Injection molding machine

Abstract

Method for setting up an injection molding machine (6), comprising at least the following steps: a. Providing an injection mold (1) with a data interface (5), b. Transfer of data from the data interface (5) of the injection mold (1) to a computing unit, c. Processing tool parameters from the data in the computing unit into a setting for the injection molding machine (6), d. Transferring the setting from the computing unit to a control and regulating unit 12 of the injection molding machine (6) and e. Providing the settings for operation of the injection molding machine (6).

Description

[0001] The invention relates to a method for setting up an injection molding machine for the production of plastic components. Furthermore, the invention specifies the injection molding machine, a system comprising such an injection molding machine and a plurality of different injection molds, a computer program, and a computer-readable medium.

[0002] Injection molding machines require precise settings, meaning settings that are perfectly tailored to the specific injection molding process. These settings often need to be configured by the operator. For a modern injection molding machine to function correctly, it is typically necessary to input a large number of parameters. This requires calculating, determining, or reading these parameters. Subsequently, all these parameters must be entered into the injection molding machine so that the injection molding process can begin. If incorrect parameters are entered, it is necessary to identify and correct them. However, such troubleshooting can be time-consuming and complicated. It is also possible that these input errors go unnoticed, resulting in a high volume of rejects.

[0003] Injection molds are used in injection molding machines. An injection mold comprises at least an ejector plate and a nozzle plate. The ejector plate and the nozzle plate can be pressed together by the injection molding machine, thus jointly defining a cavity. The nozzle plate has an opening to which a melting unit can terminate. Liquid plastic can be injected under pressure into the cavity of the nozzle plate via the melting unit. The pressure can be maintained during a curing phase until the liquid plastic has solidified. After the plastic part has completely cured, the ejector plate and the nozzle plate can be moved apart again, and the cured plastic part falls out of the opening cavity.

[0004] For the plastic component to cure completely and correctly, it is essential that key process parameters are adhered to. A separate injection mold is manufactured for each plastic component. Therefore, it is crucial that all process parameters are known for each individual injection mold so that the injection molding machine can be set up correctly.

[0005] Especially when manufacturing a large number of components, it is essential that the tool parameters are set precisely. If it is only discovered after the production of a large number of components that the tool parameters were not set correctly, a large number of components may have been produced that are of poor quality, unusable, or defective.

[0006] It is also important to know the process parameters when frequently reusing the injection mold. This allows setup times to be reduced and makes it possible to start production of a large number of components without lengthy changeover times.

[0007] Furthermore, it seems important to train employees correctly to prevent operator errors on an injection molding machine from leading to high scrap rates and / or the production of low-quality plastic components. Such production errors can occur particularly due to operator errors resulting from incorrect settings of the injection molding machine.

[0008] Based on this, the object of the invention is to at least partially solve the problems described with reference to the prior art. In particular, it aims to create a method by which the tool parameters can be transmitted to the injection molding machine without the risk of operator error. Specifically, it aims to prevent errors from occurring when determining and entering further parameters, which could lead to an incorrect injection molding process resulting in a high amount of rejects.

[0009] This problem is solved by the features of the independent claims. Further advantageous embodiments of the invention are specified in the dependent claims. It should be noted that features listed individually in the claims can be combined with one another in any technologically meaningful way and define further embodiments of the invention. Furthermore, the features specified in the claims are further specified and explained in the description, which also presents further preferred embodiments of the invention.

[0010] A method for setting up an injection molding machine contributes to solving this problem, comprising at least the following steps: a. Providing an injection mold with a data interface, b. Transferring data from the data interface of the injection mold to a computing unit, c. Processing tool parameters from the data in the computing unit into a setting for the injection molding machine, d. Transferring the setting from the computing unit to a control and monitoring unit of the injection molding machine and e. Providing the settings for operation of the injection molding machine.

[0011] An injection molding machine can be used to manufacture plastic components. For correct operation of the injection molding machine, an injection mold is installed and the machine is calibrated. Preferably, different injection molds can be used in one injection molding machine. This makes it possible to produce different plastic components with different (but precisely assigned) injection molds in a single machine. Thus, the injection molding machine is calibrated each time a different injection mold is used. Preferably, the method can (fully) automate or assist the calibration of the injection molding machine. It is possible that manual calibration or adjustment of the settings can be performed correctly and with less error using this method.

