Molding condition setting method

Abstract

A molding condition setting method for an injection molding machine for molding a molded article, the molding condition setting method comprising: (a) a step for adjusting the temperature and humidity of the periphery of the injection molding machine; (b) a step for acquiring the moisture content of a material used for molding the molded article; (c) a step for setting molding conditions for molded articles in the plurality of injection molding machines; (d) a step for molding a molded article under a plurality of molding conditions by injecting a plasticized material obtained by plasticizing the material into a molding machine by means of an injection molding machine under environmental conditions including the temperature and humidity adjusted in step (a) and the moisture content obtained in step (b); and (e) a step for determining, on the basis of the quality of the molded article molded in step (d), an optimal molding condition under the aforementioned environmental conditions, in step (a), the temperature is adjusted to the temperature of the location where the molded article is produced, and the humidity is adjusted to the humidity of the location where the molded article is produced.

Description

Technical Field

[0001] The present disclosure relates to a method for setting molding conditions. Background Art

[0002] In Patent Document 1, a method for optimizing molding conditions of an injection molding machine is disclosed. In this method, a trial production test is carried out under qualified product molding conditions, the variation range of molding variables due to environmental changes is measured, and updated molding conditions with corrected molding variables are created based on the measured variation range.

[0003] Patent Document 1: Japanese Patent Laid-Open No. 10-272663

[0004] The optimal molding conditions for molding a molded product vary depending on environmental conditions including the temperature and humidity around the injection molding machine. Therefore, a technique for determining the optimal molding conditions under the environmental conditions of the place where the molded product is to be produced is desired. Summary of the Invention

[0005] According to a first aspect of the present disclosure, there is provided a method for setting molding conditions of an injection molding machine for molding a molded product. The molding condition setting method includes: (a) a step of adjusting the temperature and humidity around the injection molding machine; (b) a step of obtaining the moisture content of the material used in the molding of the molded product; (c) a step of setting a plurality of molding conditions for the molding of the molded product by the injection molding machine; (d) a step of injecting the plasticized material obtained by plasticizing the material into a molding die through the injection molding machine under environmental conditions including the temperature and humidity adjusted in step (a) and the moisture content obtained in step (b), and molding the molded product under the plurality of molding conditions; and (e) a step of determining the optimal conditions of the molding conditions under the environmental conditions based on the quality of the molded product molded in step (d). In step (a), the temperature is adjusted to the temperature of the place where the molded product is to be produced, and the humidity is adjusted to the humidity of the place where the molded product is to be produced. Brief Description of the Drawings

[0006] Figure 1 It is an explanatory diagram showing a schematic configuration of a molding condition setting system.

[0007] Figure 2 It is an explanatory diagram showing a schematic configuration of a control device.

[0008] Figure 3 It is a perspective view of each unit in a state where the cover is removed.

[0009] Figure 4 It is a cross-sectional view showing a schematic configuration of an injection molding machine.

[0010] Figure 5 is a perspective view showing a schematic configuration of a screw.

[0011] Figure 6 is a schematic top view of a cylinder.

[0012] Figure 7 is a process chart of a molding condition setting process.

[0013] Figure 8 is a process chart of an optimum condition determination process.

[0014] Figure 9 is a figure showing an example of the time change of an effective value.

[0015] Figure 10 is a process chart of a molded product production process.

[0016] Description of Reference Numerals

[0017] 10... Injection molding system, 20... Material supply unit, 21... First housing, 22... First base, 23... First cover, 24... Material dryer, 25... Material supply section, 30... Injection molding unit, 31... Second housing, 32... Second base, 33... Second cover, 40... Inspection and storage unit, 41... Third housing, 42... Third base, 43... Third cover, 50... Controller, 80... Control device, 81... Processing section, 82... Storage section, 83... Communication section, 84... Input device, 85... Display device, 90... Thermo-hygrostat, 91... Pipe, 100... Molding condition setting system, 110... Injection molding machine, 111... Hopper, 112... Injection section, 113... Clamping section, 120... Spectrometer, 130... Molding die temperature regulator, 140... Take-out device, 150... Transfer device, 160... Gate cutting device, 201... Plasticizing section, 202... Suction and delivery section, 203... Nozzle, 210... Screw, 211... Screw housing, 212... Drive motor, 213... Groove forming surface, 214... Central portion, 215... Groove, 216... Material inlet, 217... Rib portion, 220... Cylinder, 221... Communication hole, 222... Check valve, 223... Opposing surface, 224... Guide groove, 230... Heater, 240... Flow path, 251... Injection cylinder, 252... Plunger, 253... Plunger drive section, 261... Motor, 262... Ball screw, 310... Robot, 320... Inspection device, 321... Inspection table, 322... Imaging section, 323... Weighing measurement section, 330... Stacking mechanism, 331... First arrangement section, 332... Second arrangement section, 900... Molding die, 901... Movable die, 902... Fixed die, PL... Tray, RX... Rotation axis. Detailed Description of the Invention

