Program, prediction method, prediction device, and display device

Abstract

Provided are a program and the like that can predict the temperature of a film during molding with high accuracy. The program causes a computer to execute a process of acquiring measurement data during molding, which is detected by a detection device and represents a state of a film molding machine that performs extrusion molding or a state of a film molded by the film molding machine, and predicting a film temperature during molding on the basis of the acquired measurement data.

Description

Technical Field

[0001] The present invention relates to a program, a prediction method, a prediction device, and a display device. Background Art

[0002] A film forming machine is known that forms a film by curing a molten resin extruded from an outlet of a mold. In the film forming machine, forming conditions of the film forming machine are set to meet the required specifications of the film.

[0003] Generally, the setting of the forming conditions is performed by an operator. The operator spends time calculating the optimal operating conditions based on the adjustment of various forming conditions and the data of the film formed under each forming condition. Technologies for assisting the setting operation of the forming conditions performed by the operator have been proposed (for example, see Patent Document 1).

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2019-166702 Summary of the Invention

[0007] Problems to be Solved by the Invention

[0008] Consider predicting the state of the resin (film) from the forming conditions in the forming machine, and flexibly using the prediction results for setting the forming conditions and device design. As an important index representing the state of the film, the temperature of the film can be cited. When predicting the temperature of the film, past measured values and estimated values are often used as calculation conditions. Prediction based on past measured values and estimated values may not accurately predict the temperature of the film during forming (during the forming process).

[0009] An object of the present disclosure is to provide a program or the like that can accurately predict the temperature of the film during forming.

[0010] Means for Solving the Problems

[0011] A program according to one aspect of the present disclosure causes a computer to execute the following processing: acquiring measurement data during forming detected by a detection device, the measurement data representing the state of a film forming machine performing extrusion forming or the state of a film formed by the film forming machine, and predicting the temperature of the film during forming based on the acquired measurement data.

[0012] A prediction method according to one aspect of the present disclosure is executed by a computer to perform the following processing: acquiring measurement data during forming detected by a detection device, the measurement data representing the state of a film forming machine performing extrusion forming or the state of a film formed by the film forming machine, and predicting the temperature of the film during forming based on the acquired measurement data.

[0013] One embodiment of the prediction device according to the present disclosure includes: an acquisition unit that acquires measurement data during molding detected by a detection device, the measurement data representing the state of a film molding machine performing extrusion molding or the state of a film molded by the film molding machine; and a prediction unit that predicts the temperature of the film during molding based on the acquired measurement data.

[0014] One embodiment of the display device according to the present disclosure includes: an acquisition unit that acquires measurement data during molding detected by a detection device, the measurement data representing the state of a film molding machine performing extrusion molding or the state of a film molded by the film molding machine; a prediction unit that predicts the temperature of the film during molding based on the acquired measurement data; and a display unit that displays information related to the predicted film temperature.

[0015] Advantages of the Invention

[0016] According to the present disclosure, the temperature of the film during molding can be predicted with high accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic diagram of the outline of the molding machine system of this embodiment.

[0018] Figure 2 is a block diagram showing a configuration example of the data collection device.

[0019] Figure 3 is a block diagram showing a configuration example of the information processing device.

[0020] Figure 4 is an explanatory diagram for explaining the prediction method of the temperature prediction model.

[0021] Figure 5 is a schematic diagram showing an example of the setting screen of the molding information of the temperature prediction model.

[0022] Figure 6 is a schematic diagram showing an example of the setting screen of the molding information of the temperature prediction model.

[0023] Figure 7 is a schematic diagram showing an example of the setting screen of the molding information of the temperature prediction model.

[0024] Figure 8 is a schematic diagram showing an example of the screen for displaying the prediction result of the temperature prediction model.

[0025] Figure 9 is a flowchart showing an example of the processing steps executed by the information processing device. DETAILED DESCRIPTION OF THE INVENTION

[0026] The present disclosure will be specifically described with reference to the drawings showing embodiments of the present disclosure.

[0027] Figure 1 This is a schematic diagram of the molding machine system 100 of the present embodiment. The molding machine system 100 includes a film molding machine (hereinafter simply referred to as a molding machine) 1, a plurality of detection devices 2, a data collection device 3, an information processing device 4, and a display device 5.

[0028] <Molding Machine 1>

[0029] The molding machine 1 includes an extruder 11, a casting device 12, an MD stretching device 13, a TD stretching device 14, a winding machine 15, and a control device 16.

[0030] The extruder 11 is, for example, a single-screw extruder or a twin-screw extruder, etc., and includes a cylinder 112 having a hopper 111 for charging a resin raw material, a screw 113, and a die 114. The screw 113 is rotatably inserted into the hole of the cylinder 112, and conveys, melts, and kneads the resin raw material charged into the hopper 111 in the extrusion direction ( Figure 1 the right direction in the figure), and extrudes the molten resin raw material in a film shape from a narrow gap at the front end of the die 114.

