Injection molding system

Abstract

To provide an injection molding system for preventing the number of produced molded products from becoming less than a predetermined planned production number even if some molded products are discarded.SOLUTION: An injection molding system includes an injection molding machine that molds molded products by injecting a plasticized material into a cavity partitioned by a fixed mold and a movable mold, a pallet on which the molded products are placed, a disposal section where the molded products are discarded, a robot that transports the molded products molded by the injection molding machine to the pallet or the disposal section, and a control section that controls the injection molding machine and the robot. The control section controls the robot to perform, for each molded product, a first transport operation of placing the molded product on the pallet or a second transport operation of discarding the molded product in the disposal section, and controls the injection molding machine to mold molded products in a number equal to or greater than the planned production number, which is a predetermined planned production number plus the discard number, which is the number of molded products discarded in the disposal section.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present disclosure relates to an injection molding system. [Background technology]

[0002] For example, Patent Document 1 discloses a molded product removal device that discards a predetermined number of molded products successively removed from a molding machine if the removal interval by the removal section of the molded products molded by the molding machine is longer than a predetermined interval, because there is a possibility that the quality of the molded products does not meet the standard quality. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2022-44895 Summary of the Invention [Problem to be solved by the invention]

[0004] If the molded products are discarded, the number of molded products produced becomes less than the predetermined planned production number. [Means for solving the problem]

[0005] According to a first aspect of the present disclosure, there is provided an injection molding system, which includes an injection molding machine that injects a plasticized material into a cavity partitioned by a fixed mold and a movable mold to mold a molded product, a pallet on which the molded product is placed, a disposal section in which the molded product is discarded, a robot that transports the molded product molded by the injection molding machine to the pallet or the disposal section, and a control section that controls the injection molding machine and the robot, and the control section controls the robot to perform, for each of the molded products, a first transport operation of placing the molded product on the pallet or a second transport operation of discarding the molded product in the disposal section, and controls the injection molding machine to mold the molded products in a number equal to or greater than the planned production number, which is a predetermined number, plus the disposal number, which is the number of the molded products discarded in the disposal section. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a perspective view of an injection molding system. [Diagram 2] FIG. 1 is a top view of an injection molding system. [Diagram 3] FIG. 2 is a perspective view of the tip portion of the robot arm. [Figure 4] FIG. 4 is an explanatory diagram of a flow path provided in the first unit. [Diagram 5] 1 is a process diagram of a molded product production process performed by an injection molding system. [Figure 6] 1 is a process diagram of a conveying process performed by the injection molding system. [Figure 7] FIG. 11 is a process diagram of a molded product production process in a second embodiment. [Figure 8] FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] A. First embodiment: FIG. 1 is a perspective view of an injection molding system 10. FIG. 2 is a top view of the injection molding system 10. FIG. 1 and FIG. 2 show arrows representing mutually orthogonal X, Y, and Z directions. The X and Y directions are parallel to a horizontal plane. The Z direction is parallel to a vertical direction. The X, Y, and Z directions in FIG. 1 and FIG. 2 and the X, Y, and Z directions in other figures indicate the same direction. When specifying a direction, positive and negative signs are used in combination to indicate the direction, with the positive direction indicated by the arrow being "+" and the negative direction opposite to the direction indicated by the arrow being "-".

[0008] The injection molding system 10 includes a main unit 20 in which an injection molding machine 120 for molding a molded product is disposed, and an option unit 30 in which peripheral devices are disposed. The option unit 30 is provided on the main unit 20 so as to be detachable therefrom.

[0009] The option unit 30 includes a first unit 31 and a second unit 32. The first unit 31 is disposed adjacent to the main unit 20 on the +X direction side of the main unit 20. The second unit 32 is disposed adjacent to the main unit 20 on the -X direction side of the main unit 20. The main unit 20 and each option unit 30 each have a box-shaped housing, and devices, members, etc. are disposed on or inside each housing.

[0010] The main unit 20 includes a first housing 110, an injection molding machine 120, a take-out device 130, a transport device 140, a control unit 150, and a tablet terminal 160. The injection molding machine 120, the take-out device 130, and the transport device 140 are disposed on the upper part of the first housing 110. The control unit 150 is accommodated inside the first housing 110. The tablet terminal 160 is detachably attached to a side surface of the first housing 110. A cover (not shown) that covers the injection molding machine 120, the take-out device 130, and the transport device 140 is attached to the upper part of the first housing 110.

