Forming auxiliary method and device for mixed materials of crushed materials

Abstract

The invention provides a molding assisting method and device for a crushed material mixture. A starting material plasticization time (Tv) to a predetermined plasticization end position (Xe) using only the starting material (Rv) and a crushed material plasticization time (Ts) to a predetermined plasticization end position (Xe) using only the crushed material (Rs) under plasticization conditions are measured and registered as basic time data (Do). When producing a molded article from the crushed material mixture (Rm), the crushed material mixture plasticizing time (Tm) up to the plasticizing end position (Xe) during a predetermined injection is measured to obtain measured time data (Dp), and the measured time data (Dp) is calculated on the basis of the raw material plasticizing time (Tv), the crushed material plasticizing time (Ts), and the crushed material mixture plasticizing time (Tm). The crushed material ratio (Px) in the crushed material mixture (Rm) is determined and output.

Description

Technical Field

[0001] The present invention relates to a method and device for assisting the molding of a pulverized material mixture in an injection molding machine for plasticizing a pulverized material mixture obtained by mixing an original material and a pulverized material in a predetermined ratio and performing injection molding. Background Art

[0002] Generally, in production plants using injection molding machines, in addition to raw materials, unnecessary molding materials such as sprues, runners, and defective molding products generated after molding are often reused as molding resin materials. In this case, these unnecessary molding materials are finely crushed to produce crushed materials, which are mixed with raw materials (pellets) at a predetermined ratio and used as crushed material mixed materials.

[0003] Conventionally, as molding units that perform molding using such a pulverized material mixed material, there are known a plastic molding mechanism described in Patent Document 1 and a resin molding device having a function of recycling a sprue material and a runner material described in Patent Document 2.

[0004] The purpose of the plastic molding mechanism described in Patent Document 1 is to provide a plastic molding mechanism that stably and efficiently implements the mixing of coarsely crushed materials and raw materials to reuse the recovered molded products. Specifically, the plastic molding mechanism is configured to include: a conveying unit that conveys the recovered molded products taken out from the molding mold directly to the top of the material drop port of the taking-out device; a coarse crushing unit that is arranged on the upper surface of a raw material feed amount adjustment unit fixed to the upper part of the material drop port and coarsely crushes the conveyed recovered molded products; and a raw material feed amount adjustment unit that has a through hole that allows the recovered molded products coarsely crushed by the coarse crushing unit to fall to the material drop port, and conveys the raw material to the through hole while adjusting the feed amount of the raw material to mix the recovered molded products and the raw material.

[0005] In addition, the purpose of the resin molding device described in Patent Document 2 is to simplify the overall structure of the resin molding device and facilitate cleaning when changing products without having to separately set up a large device for conveying crushed materials of runner materials and runner materials in the molding machine. Specifically, the resin molding device includes a take-out unit for taking out the runner materials and runner materials from the resin molding position of the molding machine, and a crusher for crushing the runner materials and runner materials taken out by the take-out unit, wherein the crushed material discharge port of the crusher is connected to the molding machine so as to supply the crushed material obtained by crushing the runner materials and runner materials supplied from the take-out unit into the molding machine. Summary of the invention

[0006] Problems to be solved by the invention

[0007] However, the conventional molding unit using the above-mentioned pulverized material mixed material still has the following problems.

[0008] That is, the shape and size of each particle in the crushed material used are not constant, but random, so when mixed with the original material, the mixing ratio is prone to deviation. Specifically, in terms of weight ratio, even if the original material (pellet) is 70 [wt%] and the crushed material is 30 [wt%], the molded product may not be mixed in a ratio of 70:30, which is prone to deviation.

[0009] In this case, if it is confirmed that the quality including strength etc. is not a problem if the crushed material is within 30 [wt%], for example, if the molded product exceeds 30 [wt%] due to deviation, it may become an inappropriate molded product and the quality cannot be guaranteed. Therefore, the actual mixing ratio in the molded product becomes important, rather than the ratio during mixing.

[0010] However, since mixing is performed in a molten state, it is not easy to confirm the mixing ratio in the actual molded product. As a result, when there is too much crushed material, the quality may not be guaranteed. On the contrary, when there is too little crushed material, the crushed material cannot be effectively utilized (recycled). Therefore, there has always been a need for an acquisition unit with high effectiveness and accuracy for confirming the mixing ratio in the actual molded product.

[0011] An object of the present invention is to provide a method and apparatus 1 for assisting the molding of a pulverized material mixed material Rm, which solves the problems existing in the above-mentioned background technology.

[0012] Means for solving problems

[0013] The molding assisting method of the pulverized material mixed material Rm of the present invention is characterized in that, when the pulverized material mixed material Rm obtained by plasticizing the original material Rv and the pulverized material Rs in a specified ratio (Px) is injection molded, the original material plasticizing time Tv from the original material Rv used in the pulverized material mixed material Rm under the specified plasticizing conditions to the specified plasticizing end position Xe, and the pulverized material plasticizing time Ts from the pulverized material Rs used in the pulverized material mixed material Rm under the plasticizing conditions to the specified plasticizing end position Xe are measured in advance, and are registered as basic time data Do for processing, and when the pulverized material mixed material Rm is used to produce a molded product, the pulverized material mixed material plasticizing time Tm from the specified injection to the plasticizing end position Xe is measured to obtain the actual measured time data Dp, and based on the original material plasticizing time Tv, the pulverized material plasticizing time Ts and the pulverized material mixed material plasticizing time Tm, the proportion Px of the pulverized material in the pulverized material mixed material Rm is calculated and outputted.