[0031] The casting device 12 includes a plurality of casting rolls 121 for cooling and molding the high-temperature melt extruded from the die 114. The plurality of casting rolls 121 includes a first roll 1211 and a second roll 1212. The first roll 1211 is a metal roll having a temperature adjustment part (not shown) for cooling, for example, the melt, and is axially supported below the die 114. The first roll 1211 sandwiches the film-shaped melt extruded from the die 114 between it and the second roll 1212, and together with the second roll 1212, cools the film-shaped melt in a short time and molds it into a film (sheet) shape. The casting device 12 controls the film thickness within a specified range. Thus, an unstretched film is obtained. The temperature adjustment method of the first roll 1211 is not particularly limited, and examples thereof include methods using a heat medium such as air, water, or oil, or methods such as an electric heater or induction heating. In Figure 1 the example shown, the plurality of casting rolls 121 further includes rolls for cooling or conveying the melt.

[0032] The MD stretching device 13 is equipped with a plurality of tension rollers 131. The unstretched film conveyed from the casting device 12 is threaded between the tension rollers 131 and stretched in the longitudinal direction (film feeding direction: MD). The plurality of tension rollers 131 include a heating roller 1311 having a temperature adjustment part for heating the film and a cooling roller 1312 having a temperature adjustment part for cooling the film. As a temperature adjustment method of the tension roller 131, the same method as that of the above-mentioned casting roller 121 can be cited. The film is heated to a specified temperature range where it can be stretched while being in contact with the heating roller 1311, and then stretched in the longitudinal direction by the rotational speed difference of each cooling roller 1312. For example, the film undergoes the first stretching starting from the first cooling roller 1312 and further undergoes the second stretching starting from the second cooling roller 1312. The stretching ratio in the MD direction can be adjusted by the speed ratio of the tension rollers 131. It should be noted that Figure 1 is a simple illustration, and the number of the tension rollers 131 is not limited to Figure 1 the above example.

[0033] The TD stretching device 14 laterally stretches the film longitudinally stretched by the MD stretching device 13 in the width direction (film width direction: TD). The TD stretching device 14 is, for example, a tenter stretching device such as a clip tenter or a needle tenter, and has a heating device such as a hot air blowing device (not shown). The film is heated to a specified temperature range where it can be stretched and laterally stretched. The TD stretching device 14 has a traveling mechanism including a track and a chain (not shown) and a plurality of clamps continuously mounted on the chain. The track is arranged to extend in the width direction (TD) toward the downstream direction of the film feeding direction (MD).

[0034] The clamp holds the end of the film at the entrance of the TD stretching device 14, is guided by the track and travels on the track, thereby conveying the film in the film feeding direction (MD), and releases the film at the exit of the TD stretching device 14. The film held at both ends by the clamp passes through the hot air blowing device toward the downstream direction of the film feeding direction. The heated air is blown onto both sides of the film by the hot air blowing devices provided on the upper side and the lower side of the traveling mechanism, and the film is stretched in the width direction. The stretching ratio in the TD direction can be adjusted by the amount of air. The film stretched in the width direction is wound by the winder 15.

[0035] In this specification, the casting process refers to the process performed by the casting device 12 in the forming process performed by the molding machine 1. The MD stretching process refers to the process performed by the MD stretching device 13 in the forming process performed by the molding machine 1. The TD stretching process refers to the process performed by the TD stretching device 14 in the forming process performed by the molding machine 1.

[0036] The control device 16 is a computer that controls the operation of the molding machine 1, and includes a control unit such as a CPU (Central Processing Unit) not shown, a transceiver unit that transmits and receives information to and from the data collection device 3, and a display unit. The control device 16 sends operation data indicating the operation state of the molding machine 1 to the data collection device 3.

[0037] <Detection device 2>

[0038] The detection device 2 is a sensor that detects the state of the molding machine 1 and the film (resin) molded by the molding machine 1. The detection device 2 is connected to the data collection device 3 and directly or indirectly outputs the measured data obtained by the detection to the data collection device 3. The measured data is data of sensor values in time series that represents the detected state of the molding machine 1 and the film molded by the molding machine 1. The measured data may also be data of at least one of the state of the molding machine 1 and the film. The detection device 2 can be pre-installed on the molding machine 1 or retrofitted as a component required for the operation control of the molding machine 1.

[0039] Examples of the measured data detected by the detection device 2 include temperature, length, thickness, image, weight, flow rate, position, speed, acceleration, current, voltage, pressure, time, torque, force, deformation, power consumption, etc. These measured data can be measured using a thermometer, an infrared sensor, a length measuring sensor, a laser sensor, an X-ray sensor, a camera, a weighing scale, a flow meter, a position sensor, a speed sensor, an acceleration sensor, an ammeter, a voltmeter, a pressure gauge, a timer, a torque sensor, a power meter, etc.

[0040] The detection device 2 includes, for example, a first sensor 21 that detects the measured data in the casting device 12, a second sensor 22 that detects the measured data in the MD stretching device 13, and a third sensor 23 that detects the measured data in the TD stretching device 14.

[0041] The first sensor 21 includes, for example, a laser sensor that detects the width of the film, a laser sensor that detects the thickness of the film, a contact-type thermometer or a non-contact thermal imaging camera that detects the temperature of the film, a contact-type thermometer or a non-contact thermal imaging camera that detects the temperature of the casting roll 121, a contact-type thermometer or a non-contact thermal imaging camera that detects the temperature of the heat medium in the temperature adjustment unit of the casting roll 121, a flow meter that detects the flow rate of the heat medium, etc.