[0018] A. First Embodiment:

[0019] Figure 1 FIG. 1 is an explanatory diagram showing a schematic configuration of the molding condition setting system 100. In Figure 1 , arrows indicating the X, Y, and Z directions orthogonal to each other are shown. The X and Y directions are directions parallel to the horizontal plane. The Z direction is a direction parallel to the vertical direction. Figure 1 The X, Y, and Z directions in FIG. 1 indicate the same directions as the X, Y, and Z directions in other figures. When determining the orientation, the direction indicated by the arrow, i.e., the positive direction, is set as "+", and the direction opposite to the direction indicated by the arrow, i.e., the negative direction, is set as "-", and the plus and minus signs are used in the direction markings. The molding condition setting system 100 includes an injection molding system 10, a control device 80, and a thermo-hygrostat 90.

[0020] The injection molding system 10 includes a material supply unit 20, an injection molding unit 30, an inspection and storage unit 40, and a controller 50. The material supply unit 20, the injection molding unit 30, and the inspection and storage unit 40 are arranged in sequence from the -X direction to the +X direction. Each unit is detachably connected to an adjacent other unit. Each unit has a box-shaped housing and is configured as a single unit by concentrating one or more devices or components inside the housing. Hereinafter, the housing of the material supply unit 20 is referred to as the first housing 21, the housing of the injection molding unit 30 is referred to as the second housing 31, and the housing of the inspection and storage unit 40 is referred to as the third housing 41. The first housing 21 includes a first base 22 and a first cover 23 covering the upper surface of the first base 22. The second housing 31 includes a second base 32 and a second cover 33 covering the upper surface of the second base 32. The third housing 41 includes a third base 42 and a third cover 43 covering the upper surface of the third base 42. The first cover 23, the second cover 33, and the third cover 43 are provided such that the internal spaces of the covers communicate with each other. Hereinafter, the first cover 23, the second cover 33, and the third cover 43 are collectively referred to as the cover.

[0021] The controller 50 is provided inside the second base 32. The controller 50 is composed of a PLC (programmable logic controller). The controller 50 controls the cooperative operation of various devices provided in each unit by programming using a language such as ladder diagram language. The controller 50 is connected to the control device 80.

[0022] Figure 2It is an explanatory diagram showing the schematic configuration of the control device 80. The control device 80 is composed of a computer having a processing unit 81, a storage unit 82, and a communication unit 83. The processor 81 includes one or more processors. The processing unit 81 controls the operations of each part of the injection molding system 10 by executing a program stored in the storage unit 82. The storage unit 82 is composed of a main storage device such as a RAM and an auxiliary storage device such as a hard disk drive. In addition, the control device 80 may be implemented by combining a plurality of circuits that implement at least a part of each function instead of being composed of a computer. The control device 80 is connected to an input device 84 such as a keyboard or a mouse and a display device 85 such as a liquid crystal display. In addition, the input device 84 and the display device 85 may be integrated as a touch panel. The control device 80 may be a server. In addition, the control device 80 may be composed of multiple computers. The control device 80 may be composed of, for example, one computer and multiple servers.

[0023] The thermo-hygrostat 90 is connected to the inside of the hood through a pipe 91. The thermo-hygrostat 90 adjusts the temperature and humidity inside the hood.

[0024] Figure 3 It is a perspective view of each unit in a state where the hood is removed.

[0025] The material supply unit 20 includes a material dryer 24 and a material supply section 25. The material used in the molding of the molded product is stored in the material dryer 24. The material stored in the material dryer 24 is dehumidified and dried inside the material dryer 24. As the material, for example, thermoplastic resins such as polypropylene resin (PP), polyethylene resin (PE), and polyoxymethylene resin (POM) can be used. The material supply section 25 is a loader having a conveyor for conveying the material. The material in the material dryer 24 is supplied by the material supply section 25 to the hopper 111 of the injection molding machine 110 included in the injection molding unit 30.

[0026] The injection molding unit 30 includes an injection molding machine 110, a spectrometer 120, a molding die temperature regulator 130, a take-out device 140, a transfer device 150, and a gate cutting device 160. The injection molding machine 110, the spectrometer 120, the take-out device 140, the transfer device 150, and the gate cutting device 160 are provided on the second base 32. The molding die temperature regulator 130 is housed inside the second base 32.

