [Number 3]

[0082]

[0083] Similarly, for b and c, the normal equation of [Equation 4] can also be obtained by performing partial differentiation.

[0084] [Number 4]

[0085]

[0086] Thus, after the solutions of a, b, and c are obtained, an approximate expression is obtained as f ≒ fa. After the approximate expression is obtained, the optimal solution is calculated using the Lagrange indefinite multiplier method of [Equation 5] for the constraint condition g of each setting condition.

[0087] [Number 5]

[0088]

[0089] It should be noted that, when the optimal value of a quadratic function exceeds the constraint condition, it can also be judged as a linear function and the optimal value can be calculated.

[0090] The above conversion process (calculation process) can be executed by turning on the "molded product homogenization" key 37 in the setting screen Vs.

[0091] Figure 7 The Cra shown indicates the set temperature converted by the molding condition conversion processing function unit Fc, that is, the set temperature of the additional resin material Crs corrected by the conversion process.

[0092] Depend on Figure 7 and Figure 8 It can be seen that the estimated solid phase ratio of the additional resin material Crs is slightly smaller than the estimated solid phase ratio of the initial resin material Cro without correction. That is, the initial resin material Cro is in a state of being easily melted, but the set temperature of the additional resin material Crs after correction (conversion) is set to be 4 [°C] lower than the set temperature of the initial resin material Cro.

[0093] Fig. 9 Shown in the Figure 7 The strip flow length [mm] measured by a strip flow length measuring instrument when molding is performed at the set temperature shown. Lro represents the strip flow length when the initial resin material Cro is used, Lrs represents the strip flow length when the additional resin material Crs without correcting the molding conditions is used, and Lra represents the additional resin material Cra with corrected (optimized) molding conditions. Figure 7 ) of the strip flow length. It should be noted that the strip flow length measuring instrument uses a mold formed with a slender cavity, and the smaller the viscosity of the molten resin, the longer the flow length.

[0094] Depend on Fig. 9It can be seen that the flow length Lrs of the additional resin material Crs without correcting the molding conditions tends to be longer by 4-5 [mm] relative to the flow length Lro of the initial resin material Cro, but the flow length Lra of the additional resin material Cra with the corrected (optimized) molding conditions can be roughly consistent with the flow length Lro of the initial resin material Cro, and the high effectiveness of the molding optimization device 1 (molding optimization method) of this embodiment can be confirmed. In particular, in the illustrated case, the change is only the setting temperature, and even if only the setting temperature is corrected (converted), sufficient effectiveness can be confirmed.

[0095] Next, refer to Figure 4 and Figure 5 The molding optimization method in actual production is explained.

[0096] First, when producing a molded product, the operator performs a setting process of the molding conditions in the injection molding machine M according to a normal setting procedure (step S1). That is, the molding condition setting process can be performed through the basic molding condition setting function unit Ff, and the set molding conditions can be registered. And when the setting process is completed, the production process is performed according to the normal procedure (step S2).

[0097] Assuming that the remaining amount of resin material C (initial resin material Cro) decreases through the production process of the molded product, it is time to add additional resin material C (additional resin material Crs) (step S3). It should be noted that the additional resin material Crs is a resin material of the same type but with a different manufacturing batch than the initial resin material Cro.

[0098] First, display Figure 1 The setting screen Vs shown shows the molding conditions of the initial resin material Cro (step S4). At this time, the data related to the set molding conditions are read, and if there is insufficient data for obtaining the estimated solid phase ratio of the initial resin material Cro, necessary input is performed. Then, when the necessary input is completed, the "flow analysis start" key 36 in the setting screen Vs is turned on (step S5).

[0099] Thus, the solid phase ratio calculation processing unit Fx calculates the estimated solid phase ratio of the molten resin by calculation based on the physical property value data Dc related to the initial resin material Cro and the solid phase ratio calculation formula data Dm, and the basic melting characteristic calculation function unit Fp can obtain the basic solid phase ratio characteristic Pro using the estimated solid phase ratio of the molten resin corresponding to the screw position [pitch number]. This basic solid phase ratio characteristic, that is, the basic melting characteristic (Pro) is registered as data, and as Figure 6As shown, a graphic display is performed through the graphic display section Vsg in the display 4d (step S6).

