Injection molding machine, management device, and management system

Abstract

According to the invention, the working efficiency is improved. An injection molding machine according to an embodiment includes: a mold device to which a molding material is injected by an injection device; a detection unit that, when the molding material has been injected, detects a condition relating to an object discharged from a gap provided in the mold device; and a control device that determines whether or not an abnormality has occurred in the mold device on the basis of the condition relating to the object discharged from the gap.

Description

Technical Field

[0001] This application claims priority based on Japanese Patent Application No. 2023-184952 filed on October 27, 2023. The entire contents of the Japanese Patent Application are incorporated herein by reference.

[0002] The invention relates to an injection molding machine, a management device and a management system. Background Art

[0003] Conventionally, an injection molding machine is provided with an exhaust port for exhausting gas generated by a molding material filled in a mold device from the mold device to the outside.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2001-162625

[0005] However, in the technology described in Patent Document 1, if injection molding is repeated, components contained in the exhausted gas adhere to and accumulate inside the exhaust port, and by blocking the exhaust port, it may be difficult to fully exhaust the gas from the cavity in the mold device. In the case where the gas cannot be fully exhausted from the cavity in the mold device, the gas becomes high temperature due to adiabatic compression, and the molding material may become defective due to burning. Summary of the invention

[0006] One aspect of the present invention provides a technology for improving work efficiency by understanding the status of a mold device.

[0007] An injection molding machine involved in one embodiment of the present invention comprises: a mold device, through which a molding material is injected; a detection unit, when the molding material is injected, detects a condition related to an object discharged from a gap set in the mold device; and a control device, based on the condition related to the object discharged from the gap, determines whether an abnormality has occurred in the mold device.

[0008] Effects of the Invention

[0009] According to one aspect of the present invention, the working efficiency is improved by understanding the status of the mold device. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 This is a diagram showing a state of the injection molding machine according to one embodiment when mold opening is completed.

[0011] Figure 2 It is a diagram showing a state of the injection molding machine according to one embodiment when the mold is clamped.

[0012] Figure 3 It is a diagram showing an example of the functional configuration of the control device according to the first embodiment.

[0013] Figure 4 It is a cross-sectional view showing the mold device according to the first embodiment.

[0014] Figure 5 This is a diagram showing the correspondence between the number of shots and the magnitude of the discharge sound from the start of injection molding.

[0015] Figure 6 This is a diagram illustrating an example of a setting screen output by the output control unit according to the first embodiment.

[0016] Figure 7 It is a diagram illustrating an example of a log information screen output by the output control unit according to the first embodiment.

[0017] Figure 8 This is a flowchart showing a processing procedure based on the ejection sound from the mold device, which is executed by the control device according to the first embodiment.

[0018] Fig. 9 It is a figure which shows the dimension of the exhaust port of the mold apparatus which concerns on 2nd Embodiment by example.

[0019] Fig.10 This is a conceptual diagram showing a management system according to the seventh embodiment.

[0020] In the figure: 10-injection molding machine, 700-control device, 701-CPU, 702-storage medium, 702A-threshold information storage unit, 705-communication interface, 711-acquisition unit, 712-determination unit, 713-output control unit, 714-injection molding control unit, 715-log information storage unit, 760-display device, 2011-management device, 2012-storage device. DETAILED DESCRIPTION

[0021] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, the embodiments described below are not intended to limit the embodiments of the invention, but are intended to illustrate, and all features and combinations thereof described in the embodiments may not necessarily be the essence of the invention. In addition, in each of the accompanying drawings, the same or corresponding structures are marked with the same or corresponding symbols, and the description is sometimes omitted.

[0022] Figure 1 It is a diagram showing a state of the injection molding machine according to the first embodiment when mold opening is completed.

[0023] Figure 21 is a diagram showing a state of the injection molding machine involved in the first embodiment when the mold is clamped. In this specification, the X-axis direction, the Y-axis direction and the Z-axis direction are directions perpendicular to each other. The X-axis direction and the Y-axis direction represent horizontal directions, and the Z-axis direction represents a vertical direction. When the mold clamping device 100 is horizontal, the X-axis direction is the mold opening and closing direction, and the Y-axis direction is the width direction of the injection molding machine 10. The negative side of the Y-axis direction is called the operating side, and the positive side of the Y-axis direction is called the opposite side of the operating side.

[0024] like Figure 1-2 As shown, the injection molding machine 10 includes: a mold clamping device 100 for opening and closing a mold device 800; an ejection device 200 for ejecting a molded product molded by the mold device 800; an injection device 300 for injecting a molding material into the mold device 800; a moving device 400 for moving the injection device 300 forward and backward relative to the mold device 800; a control device 700 for controlling each component of the injection molding machine 10; and a frame 900 for supporting each component of the injection molding machine 10. The frame 900 includes a mold clamping device frame 910 for supporting the mold clamping device 100 and an injection device frame 920 for supporting the injection device 300. The mold clamping device frame 910 and the injection device frame 920 are respectively installed on the floor 2 via a leveling adjuster 930. The control device 700 is arranged in the internal space of the injection device frame 920. Hereinafter, each component of the injection molding machine 10 will be described.

[0025] (Mold clamping device)

[0026] In the description of the mold clamping device 100, the moving direction of the movable platen 120 when the mold is closed (for example, the positive direction of the X axis) is set to the front, and the moving direction of the movable platen 120 when the mold is opened (for example, the negative direction of the X axis) is set to the rear.

[0027] The mold clamping device 100 performs mold closing, pressurization, mold clamping, depressurization, and mold opening of the mold device 800. The mold device 800 includes a fixed mold 810 and a movable mold 820. The mold clamping device 100 is, for example, a horizontal type, and the mold opening and closing direction is a horizontal direction. The mold clamping device 100 includes a fixed platen 110 on which the fixed mold 810 is mounted, a movable platen 120 on which the movable mold 820 is mounted, and a moving mechanism 102 that moves the movable platen 120 relative to the fixed platen 110 in the mold opening and closing direction.

[0028] The fixed platen 110 is fixed to the mold clamping device frame 910. The fixed mold 810 is mounted on the surface of the fixed platen 110 that faces the movable platen 120.

[0029] The movable platen 120 is arranged to be movable in the mold opening and closing direction relative to the mold clamping device frame 910. A guide 101 for guiding the movable platen 120 is laid on the mold clamping device frame 910. The movable mold 820 is mounted on the surface of the movable platen 120 facing the fixed platen 110.

[0030] The moving mechanism 102 closes, pressurizes, clamps, releases, and opens the mold of the mold device 800 by moving the movable platen 120 forward and backward relative to the fixed platen 110. The moving mechanism 102 includes: a toggle seat 130, which is arranged at a distance from the fixed platen 110; a connecting rod 140, which connects the fixed platen 110 and the toggle seat 130; a toggle mechanism 150, which moves the movable platen 120 relative to the toggle seat 130 in the mold opening and closing direction; a clamping motor 160, which operates the toggle mechanism 150; a motion conversion mechanism 170, which converts the rotational motion of the clamping motor 160 into a linear motion; and a mold thickness adjustment mechanism 180, which adjusts the distance between the fixed platen 110 and the toggle seat 130.

[0031] The toggle seat 130 is arranged at a distance from the fixed platen 110 and is placed on the mold clamping device frame 910 so as to be movable in the mold opening and closing direction. In addition, the toggle seat 130 may be arranged so as to be movable along a guide member laid on the mold clamping device frame 910. The guide member of the toggle seat 130 may be common to the guide member 101 of the movable platen 120.

[0032] In addition, in the present embodiment, the fixed pressure plate 110 is fixed to the mold clamping device frame 910, and the elbow seat 130 is configured to be freely movable relative to the mold clamping device frame 910 along the mold opening and closing direction, but the elbow seat 130 may also be fixed to the mold clamping device frame 910, and the fixed pressure plate 110 may be configured to be freely movable relative to the mold clamping device frame 910 along the mold opening and closing direction.

[0033] The connecting rod 140 connects the fixed platen 110 and the toggle seat 130 at a distance L in the mold opening and closing direction. A plurality of connecting rods 140 (e.g., 4) may be used. The plurality of connecting rods 140 are arranged in parallel in the mold opening and closing direction and extend according to the mold clamping force. A connecting rod strain detector 141 for detecting the strain of the connecting rod 140 may be provided on at least one of the connecting rods 140. The connecting rod strain detector 141 sends a signal indicating its detection result to the control device 700. The detection result of the connecting rod strain detector 141 is used for detecting the mold clamping force, etc.

[0034] In addition, in the present embodiment, the tie rod strain detector 141 is used as the mold clamping force detector for detecting the mold clamping force, but the present invention is not limited to this. The mold clamping force detector is not limited to the strain type, and may be a piezoelectric type, a capacitive type, a hydraulic type, an electromagnetic type, etc., and its installation position is not limited to the tie rod 140.

[0035] The toggle mechanism 150 is arranged between the movable platen 120 and the toggle seat 130, and moves the movable platen 120 in the mold opening and closing direction relative to the toggle seat 130. The toggle mechanism 150 includes a crosshead 151 that moves in the mold opening and closing direction and a pair of link groups that are extended and retracted by the movement of the crosshead 151. The pair of link groups each includes a first link 152 and a second link 153 that are connected to each other by a pin or the like so as to be retractable. The first link 152 is swingably mounted on the movable platen 120 by a pin or the like. The second link 153 is swingably mounted on the toggle seat 130 by a pin or the like. The second link 153 is mounted on the crosshead 151 via a third link 154. When the crosshead 151 is moved forward and backward relative to the toggle seat 130, the first link 152 and the second link 153 are extended and retracted, and the movable platen 120 moves forward and backward relative to the toggle seat 130.

[0036] In addition, the structure of the toggle mechanism 150 is not limited to Figure 1 and Figure 2 For example, in Figure 1 and Figure 2 In the embodiment, the number of nodes of each link group is five, but may be four. One end of the third link 154 may be connected to the node between the first link 152 and the second link 153 .

[0037] The mold clamping motor 160 is mounted on the toggle base 130 and operates the toggle mechanism 150. The mold clamping motor 160 causes the cross head 151 to move forward and backward relative to the toggle base 130, thereby extending and retracting the first link 152 and the second link 153, and causing the movable platen 120 to move forward and backward relative to the toggle base 130. The mold clamping motor 160 is directly connected to the motion conversion mechanism 170, but may also be connected to the motion conversion mechanism 170 via a belt, a pulley, or the like.

[0038] The motion conversion mechanism 170 converts the rotational motion of the mold clamping motor 160 into the linear motion of the cross head 151. The motion conversion mechanism 170 includes a screw shaft and a screw nut screwed with the screw shaft. Balls or rollers may be interposed between the screw shaft and the screw nut.

[0039] The mold clamping device 100 performs a mold closing process, a pressure increasing process, a mold clamping process, a pressure releasing process, a mold opening process, and the like under the control of the control device 700 .

[0040] In the mold closing process, the mold clamping motor 160 is driven to move the crosshead 151 to the mold closing completion position at a set moving speed, thereby moving the movable platen 120 forward and bringing the movable mold 820 into contact with the fixed mold 810. The position and moving speed of the crosshead 151 are detected using, for example, a mold clamping motor encoder 161. The mold clamping motor encoder 161 detects the rotation of the mold clamping motor 160 and sends a signal indicating the detection result to the control device 700.

[0041] In addition, the crosshead position detector for detecting the position of the crosshead 151 and the crosshead moving speed detector for detecting the moving speed of the crosshead 151 are not limited to the mold clamping motor encoder 161, and a general detector can be used. In addition, the movable platen position detector for detecting the position of the movable platen 120 and the movable platen moving speed detector for detecting the moving speed of the movable platen 120 are not limited to the mold clamping motor encoder 161, and a general detector can be used.

[0042] In the pressure increasing step, the mold clamping motor 160 is further driven to further advance the cross head 151 from the mold closing completion position to the mold clamping position, thereby generating a mold clamping force.