[0014] In addition, the molding auxiliary device 1 of the pulverized material mixed material Rm of the present invention is characterized in that when constituting a molding auxiliary device in an injection molding machine M for plasticizing the pulverized material mixed material Rm obtained by mixing the original material Rv and the pulverized material Rs in a prescribed ratio (Px) and performing injection molding, it is provided with a molding machine controller 2, and the molding machine controller 2 has: a plasticizing condition setting function part Fs, which sets the prescribed plasticizing condition; a basic time data acquisition function part Fo, which measures the original material plasticizing time Tv from the original material Rv used in the pulverized material mixed material Rm under the plasticizing condition to the prescribed plasticizing end position Xe, and the pulverized material Rs used in the pulverized material mixed material Rm under the plasticizing condition. The pulverized material plasticizing time Ts under the plasticizing conditions to the specified plasticizing end position Xe is registered as the basic time data Do; the actual time data acquisition function part Fp measures the pulverized material mixed material plasticizing time Tm in the specified injection to the plasticizing end position Xe when the pulverized material mixed material Rm is used to produce a molded product, and obtains it as the actual time data Dp; the pulverized material ratio calculation function part Fa calculates the pulverized material ratio Px in the pulverized material mixed material Rm based on the original material plasticizing time Tv, the pulverized material plasticizing time Ts and the pulverized material mixed material plasticizing time Tm; and the output processing function part Fe performs output processing on the obtained pulverized material ratio Px.

[0015] On the other hand, according to a preferred embodiment of the present invention, when implementing the molding assisting method, when the crushed material ratio is set to Px [wt%], the crushed material mixed material plasticizing time is set to Tm [seconds], the raw material plasticizing time is set to Tv [seconds], and the crushed material plasticizing time is set to Ts [seconds], the crushed material ratio Px can be obtained by Px = [(Tm-Tv) / (Ts-Tv)] × 100 [wt%] ([Calculation formula 1]). In addition, the crushed material ratio Px can be obtained and outputted at each injection or at every injection at a predetermined interval, and, with respect to the crushed material ratio Px, after the crushed material mixed material plasticizing time Tm is obtained, the delay time Td until it is reflected on the molded product can be calculated, including at least the capacity of the screw 3, and the crushed material ratio Px can be associated with the molded product based on the delay time Td. Furthermore, an upper limit value Pxu and / or a lower limit value Pxd may be set for the crushed material ratio Px, and a quality determination process may be performed to determine that molded products below the upper limit value Pxu and / or above the lower limit value Pxd are acceptable products.

[0016] On the other hand, when the molding auxiliary device 1 is implemented, the plasticizing condition setting function unit Fs may include one or more setting items of the rotation speed of the screw 3, the back pressure for the screw, the set temperature of the heating tube, and the plasticizing end position Xe of the screw. In addition, the molding machine controller 2 may be provided with a quality judgment processing function unit Fj, which sets an upper limit value Pxu and / or a lower limit value Pxd for the crushed material ratio Px obtained by the crushed material ratio calculation function unit Fa, and judges the molded products below the upper limit value Pxu and / or above the lower limit value Pxd as qualified products. In addition, the molding machine controller 2 may be provided with a display 2d for numerically displaying and / or graphically displaying the crushed material ratio Px as an output processing function unit Fe, and the molding machine controller 2 may be provided with an output processing function unit Fe, which judges the molded products exceeding the upper limit value Pxu and / or less than the lower limit value Pxd as inappropriate molded products, and performs a prescribed output processing including an alarm display through the display 2d.

[0017] Effects of the Invention

[0018] According to the method and device 1 for assisting the molding of the pulverized material mixed material Rm of the present invention, the following remarkable effects are achieved.

[0019] (1) The plasticization time Tv of the original material until the specified plasticization end position Xe using only the original material Rv and the plasticization time Ts of the pulverized material until the specified plasticization end position Xe using only the pulverized material Rs under the plasticization conditions are measured and registered as basic time data Do. When a molded product is produced using the pulverized material mixed material Rm, the plasticization time Tm of the pulverized material mixed material until the plasticization end position Xe in the specified injection is measured to obtain the actual measured time data Dp. Based on the plasticization time Tv of the original material, the plasticization time Ts of the pulverized material and the plasticization time Tm of the pulverized material mixed material, the pulverized material ratio Px in the pulverized material mixed material Rm is calculated and outputted, so that the mixing ratio Px of the pulverized material Rs with high accuracy and effectiveness in the actual molded product can be easily obtained. As a result, for example, the disadvantage that the quality cannot be guaranteed due to too much pulverized material Rs, or the disadvantage that the pulverized material Rs cannot be fully reused due to too little pulverized material Rs can be eliminated.

[0020] (2) According to a preferred method, when the crushed material ratio Px is calculated by a molding auxiliary method, when the crushed material ratio is set to Px [wt%], the crushed material mixed material plasticizing time is set to Tm [seconds], the original material plasticizing time is set to Tv [seconds], and the crushed material plasticizing time is set to Ts [seconds], if it is calculated by Px = [(Tm-Tv) / (Ts-Tv)] × 100 [wt%], it can be calculated by using a relatively simple calculation formula, so the accurate crushed material ratio Px can be obtained quickly and easily.

[0021] (3) According to a preferred method, when calculating the crushed material ratio Px, if it is calculated and outputted at each injection or at every predetermined interval, the crushed material ratio Px can be calculated at any injection or injection interval. Therefore, for example, when the crushed material Rs has a large deviation, it can be calculated at each injection; when the crushed material Rs has a small deviation, it can be calculated at every multiple injections, etc., and it can be obtained according to the purpose, with excellent flexibility and convenience.

