Method and device for assisting in molding crushed material mixture

Abstract

To eliminate problems such as the risk that quality cannot be guaranteed due to an excessive amount of crushed materials, and the problem of insufficient reuse of crushed materials due to a deficient amount of the crushed materials, by easily obtaining a highly accurate and effective mixing ratio of crushed materials in an actual molded product.SOLUTION: There is provided a method for assisting in molding a crushed material mixture, comprising: measuring a virgin material plasticization time Tv up to a predetermined plasticization end position Xe using only a virgin material Rv, and a crushed material plasticization time Ts up to the predetermined plasticization end position Xe under a plasticization condition using only a crushed material Rs to perform a registration process as a basic time data Do; measuring a plasticization time Tm of the crushed material mixture up to the plasticization end position Xe in a predetermined shot when producing a molded product using a crushed material mixture Rm to obtain actual time data Dp; and calculating a crushed material ratio Px in the crushed material mixture Rm to perform outputting based on the virgin material plasticization time Tv, the crushed material plasticization time Ts, and the crushed material mixture plasticization time Tm.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a molding support method and device for a pulverized material mixed material in an injection molding machine that plasticizes and injection molds a pulverized material mixed with virgin material and pulverized material in a predetermined ratio. [Background technology]

[0002] Generally, in production plants that use injection molding machines, not only virgin materials are used as resin materials for molding, but also unwanted moldings such as spools, runners, and defective moldings that are generated after molding are often reused. In this case, these unwanted moldings are finely crushed to produce crushed material, which is then mixed with virgin material (pellets) at a specified ratio to be used as a crushed material mixture.

[0003] Conventionally, known molding means for using such crushed mixed materials to perform molding include the plastic molding mechanism described in Patent Document 1 and the resin molding device with a spool / runner recycling function described in Patent Document 2.

[0004] The plastic molding mechanism described in Patent Document 1 is intended to provide a plastic molding mechanism for recycling recovered molded products by stably and efficiently mixing coarsely crushed material with raw materials, and specifically, it is configured with a transport means for transporting the recovered molded products removed from the molding die directly to above the material drop port of the removal device, a coarse crushing means arranged on the upper surface of the raw material feed rate adjustment means fixed to the upper part of the material drop port and coarsely crushing the transported recovered molded products, and a raw material feed rate adjustment means having a through hole for dropping the recovered molded products coarsely crushed by the coarse crushing means into the material drop port, and transporting the raw material to the through hole while adjusting the feed rate, thereby mixing the recovered molded products and the raw materials.

[0005] Furthermore, the resin molding apparatus described in Patent Document 2 is intended to eliminate the need for a separate large-scale device for transporting crushed spool / runner material to the molding machine, simplify the overall configuration of the resin molding apparatus, and facilitate cleaning when changing types. Specifically, the resin molding apparatus is equipped with an removal means for removing the spool / runner from the resin molding position of the molding machine, and a crusher for crushing the spool / runner removed by the removal means, and the crusher has a crushed material discharge port connected to the molding machine so that the crushed material obtained by crushing the spool / runner supplied from the removal means can be supplied into the molding machine. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2007-125818 A [Patent Document 2] Japanese Patent Application Publication No. 7-304038 Summary of the Invention [Problem to be solved by the invention]

[0007] However, the conventional molding method using the above-mentioned pulverized mixed material has the following problems.

[0008] That is, the crushed material used has a random shape and size, and when mixed with virgin material, the mixture ratio is likely to vary. Specifically, even if the virgin material (pellets) is mixed at 70 wt% and the crushed material at 30 wt%, the molded product is not necessarily mixed at a 70:30 ratio, and variation is likely to occur.

[0009] In this case, if it has been confirmed that there is no problem with quality, including strength, if the crushed material is within 30 wt%, for example, then if there is a molded product that exceeds 30 wt% due to variation, there is a risk that the molded product will be inappropriate and it may not be possible to guarantee quality, so the important thing is the mixing ratio in the actual molded product, not the ratio at the time of mixing.

[0010] However, since the mixing ratio in actual molded products is mixed in a molten state, it is not easy to confirm the mixing ratio, and ultimately, if there is too much crushed material, there is a risk that the quality cannot be guaranteed, and conversely, if there is too little crushed material, the crushed material cannot be effectively used (reused). Therefore, there has been a demand for an effective and accurate means of confirming the mixing ratio in actual molded products.

[0011] The present invention aims to provide a molding support method and device 1 for pulverized material mixture Rm that solves the problems existing in the background art. [Means for solving the problem]

[0012] The molding support method for pulverized material mixed material Rm according to the present invention is characterized in that, when plasticizing and injection molding a pulverized material mixed material Rm obtained by mixing virgin material Rv and pulverized material Rs at a predetermined ratio (Px), the virgin material plasticization time Tv up to a predetermined plasticization end position Xe under predetermined plasticization conditions using only the virgin material Rv used in the pulverized material mixed material Rm, and the pulverized material plasticization time Ts up to a predetermined plasticization end position Xe under predetermined plasticization conditions using only the pulverized material Rs used in the pulverized material mixed material Rm are measured in advance and registered as basic time data Do, and when producing a molded product using the pulverized material mixed material Rm, the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a predetermined shot is measured to obtain actual time data Dp, and the ratio Px of the pulverized material in the pulverized material mixed material Rm is calculated and output based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts, and the pulverized material mixed material plasticization time Tm.