[0100] Next, various information related to the additional resin material Crs is input (set) in the setting screen Vs (step S7). The specific input process is shown in FIG. Figure 5 In this case, since the manufacturing batches of the additional resin material Crs are different, various physical property values ​​such as the decomposition temperature related to the additional resin material Crs are input (set) through the resin physical property value setting column 32 (step S71). Then, when the input to the resin physical property value setting column 32 is completed and the restriction conditions for the specific molding conditions are set, the restriction conditions are set using the condition setting column 34 (steps S72, S73...).

[0101] That is, when setting the constraint conditions for the screw speed, select the label of "Screw speed" in the condition setting column 34, and set the constraint conditions involving the maximum value and minimum value corresponding to the optimization (steps S73, S74). In addition, when setting the constraint conditions for the back pressure, select the label of "Back pressure" in the condition setting column 34, and set the constraint conditions involving the maximum value and minimum value corresponding to the optimization (steps S75, S76). In addition, when setting the constraint conditions for the cycle time, select the label of "Cycle time" in the condition setting column 34, and set the constraint conditions involving the maximum value and minimum value corresponding to the optimization (steps S77, S78). Then, when the setting of the constraint conditions is completed, set the set temperature without constraint conditions and without correction (step S79). The settings involving the additional resin material Crs are performed by the second molding condition setting function unit Ff.

[0102] Thus, if the second melting characteristic Prs includes one or more of the screw speed, back pressure, and cycle time for which limiting conditions are set respectively in addition to the second solid phase ratio characteristic, then from the perspective of equalizing the molding conditions, high-precision equalization can be achieved, and the effect can be further improved. It should be noted that the second melting characteristic Prs is described, but when obtaining the above-mentioned basic melting characteristic Pro, in addition to the basic solid phase ratio characteristic, it is preferred to include one or more of the screw speed, back pressure, and cycle time for which limiting conditions are set respectively.

[0103] Then, when the above settings related to the additional resin material Crs are completed, the "molded product homogenization" key 37 in the setting screen Vs is set to ON (step S8). Thus, the solid phase ratio calculation processing unit Fx calculates the estimated solid phase ratio of the molten resin by calculation based on the physical property value data Dc and the solid phase ratio calculation formula data Dm related to the additional resin material Crs, and calculates the set temperature that is the same as the viscosity of the initial resin material Cro (step S9). In addition, the second melting characteristic calculation function unit Fq is used to obtain the second solid phase ratio characteristic Prs using the estimated solid phase ratio of the molten resin corresponding to the screw position [pitch number], and the molding condition conversion processing function unit Fc is used to convert the second melting characteristic (second solid phase ratio characteristic) Prs that is close to the basic melting characteristic (basic solid phase ratio characteristic) Pro within the range of the restriction conditions (step S10).

[0104] The second melting characteristic Prs is registered as data, and as Figure 6 As shown, the graphic display section Vsg in the display 4d performs a graphic display (step S11). In this case, together with the pre-registered basic melting characteristics Pro, Figure 6 In this way, if the basic melting characteristic Pro and the second melting characteristic Prs are graphically displayed in the graphic display section Vsg of the display 4d, the operator can accurately confirm the different states of the resin material through the graphic display, thereby improving the ease and accuracy of implementation from the perspective of achieving optimization.

[0105] Furthermore, when the operator confirms the graphic display and determines that the assimilation is sufficient, the operator turns on the confirmation key (not shown) to change the set temperature and molding conditions (update the process), and the optimization process ends (steps S12 and S13). On the other hand, when the operator confirms the display and determines that the assimilation is insufficient, the operator can change part of the settings again and make fine adjustments (steps S12, S7, etc.). Thus, when the operator finally confirms the display and determines that the assimilation is sufficient, the operator turns on the confirmation key (not shown) to change the set temperature and molding conditions (update the process), and the optimization process ends (steps S12 and S13).