[0043] In the mold clamping process, the mold clamping motor 160 is driven to maintain the position of the cross head 151 at the mold clamping position. In the mold clamping process, the mold clamping force generated in the pressure increasing process is maintained. In the mold clamping process, a cavity space 801 is formed between the movable mold 820 and the fixed mold 810 (refer to Figure 2 ), the injection device 300 fills the liquid molding material into the cavity space 801. The filled molding material is solidified to obtain a molded product.

[0044] The number of cavity spaces 801 may be one or more. In the latter case, multiple molded products can be obtained at the same time. It is also possible to configure an insert in a part of the cavity space 801 and fill the molding material in another part of the cavity space 801. A molded product in which the insert and the molding material are integrated can be obtained.

[0045] In the depressurization process, the mold clamping motor 160 is driven to retract the crosshead 151 from the mold clamping position to the mold opening start position, so that the movable platen 120 is retracted to reduce the mold clamping force. The mold opening start position and the mold closing completion position may be the same position.

[0046] In the mold opening process, the mold clamping motor 160 is driven to move the crosshead 151 back from the mold opening start position to the mold opening completion position at a set moving speed, so that the movable platen 120 is moved back and the movable mold 820 is separated from the fixed mold 810. Then, the ejector device 200 ejects the molded product from the movable mold 820.

[0047] The setting conditions in the mold closing process, the pressure increasing process and the mold clamping process are set together as a series of setting conditions. For example, the moving speed and position (including the mold closing start position, the moving speed switching position, the mold closing completion position and the mold clamping position) and the mold clamping force of the crosshead 151 in the mold closing process and the pressure increasing process are set together as a series of setting conditions. The mold closing start position, the moving speed switching position, the mold closing completion position and the mold clamping position are arranged in sequence from the back to the front, indicating the starting point and end point of the interval for setting the moving speed. Set the moving speed for each interval. The moving speed switching position can be one or more. The moving speed switching position can also be not set. Only one of the mold clamping position and the mold clamping force can be set.

[0048] The setting conditions in the pressure release process and the mold opening process are also set in the same way. For example, the moving speed and position (mold opening start position, moving speed switching position and mold opening completion position) of the crosshead 151 in the pressure release process and the mold opening process are set together as a series of setting conditions. The mold opening start position, the moving speed switching position and the mold opening completion position are arranged in sequence from the front to the back, indicating the starting point and end point of the interval for setting the moving speed. The moving speed is set for each interval. The moving speed switching position can be one or more. The moving speed switching position can also be not set. The mold opening start position and the mold closing completion position can be the same position. In addition, the mold opening completion position and the mold closing start position can be the same position.

[0049] Alternatively, the moving speed and position of the movable platen 120 may be set instead of the moving speed and position of the crosshead 151. Furthermore, the mold clamping force may be set instead of the position of the crosshead 151 (for example, the mold clamping position) and the position of the movable platen 120.

[0050] The toggle mechanism 150 amplifies the driving force of the mold clamping motor 160 and transmits it to the movable platen 120. This amplification ratio is also called a toggle ratio. The toggle ratio changes according to the angle θ (hereinafter also referred to as "link angle θ") formed by the first link 152 and the second link 153. The link angle θ is obtained according to the position of the crosshead 151. When the link angle θ is 180°, the toggle ratio is maximum.

[0051] When the thickness of the mold device 800 changes due to replacement of the mold device 800 or temperature change of the mold device 800, mold thickness adjustment is performed to obtain a predetermined mold clamping force when the mold is clamped. In the mold thickness adjustment, for example, the interval L between the fixed platen 110 and the toggle seat 130 is adjusted so that the link angle θ of the toggle mechanism 150 becomes a predetermined angle at the mold contact moment when the movable mold 820 contacts the fixed mold 810.

[0052] The mold clamping device 100 has a mold thickness adjustment mechanism 180. The mold thickness adjustment mechanism 180 adjusts the mold thickness by adjusting the interval L between the fixed platen 110 and the toggle seat 130. In addition, the mold thickness adjustment timing is performed, for example, during the period from the end of the molding cycle to the start of the next molding cycle. The mold thickness adjustment mechanism 180 has, for example, a screw shaft 181 formed at the rear end of the connecting rod 140, a screw nut 182 that is rotatable and cannot be moved forward or backward and is held on the toggle seat 130, and a mold thickness adjustment motor 183 that rotates the screw nut 182 that is screwed to the screw shaft 181.

[0053] The lead screw shaft 181 and the lead screw nut 182 are provided on each connecting rod 140. The rotational driving force of the mold thickness adjustment motor 183 can be transmitted to the plurality of lead screw nuts 182 via the rotational driving force transmission unit 185. The plurality of lead screw nuts 182 can be rotated synchronously. In addition, by changing the transmission path of the rotational driving force transmission unit 185, the plurality of lead screw nuts 182 can also be rotated individually.

[0054] The rotational driving force transmission part 185 is composed of, for example, gears. In this case, a driven gear is formed on the outer periphery of each lead screw nut 182, a driving gear is mounted on the output shaft of the mold thickness adjustment motor 183, and an intermediate gear meshing with a plurality of driven gears and the driving gear is rotatably held at the center of the toggle seat 130. In addition, the rotational driving force transmission part 185 may be composed of a belt and a pulley instead of a gear.

[0055] The operation of the mold thickness adjustment mechanism 180 is controlled by the control device 700. The control device 700 drives the mold thickness adjustment motor 183 to rotate the lead screw nut 182. As a result, the position of the toggle seat 130 relative to the connecting rod 140 is adjusted, and the interval L between the fixed platen 110 and the toggle seat 130 is adjusted. In addition, a plurality of mold thickness adjustment mechanisms may be used in combination.

[0056] The interval L is detected using the mold thickness adjustment motor encoder 184. The mold thickness adjustment motor encoder 184 detects the rotation amount and rotation direction of the mold thickness adjustment motor 183, and sends a signal indicating the detection result to the control device 700. The detection result of the mold thickness adjustment motor encoder 184 is used to monitor and control the position of the toggle seat 130 and the interval L. In addition, the toggle seat position detector for detecting the position of the toggle seat 130 and the interval detector for detecting the interval L are not limited to the mold thickness adjustment motor encoder 184, and a general detector can be used.

[0057] The mold clamping device 100 may include a mold temperature regulator for regulating the temperature of the mold device 800. The mold device 800 has a flow path of a temperature regulating medium therein. The mold temperature regulator regulates the temperature of the mold device 800 by regulating the temperature of the temperature regulating medium supplied to the flow path of the mold device 800.

[0058] Furthermore, the mold clamping device 100 of the present embodiment is a horizontal type in which the mold opening and closing direction is the horizontal direction, but may be a vertical type in which the mold opening and closing direction is the vertical direction.

[0059] The mold clamping device 100 of this embodiment includes the mold clamping motor 160 as a driving source, but may include a hydraulic cylinder instead of the mold clamping motor 160. Furthermore, the mold clamping device 100 may include a linear motor for mold opening and closing and an electromagnet for mold clamping.

[0060] (Ejector device)

[0061] In the description of the ejection device 200, similar to the description of the mold clamping device 100, the moving direction of the movable platen 120 when the mold is closed (for example, the positive direction of the X-axis) is set to the front and the moving direction of the movable platen 120 when the mold is opened (for example, the negative direction of the X-axis) is set to the rear.

[0062] The ejector device 200 is mounted on the movable platen 120 and moves forward and backward together with the movable platen 120. The ejector device 200 includes an ejector rod 210 for ejecting a molded product from the mold device 800, and a drive mechanism 220 for moving the ejector rod 210 in the moving direction of the movable platen 120 (X-axis direction).

[0063] The ejector rod 210 is arranged to be able to move forward and backward in the through hole of the movable platen 120. The front end of the ejector rod 210 contacts the ejector plate 826 of the movable mold 820. The front end of the ejector rod 210 may be connected to the ejector plate 826 or may not be connected thereto.

[0064] The driving mechanism 220 includes, for example, an ejector motor and a motion conversion mechanism that converts the rotational motion of the ejector motor into the linear motion of the ejector rod 210. The motion conversion mechanism includes a screw shaft and a screw nut screwed with the screw shaft. Balls or rollers may be interposed between the screw shaft and the screw nut.

[0065] The ejector device 200 performs an ejection process under the control of the control device 700. In the ejection process, the ejector rod 210 is moved forward from the standby position to the ejection position at a set moving speed, and the ejector plate 826 is moved forward to eject the molded product. Then, the ejector motor is driven to move the ejector rod 210 backward at the set moving speed, and the ejector plate 826 is moved backward to the original standby position.

[0066] The position and moving speed of the ejector rod 210 are detected using, for example, an ejector motor encoder. The ejector motor encoder detects the rotation of the ejector motor and sends a signal indicating the detection result to the control device 700. In addition, the ejector rod position detector that detects the position of the ejector rod 210 and the ejector rod moving speed detector that detects the moving speed of the ejector rod 210 are not limited to the ejector motor encoder, and a general detector can be used.

[0067] (Injection device)

[0068] In the description of the injection device 300, unlike the description of the mold clamping device 100 or the description of the ejection device 200, the moving direction of the screw 330 during filling (for example, the negative direction of the X-axis) is set to the front and the moving direction of the screw 330 during metering (for example, the positive direction of the X-axis) is set to the rear.

[0069] The injection device 300 is provided on a sliding base 301, and the sliding base 301 is configured to be able to move forward and backward relative to the injection device frame 920. The injection device 300 is configured to be able to move forward and backward relative to the mold device 800. The injection device 300 contacts the mold device 800 and fills the molding material measured in the cylinder 310 into the cavity space 801 in the mold device 800. The injection device 300 includes, for example: a cylinder 310 for heating the molding material; a nozzle 320 provided at the front end of the cylinder 310; a screw 330 configured to be able to move forward and backward and rotate freely in the cylinder 310; a metering motor 340 for rotating the screw 330; an injection motor 350 for moving the screw 330 forward and backward; and a load detector 360 for detecting the load transmitted between the injection motor 350 and the screw 330.

[0070] The cylinder 310 heats the molding material supplied from the supply port 311. The molding material includes, for example, resin. The molding material is formed into, for example, granules and supplied to the supply port 311 in a solid state. The supply port 311 is formed at the rear of the cylinder 310. A cooler 312 such as a water-cooled cylinder is provided on the outer periphery of the rear of the cylinder 310. A heater 313 such as a belt heater and a temperature detector 314 are provided on the outer periphery of the cylinder 310 in front of the cooler 312.

[0071] The cylinder 310 is divided into a plurality of regions in the axial direction (e.g., X-axis direction) of the cylinder 310. Heaters 313 and temperature detectors 314 are respectively provided in the plurality of regions. Set temperatures are respectively set in the plurality of regions, and the control device 700 controls the heater 313 so that the detection temperature of the temperature detector 314 becomes the set temperature.

[0072] The nozzle 320 is set at the front end of the cylinder 310 and is pressed against the mold device 800. A heater 313 and a temperature detector 314 are provided on the outer periphery of the nozzle 320. The control device 700 controls the heater 313 so that the detected temperature of the nozzle 320 becomes the set temperature.

[0073] The screw 330 is arranged to be rotatable and to be able to move forward and backward freely in the cylinder 310. When the screw 330 is rotated, the molding material is sent forward along the spiral groove of the screw 330. While the molding material is sent forward, it is gradually melted by the heat from the cylinder 310. As the liquid molding material is sent forward to the front of the screw 330 and accumulated in the front part of the cylinder 310, the screw 330 moves backward. Then, when the screw 330 is moved forward, the liquid molding material accumulated in front of the screw 330 is ejected from the nozzle 320 and filled into the mold device 800.

[0074] At the front part of the screw 330, a backflow prevention ring 331 is movably mounted as a backflow prevention valve for preventing the molding material from flowing back from the front to the rear of the screw 330 when the screw 330 is pushed forward.

[0075] When the screw 330 is advanced, the backflow prevention ring 331 is pushed backward by the pressure of the molding material in front of the screw 330, and retreats relative to the screw 330 to a closed position that blocks the flow path of the molding material (see Figure 2 ). Thus, the molding material accumulated in front of the screw 330 is prevented from flowing backward.