[0011] The injection molding machine 120 is configured so that a molding die 121 can be attached thereto. The molding die 121 is composed of a fixed die 122 and a movable die 123. The fixed die 122 and the movable die 123 define a cavity, which is a space corresponding to the shape of the molded product. Specifically, by clamping the fixed die 122 and the movable die 123, a cavity having a shape corresponding to the irregularities provided on the fixed die 122 and the movable die 123 is defined between the fixed die 122 and the movable die 123. The molding die 121 may be made of metal, resin, or ceramic. The metallic molding die 121 is also called a metal mold.

[0012] The injection molding machine 120 includes an injection unit 124 and a clamping unit 125. The injection unit 124 plasticizes the material supplied from the supply device 320 described later to generate a plasticized material, and injects the generated plasticized material into the cavity of the mold 121. "Plasticization" is a concept that includes melting, and refers to changing a solid into a state having fluidity. Specifically, in the case of a material in which glass transition occurs, plasticization refers to raising the temperature of the material to the glass transition point or higher. In the case of a material in which glass transition does not occur, plasticization refers to raising the temperature of the material to the melting point or higher. Hereinafter, the injection of the plasticized material into the cavity of the mold 121 is also referred to as a shot. The clamping unit 125 opens and closes the mold 121 attached to the injection molding machine 120. The injection unit 124 and the clamping unit 125 are arranged horizontally on the first housing 110.

[0013] The removal device 130 is a device that removes the molded product molded by the injection molding machine 120 from the injection molding machine 120. The removal device 130 moves the molded product removed from the injection molding machine 120 to the conveying device 140 and places it on the conveying device 140.

[0014] The transport device 140 transports the molded product removed by the removal device 130 from the end on the -X direction side to the end on the +X direction side of the transport device 140. In the process of transporting the molded product, the transport device 140 cuts off the gate portion and runner remaining in the molded product.

[0015] The control unit 150 controls the injection molding machine 120 and each peripheral device disposed in the main unit 20 and the option unit 30. The control unit 150 is configured with a PLC (Programmable Logic Controller). The control unit 150 is programmed in a language such as ladder programming language to control the coordinated operations of the injection molding machine 120 and each peripheral device.

[0016] The tablet terminal 160 displays various information related to the operation of the injection molding machine 120 and peripheral devices, and accepts operations from the user.

[0017] The first unit 31 includes a second housing 210, a robot 220, an inspection device 230, a stacking mechanism 240, and a disposal unit 250. The robot 220, the inspection device 230, and the disposal unit 250 are disposed on the upper part of the second housing 210. The stacking mechanism 240 is accommodated inside the second housing 210 so that a part of the stacking mechanism 240 protrudes from the upper part of the second housing 210. A cover (not shown) is attached to the upper part of the second housing 210 to cover the robot 220, the inspection device 230, the stacking mechanism 240, and the disposal unit 250. The first unit 31 further includes a suction blower 260, an ionizer 270, and a pressure detector 280 (not shown). The suction blower 260, the ionizer 270, and the pressure detector 280 are accommodated inside the second housing 210.

[0018] The robot 220 is a device that transports molded products. The robot 220 is configured as a SCARA robot. The robot 220 holds the molded product transported by the transport device 140 to the end of the transport device 140 on the +X direction side, and transports the molded product to the inspection device 230, the pallet PL arranged in the stacking mechanism 240, or the disposal section 250. The robot 220 also transports the molded product that has been inspected by the inspection device 230 to the pallet PL or the disposal section 250. The robot 220 is not limited to a SCARA robot, and may be configured as a vertical articulated robot having multiple axes. The robot 220 includes a holding section 221 and a detection section 226.

[0019] FIG. 3 is a perspective view of the tip of the arm of the robot 220. The holding unit 221 is provided on the bottom surface of a holding member 222 having a substantially rectangular parallelepiped shape attached to the tip of the arm of the robot 220. In the example shown in FIG. 3, the robot 220 is provided with six holding units 221. The holding unit 221 holds the molded product when the robot 220 transports the molded product. The bottom surface of the holding unit 221 is also called a contact surface 223. The contact surface 223 is a surface that comes into contact with the molded product when the holding unit 221 holds the molded product. The contact surface 223 is provided with an opening 224 that communicates with a flow path 290 described later. The robot 220 may be provided with one or more and five or less holding units 221, or may be provided with seven or more holding units 221. The robot 220 may hold the molded products one by one, or may hold multiple molded products at the same time.