[0042] The second sensor 22 includes, for example, a laser sensor for detecting the width of the film, a laser sensor for detecting the thickness of the film, a contact thermometer or a non-contact thermal imaging camera for detecting the temperature of the film, a contact thermometer or a non-contact thermal imaging camera for detecting the temperature of the tension roller 131, a contact thermometer or a non-contact thermal imaging camera for detecting the temperature of the heat medium in the temperature adjustment unit of the tension roller 131, a flowmeter for detecting the flow rate of the heat medium, and the like.

[0043] The third sensor 23 includes, for example, a laser sensor for detecting the width of the film, a laser sensor for detecting the thickness of the film, a contact thermometer or a non-contact thermal imaging camera for detecting the temperature of the film, a contact thermometer or a non-contact thermal imaging camera for detecting the temperature of the air blown out from the hot air blowing device, a speedometer for detecting the speed of the air, a tachometer for detecting the rotational speed of the fan of the hot air blowing device, and the like.

[0044] The detection device 2 is provided at an appropriate position of the molding machine 1 to detect measurement data when passing through a desired passing position in the molding machine 1. It should be noted that the measurement data detected by the detection device 2 is not limited to the data of the sensor value directly detected by the detection device 2, and may also include the data of the calculated value indirectly calculated based on the sensor value.

[0045] As the measurement data detected by the detection device 2, for example, the film width, film thickness, initial film temperature, temperature of the casting roll 121, heat transfer coefficient between the casting roll 121 and the film, temperature of the tension roll 131, heat transfer coefficient between the tension roll 131 and the film, temperature of the air blown out from the hot air blowing device, speed of the air blown out from the hot air blowing device, etc. can be cited, but it is not limited thereto.

[0046] The above heat transfer coefficient is an example of a calculated value and can be calculated based on the temperature and flow rate of the heat medium (such as water) in the temperature adjustment unit of the casting roll 121 or the tension roll 131. Similarly, the speed of the air can be calculated based on the rotational speed of the fan of the hot air blowing device.

[0047] <Data collection device 3>

[0048] Figure 2 It is a block diagram showing a configuration example of the data collection device 3. The data collection device 3 is a computer, including a control unit 31, a storage unit 32, a communication unit 33, and a data input unit 34, and the storage unit 32, the communication unit 33, and the data input unit 34 are connected to the control unit 31. The data collection device 3 is, for example, a PLC (Programmable Logic Controller).

[0049] The control unit 31 includes arithmetic processing circuits such as a CPU (Central Processing Unit), a multi-core CPU, an ASIC (Application Specific Integrated Circuit), and an FPGA (Field-Programmable Gate Array), and internal storage devices such as a ROM (Read Only Memory) and a RAM (Random Access Memory). The control unit 31 executes a control program stored in the storage unit 32 described later to execute a process of collecting molding information and sending it to the information processing device 4. It should be noted that each functional unit of the data collection device 3 can be implemented in software, in hardware, or by a combination of software and hardware.

[0050] The storage unit 32 includes non-volatile memories such as a hard disk, an EEPROM (Electrically Erasable Programmable ROM), and a flash memory. The storage unit 32 stores a control program for causing a computer to execute a process of collecting molding information.

[0051] The communication unit 33 includes a communication module for communicating with an external device via a communication network such as a LAN or the Internet. The control unit 31 can transmit and receive various information between the control device 16 and the information processing device 4 via the communication unit 33. The control unit 31 acquires operation data of the molding machine 1 via the communication unit 33.

[0052] The data input unit 34 is an input interface for inputting a signal output from the detection device 2. The data input unit 34 is connected to the detection device 2. The control unit 31 acquires measurement data output from the detection device 2 at any time via the data input unit 34. It should be noted that the data collection device 3 can also acquire measurement data via the control device 16 and the communication unit 33.

[0053] <Information processing device 4>

[0054] Figure 3 is a block diagram showing a configuration example of the information processing device 4. The information processing device 4 corresponds to a prediction device that predicts the temperature of a film (film temperature) based on molding information including measurement data.

[0055] The information processing device 4 is a computer, including a control unit 41, a storage unit 42, a communication unit 43, a display unit 44, and an operation unit 45. The storage unit 42, the communication unit 43, the display unit 44, and the operation unit 45 are connected to the control unit 41. The information processing device 4 may also be a server device connected to a network. It is preferable that the information processing device 4 is set as a local device installed in the factory where the molding machine 1 is installed, so that prediction processing can be performed within the factory. The information processing device 4 may be configured by multiple computers for distributed processing, may be implemented by multiple virtual machines installed in a single server, or may also be implemented using a cloud server.

[0056] The control unit 41 includes arithmetic processing circuits such as a CPU, a multi-core CPU, an ASIC, and an FPGA, internal storage devices such as a ROM and a RAM, and I / O terminals. The control unit 41 functions as the information processing device 4 of the present embodiment by executing the program 4P stored in the storage unit 42 described later. It should be noted that each functional unit of the information processing device 4 may be implemented in software, in hardware, or by a combination of software and hardware.

