Quality estimation method, quality estimation device, and computer program

Abstract

The present invention performs the following processing: acquiring physical quantity data of a time sequence related to the operation of the injection molding machine obtained during the injection molding process of the molded article using the injection molding machine; storing the acquired physical quantity data in a storage unit at each injection; storing quality data representing the quality of the injection-molded article when the acquired physical quantity data is obtained in association with the physical quantity data; calculating the quality of the molded article based on the physical quantity data acquired in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit; and performing prescribed processing when the quality of the molded article is lower than the specified quality.

Description

Technical Field

[0001] This invention relates to a quality estimation method, a quality estimation apparatus, and a computer program. Background Technology

[0002] An injection molding machine that monitors the state of resin in the injection cylinder has been disclosed. It detects the energy consumed for resin plasticization, infers the resin state in the injection cylinder based on the energy consumed, and thereby determines the molding quality (e.g., Patent Document 1). Specifically, the injection molding machine compares the detected energy consumed with a standard electrical force, i.e., a reference electrical force, consumed to produce a molded article of appropriate quality. If the difference exceeds a specified limit, the quality of the molded article is determined to be problematic.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2012-091424 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] However, in Patent Document 1, the monitoring done to estimate the quality of the molded article is of the upper and lower limits of energy consumption, but not of its fluctuation. Although the fluctuation of the monitored values ​​may sometimes be due to changes caused by abnormalities in the quality of the molded article, these changes cannot be captured, and sometimes abnormalities in the quality of the molded article cannot be detected.

[0008] The purpose of this disclosure is to provide a quality estimation method, quality estimation device, and computer program that can capture the shift of physical quantity data in a time series related to the operation of an injection molding machine to estimate the quality of the molded article.

[0009] Methods for solving problems

[0010] One aspect of this disclosure is a quality estimation method comprising the following processes: acquiring physical quantity data of a time series related to the operation of an injection molding machine during an injection molding process of a molded article using an injection molding machine; storing the acquired physical quantity data in a storage unit at each injection; storing quality data representing the quality of the injection-molded article at the time the acquired physical quantity data is obtained in association with the physical quantity data; calculating the quality of the molded article based on the physical quantity data acquired in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit; and performing prescribed processing when the quality of the molded article is lower than a specified quality.

[0011] One aspect of this disclosure is a quality estimation apparatus comprising a processing unit that performs the following processes: acquiring physical quantity data of a time series related to the operation of an injection molding machine during an injection molding process of a molded article using an injection molding machine; storing the acquired physical quantity data in a storage unit at each injection; storing quality data representing the quality of the injection-molded article at the time the acquired physical quantity data is obtained in association with the physical quantity data; calculating the quality of the molded article based on the physical quantity data acquired in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit; and performing a prescribed process when the quality of the molded article is lower than a specified quality.

[0012] A computer program of one aspect of this disclosure causes a computer to perform the following processes: acquiring time-series physical quantity data related to the operation of the injection molding machine obtained during the injection molding process of a molded article using the injection molding machine; storing the acquired physical quantity data in a storage unit at each injection; storing quality data representing the quality of the injection-molded article at the time the acquired physical quantity data is obtained in association with the physical quantity data; calculating the quality of the molded article based on the physical quantity data acquired in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit; and performing a specified process when the quality of the molded article is lower than a specified quality.

[0013] Invention Effects

[0014] According to this disclosure, a quality estimation method, a quality estimation device, and a computer program are provided that can capture the shift of physical quantity data in a time series related to the operation of an injection molding machine to estimate the quality of the molded article. Attached Figure Description

[0015] Figure 1 This is a schematic diagram showing an example of the configuration of the injection molding system according to Embodiment 1.

[0016] Figure 2 This is a flowchart illustrating the steps for collecting and processing reference data in Implementation 1.

[0017] Figure 3 This is a flowchart illustrating the data collection and processing steps of Implementation Method 1.

[0018] Figure 4 This is a conceptual diagram illustrating the data collection method of Implementation Method 1.

[0019] Figure 5 This is a conceptual diagram illustrating the contents of a file saved using the data collection method of Implementation 1.

[0020] Figure 6 This is a chart showing an example of an item in the log data.

[0021] Figure 7 This is a chart showing an example of an item in the log data.

[0022] Figure 8 This is a flowchart illustrating the quality estimation process steps of Implementation 1.

[0023] Figure 9 This is a flowchart illustrating the quality estimation process steps of Embodiment 2. Detailed Implementation

[0024] The quality estimation method, quality estimation apparatus, and computer program of this disclosure are described below with reference to the accompanying drawings. It should be noted that this disclosure is not limited to these examples and is intended to include all modifications expressed in and equivalent to those in the claims. Furthermore, at least some of the embodiments described below may be combined arbitrarily.