[0013] In addition, the molding support device 1 for the pulverized material mixture Rm according to the present invention, when configuring a molding support device for an injection molding machine M that plasticizes the pulverized material mixture Rm obtained by mixing virgin material Rv and pulverized material Rs at a predetermined ratio (Px) and performs injection molding, includes a plasticization condition setting function unit Fs that sets predetermined plasticization conditions, and measures a virgin material plasticization time Tv up to a predetermined plasticization end position Xe under plasticization conditions using only the virgin material Rv used in the pulverized material mixture Rm, and a pulverized material plasticization time Ts up to a predetermined plasticization end position Xe under plasticization conditions using only the pulverized material Rs used in the pulverized material mixture Rm, and sets a basic time The molding machine controller 2 has a basic time data acquisition function unit Fo that registers and processes the time interval data Do as interval data Do, an actual time data acquisition function unit Fp that measures the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a specified shot when producing a molded product using the pulverized material mixed material Rm and acquires it as actual time data Dp, a pulverized material ratio calculation function unit Fa that calculates the pulverized material ratio Px in the pulverized material mixed material Rm based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts and the pulverized material mixed material plasticization time Tm, and an output processing function unit Fe that outputs and processes the obtained pulverized material ratio Px.

[0014] On the other hand, in the present invention, when the molding support method is carried out according to a preferred embodiment of the invention, the crushed material ratio Px can be calculated by Px=[(Tv-Tv) / (Ts-Tv)]×100[wt%] ([Equation 1]), where the crushed material ratio is Px [wt%], the crushed material mixed material plasticization time is Tm [seconds], the virgin material plasticization time is Tv [seconds], and the crushed material plasticization time is Ts [seconds]. In addition, the crushed material ratio Px can be calculated for each shot or for each shot at a predetermined interval and output processing is performed, and the crushed material ratio Px can be calculated by calculating the delay time Td from the crushed material mixed material plasticization time Tm to the molded product, including at least the capacity of the screw 3, and the crushed material ratio Px can be linked to the molded product based on this delay time Td. Furthermore, an upper limit value Pxu and / or a lower limit value Pxd can be set for the pulverized material ratio Px, and a quality determination process can be performed in which a molded product that is equal to or smaller than the upper limit value Pxu and / or equal to or larger than the lower limit value Pxd is determined to be a quality product.

[0015] On the other hand, when implementing the molding support device 1, the plasticization condition setting function unit Fs can include one or more setting items, such as the number of revolutions of the screw 3, the back pressure for the screw, the set temperature of the heating barrel, and the plasticization end position Xe of the screw. The molding machine controller 2 can be provided with a pass / fail judgment processing function unit Fj that sets an upper limit value Pxu and / or a lower limit value Pxd for the crushed material ratio Px obtained by the crushed material ratio calculation function unit Fa, and judges a molded product that is equal to or lower than the upper limit value Pxu and / or equal to or higher than the lower limit value Pxd as a pass / fail product. Furthermore, the molding machine controller 2 can be provided with a display 2d that displays the crushed material ratio Px numerically and / or graphically as the output processing function unit Fe, and the molding machine controller 2 can be provided with an output processing function unit Fe that judges a molded product that exceeds the upper limit value Pxu and / or is lower than the lower limit value Pxd as an inappropriate molded product and performs a predetermined output process including displaying an alarm on the display 2d. Effect of the Invention

[0016] According to the molding support method and device 1 for the pulverized material mixture Rm of the present invention, the following remarkable effects are obtained.

[0017] (1) The virgin material plasticization time Tv until the predetermined plasticization end position Xe by only the virgin material Rv and the pulverized material plasticization time Ts until the predetermined plasticization end position Xe under the plasticization condition by only the pulverized material Rs are measured and registered as basic time data Do, and the pulverized material mixed material plasticization time Tm until the plasticization end position Xe in a predetermined shot is measured during the production of a molded product by the pulverized material mixed material Rm to obtain the actual measured time data Dp, and the pulverized material ratio Px in the pulverized material mixed material Rm is calculated and output based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts, and the pulverized material mixed material plasticization time Tm, so that the mixing ratio Px of the pulverized material Rs in the actual molded product can be easily obtained with high accuracy and effectiveness. This makes it possible to eliminate, for example, the disadvantage that the quality cannot be guaranteed because the pulverized material Rs is too much, or the problem that the pulverized material Rs cannot be fully reused because the pulverized material Rs is too little.

[0018] (2) In a preferred embodiment, when calculating the pulverized material ratio Px using the molding support method, if the pulverized material ratio is Px [wt %], the pulverized material mixed material plasticization time is Tm [seconds], the virgin material plasticization time is Tv [seconds], and the pulverized material plasticization time is Ts [seconds], then Px can be calculated using a relatively simple calculation formula: [(Tv-Tv) / (Ts-Tv)] x 100 [wt %]. Therefore, an accurate pulverized material ratio Px can be obtained quickly and easily.

[0019] (3) In a preferred embodiment, when calculating the crushed material ratio Px, the crushed material ratio Px can be calculated by output processing for each shot or for each shot at a predetermined interval.Therefore, it is possible to obtain the crushed material ratio Px according to the purpose, for example, by calculating it for each shot when the crushed material Rs has a large variation, and by calculating it for each multiple shots when the crushed material Rs has a small variation, which provides excellent flexibility and convenience.