[0057] The storage unit 42 includes non-volatile memories such as a hard disk, a flash memory, and an SSD (Solid State Drive). The storage unit 42 may also be an external storage device connected to the information processing device 4. The storage unit 42 stores various programs and data referred to by the control unit 41. The storage unit 42 of the present embodiment stores a program 4P for causing a computer to execute processing related to prediction of film temperature and a temperature prediction model 421 required for execution of the program 4P.

[0058] The program (program product) including the program 4P may also be provided by a non-transitory recording medium 4A that records the program in a readable manner. The storage unit 42 stores the program read from the recording medium 4A by a reading device (not shown). The recording medium 4A is, for example, a magnetic disk, an optical disk, or a semiconductor memory. Additionally, the program may be downloaded from an external server connected to a communication network and stored in the storage unit 42. The program 4P may be a single computer program or may be composed of multiple computer programs. Additionally, it may be executed on a single computer or on multiple computers connected to each other via a communication network.

[0059] The communication unit 43 includes a communication module for communicating with an external device via a network such as a LAN or the Internet. The control unit 41 can transmit and receive various information to and from the data collection device 3 via the communication unit 43.

[0060] The display unit 44 includes a display device such as a liquid crystal display or an organic EL (Electroluminescence) display. The display unit 44 displays various information including information related to the predicted film temperature according to an instruction from the control unit 41.

[0061] The operation unit 45 is an interface for receiving operations from the user. The operation unit 45 includes, for example, a touch panel device built into the display, a keyboard, a mouse, a speaker, and a microphone. The operation unit 45 receives operation inputs from the user and sends a control signal corresponding to the operation content to the control unit 41. It should be noted that the display unit 44 and the operation unit 45 may be omitted.

[0062] The information processing device 4 and the data collection device 3 are not limited to independent devices. For example, the information processing device 4 and the data collection device 3 may be integrated. Additionally, the control device 16 may function as the information processing device 4.

[0063] <Display device 5>

[0064] The display device 5 predicts the temperature of the film based on the molding information and displays information related to the predicted film temperature. The display device 5 has the same hardware configuration as the information processing device 4. Although detailed illustrations and descriptions are omitted, it is a computer and includes a control unit, a storage unit, a communication unit, a display unit, and an operation unit, etc. The storage unit includes a non-volatile memory and stores various programs and data including a control program for causing the computer to perform prediction and display processing of the film temperature. The display device 5 may also be portable. It should be noted that the information processing device 4 may also function as the display device 5.

[0065] <Method for predicting film temperature>

[0066] In film molding, the information processing device 4 of the present embodiment obtains predicted values of the film temperature for the casting process, the MD stretching process, and the TD stretching process during molding based on the measurement data obtained during molding. That is, the information processing device 4 predicts the film temperature during the operation of the molding machine 1.

[0067] The film temperature may be predicted for specific prediction points, but it is preferably possible to predict, for example, the change in the film temperature. The change in the film temperature includes, for example, a time change, a position change, a process change, etc. The film after passing through the starting position of each process moves in the flow direction as the process progresses, and the transport time and transport amount (change in position) increase. The time change is the change in the film temperature caused by the passage of the transport time from the starting time when passing through the starting position. The position change is the change in the film temperature caused by the change in the transport amount from the starting position. The process change is the change in the film temperature caused by the progress of the process. In the present embodiment, the time change of the film temperature is predicted.

[0068] The information processing device 4 predicts the film temperature using a temperature prediction model 421 that predicts the film temperature based on the molding information including the measurement data. The temperature prediction model 421 is a model that can simulate and anticipate the film temperature corresponding to the calculation conditions of the set molding information. The temperature prediction model 421 can be, for example, CAE (Computer Aided Engineering) analysis software.

[0069] Figure 4 is an explanatory diagram showing the prediction method of the temperature prediction model 421. As Figure 4 shown on the upper side, the temperature prediction model 421 unfolds the flow path in the molding machine 1 into a two-dimensional flat plate flow, and calculates the energy balance of the heat transfer amount and the heat generation amount of the inflow and outflow between the units by dividing the flow path between the flat plates into units. The temperature prediction model 421 sets the initial film position of each process as the handling start position, and sequentially calculates the energy balance in each unit along the handling direction, thereby predicting the film temperature at each unit position.

[0070] In Figure 4 the lower side shows the i-th unit. In the i-th unit, the heat generation amount accompanying the change in the film temperature is equal to the sum of the heat transfer amounts from the four directions of the upper, lower, left, and right of the i-th unit. Therefore, the energy balance in the i-th unit can be expressed by the following equation (1).

[0071] ΔTi(ρ×Cp×D×W×vΔt)=-h1(Ti-Ta1)-h2(Ti-Ta2)-h3(Ti-Ta3)-h4(Ti-Ta4)…(1)

[0072] Here, Ti is the film temperature in the i-th unit, ΔTi is the change amount of the film temperature, ρ is the density of the film resin, Cp is the specific heat of the film resin, D is the thickness of the film, W is the width of the film, v is the speed of the film, Δt is the elapsed time, h1 is the heat transfer coefficient on the left surface side of the unit, Ta1 is the temperature of the substance in contact with the left surface of the unit, h2 is the heat transfer coefficient on the right surface side of the unit, Ta2 is the temperature of the substance in contact with the right surface of the unit, h3 is the heat transfer coefficient on the lower surface side of the unit, Ta3 is the temperature of the substance in contact with the lower surface of the unit, h4 is the heat transfer coefficient on the upper surface side of the unit, and Ta4 is the temperature of the substance in contact with the upper surface of the unit.