[0012] As per step a., an injection mold with a data interface is provided. The injection mold can be used or configured to produce plastic components. In an injection mold, liquid plastic can be formed into a cavity and harden within it. The injection mold is specifically designed for a particular or specified plastic component, thus serving to produce exactly one single, pre-defined plastic component. This makes it possible to produce a large number of (identical) plastic components with a single mold.

[0013] The injection mold can be multi-part and can include (at least) an ejector plate and a nozzle plate. The ejector plate and the nozzle plate can be assembled to form a cavity. In particular, the ejector plate and the nozzle plate can completely seal the cavity, except for an inlet in the nozzle plate. The ejector plate and the nozzle plate can have adjacent (lateral) surfaces, each with a recess, forming a cavity that is sealed (except for the inlet) when the surfaces are in contact. The injection mold is preferably usable in the injection molding machine. Preferably, the nozzle plate is fixed in position within the injection molding machine, while the ejector plate is movable towards the nozzle plate.With a cavity formed between the ejector plate and the nozzle plate, liquid plastic can be introduced into the cavity under pressure via the nozzle plate inlet. The plastic can then harden within the cavity.

[0014] Furthermore, at least one data interface is provided on the injection mold, which is configured for exchanging or reading data. In particular, it is possible to store, modify, and / or read tool-specific data from the injection mold via this interface. The data interface allows different parameters of the injection mold to be retrieved when data is read. This enables injection molds to be used multiple times, and it is possible to store all data required for using the injection mold in an injection molding machine directly on the injection mold. Therefore, it is not necessary to manually search for the parameters of each injection mold in an external database or document collection.

[0015] In step b, the data interface enables the transfer of data from the injection mold's data interface to a computing unit. Specifically, the injection mold may be equipped with electronic means that initiate and / or execute a data transfer from the injection mold to a receiver (at least partially) (active data interface). It is also possible for (external) electronic means to be provided that interact with the (passive) data interface of the injection mold to make the data available to a receiver (directly or indirectly). Thus, by using electronic means, the receiver can obtain data via the injection mold's data interface that is (uniquely) linked to or inherent in the injection mold.

[0016] In particular, it is possible for at least one of the following parameters to be provided or made available via the data interface (hereinafter also referred to in part as "tool parameters"): (1) a tool temperature of the injection mold, (2) a material specification, (3) a shot volume, i.e., the amount of liquid plastic injected into the cavity per injection process, (4) a filling speed, and (5) a tool locking mechanism of the injection mold, i.e., a reduction in the travel speed of the ejector plate towards the nozzle plate immediately before contact. Each of these data sets can specify a value or range of values ​​tailored to the cavity or the injection-molded component to be produced, which can be transmitted or displayed.

[0017] The mold temperature of an injection mold refers to a temperature, temperature range, and / or profile that must be maintained within the mold during component production, particularly when the plastic molten material is injected into the cavity. It is essential to set an optimal mold temperature so that the liquid plastic can properly adhere to the cavity walls and spread completely within them. An excessively high mold temperature can result in poor surface quality and / or prevent the component from emerging from the mold with sufficient rigidity. Conversely, an excessively low mold temperature can prevent the liquid plastic from spreading correctly within the cavity walls and / or cause it to cure uncontrollably, prematurely, and / or too quickly on the colder inner surfaces.

[0018] Since the cavity is usually designed / engineered to meet a specific flow and / or curing behavior of the injected material, a suitable material specification for the injection mold can also be provided.

[0019] The shot volume of an injection mold refers to a quantity or mass specification that must be adhered to when the plastic molten metal is injected into the cavity. An insufficient shot volume can result in the cavity not being completely filled. This can lead to external defects in the cured plastic part. Conversely, an excessive shot volume can cause excessive pressure within the injection mold cavity, potentially resulting in overmolding (an undesirable increase in the amount of plastic molten metal in the cavity) in the cured plastic part.

[0020] The specified and provided filling speed must also be maintained during an injection molding process. An incorrect filling speed (too fast or too slow) can cause the liquid plastic to spread unevenly within the cavity. This can lead to defects in the plastic.

[0021] A tool locking mechanism can increase the service life of the injection mold and improve the safety of the injection molding process. For example, a tool locking mechanism can be configured so that the ejector plate and the nozzle plate are brought together more slowly or with less force towards the end of the closing process or at a predetermined minimum distance from each other, before the two plates come into contact.

[0022] It is also possible to retrieve further parameters of the injection mold via the data interface. In particular, the number of shots (already executed) can be stored or provided via the data interface. This makes it possible to track the number of shot cycles of the injection mold and store it as a parameter.