[0020] (4) In a preferred embodiment, when calculating the crushed material ratio Px, after the crushed material mixed material plasticization time Tm is calculated, the delay time Td until it is reflected in the molded product is calculated including at least the capacity of the screw 3, and the crushed material ratio Px and the molded product are linked based on this delay time Td. This makes it possible to match the crushed material ratio Px and the molded product based on it, thereby further improving the accuracy and reliability of the crushed material ratio Px.

[0021] (5) In a preferred embodiment, the molding machine controller 2 is provided with an upper limit value Pxu and / or a lower limit value Pxd for the crushed material ratio Px obtained by the crushed material ratio calculation function unit Fa, and a pass / fail judgment processing function unit Fj is provided which judges molded products that are below the upper limit value Pxu and / or above the lower limit value Pxd to be pass / fail as good products. This makes it possible to easily and accurately judge the pass / fail of molded products, thereby further improving the quality and reliability of the molded products.

[0022] (6) In a preferred embodiment, when configuring the plasticization condition setting function unit Fs, by including one or more setting items such as the rotation speed of the screw 3, the back pressure on the screw 3, the set temperature of the heating barrel, and the plasticization end position Xe of the screw 3, it becomes possible to set plasticization conditions at the same level as the actual production process, and therefore a rational and reliable crushed material ratio Px can be obtained.

[0023] (7) In a preferred embodiment, when configuring the output processing function unit Fe, a display 2d is provided which displays the crushed material ratio Px numerically and / or graphically, allowing the operator to easily check the crushed material ratio Px by visual means, thereby enabling the operator to quickly and reliably check the actual status of the crushed material ratio Px.

[0024] (8) In a preferred embodiment, when configuring the molding machine controller 2, an output processing function unit Fe is provided which determines that a molded product that exceeds the upper limit value Pxu and / or is below the lower limit value Pxd is an improper molded product and performs predetermined output processing including displaying an alarm on the display 2d. This makes it possible to easily and reliably know that an improper molded product has occurred, and therefore makes it possible to quickly take necessary error response measures, such as discarding the relevant molded product or changing the plasticization conditions. [Brief description of the drawings]

[0025] [Figure 1] A flowchart showing a basic time data acquisition process of a pulverized material mixing method according to a preferred embodiment of the present invention; [Diagram 2] A flowchart showing the procedure for acquiring actual time data during production in the molding support method; [Diagram 3] FIG. 2 is a diagram showing the mechanical structure of an injection molding machine capable of implementing the molding support method; [Figure 4] A block diagram of a processing system (control system) in an injection molding machine that can implement the molding support method. [Diagram 5] A graph showing the ratio of crushed material used in the molding support method versus the average plasticization time. [Figure 6]FIG. 2 is a graph showing the calculated value of the crushed material ratio with respect to the shot number when the molding support method is implemented; [Figure 7] FIG. 1 is a screen diagram showing an example of a display on a display provided in a molding support device for a pulverized material mixture according to a preferred embodiment of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Next, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0027] First, an outline of an injection molding machine M that can utilize the molding support method for a pulverized material mixture according to this embodiment will be described with reference to FIGS. 3 and 4. FIG.

[0028] 3 shows an injection molding machine M, in particular an injection unit Mi without a mold clamping device. In the injection unit Mi, reference numeral 6 denotes a heating barrel, and a nozzle 6n is provided at the front end of the heating barrel 6 via a head portion 6s. The nozzle 6n has a function of injecting the molten resin inside the heating barrel 6 into a mold C shown by an imaginary line.

[0029] On the other hand, a hopper 6h is provided at the upper part near the rear end of the heating cylinder 6. The lower end opening of this hopper 6h is connected to the inside of the heating cylinder 6 through a material drop port 6d formed through the heating cylinder 6. As a result, the pulverized material mixture Rm in the hopper 6h is supplied to the inside of the heating cylinder 6 through the material drop port 6d. The pulverized material mixture Rm is a mixed resin material obtained by mixing virgin material Rv and pulverized material Rs at a predetermined ratio Px.

[0030] In FIG. 3, 7h denotes a heater attached to the outer peripheral surface of the hopper 6h to heat the resin material Rm contained inside the hopper 6h, and 8j denotes a water jacket formed on the heating cylinder 6 around the material drop port 6d. The heater 7h is connected to a power supply circuit 8e in the temperature control driver 8d, and the water jacket 8j is connected to a temperature-controlled water circulation circuit 8w in the temperature control driver 8d. The temperature-controlled water circulation circuit 8w can control the temperature (heat or cool) of the resin material Rm passing through the material drop port 6d by circulating a temperature-controlled aqueous medium (hot water or cooling water) through the water jacket 8j. Furthermore, the power supply circuit 8e and the temperature-controlled water circulation circuit 8w are each connected to the controller body 20. As a result, the controller body 20 gives the temperature control driver 8d a control command for the power supply circuit 8e and the temperature-controlled water circulation circuit 8w.