[0073] Each unit can also be further divided in the thickness direction of the film. For example, each unit can be equally spaced and divided into three parts in the thickness direction for analysis, thereby predicting the three film temperatures of the front, center, and back of the film.

[0074] In the temperature prediction model, the conveyance time at a specified passing position is calculated based on the molding information, and the temporal change of the film temperature is obtained by establishing a correspondence between the film temperature and the conveyance time. The temperature prediction model 421 is not limited to using the above analysis method, as long as it can predict the film temperature based on the molding information.

[0075] The information processing device 4 acquires the measurement data detected by the detection device 2 and provides the acquired measurement data as an input to the temperature prediction model 421.

[0076] The molding information as an input to the temperature prediction model 421 may additionally include the operation data of the molding machine 1. As the operation data included in the molding information, for example, the film speed, the discharge amount of the film, the starting position coordinates of the film, the ending position coordinates of the film, the position coordinates of the casting roll 121, the position coordinates of the tension roll 131, the stretching ratio, the stretching angle, etc. can be cited. The operation data may additionally include various setting data determined based on the design of the molding machine 1 or based on the measurement data and other operation data. It should be noted that the operation data can acquire the control value based on the control device 16, but it can also acquire the sensor value of the actual operation status detected by the detection device 2. That is, the above examples of the operation data can be included in the measurement data.

[0077] The molding information as an input to the temperature prediction model 421 may also include resin physical properties. As the resin physical properties, for example, the thermal conductivity, specific heat, density, etc. of the resin can be cited. The resin physical properties can be obtained, for example, by accepting the input from the user, or by obtaining from a specified physical property database that stores physical property information.

[0078] Figures 5 - 7 It is a schematic diagram showing an example of the setting screen 440 of the molding information of the temperature prediction model 421. The setting screen 440 is a screen for setting the calculation conditions of the molding information input to the temperature prediction model 421. Use Figures 5 - 7 Specifically explain the molding information used in the temperature prediction of each process.

[0079] Figure 5 Show an example of the setting screen of the molding information related to the temperature prediction of the casting process. As Figure 5 shown, the molding information used in the prediction of the film temperature in the casting process includes, for example, the operation data related to the film speed, the discharge amount of the film, the starting XY coordinates of the film (the outlet XY coordinates of the mold 114), the ending XY coordinates of the film, and the XY coordinates of each casting roll 121, etc. The molding information additionally includes the measurement data related to the film width, film thickness, initial film temperature (temperature near the starting position), the temperature of each casting roll 121, and the heat transfer coefficient between each casting roll 121 and the film.

[0080] The forming information may also include setting data and resin physical properties related to the air temperature in the case of air conveyance, the heat transfer coefficient of the air, the roll diameters of the respective casting rolls 121, the holding state of the next casting roll 121, the atmosphere temperature on the opposite side of the roll, the heat transfer coefficient on the opposite side of the roll, etc. In this specification, the roll surface refers to the surface of the film that contacts the roll, and the opposite side of the roll refers to the surface on the opposite side of the above roll surface in the film.

[0081] In Figure 5 the black dots included in the figure showing the equipment configuration are specified passing positions, and the film is conveyed by passing through the passing positions in the order of the numbers marked in circles. The conveyance amount (change in position) from the starting position to the passing position and the conveyance time elapsed until passing through the passing position are corresponded to and displayed with the numbers marked in circles.

[0082] Figure 6 An example of a setting screen showing the forming information related to the temperature prediction of the MD stretching process is shown. The forming information used in the prediction of the film temperature in the MD stretching process includes, for example, operation data related to the initial film speed (speed near the starting position), the discharge amount of the film, the stretching ratio of the first stretching, the film speed after the first stretching, the stretching ratio of the second stretching, the film speed after the second stretching, and the XY coordinates of the respective tension rolls 131. The forming information further includes measurement data related to the film width, the film thickness before MD stretching, the initial film temperature (temperature near the starting position), the film thickness after MD stretching, the temperature of the respective tension rolls 131, and the heat transfer coefficient between the respective tension rolls 131 and the film.

[0083] The forming information also includes setting data and resin physical properties related to the air temperature in the case of air conveyance, the heat transfer coefficient of the air, the identification information of the tension rolls 131 at the start of the first stretching and the second stretching, the roll diameters of the respective tension rolls 131, the holding state of the next tension roll 131, the atmosphere temperature on the opposite side of the roll, the heat transfer coefficient on the opposite side of the roll, the types of the temperature adjustment units of the respective tension rolls 131, etc.

[0084] Figure 7 An example of a setting screen showing the forming information related to the temperature prediction of the TD stretching process is shown. The forming information used in the prediction of the film temperature in the TD stretching process includes, for example, operation data related to the film speed (assembly line speed), the discharge amount of the film, the stretching angle, and the stretching ratio. The forming information further includes measurement data related to the film width, the film thickness before TD stretching, the initial film temperature, the film thickness after TD stretching, the temperature of the air blown out from the hot air blowing device, the speed of the above air, etc. The temperature and speed of the air include the temperature and speed on the upper side of the film and the temperature and speed on the lower side of the film. The temperature and speed of the air can be detected for each interval in the case of dividing the entire conveyance section of the film in the TD stretching process at regular intervals in the film feeding direction.