[0022] (4) According to a preferred method, when calculating the crushed material ratio Px, after calculating the crushed material mixed material plasticization time Tm, the delay time Td is calculated until it is reflected in the molded product, including at least the capacity of the screw 3. If the crushed material ratio Px is associated with the molded product based on the delay time Td, the crushed material ratio Px can be made consistent with the molded product based on the crushed material ratio Px, thereby further improving the accuracy and reliability of the crushed material ratio Px.

[0023] (5) According to a preferred embodiment, if a quality judgment processing function unit Fj is provided in the molding machine controller 2, the quality judgment processing function unit Fj sets an upper limit value Pxu and / or a lower limit value Pxd for the crushed material ratio Px obtained by the crushed material ratio calculation function unit Fa, and judges the molded products below the upper limit value Pxu and / or above the lower limit value Pxd as qualified products, the quality of the molded products can be easily and accurately judged, thereby further improving the quality assurance and reliability of the molded products.

[0024] (6) According to a preferred embodiment, when constituting the plasticizing condition setting function section Fs, if one or more setting items are included among the rotation speed of the screw 3, the back pressure on the screw 3, the set temperature of the heating tube, and the plasticizing end position Xe of the screw 3, the plasticizing condition can be set at the same level as the actual production process, thereby obtaining a reasonable and highly reliable crushed material ratio Px.

[0025] (7) According to a preferred embodiment, when constituting the output processing functional unit Fe, if a display 2d is provided for numerically displaying and / or graphically displaying the crushed material ratio Px, the operator can easily confirm the crushed material ratio Px by visual means, thereby being able to quickly and reliably confirm the actual status of the crushed material ratio Px.

[0026] (8) According to a preferred embodiment, when constructing the molding machine controller 2, if an output processing function unit Fe is provided, and the output processing function unit Fe determines that a molded product that exceeds the upper limit value Pxu and / or is less than the lower limit value Pxd is an inappropriate molded product, and performs a prescribed output processing including an alarm display through the display 2d, it is possible to easily and reliably know that an inappropriate molded product has been generated, and thus necessary error response processing such as discarding the corresponding molded product or changing the plasticizing conditions can be quickly performed. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a flowchart showing a basic time data acquisition process procedure of a pulverized material mixed material molding support method according to a preferred embodiment of the present invention.

[0028] Figure 2 This is a flowchart showing the procedure for obtaining the actual measurement time data during production in the molding assisting method.

[0029] Figure 3 This is a structural diagram showing the mechanical structure of an injection molding machine capable of implementing the molding assist method.

[0030] Figure 4 This is a system block diagram of a processing system (control system) in an injection molding machine capable of implementing the molding assist method.

[0031] Figure 5This is a characteristic diagram of the average plasticizing time used in this molding assist method relative to the ratio of the crushed material.

[0032] Figure 6 It is a graph showing the change of the calculated value of the crushed material ratio with respect to the shot number when the molding assist method is implemented.

[0033] Figure 7 This is a screen diagram showing a display example of a display included in the crushed material mixed material molding auxiliary device according to a preferred embodiment of the present invention. DETAILED DESCRIPTION

[0034] Next, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0035] First, refer to Figure 3-Figure 4 An outline of an injection molding machine M to which the pulverized material mixed material molding assisting method according to the present embodiment can be applied will be described.

[0036] Figure 3 The figure shows an injection molding machine M, in particular, an injection molding machine Mi in which a mold clamping device is omitted. In the injection molding machine Mi, 6 is a heating cylinder, and a nozzle 6n is provided at the front end of the heating cylinder 6 via a head 6s. The nozzle 6n has a function of injecting the molten resin inside the heating cylinder 6 into the mold C shown by the imaginary line.

[0037] On the other hand, a hopper 6h is provided at the upper part near the rear end of the heating cylinder 6. The lower end opening of the hopper 6h is connected to the inside of the heating cylinder 6 through a material drop port 6d formed through the heating cylinder 6. Thus, the crushed material mixed material Rm in the hopper 6h is supplied to the inside of the heating cylinder 6 through the material drop port 6d. The crushed material mixed material Rm is a mixed resin material obtained by mixing the raw material Rv and the crushed material Rs at a predetermined ratio Px.

[0038] It should be noted that in Figure 3 In the figure, 7h indicates a heater attached to the outer peripheral surface of the hopper 6h to heat the resin material Rm contained in the hopper 6h, and 8j indicates a water jacket formed by the heating cylinder 6 around the material drop port 6d. The heater 7h is connected to the power supply circuit 8e in the temperature control driver 8d, and the water jacket 8j is connected to the temperature control water circulation circuit 8w in the temperature control driver 8d. The temperature control water circulation circuit 8w can control the temperature (heat or cool) of the resin material Rm passing through the material drop port 6d by circulating the temperature-controlled water medium (hot water or cooling water) in the water jacket 8j. Furthermore, the power supply circuit 8e and the temperature control water circulation circuit 8w are respectively connected to the controller body 20. Thus, the controller body 20 gives the temperature control driver 8d a control instruction to the power supply circuit 8e and the temperature control water circulation circuit 8w.

[0039] In addition, the screw 3 is loaded inside the heating tube 6 so that it can rotate freely and advance and retreat freely. It should be noted that, considering durability, etc., the surface of the screw is subjected to a coating treatment based on a prescribed surface raw material (metal). The screw 3 has a metering zone Zm, a compression zone Zc, and a feed zone Zf from the front side to the rear side. On the other hand, the rear end of the screw 3 is connected to the screw drive unit 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 is shown as an electric method using an electric motor, but it can also be a hydraulic method using a hydraulic circuit, and the driving method is not limited. Moreover, 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 20. Thus, the controller body 20 gives control commands to the power driver 13d for the screw rotating mechanism 13r and the screw advancing and retracting mechanism 13m. The 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.