[0031] The screw 3 is loaded inside the heating cylinder 6 so that it can rotate and move forward and backward. The surface of the screw is coated with a predetermined surface material (metal) in consideration of durability. The screw 3 has a metering zone Zm, a compression zone Zc, and a feed zone Zf from the front to the rear. Meanwhile, the rear end of the screw 3 is connected to a screw drive unit 13. The screw drive unit 13 includes a screw rotation mechanism 13r that rotates the screw 3 and a screw advance and retreat mechanism 13m that advances and retreats the screw 3. In the illustrated example, the drive system of the screw rotation mechanism 13r and the screw advance and retreat mechanism 13m is an electric system using an electric motor, but may be a hydraulic system using a hydraulic circuit, and the drive system is not limited. The screw rotation mechanism 13r and the screw advance and retreat mechanism 13m are connected to a power supply driver 13d, and the power supply driver 13d is connected to the controller body 20. As a result, control commands for the screw rotation mechanism 13r and the screw advance / retract mechanism 13m are given to the power supply driver 13d from the controller body 20. In addition, physical quantities such as the speed and position of the screw 3 are detected by a speed sensor, a position sensor, and the like (not shown), and the detection signals are given to the power supply driver 13d.

[0032] Furthermore, the heating cylinder 6 has, from the front to the rear, a heating cylinder front part 6f, a heating cylinder middle part 6m, and a heating cylinder rear part 6r, and a front heating part 7f, a middle heating part 7m, and a rear heating part 7r are respectively attached to the outer circumferential surface of each part 6f, 6m, and 6r. Similarly, a head heating part 7s is attached to the outer circumferential surface of the head part 6s, and a nozzle heating part 7n is attached to the outer circumferential surface of the nozzle 6n. Each of these heating parts 7f, 7m, 7r, 7s, and 7n can be composed of a band heater or the like. Therefore, the nozzle heating part 7n, the head heating part 7s, the front heating part 7f, the middle heating part 7m, and the rear heating part 7r constitute the heating group part 7 (FIG. 4). The heating group part 7 is connected to a heater driver 7d, and the heater driver 7d is connected to the controller main body 20. As a result, control commands for each heating section 7f, 7m, 7r, 7s, and 7n are given from the controller main body 20 to the heater driver 7d, and the heating temperature is detected by a temperature sensor (such as a thermocouple) not shown in the figure, and this detection signal is given to the heater driver 7d.

[0033] 4 shows the molding machine controller 2 that controls the entire injection molding machine M. The molding machine controller 2 includes the above-mentioned controller body 20 having a computer function with built-in hardware such as a CPU and an internal memory 20m, and the controller body 20 is connected to a display 2d. The display 2d includes a display unit 2dd that displays necessary information, and is provided with a touch panel 2dt, and various input operations such as input, setting, and selection can be performed using the touch panel 2dt. The controller body 20 is also connected to a driver group 24 that drives (operates) various actuators. The driver group 24 includes a temperature control driver 8d including the power supply circuit 8e and the temperature control water circulation circuit 8w described above, a power supply driver 13d, and a heater driver 7d shown in FIG. 3.

[0034] Therefore, the molding machine controller 2 includes an HMI control system and a PLC control system, and the internal memory 20m stores a PLC program and an HMI program. The PLC program executes the sequence operations of various processes in the injection molding machine M and the monitoring of the injection molding machine M, while the HMI program executes the setting and display of operation parameters of the injection molding machine M and the display of operation monitoring data of the injection molding machine M. In addition, the internal memory 20m stores a flow analysis processing program as well as a pulverized material processing program Pi.

[0035] In addition, the internal memory 20m attached to the controller main body 20 stores an application program for realizing the molding support method according to this embodiment in relation to the present invention, that is, a pulverized material support processing program Pi, and also stores a flow analysis processing program Ps. The flow analysis processing program Ps can utilize the molding support device for an injection molding machine already proposed by the applicant (see JP 2020-1183 A and JP 2021-121959 A). That is, the estimation processing function can numerically estimate accurate information (data) on the melting state of the resin material.

[0036] As a result, the molding machine controller 2 is a main functional part related to the molding support device 1, and includes a plasticization condition setting functional part Fs for setting predetermined plasticization conditions, a basic time data acquisition functional part Fo for measuring the virgin material plasticization time Tv up to the predetermined plasticization end position Xe under the plasticization conditions using only the virgin material Rv used in the pulverized material mixed material Rm and the pulverized material plasticization time Ts up to the predetermined plasticization end position Xe under the plasticization conditions using only the pulverized material Rs used in the pulverized material mixed material Rm, and registering and processing the same as basic time data Do, and a production of molded products using the pulverized material mixed material Rm. The system is equipped with an actual time data acquisition function unit Fp that measures the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a specified shot at a time and acquires it as actual time data Dp, a pulverized material ratio calculation function unit Fa that calculates the pulverized material ratio Px in the pulverized material mixed material Rm based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts and the pulverized material mixed material plasticization time Tm, and an output processing function unit Fe that outputs and processes the obtained pulverized material ratio Px, and the molding support method for the pulverized material mixed material Rm of this embodiment is executed based on the above-mentioned pulverized material support processing program Pi.

[0037] Next, the principle of the molding support method (molding support device 1) according to this embodiment will be described with reference to FIGS.

[0038] Usually, in a production factory or the like that uses an injection molding machine M, unnecessary molded objects such as spools, runners, and molded defective products are generated after molding. Therefore, in particular when the mechanical strength and quality of the molded products are not required to be high, not only virgin materials such as pellets are often used as the resin material for molding, but also the unnecessary molded objects described above are often reused.