[0085] The forming information may also include setting data and resin physical properties related to the film width after TD stretching, stretching distance, number of sections, section distance, passing time, total passing time, heat transfer coefficients on the upper and lower sides of the film, etc.

[0086] It should be noted that since the discharge amount of the film can be determined based on the film speed, film width, and film thickness, the configuration may be such that only 3 of the above 4 items are set as necessary input items. Additionally, instead of obtaining the operation data of the film speed after the first stretching, the film speed after the first stretching can be calculated based on the initial film speed and the stretching ratio of the first stretching. The same applies to the film speed after the second stretching. Instead of obtaining the measurement data of the film thickness after MD stretching, the film thickness after MD stretching can be calculated based on the initial film speed, the stretching ratio of the first stretching, and the stretching ratio of the second stretching. Similarly, the film thickness after TD stretching can also be calculated based on the film speed and the stretching ratio.

[0087] When the information processing device 4 obtains the sensor values during forming through the data collection device 3, in the setting screen 440, the obtained sensor values or the calculated values obtained from these sensor values are automatically input into the respective input fields of the measurement data items. The information processing device 4 also inputs the resin physical properties of the resin used during forming into the respective input fields of the resin physical property items, and inputs the operation data and the setting data of the molding machine 1 obtained through the control device 16 into the respective input fields of the operation data items. The information processing device 4 can also directly input the forming information into the temperature prediction model 421 without going through the setting screen 440. In the temperature prediction model 421, the film temperature is predicted based on the calculation conditions of the forming information input through the setting screen 440.

[0088] Figure 8 It is a schematic diagram showing an example of the screen 441 that displays the prediction result of the temperature prediction model 421. Figure 8 It shows an example of the screen 441 that displays the prediction result of the film temperature in the casting process. The temperature prediction model 421 outputs the predicted value of the film temperature corresponding to the transfer time. The screen 441 that displays the prediction result includes a curve graph with the vertical axis representing the film temperature and the horizontal axis representing the transfer time, and displays the prediction result of the film temperature in time series.

[0089] The information processing device 4 generates a line graph that shows the film temperatures of the front, center, and back of the film over time based on the prediction results of the temperature prediction model 421. It should be noted that the temperature prediction model 421 can also predict the film temperature of any one of the front, center, and back. The information processing device 4 displays a screen containing the generated line graph through the display unit 44. It should be noted that the prediction result of the temperature prediction model 421 can also be the predicted value of the film temperature for the conveyance amount (position change) from the starting position of the casting process. It should be noted that Figure 5 the setting screen 440 and Figure 6 the screen 441 that shows the prediction results can also be configured to be displayed side by side within one screen or the like and simultaneously displayed in the display unit 44.

[0090] In the case of the MD stretching process, the temperature prediction model 421 predicts the temporal changes in the film temperatures of the roller surface, center, and the opposite side of the roller of the film in the MD stretching process. In the case of the TD stretching process, the temperature prediction model 421 predicts the temporal changes in the film temperatures of the front, center, and back of the film in the TD stretching process.

[0091] After each process ends, the information processing device 4 predicts the film temperature in real time using the measured values of the molding information obtained during molding. The information processing device 4 can also predict the film temperature in the middle of each process. In the case of predicting in the middle of a process, the information processing device 4 can use the measured values of the molding information for which the measured values during molding have been obtained among the molding information to be set, and use estimated values or past measured values, etc. as reference values for the molding information for which the measured values during molding have not been obtained. The information processing device 4 always displays the prediction results of the temperature prediction model 421 on the display unit 44. The user can grasp the predicted value of the film temperature corresponding to the actual molding information during the operation of the molding machine 1.

[0092] Figures 5 - 7 The setting screen 440 shown can also be configured to be able to select the molding information items that are inputs to the temperature prediction model 421. The information processing device 4 uses the setting screen 440 to accept the designation of whether each molding information needs to be input based on the user's operation of the operation unit 45. The information processing device 4 predicts the film temperature by using only the measured values of the molding information designated as being required to be input as the input to the temperature prediction model 421. Regarding the molding information designated as not requiring input, for example, reference values can be used, or the molding information designated as not requiring input can be not used to predict the film temperature. According to the above configuration, the user can select the data that should reflect the actual molding conditions, improving the customization in temperature prediction.

[0093] The information processing device 4 may also generate proposal information related to proposals for molding conditions based on the predicted value of the obtained film temperature. The proposal information includes, for example, the type of molding information to be adjusted to increase or decrease the predicted film temperature, the recommended value of the molding information, and the like. The information processing device 4 can, for example, pre-store the correspondence between the molding information and the film temperature obtained from past molding actual results, and determine the proposal information based on this correspondence. When generating the proposal information, the information processing device 4 may also acquire the film temperature range to be satisfied and determine the proposal information that satisfies the acquired film temperature range. The information processing device 4 may also accept the film temperature range to be satisfied by accepting the operation of the operation unit 45 of the user.