[0106] The above describes the case where the manufacturing batch of the resin material is changed in the condition of switching from the initial resin material Cro to the additional resin material Crs, but the molding optimization method (molding optimization device 1) of this embodiment can also be used in the same way when the grade of the resin material is changed, that is, the type of resin material is the same, but it is changed to a grade that is slightly easier to melt due to changes in the grade of the resin material, specifically, the external environment, etc., or when the same resin material from another company is used.

[0107] Next, refer to Figure 10-13 The following describes verification results for confirming the effectiveness of the molding optimization method of the present embodiment when the grade of the resin material is changed.

[0108] In the verification test, the above-mentioned GPPS pellet material was used as the resin material C, the initial resin material used initially was used as the sample Cgo, and the additional resin material used additionally was used as the sample Cgs. Therefore, the initial resin material Cgo and the additional resin material Cgs are the same resin materials with different grades.

[0109] Fig.10 The physical property values ​​of the initial resin material Cgo and the additional resin material Cgs are shown in FIG. 1 , and the viscosity (calculated value) based on the physical property values ​​is also shown in FIG. Figure 6 The physical property values ​​shown are different, and the latent heat of melting is 0. Fig.10 It can be seen that due to the difference in grades, the viscosity of the initial resin material Cgo is 9.04 [g / 10 min], and the viscosity of the additional resin material Cgs is 14.34 [g / 10 min]. It can be confirmed that the fluidity of the additional resin material Cgs is quite high.

[0110] in addition, Fig.12 The Fig.10 The characteristic line Qgo of the specific heat [J / g·K] of the initial resin material Cgo relative to the temperature [Cel], and the characteristic line Qgs of the specific heat [J / g·K] of the additional resin material Cgs relative to the temperature [Cel] are shown. It can be confirmed that the characteristic lines Qgo and Qgs are also very different. It should be noted that the characteristic lines Qgo and Qgs use data collected by a thermal analysis device.

[0111] On the other hand, Figure 11(a) shows the set temperature for the initial resin material Cgo and the corrected (converted) set temperature for the additional resin material Cgs, that is, the set temperature for the corrected (converted) additional resin material Cga, and Figure 11(b) shows the molding conditions for the initial resin material Cgo and the corrected (converted) molding conditions for the additional resin material Cgs, that is, the molding conditions for the corrected (converted) additional resin material Cga.

[0112] As can be seen from FIG. 11( a ) and FIG. 11( b ), the set temperature of the additional resin material Cga after correction (conversion) is set to be 9.8 [° C.] lower than the set temperature of the initial resin material Cgo, and the screw speed is set to be 50 [rpm] slower.

[0113] Fig.13The strip flow length [mm] measured by a strip flow length measuring device when molding is performed at the set temperature shown in FIG11(a) and the molding conditions shown in FIG11(b) is shown. Lgo represents the strip flow length when the initial resin material Cgo is used, Lgs represents the strip flow length when the additional resin material Cgs without correcting the molding conditions is used, and Lga represents the strip flow length of the additional resin material Cga with corrected (optimized) molding conditions.

[0114] Depend on Fig.13 It can be seen that, relative to the flow length Lgo of the initial resin material Cgo, the flow length Lgs of the additional resin material Cgs whose molding conditions have not been corrected tends to be longer by 22-24 [mm], but the flow length Lga of the additional resin material Cga whose molding conditions have been corrected (optimized) can be roughly consistent with the flow length Lgo of the initial resin material Cgo. Even for resin materials of different grades, the high effectiveness of the molding optimization device 1 (molding optimization method) of this embodiment can be confirmed.

[0115] Therefore, if the conditions for switching from the initial resin material Cro, Cgo to the additional resin material Crs.Cgs include a change in the manufacturing batch of the resin material and / or a change in the grade of the resin material, all issues arising during actual production can be roughly covered. Therefore, from the perspective of solving the issues, the molding optimization method (molding optimization device 1) of the present invention can be most effectively utilized.