[0025] Figure 1 This is a schematic diagram showing an example of the configuration of the injection molding system according to Embodiment 1. The injection molding system of Embodiment 1 includes an injection molding machine 1, a recording device 6, and an information processing device (quality estimation device) 7.

[0026] <Injection Molding Machine 1>

[0027] The injection molding machine 1 includes a mold closing device 2 for closing the mold 21, an injection device 3 for melting and injecting the molding material, multiple sensors 4, and a control device 5.

[0028] The mold clamping device 2 includes a fixed platen 22 fixed to a base 20, a mold clamping housing 23 slidable on the base 20, and a movable platen 24 slidable on the base 20. The fixed platen 22 and the mold clamping housing 23 are connected by multiple rods, such as four rods 25, 25, ... The movable platen 24 is configured to slide freely between the fixed platen 22 and the mold clamping housing 23. A mold clamping mechanism 26 is provided between the mold clamping housing 23 and the movable platen 24. The mold clamping mechanism 26 is, for example, a toggle mechanism. It should be noted that the mold clamping mechanism 26 can also be a direct-pressure mold clamping mechanism, i.e., a mold clamping cylinder. A fixed mold 28 and a movable mold 27 are respectively provided on the fixed platen 22 and the movable platen 24. When the mold clamping mechanism 26 is driven, the mold 21 opens and closes.

[0029] In addition, the mold closing device 2 includes an ejector pin for removing the molded article from the mold 21 and a drive motor for driving the ejector pin.

[0030] The injection device 3 is mounted on the base 30. The injection device 3 includes a heating cylinder 31 with a nozzle 31a at its front end and a screw 32 arranged within the heating cylinder 31 in a manner rotatable in both the circumferential and axial directions. A heater for melting the molding material is provided inside or around the heating cylinder 31. The screw 32 is driven by a drive device 35 in both the rotational and axial directions.

[0031] A hopper 33 for feeding molding material is provided near the rear end of the heating cylinder 31. Additionally, the injection molding machine 1 is equipped with a mechanism that allows the injection device 3 to move in the front-to-back direction (in...) Figure 1 The nozzle contact device 34 moves in the left-right direction. When the nozzle contact device 34 is driven, the injection device 3 moves forward so that the nozzle 31a of the heating cylinder 31 contacts the sealing part of the fixed plate 22.

[0032] Multiple sensors 4 are components and circuits that detect physical quantities related to the quality of the molded product. In other words, multiple sensors 4 are components and circuits that detect physical quantities of a time series related to the operation of the injection molding machine 1 obtained during the injection molding process of the molded product using the injection molding machine 1.

[0033] As sensors required for the operation control of injection molding machine 1, sensor 4 includes sensors installed on injection molding machine 1 and sensors separately installed to estimate the state of injection molding machine 1. All or part of the plurality of sensors 4 are connected to recording device 6, and the sensors 4 output signals representing detected physical quantities to recording device 6. The information processing device 7, described later, acquires physical quantity data from the sensors 4 via recording device 6. The physical quantity data is data representing a time series of sensor values ​​of the detected physical quantities.

[0034] In addition, a portion of the multiple sensors 4 are connected to the control device 5, and the information processing device 7 can also acquire physical quantity data from the sensor 4 via the control device 5.

[0035] Physical quantities include temperature, position, velocity, acceleration, current, voltage, pressure, time, image data, torque, force, strain, power consumption, weight, etc. These physical quantities can be measured using thermometers, position sensors, velocity sensors, accelerometers, ammeters, voltmeters, pressure gauges, timers, cameras, torque sensors, power meters, weights, etc.

[0036] Multiple sensors 4 include, for example, a speed sensor for detecting the speed of the screw 32, a speed sensor for detecting the speed of the movable disc 24, and a speed sensor for detecting the speed of the ejector pin.

[0037] Multiple sensors 4 include, for example, a torque sensor that detects the torque of the motor driving the screw 32, a torque sensor that detects the torque of the motor driving the movable disk 24, and a torque sensor that detects the torque of the motor driving the ejector pin.

[0038] Multiple sensors 4 include, for example, a pressure sensor that detects the pressure inside the screw 32 or the heating cylinder 31, and a pressure sensor that detects the pressure applied to the mold 21.

[0039] Multiple sensors 4 include force sensors that detect the pressure applied to the screw 32 along its length.

[0040] Multiple sensors 4 include, for example, a position sensor that detects the position of the screw 32, a position sensor that detects the position of the movable disk 24, and a position sensor that detects the position of the ejector pin.

[0041] Multiple sensors 4 include, for example, a rotational speed sensor that detects the rotational speed of the motor that drives the screw 32, a rotational speed sensor that detects the rotational speed of the motor that drives the movable disk 24, and a rotational speed sensor that detects the rotational speed of the motor that drives the ejector pin.