[0027] The injection molding machine 110 is configured to be able to mount a molding die. The injection molding machine 110 includes a hopper 111, an injection unit 112, and a mold clamping unit 113. The material supplied from the material supply unit 25 is stored in the hopper 111. The hopper 111 is preferably formed of a material that transmits infrared rays. The injection unit 112 plasticizes the material supplied from the hopper 111 to generate a plasticized material, and injects the generated plasticized material into the cavity of the molding die. The mold clamping unit 113 opens and closes the molding die mounted on the injection molding machine 110. The injection unit 112 and the mold clamping unit 113 are arranged in the horizontal direction.

[0028] Figure 4 It is a cross-sectional view showing a schematic configuration of the injection molding machine 110. The injection unit 112 includes a plasticizing unit 201, a suction and delivery unit 202, and a nozzle 203.

[0029] The plasticizing unit 201 plasticizes at least a part of the material supplied from the hopper 111 to generate a plasticized material. Here, "plasticizing" includes the concept of melting and means changing from a solid state to a state with fluidity. Specifically, in the case of a material that undergoes a glass transition, plasticizing means setting the temperature of the material above the glass transition point. In the case of a material that does not undergo a glass transition, plasticizing means setting the temperature of the material above the melting point. The plasticizing unit 201 includes a screw 210, a cylinder 220, and a heater 230.

[0030] The screw 210 is housed in a screw case 211. The screw 210 is connected to a drive motor 212 and rotates in the screw case 211 by the rotational driving force generated by the drive motor 212. The axial direction of the rotation axis RX of the screw 210 is along the X direction. The rotation speed of the screw 210 is controlled by controlling the rotation speed of the drive motor 212 by a controller 50. In addition, the screw 210 may be driven by the drive motor 212 via a speed reducer. The screw 210 is also referred to as a rotor or a flat screw.

[0031] The cylinder 220 is provided on the +X direction side of the screw 210. A communication hole 221 is formed in the center of the cylinder 220. The communication hole 221 forms at least a part of a flow path 240 through which the plasticized material flows. The communication hole 221 is connected to an injection cylinder 251 described later. In the communication hole 221, a check valve 222 is provided at a position upstream of the injection cylinder 251. A heater 230 is provided inside the cylinder 220. The temperature of the heater 230 is controlled by the controller 50.

[0032] Figure 5It is a perspective view showing a schematic configuration of the screw 210. The screw 210 has a substantially cylindrical shape with a length in the direction along the rotation axis RX smaller than the length in the direction perpendicular to the rotation axis RX. On the groove forming surface 213 of the screw 210 facing the cylinder 220, a spiral groove 215 is formed centering on the central portion 214. The groove 215 communicates with the material inlet 216 formed on the side surface of the screw 210. The material supplied from the hopper 111 is supplied to the groove 215 through the material inlet 216. The groove 215 is formed by being separated by the rib portion 217. In Figure 5 An example in which three grooves 215 are formed is shown, but the number of grooves 215 can be one, or two or more. In addition, the groove 215 is not limited to a spiral shape, and can also be a helical shape or an involute curve shape, or can also be a shape extending in a manner of drawing an arc from the central portion 214 to the outer periphery.

[0033] Figure 6 It is a schematic top view of the cylinder 220. The cylinder 220 has an opposing surface 223 opposing the groove forming surface 213 of the screw 210. A communication hole 221 is formed at the center of the opposing surface 223. A plurality of guiding grooves 224 that are connected to the communication hole 221 and extend spirally from the communication hole 221 to the outer periphery are formed on the opposing surface 223. The material supplied to the groove 215 of the screw 210 is plasticized between the screw 210 and the cylinder 220 by the rotation of the screw 210 and the heating of the heater 230, and at the same time, flows along the groove 215 and the guiding grooves 224 by the rotation of the screw 210, and is guided to the central portion 214 of the screw 210. The material flowing into the central portion 214 flows out from the communication hole 221 provided at the center of the cylinder 220 to the suction and delivery portion 202. In addition, the guiding grooves 224 may not be provided on the cylinder 220. Further, the guiding grooves 224 may not be connected to the communication hole 221.

[0034] The suction and delivery portion 202 has an injection cylinder 251, a plunger 252, and a plunger driving portion 253. The suction and delivery portion 202 has a function of injecting the plasticized material in the injection cylinder 251 into the cavity of the molding die 900. The suction and delivery portion 202 controls the injection amount, injection speed, and injection pressure of the plasticized material from the nozzle 203 under the control of the controller 50. The injection cylinder 251 is a substantially cylindrical member connected to the communication hole 221 of the cylinder 220, and the plunger 252 is provided inside. The plunger 252 slides inside the injection cylinder 251 and presses the plasticized material in the injection cylinder 251 to the nozzle 203. The plunger 252 is driven by the plunger driving portion 253 constituted by an electric motor.

[0035] A flow path 240 is formed in the nozzle 203. The plasticized material in the injection cylinder 251 is pressed to the nozzle 203 by the plunger 252, and the plasticized material is injected from the nozzle 203 into the molding die 900.