[0020] 1 and 2 detects the number of molded products placed on the pallet PL by capturing an image of the surface of the pallet PL. The detection unit 226 is, for example, a camera.

[0021] The inspection device 230 inspects the molded product molded by the injection molding machine 120. The inspection device 230 includes an inspection table 231 on which the molded product is placed, and a camera 232 that captures an image of the molded product placed on the inspection table 231. The inspection device 230 inspects the appearance of the molded product based on the image captured by the camera 232. The inspection device 230 judges whether the molded product is good or defective based on the difference between the shape of the molded product and the shape of a reference molded product previously stored in the control unit 150. The inspection device 230 transmits the inspection result of the molded product to the control unit 150. The inspection device 230 may inspect the molded products one by one, or may inspect multiple molded products simultaneously.

[0022] The stacking mechanism 240 is a mechanism for stacking pallets PL on which molded products are placed. The stacking mechanism 240 includes a first arrangement section 241 and a second arrangement section 242. The pallets PL are arranged in each of the first arrangement section 241 and the second arrangement section 242.

[0023] The first arrangement section 241 carries a pallet PL on which a plurality of molded products inspected by the inspection device 230 are placed. The robot 220 transports the molded products to the pallet PL carried on the first arrangement section 241. When a predetermined number of molded products are placed on the pallet PL, the first arrangement section 241 lowers the pallet PL into the inside of the second housing 210. The second arrangement section 242 slides and moves the pallet PL carried on the top of the second arrangement section 242 onto the lowered pallet PL of the first arrangement section 241. A plurality of pallets PL are stacked vertically on the second arrangement section 242, and when the top pallet PL moves to the first arrangement section 241, the second arrangement section 242 raises the remaining pallets PL.

[0024] Molded products are discarded in the disposal section 250. The disposal section 250 is a tray, a container that opens in the +Z direction, or the like.

[0025] 4 is an explanatory diagram of the flow path 290 provided in the first unit 31. The flow path 290 connects the suction blower part 260 and the opening 224 of the holder 221.

[0026] The suction blower section 260 blows gas into the flow path 290 or sucks gas from within the flow path 290. The suction blower section 260 is, for example, a vacuum ejector. The suction blower section 260 sucks gas from within the flow path 290, causing the holder 221 to hold the molded product. The suction blower section 260 blows gas into the flow path 290, causing the molded product to move away from the holder 221. The suction blower section 260 may be provided with a portion that sucks gas from within the flow path 290 and a portion that blows gas into the flow path 290, separately. The suction blower section 260 may have, for example, a vacuum pump that sucks gas from within the flow path 290 and a compressor that blows gas into the flow path 290.

[0027] The ionizer 270 supplies ions into the flow channel 290. The ionizer 270 is connected to the middle of the flow channel 290.

[0028] The pressure detection unit 280 detects the pressure inside the flow path 290. The pressure detection unit 280 is, for example, a pressure sensor.

[0029] 1 and 2 includes a third housing 310 and a supply device 320. The supply device 320 is provided on the upper part of the third housing 310. The supply device 320 stores materials to be used in the injection molding machine 120. The supply device 320 dehumidifies and dries the stored materials and supplies them to the injection molding machine 120. A cover (not shown) that covers the supply device 320 is attached to the upper part of the third housing 310.

[0030] FIG. 5 is a process diagram of the molded product production process executed by the injection molding system 10. First, in step S10, the control unit 150 accepts input of the planned production number of molded products from the user. The planned production number is a predetermined number. The control unit 150 stores the planned production number plus one as the production number. The production number is the number of molded products produced by the injection molding system 10. Note that the control unit 150 may also store the planned production number plus two or more as the production number.

[0031] In step S20, the control unit 150 controls the injection molding machine 120 to start molding a molded product and executes a waste shot. Specifically, the control unit 150 controls the injection molding machine 120 to execute a predetermined number of shots, and controls the robot 220 to transport the molded product to the disposal unit 250.