[0023] The data transfer can be wireless in step b. The tool parameters can be stored as data on the data interface and transferred from the data interface to the processing unit.

[0024] Preferably, the data interface can be connected to or connectable to a database. The database can be encompassed by the data interface, connected to it (electronically), and / or linked to it via data technology. The data accessible via the data interface can be physically connected to the data interface or accessible via a (preferably wireless) connection. It is possible to design the data interface so that the data can be accessed decentrally. Access can depend on a network connection or be local, or even without a network connection. Data stored in a network can be stored on an internal server accessible wirelessly or via cable. It is also possible for the data to be stored in a cloud or another location accessible via the internet. Preferably, the data interface can be designed as a receiver / transmitter unit.This allows the data interface to retrieve the requested data and send it to the accessing device upon access. Preferably, the data interface is designed and / or configured so that all data can be (collectively) provided and / or transmitted (automatically) when it is used.

[0025] The data transfer in step b. can be wireless. The data interface can include data for automatically establishing a data connection with a decentralized data storage system, from which the computing unit retrieves tool parameters as data.

[0026] The data can include connection data that allows a connection to be established to a decentralized data storage system (external storage) from which the tool parameters can be retrieved. The data interface can be passive, allowing the tool parameters to be read (in code). In this case, the data interface may simply provide data in the form of a link to a central or decentralized storage system where the data can be accessed. If the data interface is designed as a passive link, it could be a barcode, a QR code, and / or an (alpha)numeric code. In this passive case, the data interface could be implemented as a plaque, sign, etc., on which the tool parameters are printed (in code) and / or engraved (in code).

[0027] The tool parameters themselves can be stored on external storage. The passive data interface can include means for establishing a (data) connection to the external (data) storage. The data can then be stored on a server, in the cloud, or on an output device. In this case, the data interface can also include location information for the storage location where the data is stored, so that it can be found there.

[0028] In step c., the processing of tool parameters from the data in the computing unit into a setting for the injection molding machine can be carried out by directly using and converting the data or by determining the tool parameters based on the data.

[0029] The data can include tool parameters, allowing the settings for the injection molding machine to be configured using a calculation table or program. Specifically, the processing unit can automatically recognize, categorize, and convert the tool parameters. The resulting settings can include a machine-readable code for the injection molding machine or instructions for parameter input.

[0030] Data processing can take place in the processing unit on an external device or directly on the injection molding machine. The processing unit can also be integrated into the injection molding machine itself. For example, it might be incorporated into the machine's control unit or housed in a module attached to the machine. The processing unit on an external device could, for instance, be stored and executed on a mobile output device or a PC.

[0031] In step c, predetermined data is removed and / or converted into tool parameters, depending on the injection molding machine, thus creating a machine-specific setting. It is possible to convert the data into a multitude of tool parameters during processing. This makes it possible to determine or calculate settings for virtually any injection molding machine. However, to prepare a setting for a specific injection molding machine, the data may need to be selected or adjusted to create a correct data set for that specific setting. Alternatively, all data can be used to create a universal setting. This involves determining as many tool parameters as possible, allowing for the derivation of multiple settings that can be used to operate a variety of injection molding machines.However, it may also be known, for example during data preparation, which tool parameters are required by the injection molding machine on which the injection mold will be used. In such a case, it is possible to process only the necessary data in order to directly create a specific setting for the injection mold.

[0032] It is possible that the injection molding machine settings are displayed as editable between step c and step d. The computing unit may have a display unit through which the injection molding machine settings can be viewed. The settings can be edited via an input unit on the computing unit. Manual editing is also possible if the settings can be entered manually on the injection molding machine.

[0033] The transfer of settings from the computing unit to the control unit of the injection molding machine can be automated or manual. The control unit may have an input field where the setting can be entered. Alternatively, the computing unit may be integrated into the control unit, and the setting may be transferred electronically within the control unit. The control unit may also have receivers that can receive and adopt settings sent by the computing unit.

[0034] The settings for operating the injection molding machine can be provided by the control unit in step e. With these settings provided, the production of plastic parts on the injection molding machine can begin.

[0035] It is possible for the process to be initiated (fully) automatically when the injection mold is inserted into the injection molding machine. It is possible for the entire injection molding process to be initiated on the injection molding machine simply by inserting the mold. Specifically, the injection molding machine can detect the insertion of a mold, for example, via sensors connected to the control unit. Immediately after the mold is detected, the machine settings can be automatically configured using data from the mold's data interface. In other words, no manual adjustment, modification, or initiation of the manufacturing process on the injection molding machine is required. This enables fully automated operation of the injection molding machine.Only the injection molds are replaced, and human error in setting up the injection molding machine is minimized as a matter of priority.