[0116] Thus, according to the molding optimization method of the injection molding machine M of the present embodiment, as a basic method, the basic molding conditions for the initial resin material Cro, Cgo used at the initial stage of producing a predetermined molded product, and the basic melting characteristics Pro.Pgo related to the melting state of the initial resin material Cro, Cgo based on the basic molding conditions are preliminarily obtained, and when the additional resin material Crs.Cgs switched from the initial resin material Cro, Cgo for producing the molded product is used, the second molding conditions for the additional resin material Crs.Cgs, and the second melting characteristics Prs, Pgs related to the melting state of the additional resin material Crs.Cgs based on the second molding conditions are obtained, and The second melting characteristics Prs, Pgs are similar to the basic melting characteristics Pro.Pgo, and the second molding conditions are converted to at least the set temperature through a specified conversion unit. Therefore, for example, when a specified molded product is produced, when a new resin material with a different manufacturing batch is added, there is no need for the operator to set the molding conditions again when, for example, the cause cannot be fully determined. This improves production efficiency and reduces defective products. Even when there is a change in the resin material, the homogeneity and quality can be improved by ensuring the same molded product. This allows accurate optimization from a relative point of view, that is, optimization of changes in manufacturing batches and grades of resin materials. Moreover, the molding optimization device 1 of the present embodiment has a molding machine controller 4 provided with an optimization processing unit 5, and the optimization processing unit 5 has a basic molding condition setting function unit Ff, a basic melting characteristic calculation function unit Fp, a second molding condition setting function unit Fs and a second melting characteristic calculation function unit Fq, and has a molding condition conversion processing function unit Fc, which performs conversion processing on the second molding condition including at least the set temperature through a prescribed conversion unit in such a way that the second melting characteristic Prs, Pgs approximates the basic melting characteristic Pro.Pgo, thereby being able to easily and accurately implement the molding optimization method in the injection molding machine M.

[0117] The preferred embodiments are described in detail above, but the present invention is not limited to such embodiments, and the details of the composition, shape, raw materials, quantity, method, etc. can be arbitrarily changed, added, or deleted without departing from the scope of the present invention.

[0118] For example, the initial resin material Cro used in the initial stage does not refer to the initial initial resin material Cro, but refers to the resin material used before the additional resin material Crs, and this designation can be arbitrarily performed by the operator. Specifically, when the molded product using the resin material of the manufacturing batch used for the Nth time is the best, the manufacturing batch used for the Nth time can be selected as the initial resin material Cro, and the manufacturing batch used after the N+1th time can be selected as the additional resin material Crs. In addition, the case where the solid phase ratio characteristics (estimated solid phase ratio characteristics) are used in the basic melting characteristics Pro... and the second melting characteristics Prs... are shown, but various indicators such as those that can quantitatively represent the melting state (melting mode) of the resin material can be used. On the other hand, it is preferred to display the basic melting characteristics Pro... and the second melting characteristics Prs... graphically, but the display is not a necessary component. In addition, as molding conditions for setting limiting conditions, screw speed, back pressure, and cycle time are shown, but other molding conditions can also be set in addition, and the setting of limiting conditions is not necessarily a necessary component. On the other hand, the conditions for switching from the initial resin material Cro, Cgo to the additional resin material Crs.Cgs include a change in the manufacturing batch of the resin material and / or a change in the grade of the resin material, but the same can also be applied when switching according to other conditions such as different manufacturers of the resin material.

[0119] Industrial Applicability

[0120] The molding optimization method and device of the present invention can be used in various injection molding machines that use a screw to inject plasticized molten resin into a mold to produce molded products.

Claims

1. A molding optimization method for an injection molding machine, the molding optimization method for the injection molding machine optimizing molding conditions when a molded product is produced by injecting a plasticized molten resin into a mold using a screw, the molding optimization method being characterized in that basic molding conditions as a basic for an initial resin material used in an initial stage of producing a predetermined molded product and basic melting characteristics as a basic involving a melting state of the initial resin material based on the basic molding conditions are obtained in advance, when an additional resin material switched from the initial resin material used to produce the molded product is used, second molding conditions for the additional resin material and second melting characteristics as a involving a melting state of the additional resin material based on the second molding conditions are obtained, and a conversion process including at least a set temperature is performed on the second molding condition by a predetermined conversion unit in a manner that the second melting characteristics are close to the basic melting characteristics.