[0036] The mold clamping unit 113 opens and closes the molding die 900 installed in the injection molding machine 110. The mold clamping unit 113 rotates the ball screw 262 by driving the motor 261 under the control of the controller 50, and moves the movable die 901 coupled to the ball screw 262 relative to the fixed die 902, thereby opening and closing the molding die 900.

[0037] Figure 3 The spectrometer 120 shown is provided in the hopper 111. The spectrometer 120 measures the moisture content of the material stored in the hopper 111. The spectrometer 120 measures the moisture content of the material, for example, by irradiating the material in the hopper 111 with near-infrared rays and measuring the light reflected by the material without being absorbed by the material.

[0038] The molding die temperature regulator 130 circulates the heat medium in the cooling pipes provided in the molding die 900 to adjust the temperature of the molding die 900.

[0039] The take-out device 140 is a device that takes out the molded product molded by the injection molding machine 110 from the injection molding machine 110. The take-out device 140 is arranged on the -Y direction side of the injection molding machine 110. The take-out device 140 is composed of a hand part that holds the molded product and a linear actuator that moves the hand part along the X direction and the Y direction. The take-out device 140 takes out the molded product from the injection molding machine 110 by the hand part, and moves the molded product taken out from the injection molding machine 110 to the -X direction side end of the conveying device 150 by the linear actuator and places it on the conveying device 150.

[0040] The conveying device 150 is a device that conveys the molded product taken out by the take-out device 140. The conveying device 150 is arranged on the -Y direction side of the injection molding machine 110 and is arranged on the +X direction side of the take-out device 140. The conveying device 150 is composed of a linear actuator that can move the molded product along the X direction. The conveying device 150 moves the molded product placed on the conveying device 150 from the -X direction side end to the +X direction side end. A gate cutting device 160 that cuts off the gate part or the runner remaining in the molded product is arranged above the conveying device 150. The gate part or the runner of the molded product being conveyed on the conveying device 150 is cut off by the gate cutting device 160 during the conveying process.

[0041] The inspection and storage unit 40 includes a robot 310, an inspection device 320, and a stacking mechanism 330.

[0042] The robot 310 is a device that moves the molded products carried by the transfer device 150. The robot 310 is configured as a scalar robot. The robot 310 holds the molded product carried to the end on the +X direction side of the transfer device 150 and moves it to the inspection device 320. In addition, the robot 310 moves the molded product that has completed the inspection by the inspection device 320 to the pallet PL of the stacking mechanism 330. Furthermore, the robot 310 is not limited to a scalar robot and may be composed of a vertical multi-joint robot having multiple axes.

[0043] The inspection device 320 inspects the molded products molded by the injection molding machine 110. The inspection device 320 includes: an inspection table 321 for placing the molded product, an imaging unit 322 for imaging the image of the molded product placed on the inspection table 321, and a weight measurement unit 323 for measuring the weight of the molded product.

[0044] The imaging unit 322 is a camera equipped with imaging elements such as a CCD (Charge Coupled Device) sensor and a CMOS (Complementary Metal Oxide Semiconductor) sensor, and is also attached with an illumination unit. The inspection device 320 images the molded product on the inspection table 321 through the imaging unit 322, analyzes the captured image, and performs an appearance inspection including the shape of the molded product. After the appearance inspection is completed, the molded product is moved by the robot 310 to the weight measurement unit 323.

[0045] The weight measurement unit 323 is composed of a weight sensor such as a load cell. The inspection device 320 measures the weight of the molded product placed on the weight measurement unit 323. After the inspection is completed, the molded product is moved by the robot 310 to the pallet PL. In addition, the molded products determined to be non-conforming by the inspection device 320 are discharged by the robot 310 to a non-conforming product discharge area (not shown).

[0046] The stacking mechanism 330 is a mechanism for stacking trays PL on which molded products are placed. The stacking mechanism 330 includes a first placement section 331 and a second placement section 332. The tray PL is placed in each of the first placement section 331 and the second placement section 332. The first placement section 331 carries the tray PL on which a plurality of molded products inspected by the inspection device 320 are placed. The robot 310 conveys the molded products to the tray PL carried on the first placement section 331. When a predetermined number of molded products are placed on the tray PL, the first placement section 331 causes the tray PL to descend into the interior of the second housing 31. The second placement section 332 slides the uppermost tray PL carried on the second placement section 332 onto the tray PL of the first placement section 331 after the descent and moves it. A plurality of trays PL are stacked in the vertical direction in the second placement section 332, and when the uppermost tray PL moves to the first placement section 331, the second placement section 332 raises the remaining trays PL.

