Injection molding machine, management device, and management system

Abstract

To realize enhancement of work efficiency.SOLUTION: An injection molding machine comprises: a mold assembly to which a molding material is injected by the injection molding machine according to one embodiment; a detection unit for detecting a state related to an object discharged from a gap provided on the mold assembly when the molding material is injected; and a control device for determining whether or not abnormality has occurred in the mold assembly on the basis of the state related to the object discharged from the gap.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to an injection molding machine, a management device, and a management system. [Background technology]

[0002] 2. Description of the Related Art Conventionally, an air vent is provided in an injection molding machine to exhaust gas generated by a molding material filled in a mold device from the mold device to the outside. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2001-162625 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, with the technology described in Patent Document 1, when injection molding is repeatedly performed, components contained in the discharged gas may adhere to and accumulate on the inside of the air vent, blocking the air vent and making it difficult to sufficiently discharge the gas from the cavity in the mold device. If the gas cannot be sufficiently discharged from the cavity in the mold device, the gas may become hot due to adiabatic compression, causing the molding material to burn and become defective.

[0005] One aspect of the present invention provides a technique for improving work efficiency by understanding the status of a die device. [Means for solving the problem]

[0006] An injection molding machine according to one embodiment of the present invention comprises a mold device into which molding material is injected by an injection device, a detection unit that detects a condition relating to an object discharged through a gap provided in the mold device when the molding material is injected, and a control device that determines whether an abnormality has occurred in the mold device based on the condition relating to the object discharged through the gap. Effect of the Invention

[0007] According to one aspect of the present invention, by understanding the status of the mold device, improvement of work efficiency is achieved. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram showing a state when mold opening of an injection molding machine according to an embodiment is completed. [Diagram 2] FIG. 2 is a diagram showing a state during mold clamping of the injection molding machine according to one embodiment. [Diagram 3] FIG. 3 is a diagram illustrating an example of a functional configuration of the control device according to the first embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing the mold device according to the first embodiment. [Diagram 5] FIG. 5 is a diagram showing the relationship between the number of shots after the start of injection molding and the volume of the discharge sound. [Figure 6] FIG. 6 is a diagram illustrating an example of a setting screen output by the output control unit according to the first embodiment. [Figure 7] FIG. 7 is a diagram illustrating a log information screen output by the output control unit according to the first embodiment. [Figure 8] FIG. 8 is a flowchart showing a processing procedure based on the discharge sound from the mold device, which is executed by the control device according to the first embodiment. [Figure 9] FIG. 9 is a diagram illustrating the dimensions of the air vents of the mold assembly according to the second embodiment. [Figure 10] FIG. 10 is a conceptual diagram showing a management system according to the seventh embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The embodiment described below is an example, not a limitation of the invention, and all features and combinations described in the embodiment are not necessarily essential to the invention. In addition, the same or corresponding components in each drawing are denoted by the same or corresponding reference numerals, and the description may be omitted.

[0010] FIG. 1 is a diagram showing a state of the injection molding machine according to the first embodiment when mold opening is completed. FIG. 2 is a diagram showing a state of the injection molding machine according to the first embodiment when mold clamping is performed. In this specification, the X-axis direction, the Y-axis direction, and the Z-axis direction are perpendicular to each other. The X-axis direction and the Y-axis direction represent the horizontal direction, and the Z-axis direction represents the vertical direction. When the mold clamping device 100 is of a horizontal type, the X-axis direction is the mold opening / closing direction, and the Y-axis direction is the width direction of the injection molding machine 10. The negative side of the Y-axis direction is called the operation side, and the positive side of the Y-axis direction is called the anti-operation side.

[0011] As shown in FIG. 1 and FIG. 2, the injection molding machine 10 includes a mold clamping device 100 that opens and closes a mold device 800, an ejector device 200 that ejects a molded product molded by the mold device 800, an injection device 300 that injects a molding material into the mold device 800, a moving device 400 that moves the injection device 300 forward and backward relative to the mold device 800, a control device 700 that controls each component of the injection molding machine 10, and a frame 900 that supports each component of the injection molding machine 10. The frame 900 includes a mold clamping device frame 910 that supports the mold clamping device 100, and an injection device frame 920 that supports the injection device 300. The mold clamping device frame 910 and the injection device frame 920 are each installed on the floor 2 via a leveling adjuster 930. The control device 700 is disposed in the internal space of the injection device frame 920. Hereinafter, each component of the injection molding machine 10 will be described.

[0012] (mold clamping device) In the description of the clamping unit 100, the moving direction of the movable platen 120 during mold closing (for example, the positive direction of the X-axis) is the front, and the moving direction of the movable platen 120 during mold opening (for example, the negative direction of the X-axis) is the rear.