[0076] On the other hand, when the screw 330 is rotated, the backflow prevention ring 331 is pushed forward by the pressure of the molding material conveyed forward along the spiral groove of the screw 330, and moves forward relative to the screw 330 to an open position (refer to Figure 1 ). As a result, the molding material is transported to the front of the screw 330.

[0077] The backflow prevention ring 331 may be of a co-rotating type that rotates together with the screw 330 or a non-co-rotating type that does not rotate together with the screw 330 .

[0078] In addition, the injection device 300 may include a driving source that moves the backflow prevention ring 331 forward and backward relative to the screw 330 between the open position and the closed position.

[0079] The metering motor 340 rotates the screw 330. The driving source for rotating the screw 330 is not limited to the metering motor 340, and may be, for example, a hydraulic pump or the like.

[0080] The injection motor 350 moves the screw 330 forward and backward. A motion conversion mechanism that converts the rotational motion of the injection motor 350 into the linear motion of the screw 330 is provided between the injection motor 350 and the screw 330. The motion conversion mechanism includes, for example, a screw shaft and a screw nut screwed with the screw shaft. A ball or roller may be provided between the screw shaft and the screw nut. The driving source that moves the screw 330 forward and backward is not limited to the injection motor 350, and may be, for example, a hydraulic cylinder.

[0081] The load detector 360 detects the load transmitted between the injection motor 350 and the screw 330. The detected load is converted into pressure by the control device 700. The load detector 360 is provided on the load transmission path between the injection motor 350 and the screw 330, and detects the load acting on the load detector 360.

[0082] The load detector 360 sends a signal of the detected load to the control device 700. The load detected by the load detector 360 is converted into a pressure acting between the screw 330 and the molding material, and is used to control or monitor the pressure applied to the molding material to the screw 330, the back pressure on the screw 330, and the pressure acting on the molding material from the screw 330.

[0083] In addition, the pressure detector for detecting the pressure of the molding material is not limited to the load detector 360 , and a common detector can be used. For example, a nozzle pressure sensor or a mold internal pressure sensor can also be used. The nozzle pressure sensor is provided at the nozzle 320 .

[0084] The injection device 300 performs a metering process, a filling process, a pressure-maintaining process, etc. under the control of the control device 700. The filling process and the pressure-maintaining process can be collectively referred to as an injection process.

[0085] In the metering process, the metering motor 340 is driven to rotate the screw 330 at a set speed, and the molding material is transported to the front along the spiral groove of the screw 330. As a result, the molding material gradually melts. As the liquid molding material is transported to the front of the screw 330 and accumulated in the front part of the cylinder 310, the screw 330 retreats. The rotation speed of the screw 330 is detected using, for example, a metering motor encoder 341. The metering motor encoder 341 detects the rotation of the metering motor 340 and sends a signal indicating the detection result to the control device 700. In addition, the screw speed detector that detects the rotation speed of the screw 330 is not limited to the metering motor encoder 341, and a common screw speed detector can be used.

[0086] In order to prevent the screw 330 from retreating rapidly during the metering process, the injection motor 350 may be driven to apply a set back pressure to the screw 330. The back pressure on the screw 330 is detected, for example, using a load detector 360. When the screw 330 retreats to the metering completion position and a predetermined amount of molding material is accumulated in front of the screw 330, the metering process is completed.

[0087] The position and speed of the screw 330 in the metering process are set together as a series of setting conditions. For example, the metering start position, the speed switching position and the metering completion position are set. These positions are arranged in sequence from the front to the back, indicating the starting point and end point of the interval for setting the speed. The speed is set for each interval. The speed switching position can be one or more. The speed switching position can also be not set. In addition, the back pressure is set for each interval.

[0088] In the filling process, the injection motor 350 is driven to move the screw 330 forward at a set moving speed, so that the liquid molding material accumulated in front of the screw 330 is filled in the cavity space 801 in the mold device 800. The position and moving speed of the screw 330 are detected using, for example, an injection motor encoder 351. The injection motor encoder 351 detects the rotation of the injection motor 350 and sends a signal indicating the detection result to the control device 700. If the position of the screw 330 reaches the set position, a switch is made from the filling process to the pressure holding process (so-called V / P switching). The position where the V / P switching is performed is also referred to as the V / P switching position. The set moving speed of the screw 330 can be changed according to the position and time of the screw 330.

[0089] The position and moving speed of the screw 330 in the filling process are set as a series of setting conditions. For example, the filling start position (also called the "injection start position"), the moving speed switching position and the V / P switching position are set. These positions are arranged in sequence from the back to the front, indicating the starting point and end point of the interval for setting the moving speed. The moving speed is set for each interval. The moving speed switching position can be one or more. The moving speed switching position can also be not set.

[0090] The upper limit value of the pressure of the screw 330 is set in each interval of setting the moving speed of the screw 330. The pressure of the screw 330 is detected by the load detector 360. When the pressure of the screw 330 is below the set pressure, the screw 330 moves forward at the set moving speed. On the other hand, when the pressure of the screw 330 exceeds the set pressure, the screw 330 moves forward at a moving speed slower than the set moving speed for the purpose of protecting the mold so that the pressure of the screw 330 becomes below the set pressure.

[0091] In addition, in the filling process, after the position of the screw 330 reaches the V / P switching position, the screw 330 may be temporarily stopped at the V / P switching position, and then the V / P switching may be performed. Instead of stopping the screw 330, the screw 330 may be moved forward or backward at a slow speed just before the V / P switching. Furthermore, the screw position detector for detecting the position of the screw 330 and the screw moving speed detector for detecting the moving speed of the screw 330 are not limited to the injection motor encoder 351, and a common screw position detector may be used.

[0092] In the pressure holding process, the injection motor 350 is driven to push the screw 330 forward, and the pressure of the molding material in the front end of the screw 330 (hereinafter also referred to as "holding pressure") is maintained at a set pressure, and the molding material remaining in the cylinder 310 is pushed toward the mold device 800. The insufficient amount of molding material caused by cooling shrinkage in the mold device 800 can be supplemented. The holding pressure is detected using a load detector 360, for example. The setting value of the holding pressure can be changed according to the elapsed time from the start of the pressure holding process. The holding pressure and the holding time of the holding pressure in the pressure holding process can be set separately in multiples, or can be set together as a series of setting conditions.

[0093] In the pressure holding process, the molding material in the cavity space 801 in the mold device 800 is gradually cooled. When the pressure holding process is completed, the entrance of the cavity space 801 is blocked by the solidified molding material. This state is called gate sealing, which prevents the molding material from flowing back from the cavity space 801. After the pressure holding process, the cooling process begins. The molding material in the cavity space 801 is solidified in the cooling process. In order to shorten the molding cycle time, a metering process can be performed in the cooling process.

[0094] In addition, the injection device 300 of this embodiment is a coaxial screw type, but it can also be a screw pre-plasticization type. The pre-plasticization type injection device supplies the molding material melted in the plasticizing cylinder to the injection cylinder, and injects the molding material from the injection cylinder into the mold device. In the plasticizing cylinder, the screw is configured to be able to rotate freely and cannot move forward or backward, or the screw is configured to rotate freely and move forward and backward freely. On the other hand, in the injection cylinder, the plunger is configured to move forward and backward freely.

[0095] Furthermore, the injection device 300 of the present embodiment is a horizontal type in which the axial direction of the cylinder 310 is in the horizontal direction, but it may be a vertical type in which the axial direction of the cylinder 310 is in the up-down direction. The mold clamping device combined with the vertical injection device 300 may be a vertical type or a horizontal type. Similarly, the mold clamping device combined with the horizontal injection device 300 may be a horizontal type or a vertical type.

[0096] (Mobile device)

[0097] In the description of the moving device 400, similar to the description of the injection device 300, the moving direction of the screw 330 during filling (for example, the negative direction of the X axis) is set to the front and the moving direction of the screw 330 during metering (for example, the positive direction of the X axis) is set to the rear.

[0098] The moving device 400 moves the injection device 300 forward and backward relative to the mold device 800. In addition, the moving device 400 presses the nozzle 320 against the mold device 800 to generate nozzle contact pressure. The moving device 400 includes a hydraulic pump 410, a motor 420 as a driving source, a hydraulic cylinder 430 as a hydraulic actuator, and the like.

[0099] The hydraulic pump 410 has a first port 411 and a second port 412. The hydraulic pump 410 is a bidirectionally rotatable pump, and by switching the rotation direction of the motor 420, the hydraulic pump 410 sucks working fluid (for example, oil) from one of the first port 411 and the second port 412 and discharges it from the other to generate hydraulic pressure. Alternatively, the hydraulic pump 410 can also suck working fluid from a tank and discharge the working fluid from one of the first port 411 and the second port 412.

[0100] The motor 420 operates the hydraulic pump 410. The motor 420 drives the hydraulic pump 410 with a rotation direction and torque corresponding to a control signal from the control device 700. The motor 420 may be an electric motor or an electric servomotor.

[0101] The hydraulic cylinder 430 has a cylinder body 431, a piston 432, and a piston rod 433. The cylinder body 431 is fixed to the injection device 300. The piston 432 divides the interior of the cylinder body 431 into a front chamber 435 as a first chamber and a rear chamber 436 as a second chamber. The piston rod 433 is fixed to the fixed platen 110.

[0102] The front chamber 435 of the hydraulic cylinder 430 is connected to the first port 411 of the hydraulic pump 410 via the first flow path 401. The working fluid discharged from the first port 411 is supplied to the front chamber 435 via the first flow path 401, thereby pushing the injection device 300 forward. The injection device 300 moves forward, and the nozzle 320 is pressed against the fixed mold 810. The front chamber 435 functions as a pressure chamber that generates the nozzle contact pressure of the nozzle 320 by the pressure of the working fluid supplied from the hydraulic pump 410.

[0103] On the other hand, the rear chamber 436 of the hydraulic cylinder 430 is connected to the second port 412 of the hydraulic pump 410 via the second flow path 402. The hydraulic fluid discharged from the second port 412 is supplied to the rear chamber 436 of the hydraulic cylinder 430 via the second flow path 402, thereby pushing the injection device 300 backward. The injection device 300 retreats, and the nozzle 320 is separated from the fixed mold 810.

[0104] In this embodiment, the moving device 400 includes the hydraulic cylinder 430 , but the present invention is not limited thereto. For example, an electric motor and a motion conversion mechanism that converts the rotational motion of the electric motor into the linear motion of the injection device 300 may be used instead of the hydraulic cylinder 430 .

[0105] (Control device)

[0106] The control device 700 is constituted by a computer, for example. Figure 1-2 As shown, the control device 700 includes a CPU (Central Processing Unit) 701, a storage medium such as a memory 702, an input interface 703, an output interface 704, and a communication interface 705. The control device 700 performs various controls by causing the CPU 701 to execute a program stored in the storage medium 702. In addition, the control device 700 receives signals from the outside through the input interface 703 and sends signals to the outside through the output interface 704.

[0107] The control device 700 repeatedly produces molded products by repeatedly performing metering steps, mold closing steps, pressure increasing steps, mold clamping steps, filling steps, pressure holding steps, cooling steps, pressure releasing steps, mold opening steps, and ejection steps. A series of actions for obtaining molded products, such as the actions from the start of a metering step to the start of the next metering step, are also referred to as "injection" or "molding cycle". In addition, the time required for one injection is also referred to as "molding cycle time" or "cycle time".

[0108] A molding cycle, for example, includes a metering process, a mold closing process, a pressure increasing process, a mold closing process, a filling process, a pressure holding process, a cooling process, a pressure releasing process, a mold opening process, and an ejection process in sequence. The order here is the order in which each process starts. The filling process, the pressure holding process, and the cooling process are performed during the mold closing process. The start of the mold closing process can coincide with the start of the filling process. The completion of the pressure releasing process coincides with the start of the mold opening process.