[0040] Moreover, the heating tube 6 has a heating tube front portion 6f, a heating tube middle portion 6m, and a heating tube rear portion 6r from the front side to the rear side, and a front heating portion 7f, a middle heating portion 7m, and a rear heating portion 7r are attached to the outer peripheral surface of each portion 6f, 6m, and 6r, respectively. Similarly, a head heating portion 7s is attached to the outer peripheral surface of the head portion 6s, and a nozzle heating portion 7n is attached to the outer peripheral surface of the nozzle 6n. Each of these heating portions 7f, 7m, 7r, 7s, and 7n can be composed of a belt heater or the like. Therefore, the nozzle heating portion 7n, the head heating portion 7s, the front heating portion 7f, the middle heating portion 7m, and the rear heating portion 7r constitute the heating group portion 7( Figure 4 ). Moreover, the heating group 7 is connected to a heater driver 7d, and the heater driver 7d is connected to a controller main body 20. Thus, a control command for each heating part 7f, 7m, 7r, 7s, 7n is given to the heater driver 7d from the controller main body 20, and 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 7d.

[0041] on the other hand, Figure 4The molding machine controller 2 that is in charge of the overall control of the injection molding machine M is shown. The molding machine controller 2 has the above-mentioned controller body 20 with computer functions that has hardware such as a CPU and an internal memory 20m built in, and a display 2d is connected to the controller body 20. The display 2d has a display unit 2dd for displaying necessary information, and is attached with a touch panel 2dt, which can be used to perform various input operations such as input, setting, and selection. In addition, a driver group 24 that drives (operates) various actuators is connected to the controller body 20. The driver group 24 includes Figure 3 The power supply circuit 8e and the temperature control driver 8d, power supply driver 13d and heater driver 7d of the temperature control water circulation circuit 8w are shown.

[0042] Therefore, the molding machine controller 2 includes an HMI control system and a PLC control system, and stores the PLC program and the HMI program in the internal memory 20m. Through the PLC program, the timing actions of various processes in the injection molding machine M, the monitoring of the injection molding machine M, etc. are executed, and through the HMI program, the setting and display of the action parameters of the injection molding machine M, the display of the action monitoring data of the injection molding machine M, etc. are executed. It should be noted that, in addition to this, the internal memory 20m stores the flow analysis processing program and the crushed material processing program Pi.

[0043] In addition, an application program for implementing the molding assist method of the present embodiment, i.e., a crushing material assist processing program Pi, is stored in the internal memory 20m attached to the controller body 20 in association with the present invention, and a flow analysis processing program Ps is stored. It should be noted that the flow analysis processing program Ps can utilize the molding assist device of the injection molding machine already proposed by the applicant (refer to Japanese Patent Publication No. 2020-1183 and Japanese Patent Application No. 2021-121959). That is, accurate information (data) of the melting state of the resin material can be numerically estimated through the estimation processing function.

[0044] Thus, the molding machine controller 2 includes: a plasticizing condition setting function unit Fs, which is the main function unit of the molding auxiliary device 1 and sets the specified plasticizing condition; a basic time data acquisition function unit Fo, which measures the original material plasticizing time Tv from the original material Rv used in the crushed material mixed material Rm to the specified plasticizing end position Xe under the plasticizing condition, and the crushed material plasticizing time Ts from the crushed material Rs used in the crushed material mixed material Rm to the specified plasticizing end position Xe under the plasticizing condition, and registers them as basic time data Do; and an actual time data acquisition function unit Fp, which measures the actual time data acquisition time Tv from the original material Rv used in the crushed material mixed material Rm to the specified plasticizing end position Xe under the plasticizing condition, and registers them as basic time data Do; When the crushed material mixture Rm is used to produce a molded product, the crushed material mixture plasticization time Tm from the specified injection to the plasticization end position Xe is measured and obtained as the measured time data Dp; a crushed material ratio calculation function unit Fa is used to calculate the crushed material ratio Px in the crushed material mixture Rm based on the original material plasticization time Tv, the crushed material plasticization time Ts and the crushed material mixture plasticization time Tm; and an output processing function unit Fe is used to output the obtained crushed material ratio Px, and the molding auxiliary method of the crushed material mixture Rm of this embodiment is executed based on the above-mentioned crushed material auxiliary processing program Pi.

[0045] Next, refer to Figure 4-Figure 7 , the principle of the forming assisting method (forming assisting device 1) of this embodiment will be described.

[0046] Typically, in a production plant using an injection molding machine M, unwanted molded products such as sprue materials, runner materials, and defective molded products are generated after molding. Therefore, in particular when the requirements for the mechanical strength and quality of the molded products are not so high, in addition to raw materials such as pellets, the above-mentioned unwanted molded products are often reused as resin materials for molding.

[0047] When the molded object is not needed for reuse, it is finely pulverized to obtain a pulverized material, which is mixed into the original material in a specified ratio and used as a pulverized material mixed material. The pulverized material is generally used by pulverizing the unnecessary molded object with a pulverizer, but the shape and size of the obtained pulverized material Rs are random. As a result, during plasticization, the molten resin in the heating cylinder 6 generates gaps, and due to insufficient melting of the resin, deviations in the melting state, etc., it is easy to cause a decrease in molding quality, and then it is easy to cause an increase in molding defects, and there is a difficulty in stable molding and production.