[0042] Multiple sensors 4 include load sensors that detect the clamping force based on the clamping device 2.

[0043] The multiple sensors 4 include a temperature sensor for detecting the temperature of the hopper 33, a temperature sensor for detecting the temperature of one or more parts of the heating cylinder 31, and a temperature sensor for detecting the temperature of one or more parts of the nozzle 31a.

[0044] In addition, sensor 4 includes an arbitrary detector capable of detecting physical quantities used for estimating the quality of molded products.

[0045] The control device 5 is a computer that controls the operation of the injection molding machine 1. The control device 5 sets the molding conditions for the injection molding machine 1 to operate. Based on the various set values ​​of the molding conditions and the detection values ​​of the sensor 4, the control device 5 outputs command signals to the injection molding machine 1 to make the injection molding machine 1 operate.

[0046] In addition, the control device 5 includes a communication unit (not shown) for sending and receiving information with the information processing device 7, and an operation panel, etc. Specifically, the control device 5 sends data related to the molding conditions set for the injection molding machine 1 to the information processing device 7. The data related to the molding conditions is, for example, the name of the molding conditions used to identify the molding conditions set for the injection molding machine 1. The data related to the molding conditions may also be the content of the molding conditions themselves. There are no particular limitations as long as the data related to the molding conditions reflects the content of the molding conditions.

[0047] In addition, during the injection molding process, the control device 5 outputs a signal related to the instruction value based on the molding conditions to the recording device 6.

[0048] Furthermore, the control device 5 receives and displays the estimated results related to the quality of the molded product sent from the information processing device 7. Additionally, the control device 5 outputs an alarm based on the estimated results of the molded product quality. Furthermore, the control device 5 receives and displays information from the information processing device 7 indicating methods for changing setting values ​​related to molding conditions.

[0049] The recording device 6 is, for example, a PLC (Programmable Logic Controller). The recording device 6 samples and performs AD conversion on the analog signals output from multiple sensors 4 at predetermined intervals, storing the physical quantity data as a time-series physical quantity in its built-in memory. Additionally, the recording device 6 samples and performs AD conversion on the command value signals output from the control device 5 at predetermined intervals, storing the command value data as a time-series command value in its built-in memory. For example, the recording device 6 stores the physical quantity data and command value data in the form of a CSV file. The recording device 6 transmits the recorded physical quantity data and command value data file to the information processing device 7 at each injection molding cycle. The physical quantity data is data related to the operation of the injection molding machine 1 and the quality of the molded product, obtained during the injection molding process of the molded product using the injection molding machine 1.

[0050] <Information Processing Device 7>

[0051] The information processing device 7 is a computer that estimates the quality or defect level of the molded article manufactured by the injection molding machine 1. Furthermore, if the quality of the molded article is lower than the specified quality, the information processing device 7 issues an alarm report and performs processing to suggest changes to the set values ​​of the molding conditions. The information processing device 7 performs processing to issue an alarm or suggest changes to the set values ​​of the molding conditions when the quality of the molded article is lower than the specified quality. The information processing device 7, as hardware, includes a processing unit 71, a storage unit 72, an operation unit 73, an acquisition unit 74, and a display unit 75. It should be noted that the information processing device 7 can also be a server device connected to a network. Furthermore, the information processing device 7 can be configured by multiple computers performing distributed processing, or it can be implemented using multiple virtual devices installed within a single server, or it can be implemented using a cloud server.

[0052] The processing unit 71 is a processor equipped with I / O terminals, a timing unit, and other processing circuits such as a CPU (Central Processing Unit), a multi-core CPU, a GPU (Graphics Processing Unit), a GPGPU (General-purpose computing on Graphics Processing Unit), a TPU (Tensor Processing Unit), an ASIC (Application Specific Integrated Circuit), a FPGA (Field-Programmable Gate Array), and an NPU (Neural Processing Unit), as well as internal storage devices such as ROM (Read Only Memory) and RAM (Random Access Memory). The processing unit 71 implements the quality estimation method of Embodiment 1 by executing the computer program (program product) 72a stored in the storage unit 72 (described later). It should be noted that the functional units of the information processing apparatus 7 can be implemented in software, or some or all of them can be implemented in hardware.

[0053] Storage unit 72 is a non-volatile memory such as a hard disk, EEPROM (Electrically Erasable Programmable ROM), or flash memory. Storage unit 72 stores a computer program 72a used to enable a computer to estimate the quality of the molded product, etc.