[0109] In addition, in order to shorten the molding cycle time, multiple processes can be performed simultaneously. For example, the metering process can be performed in the cooling process of the previous molding cycle, or during the mold closing process. In this case, the mold closing process can be performed at the very beginning of the molding cycle. Furthermore, the filling process can be started in the mold closing process. Furthermore, the ejection process can be started in the mold opening process. In the case of an on-off valve that opens and closes the flow path of the nozzle 320, the mold opening process can be started in the metering process. This is because, even if the mold opening process is started in the metering process, if the on-off valve closes the flow path of the nozzle 320, the molding material will not leak from the nozzle 320.

[0110] In addition, a primary molding cycle may include processes other than the metering process, the mold closing process, the pressure increasing process, the mold clamping process, the filling process, the pressure holding process, the cooling process, the pressure releasing process, the mold opening process, and the ejection process.

[0111] For example, after the pressure holding process is completed and before the metering process begins, a pre-metering suction process can be performed to retract the screw 330 to a preset metering start position. The pressure of the molding material accumulated in front of the screw 330 can be reduced before the metering process begins, and the screw 330 can be prevented from retreating sharply when the metering process begins.

[0112] Furthermore, after the metering process is completed and before the filling process begins, a post-metering backsucking process may be performed in which the screw 330 is retracted to a preset filling start position (also referred to as an "injection start position"). The pressure of the molding material accumulated in front of the screw 330 can be reduced before the filling process begins, and the molding material can be prevented from leaking from the nozzle 320 before the filling process begins.

[0113] The control device 700 is connected to an operation device 750 that receives input operations from a user or a display device 760 that displays a screen. The operation device 750 and the display device 760 may be formed of, for example, a touch panel 770 and integrated. The touch panel 770 as the display device 760 displays a screen under the control of the control device 700. On the screen of the touch panel 770, for example, information such as the settings of the injection molding machine 10 and the current state of the injection molding machine 10 may be displayed. The touch panel 770 can receive operations in the displayed screen area. In addition, in the screen area of ​​the touch panel 770, for example, operation parts such as buttons and input fields that receive input operations from the user may be displayed. The touch panel 770 as the operation device 750 detects the input operation of the user on the screen and outputs a signal corresponding to the input operation to the control device 700. Thus, for example, the user can operate the operation part set on the screen while confirming the information displayed on the screen to perform settings of the injection molding machine 10 (including input of a set value). In addition, by the user operating the operation part set on the screen, the injection molding machine 10 corresponding to the operation part can be operated. In addition, the operation of the injection molding machine 10 may be, for example, the operation (including stopping) of the mold clamping device 100, the ejection device 200, the injection device 300, the moving device 400, etc. Furthermore, the operation of the injection molding machine 10 may be the switching of the screen displayed on the touch panel 770 as the display device 760, etc.

[0114] In addition, the operating device 750 and the display device 760 of this embodiment are described as being integrated into a touch panel 770, but they may be provided independently. In addition, a plurality of operating devices 750 may be provided. The operating device 750 and the display device 760 are arranged on the operating side (negative direction of the Y axis) of the mold clamping device 100 (more specifically, the fixed platen 110).

[0115] Figure 3 FIG. 1 is a diagram showing an example of the functional structure of the control device 700 according to the present embodiment. Figure 3 As shown, Figure 3 Components of the control device 700 of the injection molding machine 10 are shown as functional blocks. Figure 3 The functional blocks shown are conceptual functional blocks and may not necessarily be physically configured as shown. All or part of each functional block may be functionally or physically dispersed / integrated in any unit. All or any part of each processing function performed in each functional block is implemented by a program executed by CPU 701. Alternatively, each functional block may be implemented as hardware based on wired logic. Figure 3 As shown, the CPU 701 of the control device 700 includes an acquisition unit 711, a determination unit 712, an output control unit 713, an injection molding control unit 714, and a log information storage unit 715. In addition, the control device 700 includes a threshold information storage unit 702A in the storage medium 702.

[0116] The control device 700 according to the present embodiment acquires the condition related to the object discharged from the gap provided in the mold device 800, and determines whether an abnormality has occurred in the mold device 800 based on the condition related to the object discharged from the gap. In the present embodiment, as an example of the condition related to the object discharged from the gap of the mold device 800, a condition related to the flow of the gas (an example of the object) discharged from the gap is used. More specifically, an example is used in which the sound level of the air (an example of the gas) and the gas (an example of the gas) discharged from the gap of the mold device 800 is used.

[0117] Figure 4 2 is a cross-sectional view showing a mold device 800 according to the present embodiment. Figure 4 In the example shown, a fixed mold 810 and a movable mold 820 included in the mold device 800 are shown. Figure 4 In the example shown, a gate 802 is formed in the fixed mold 810. In addition, a runner may be provided between the cavity space 801 and the gate 802 (not shown).

[0118] In this embodiment, liquid molding material is injected by the injection device 300, and the liquid molding material is filled in the cavity space 801. The mold device 800 is provided with an exhaust port 803 so that when the cavity space 801 is filled with molding material, the air existing in the cavity space 801 before filling and the gas generated from the flow front (flow front) of the molding material during filling are exhausted.

[0119] The exhaust port 803 is formed as a groove having a depth of several μm to several tens of μm provided on the parting line surface of the mold device 800 .

[0120] Furthermore, the air existing in the cavity space 801 before filling and the gas generated from the flow front (flow front) of the molding material during filling are discharged to the outside of the cavity space 801 through the exhaust port 803. The air and gas discharged from the outlet 804 of the exhaust port 803 are discharged to the outside of the mold device 800 through the air guide groove 805.

[0121] When air and gas pass through the exhaust port 803 due to the filling of the molding material, a sound is generated. Hereinafter, the sound generated when air and gas pass through the exhaust port 803 is referred to as an exhaust sound. When the exhaust sound is generated, the passing of air and gas through the exhaust port 803 can be recognized.

[0122] Normally, injection molding is started by the injection molding machine 10 in a state where no resin or oil generated by gas adheres to the exhaust port 803. However, if injection molding is repeatedly performed by the injection molding machine 10, when the gas generated from the flow front passes through the exhaust port 803 from the cavity space 801, the resin or oil contained in the exhausted gas adheres to and accumulates on the inner wall surface of the exhaust port 803, and gradually accumulates as mold deposits.

[0123] As mold scale gradually accumulates on the exhaust port 803, the exhaust port 803 is closed, and the cross-sectional area of ​​the air and gas flow path of the exhaust port 803 becomes smaller. As the cross-sectional area of ​​the flow path becomes smaller, the exhaust sound gradually becomes louder.

[0124] Moreover, when the exhaust port 803 is closed and the air and gas cannot be discharged, no exhaust sound is generated. In other words, it means that when the exhaust sound is not generated, the air and gas cannot be discharged from the mold device 800. In the case where the air and gas cannot be discharged, the gas in the cavity space 801 near the exhaust port 803 is instantly compressed and becomes a high temperature (the result is a state close to adiabatic compression), and the molded product may be burned. In addition, when the molding material is a molten resin, a flammable gas is generated from the flow front (flow front end). When the flammable gas is compressed and becomes a high temperature, the flammable gas burns, and the molded product may also be burned. That is, the defective rate of the molded product may increase.

[0125] Figure 5 15 is a graph showing the correspondence between the number of shots and the magnitude of the discharge sound from the start of injection molding. Line 1501, for example, represents the magnitude of the discharge sound detected at each shot when injection molding is performed using any molding material. Line 1502, for example, represents the magnitude of the discharge sound detected at each shot when injection molding is performed using a molding material that generates less gas than the molding material of line 1501.

[0126] In line 1501, as the number of shots increases, the discharge sound becomes louder. Moreover, at shot number S1, the discharge sound suddenly becomes smaller. Therefore, it can be recognized that at shot number S1, the exhaust port 803 is closed and the air and gas cannot be discharged.

[0127] In line 1502, as the number of shots increases, the discharge sound does not increase, but the discharge sound decreases sharply at shot number S2. Therefore, it can be recognized that at shot number S2, the exhaust port 803 is closed and the air and gas cannot be discharged.

[0128] Therefore, the control device 700 according to the present embodiment determines whether an abnormality has occurred in the mold device 800 based on the discharge sound (an example of a condition) related to the air and gas (an example of an object) discharged from the exhaust port (an example of a gap) 803. The abnormality to be determined is, for example, the closure of the gas exhaust port 803.

[0129] Back to Figure 3 In this embodiment, a case where a microphone 781 provided in the injection molding machine 10 is used to detect a condition related to an object ejected from a gap of the mold device 800 will be described.

[0130] The microphone (an example of a detection unit) 781 detects sounds in the surroundings including the mold device 800 , converts the detected sounds into electric signals, and outputs the electric signals to the control device 700 .

[0131] When the molding material is injected from the injection device 300 , the microphone 781 according to the present embodiment outputs an electrical signal indicating the discharge sound (an example of the condition) of air and gas discharged from the gap of the mold device 800 to the control device 700 .

[0132] The microphone 781 can be set at any position as long as it can detect the emitted sound. Figure 1 The present embodiment is not limited to the example in which the microphone 781 is provided on the movable platen 120, and for example, the microphone 781 may be provided at the position 782 of the connecting rod 140, the position 783, 784, 785 of the frame 900 or the mold clamping device frame 910, etc. In this way, any position may be used as long as the discharge sound from the mold device 800 can be detected.

[0133] Back to Figure 3 The various sensors 790 are set as a sensor group provided in the injection molding machine 10. Specific sensors included in the various sensors 790 will be described in the embodiment described later.

[0134] The threshold information storage unit 702A stores a threshold value for determining whether the mold device 800 is abnormal. For example, the threshold information storage unit 702A stores a threshold value T1 related to the size of the discharge sound. The threshold values ​​stored in the threshold information storage unit 702A involved in this embodiment are set as an example by the user. In addition, this embodiment is not limited to the method of setting the threshold value by the user, and the injection molding machine 10 can also automatically set it.

[0135] The acquisition unit 711 acquires the detection results performed by the microphone 781 and various sensors 790 provided in the injection molding machine 10. For example, the acquisition unit 711 acquires an electrical signal representing the discharge sound from the microphone 781. As another example, the acquisition unit 711 acquires a signal representing the detection result from the various sensors 790. Furthermore, the acquisition unit 711 acquires the threshold value T1 from the threshold value information storage unit 702A. The specific value of the threshold value T1 will be described later.

[0136] The determination unit 712 determines whether an abnormality has occurred in the mold device 800 based on the change in the magnitude of the discharge sound represented by the electrical signal obtained from the microphone 781. Specifically, the determination unit 712 determines whether the magnitude of the discharge sound represented by the electrical signal obtained from the microphone 781 is less than the threshold value T1 obtained from the threshold value information storage unit 702A. If it is determined that the magnitude of the discharge sound is less than the threshold value T1, it is determined that the exhaust port 803 is closed and there is a possibility that gas burning occurs in the molded product.

[0137] Furthermore, the determination unit 712 according to the present embodiment determines whether an abnormality has occurred in the mold device 800 based on the time when the discharge sound is generated. Specifically, the determination unit 712 determines whether there is a delay in the time from the start of filling to the detection of the discharge sound. That is, if there is a delay in the time until the discharge sound is detected, the temperature of the molding material decreases due to the delayed filling, or the surface temperature of the inner wall of the cavity space 801 decreases, thereby reducing the fluidity of the molding material and possibly causing a short shot in the molded product.

[0138] Therefore, in the present embodiment, when the molded product is a non-defective product, a value obtained by adding a predetermined margin to the time from the start of filling to the detection of the discharge sound is defined as the threshold value Tt.

[0139] Furthermore, the determination unit 712 determines whether the time from the start of injection molding to the detection of the discharge sound in the current injection of the molding material is longer than the threshold value Tt, in other words, whether it is longer than the time from the start of the previous injection molding to the detection of the discharge sound. If the determination unit 712 determines that it is longer than the threshold value Tt, it determines that a short shot may occur in the molded product.

[0140] The output control unit 713 controls the output of information to one or more of the display device 760, a speaker (not shown), and an external device. The external device may be, for example, a take-out machine for molded products, a mobile communication terminal (not shown) held by a user, or a management device (not shown) for managing a work site.

[0141] Then, the output control unit 713 outputs information based on the determination result of the determination unit 712 according to the setting of the setting screen (described later).