[0048] Specifically, during production, even if the crushed material ratio Px is set in advance to 30 [wt%] (crushed material: 30 [wt%], original material: 70 [wt%]) as a molding condition, the content of crushed material Rs in the actual molded product will deviate. As a result, there are difficulties such as too much crushed material Rs and the quality cannot be guaranteed, or too little crushed material Rs and the crushed material Rs cannot be fully reused.

[0049] Therefore, in the present invention, as the property of the crushed material Rs, attention is paid to the possibility that the plasticizing time may be affected by the voids in the resin generated in the heating tube 6 during plasticization or the behavior of the heating tube 6 and the screw 3, that is, the more crushed material Rs, the longer the plasticizing time, and the less crushed material Rs, the shorter the plasticizing time, and its verification is carried out.

[0050] Figure 5 The characteristics of the average plasticizing time [seconds] when the crushed material ratio Px, that is, the mixing ratio of the crushed material Rs [wt%] to the original material Rv [wt%] is changed are shown. Specifically, the results of the average plasticizing time [seconds] of the crushed material mixed material Rm1 with the original material Rv being 100 [wt%] and the crushed material Rs being 0 [wt%], the crushed material mixed material Rm2 with the original material Rv being 70 [wt%] and the crushed material Rs being 30 [wt%], the crushed material mixed material Rm3 with the original material Rv being 30 [wt%] and the crushed material Rs being 70 [wt%], and the crushed material mixed material Rm4 with the original material Rv being 0 [wt%] and the crushed material Rs being 100 [wt%] are shown.

[0051] Depend on Figure 5 It can be seen that the crushed material ratio (mixing ratio) Px has a clear correlation with the average plasticizing time [seconds], and the plasticizing time changes roughly as a linear function relative to the amount of crushed material. That is, if the plasticizing time is measured, the crushed material ratio Px corresponding to the measured time can be estimated.

[0052] Therefore, as an estimated formula (calculation formula), when the proportion of crushed material is set to Px [wt%], the plasticizing time of crushed material mixed material is set to Tm [seconds], the plasticizing time of original material is set to Tv [seconds], and the plasticizing time of crushed material is set to Ts [seconds], it is calculated by the following formula.

[0053] Px=[(Tm-Tv) / (Ts-Tv)]×100[wt%]

[0054] The calculation process based on this calculation formula can be executed by the pulverized material ratio calculation function unit Fa. In this way, the pulverized material ratio Px can be obtained by using a relatively simple calculation formula, so that an accurate pulverized material ratio Px can be obtained quickly and easily.

[0055] Figure 6 The graph showing the change in the calculated value of the crushed material ratio relative to the injection number is shown. Figure 6 The variation curve obtained at each injection is shown, but in actual production, it can also be obtained at each injection at a predetermined interval. In this way, the crushed material ratio Px can be obtained at any injection or injection interval, so for example, when the crushed material Rs has a large deviation, it can be obtained at each injection, and when the crushed material Rs has a small deviation, it can be obtained at each multiple injections, etc., and it can be obtained according to the purpose, and the flexibility and convenience are excellent. Figure 6 Two kinds of pulverized material mixed materials Rm were used, with the pulverized material ratio Px (set ratio) set to 30 [wt %] and 70 [wt %]. Figure 6 It can be seen that variations occur in each injection.

[0056] So, for example, in Figure 6 In the variation curve diagram of 30 [wt%] shown in FIG. 1 , an upper limit value Pxu and a lower limit value Pxd can be set, and the quality judgment can be performed by the quality judgment processing function unit Fj set in the molding machine controller 2. That is, in the molding machine controller 2, for the crushed material ratio Px obtained by the crushed material ratio calculation function unit Fa, one of the upper limit value Pxu or the lower limit value Pxd, or both the upper limit value Pxu and the lower limit value Pxd can be set, and the molded products below the upper limit value Pxu and / or above the lower limit value Pxd are judged as qualified products. If such a quality judgment processing function unit Fj is set, the quality of the molded products can be easily and accurately judged, so the quality assurance and reliability assurance of the molded products can be further improved.

[0057] In addition, the molding machine controller 2 has an output processing function unit Fc, so the display 2d is set Figure 7 The display screen Vm shown as an example in the figure can display information related to the crushed material ratio Px in real time. The display screen Vm shown as an example has a graphic display part Vmg for graphically displaying the crushed material ratio Px at the top, and the crushed material ratio Px is displayed as a horizontal bar graph, and the upper limit value Pxu and the lower limit value Pxd are indicated by triangular pointer marks. Figure 7The state where the crushed material ratio Px is 30 [wt%] is shown, and the state where the upper limit value Pxu is displayed as 35 [wt%] and the lower limit value Pxd is displayed as 25 [wt%] is shown. In addition, a numerical display part Vmn of the measured crushed material ratio Px, the set upper limit value Pxu, and the set lower limit value Pxd is provided below the graphic display part Vmg, and an alarm display part Vma is provided at the bottom of the numerical display part Vmn. The alarm display part Vma is provided with a normal display lamp 4s at the center, an upper limit alarm display lamp 4u is provided on the right side thereof, and a lower limit alarm display lamp 4d is provided on the left side of the normal display lamp 4s. Figure 7 The normal display lamp 4s is shown to be lit.