[0094] In addition, the information processing device 4 may also predict the film temperature at the timing before the change of the molding information by inputting the change value for a part of the molding information and the measured value during molding for the remaining molding information into the temperature prediction model 421. When the prediction result satisfies the specified conditions, the information processing device 4 may also send an instruction to change the molding information to the control device 16. The information processing device 4 may also generate the above-mentioned proposal information based on the obtained prediction result.

[0095] It should be noted that the information processing device 4 is not limited to predicting the film temperature for each process, and may also predict the film temperature for all molding processes that integrate each process. The information processing device 4 may be configured to obtain the prediction result of the film temperature for one molding process formed by integrating each process through the temperature prediction model 421, or may be configured to generate the prediction of all molding processes by integrating the prediction results of the temperature prediction model 421 obtained for each process.

[0096] Figure 9 It is a flowchart showing an example of the processing steps executed by the information processing device 4. The control unit 41 of the information processing device 4 executes the following processing according to the program 4P stored in the storage unit 42. Hereinafter, the casting process will be used as an example for explanation, but the control unit 41 may also execute the same processing for the MD stretching process and the TD stretching process. The control unit 41, for example, starts the following processing at an appropriate timing after the end of the casting process or during the casting process during molding. The control unit 41 may also start the processing in response to the acceptance of a prediction request through the operation unit 45.

[0097] The control unit 41 of the information processing device 4, for example, refers to the physical property database stored in the storage unit 42 and acquires the resin physical properties of the raw material resin used in molding (step S11).

[0098] The control unit 41 obtains the measurement data during molding detected by the detection device 2 and the operation data during molding sent from the control device 16 through the data collection device 3 (step S12). The operation data may include design data obtained through the control device 16 or based on known equipment configurations, etc. The control unit 41 can obtain various molding information centrally, or can obtain the molding information individually at the timing when the molding information is detected.

[0099] The control unit 41 inputs the molding information including the obtained resin physical properties, measurement data, and operation data into the temperature prediction model 421 (step S13). Specifically, the control unit 41 automatically inputs the obtained molding information into the input item column shown in the setting screen 440 described Figure 5 as above, thereby providing input data to the temperature prediction model 421. In this case, the control unit 41 can also accept the designation of whether to input to each molding information item based on the operation of the operation unit 45 by the user, and only input the measured values of the molding information for which the designation of need to input has been accepted into the temperature prediction model 421.

[0100] The control unit 41 obtains the predicted value of the film temperature output from the temperature prediction model 421 (step S14). The control unit 41 generates a screen showing the prediction result of the film temperature based on the obtained predicted value of the film temperature, and causes the display unit 44 to display the screen showing the generated prediction result (step S15). The control unit 41 generates a screen showing, for example, the time change of the film temperature in the form of a curve graph.

[0101] The control unit 41 generates proposal information related to the proposal of molding conditions based on the obtained predicted value of the film temperature (step S16). The proposal information includes, for example, the type of molding information to be adjusted, the recommended value of the molding information, etc. The control unit 41 causes the display unit 44 to display the screen showing the generated proposal information (step S17). The control unit 41 can also display a screen showing the prediction result and the proposal information simultaneously on the display unit 44. The control unit 41 ends the process. The control unit 41 returns the process to step S12, obtains the newly detected molding information, and uses the obtained new molding information to predict the film temperature again. Steps S16 and S17 can also be omitted.

[0102] The above has described an example in which a series of processes are performed by the information processing device 4, but the display device 5 can also perform the same processes to predict and display the film temperature.

[0103] According to the present embodiment, by providing a plurality of detection devices 2 in the molding machine system 100, it is possible to obtain the molding information during molding in real time. By using the obtained molding information, it is possible to accurately predict the temperature of the film during molding. It is possible to predict the film temperature in real time during the film molding process instead of performing pre-molding prediction based on a reference value obtained in advance.

[0104] Since it can reflect the actual molding situation in the prediction of the film temperature, the prediction accuracy is improved compared with the case where the prediction of the film temperature only uses past measured values and estimated values. In film molding, since the resin is melted and molded, the state of the resin changes diversely. In addition, it includes multiple processes. Therefore, in each molding, the actual molding information is highly likely to change corresponding to the molding machine 1 and the state of the resin, and may deviate from the temperature behavior predicted before molding. By predicting during the molding of the film, the film temperature during molding can be grasped more accurately.

[0105] By predicting the change in the film temperature, the behavior of the film temperature moving in the flow path can be grasped. By using the temperature prediction model 421, the film temperature can be predicted efficiently and with high accuracy.

[0106] Regarding the above-described embodiments, the following remarks are also disclosed.

[0107] (Remark 1)

[0108] A program that causes a computer to execute the following processing: obtaining measurement data during molding detected by a detection device, the measurement data during molding representing the state of an extrusion molding film molding machine or the state of a film molded by the film molding machine,

[0109] Predicting the film temperature during molding based on the obtained measurement data.

[0110] (Remark 2)

[0111] In the program according to Remark 1, predicting the film temperature during the casting process, the MD stretching process, or the TD stretching process.