[0142] For example, the output control unit 713 outputs screen information to the display device 760 . Figure 6 FIG. 7 is a diagram illustrating a setting screen output by the output control unit 713 according to the present embodiment. Figure 6 In the setting screen shown, the user can set the criteria for determining whether there is an abnormality.

[0143] exist Figure 6 The setting screen 1600 shown shows a setting column 1601 for the unit of sound volume, an actual column 1602 for the normal value of the discharge sound, a setting column 1603 for the threshold value during abnormality, a setting column 1604 for the alarm during abnormality, a setting column 1605 for production stop during abnormality, and an actual column 1606 for the volume of the discharge sound during the most recent molding.

[0144] The setting column 1601 of the unit of the sound volume is switched to "dB" (decibel) or "Pa" (Pascal) according to the operation from the user. According to the switching of the setting column 1601 of the unit of the sound volume, the display of the actual column 1602 of the normal value of the discharge sound, the setting column 1603 of the threshold value in the abnormality, and the actual column 1606 of the volume of the discharge sound during the most recent molding are switched.

[0145] In the injection molding machine 10, when injection molding is performed immediately after cleaning of the mold device 800, the actual column 1602 of the normal value of the discharge sound displays the detection result of the magnitude of the discharge sound detected by the microphone 781 as the normal value of the discharge sound. The discharge sound generated by the injection molding immediately after cleaning is the discharge sound in a state where mold scale is not accumulated in the exhaust port 803. The user can set the setting column 1603 of the threshold value in the abnormality shown below by referring to the normal value of the discharge sound displayed in the actual column 1602.

[0146] The abnormal threshold setting column 1603 is a column for receiving the threshold T1 of the discharge sound volume when abnormal from the user. The threshold T1 set in the abnormal threshold setting column 1603 is stored in the threshold information storage unit 702A. And the determination unit 712 determines whether the discharge sound detected by the microphone 781 is small based on the threshold T1 read from the threshold information storage unit 702A.

[0147] The threshold value T1 of the exhaust sound in the abnormal state is set to a value smaller than the normal value shown in the actual column 1602 of the normal value of the exhaust sound so that the normal value shown in the actual column 1602 is not detected as abnormal. In addition, the threshold value T1 of the exhaust sound can be automatically set based on the normal value shown in the actual column 1602.

[0148] Thus, the determination unit 712 determines that an abnormality has occurred in the mold device 800 when the magnitude of the discharge sound detected by the current injection of the molding material is smaller than the threshold value Tl, in other words, when it is smaller than the magnitude of the sound detected by the previous injection of the molding material.

[0149] When the determination unit 712 determines that the discharge sound is small, the abnormal alarm setting column 1604 is set as a column for receiving a selection from the user whether to output the alarm sound. The abnormal alarm setting column 1604 receives a selection of "ON" or "OFF" from the user. In the case of "ON", the output control unit 713 outputs the alarm sound through the speaker (not shown) when the discharge sound becomes small. In the case of "OFF", the output control unit 713 does not output the alarm sound through the speaker (not shown) when the discharge sound becomes small.

[0150] The setting column 1605 for stopping production in case of abnormality is set as a column for accepting a selection from the user whether to stop injection molding when the determination unit 712 determines that the discharge sound is small. The setting column 1605 for stopping production in case of abnormality accepts a selection of "ON" or "OFF" from the user. In the case of "ON", the injection molding control unit 714 (described later) stops injection molding when the discharge sound becomes smaller. In the case of "OFF", the injection molding control unit 714 continues injection molding even when the injection sound becomes smaller.

[0151] When injection molding is performed in the injection molding machine 10 , the actual column 1606 of the discharge sound level during the most recent molding displays the detection result of the discharge sound level detected by the microphone 781 during the most recent injection molding.

[0152] The injection molding control unit 714 executes processing for producing a molded product in the injection molding machine 10. In addition, the injection molding control unit 714 performs control related to injection molding based on the determination result of the determination unit 712 according to the setting of the above-mentioned setting screen. For example, when "ON" is set in the setting column 1605 for stopping production in abnormality, the injection molding control unit 714 stops injection molding when the discharge sound becomes smaller.

[0153] The log information storage unit 715 stores (saves) log information related to injection molding of the injection molding machine 10 in the storage medium 702. The log information related to injection molding may include setting information set for injection molding of the injection molding machine 10, actual information showing detection results based on various sensors 790 for the injection molding machine 10 to perform injection molding, and determination results based on the determination unit 712.

[0154] Figure 7 It is a diagram illustrating an example of a log information screen output by the output control unit 713 according to the present embodiment. Figure 7 The log information screen shown displays log information related to injection molding. In addition, in the log information screen, the log information storage unit 715 can be set to store log information.

[0155] exist Figure 7 The log information screen 1700 shown shows the total number 1711, the number of qualified products 1712, the number of unqualified products 1713, the number of scrapped products 1714, a deposit button 1715, a monitoring setting button 1716, a save button 1717, an update button 1718, a statistical overview 1720 and an actual overview 1730.

[0156] The statistical overview 1720 shows the statistical information (e.g., average, range, maximum, minimum, standard deviation) of each setting column 1721 to 1727. The contents shown in the setting columns 1721 to 1727 can be set by the staff. In this embodiment, the items shown in the setting columns 1721 to 1727 can be displayed, monitored, and log information can be saved. In addition, the monitoring of this embodiment indicates whether it is a qualified product based on a specified standard.

[0157] The statistical information is information calculated based on the actual value (an example of a parameter) obtained each time a molded product is manufactured by injection molding by the injection molding machine 10. For example, in the statistical overview 1720, the average, range, maximum, minimum, and standard deviation calculated for each setting column 1721 to 1727 are included. In addition, this embodiment shows an example of statistical information, and it may be statistical information other than the average, range, maximum, minimum, and standard deviation, such as an integral value. In addition, the items that become the object of calculating the statistical information are not limited to the items set in the setting columns 1721 to 1727, and may also be other items.

[0158] The output control unit 713 calculates statistical information based on actual values ​​(an example of parameters) obtained by various sensors 790 and microphone 781 during injection molding in the range shown in the actual list 1730. Then, the output control unit 713 displays the calculated statistical information in the statistical list 1720.

[0159] The "monitoring", "monitoring value" and "range" of the statistical list 1720 are set as information for determining whether the molded product in the setting column is defective.

[0160] When the monitoring of the statistical overview 1720 is "off", it means that the control device 700 does not monitor, and when it is "on", it means that the control device 700 monitors. When "on", the control device 700 determines whether the actual value measured in the items shown in the setting column meets the benchmarks shown in the "monitoring value" and "range" (for example, whether the "monitoring value" is included in the "range" as the median). As another example, the control device 700 can use the set monitoring value as the median to determine whether it meets the benchmark based on the set positive tolerance and negative tolerance, or whether it meets the benchmark of the set upper limit value and lower limit value. In addition, the monitoring method of the actual value is not limited to the above method, and any method can be used. The switching of the monitoring is performed by the monitoring setting button 1716.

[0161] “Failure” in the statistical list 1720 indicates the number of molded products that do not satisfy the criteria indicated by “Monitoring value” and “Range”.

[0162] The “cycle time” in the setting column 1721 , the “filling time” in the setting column 1722 , and the “metering time” in the setting column 1723 are items set in order to monitor the time required for the cycle, filling, and metering.

[0163] The "VP switching position" in the setting column 1724 is an item set to monitor the position of the screw 330 when switching from the filling process to the pressure holding process (V / P switching position). The "minimum buffer position" in the setting column 1725 is an item set to monitor the position when the screw 330 moves to the front when pressure is applied after the molding material is filled into the mold device 800. The "filling peak pressure" in the setting column 1726 is an item set to monitor the peak value of the pressure when the molding material is filled.

[0164] The "volume of exhaust sound" in the setting column 1727 is an item set in order to monitor the exhaust sound generated by the air and gas exhausted each time a molded product is molded.

[0165] The setting fields 1721 to 1727 can be changed to items that the staff member wants to monitor. The description of the changing method is omitted.

[0166] For example, the “time until the discharge sound is detected” can be set in the setting column 1727. Furthermore, the determination unit 712 can determine whether the time from the start of injection molding to the detection of the discharge sound is longer than the threshold value Tt based on the settings of the “monitoring value” and “range” in the setting column 1727.

[0167] The actual list 1730 shows the setting information (e.g., setting value) of the items set in the setting columns 1721 to 1727 or the actual values ​​measured by various sensors at each injection. The items set in the setting columns 1721 to 1727 are set from "CH1" to "CH7". In addition, at each injection, as information indicating the injection, the "shot number", the "time" of injection molding, and the "discrimination" of injection molding are associated.

[0168] The save button 1715 is set as a button for accepting a selection of whether to save the actual values ​​shown in the actual list 1730 as log information. When the save button 1715 is pressed (displayed as "data save is on"), the log information storage unit 715 saves the information shown in the actual list 1730 (for example, the actual values ​​based on various sensors) and the like as log information in the storage medium 702.

[0169] That is, in this embodiment, the size of the discharge sound of each shot and the like can be stored in the storage medium 702 as log information.

[0170] The monitoring setting button 1716 is set as a button for accepting whether to monitor according to the monitoring items of the statistical list 1720. When the monitoring setting button 1716 is pressed (displayed as "monitoring on"), each time the material is poured, it is monitored whether it is a defective product, and the monitoring result is included in the log information. When the monitoring setting button 1716 is pressed, the monitoring of each setting column 1721 to 1727 of the statistical list 1720 can be switched to "off" or "on".

[0171] The save button 1717 is set as a button for accepting whether to save the statistical value (for example, average, range, maximum, minimum, standard deviation, etc.) of each setting column 1721 to 1727. When the save button 1717 is pressed, the log information storage unit 715 saves the statistical value of each setting column 1721 to 1727 and the actual value shown in the actual overview 1730 as log information in the storage medium 702. In this embodiment, an example of saving statistical values ​​and actual values ​​is described, but it is not limited to saving statistical values ​​and actual values. For example, when a setting is shown in the actual overview 1730, the log information storage unit 715 can save the setting value together. Moreover, even if the setting value is not shown in the actual overview 1730, the log information storage unit 715 can save the setting value in association with the actual value shown in the actual overview 1730.

[0172] The update button 1718 is set as a button for accepting whether to update the statistical overview 1720 and the actual overview 1730 each time the injection molding by the injection molding machine 10 is completed. When the update button 1718 is pressed (displayed as "always"), the statistical overview 1720 and the actual overview 1730 are updated each time the injection molding by the injection molding machine 10 is completed.

[0173] The total number 1711 indicates the number of molded products molded in the injection molding machine 10. The number of qualified products 1712 indicates the number of molded products determined as qualified products based on "monitoring", "monitoring value" and "range". The number of unqualified products 1713 indicates the number of molded products determined as unqualified products based on "monitoring", "monitoring value" and "range". The number of rejected products 1714 indicates the number of molded products that were rejected.

[0174] As described above, when a molded product is produced from a molding material through the injection molding machine 10, the output control unit 713 of the control device 700 displays the actual values ​​(an example of the detection results) detected by various sensors in the process of producing each molded product on the actual overview 1730 of the display device 760.

[0175] For example, in the actual list 1730, "CH7" corresponds to "the magnitude of the discharge sound." That is, in the "CH7" column of the actual list 1730, the magnitude of the discharge sound detected by the microphone 781 at each pouring is displayed as an actual value.

[0176] Furthermore, when the save button 1715 is pressed, the log information storage unit 715 stores the information shown in the actual list 1730 (for example, actual values ​​based on various sensors, etc.) as log information in the storage medium 702, so that the size of the discharge sound generated each time the molded object is molded is stored as log information in the storage medium 702. Therefore, for each molded product, the size of the discharge sound generated when the molded product is molded can be managed. Furthermore, when "the time until the discharge sound is detected" is set in any channel of the actual list 1730, the time until the discharge sound generated when the molded product is molded can be managed for each molded product.