[0032] In step S30, the control unit 150 controls the injection molding machine 120 to mold a molded product. In step S30, the injection molding machine 120 executes a shot. The control unit 150 controls the robot 220 to transport the molded product molded by the injection molding machine 120 to the inspection device 230.

[0033] In step S40, the inspection device 230 inspects the molded product molded in step S30.

[0034] In step S50, the control unit 150 judges whether the molded product inspected in step S40 is a pass or fail. If the molded product is a pass, step S60 is executed. If the molded product is a defective product, steps S70 and S80 are executed. Note that, if multiple molded products are inspected in step S40, the control unit 150 executes step S60 for the molded products judged to be pass or fail, and executes steps S70 and S80 for the molded products judged to be defective.

[0035] In step S60, the control unit 150 controls the robot 220 to move the molded product inspected in step S40 from the inspection device 230 to the pallet PL and place it on the pallet PL. Hereinafter, the placing of the molded product on the pallet PL by the robot 220 is also referred to as performing a first transport operation.

[0036] In step S70, the control unit 150 controls the robot 220 to move the molded products inspected in step S40 to the disposal unit 250 and have them disposed of in the disposal unit 250. Hereinafter, the disposal of the molded products in the disposal unit 250 by the robot 220 is also referred to as performing a second transport operation. The number of molded products disposed of in the disposal unit 250 is also referred to as the number of discards. That is, the control unit 150 executes either the first transport operation or the second transport operation for each molded product.

[0037] In step S80, the control unit 150 stores the planned production quantity plus one and the number to be discarded as the production quantity. That is, the control unit 150 controls the injection molding machine 120 to mold the number of molded products equal to the planned production quantity plus one and the number to be discarded.

[0038] In step S90, the detection unit 226 detects the number of molded products placed on the pallet PL.

[0039] In step S100, the control unit 150 first calculates the number of molded products placed on the pallet PL in step S60 based on the number of molded products detected by the detection unit 226. When steps S30 to S120 are repeatedly executed, the control unit 150 calculates, for example, the difference between the number of molded products detected in the current step S90 and the number of molded products detected in the immediately preceding step S90 as the number of mounted products. Next, the control unit 150 calculates the number of shortages, which is the difference between the number of molded products determined to be non-defective in step S50 and the number of mounted products, and determines whether the number of shortages is greater than 0. In other words, the number of shortages is the difference between the number of molded products not discarded in the disposal unit 250 among the molded products molded by the injection molding machine 120 and the number of molded products detected by the detection unit 226. When the number of shortages is greater than 0, step S110 is executed. When the number of shortages is equal to or less than 0, step S120 is executed. If the shortage number is a negative value, the control unit 150 may display an error on the tablet terminal 160.

[0040] In step S110, the control unit 150 stores the planned production quantity plus one, the number to be discarded, and the number in shortfall as the production quantity. That is, the control unit 150 controls the injection molding machine 120 to mold the number of molded products equal to the planned production quantity plus one, the number to be discarded, and the number in shortfall.

[0041] In step S120, the control unit 150 determines whether or not the production of all molded products has been completed. Specifically, the control unit 150 determines whether or not the production of molded products equal to or greater than the production number has been completed. If the production of molded products has not been completed, the control unit 150 returns the process to step S30. If the production of all molded products has been completed, the control unit 150 ends the molded product production process. The molded product production process is executed as described above.

[0042] If the injection molding machine 120 temporarily stops molding the molded product due to a shortage of material or the like while steps S30 to S120 are being executed, the trial shot of step S20 is executed immediately after molding of the molded product is resumed. Also, if all molded products molded by a predetermined number of consecutive shots are determined to be defective by the inspection device 230 while steps S30 to S120 are being executed, the control unit 150 causes the tablet terminal 160 to display an error.

[0043] 6 is a process diagram of the transport process executed by the injection molding system 10. In the transport process, the robot 220 holds and transports the molded product. The transport process is executed when the first transport operation and the second transport operation are executed. The transport process may also be executed when the molded product is transported from the transport device 140 to the inspection device 230, or when the molded product is transported from the transport device 140 to the disposal section 250.

[0044] In step S210, the control unit 150 controls the robot 220 to move the holder 221 above the molded product to be transported. The control unit 150 moves the holder 221 above the molded product placed on the inspection table 231, for example.