[0013] The mold clamping device 100 performs mold closing, pressurization, mold clamping, depressurization, and mold opening of the mold device 800. The mold device 800 includes a fixed mold 810 and a movable mold 820. The mold clamping device 100 is, for example, a horizontal type, and the mold opening and closing direction is horizontal. The mold clamping device 100 has a fixed platen 110 to which the fixed mold 810 is attached, a movable platen 120 to which the movable mold 820 is attached, and a movement mechanism 102 that moves the movable platen 120 in the mold opening and closing direction relative to the fixed platen 110.

[0014] The stationary platen 110 is fixed to the mold clamping unit frame 910. A stationary mold 810 is attached to the surface of the stationary platen 110 that faces the movable platen 120.

[0015] The movable platen 120 is disposed so as to be movable in the mold opening / closing direction relative to the mold clamping unit frame 910. A guide 101 for guiding the movable platen 120 is disposed on the mold clamping unit frame 910. A movable mold 820 is attached to the surface of the movable platen 120 facing the fixed platen 110.

[0016] The moving mechanism 102 advances and retreats the movable platen 120 relative to the fixed platen 110, thereby performing mold closing, pressurization, mold clamping, depressurization, and mold opening of the mold apparatus 800. The moving mechanism 102 has a toggle support 130 disposed at a distance from the fixed platen 110, a tie bar 140 connecting the fixed platen 110 and the toggle support 130, a toggle mechanism 150 that moves the movable platen 120 in the mold opening and closing direction relative to the toggle support 130, a mold clamping motor 160 that operates the toggle mechanism 150, a motion conversion mechanism 170 that converts the rotational motion of the mold clamping motor 160 into linear motion, and a mold thickness adjustment mechanism 180 that adjusts the distance between the fixed platen 110 and the toggle support 130.

[0017] The toggle support 130 is disposed at a distance from the fixed platen 110, and is placed on the mold clamping unit frame 910 so as to be freely movable in the mold opening and closing direction. The toggle support 130 may be disposed so as to be freely movable along a guide laid on the mold clamping unit frame 910. The guide of the toggle support 130 may be the same as the guide 101 of the movable platen 120.

[0018] In this embodiment, the fixed platen 110 is fixed to the mold clamping unit frame 910, and the toggle support 130 is arranged so as to be freely movable in the mold opening and closing direction relative to the mold clamping unit frame 910, but the toggle support 130 may be fixed to the mold clamping unit frame 910, and the fixed platen 110 may be arranged so as to be freely movable in the mold opening and closing direction relative to the mold clamping unit frame 910.

[0019] The tie bar 140 connects the fixed platen 110 and the toggle support 130 at a distance L in the mold opening / closing direction. A plurality of tie bars 140 (for example, four) may be used. The plurality of tie bars 140 are arranged parallel to the mold opening / closing direction and extend according to the mold clamping force. At least one tie bar 140 may be provided with a tie bar strain detector 141 that detects strain of the tie bar 140. The tie bar strain detector 141 sends a signal indicating the detection result to the control device 700. The detection result of the tie bar strain detector 141 is used for detecting the mold clamping force, etc.

[0020] In this embodiment, the tie bar strain detector 141 is used as the clamping force detector for detecting the clamping force, but the present invention is not limited to this. The clamping force detector is not limited to the strain gauge type, and may be a piezoelectric type, a capacitive type, a hydraulic type, an electromagnetic type, or the like, and the attachment position thereof is also not limited to the tie bar 140.

[0021] The toggle mechanism 150 is disposed between the movable platen 120 and the toggle support 130, and moves the movable platen 120 relative to the toggle support 130 in the mold opening / closing direction. The toggle mechanism 150 has a crosshead 151 that moves in the mold opening / closing direction, and a pair of link groups that bend and stretch with the movement of the crosshead 151. Each of the pair of link groups has a first link 152 and a second link 153 that are connected to bendable and stretchable by a pin or the like. The first link 152 is attached to the movable platen 120 by a pin or the like so as to be swingable. The second link 153 is attached to the toggle support 130 by a pin or the like so as to be swingable. The second link 153 is attached to the crosshead 151 via a third link 154. When the crosshead 151 is advanced or retreated relative to the toggle support 130, the first link 152 and the second link 153 bend and stretch, and the movable platen 120 advances or retreats relative to the toggle support 130.

[0022] The configuration of toggle mechanism 150 is not limited to the configuration shown in Figures 1 and 2. For example, although the number of joints in each link group is five in Figures 1 and 2, it may be four, and one end of third link 154 may be connected to a joint between first link 152 and second link 153.

[0023] The mold clamping motor 160 is attached to the toggle support 130 and operates the toggle mechanism 150. The mold clamping motor 160 advances and retreats the crosshead 151 relative to the toggle support 130, thereby bending and extending the first link 152 and the second link 153 and advancing and retreating the movable platen 120 relative to the toggle support 130. The mold clamping motor 160 is directly connected to the motion conversion mechanism 170, but may also be connected to the motion conversion mechanism 170 via a belt, a pulley, or the like.

[0024] The motion conversion mechanism 170 converts the rotational motion of the mold clamping motor 160 into the linear motion of the crosshead 151. The motion conversion mechanism 170 includes a screw shaft and a screw nut that screws onto the screw shaft. A ball or roller may be interposed between the screw shaft and the screw nut.