[0177] Next, a description will be given of a procedure of a process based on the discharge sound from the mold device 800 which is executed by the control device 700 according to the present embodiment. Figure 8 This is a flowchart showing a processing procedure based on the discharge sound from the mold device 800, which is executed by the control device 700 according to the present embodiment.

[0178] First, the determination unit 712 determines whether "ON" is selected in the setting column 1605 for stopping production when abnormality occurs. In other words, it determines whether the operation is stopped when an abnormality is detected by the size of the exhaust sound (S1801). Figure 8 In the illustrated processing sequence, the description is made assuming that “ON” is set in the setting field 1604 for the alarm at the time of abnormality, and that the setting for causing the log information storage unit 715 to store log information is made.

[0179] When the determination unit 712 determines that the operation stop is selected ( S1801 : Yes), the injection molding control unit 714 performs a molding process for producing a molded product in the injection molding machine 10 ( S1802 ).

[0180] Then, the acquisition unit 711 acquires the sound from the mold device 800 during the filling of the molding material through the microphone 781 ( S1803 ).

[0181] Then, the determination unit 712 determines whether the time until the discharge sound is detected is greater than the threshold value Tt (S1804). When the determination unit 712 determines that the time until the discharge sound is detected is greater than the threshold value Tt, the output control unit 713 regards the molded product as a molded product that may have a short injection, and outputs an instruction to discard the molded product to the unloader (S1805).

[0182] When the determination unit 712 determines that the time until the discharge sound is detected is less than the threshold value Tt, the process proceeds to S1806 without performing any special processing.

[0183] Then, the determination unit 712 determines whether the magnitude of the discharge sound is less than the threshold value T1 read from the threshold value information storage unit 702A (S1806). If it is determined that the magnitude of the discharge sound is greater than the threshold value T1 (S1806: No), the molding process is performed again from S1802.

[0184] On the other hand, when the determination unit 712 determines that the size of the discharge sound is smaller than the threshold value T1 (S1806: Yes), the output control unit 713 outputs an alarm sound indicating that an abnormality has occurred in the mold device 800 from a speaker (not shown) (S1807).

[0185] Then, the log information storage unit 715 stores the fact that the magnitude of the discharge sound is smaller than the threshold value T1 and the fact that an abnormality has occurred in the mold device 800 in the storage medium 702 as log information (S1808).

[0186] Then, the injection molding control unit 714 stops the molding process for producing the molded product in the injection molding machine 10 (S1809).

[0187] On the other hand, when the determination unit 712 determines that the operation stop is not selected ( S1801 : No), the injection molding control unit 714 performs a molding process for producing a molded product in the injection molding machine 10 ( S1810 ).

[0188] Next, the acquisition unit 711 acquires the discharge sound from the mold device 800 during the filling of the molding material from the microphone 781 ( S1811 ).

[0189] Then, the determination unit 712 determines whether the time until the discharge sound is detected is greater than the threshold value Tt (S1812). When the determination unit 712 determines that the time until the discharge sound is detected is greater than the threshold value Tt, the output control unit 713 regards the molded product as a molded product that may have a short injection, and outputs an instruction to discard the molded product to the unloader (S1813).

[0190] When the determination unit 712 determines that the time until the discharge sound is detected is less than the threshold value Tt, the process proceeds to S1814 without performing any special processing.

[0191] Then, the determination unit 712 determines whether the magnitude of the discharge sound is less than the threshold value T1 read from the threshold value information storage unit 702A (S1814). If it is determined that the magnitude of the discharge sound is greater than the threshold value T1 (S1814: No), the molding process is performed again from S1810.

[0192] On the other hand, when the determination unit 712 determines that the size of the discharge sound is smaller than the threshold value T1 (S1814: Yes), the output control unit 713 outputs an alarm sound indicating that an abnormality has occurred in the mold device 800 from a speaker (not shown) (S1815).

[0193] Then, the log information storage unit 715 stores the fact that the magnitude of the discharge sound is smaller than the threshold value T1 and the fact that an abnormality has occurred in the mold device 800 in the storage medium 702 as log information (S1816).

[0194] The injection molding control unit 714 continues the molding process (S1817) for producing a molded product in the injection molding machine 10. During this molding process, the alarm sound may be continuously outputted and the processes according to S1811 to S1813 may be performed.

[0195] In this embodiment, it is determined whether an abnormality has occurred in the mold device 800 based on the discharge sound detected by the microphone 781 provided outside the mold device 800. That is, in order to detect the abnormality of the mold device 800, it is not necessary to provide a sensor on the mold device 800. That is, since it is not necessary to process the mold device 800, the workload can be reduced. In addition, it is not necessary to install a sensor for each mold device 800, so that the cost can be reduced.

[0196] In the past, there has been a technique for predicting the pass / fail status of a molded product by installing a sensor for detecting temperature or pressure in a cavity space, but in this technique, a sensor hole for installing the sensor needs to be installed in the mold device. Depending on the position to be measured, the sensor may not be able to enter the mold device, or a sensor mark may remain on the molded product that becomes an exterior component, so the sensor cannot be installed.

[0197] In contrast, in the present embodiment, since whether an abnormality has occurred in the mold device 800 is determined based on the discharge sound detected by the microphone 781 disposed outside the mold device 800, there is no need to provide a sensor hole or the like on the mold device 800, thereby reducing the workload, and since no sensor traces remain, the accuracy of the molded product can be improved.

[0198] Furthermore, when adding sensors to an existing mold device that is not equipped with sensors, large-scale modifications may be required. Furthermore, when disassembling and cleaning a mold device with built-in sensors, the disassembly and assembly operations must be performed carefully to avoid sensor failure, so disassembly and cleaning takes time and increases the workload.

[0199] In contrast, in this embodiment, since it is determined whether an abnormality has occurred in the mold device 800 based on the discharge sound detected by the microphone 781 provided outside the mold device 800, the time for disassembly and cleaning can be shortened, and the workload can be reduced.

[0200] (Variation of the first embodiment)

[0201] In the above embodiment, the microphone 781 is provided outside the mold device 800. However, the above embodiment is not limited to the example in which the microphone 781 is provided outside the mold device 800, and the microphone 781 may be provided in the mold device 800.

[0202] exist Figure 4 In the example shown, for example, the microphone 781 may be provided at a position 791 near the exhaust port 803 of the mold device 800. As another example, the microphone 781 may be provided at a position 792 near the outlet 804 of the exhaust port 803. Furthermore, the microphone 781 may be provided at a position 793 on the outer peripheral side of the outlet 804 of the exhaust port 803. Furthermore, the microphone 781 may be provided at positions 794 and 795 on the outer periphery of the mold device 800.

[0203] In this modification, by installing the microphone 781 near the exhaust port 803 of the mold device 800, when the microphone 781 collects the exhaust sound, it is possible to suppress the influence of other sounds or the operation sound of the injection molding machine 10. Therefore, this modification can improve the detection accuracy of the exhaust sound.

[0204] (Second embodiment)

[0205] In the above-mentioned embodiment and modification, the case where the exhaust port 803 of the mold device 800 is completely closed, in other words, the case where the gas discharge from the gap is suppressed is described as an abnormality of the mold device 800. However, in this embodiment, the abnormality of the mold device is not limited to the case where the exhaust port 803 is completely closed. For example, when mold scale gradually accumulates at the exhaust port 803, it can be determined as an abnormality of the mold device 800.

[0206] In the above-mentioned embodiment and modification, an example of determining whether the discharge sound is less than the threshold value T1 is described. However, in the above-mentioned embodiment and modification, it is not limited to the method of determining whether the discharge sound is less than the threshold value T1. Therefore, in the second embodiment, as an example of a condition related to an object discharged from the exhaust port (an example of a gap) 803 of the mold device 800, an example of using the frequency of the discharge sound is described. The control device 700 involved in this embodiment determines whether the gas burn is approaching based on the frequency of the discharge sound detected by the microphone 781.

[0207] However, in the past, users checked whether gas burning was occurring by referring to molded products molded by injection molding machines. When gas burning was confirmed, users stopped production by the injection molding machine and cleaned the mold device. Sometimes, the mold device needed to be disassembled and cleaned, which took time and manpower.

[0208] The number of shots from cleaning until gas burning occurs varies depending on various factors such as the batch of molding material (difference in minute components), the moisture content in the molding material, the state of the parting line surface of the mold device, the surface state of the mold device, the cleanliness of the mold device, the degree of gas generation from the molding material (plasticization deviation), the temperature and size of the mold device, and the clamping force. Therefore, it is difficult to calculate the number of shots that do not cause gas burning by calculation.

[0209] Therefore, in order to suppress the occurrence of gas burning, the user repeats the injection molding from cleaning to gas burning multiple times and counts the number of shots until gas burning occurs. In addition, for example, the user performs an application such as stopping the injection molding when the number of shots is less than the minimum number of shots in the multiple shots until gas burning occurs and cleaning the mold device. In addition, the user tends to determine the number of shots for cleaning with a certain margin from the minimum number of shots.

[0210] For example, if gas burning occurred at 10,000 shots for the first time, at 6,000 shots for the second time, and at 13,000 shots for the third time, the mold device was cleaned after 5,000 shots after the fourth time to allow for a certain margin.

[0211] In this case, the injection molding is stopped at 5000 shots and the mold device is cleaned, but there is a possibility that gas burning will not occur until around 13000 shots. That is, since the frequency of cleaning the mold device increases, there is a possibility that productivity will decrease.

[0212] Therefore, in this embodiment, a method of determining whether a gas burn is imminent will be described.

[0213] The acquisition unit 711 involved in this embodiment acquires the discharge sound from the microphone 781. The discharge sound can also be regarded as vibration. Moreover, the acquisition unit 711 calculates the frequency of the discharge sound based on the acquired discharge sound. In addition, in this embodiment, the frequency of the discharge sound can also be acquired from a vibration sensor or the like instead of the microphone 781.

[0214] As described above, whenever the injection molding machine 10 repeats injection molding, mold deposits accumulate at the exhaust port 803, and the cross-sectional area of ​​the exhaust port 803 becomes smaller. Therefore, the acquisition unit 711 involved in this embodiment calculates the cross-sectional area of ​​the exhaust port 803 based on the frequency of the exhaust sound. The frequency of the exhaust sound is expressed by the following formula (1). The variables shown in formula (1) are set to a positive integer n, a sound velocity v, a length L of the resonant tube, and a diameter d of the tube.

[0215] f=nv / (2(L+0.8×d)……(1)

[0216] The length L of the resonant pipe corresponds to the length of the exhaust port 803, and the area derived from the diameter d of the pipe corresponds to the cross-sectional area of ​​the exhaust port 803. Next, the dimensions of the exhaust port 803 will be described.

[0217] Fig. 9 2 is a diagram showing the dimensions of the exhaust port 803 of the mold device 800 according to the present embodiment. Fig. 9 A portion of the mold device 800 shown includes an exhaust port 803 and an air guide groove 805 for exhausting gas and air from the cavity space 801. The air guide groove 805 is provided on the outer peripheral side of the exhaust port 803 and has a larger cross-sectional area than the exhaust port 803.

[0218] The exhaust port 803 is formed to have a pad length La, a depth da, and a width wa. The pad length La corresponds to the length L of the tube in equation (1), and the area calculated from the depth da and the width wa corresponds to the area derived from the diameter d of the tube.

[0219] When the exhaust port 803 begins to be blocked by mold deposits, the cross-sectional area of ​​the exhaust port 803 corresponding to the area of ​​the tube diameter d decreases. As the cross-sectional area of ​​the exhaust port 803 decreases, it can be seen from equation (1) that the frequency of the exhaust sound increases.

[0220] Therefore, in this embodiment, the threshold value Tf of the frequency of the exhaust sound is stored in the threshold information storage unit 702A. The threshold value Tf can be determined based on the frequency of the exhaust sound detected by the microphone 781 before the exhaust port 803 is completely closed during the test run, for example.