[0036] The solution to the problem is provided by an injection molding machine comprising at least one injection mold and means set up to carry out the procedure proposed here.

[0037] The injection molding machine may include a computing unit and / or a data input unit. The computing unit and input unit may be integrated into the control unit of the injection molding machine. Alternatively, the computing unit and input unit may be mounted on or attached to the injection molding machine as connected or separate units, and may be physically or wirelessly connected to the control unit.

[0038] The processing unit can be part of an external computer network. For example, it might be part of a network that monitors and / or controls multiple injection molding machines. This allows the processing unit to calculate settings for combinations of different injection molds and machines operating in parallel within a machine network or park, either simultaneously, in parallel, or sequentially. The computer network could be connected via a central server or a cloud network.

[0039] A system contributing to the solution of the task comprises an injection molding machine and a plurality of different injection molding tools with a data interface and means that are set up for the automatic adjustment of the injection molding machine with data from the plurality of different injection molding tools to carry out the process.

[0040] The system can be a (possibly interconnected) network consisting of a (single) injection molding machine and a plurality of different injection molds. The system can thus represent a plastics manufacturing system in which a (predetermined) injection molding machine is operated with a plurality of different injection molds, in which the process is carried out. In other words, different plastic components can be manufactured on the system, with a specific setting of the injection molding machine being applied for each mold change, depending on the injection mold. In this way, a large number of different plastic components can be manufactured on one injection molding machine without the risk of serious operator errors. Preferably, the system comprises a network of multiple injection molding machines with a plurality of different injection molds, wherein the injection molds (or...a predetermined selection of different injection molding tools) which may be interchangeable among the injection molding machines and the procedure is carried out with each tool change.

[0041] The injection molding machine and the system offer particular advantages and mitigation of the problems mentioned at the outset. The specific advantages and design features described for the process are applicable and transferable to the described injection molding machine and system, and vice versa.

[0042] Furthermore, a computer program may be provided, comprising commands that cause the injection mold described above to execute the process steps for retrieving the mold parameters of the injection mold.

[0043] A computer-readable medium may be provided on which the computer program is stored.

[0044] The steps and features described with reference to the process, the injection molding machine and the system can also be used to further characterize the computer program, and vice versa.

[0045] The invention and its technical context are explained in more detail below with reference to two figures. The illustrations are schematic and not intended to demonstrate scale relationships. The explanations given with reference to individual details of the figure can be extracted and freely combined with information from the preceding description, unless a person skilled in the art would necessarily conclude otherwise, or such a combination is explicitly excluded. The figures schematically show: Fig. 1: an injection molding machine with a built-in injection mold, Fig. 2: an injection mold with a data interface, Fig. 3. A first configuration of a system with an injection molding machine and a plurality of different injection molds, and Fig. 4 another configuration of a system with an injection molding machine and a selected injection mold.

[0046] Fig. Figure 1 shows the general structure of an injection molding machine 6. This can be fundamentally divided into a plasticizing unit 7 and a clamping unit 8. The plasticizing unit 7 is, for example, assigned a screw drive 9, whereby the desired plastic is fed to the downstream feed screw and then conveyed by the feed screw to the nozzle 10. In the area of ​​the nozzle 10, the nozzle plate 3 of the injection mold assembly is movably arranged, with the movement being carried out, for example, by a hydraulic cylinder 11. The injection mold assembly on the nozzle plate 3 and the ejector plate 2 together form the injection mold 1. A cavity 4 is formed between the nozzle plate 3 and the ejector plate 2, which is closed by the nozzle plate 3 and the ejector plate 2 when the injection mold 1 closes.

[0047] The injection molding machine 6 includes a control unit 12. The control unit 12 comprises an input unit and a processing unit. When the injection mold 1 is provided, a data interface 5 transmits (see Fig. 2) Data is transmitted from the injection mold 1 to the processing unit. In the processing unit, tool parameters are derived from the data and used to configure the injection molding machine 6. The control unit 12 has a display unit with an input unit where the settings of the injection molding machine 6 can be edited. The processing unit internally transmits the settings of the injection molding machine 6 to the control unit 12, which then makes them available for operating the injection molding machine 6.