[0045] In step S220, the control unit 150 controls the suction blower unit 260 to suck in the gas inside the flow path 290. This causes the holding unit 221 to hold the molded product. Holding the molded product by sucking in the gas inside the flow path 290 is also referred to as a first operation.

[0046] In step S230, the control unit 150 controls the robot 220 to move the holding unit 221 above a location where the molded products held by the holding unit 221 are to be separated. The control unit 150 moves the holding unit 221, for example, above the pallet PL or the disposal unit 250.

[0047] In step S240, the control unit 150 controls the ionizer 270 to supply ions into the flow channel 290.

[0048] In step S250, the control unit 150 controls the suction blower unit 260 to blow gas into the flow path 290. This causes the molded article to move away from the holder 221. Blowing gas into the flow path 290 to move the molded article away from the robot 220 is also referred to as a second operation. The second operation includes steps S240 to S270.

[0049] In step S260, the control unit 150 controls the suction blower unit 260 to stop blowing the gas into the flow path 290.

[0050] In step S270, the control unit 150 controls the ionizer 270 to stop the supply of ions into the flow channel 290.

[0051] In step S280, control unit 150 controls suction blower unit 260 to suck in the gas within flow path 290. Suctioning the gas within flow path 290 after the second operation is also referred to as a third operation.

[0052] In step S290, the control unit 150 judges whether the molded product is separated from the robot 220 based on the pressure in the flow path 290 detected by the pressure detection unit 280. Specifically, the control unit 150 judges whether the molded product is separated from the robot 220 by comparing the pressure in the flow path 290 after the second operation is performed and before the third operation is performed with the pressure in the flow path 290 after the third operation is performed. If the pressure in the flow path 290 after the third operation is performed is approximately the same as the pressure in the flow path 290 after the second operation is performed and before the third operation is performed, the control unit 150 judges that the molded product is separated from the robot 220. If the pressure in the flow path 290 after the third operation is performed is lower than the pressure in the flow path 290 after the second operation is performed and before the third operation is performed, the control unit 150 judges that the molded product is not separated from the robot 220. If it is judged that the molded product is separated from the robot 220, the control unit 150 ends the conveying process. If it is determined that the molded article has not been separated from the robot 220, the control unit 150 returns the process to step S240. The transport process is performed as described above.

[0053] According to the injection molding system 10 in the first embodiment described above, when a molded product is discarded, the control unit 150 controls the injection molding machine 120 to mold a number of molded products equal to or greater than the planned production number plus the number to be discarded. Therefore, even if a molded product molded by the injection molding machine 120 is discarded, it is possible to prevent the number of molded products produced by the injection molding system 10 from becoming less than the planned production number.

[0054] Furthermore, in this embodiment, the control unit 150 controls the robot 220 to cause the disposal unit 250 to discard molded products determined to be defective by the inspection device 230. This reduces the possibility of discarding good molded products, compared to, for example, discarding molded products in which an abnormality occurred in the injection molding machine 120 during molding, and not discarding molded products in which an abnormality did not occur in the injection molding machine 120 during molding.

[0055] In this embodiment, the control unit 150 calculates the shortage number, which is the difference between the number of molded products not discarded in the discard unit 250 among the number of molded products molded by the injection molding machine 120 and the number of molded products detected by the detection unit 226, and controls the injection molding machine 120 to mold the number of molded products equal to the planned production number plus the discard number and the shortage number. Therefore, for example, even if a molded product falls while being transported from the inspection device 230 to the pallet PL, the number of molded products that fell is additionally molded. Therefore, it is possible to prevent the number of molded products produced by the injection molding system 10 from being less than the planned production number.

[0056] In addition, in this embodiment, when the control unit 150 executes the second operation of controlling the suction blower unit 260 to blow gas into the flow path 290 to separate the molded article from the robot 220, it controls the ionizer 270 to supply ions into the flow path 290. Therefore, when the molded article is separated from the robot 220, static electricity of the molded article can be removed, and the molded article can be prevented from remaining attached to the robot 220 due to static electricity.