[0054] In addition, the storage unit 72 stores time-series physical quantity data obtained from the injection molding machine 1 at each injection. The storage unit 72 stores a folder for temporarily storing files of physical quantity data acquired by the recording device 6 at each injection (hereinafter referred to as temporary storage folder 72b) and a folder for distinguishing temporarily stored files according to molding conditions and data collection period (hereinafter referred to as classification folder 72c).

[0055] The computer program 72a of Embodiment 1 can also be recorded on the recording medium 8 in a manner readable by a computer. The storage unit 72 stores the computer program 72a read from the recording medium 8 by a reading device. The recording medium 8 is a semiconductor memory such as flash memory. Alternatively, the recording medium 8 can also be an optical disc such as a CD (Compact Disc)-ROM, a DVD (Digital Versatile Disc)-ROM, or a BD (Blu-ray Disc). Furthermore, the recording medium 8 can also be a floppy disk, a hard disk, or an optical disk. In addition, the computer program 72a of Embodiment 1 can be downloaded from an external server connected to a communication network and stored in the storage unit 72.

[0056] The operation unit 73 includes input devices such as touch panels, soft keys, hard keys, keyboards, and mice.

[0057] The acquisition unit 74 is a communication circuit that acquires physical quantity data output from the recording device 6 and instruction value data based on molding conditions. Furthermore, the acquisition unit 74 communicates with the control device 5 to acquire other data necessary for estimating the quality of the molded product, such as data related to molding conditions.

[0058] Display unit 75 is a liquid crystal panel, organic EL display, e-reader, plasma display, etc. Display unit 75 displays various information corresponding to the image data supplied from processing unit 71.

[0059] Figure 2 This is a flowchart illustrating the data collection and processing steps of Embodiment 1. The processing unit 71 of the information processing device 7 collects time-series physical quantity data and command value data related to the operation of the injection molding machine 1, detected by multiple sensors 4 during the injection molding process of the molded article using the injection molding machine 1 (step S111). This physical quantity data is information used to estimate the quality of the molded article. Step S111 is repeated, and physical quantity data is collected over multiple injection molding cycles.

[0060] Figure 3 This is a flowchart illustrating the data collection and processing steps of Implementation Method 1. Figure 4 This is a conceptual diagram illustrating the data collection method of Implementation Method 1. Figure 5 This is a conceptual diagram illustrating the contents of a file saved using the data collection method of Implementation Method 1. Figure 6 and Figure 7 This is a chart showing an example of an item in the log data.

[0061] When the injection molding process of the injection molding machine 1 begins, the recording device 6 begins recording time-series physical quantity data and command value data detected by the sensor 4 (step S131). That is, the recording device 6 begins the process of saving signals representing physical quantities output from multiple sensors 4 in the form of time-series physical quantity data. The specific content of the physical quantity data will be described later. In addition, the recording device 6 begins the process of saving the command value signal that causes the injection molding machine 1 to operate, together with the physical quantity data, in the form of time-series command value data.

[0062] Next, the recording device 6 determines whether one injection molding cycle has ended (step S132). If it is determined that one injection molding cycle has not ended (step S132: No), the recording device 6 continues to record physical quantity data. If it is determined that one injection molding cycle has ended (step S132: Yes), the recording of physical quantity data and command value data ends (step S133).

[0063] Then, the recording device 6 transmits the physical quantity data of the time series of one injection to the information processing device 7 (step S134).

[0064] The information processing device 7 receives a file containing physical quantity data and instruction value data transmitted from the recording device 6, and saves the file containing the received physical quantity data and instruction value data in a temporary storage folder 72b (step S151). More specifically, as follows... Figure 4 As shown, when a file containing physical quantity data and instruction value data is saved in the temporary storage folder 72b, the information processing device 7 begins to save the physical quantity data and instruction value data as a file with a first extension. Once the saving of the physical quantity data and instruction value data is complete, the file extension in the temporary storage folder 72b is changed from the first extension to the second extension. For example, the second extension is "csv", and the first extension is a name different from the second extension.

[0065] The filename for the file containing the time-series physical quantity data and instruction value data of a single injection is not specifically limited and can include the injection number. The physical quantity data and instruction value data can be saved in CSV format as data items, such as... Figure 5 As shown, the corresponding information is established and stored, including the consecutive number "No." of the recording point, the date of recording, the time of recording, the elapsed time from the previous recording point to the current recording point (in μ seconds, for example), and various command values ​​and monitoring values ​​(physical quantities) output from the control device 5 to the injection molding machine 1.

[0066] As various instruction values ​​and physical quantity monitoring values ​​stored in the file, for example, can be cited as... Figure 6 and Figure 7The data shown is as follows. The "Instruction / Monitor Items" column on the left indicates the content of the instruction values ​​output to the injection molding machine 1 and the content of the detected physical quantities. The columns "Injection" and "Metering" indicate the instruction values ​​and monitored values ​​associated with the action of the screw 32, "Mold Platen" indicates the instruction values ​​and monitored values ​​associated with the action of the mold clamping device 2, and "Ejection" indicates the known position and monitored value associated with the action of the ejector pin used to remove the molded part from the mold 21. Items marked as checked indicate the presence of instruction values ​​or monitored values ​​for recorded objects.