[0058] In the display screen Vm, the pulverized material ratio Px is displayed in real time by the graphic display part Vmg and the numerical display part Vmn, and when it does not deviate from the upper limit value Pxu and the lower limit value Pxd set in the numerical display part Vmn, the normal display lamp 4s is lit. Figure 7 On the other hand, when the upper limit value Pxu or the lower limit value Pxd is deviated, the corresponding upper limit warning indicator lamp 4u or the lower limit warning indicator lamp 4d can be lit.

[0059] In this way, when constituting the output processing function section Fe, if a display screen Vm having a numerical display section and / or a graphic display section for displaying the crushed material ratio Px is provided on the display 2d, the operator can easily confirm the crushed material ratio Px by visual means, thereby being able to quickly and reliably confirm the actual status of the crushed material ratio Px.

[0060] In addition, if a molded product that exceeds the upper limit value Pxu and / or is less than the lower limit value Pxd is determined to be an inappropriate molded product in the display screen Vm of the output processing function unit Fe, and an alarm display unit is set through the display 2d to perform the specified output processing, it can be easily and reliably known that an inappropriate molded product has been generated, so the necessary error response processing such as discarding the corresponding molded product or changing the plasticizing conditions can be quickly performed.

[0061] It should be noted that when calculating the crushed material ratio Px, after calculating the crushed material mixed material plasticization time Tm, the delay time Td until it is reflected on the molded product can be calculated, including at least the capacity of the screw 3, and the crushed material ratio Px is associated with the molded product based on the delay time Td. In this way, the molded product based on the crushed material ratio Px can be consistent, so the accuracy and reliability of the crushed material ratio Px can be further improved.

[0062] Next, refer to the figures and follow the Figure 1 and Figure 2The flowchart shown explains the operation of the molding assisting device 1 including the molding assisting method of the pulverized material mixed material Rm according to the present embodiment.

[0063] First, refer to Figure 1 The flowchart shown explains the processing in the preparation stage before performing the production process using the molding assist method according to the present embodiment.

[0064] First, the basic time data acquisition function Fo of the molding machine controller 2 is used to obtain the original material plasticization time Tv for the original material Rv related to the specified resin material. In this case, the original material Rv such as pellets is prepared (step S1). In addition, the specified plasticization conditions are set by the plasticization condition setting function Fs in the molding machine controller 2 (step S2). The specific plasticization conditions can include one or more setting items of the rotation speed of the screw 3, the back pressure of the screw 3, the set temperature of the heating cylinder, and the plasticization end position Xe of the screw 3. If such setting items are included, the plasticization conditions of the same level as the actual production process can be set, so that a reasonable and reliable crushed material ratio Px can be obtained.

[0065] Then, only the original material Rv is put into the hopper 6h, that is, 100[%] of the original material Rv is put into the hopper 6h (step S3). If the preparation for the plasticizing process is completed, the plasticizing process is performed based on the set plasticizing conditions (step S4). The plasticizing process sets the screw 3 at the most advanced position (or a specified set position) and performs the plasticizing process from this position. During the plasticizing process, the screw 3 rotates, and the plasticized molten resin accumulates in front of the screw 3, and the screw 3 gradually retreats accordingly. If the screw 3 retreats and reaches the set specified plasticizing end position Xe, the plasticizing process is terminated (step S5). In addition, by the end of the plasticizing process, the original material plasticizing time Tv from the start time of the plasticizing process to the time of reaching the plasticizing end position Xe is obtained (step S6).

[0066] On the other hand, the acquisition process of the pulverized material plasticization time Ts is carried out by performing the same process. In this case, only the pulverized material Rs is prepared (step S7). The pulverized material Rs is obtained by crushing unnecessary molding objects such as runner materials, runner materials and defective molding products generated after the production (molding) of the molded products using the above-mentioned specified resin material using a pulverizer not shown in the figure, and the size and shape of the obtained pulverized material Rs are random. In addition, the specified plasticization conditions are set by the plasticization condition setting function unit Fs (step S8). In this case, basically, the same conditions as the plasticization conditions used in the acquisition process of the above-mentioned original material plasticization time Tv are set.

[0067] Then, only the crushed material Rs is put into the hopper 6h, that is, 100[%] of the crushed material Rs is put into the hopper 6h (step S9). If the preparation for the plasticizing process is completed, the plasticizing process is performed based on the set plasticizing conditions (step S10). The plasticizing process sets the screw 3 to the most advanced position (or a specified set position) and performs the plasticizing process from this position. Thus, similarly to the case of the original material Rv, if the screw 3 retreats and reaches the set specified plasticizing end position Xe, the plasticizing process is terminated (step S11). In addition, by the end of the plasticizing process, the crushed material plasticizing time Ts from the start time of the plasticizing process to the time of reaching the plasticizing end position Xe is obtained (step S12).

[0068] Through the above acquisition process, the original material plasticization time Tv and the crushed material plasticization time Ts are obtained, and thus the basic time data acquisition function Fo of the molding machine controller 2 is registered in the database of the internal memory 20m (step S13). As an example of a database, Figure 4 The database DB1 of the crushed material Rsa, the database DB2 of the crushed material Rsb, etc. are shown in the figure. Thus, the acquisition of the basic time data related to the specified resin material is completed. Therefore, when there are other resin materials, the basic time data can be acquired through the same processing sequence (step S14). Furthermore, when the plasticization time Tv of the original material and the plasticization time Ts of the crushed material are changed by changing the plasticization conditions, the basic time data can also be acquired through the same processing sequence, and the registration items of the database can be updated (step S15). Then, if based on Figure 1 When the processing of the preparation stage before the production process is completed, the prescribed production process (step SP) is implemented.

[0069] Next, refer to Figure 2 The flowchart shown in the figure explains the processing of the production process using the molding assist method according to the present embodiment.