[0057] In this embodiment, the ionizer 270 is provided inside the second housing 210. Therefore, unlike the case where the ionizer 270 is provided on the upper part of the first housing 110 or the second housing 210, the ionizer 270 does not get in the way of the user's work when replacing the mold of the injection molding machine 120 or performing maintenance of peripheral devices. Furthermore, the injection molding system 10 can be easily made compact. In addition, when the ionizer 270 is provided on the upper part of the first housing 110 or the second housing 210, the ions supplied from the ionizer 270 may not reach the molded product due to the airflow in the cover provided on the first housing 110 or the second housing 210. In contrast, in this embodiment, the ionizer 270 supplies ions into the flow path 290 through which the gas blown to the molded product flows, so that the ions can be blown onto the molded product without being affected by the airflow in the cover provided on the first housing 110 or the second housing 210.

[0058] Furthermore, in this embodiment, the control unit 150 controls the suction blower unit 260 and the ionizer 270 to start the supply of ions from the ionizer 270 into the flow path 290, then blow gas into the flow path 290, and stop the supply of ions from the ionizer 270 after stopping the blowing of gas into the flow path 290. Therefore, power consumption can be reduced compared to the case where ions are constantly supplied from the ionizer 270 into the flow path 290.

[0059] Furthermore, in this embodiment, the control unit 150 executes a third operation of controlling the suction blower unit 260 to suck in the gas inside the flow path 290 after the second operation, and judges whether or not the molded product has been separated from the robot 220 based on the pressure detected by the pressure detection unit 280 when the third operation is executed. Therefore, it is possible to recognize that the molded product has not been separated from the robot 220 even though the second operation has been executed.

[0060] B. Second embodiment: In the second embodiment, the molded product production process is different from that in the first embodiment. The configurations of the respective parts of the injection molding system 10 in the second embodiment are the same as those in the first embodiment.

[0061] Fig. 7 is a process diagram of a molded product production process in the second embodiment. Note that the same reference numerals are given to the parts in which the same processes as those in the molded product production process in the first embodiment shown in Fig. 5 are executed, and the description thereof will be omitted.

[0062] In step S310, the injection molding system 10 executes a trial injection process.

[0063] FIG. 8 is a process diagram of the waste injection process. The same reference numerals are attached to the parts in which the same processes as those in the molded product production process of the first embodiment shown in FIG. 5 are executed, and the description is omitted. In the waste injection process, the control unit 150 executes the second conveying operation for the molded products molded from the start of molding of the molded products in the injection molding machine 120 until the molded products are judged to be good products by the inspection device 230. For example, if the first to fourth molded products are judged to be defective products by the inspection device 230 and the fifth molded product is judged to be good products by the inspection device 230 after the start of molding of the molded products, the control unit 150 controls the robot 220 to discard the first to fourth molded products in the discarding unit 250 and place the fifth molded product on the pallet PL.

[0064] According to the injection molding system 10 in the second embodiment described above, the throw-away process is completed when the molded product is determined to be a non-defective product by the inspection device 230. Therefore, compared to the case where the throw-away process is completed when the molded product molded with a predetermined number of shots is discarded, it is possible to prevent the discarding of a non-defective molded product and the start of production of a molded product despite the fact that a defective product has been molded.

[0065] C. Other embodiments: (C-1) In the above embodiment, when molded articles are discarded in the disposal section 250, the control section 150 controls the injection molding machine 120 to mold the number of molded articles equal to the planned production quantity plus one and the number to be discarded. In contrast, when molded articles are discarded in the disposal section 250, the control section 150 may control the injection molding machine 120 to mold the number of molded articles equal to the planned production quantity plus the number to be discarded.

[0066] (C-2) In the above embodiment, the control unit 150 controls both the injection molding machine 120 and the robot 220. In contrast to this, the control unit 150 may separately include a first control unit that controls the injection molding machine 120 and a second control unit that controls the robot 220.

[0067] (C-3) In the above embodiment, the injection molding system 10 includes the pressure detection unit 280. In contrast, the injection molding system 10 may not include the pressure detection unit 280. In this case, in the conveying process shown in FIG. 6, the third operation of step S280 and step S290 may not be executed.

[0068] (C-4) In the above embodiment, in the second operation of the transfer process shown in Fig. 6, the control unit 150 starts the supply of ions from the ionizer 270 into the flow path 290, then blows gas into the flow path 290, and stops the supply of ions from the ionizer 270 after stopping the blowing of gas into the flow path 290. In contrast to this, the control unit 150 may control the ionizer 270 to constantly supply ions into the flow path 290.