[0112] (Remark 3)

[0113] In the program according to Remark 1 or Remark 2, predicting the film temperature using a temperature prediction model that predicts the film temperature based on measurement data.

[0114] (Remark 4)

[0115] In the program according to any one of Remarks 1 to 3, predicting the change in the film temperature.

[0116] (Remark 5)

[0117] In the program according to any one of Remarks 1 to 4, generating proposal information related to a proposal for molding conditions in the film molding machine based on the prediction result of the film temperature.

[0118] (Remark 6)

[0119] In the procedure described in any one of Note 1 to Note 5, the measurement data includes at least one of the film speed, film width, film thickness, discharge amount, film temperature, film position coordinates, roll temperature, and heat transfer coefficient in the casting process.

[0120] (Note 7)

[0121] In the procedure described in any one of Note 1 to Note 6, the measurement data includes at least one of the film speed, film width, film thickness, discharge amount, film temperature, draw ratio, roll position coordinates, roll temperature, and heat transfer coefficient in the MD stretching process.

[0122] (Note 8)

[0123] In the procedure described in any one of Note 1 to Note 7, the measurement data includes at least one of the film speed, film width, film thickness, film temperature, draw angle, draw ratio, and air temperature in the TD stretching process.

[0124] It should be noted that the embodiments disclosed herein are illustrative in all aspects and not restrictive. The technical features described in each embodiment can be combined with each other, and the scope of the present invention is intended to include all changes within the claims and the scope equivalent to the claims.

[0125] The order shown in each embodiment is not limited. Within the range of no contradiction, the order of each processing step can be changed for execution. In addition, multiple processes can be executed in parallel. The processing entity of each process is not limited, and the processing of each device can also be executed by other devices within the range of no contradiction.

[0126] The matters described in each embodiment can be combined with each other. In addition, the independent claims and dependent claims described in the claims can be combined with each other in any combination regardless of the citation form. In addition, the claims use the form of claims that cite two or more other claims (multiple claim form), but are not limited thereto. It can also be described in the form of multiple claims (multiple claim citing multiple claims) that cite at least one multiple claim.

[0127] Explanation of Reference Numerals

[0128] 100 Molding Machine System

[0129] 1 Film Molding Machine

[0130] 11 Extruder

[0131] 12 Casting Device

[0132] 121 Casting Roll

[0133] 13 MD Stretching Device

[0134] 131 Tension roller

[0135] 14 TD stretching device

[0136] 15 Winder

[0137] 16 Control device

[0138] 2 Detection device

[0139] 21 First sensor

[0140] 22 Second sensor

[0141] 23 Third sensor

[0142] 3 Data collection device

[0143] 31 Control unit

[0144] 32 Storage unit

[0145] 33 Communication unit

[0146] 34 Data input unit

[0147] 4 Information processing device (prediction device)

[0148] 41 Control unit

[0149] 42 Storage unit

[0150] 43 Communication unit

[0151] 44 Display unit

[0152] 45 Operation unit

[0153] 4A Recording medium

[0154] 4P Program

[0155] 421 Temperature prediction model

[0156] 5 Display device

Claims

1. A program that causes a computer to perform the following processing: Obtain measurement data during molding detected by a detection device, the measurement data representing the state of a film molding machine performing extrusion molding or the state of a film molded by the film molding machine, Predict the film temperature during molding based on the obtained measurement data.

2. The program according to claim 1, wherein The film temperature in the casting process, MD stretching process, or TD stretching process is predicted.

3. The program according to claim 1 or 2, wherein A temperature prediction model for predicting the film temperature based on measurement data is used to predict the film temperature.

4. The program according to claim 1 or 2, wherein The change in the film temperature is predicted.

5. The program according to claim 1 or 2, wherein Proposal information related to proposals for molding conditions in the film molding machine is generated based on the prediction result of the film temperature.

6. The program according to claim 1 or 2, wherein The measurement data includes at least one of the film speed, film width, film thickness, discharge amount, film temperature, film position coordinates, roll temperature, and heat transfer coefficient in the casting process.

7. The program according to claim 1 or 2, wherein The measurement data includes at least one of the film speed, film width, film thickness, discharge amount, film temperature, draw ratio, roll position coordinates, roll temperature, and heat transfer coefficient in the MD stretching process.

8. The program according to claim 1 or 2, wherein The measurement data includes at least one of the film speed, film width, film thickness, film temperature, draw angle, draw ratio, and air temperature in the TD stretching process.

9. A prediction method that causes a computer to perform the following processing: Obtain measurement data during molding detected by a detection device, the measurement data representing the state of a film molding machine performing extrusion molding or the state of a film molded by the film molding machine, Predict the film temperature during molding based on the obtained measurement data.

10. A prediction device, comprising: An acquisition unit that acquires measurement data during molding detected by a detection device, the measurement data representing the state of a film molding machine performing extrusion molding or the state of a film molded by the film molding machine; and A prediction unit that predicts the film temperature during molding based on the obtained measurement data.

11. A display device, comprising: An acquisition unit that acquires measurement data during molding detected by a detection device, the measurement data representing the state of a film molding machine performing extrusion molding or the state of a film molded by the film molding machine; A prediction unit that predicts the film temperature during molding based on the obtained measurement data; And A display unit that displays information related to the predicted film temperature.

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