[0067] Next, the processing unit 71 of the information processing device 7 continuously monitors whether there are any files stored in the temporary storage folder 72b, and determines whether there are any files with the second extension in the temporary storage folder 72b (step S152). If it is determined that there are no files with the second extension in the temporary storage folder (step S152: No), the processing unit 71 continues to monitor the files stored in the temporary storage folder 72b.

[0068] If it is determined that a file with the second extension exists in the folder used for temporary storage (step S152: Yes), the processing unit 71 obtains the current molding condition data from the injection molding machine 1 (step S153). The molding condition data includes data representing the molding conditions set for the injection molding machine 1, the name assigned to the molding conditions, and other data representing the molding conditions. The molding conditions set for the injection molding machine 1 vary depending on the molded product; if the molding conditions are different, the content of the physical quantity data collected from the injection molding machine 1 also changes. The information processing device 7 obtains the molding condition data to distinguish and save the physical quantity data according to the molding conditions.

[0069] Next, the processing unit 71 determines whether a classification folder 72c has been created as the folder for storing physical quantity data in the temporary storage folder 72b. The folder name of the classification folder 72c contains a string reflecting the molding conditions and the period of collection of physical quantity data (step S154).

[0070] If it is determined that the classification folder 72c has not been created (step S154: No), the processing unit 71 creates a folder whose name includes a string reflecting the molding conditions and the period during which the physical quantity data was collected, as the folder for storing physical quantity data (step S155). For example, the folder name is set to "Molding Condition Name / YYYY / MM / DD / Collection Start Time-Collection End Time". "Molding Condition Name" is the name assigned to the molding conditions set for the injection molding machine 1. "YYYY", "MM", and "DD" represent the year, month, and day of physical quantity data collection. "Collection Start Time" and "Collection End Time" represent the time (start time and end time) at which the physical quantity data to be stored in this folder was collected. There is no particular limitation on the time interval between the collection start time and the collection end time. The collection end time can be set as follows, for example. In the first example, the processing unit 71 sets the timing of the molding condition change as the collection end time. In the second example, if more than 30 minutes have passed since the most recent injection, the processing unit 71 sets the time after 30 minutes as the collection end time. In the third example, the processing unit 71 sets a collection period of 30 minutes or similar.

[0071] It should be noted that in Examples 1 and 3, since the end time of physical quantity data collection is not determined, the folder name can be set as a temporary name in advance. For example, the processing unit 71 can be set as a folder with the temporary name "current", or it can be left blank in advance with the collection end time. There are no particular restrictions on the naming method of the temporary name.

[0072] It should be noted that the example described here, where the name of the category folder 72c includes the name of the molding condition, can also include text reflecting the molding conditions set for the injection molding machine 1. For example, text representing the content of the molding conditions can be used instead of the molding condition name. In short, it is sufficient to be able to identify the molding conditions set for the injection molding machine 1.

[0073] When it is determined in step S154 that a classification folder 72c has been created (step S154: Yes), or the processing unit 71, which has ended the processing in step S155, moves the files with the second extension saved in the temporary storage folder 72b to the classification folder 72c corresponding to the molding conditions and data collection period (step S156), and ends the processing. That is, during the collection period contained in the folder name of classification folder 72c, the processing unit 71 moves and saves the physical quantity data obtained during injection molding with the molding conditions contained in the folder name to the classification folder 72c at each injection.

[0074] It should be noted that the processing in step S156 is an example of the process of storing the acquired physical quantity data in the storage unit 72 in association with the molding conditions set for the injection molding machine 1 at each injection.

[0075] return Figure 2 The processing unit 71 acquires quality data indicating the quality of the molded article manufactured by the injection molding machine 1 (step S112). There is no particular limitation on the method of acquiring the quality data. The operator can visually judge the quality of the molded article and input the judgment result into the information processing device 7. Alternatively, the computer can use a camera, position sensor, weight sensor, etc. to judge the quality of the molded article.

[0076] Then, the processing unit 71 associates and stores quality data, representing the quality of the injection-molded article when the saved physical quantity data is obtained, with the file containing that physical quantity data (step S113). For example, the processing unit 71 saves a quality data file that establishes a correspondence between the injection number and the quality data in a category folder 72c. It should be noted that the association method between each file and the quality data saved in the category folder 72c is just one example, and the data association method is not particularly limited. Quality data can also be recorded in the physical quantity data file, or it can be recorded using the file's attributes or other attribute information.