[0069] (C-5) In the above embodiment, the injection molding system 10 includes the inspection device 230, the detection unit 226, the suction blower unit 260, and the ionizer 270. In contrast, the injection molding system 10 does not need to include at least one of the inspection device 230, the detection unit 226, the suction blower unit 260, and the ionizer 270.

[0070] D. Other forms: The present disclosure is not limited to the above-mentioned embodiment, and can be realized in various forms without departing from the spirit of the present disclosure. For example, the present disclosure can be realized in the following forms. The technical features in the above-mentioned embodiments corresponding to the technical features in each form described below can be appropriately replaced or combined in order to solve some or all of the problems of the present disclosure, or to achieve some or all of the effects of the present disclosure. Furthermore, if the technical feature is not described as essential in this specification, it can be appropriately deleted.

[0071] (1) According to one aspect of the present disclosure, there is provided an injection molding system comprising an injection molding machine that injects a plasticized material into a cavity partitioned by a fixed mold and a movable mold to mold a molded product, a pallet on which the molded product is placed, a disposal section in which the molded product is discarded, a robot that transports the molded product molded by the injection molding machine to the pallet or the disposal section, and a control section that controls the injection molding machine and the robot, wherein the control section controls the robot to perform, for each of the molded products, a first transport operation of placing the molded product on the pallet or a second transport operation of discarding the molded product in the disposal section, and controls the injection molding machine to mold the molded products in a number equal to or greater than the planned production number, which is a predetermined number, plus the disposal number, which is the number of the molded products discarded in the disposal section. According to this embodiment, even if a molded product molded by the injection molding machine is discarded, it is possible to prevent the number of molded products produced by the injection molding system from becoming less than the planned production number.

[0072] (2) In the above embodiment, the apparatus may further include an inspection device that inspects the molded products molded by the injection molding machine, and the control unit may execute the second conveying operation for the molded products determined to be defective by the inspection device, and control the injection molding machine to mold a number of the molded products equal to or greater than the planned production number plus the number to be discarded. According to this embodiment, the possibility of discarding a good molded product can be reduced compared to a case in which a molded product in which an abnormality occurred in the injection molding machine during molding is discarded, but a molded product in which no abnormality occurred in the injection molding machine during molding is not discarded.

[0073] (3) In the above embodiment, the apparatus may further include an inspection device that inspects the molded product molded by the injection molding machine, and the control unit may control the robot to perform the second conveying operation for the molded product molded between the time when the injection molding machine starts molding the molded product and the time when the molded product is determined to be a pass product by the inspection device. According to this embodiment, compared to a case where molded products molded with a predetermined number of shots are discarded before production of the molded products is started in the injection molding machine, it is possible to prevent the discarding of good molded products and the starting of production of molded products despite the fact that defective products have been molded.

[0074] (4) In the above embodiment, the apparatus may further include a detection unit that detects the number of the molded products placed on the pallet, and the control unit may calculate a shortage number, which is the difference between the number of the molded products molded by the injection molding machine that have not been discarded in the disposal unit and the number of the molded products detected by the detection unit, and control the injection molding machine to mold a number of the molded products equal to the planned production number plus the discard number and the shortage number. According to this embodiment, for example, if a molded product falls while being transferred from the inspection device to the pallet, it is possible to mold additional molded products in the same number as the fallen products.

[0075] (5) In the above embodiment, the robot has an opening on a contact surface that comes into contact with the molded product, and the injection molding system further includes a suction blower unit that blows gas into a flow path communicating with the opening or sucks in the gas in the flow path, and an ionizer that supplies ions into the flow path, and the control unit controls the suction blower unit and the ionizer, and when performing the first conveying operation and the second conveying operation, controls the suction blower unit to perform a first operation of holding the molded product by sucking in the gas in the flow path, and a second operation of separating the molded product from the robot by blowing the gas into the flow path, and in the second operation, controls the ionizer to supply the ions into the flow path. According to this embodiment, since static electricity can be removed from the molded product when the molded product is separated from the robot, it is possible to prevent the molded product from remaining attached to the robot due to static electricity.

[0076] (6) In the above embodiment, in the second operation, the control unit may start supplying the ions from the ionizer into the flow path, then blow the gas into the flow path, and stop supplying the ions from the ionizer after stopping blowing the gas into the flow path. According to this embodiment, power consumption can be reduced compared to a case in which ions are constantly supplied from the ionizer into the flow path.