[0048] Fig. Figure 2 shows an example of an injection mold 1. The injection mold comprises the ejector plate 2 and the nozzle plate 3. The data interface 5 is attached to the nozzle plate 3. The data interface 5 is in Fig. 2 is designed as an electronic data interface. It is also possible that the data interface 5 is a passive data interface. The passive data interface can be implemented, for example, as a QR code, barcode, numerical code, or the like. The passive data interface can be integrated into the nozzle plate 3, printed onto it, or affixed to it. The data interface 5 is accessible from the outside and can also be accessed when the injection mold 1 is installed in the injection molding machine 6. It is also possible that the data interface 5 is not visible from the outside or is integrated into the nozzle plate 3.

[0049] Fig. Figure 3 shows an example of a system comprising an injection molding machine 6 to which a multitude of injection molds 1 are assigned. Each of the injection molds 1 has a data interface 5, which provides data for a link 13 that can be used to access a decentralized (external) data storage device 14. For example, a user with a mobile handheld device 15, which may include a scanner for the data interface 5, can read the data / link from the data interface 5 and is then directed to a data record in the decentralized data storage device 14. This can be performed and / or visualized in a menu environment and / or a data processing program on the handheld device 15. The specific mold parameters for the selected injection mold 1 can be retrieved from the decentralized data storage device 14 and either manually transferred to the control unit 12 or automatically sent to it.It is possible that the tool parameters, possibly after adjustment via the handheld device 15, are made available to the control and monitoring unit 12 via the handheld device 15.

[0050] Using the tool parameters, the control unit 12 can, if necessary, even automatically identify the desired injection mold 1 in a warehouse and, for example, initiate its transport to the injection molding machine 6.

[0051] Fig.Figure 4 shows an example of how the system or procedure can be implemented with a data interface 5, which is an active data interface. The data interface 5 on the injection mold 1 transmits the tool parameters of a specific injection mold 1 directly to the control unit 12 of the injection molding machine 6. The transmission can be wireless or wired. The transmission can occur when the injection mold 1 is near the injection molding machine 6, when the injection mold 1 is inserted into the injection molding machine 6, or when a data transmission is initiated at the data interface 5 of the injection mold 1. Reference sign 1 injection mold 2 ejector plate 3 nozzle plate 4 Cavity 5 Data interface 6 injection molding machines 7 plasticizing units 8 locking units 9 worm drive 10 nozzles 11 hydraulic cylinders 12 Control and regulation unit 13 Link 14 decentralized data storage 15 handheld device

Claims

[1] Method for setting up an injection molding machine (6), comprising at least the following steps: a. Providing an injection mold (1) with a data interface (5), b. Transfer of data from the data interface (5) of the injection mold (1) to a computing unit, c. Processing tool parameters from the data in the computing unit into a setting for the injection molding machine (6), d. Transferring the setting from the computing unit to a control and regulating unit 12 of the injection molding machine (6) and e. Providing the settings for operation of the injection molding machine (6). [2] Method according to claim 1, wherein in step b. the transmission is wireless, wherein tool parameters are stored as data on the data interface (5) and are transmitted from the data interface (5) to the computing unit. [3] Method according to one of the preceding claims, wherein in step b. the transmission is wireless, wherein the data interface (5) comprises data for automatically establishing a data connection with a decentralized data storage (14) from which the computing unit retrieves tool parameters as data. [4] Method according to one of the preceding claims, wherein in step c. predetermined transmitted data are removed and / or converted to tool parameters depending on the injection molding machine (6) so that a machine-specific setting is created. [5] Method according to one of the preceding claims, wherein the setting of the injection molding machine (6) is displayed in an editable manner between step c. and step d. [6] Method according to any of the preceding claims, wherein the method is automatically initiated when the injection mold (1) is inserted into the injection molding machine (6). [7] Injection molding machine (6) comprising at least one injection mold (1) and means configured to carry out a method according to any of the preceding claims. [8] Injection molding machine (6) according to claim 7, wherein the injection molding machine (6) comprises the computing unit and / or an input unit for data. [9] Injection molding machine (6) according to claim 7 or 8, wherein the computing unit is part of an external computer network. [10] System comprising an injection molding machine (6) and a plurality of different injection molding tools (1) with a data interface (5) and means which are set up for automatically setting from the injection molding machine (6) with data of the plurality of different injection molding tools (1) for carrying out the method according to one of claims 1 to 6. [11] Computer program comprising commands that cause the injection molding machine (6) of claims 7 to 9 to perform the process steps according to claims 1 to 6. [12] Computer-readable medium on which the computer program according to claim 11 is stored.

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