[0047] Figure 7 It is a process chart of the molding condition setting process. A molding condition setting method for an injection molding machine 110 that molds a molded product is implemented through the molding condition setting process. In the molding condition setting process, first, the optimal condition determination process is executed in step S1, and then, the molded product production process is executed in step S2.

[0048] Figure 8 It is a process chart of the optimal condition determination process. First, in step S10, the thermo-hygrostat 90 adjusts the temperature inside the hood to the temperature of the place where the molded product is produced, and adjusts the humidity inside the hood to the humidity of the place where the molded product is produced. That is, the thermo-hygrostat 90 adjusts the temperature around the injection molding machine 110 to the temperature of the place where the molded product is produced, and adjusts the humidity around the injection molding machine 110 to the humidity of the place where the molded product is produced. Here, the place where the molded product is produced refers to, for example, a factory where a molded product is produced using an injection molding machine, the destination of shipment or rental of the injection molding machine.

[0049] In step S20, the spectrometer 120 obtains the moisture content of the material stored in the hopper 111. Hereinafter, the temperature around the injection molding machine 110, the humidity around the injection molding machine 110, and the moisture content of the material are also collectively referred to as environmental conditions.

[0050] In step S30, the control device 80 sets the set values of the factors related to the molding of the molded product. The factors include the temperature of the molding die 900, the temperature of the plasticized material, the pressure of the plasticized material, the injection rate of the plasticized material, and the cooling time of the molding die 900. Here, the cooling time of the molding die 900 refers to the time taken for the cooling of the molding die 900 after the plasticized material is filled into the molding die 900. The control device 80 may set the value input by the user to the control device 80 via the input device 84 as the set value of the factor, or may set a predetermined value as the set value of the factor. Hereinafter, the set value of the factor will be simply referred to as the set value.

[0051] In step S40, the control device 80 sets multiple molding conditions for the molded product of the injection molding machine 110. The molding conditions have multiple parameters such as the barrel temperature, injection pressure, holding time, screw speed, etc. For example, the control device 80 sets the molding conditions so that the effective value of the factor in the process of molding the molded product becomes a value close to the set value set in step S30. Here, the effective value of the factor refers to the actual value of the factor in the process of molding the molded product. Hereinafter, the effective value of the factor will be simply referred to as the effective value. For example, the temperature of the plasticized material changes with the barrel temperature. The control device 80 sets the barrel temperature so that the effective value of the temperature of the plasticized material in the process of molding the molded product becomes a value close to its set value. In addition, the pressure of the plasticized material and the injection speed of the plasticized material vary according to the injection pressure and the holding time. Here, the injection pressure refers to the pressure at which the plunger 252 pushes the plasticized material toward the nozzle 203. The control device 80 sets the injection pressure and the holding time so that the effective value of the pressure of the plasticized material in the process of molding the molded product becomes a value close to its set value. In addition, the control device 80 sets the injection pressure and the holding time so that the effective value of the injection speed of the plasticized material in the process of molding the molded product becomes a value close to its set value.

[0052] In addition, in step S40, the control device 80 sets a first molding condition and a second molding condition different from the first molding condition with respect to a first parameter that is included in the first molding condition. The first parameter may be a parameter determined by the control device 80 or a parameter specified by the user operating the input device 84. For example, when the first parameter is the barrel temperature and the barrel temperature in the first molding condition is 200 °C, the control device 80 sets the barrel temperature in the second molding condition to 210 °C. In addition, the first parameter is not limited to one parameter and may be multiple parameters. The control device 80 is not limited to the first molding condition and the second molding condition and may also set multiple different molding conditions including the first molding condition and the second molding condition.

[0053] In step S50, the injection molding machine 110 injects the plasticized material into the molding die 900 under the environmental conditions including the temperature and humidity adjusted in step S10 and the moisture content of the material obtained in step S20, thereby molding the molded product under the multiple molding conditions set in step S40. That is, the injection molding machine 110 molds the molded product under the first molding condition and the second molding condition. Hereinafter, the molded product molded under the first molding condition is referred to as the first molded product, and the molded product molded under the second molding condition is referred to as the second molded product.

[0054] In step S50, step S51 and step S52 are executed. In step S51, the control device 80 monitors the effective value of the factor during the period when the molded product is being molded. Figure 9 It is a diagram showing an example of the time change of the effective value. Figure 9 The horizontal axis of shows the elapsed time, and the vertical axis shows the effective value of the pressure of the plasticized material. In Figure 9 the time change of the effective value of the pressure of the plasticized material is shown.

[0055] In step S52, the control device 80 stores the first information obtained by associating the environmental conditions under which the molded product is molded, the molding conditions used in the molding of the molded product, and the effective value when the molded product is molded into the storage unit 82. In other words, the first information is the information obtained by associating the environmental conditions including the temperature and humidity adjusted in step S10 and the moisture content of the material obtained in step S20, the molding conditions set in step S40, and the effective value when the molded product is molded under the above environmental conditions with the above molding conditions.