[0039] When the unnecessary moldings are reused, they are finely crushed to obtain crushed material, which is mixed with virgin material at a predetermined ratio to be used as crushed material mixture. Crushed material is generally used by crushing the unnecessary moldings with a crusher, but the shape and size of the crushed material Rs obtained are random. As a result, during plasticization, voids are generated in the molten resin in the heating cylinder 6, which causes insufficient melting of the resin and variation in the melting state, which tends to lead to a decrease in molding quality and even an increase in molding defects, making it difficult to perform stable molding and production.

[0040] Specifically, even if the crushed material ratio Px is set to 30 wt% (crushed material: 30 wt%, virgin material: 70 wt%) as a molding condition during production, the content of crushed material Rs in the actual molded product varies, resulting in problems such as, for example, there being too much crushed material Rs and the quality cannot be guaranteed, or there being too little crushed material Rs and the crushed material Rs cannot be fully reused.

[0041] For this reason, in the present invention, the properties of the pulverized material Rs may affect the plasticization time due to voids in the resin that occur in the heating barrel 6 during plasticization or due to its behavior relative to the heating barrel 6 and the screw 3, that is, the more pulverized material Rs there is, the longer the plasticization time will be, and the less pulverized material Rs there is, the shorter the plasticization time will be, and we have focused on this possibility and conducted verification.

[0042] Figure 5 shows the characteristics of the average plasticization time [seconds] when changing the crushed material ratio Px, that is, the mixing ratio of crushed material Rs [wt%] to virgin material Rv [wt%]. Specifically, the results of measuring the average plasticization time [seconds] of each of the crushed material mixed material Rm1 with virgin material Rv of 100 [wt%] and crushed material Rs of 0 [wt%], crushed material mixed material Rm2 with virgin material Rv of 70 [wt%] and crushed material Rs of 30 [wt%], crushed material mixed material Rm3 with virgin material Rv of 30 [wt%] and crushed material Rs of 70 [wt%], and crushed material mixed material Rm4 with virgin material Rv of 0 [wt%] and crushed material Rs of 100 [wt%] are shown.

[0043] As is clear from Figure 5, it can be confirmed that there is a clear correlation between the crushed material ratio (mixing ratio) Px and the average plasticization time [seconds], and the plasticization time changes almost linearly with respect to the amount of crushed material. In other words, if the plasticization time is actually measured, the crushed material ratio Px corresponding to the actually measured time can be estimated.

[0044] Therefore, the estimation formula (calculation formula) is as follows: the crushed material ratio is Px [wt%], the crushed material mixed material plasticization time is Tm [seconds], the virgin material plasticization time is Tv [seconds], and the crushed material plasticization time is Ts [seconds]. Px=[(Tv-Tv) / (Ts-Tv)]×100[wt%] The calculation process using this formula can be executed by the crushing material ratio calculation function Fa. In this way, the crushing material ratio Px can be calculated using a relatively simple formula, so that the accurate crushing material ratio Px can be obtained quickly and easily.

[0045] FIG. 6 shows a graph of the variation of the pulverized material ratio calculation value with respect to the shot number. Although FIG. 6 shows a graph of the variation obtained for each shot, in actual production, it may be obtained for each shot at a predetermined interval. In this way, the pulverized material ratio Px can be obtained for any shot or shot interval, so that it is possible to obtain it according to the purpose, for example, for the pulverized material Rs with large variation, it is obtained for each shot, and for the pulverized material Rs with small variation, it is obtained for each multiple shots, and it is excellent in flexibility and convenience. In FIG. 6, two types of pulverized material mixed materials Rm set to 30 [wt%] and 70 [wt%] as the pulverized material ratio Px (set ratio) were used. As is clear from FIG. 6, it can be confirmed that there is variation for each shot.

[0046] Therefore, for example, in the variation graph of 30 [wt%] shown in Fig. 6, an upper limit value Pxu and a lower limit value Pxd can be set, and a pass / fail judgment can be performed by the pass / fail judgment processing function unit Fj provided in the molding machine controller 2. That is, in the molding machine controller 2, for the pulverized material ratio Px obtained by the pulverized material ratio calculation function unit Fa, one of the upper limit value Pxu and the lower limit value Pxd, or both the upper limit value Pxu and the lower limit value Pxd can be set, and a molded product that is less than the upper limit value Pxu and / or more than the lower limit value Pxd can be judged as a pass / fail product. By providing such a pass / fail judgment processing function unit Fj, a pass / fail judgment for a molded product can be easily and accurately performed, and the quality assurance and reliability assurance for the molded product can be further improved.

[0047] Furthermore, since the molding machine controller 2 has an output processing function unit Fe, the display 2d can be provided with a display screen Vm, an example of which is shown in FIG. 7, to display information related to the crushed material ratio Px in real time. The example display screen Vm has a graphic display unit Vmg at the top that graphically displays the crushed material ratio Px, and displays the crushed material ratio Px in the form of a horizontal bar graph, and indicates the upper limit value Pxu and the lower limit value Pxd with triangular pointer marks. FIG. 7 shows a state in which the crushed material ratio Px is 30 [wt%], and also shows a state in which the upper limit value Pxu is displayed at 35 [wt%] and the lower limit value Pxd is displayed at 25 [wt%]. In addition, below the graphic display unit Vmg, a numerical display unit Vmn is provided for the measured crushed material ratio Px, the set upper limit value Pxu, and the set lower limit value Pxd, and an alarm display unit Vma is provided at the bottom below the numerical display unit Vmn. This alarm display unit Vma has a normal indicator light 4s at the center, an upper limit alarm indicator light 4u to the right of it, and a lower limit alarm indicator light 4d to the left of the normal indicator light 4s. Figure 7 shows the state where the normal indicator light 4s is lit.