[0221] Then, the determination unit 712 determines whether an abnormality has occurred in the mold device 800 based on the change in the frequency of the discharge sound (an example of vibration) calculated by the acquisition unit 711. Specifically, the determination unit 712 determines whether the frequency of the discharge sound (an example of vibration) calculated by the acquisition unit 711 is greater than the threshold value Tf stored in the threshold value information storage unit 702A. In the case where it is determined that it is greater than the threshold value Tf stored in the threshold value information storage unit 702A, it is determined that the exhaust port 803 is closed and gas burning is about to occur. In addition, the output control unit 713 displays the situation of gas burning approaching on the display device 760. The user can recognize that gas burning is approaching. Therefore, the user can stop the injection molding machine 10 and clean the mold device 800 before gas burning occurs.

[0222] Furthermore, the output control unit 713 may display the actual value of the frequency of the discharge sound in the setting column (e.g., setting column 1727) of the log information screen. Furthermore, in the log information screen, it is also possible to accept settings for monitoring the frequency of the discharge sound. Thus, a molded product formed when the frequency of the discharge sound is greater than the threshold value Tf can also be judged as a defective product. Furthermore, the actual value of the frequency of the discharge sound can be stored as log information.

[0223] Furthermore, in this embodiment, the method of determining whether a gas burn is imminent is limited to determining the frequency of the exhaust sound. Figure 5 As shown in FIG. 1 , the exhaust sound becomes louder as the gas burn approaches. Therefore, the determination unit 712 can determine whether the gas burn is approaching based on whether the size of the exhaust sound is greater than a predetermined threshold.

[0224] In this embodiment, since the output control unit 713 notifies that gas burning is imminent, the mold device 800 can be cleaned before gas burning occurs. Therefore, productivity can be improved. Furthermore, the determination involved in this embodiment can also be combined with the determination of the above-mentioned embodiment.

[0225] In the present embodiment, since the molded product can be continuously produced until just before gas burning occurs in the molded product, the frequency of cleaning the mold device 800 can be minimized, thereby achieving an improvement in productivity.

[0226] (Third embodiment)

[0227] In the above embodiment, an example of detecting the sound of gas and air discharged from the mold device 800 using the microphone 781 is described. However, in the above embodiment, the method using the microphone 781 is not limited. Therefore, in the third embodiment, as an example of detecting the condition related to the object discharged from the exhaust port (an example of the gap) 803 of the mold device 800, an example of detecting the flow rate of gas and air discharged from the mold device 800 is described. That is, in the above embodiment, as an example of the condition of gas discharge from the gap, an example of determining whether gas burn is approaching or whether the exhaust port 803 of the mold device 800 is completely closed based on the frequency or size of the discharge sound is described. However, in the above embodiment, the condition of gas discharge from the gap is not limited to the frequency or size of the discharge sound. In this embodiment, as an example of the condition of gas discharge from the gap, it is determined whether gas burn is approaching based on the flow rate of gas and air.

[0228] This embodiment is an example in which a flow meter is included as the various sensors 790 of the injection molding machine 10. The flow meter involved in this embodiment can be provided at Figure 4 The position 791 near the exhaust port 803 of the mold device 800 shown may also be set at a position 792 near the outlet 804 of the exhaust port 803 .

[0229] The acquisition unit 711 calculates the flow rate by dividing the flow rate detected by the flow meter by the measurement time.

[0230] When the mold device 800 has a plurality of exhaust ports 803, if one exhaust port 803 is buried by mold deposits, air and gas are exhausted from other exhaust ports 803. Therefore, the flow rate and flow rate of exhaust from other exhaust ports 803 increase.

[0231] In this embodiment, the threshold value Tr of the flow rate is stored in the threshold value information storage unit 702A. The threshold value Tr can be determined based on the flow rate detected by the flow meter when one exhaust port 803 is buried by mold deposit during the test run, for example.

[0232] Furthermore, the determination unit 712 determines whether the flow rate calculated by the acquisition unit 711 is greater than the threshold value Tr stored in the threshold value information storage unit 702A. If it is determined that the flow rate is greater than the threshold value Tr stored in the threshold value information storage unit 702A, it is determined that the gas burning is about to occur due to the closure of any one of the plurality of exhaust ports 803. Furthermore, the output control unit 713 displays the situation that the gas burning is about to occur on the display device 760. The user can recognize that the gas burning is about to occur. Therefore, the user can stop the injection molding machine 10 and clean the mold device 800 before the gas burning occurs.

[0233] Then, the determination unit 712 determines whether the flow rate calculated by the acquisition unit 711 is "0". When the flow rate is "0", the determination unit 712 determines that the exhaust port 803 is completely closed. The control when the exhaust port 803 is completely closed is the same as that in the above embodiment, and thus the description thereof is omitted.

[0234] Furthermore, the output control unit 713 can display the actual value of the flow rate in the setting column (e.g., setting column 1727) of the log information screen. Furthermore, in the log information screen, it is also possible to accept settings for flow rate monitoring. Thus, a molded product formed when the flow rate is greater than the threshold value Tr can also be judged as a defective product. Furthermore, the actual value of the flow rate can be stored as log information.

[0235] (Fourth embodiment)

[0236] In the fourth embodiment, as an example of detecting the condition of the object discharged from the exhaust port (an example of the gap) 803 of the mold device 800, an example of detecting the temperature of the gas and air discharged from the mold device 800 will be described.

[0237] When the exhaust port 803 of the mold device 800 is closed and the flow path cross-sectional area of ​​the exhaust port 803 becomes smaller, the air and gas in the cavity space 801 are not easy to be discharged, so the air and gas are instantly compressed and become high temperature (in other words, become a state close to adiabatic compression).

[0238] This embodiment is an example in which a temperature sensor is included as one of the various sensors 790 of the injection molding machine 10. The temperature sensor may be a radiation thermometer or a thermocouple. The temperature sensor involved in this embodiment may be provided at Figure 4 The position 791 near the exhaust port 803 of the mold device 800 shown may also be set at a position 792 near the outlet 804 of the exhaust port 803 .

[0239] The acquisition unit 711 acquires the temperature of the air and gas detected by the temperature sensor.

[0240] In this embodiment, the temperature threshold value Tte is stored in the threshold value information storage unit 702A. The threshold value Tte can be determined based on the temperature detected by the temperature sensor before the exhaust port 803 is completely closed during the test run, for example.

[0241] Furthermore, the determination unit 712 determines whether the temperature acquired by the acquisition unit 711 is greater than the threshold value Tte stored in the threshold value information storage unit 702A. If it is determined that the temperature is greater than the threshold value Tte stored in the threshold value information storage unit 702A, it is determined that the exhaust port 803 is closed and gas burning is about to occur. Furthermore, the output control unit 713 displays the situation of gas burning approaching on the display device 760. The user can recognize that gas burning is approaching. Therefore, the user can stop the injection molding machine 10 and clean the mold device 800 before gas burning occurs.

[0242] Furthermore, the output control unit 713 can display the actual value of the temperature in the setting column (e.g., setting column 1727) of the log information screen. Furthermore, in the log information screen, it is also possible to accept settings for temperature monitoring. Thus, a molded product formed when the temperature becomes greater than the threshold value Tte can also be judged as a defective product. Furthermore, the temperature can be stored as log information.

[0243] (Fifth embodiment)

[0244] In the fifth embodiment, as a detection example of a condition related to an object discharged from an exhaust port (an example of a gap) 803 of the mold device 800, a detection example of one or more of the concentration of components of the gas and air discharged from the mold device 800 (in the case of gas burning, the concentration of the components changes after combustion) and the moisture content (humidity) is described.

[0245] When the exhaust port 803 of the mold device 800 is closed and the flow path cross-sectional area of ​​the exhaust port 803 becomes smaller, the air and gas in the cavity space 801 are not easy to be discharged, so the air and gas are instantly compressed and become high temperature (in other words, become a state close to adiabatic compression).

[0246] The gas generated from the flow front (flow front) of the molding material varies depending on the type of molding material, but most of them contain flammable gases such as methane and ethylene. Moreover, when flammable gases are contained, they may burn beyond the ignition point.

[0247] When methane is contained, the composition changes as follows due to combustion.

[0248] Complete combustion: CH4+2O2→CO2+2H2O

[0249] Incomplete combustion: 2CH4+3O2→2CO+4H2O

[0250] When ethylene is contained, the composition changes as follows due to combustion.

[0251] C2H4+3O2→2H2O+2CO2

[0252] That is, when the exhaust port 803 is not blocked by mold scale, since the combustible gas does not burn, a large amount of methane, ethylene and oxygen are detected. On the other hand, when the exhaust port 803 is gradually blocked by mold scale, since the combustible gas burns, methane, ethylene and oxygen decrease, and a large amount of carbon dioxide, carbon monoxide and water are detected.

[0253] Therefore, the present embodiment provides an example in which various sensors 790 of the injection molding machine 10 include a gas detection sensor that can detect changes in the concentration or moisture content of methane, ethylene, oxygen, carbon dioxide, or carbon monoxide. The gas detection sensor can be provided at Figure 4 The position 791 near the exhaust port 803 of the mold device 800 shown may also be set at a position 792 near the outlet 804 of the exhaust port 803 .

[0254] In the present embodiment, an example in which methane and ethylene are included as the combustible gas generated from the molding material is shown, but a molding material that generates other combustible gases may also be used.

[0255] The acquisition unit 711 acquires the concentration of methane, ethylene, oxygen, carbon dioxide, or carbon monoxide components or the amount of water detected by the gas detection sensor.

[0256] In this embodiment, the threshold value Tc related to the concentration or moisture content of the gas component is stored in the threshold value information storage unit 702A. The threshold value Tc can be determined based on the concentration or moisture content of the component detected by the gas detection sensor before the exhaust port 803 is completely closed during the test operation.

[0257] Furthermore, the determination unit 712 performs determination using the threshold value Tc stored in the threshold value information storage unit 702A as a determination reference. For example, the determination unit 712 determines whether the concentration or water content of the gas component acquired by the acquisition unit 711 is within a prescribed range based on the threshold value Tc. The determination unit 712 may determine whether the concentration or water content of the first component is greater than the threshold value Tc, or may determine whether the concentration of the second component is less than the threshold value Tc. The first component is, for example, a component that increases due to gas burning, and the second component is, for example, a component that decreases due to gas burning. There is a method as follows: when the determination unit 712 determines that the concentration or water content of the first component is greater than the threshold value Tc stored in the threshold value information storage unit 702A, it determines that the exhaust port 803 is closed and gas burning has occurred. Then, the output control unit 713 displays the occurrence of gas burning on the display device 760. The user can recognize that gas burning has occurred and the exhaust port 803 is completely closed. Therefore, the user can stop the injection molding machine 10 before the exhaust port 803 is completely closed, and clean the mold device 800, etc.

[0258] Furthermore, the output control unit 713 may display the actual value of the concentration of the gas component or the water content in the setting column (e.g., setting column 1727) of the log information screen. Furthermore, in the log information screen, it is also possible to accept settings for monitoring the concentration of the gas component or the water content. Thus, when the concentration of the gas component or the water content becomes greater than the threshold value Tc, the molded product can be judged as a defective product. Furthermore, the actual value of the concentration of the gas component or the water content can be stored as log information.

[0259] In the present embodiment, the determination based on the concentration of the gas component or the amount of water may be performed using a single gas or by combining determinations based on a plurality of gases.

[0260] (Sixth embodiment)

[0261] In the sixth embodiment, as an example of detecting a condition related to an object discharged from an exhaust port (an example of a gap) 803 of the mold device 800, an example of detecting the smell of gas and air discharged from the mold device 800 will be described.

[0262] When the exhaust port 803 of the mold device 800 is closed and the flow path cross-sectional area of ​​the exhaust port 803 becomes smaller, the air and gas in the cavity space 801 are not easy to be discharged, so the air and gas are instantly compressed and become high temperature (in other words, become a state close to adiabatic compression).

[0263] The gas generated from the flow front (flow front) of the molding material varies depending on the type of molding material, but most of them contain flammable gases such as methane and ethylene. Moreover, when flammable gases are contained, they burn beyond the ignition point.

[0264] Furthermore, when combustible gas or the like burns, gas burning also occurs in the molded product. When gas burning occurs in the molded product, a part of the molded product is carbonized, thereby generating a burning smell.