2. The molding optimization method of the injection molding machine according to claim 1, characterized in that: The basic melting characteristics include at least basic solid phase ratio characteristics with respect to the screw position.

3. The molding optimization method of the injection molding machine according to claim 1, characterized in that: The basic melting characteristics, the second melting characteristics at least include a second solid phase ratio characteristic for the screw position.

4. The molding optimization method of the injection molding machine according to claim 2, characterized in that: The basic solid phase ratio characteristic uses an estimated solid phase ratio of the molten resin corresponding to the screw position, which is obtained by calculation processing based on the physical property value data related to the initial resin material and solid phase ratio calculation formula data.

5. The molding optimization method of the injection molding machine according to claim 3, characterized in that: The second solid phase ratio characteristic uses an estimated solid phase ratio of the molten resin corresponding to the screw position, which is obtained by calculation processing based on physical property value data related to the additional resin material and solid phase ratio calculation formula data.

6. The molding optimization method of the injection molding machine according to claim 2, characterized in that: In addition to the basic solid phase ratio characteristics, the basic melting characteristics further include one or more of the screw rotation speed, back pressure, and cycle time, for which limiting conditions are respectively set.

7. The molding optimization method of the injection molding machine according to claim 3, characterized in that: In addition to the second solid phase ratio characteristic, the second melting characteristic further includes one or more of a screw rotation speed, a back pressure, and a cycle time for which restriction conditions are respectively set.

8. The molding optimization method of the injection molding machine according to claim 1, characterized in that: The conditions for switching from the initial resin material to the additional resin material include a change in the production lot of the resin material.

9. The molding optimization method of the injection molding machine according to claim 1, characterized in that: The conditions for switching from the initial resin material to the additional resin material include a change in the grade of the resin material.

10. The molding optimization method of an injection molding machine according to claim 1, characterized in that: The conditions for switching from the initial resin material to the additional resin material include a change in the production lot of the resin material and a change in the grade of the resin material.

11. A molding optimization device for an injection molding machine, which optimizes molding conditions when a molded product is produced by injecting a plasticized molten resin into a mold using a screw, the molding optimization device being characterized in that it has a molding machine controller provided with an optimization processing unit, the optimization processing unit having: a basic molding condition setting function unit, which sets basic molding conditions for an initial resin material used in the initial stage of producing a specified molded product; a basic melting characteristic calculation function unit, which calculates basic melting characteristics related to the melting state of the initial resin material based on the basic molding conditions; a second molding condition setting function unit, which sets a second molding condition for an additional resin material switched from the initial resin material for producing the molded product; a second melting characteristic calculation function unit, which calculates a second melting characteristic related to the melting state of the additional resin material based on the second molding condition; and a molding condition conversion processing function unit, which performs conversion processing on the second molding condition including at least a set temperature through a specified conversion unit in a manner such that the second melting characteristic approximates the basic melting characteristic.

12. The molding optimization device for an injection molding machine according to claim 11, characterized in that: The optimization processing unit includes: a basic melting characteristic calculation function unit, which obtains at least a basic solid phase ratio characteristic for the screw position as the basic melting characteristic; and a second melting characteristic calculation function unit, which obtains at least a second solid phase ratio characteristic for the screw position as the second melting characteristic.

13. The molding optimization device for an injection molding machine according to claim 12, characterized in that: The molding machine controller includes a solid phase ratio calculation processing unit, which calculates the estimated solid phase ratio of the basic solid phase ratio characteristic of the molten resin corresponding to the screw position by calculating and processing the physical property value data and solid phase ratio calculation formula data related to the initial resin material, and calculates the estimated solid phase ratio of the second solid phase ratio characteristic of the molten resin corresponding to the screw position by calculating and processing the physical property value data and solid phase ratio calculation formula data related to the additional resin material.

14. The molding optimization device for an injection molding machine according to claim 11, characterized in that: The molding machine controller includes a display having a graphic display unit that graphically displays the basic melting characteristics and the second melting characteristics.

Images