[0048] On this display screen Vm, the crushed material ratio Px is displayed in real time by the graphic display section Vmg and the numerical display section Vmn, and when the ratio is within the upper limit value Pxu and the lower limit value Pxd set in the numerical display section Vmn, the normal indicator light 4s is turned on, as shown in Fig. 7. On the other hand, when the ratio is outside the upper limit value Pxu or the lower limit value Pxd, the corresponding upper limit alarm indicator light 4u or lower limit alarm indicator light 4d can be turned on.

[0049] In this way, when configuring the output processing function unit Fe, if a display screen Vm having a numerical display section and / or a graphic display section for the crushed material ratio Px is provided on the display 2d, the operator can easily check the crushed material ratio Px by visual means, and therefore the actual situation of the crushed material ratio Px can be quickly and reliably confirmed.

[0050] Furthermore, if a molded product that exceeds the upper limit value Pxu and / or is below the lower limit value Pxd is judged to be an improper molded product on the display screen Vm of the output processing function unit Fe, and an alarm display unit is provided on the display 2d to perform a specified output processing, it will be possible to easily and reliably know that an improper molded product has occurred, and therefore it will be possible to quickly take the necessary error response measures, such as discarding the relevant molded product or changing the plasticization conditions.

[0051] In addition, when calculating the pulverized material ratio Px, after calculating the pulverized material mixed material plasticization time Tm, the delay time Td until it is reflected in the molded product can be calculated, including at least the capacity of the screw 3, and the pulverized material ratio Px and the molded product can be linked based on this delay time Td. In this way, the molded product based on the pulverized material ratio Px can be matched, so that the accuracy and reliability of the pulverized material ratio Px can be further improved.

[0052] Next, the operation of the molding support device 1 including the molding support method for the pulverized material mixture Rm according to this embodiment will be described according to the flowcharts shown in FIGS. 1 and 2 with reference to the various figures.

[0053] First, a preparatory process prior to carrying out a production process using the molding support method according to this embodiment will be described with reference to the flowchart shown in FIG.

[0054] First, the basic time data acquisition function Fo provided in the molding machine controller 2 performs an acquisition process of the virgin material plasticization time Tv for the virgin material Rv related to a predetermined resin material. In this case, the virgin material Rv such as pellets is prepared (step S1). In addition, the plasticization condition setting function Fs in the molding machine controller 2 sets predetermined plasticization conditions (step S2). The specific plasticization conditions can include one or more setting items such as the rotation speed of the screw 3, the back pressure for the screw 3, the set temperature of the heating barrel, and the plasticization end position Xe of the screw 3. If such setting items are included, it becomes possible to set the plasticization conditions at the same level as the actual production process, so that a rational and reliable crushed material ratio Px can be obtained.

[0055] Then, only the virgin material Rv, i.e., 100% virgin material Rv, is charged into the hopper 6h (step S3). When preparation for the plasticization process is completed, the plasticization process is executed based on the set plasticization conditions (step S4). In the plasticization process, the screw 3 is set to the most forward position (or a predetermined set position), and the plasticization process is performed from this position. In the plasticization process, the screw 3 rotates, and the plasticized molten resin is accumulated in front of the screw 3, and the screw 3 gradually retreats in response to this. When the screw 3 retreats and reaches the set predetermined plasticization end position Xe, the plasticization process is terminated (step S5). In addition, when the plasticization process is terminated, the virgin material plasticization time Tv from the start of the plasticization process to the time when the plasticization end position Xe is reached is captured (step S6).

[0056] On the other hand, the pulverized material plasticization time Ts is acquired by performing the same process. In this case, only the pulverized material Rs is prepared (step S7). The pulverized material Rs is obtained by pulverizing unnecessary moldings such as spools, runners, and molding defects generated after the production (molding) of moldings using the above-mentioned specified resin material using a crusher (not shown), and the size and shape of the obtained pulverized material Rs are random. In addition, the plasticization condition setting function unit Fs sets a specified plasticization condition (step S8). In this case, the same conditions as the plasticization conditions used in the acquisition process of the virgin material plasticization time Tv are basically set.

[0057] Then, only the crushed material Rs, i.e., 100% crushed material Rs, is charged into the hopper 6h (step S9). Once preparation for the plasticization process is complete, the plasticization process is carried out based on the set plasticization conditions (step S10). In the plasticization process, the screw 3 is set to the most forward position (or a predetermined set position), and the plasticization process is carried out from this position. As a result, as in the case of the virgin material Rv, the screw 3 retreats, and when the set predetermined plasticization end position Xe is reached, the plasticization process is ended (step S11). Furthermore, upon the end of the plasticization process, the crushed material plasticization time Ts from the start of the plasticization process to the time when the plasticization end position Xe is reached is captured (step S12).