[0077] Figure 8 This is a flowchart illustrating the quality estimation process steps of Embodiment 1. The processing unit 71 of the information processing device 7 collects time-series physical quantity data related to the operation of the injection molding machine 1, which is detected by multiple sensors 4 during the injection molding process of the molded article using the injection molding machine 1 (step S171).

[0078] Then, the processing unit 71 reads the reference data for qualified products when the molding conditions are common when the collected physical quantity data is obtained from the storage unit 72 (step S172). The reference data for qualified products is physical quantity data in the file stored in the classification folder 72c, where the quality data represents physical quantity data that is above a specific reference for qualified products.

[0079] Next, the processing unit 71 compares the time-series waveform represented by the physical quantity data obtained in the quality estimation of the molded product with the time-series waveform represented by the reference data read, and calculates the difference between the time-series waveforms as the quality of the molded product (step S173). The difference is, for example, the sum of squares error of the time-series waveforms.

[0080] It should be noted that, more preferably, the time series waveforms of the common periods of the processes constituting the injection molding cycle can be compared with each other. The processing unit 71 can determine the time of each process constituting the injection molding process in one cycle by referring to the molding conditions. The processing unit 71 can extract the time series waveforms in one cycle that correspond to the determined time of each process. By comparing the time series waveforms of the same process with each other, the processing unit 71 can more accurately estimate the quality of the molded product.

[0081] Next, the processing unit 71 determines whether the calculated quality is lower than the specified quality (step S174). If it is determined that the quality of the molded product is lower than the specified quality (step S174: Yes), an alarm process (specified process) is executed (step S175). That is, the processing unit 71 notifies the operator that the quality of the molded product has deteriorated through sound, light, etc. The alarm method is not particularly limited, and the processing unit 71 may also send an alarm signal to the control device 5. Alternatively, the processing unit 71 may be configured to send an alarm signal to a terminal held by the operator.

[0082] Next, the processing unit 71 determines a method for changing the setpoints related to the molding conditions based on the physical quantity data obtained in the quality estimation and the physical quantity data stored in the storage unit 72 (step S176), and displays the determined method for changing the setpoints on the display unit 75 (step S177). For example, by comparing the time series waveform of the physical quantity data detected in quality management with the time series waveform of the reference data according to the detected physical quantity items, the physical quantity with the large difference is determined, and the display unit 75 displays whether the physical quantity is larger or smaller than the reference data, or it can be displayed via the control device 5.

[0083] It should be noted that the processing unit 71 may also be configured to send a method for changing the setting value of the molding conditions to the control device 5 and display it on the display of the control device 5.

[0084] It should be noted that, Figure 8 The process shown represents a process that estimates the quality of a molded article based on physical quantity data from a single injection, but the processing unit 71 repeats this process during the molding process. Figure 8 The process shown allows for monitoring the quality of molded products mass-produced through repeated injection molding cycles.

[0085] As described above, the injection molding system according to Embodiment 1 can save physical quantity data obtained from each injection in the injection molding process in a way that establishes a correlation with the molding conditions and the data collection period. By establishing a correlation with the molding conditions and the data collection period, the physical quantity data can be used easily and effectively.

[0086] In addition, a folder named 72c is created that displays a string related to the molding conditions and a category folder 72c during data collection. The corresponding physical quantity data files are stored in this category folder 72c. This makes it easier to retrieve and refer to the results of injection molding in the past, i.e., physical quantity data, and enables more efficient and convenient use of physical quantity data.

[0087] For example, in practical applications, physical quantity data obtained in quality management can be compared with past physical quantity data collected under similar conditions and during similar periods to identify similar physical quantity data. If a correlation is established between past physical quantity data and the quality data of the molded product, the quality of the molded product can be inferred by comparing the physical quantity data.

[0088] Furthermore, the information processing device 7 of Embodiment 1 can more accurately determine similar physical quantity data and estimate the quality of the molded product by comparing the time series waveforms of the time series waveforms representing physical quantity data that constitute the common parts of the injection molding cycle with each other.

[0089] Furthermore, since the command values ​​and monitoring values ​​are linked together and stored in the file, it is possible to identify files where the molding conditions and physical quantity data are similar and the quality data is good, and to infer the method of changing the setting values ​​based on the current molding conditions based on the command values ​​at this time.

[0090] Furthermore, by comparing physical quantity data, an alarm can be issued and the operator can be notified of the molding abnormality when the quality of the molded product is lower than the specified quality.

[0091] Furthermore, when transferring the recorded physical quantity data file to the information processing device 7 for storage in the temporary storage folder 72b and allocation to the classification folder 72c, file movement can be reliably performed by changing the file extension. Specifically, it is possible to determine whether physical quantity data is being transmitted based on the file extension, and upon confirming that the file transmission is complete, the file in the temporary storage folder 72b is moved to the classification folder 72c.