[0056] In step S60, the inspection device 320 inspects the molded product molded in step S50.

[0057] In step S70, the control device 80 determines the optimal conditions for the molding conditions under the environmental conditions including the temperature and humidity adjusted in step S10 and the moisture content of the material obtained in step S20 based on the quality of the molded product molded in step S50. The control device 80 determines the molding conditions that molded the molded product with the best quality among the molding conditions set in step S40 as the optimal conditions. The molded product with the best quality is, for example, a molded product with no appearance defects and the dimensions and weight of the molded product being closest to the standard values of the dimensions and weight of the molded product, respectively. In other words, the control device 80 selects the optimal conditions from among the first molding condition and the second molding condition according to the comparison result between the first molded product and the second molded product. The control device 80 determines the molding conditions that molded the molded product with better quality among the first molding condition and the second molding condition as the optimal conditions. As described above, the optimal condition determination process is executed.

[0058] Figure 10 It is a process diagram for the production process of a molded product. The production process of the molded product is carried out at the "place for producing the molded product" described in step S10 of the optimal condition determination process. As described in step S10, the temperature and humidity at the place for producing the molded product are the same as the temperature and humidity around the injection molding machine 110 adjusted in step S10. The molding condition setting system used in the production process of the molded product can also be a system without a thermostat and a hood. In addition, the injection molding machine used in the production process of the molded product can be the same injection molding machine as the injection molding machine 110 used in the optimal condition determination process, or it can be another injection molding machine.

[0059] In step S110, the injection molding machine 110 molds the molded product under the environmental conditions including the temperature and humidity adjusted in step S10 of the optimal condition determination process and the moisture content of the material obtained in step S20, with the optimal conditions determined in step S70. The moisture content of the material stored in the hopper 111 of the injection molding machine 110 is the same as the moisture content obtained in step S20. In addition, when the moisture content of the material stored in the hopper 111 is different from the moisture content obtained in step S20, the material dryer 24 is used to dry the material so that they become equal.

[0060] In step S120, the control device 80 determines whether the effective value of the factor deviates from a predetermined range and has changed. When the effective value deviates from the predetermined range and changes, step S130 is executed. When the effective value does not deviate from the predetermined range and changes, step S140 is executed. In addition, the control device 80 can also determine whether there is an abnormality in the waveform of the curve showing the time change of the effective value as shown in Figure 9 When an abnormality occurs, step S130 is executed, and when there is no abnormality, step S140 is executed.

[0061] In step S130, the control device 80 corrects the optimal conditions based on the first information. For example, when the temperature of the plasticized material, which is one of the factors, is lower than the predetermined lower limit value, the control device 80 corrects the barrel temperature of the optimal conditions to increase the temperature of the plasticized material. The control device 80 corrects the barrel temperature of the optimal conditions to a value obtained by multiplying the barrel temperature of the optimal conditions by a coefficient. The above coefficient is a value calculated based on the relationship between the effective value of the temperature of the plasticized material included in the first information and the barrel temperature, and is a value obtained by multiplying the above coefficient by the barrel temperature of the optimal conditions so that the temperature of the plasticized material exceeds the predetermined lower limit value. After step S130 is executed, step S110 is executed. Thus, the molded product is molded with the corrected optimal conditions.

[0062] In step S140, the control device 80 determines whether a predetermined number of molded products have been molded. If a predetermined number of molded products have been molded, the control device 80 ends the molded product production process. If a predetermined number of molded products have not been molded, the control device 80 returns the process to step S110. As described above, the molded product production process is executed.

[0063] According to the first embodiment described above, the molded product is molded under a plurality of molding conditions under the environmental conditions of the place where the molded product is produced, and the optimal conditions of the molding conditions are determined based on the quality of the molded product after molding. Here, the environmental conditions of the place where the molded product is produced are reproduced by adjusting the temperature and humidity around the injection molding machine 110 to the temperature and humidity of the place where the molded product is produced, respectively. Therefore, it is possible to determine the optimal molding conditions under the environmental conditions of the place where the molded product is produced. In addition, since it is possible to determine the optimal conditions of the place where the molded product is produced at a place different from the temperature and humidity of the place where the molded product is produced, it is not necessary to investigate the optimal conditions of the place where the molded product is produced. Moreover, even when the temperature and humidity of the place where the molded product is produced change according to the season, it is possible to determine the optimal conditions corresponding to the season.

[0064] In addition, in the present embodiment, the optimal conditions are selected from the first molding conditions and the second molding conditions according to the comparison result between the first molded product and the second molded product. Therefore, it is possible to determine the molding conditions for the molded product with better quality among the first molding conditions and the second molding conditions as the optimal conditions.