[0058] The virgin material plasticization time Tv and the pulverized material plasticization time Ts are obtained by the above-mentioned import process, and are registered in the database of the internal memory 20m by the basic time data acquisition function unit Fo of the molding machine controller 2 (step S13). FIG. 4 shows an example of the database, a database DB1 of the pulverized material Rsa, a database DB2 of the pulverized material Rsb, etc. This completes the acquisition of basic time data related to the predetermined resin material, so if there is another resin material, the basic time data can be acquired by a similar processing procedure (step S14). Furthermore, even if the virgin material plasticization time Tv and the pulverized material plasticization time Ts are changed by changing the plasticization conditions, the basic time data can be acquired by a similar processing procedure, and the registered items in the database can be updated (step S15). Then, when the processing of the preparation stage before the production process based on the flowchart of FIG. 1 is completed, the predetermined production process is carried out (step SP).

[0059] Next, a production process using the molding support method according to this embodiment will be described with reference to the flowchart shown in FIG.

[0060] Assume that a production process is being carried out using a pulverized material mixed material Rm, which is a mixture of virgin material Rv and pulverized material Rs made of a specific resin material, by an injection molding machine M (step SP). Note that the pulverized material mixed material Rm as a molding condition can be preset by the pulverized material weight input section 34s and the virgin material weight input section 34v of the material input section 34 shown in FIG.

[0061] Meanwhile, during the production process, the molding machine controller 2 monitors the molding cycle of the molding process (step S21). Then, when the molding cycle shifts to the plasticization process and the plasticization end position Xe is confirmed, the actual measured time data of the plasticization time in that shot, that is, the actual measured time data Dp is acquired by the actual measured time data acquisition function Fp (steps S22, S23, S24).

[0062] When the molding machine controller 2 obtains the actual measurement time data Dp, the pulverized material ratio calculation function unit Fa performs an estimation process (calculation process) of the pulverized material ratio Px (step S25). Specifically, the molding machine controller 2 uses the virgin material plasticization time Tv and the pulverized material plasticization time Ts, which are the basic time data Do registered in the database, and the pulverized material mixed material plasticization time Tm, which is the actual measurement time data Dp, to obtain the pulverized material ratio Px by Px=[(Tv-Tv) / (Ts-Tv)]×100 [wt%].

[0063] The obtained pulverized material ratio Px is output by the output processing function unit Fe of the molding machine controller 2. Specifically, the obtained pulverized material ratio Px is displayed on the display screen Vm of FIG. 7 using the graphic display unit Vmg and the numerical display unit Vmn (step S26). After that, if the next shot continues, the same monitoring process is continued (steps S27, S21, ...).

[0064] The molding machine controller 2 also performs a judgment process by the pass / fail judgment process function unit Fj (step S28). That is, the judgment process is performed based on the set upper limit value Pxu and lower limit value Pxd for the crushed material ratio Px. As a result, when the crushed material ratio Px is equal to or less than the upper limit value Pxu or equal to or more than the lower limit value Pxd, it is judged to be normal, and the normal indicator lamp 4s is turned on. On the other hand, when the crushed material ratio Px exceeds the upper limit value Pxu or is less than the lower limit value Pxd, the obtained molded product is judged to be an inappropriate molded product, and the necessary error response process is performed by the alarm display unit Vma provided on the display 2d (steps S9, S30).

[0065] Thus, according to the molding support method (molding support device 1) of the pulverized material mixed material of this embodiment, as a basic configuration, the virgin material plasticization time Tv up to a predetermined plasticization end position Xe using only the virgin material Rv and the pulverized material plasticization time Ts up to a predetermined plasticization end position Xe under plasticization conditions using only the pulverized material Rs are measured and registered as basic time data Do, and the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a predetermined shot is measured during the production of a molded product using the pulverized material mixed material Rm to obtain actual time data Dp, and the pulverized material ratio Px in the pulverized material mixed material Rm is calculated and output based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts and the pulverized material mixed material plasticization time Tm, so that a highly accurate and effective mixing ratio Px of the pulverized material Rs in the actual molded product can be easily obtained. This makes it possible to eliminate, for example, the drawback that there is a risk that the quality cannot be guaranteed because there is too much pulverized material Rs, or the inconvenience that the pulverized material Rs cannot be fully reused because there is too little pulverized material Rs.

[0066] Although the preferred embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the detailed configuration, shape, material, ingredients, quantities, values, methods, etc. can be changed, added, or deleted as desired without departing from the gist of the present invention.

[0067] For example, the plasticization condition setting function unit Fs has been shown to include one or more setting items, such as the rotation speed of the screw 3, the back pressure for the screw 3, the set temperature of the heating barrel 6, and the plasticization end position Xe of the screw 3, but other plasticization conditions may be included. In addition, the case where both the upper limit value Pxu and the lower limit value Pxd are set for the crushed material ratio Px has been shown, but this does not exclude the case where only one of the upper limit value Pxu and the lower limit value Pxd is set, and in particular, only the upper limit value Pxu may be set. Furthermore, the upper limit value Pxu and the lower limit value Pxd may each be set in multiple stages. For example, the upper limit value Pxu may be set to a first upper limit value (preliminary upper limit value) and a second upper limit value (main upper limit value), etc., to perform a more detailed judgment, such as issuing a preliminary alarm. On the other hand, although the virgin material plasticization time Tv and the pulverized material plasticization time Ts are registered as basic time data Do, they may be registered as an arithmetic formula for calculating the pulverized material ratio Px, and the pulverized material ratio Px may be calculated from this arithmetic formula and the actual time data Dp. Also, the pass / fail judgment processing function unit Fj provided in the molding machine controller 2 is not an essential component and does not necessarily have to be provided. Furthermore, it is desirable to provide an alarm display provided in the output processing function unit Fe, but it is not necessarily a required component. [Industrial Applicability]