[0092] It should be noted that in this embodiment 1, an example of recording instruction value data together with physical quantity data is described, but it can also be configured to record and save only physical quantity data and estimate the quality of the molded product.

[0093] (Implementation Method 2)

[0094] The quality estimation process of the injection molding system in Embodiment 2 differs from that in Embodiment 1. Other components of the injection molding system are the same as those in Embodiment 1; therefore, the same reference numerals are used to denote the similarities, and detailed descriptions are omitted.

[0095] Figure 9 This is a flowchart illustrating the quality estimation process steps of Embodiment 2. Figure 9 The processing of steps S271-S272 and S274-S277 shown is the same as that of steps S171-S172 and S174-S177 in Embodiment 1, except for the quality estimation process.

[0096] In Embodiment 2, the processing unit 71 of the information processing apparatus 7 determines the quality of the molded product by comparing the increase or decrease or periodic change of characteristic quantities based on the physical quantity data obtained in quality management collected in step S271 with the increase or decrease or periodic change of characteristic quantities based on reference data (step S273). For example, the processing unit 71 calculates the similarity of the increase or decrease or periodic change of characteristic quantities as the quality of the molded product. The higher the similarity with the reference data when the product is qualified, the higher the quality of the molded product; the lower the similarity, the lower the quality of the molded product. The quality of the molded product can then be calculated.

[0097] According to the injection molding system of Embodiment 2 constructed in the manner described above, the quality of the molded article can be estimated effectively using past physical quantity data, just as in Embodiment 1.

[0098] The appendix discloses the means used to solve the problem.

[0099] (Note 1)

[0100] A quality estimation method comprising the following processes:

[0101] To acquire time-series physical quantity data related to the operation of an injection molding machine during the injection molding process of a molded article using an injection molding machine;

[0102] The acquired physical quantity data is stored in the storage unit at each injection.

[0103] Quality data, representing the quality of the injection-molded article when the acquired physical quantity data is obtained, is stored in association with the physical quantity data.

[0104] The quality of the molded article is calculated based on the physical quantity data obtained in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit; and

[0105] If the quality of the molded product is lower than the specified quality, the prescribed treatment shall be performed.

[0106] (Note 2)

[0107] In the quality estimation method described in Appendix 1, the quality of the molded product is calculated based on the difference between the time-series waveform represented by the physical quantity data obtained in the quality estimation and the time-series waveform represented by the physical quantity data stored in the storage unit.

[0108] (Note 3)

[0109] In the quality estimation method described in Appendix 1 or Appendix 2

[0110] The quality of the molded product is calculated based on the difference in time-series waveforms representing multiple physical quantities common to the processes that constitute the injection molding cycle.

[0111] (Note 4)

[0112] In any one of the quality estimation methods described in Appendix 1 to Appendix 3

[0113] The physical quantity data is stored in the storage unit in association with the molding conditions set for the injection molding machine.

[0114] The quality of the molded product is calculated based on the difference in time series waveforms represented by multiple physical quantities that are common to the molding conditions.

[0115] (Note 5)

[0116] In any one of the quality estimation methods described in Appendix 1 to Appendix 4

[0117] Create a folder with a name containing a string and the period during which the physical quantity data was collected, where the string reflects the molding conditions set for the injection molding machine.

[0118] During the collection period contained in the folder name, physical quantity data obtained during injection molding under the molding conditions contained in the folder name are saved in the folder at each injection.

[0119] (Note 6)

[0120] In any one of the quality estimation methods described in Appendix 1 to Appendix 5

[0121] Physical quantity data is stored in a file that contains the date and time of injection molding, the time information of the detection time used to determine the physical quantity data, the acquired physical quantity data, and the instruction values ​​related to the action of the injection molding machine when the physical quantity data is acquired.

[0122] (Note 7)

[0123] In any of the quality estimation methods described in Appendix 1 to Appendix 6

[0124] A method for determining changes to settings related to molding conditions based on physical quantity data obtained in quality estimation and physical quantity data stored in the storage unit.

[0125] (Postscript 8)

[0126] In any of the quality estimation methods described in Appendix 1 to Appendix 7

[0127] The specified processing includes processing related to alarm reporting.