[0070] Now, it is assumed that a production process using a crushed material mixed material Rm is being carried out by an injection molding machine M (step SP), and the crushed material mixed material Rm is obtained by mixing a raw material Rv using a predetermined resin material and a crushed material Rs. It should be noted that the crushed material mixed material Rm as a molding condition can be set in advance by Figure 4 The material input section 34 shown is implemented by a crushed material weight input section 34s and a raw material weight input section 34v.

[0071] On the other hand, in the production process, the molding machine controller 2 monitors the molding cycle of the molding process (step S21). Then, if the molding cycle shifts to the plasticizing process and the plasticizing end position Xe is confirmed, the actual time data acquisition process of the plasticizing time in the injection is performed, that is, the actual time data acquisition function Fp performs the acquisition process of the actual time data Dp (steps S22, S23, S24).

[0072] After obtaining the measured time data Dp, the molding machine controller 2 performs an estimation process (calculation process) of the crushed material ratio Px through the crushed material ratio calculation function unit Fa (step S25). Specifically, the crushed material ratio Px is obtained by Px=[(Tm-Tv) / (Ts-Tv)]×100[wt%] using the original material plasticization time Tv and the crushed material plasticization time Ts registered in the database as the basic time data Do, and using the crushed material mixed material plasticization time Tm as the measured time data Dp.

[0073] Then, the obtained crushed material ratio Px is subjected to a predetermined output process by the output processing function unit Fe of the molding machine controller 2. Figure 7 The display screen Vm is used to display the obtained crushed material ratio Px using the graphic display part Vmg and the numerical display part Vmn (step S26). Afterwards, when the next injection is continued, the same monitoring process is continued (steps S27, S21 ...).

[0074] In addition, the molding machine controller 2 performs a determination process through the quality determination processing function unit Fj (step S28). That is, the crushed material ratio Px is determined based on the set upper limit value Pxu and lower limit value Pxd. Thus, when the crushed material ratio Px is below the upper limit value Pxu or above the lower limit value Pxd, it is determined to be normal, and the normal display lamp 4s is lit. In contrast, when the crushed material ratio Px exceeds the upper limit value Pxu or is less than the lower limit value Pxd, the obtained molded product is determined to be an inappropriate molded product, and the necessary error response process is performed through the alarm display unit Vma provided on the display 2d (steps S29, S30).

[0075] Thus, according to the molding assisting method (molding assisting device 1) of the present embodiment, as a basic structure, the original material plasticizing time Tv until the specified plasticizing end position Xe using only the original material Rv and the pulverized material plasticizing time Ts until the specified plasticizing end position Xe using only the pulverized material Rs under the plasticizing condition are measured and registered as basic time data Do, and when the molded product is produced using the pulverized material mixed material Rm, the pulverized material mixed material plasticizing time Tm until the plasticizing end position Xe in the specified injection is measured to obtain the measured time data Dp, and based on the original material plasticizing time Tv, the pulverized material plasticizing time Ts and the pulverized material mixed material plasticizing time Tm, the pulverized material ratio Px in the pulverized material mixed material Rm is calculated and outputted, so that the mixing ratio Px of the pulverized material Rs with high accuracy and effectiveness in the actual molded product can be easily obtained. As a result, for example, it is possible to eliminate the disadvantage that the quality cannot be guaranteed due to too much pulverized material Rs, or the disadvantage that the pulverized material Rs cannot be fully reused due to too little pulverized material Rs.

[0076] The preferred embodiment is described in detail above, but the present invention is not limited to such an embodiment, and the subtle structure, shape, raw materials, materials, quantity, numerical value, method, etc. can be arbitrarily changed, added, or deleted without departing from the gist of the present invention.

[0077] For example, the plasticizing condition setting function unit Fs includes one or more setting items of the rotation speed of the screw 3, the back pressure of the screw 3, the set temperature of the heating tube 6, and the plasticizing end position Xe of the screw 3, but other plasticizing conditions may also be included. In addition, the case where both the upper limit value Pxu and the lower limit value Pxd are set for the crushed material ratio Px is shown, but the case where only one of the upper limit value Pxu and the lower limit value Pxd is set is not excluded, and in particular, only the upper limit value Pxu may be set. In addition, the upper limit value Pxu and the lower limit value Pxd may also be set in multiple stages respectively. For example, a more detailed judgment such as issuing a preliminary alarm may also be made by setting a first upper limit value (preliminary upper limit value) and a second upper limit value (formal upper limit value) for the upper limit value Pxu. On the other hand, the case where the original material plasticizing time Tv and the crushed material plasticizing time Ts are respectively registered as basic time data Do is shown, but it may also be registered as an arithmetic formula for obtaining the crushed material ratio Px, and the crushed material ratio Px is obtained by the arithmetic formula and the measured time data Dp. In addition, the quality determination processing function unit Fj of the molding machine controller 2 is not an essential component and does not necessarily need to be provided. In addition, it is preferable to provide an alarm display of the output processing function unit Fe, but it is not an essential component.

[0078] Industrial Applicability

[0079] The present invention can be used as a method and apparatus for assisting the molding of a pulverized material mixture in various injection molding machines for plasticizing a pulverized material mixture obtained by mixing an original material and a pulverized material at a predetermined ratio and performing injection molding.