[0065] In addition, in the present embodiment, the moisture content of the material used in the molding of the molded product is measured by the spectrometer 120. Therefore, it is possible to measure the moisture content of the material from the outside of the part where the material is stored.

[0066] In addition, in the present embodiment, the spectrometer 120 is arranged in the hopper 111 for storing the material. Therefore, it is possible to measure the moisture content of the material just before it is used in the molding of the molded product.

[0067] In addition, in the present embodiment, the molding conditions are set so that the effective value of the factor in the process of molding the molded product becomes a value close to its set value. Therefore, compared with the case where there is no limitation on the setting of the molding conditions, the range of the molding conditions that can be set can be narrowed. As a result, the number of the set molding conditions can be reduced, and the time required to determine the optimal conditions can be shortened.

[0068] In addition, in the present embodiment, in the process of molding the molded product, first information including environmental conditions, molding conditions, and effective values when molding the molded product under the above environmental conditions with the above molding conditions is stored in the storage unit 82. Therefore, the user can confirm the first information after the molded product is molded.

[0069] In addition, in the present embodiment, in the process of molding the molded product by the injection molding machine 110 under the optimal conditions, when the effective value deviates from a predetermined range and changes, the optimal conditions are corrected based on the first information. Therefore, when the quality of the molded product deteriorates during the process of molding the molded product under the optimal conditions, the quality of the molded product can be improved.

[0070] B. Other embodiments:

[0071] (B-1) In the above embodiment, the moisture content of the material used in molding is measured by the spectrometer 120. In contrast, the moisture content of the material used in molding can also be measured by a device other than the spectrometer.

[0072] (B-2) In the above embodiment, the spectrometer 120 is arranged in the hopper 111 for storing the material. In contrast, the spectrometer 120 is not limited to the hopper 111, and can be arranged at a position where the moisture content of the material can be measured.

[0073] (B-3) In the above embodiment, the set value of the factor is set in the step S30 of the optimal condition determination process, and in the step S40, the molding conditions are set such that the effective value of the factor in the process of molding the molded product becomes a value close to the set value. In contrast, the set value of the factor may not be set in the optimal condition determination process. That is, the step S30 of the optimal condition determination process may not be executed.

[0074] (B-4) In the above embodiment, the factors include the temperature of the molding die 900, the temperature of the plasticized material, the pressure of the plasticized material, the injection speed of the plasticized material, and the cooling time of the molding die 900. In contrast, the factors only need to include at least one of the temperature of the molding die 900, the temperature of the plasticized material, the pressure of the plasticized material, the injection speed of the plasticized material, and the cooling time of the molding die 900.

[0075] (B-5) In the above embodiment, in the step S52 of the optimal condition determination process, first information including environmental conditions, molding conditions, and effective values when molding the molded product under the above environmental conditions with the above molding conditions is stored in the storage unit 82. In contrast, in the process of molding the molded product, the first information may not be stored in the storage unit 82. That is, the step S52 of the optimal condition determination process may not be executed.

[0076] In the above-described embodiment, the molded product production process is executed in the molding condition setting process. In contrast, the molded product production process may not be executed.

[0077] C. Other methods:

[0078] The present disclosure is not limited to the above-described embodiments and can be implemented in various ways without departing from its gist. For example, the present disclosure can also be implemented by the following methods. To solve part or all of the problems of the present disclosure, or to achieve part or all of the effects of the present disclosure, the technical features in the above-described embodiments corresponding to the technical features in each of the following-described methods can be appropriately replaced or combined. In addition, if the technical feature is not described as an essential technical feature in this specification, it can be appropriately deleted.

[0079] (1) According to one aspect of the present invention, there is provided a method for setting molding conditions of an injection molding machine for molding a molded product. The molding condition setting method includes: (a) a step of adjusting the temperature and humidity around the injection molding machine; (b) a step of obtaining the moisture content of the material used in the molding of the molded product; (c) a step of setting a plurality of molding conditions for the molded product of the injection molding machine; (d) a step of injecting the plasticized material obtained by plasticizing the material into a molding die by the injection molding machine under environmental conditions including the temperature and humidity adjusted in step (a) and the moisture content obtained in step (b) to mold the molded product under the plurality of molding conditions; and (e) a step of determining the optimum condition of the molding conditions under the environmental conditions based on the quality of the molded product molded in step (d). In step (a), the temperature is adjusted to the temperature of the place where the molded product is produced, and the humidity is adjusted to the humidity of the place where the molded product is produced.

[0080] According to such an aspect, it is possible to determine the optimum molding conditions under the environmental conditions of the place where the molded product is produced.