[0068] The present invention can be used as a molding support method and device for a pulverized material mixture in various injection molding machines that plasticize and injection mold a pulverized material mixture made by mixing virgin material and pulverized material in a predetermined ratio. [Explanation of symbols]

[0069] 1: Molding support device, 2: Molding machine controller, 2d: Display, 3: Screw, Rm: Crushed material mixed material, Rv: Virgin material, Rs: Crushed material, Px: Crushed material ratio, Fs: Plasticization condition setting function, Fo: Basic time data acquisition function, Fp: Actual time data acquisition function, Fa: Crushed material ratio calculation function, Fe: Output processing function, Fj: Good / bad judgment processing function, Pxu: Upper limit, Pxd: Lower limit, Vmn: Numerical display, Vmg: Graphic display, Vma: Alarm display

Claims

1. A method for supporting the molding of crushed material mixed materials in an injection molding machine, which performs injection molding by plasticizing a crushed material mixed material in which virgin material and crushed material are mixed in a predetermined ratio, comprising: measuring in advance a virgin material plasticization time up to a predetermined plasticization end position under predetermined plasticization conditions using only the virgin material used in the crushed material mixed material, and a crushed material plasticization time up to a predetermined plasticization end position under the plasticization conditions using only the crushed material used in the crushed material mixed material, and registering and processing these as basic time data; and during the production of a molded product using the crushed material mixed material, measuring the crushed material mixed material plasticization time up to the plasticization end position in a predetermined shot to obtain actual time data, and calculating and outputting the crushed material ratio in the crushed material mixed material based on the virgin material plasticization time, the crushed material plasticization time, and the crushed material mixed material plasticization time.

2. The forming support method for pulverized mixed material according to claim 1, characterized in that the pulverized material ratio is calculated by the following calculation formula, where the pulverized material ratio is Pm [wt %], the pulverized mixed material plasticization time is Tm [seconds], the virgin material plasticization time is Tv [seconds], and the pulverized material plasticization time is Ts [seconds]. Pm=[(Tm-Tv) / (Ts-Tv)]×100 [wt%]

3. 2. The molding support method for a pulverized material mixture according to claim 1, wherein the pulverized material ratio is determined for each shot or for each shot at a predetermined interval, and outputted.

4. The molding support method for pulverized mixed material described in claim 1, characterized in that the pulverized material ratio is calculated by calculating the delay time from when the pulverized mixed material plasticization time is determined until it is reflected in the molded product, including at least the screw capacity, and the pulverized material ratio is linked to the molded product based on this delay time.

5. The molding support method for pulverized mixed material as described in claim 1, characterized in that an upper limit and / or a lower limit are set for the pulverized material ratio, and a quality judgment process is performed in which a molded product that is below the upper limit and / or above the lower limit is judged to be a good product.

6. A molding support device for a pulverized mixed material of an injection molding machine that performs injection molding by plasticizing a pulverized mixed material obtained by mixing virgin material and pulverized material at a predetermined ratio, the molding support device comprising: a plasticization condition setting function unit that sets predetermined plasticization conditions; a basic time data register that measures a virgin material plasticization time to a predetermined plasticization end position under the plasticization conditions by only the virgin material used in the pulverized mixed material, and a basic time data register that registers and processes the basic time data. A molding support device for pulverized material mixed material, characterized in that it is equipped with a molding machine controller having a data acquisition function unit, an actual time data acquisition function unit that measures the plasticization time of the pulverized material mixed material up to the plasticization end position in a specified shot when producing a molded product from the pulverized material mixed material and acquires it as actual time data, a pulverized material ratio calculation function unit that calculates the pulverized material ratio in the pulverized material mixed material based on the virgin material plasticization time, the pulverized material plasticization time, and the pulverized material mixed material plasticization time, and an output processing function unit that outputs and processes the obtained pulverized material ratio.

7. The molding support device for crushed mixed material as described in claim 6, characterized in that the plasticization condition setting function unit includes one or more setting items: the screw rotation speed, the back pressure for the screw, the set temperature of the heating barrel, and the plasticization end position of the screw.

8. The molding machine controller is characterized in that it is equipped with an upper limit and / or lower limit for the crushed material ratio obtained by the crushed material ratio calculation function unit, and a pass / fail judgment processing function unit that judges molded products that are below the upper limit and / or above the lower limit as pass / fail.The molding support device for crushed material mixed material as described in claim 6.

9. The molding support device for a pulverized mixed material according to claim 6, characterized in that the molding machine controller is provided with a display for displaying the pulverized material ratio numerically and / or graphically as the output processing function unit.

10. The molding support device for crushed mixed material as described in claim 8, characterized in that the molding machine controller is equipped with an output processing function unit that determines that a molded product that exceeds an upper limit value and / or is below a lower limit value is an inappropriate molded product and performs a predetermined output processing including displaying an alarm on a display.

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