[0128] (Note 9)

[0129] In any of the quality estimation methods described in Appendix 1 to Appendix 8

[0130] The quality of the molded product is estimated by comparing the increase or decrease or periodic change of the characteristic quantity calculated based on the physical quantity data obtained in the quality estimation with the increase or decrease or periodic change of the characteristic quantity calculated based on the physical quantity data stored in the storage unit. Explanation of reference numerals in the attached figures

[0131] 1: Injection molding machine

[0132] 2: Mold closing device

[0133] 3: Injection device

[0134] 4: Sensors

[0135] 5: Control device

[0136] 6: Recording device

[0137] 7: Information processing device

[0138] 8: Recording media

[0139] 20: Base

[0140] 21: Mold

[0141] 22: Fixed plate

[0142] 23: Mold shell

[0143] 24: Movable disc

[0144] 25: Tie rod

[0145] 26: Mold Closing Mechanism

[0146] 27: Movable mold

[0147] 28: Fixed mold

[0148] 30: Abutment

[0149] 31: Heating cylinder

[0150] 31a: Nozzle

[0151] 32: Screw

[0152] 33: Hopper

[0153] 34: Nozzle contact device

[0154] 35: Drive unit

[0155] 71: Processing Department

[0156] 72: Storage Department

[0157] 72a: Computer Program

[0158] 72b: Temporary storage folder

[0159] 72c: Categorized Folders

[0160] 73: Operations Department

[0161] 74: Acquisition Department

[0162] 75: Display section.

Claims

1. A method for estimating quality, characterized in that, Includes the following processing: To acquire time-series physical quantity data related to the operation of an injection molding machine during the injection molding process of a molded article using an injection molding machine; The acquired physical quantity data is stored in the storage unit at each injection. Quality data, representing the quality of the injection-molded article when the acquired physical quantity data is obtained, is stored in association with the physical quantity data. The quality of the molded article is calculated based on the physical quantity data obtained in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit. as well as If the quality of the molded product is lower than the specified quality, the prescribed treatment shall be performed.

2. The quality estimation method according to claim 1, characterized in that, The quality of the molded product is calculated based on the difference between the time-series waveform represented by the physical quantity data obtained in the quality estimation and the time-series waveform represented by the physical quantity data stored in the storage unit.

3. The quality estimation method according to claim 1 or 2, characterized in that, The quality of the molded product is calculated based on the difference in time-series waveforms representing multiple physical quantities common to the processes that constitute the injection molding cycle.

4. The quality estimation method according to any one of claims 1 to 3, characterized in that, The physical quantity data is stored in the storage unit in association with the molding conditions set for the injection molding machine. The quality of the molded product is calculated based on the difference in time series waveforms represented by multiple physical quantities that are common to the molding conditions.

5. The quality estimation method according to any one of claims 1 to 4, characterized in that, Create a folder with a name containing a string and the period during which the physical quantity data was collected, where the string reflects the molding conditions set for the injection molding machine. During the collection period contained in the folder name, physical quantity data obtained during injection molding under the molding conditions contained in the folder name are saved in the folder at each injection.

6. The quality estimation method according to any one of claims 1 to 5, characterized in that, Physical quantity data is stored in a file that contains the date and time of injection molding, the time information of the detection time used to determine the physical quantity data, the acquired physical quantity data, and the instruction values ​​related to the action of the injection molding machine when the physical quantity data is acquired.

7. The quality estimation method according to any one of claims 1 to 6, characterized in that, A method for determining changes to settings related to molding conditions based on physical quantity data obtained in quality estimation and physical quantity data stored in the storage unit.

8. The quality estimation method according to any one of claims 1 to 7, characterized in that, The specified processing includes processing related to alarm reporting.

9. The quality estimation method according to any one of claims 1 to 8, characterized in that, The quality of the molded product is estimated by comparing the increase or decrease or periodic change of the characteristic quantity calculated based on the physical quantity data obtained in the quality estimation with the increase or decrease or periodic change of the characteristic quantity calculated based on the physical quantity data stored in the storage unit.

10. A quality estimation apparatus comprising a processing unit, characterized in that, The processing unit performs the following processing: To acquire time-series physical quantity data related to the operation of an injection molding machine during the injection molding process of a molded article using an injection molding machine; The acquired physical quantity data is stored in the storage unit at each injection. Quality data, representing the quality of the injection-molded article when the acquired physical quantity data is obtained, is stored in association with the physical quantity data. The quality of the molded article is calculated based on the physical quantity data obtained in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit. as well as If the quality of the molded product is lower than the specified quality, the prescribed treatment shall be performed.

11. A computer program, characterized in that, Used to cause the computer to perform the following processes: To acquire time-series physical quantity data related to the operation of an injection molding machine during the injection molding process of a molded article using an injection molding machine; The acquired physical quantity data is stored in the storage unit at each injection. Quality data, representing the quality of the injection-molded article when the acquired physical quantity data is obtained, is stored in association with the physical quantity data. The quality of the molded article is calculated based on the physical quantity data obtained in the quality estimation of the molded article and the physical quantity data and quality data stored in the storage unit. as well as If the quality of the molded product is lower than the specified quality, the prescribed treatment shall be performed.

Images