[0081] (2) In the above aspect, it may be that in step (c), a first molding condition and a second molding condition different from the first molding condition with respect to a first parameter included in the first molding condition are set. Step (d) includes: a step of molding a first molded product by the injection molding machine under the first molding condition; and a step of molding a second molded product by the injection molding machine under the second molding condition. In step (e), the optimum condition is selected from the first molding condition and the second molding condition based on the comparison result between the first molded product and the second molded product.

[0082] (3) In the above method, it may also be that in the step (b), the moisture content is measured by a spectrometer.

[0083] According to such a method, it is possible to measure the moisture content of the material from the outside of the part where the material is stored.

[0084] (4) In the above method, it may also be that the spectrometer is arranged in the hopper for storing the material.

[0085] According to such a method, it is possible to measure the moisture content of the material just before it is used in the molding of the molded product.

[0086] (5) In the above method, it may also be that there is further provided: (f) a step of setting a set value of the factor related to the molding of the molded product among the factors adjusted according to the environmental conditions, and in the step (c), the molding conditions are set in such a way that the effective value of the factor in the step (d) becomes a value close to the set value, and the factor includes at least any one of the temperature of the molding die, the temperature of the plasticized material, the pressure of the plasticized material, the injection speed of the plasticized material, and the cooling time of the molding die.

[0087] According to such a method, compared with the case where there is no limitation on the setting of the molding conditions, it is possible to narrow the range of the molding conditions that can be set. Thereby, it is possible to reduce the number of the set molding conditions and shorten the time required to determine the optimum conditions.

[0088] (6) In the above method, it may also be that the step (d) includes: a step of monitoring the effective value; and a step of storing first information obtained by associating the environmental conditions, the molding conditions, and the effective value when the molded product is molded under the environmental conditions with the molding conditions in a storage unit.

[0089] According to such a method, the user can confirm the first information after the molded product is molded.

[0090] (7) In the above method, it may also be that there is further provided (g) a step of the injection molding machine molding the molded product under the environmental conditions with the optimum conditions, and in the step (g), when the effective value deviates from a predetermined range and changes, the optimum conditions are corrected based on the first information.

[0091] According to such a method, when the quality of the molded product deteriorates during the molding of the molded product with the optimum conditions, it is possible to improve the quality of the molded product.

Claims

1. A molding condition setting method, characterized in that: This is a method for setting molding conditions for an injection molding machine that molds a molded product, and has: (a) a step of adjusting the temperature and humidity around the injection molding machine; (b) a step of obtaining the water content of a material used in molding the molded article; (c) a step of setting a plurality of molding conditions of the molded product by the injection molding machine; (d) a step of molding the molded product under a plurality of molding conditions by injecting the plasticized material after plasticizing the material into a molding mold using the injection molding machine under environmental conditions including the temperature and humidity adjusted in the step (a) and the moisture content obtained in the step (b); and (e) a step of determining optimal conditions for the molding conditions under the environmental conditions based on the quality of the molded product molded in the step (d), In the step (a), The temperature is adjusted to the temperature of the place where the molded product is produced, The humidity is adjusted to the humidity of the place where the molded product is produced.

2. The molding condition setting method according to claim 1, characterized in that: In the step (c), a first molding condition and a second molding condition different from the first molding condition with respect to a first parameter included in the first molding condition are set. The step (d) comprises: The injection molding machine molds a first molded product under the first molding condition; and The injection molding machine performs molding of a second molded product under the second molding conditions, In the step (e), the optimal condition is selected from among the first molding condition and the second molding condition based on a comparison result between the first molded product and the second molded product.

3. The molding condition setting method according to claim 1, characterized in that: In the step (b), the water content is measured by a spectrometer.

4. The molding condition setting method according to claim 3, characterized in that: The spectrometer is arranged in a hopper storing the material.

5. The molding condition setting method according to claim 1, characterized in that: The molding condition setting method further comprises: (f) setting a setting value of a factor related to molding of the molded product among the factors adjusted according to the environmental conditions; In the step (c), the molding conditions are set so that the effective value of the factor in the step (d) becomes a value close to the set value, The factors include at least any one of the temperature of the molding die, the temperature of the plasticized material, the pressure of the plasticized material, the injection speed of the plasticized material, and the cooling time of the molding die.

6. The molding condition setting method according to claim 5, characterized in that: The step (d) comprises: A process for monitoring the effective value; and A step of storing, in a storage unit, first information in which the environmental condition, the molding condition, and the effective value when the molded product is molded under the environmental condition and the molding condition are associated with each other.

7. The molding condition setting method according to claim 6, characterized in that: The molding condition setting method further comprises: (g) a step of molding the molded product under the optimal conditions under the environmental conditions by an injection molding machine; In the step (g), when the effective value deviates from a predetermined range and changes, the optimal condition is corrected based on the first information.

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