[0077] (7) In the above embodiment, the apparatus may further include a pressure detection unit that detects pressure within the flow path, and the control unit may perform a third operation after the second operation by controlling the suction blower unit to suck in the gas within the flow path, and may determine whether the molded product has moved away from the robot based on the pressure detected by the pressure detection unit when the third operation is performed. According to this embodiment, it is possible to recognize that the second operation has been executed but the molded product has not yet been separated from the robot. [Explanation of symbols]

[0078] 10... injection molding system, 20... main unit, 30... option unit, 31... first unit, 32... second unit, 110... first housing, 120... injection molding machine, 121... molding die, 122... fixed die, 123... movable die, 124... injection section, 125... mold clamping section, 130... removal device, 140... conveying device, 150... control section, 160... tablet terminal, 210... second housing, 220... robot , 221...holding section, 222...holding member, 223...contact surface, 224...opening, 226...detection section, 230...inspection device, 231...inspection table, 232...camera, 240...stacking mechanism, 241...first arrangement section, 242...second arrangement section, 250...disposal section, 260...suction and blowing section, 270...ionizer, 280...pressure detection section, 290...flow path, 310...third housing, 320...supply device, PL...pallet

Claims

1. 1. An injection molding system comprising: an injection molding machine that injects a plasticized material into a cavity defined by a fixed mold and a movable mold to form a molded product; A pallet on which the molded product is placed; A disposal section where the molded product is disposed of; a robot that transports the molded product molded by the injection molding machine to the pallet or to the disposal section; a control unit that controls the injection molding machine and the robot, The control unit is controlling the robot to execute, for each of the molded products, a first conveying operation of placing the molded product on the pallet or a second conveying operation of disposing of the molded product in the disposal section; Controlling the injection molding machine to mold the molded products in a number equal to or greater than the sum of a planned production number, which is a predetermined number, and a discard number, which is the number of the molded products discarded in the discard section. Injection molding system.

2. 2. The injection molding system of claim 1, The injection molding machine further includes an inspection device for inspecting the molded product molded by the injection molding machine, The control unit is performing the second transport operation on the molded product determined to be a defective product by the inspection device; Controlling the injection molding machine to mold the molded products in a number equal to or greater than the sum of the planned production number and the number to be discarded. Injection molding system.

3. 2. The injection molding system of claim 1, The injection molding machine further includes an inspection device for inspecting the molded product molded by the injection molding machine, The control unit is controlling the robot to perform the second transport operation for the molded product that is molded during the period from when the molding of the molded product is started by the injection molding machine until the molded product is determined to be a non-defective product by the inspection device; Injection molding system.

4. 2. The injection molding system of claim 1, A detection unit that detects the number of the molded products placed on the pallet is further provided, The control unit is calculating a shortage number, which is a difference between the number of the molded products that have been molded by the injection molding machine and have not been disposed of in the disposal section and the number of the molded products detected by the detection section; Controlling the injection molding machine to mold the number of molded products equal to the planned production number plus the number of discarded products and the number of products in shortfall. Injection molding system.

5. 2. The injection molding system of claim 1, the robot has an opening on a contact surface that comes into contact with the molded product, The injection molding system comprises: a suction / blower unit that blows gas into a flow passage communicating with the opening or sucks the gas into the flow passage; An ionizer that supplies ions into the flow path, The control unit is Controlling the suction blower unit and the ionizer; When the first conveying operation and the second conveying operation are performed, the suction and blowing unit is controlled to perform a first operation of holding the molded product by sucking the gas in the flow path, and a second operation of separating the molded product from the robot by blowing the gas into the flow path, In the second operation, the ionizer is controlled to supply the ions into the flow path. Injection molding system.

6. 6. The injection molding system of claim 5, In the second operation, the control unit After starting the supply of the ions from the ionizer into the flow path, the gas is blown into the flow path; After stopping the blowing of the gas into the flow path, the supply of the ions from the ionizer is stopped. Injection molding system.

7. 6. The injection molding system of claim 5, A pressure detection unit that detects a pressure in the flow path is further provided. The control unit is After the second operation, a third operation is performed in which the suction blower unit is controlled to suction the gas in the flow path; determining whether or not the molded product is separated from the robot based on the pressure detected by the pressure detection unit when the third operation is executed; Injection molding system.

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