[0080] Explanation of symbols

[0081] 1: Molding auxiliary device, 2: Molding machine controller, 2d: Display, 3: Screw, Rm: Mixed material of crushed material, Rv: Raw material, Rs: Crushed material, Px: Crushed material ratio, Fs: Plasticizing condition setting function, Fo: Basic time data acquisition function, Fp: Measured time data acquisition function, Fa: Crushed material ratio calculation function, Fe: Output processing function, Fj: Good or bad judgment processing function, Pxu: Upper limit value, Pxd: Lower limit value, Vmn: Numerical display, Vmg: Graphic display, Vma: Alarm display

[0082] Prior art literature

[0083] Patent Document 1: Japanese Patent Publication No. 2007-125818

[0084] Patent Document 2: Japanese Patent Publication No. H7(1995)-304038

Claims

1. A method for assisting the molding of a pulverized material mixture, which is a method for assisting the molding of a pulverized material mixture by an injection molding machine that plasticizes a pulverized material mixture obtained by mixing an original material and a pulverized material in a predetermined ratio and performs injection molding, characterized in that: The plasticizing time of the original material from the original material used in the pulverized material mixture under the specified plasticizing conditions to the specified plasticizing end position, and the plasticizing time of the pulverized material from the pulverized material used in the pulverized material mixture under the specified plasticizing conditions to the specified plasticizing end position are measured in advance, and are registered as basic time data. When the pulverized material mixture is used to produce a molded product, the plasticizing time of the pulverized material mixture in the specified injection to the plasticizing end position is measured to obtain the actual time data. Based on the plasticizing time of the original material, the plasticizing time of the pulverized material and the plasticizing time of the pulverized material mixture, the proportion of the pulverized material in the pulverized material mixture is calculated and outputted.

2. The method for assisting the forming of a crushed material mixed material according to claim 1, characterized in that: When the crushed material ratio is set to Px, the unit is wt%, the crushed material mixed material plasticizing time is set to Tm, the unit is second, the original material plasticizing time is set to Tv, the unit is second, and the crushed material plasticizing time is set to Ts, the unit is second, the crushed material ratio is calculated by the following calculation formula: Px=[(Tm-Tv) / (Ts-Tv)]×100[wt%].

3. The method for assisting the forming of a crushed material mixed material according to claim 1, characterized in that: The crushed material ratio is obtained at each injection or at predetermined intervals and outputted.

4. The method for assisting the forming of a crushed material mixed material according to claim 1, characterized in that: Regarding the pulverized material ratio, after the pulverized material mixed material plasticization time is calculated, the delay time until it is reflected in the molded product is calculated, including at least the capacity of the screw, and the pulverized material ratio is associated with the molded product based on the delay time.

5. The method for assisting the forming of a crushed material mixed material according to claim 1, characterized in that: By setting an upper limit value for the crushed material ratio, a quality determination process is performed in which a molded product having a value below the upper limit value is determined as a non-defective product.

6. The method for assisting the forming of a crushed material mixed material according to claim 1, characterized in that: By setting a lower limit value for the crushed material ratio, a quality determination process is performed in which a molded product having a value above the lower limit value is determined as a non-defective product.

7. A pulverized material mixed material molding auxiliary device, which is a pulverized material mixed material molding auxiliary device for an injection molding machine that plasticizes a pulverized material mixed material obtained by mixing an original material and a pulverized material in a predetermined ratio and performs injection molding, characterized in that: The molding assisting device is provided with a molding machine controller, which has: a plasticizing condition setting function unit, which sets a specified plasticizing condition; a basic time data acquisition function unit, which measures the plasticizing time of the original material used in the pulverized material mixed material under the plasticizing condition to the specified plasticizing end position, and the plasticizing time of the pulverized material used in the pulverized material mixed material under the plasticizing condition to the specified plasticizing end position, and registers them as basic time data; an actual time data acquisition function unit, which measures the plasticizing time of the pulverized material mixed material to the plasticizing end position in a specified injection when a molded product is produced using the pulverized material mixed material, and acquires them as actual time data; a pulverized material ratio calculation function unit, which calculates the pulverized material ratio in the pulverized material mixed material based on the original material plasticizing time, the pulverized material plasticizing time and the pulverized material mixed material plasticizing time; and an output processing function unit, which performs output processing on the obtained pulverized material ratio.

8. The crushed material mixed material forming auxiliary device according to claim 7, characterized in that: The plasticizing condition setting function unit includes one or more setting items of the screw rotation speed, the back pressure on the screw, the set temperature of the heating cylinder, and the plasticizing end position of the screw.

9. The crushed material mixed material forming auxiliary device according to claim 7, characterized in that: The molding machine controller includes a display for numerically displaying and / or graphically displaying the crushed material ratio as the output processing function unit.

10. The crushed material mixed material forming auxiliary device according to claim 7, characterized in that: The molding machine controller includes a quality determination processing function unit that sets an upper limit value for the pulverized material ratio obtained by the pulverized material ratio calculation function unit and determines that the molded products below the upper limit value are good products.

11. The crushed material mixed material forming auxiliary device according to claim 10, characterized in that: The molding machine controller includes the output processing function unit that determines a molded product exceeding the upper limit value as an inappropriate molded product and performs a predetermined output process including an alarm display through a display.

12. The crushed material mixed material forming auxiliary device according to claim 7, characterized in that: The molding machine controller includes a quality determination processing function unit that sets a lower limit value for the pulverized material ratio obtained by the pulverized material ratio calculation function unit and determines that the molded products having a value above the lower limit value are acceptable products.

13. The crushed material mixed material forming auxiliary device according to claim 12, characterized in that: The molding machine controller includes the output processing function unit that determines that a molded product having a value smaller than the lower limit value is an inappropriate molded product and performs a predetermined output process including an alarm display through a display.

Images