[0265] Therefore, the present embodiment is set as an example that the various sensors 790 of the injection molding machine 10 include an odor sensor. The odor sensor can detect the intensity of the burning odor. As the odor sensor, for example, a sensor that can detect the odor intensity by a semiconductor method (when the odor gas contacts a metal oxide semiconductor, the conductivity becomes higher and the detection value changes) is used. The odor sensor can be set Figure 4 The position 791 near the exhaust port 803 of the mold device 800 shown may also be set at a position 792 near the outlet 804 of the exhaust port 803 .

[0266] The acquisition unit 711 acquires the intensity of the smell of burning of the molded product detected by the olfactory sensor.

[0267] In this embodiment, the threshold value Ts indicating the intensity of the smell of the molded product being burned is stored in the threshold value information storage unit 702A. The threshold value Ts can be determined, for example, based on the intensity of the smell detected by the smell sensor when the molded product is burned before the exhaust port 803 is completely closed during the test run.

[0268] Furthermore, the determination unit 712 determines whether the intensity of the odor acquired by the acquisition unit 711 is greater than the threshold value Ts stored in the threshold value information storage unit 702A. If it is determined that it is greater than the threshold value Ts stored in the threshold value information storage unit 702A, it is determined that the exhaust port 803 is closed and gas burning occurs. Then, the output control unit 713 displays the occurrence of gas burning on the display device 760. The user can recognize that gas burning occurs and the exhaust port 803 is completely closed. Therefore, the user can stop the injection molding machine 10 before the exhaust port 803 is completely closed, and clean the mold device 800, etc.

[0269] Furthermore, the output control unit 713 may display the actual value of the intensity of the above-mentioned odor in the setting column (e.g., setting column 1727) of the log information screen. Furthermore, in the log information screen, it is also possible to accept settings for monitoring the intensity of odor. Thus, a molded product formed when the odor intensity is greater than the threshold value Ts can be judged as a defective product. Furthermore, the actual value of the odor intensity can be stored as log information.

[0270] The first to sixth embodiments and the modified examples described above are not limited to the control method performed by any one of them, and a combination of control may be performed.

[0271] In the above-mentioned embodiment and modification, an example of detecting the condition of gas and air discharged from the exhaust port 803 of the mold device 800 is described. However, the above-mentioned embodiment and modification are not limited to the method of detecting the condition of gas and air discharged from the exhaust port 803. The object to be detected can be discharged from the gap of the mold device 800, for example, it can also be discharged from the gap generated on the parting line surface.

[0272] The above-mentioned embodiment and modification examples have described an example of detecting the conditions of gas and air discharged from the mold device 800. However, the above-mentioned embodiment and modification examples do not limit the detection object to gas and air, and may be any gas such as gas or air, or may be an object other than gas such as a molding material discharged from the mold device 800.

[0273] (Seventh Implementation Method)

[0274] In the above embodiment, an example is described in which the control device 700 of the injection molding machine 10 performs abnormality determination of the mold device 800 based on the condition of the object discharged from the mold device 800. However, the above embodiment is not limited to the method in which the control device 700 of the injection molding machine 10 performs abnormality determination of the mold device 800. Therefore, in the seventh embodiment, an example is set in which the management device that controls the injection molding machine 10 performs abnormality determination of the mold device 800.

[0275] Fig.10 : is a conceptual diagram showing a management system according to the seventh embodiment. Fig.10 In the illustrated example, four injection molding machines 10 are installed in the factory 2100 .

[0276] Furthermore, in the factory 2100, as a management system, a management device 2011 and four injection molding machines 10 are connected via a communication line. The management device 2011 can be connected to an external device via a communication network (not shown). On the other hand, the four injection molding machines 10 can communicate with the management device 2011, but are set in a manner that cannot be connected to an external device. Thus, the safety of the four injection molding machines 10 is maintained.

[0277] In the present embodiment, the injection molding machine 10 does not include the threshold value information storage unit 702A, but the storage device 2012 of the management device 2011 includes the threshold value information storage unit 702A.

[0278] The management device 2011 receives log information about injection molding performed by each of the four injection molding machines 10 from the injection molding machines 10 and registers the log information in the storage device 2012. Thus, the management device 2011 can store log information about injection molding performed by each of the four injection molding machines 10.

[0279] The control device 700 of the injection molding machine 10 transmits the detection results of one or more of the microphone 781 and the various sensors 790 to the management device 2011. The management device 2011 includes at least the determination unit 712 and the output control unit 713 shown in the above-mentioned embodiment and the modified example.

[0280] Then, the determination unit 712 of the management device 2011 determines the condition related to the object (e.g., air or gas) discharged from the exhaust port 803 based on the detection results of the microphone 781 and any one or more of the various sensors 790, and determines whether an abnormality has occurred in the mold device 800 based on the condition related to the object (e.g., air or gas).

[0281] The determination performed by the determination unit 712 of the management device 2011 according to the present embodiment may be any one of the above-described embodiments and modifications, or may be a combination of the determinations shown in the above-described embodiments and modifications.

[0282] The output control unit 713 outputs the content that an abnormality has occurred in the mold device 800 to a display device (not shown) or a speaker of the management device 2011. In addition, the output control unit 713 outputs the content that an abnormality has occurred in the mold device 800 to the display device 760 or the speaker of the injection molding machine 10 to be monitored. In addition, the output control unit 713 may output an instruction to stop injection molding to the injection molding machine 10 to be monitored.

[0283] The management device 2011 according to this embodiment may include a log information storage unit 715. The log information storage unit 715 of the management device 2011 may store information based on detection results of one or more of the microphone 781 and the various sensors 790 transmitted from the injection molding machine 10 in the storage device 2012.

[0284] <Function>

[0285] In the past, in order to confirm the state of the molding material during injection molding, sensors (such as temperature sensors or pressure sensors) were mostly installed in the cavity space where the molding material flows. Since the pressure and temperature in the cavity space are high, the load on the sensor is high, and the possibility of malfunction in the sensor is high.

[0286] In contrast, in the above-mentioned embodiment and modified example, the sensor is disposed outside the cavity space. Since the sensor is disposed outside the cavity space, the load on the sensor is small, and the possibility of a malfunction in the sensor can be reduced.

[0287] In the above-mentioned embodiment and modification, when mold deposits accumulate at the exhaust port 803 and are closed, and objects (e.g., air and gas) are difficult to be discharged from the cavity space 801, the state of the object (e.g., the magnitude of the discharge sound (vibration), the frequency of the vibration caused by the discharge, the flow rate or flow velocity of the discharged object, the temperature of the discharged object, the concentration of each component of the discharged object, the water content (humidity), and the intensity of the odor) changes. Therefore, in the above-mentioned embodiment and modification, the control device 700 or the management device 2011 determines the state of the object based on a specified threshold. Based on this determination, it is possible to identify whether there is a possibility of one or more of gas burning of the molded product and short injection of the molded product. Since the determination result is output to the display device 760, etc., the user can recognize the change of the molded product.

[0288] That is, in the above-mentioned embodiment and modification, as an example of the condition of gas discharge from the gap, it is determined whether an abnormality has occurred in the mold device 800 based on the size of the discharge sound (vibration), the frequency of the vibration caused by the discharge, the flow rate or flow velocity of the discharged gas, the temperature of the discharged gas, the concentration of each component of the discharged gas, the water content (humidity) and the odor intensity. In the determination based on the condition of gas discharge from the gap, a sensor (for example, microphone 781 or various sensors 790) for detecting the condition is set at a position further outside than the cavity space 801, so that the degree of freedom of the setting position can be improved compared with the past. In addition, the sensor does not need to withstand the pressure in the cavity space 801, so a low-cost sensor can be used.

[0289] In an example of a condition where gas is discharged from a gap, the magnitude of the discharge sound (vibration) and the frequency of the vibration caused by the discharge are easier to detect by setting a sensor than the flow rate or velocity of the discharged gas, the temperature of the discharged gas, the concentration of each component of the discharged gas, the moisture content (humidity), and the odor intensity. That is, in the case of the flow rate or velocity of the discharged gas, the temperature of the discharged gas, the concentration of each component of the discharged gas, the moisture content (humidity), and the odor intensity, it is necessary to set a pipeline or the like so that the gas discharged from the vent 803 does not mix with the surrounding gas or does not deteriorate based on the surrounding gas, or to set a sensor (for example, various sensors 790) near the outlet 804 of the exhaust port 803 and directly detect the gas discharged from the outlet 804.

[0290] In contrast, when the magnitude of the discharge sound (vibration) and the frequency of the vibration caused by the discharge are used, a sensor (e.g., microphone 781) is provided at a position away from the mold clamping device 100. Therefore, for example, the sensor (e.g., microphone 781) can be provided on the frame 900 side. That is, in order to determine whether an abnormality of the mold device 800 has occurred when the gas is discharged from the gap, the mold device 800 does not need to be processed, so the cost for detecting the abnormality can be reduced. In addition, the installation of the sensor (e.g., microphone 781) becomes easy, so the workload can be reduced.

[0291] In the above-mentioned embodiment and modification, the possibility of one or more of gas burning and short injection occurring in the molded product can be detected. The user can stop the injection molding of the injection molding machine 10 and clean it according to the detection result. Therefore, the cleaning frequency of the mold device 800 is minimized, thereby achieving an improvement in productivity.

[0292] The above is a description of the embodiments of the injection molding machine, management device and management system involved in the present invention, but the present invention is not limited to the above embodiments, etc. Various changes, modifications, replacements, additions, deletions and combinations can be made within the scope of the technical solution. These contents certainly also fall within the technical scope of the present invention.

Claims

1. An injection molding machine comprising: a mold device into which a molding material is injected through an injection device; a detection unit that detects a condition related to an object ejected from a gap provided in the mold device when the molding material is injected; and The control device determines whether an abnormality has occurred in the mold device based on a condition related to the object discharged from the gap.

2. The injection molding machine according to claim 1, wherein: The control device determines whether an abnormality has occurred in the mold device based on a condition related to a flow of gas exhausted from the gap.

3. The injection molding machine according to claim 2, wherein: The detection unit detects a discharge sound generated when the gas is discharged from the gap. The control device determines whether an abnormality has occurred in the mold device based on a change in the magnitude of the discharge sound or a timing at which the discharge sound is emitted.

4. The injection molding machine according to claim 3, wherein: The control device determines that an abnormality has occurred in the mold device when the magnitude of the sound detected during the current injection of the molding material is smaller than the magnitude of the sound detected during the previous injection of the molding material.

5. The injection molding machine according to claim 3, wherein: In the injection of the molding material this time, when the time from the start of injection molding to the detection of the discharge sound is longer than the time from the start of previous injection molding to the detection of the discharge sound, the control device determines that an abnormality has occurred in the mold device.

6. The injection molding machine according to claim 2, wherein: The detection unit detects vibration generated when the gas is discharged from the gap. The control device determines whether an abnormality has occurred in the mold device based on a change in the frequency of the vibration.

7. The injection molding machine according to claim 1, wherein: The detection unit detects the speed, temperature, concentration of a predetermined component, intensity of an odor, or moisture contained in the object discharged from the gap. The control device determines whether an abnormality has occurred in the mold device using a predetermined threshold value as a determination reference regarding the speed, temperature, concentration of a predetermined component, intensity of an odor, or moisture contained in the object.

8. The injection molding machine according to claim 1, wherein: When the control device determines that an abnormality has occurred in the mold device, the control device stops injection of the molding material into the mold device or outputs a message indicating that an abnormality has occurred in the mold device.

9. The injection molding machine according to claim 1, wherein: The detection unit is provided outside the mold device, or is provided near an exhaust port of the mold device or at a position outside the exhaust port.

10. A management device comprising: an acquisition unit that acquires, from a detection unit provided in the injection molding machine, a condition related to an object discharged from a gap provided in the mold device when a molding material is injected into the mold device in the injection molding machine; and The control device determines whether a malfunction has occurred in the mold device based on a condition related to the object discharged from the gap.

11. A management system comprising: The management device according to claim 10; and The injection molding machine.

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