[0025] The mold clamping unit 100 performs a mold closing process, a pressure increase process, a mold clamping process, a pressure release process, a mold opening process, and the like under the control of the control device 700.

[0026] In the mold closing process, the mold clamping motor 160 is driven to move the crosshead 151 forward at a set moving speed to a mold closing completion position, thereby moving the movable platen 120 forward and bringing the movable mold 820 into contact with the fixed mold 810. The position and moving speed of the crosshead 151 are detected by using, for example, a mold clamping motor encoder 161. The mold clamping motor encoder 161 detects the rotation of the mold clamping motor 160 and sends a signal indicating the detection result to the control device 700.

[0027] The crosshead position detector that detects the position of the crosshead 151 and the crosshead movement speed detector that detects the movement speed of the crosshead 151 are not limited to the mold clamping motor encoder 161, and general devices can be used. Furthermore, the movable platen position detector that detects the position of the movable platen 120 and the movable platen movement speed detector that detects the movement speed of the movable platen 120 are not limited to the mold clamping motor encoder 161, and general devices can be used.

[0028] In the pressure increasing step, the mold clamping motor 160 is further driven to move the crosshead 151 further forward from the mold closing completion position to the mold clamping position, thereby generating a mold clamping force.

[0029] In the mold clamping process, the mold clamping motor 160 is driven to maintain the position of the crosshead 151 at the mold clamping position. In the mold clamping process, the mold clamping force generated in the pressure increase process is maintained. In the mold clamping process, a cavity space 801 (see FIG. 2) is formed between the movable mold 820 and the fixed mold 810, and the injection device 300 fills the cavity space 801 with liquid molding material. The filled molding material is solidified to obtain a molded product.

[0030] The number of cavity spaces 801 may be one or more. In the latter case, multiple molded products are obtained at the same time. An insert material may be placed in a part of the cavity space 801, and another part of the cavity space 801 may be filled with a molding material. A molded product in which the insert material and the molding material are integrated is obtained.

[0031] In the depressurization process, the mold clamping motor 160 is driven to move the crosshead 151 back from the mold clamping position to the mold opening start position, thereby moving the movable platen 120 back and reducing the mold clamping force. The mold opening start position and the mold closing completion position may be the same position.

[0032] In the mold opening process, the mold clamping motor 160 is driven to move the crosshead 151 backward at a set moving speed from the mold opening start position to the mold opening completion position, thereby moving the movable platen 120 backward and separating the movable mold 820 from the fixed mold 810. After that, the ejector unit 200 ejects the molded product from the movable mold 820.

[0033] The setting conditions in the mold closing process, the pressure increase process, and the mold clamping process are set together as a series of setting conditions. For example, the moving speed and position of the crosshead 151 in the mold closing process and the pressure increase process (including the mold closing start position, the moving speed switching position, the mold closing completion position, and the mold clamping position) and the mold clamping force are set together as a series of setting conditions. The mold closing start position, the moving speed switching position, the mold closing completion position, and the mold clamping position are arranged in this order from the rear side to the front, and represent the start point and the end point of the section in which the moving speed is set. The moving speed is set for each section. There may be one or more moving speed switching positions. The moving speed switching position does not have to be set. Only one of the mold clamping position and the mold clamping force may be set.

[0034] The setting conditions in the depressurization process and mold opening process are set in the same manner. For example, the movement speed and position of the crosshead 151 in the depressurization process and mold opening process (mold opening start position, movement speed switching position, and mold opening completion position) are set together as a series of setting conditions. The mold opening start position, movement speed switching position, and mold opening completion position are arranged in this order from the front to the rear, and represent the start and end points of the section in which the movement speed is set. The movement speed is set for each section. There may be one or more movement speed switching positions. The movement speed switching position does not have to be set. The mold opening start position and the mold closing completion position may be the same position. Also, the mold opening completion position and the mold closing start position may be the same position.

[0035] Note that the moving speed and position of the movable platen 120 may be set instead of the moving speed and position of the crosshead 151. Moreover, the clamping force may be set instead of the position of the crosshead (e.g., the clamping position) or the position of the movable platen.

[0036] Incidentally, the toggle mechanism 150 amplifies the driving force of the mold clamping motor 160 and transmits it to the movable platen 120. The amplification ratio is also called the toggle ratio. The toggle ratio changes according to the angle θ between the first link 152 and the second link 153 (hereinafter also referred to as the "link angle θ"). The link angle θ is determined from the position of the crosshead 151. When the link angle θ is 180°, the toggle ratio is maximum.

[0037] When the thickness of the mold device 800 changes due to replacement of the mold device 800 or a temperature change of the mold device 800, a mold thickness adjustment is performed so that a predetermined clamping force is obtained during mold clamping. In the mold thickness adjustment, for example, the distance L between the fixed platen 110 and the toggle support 130 is adjusted so that the link angle θ of the toggle mechanism 150 becomes a predetermined angle at the mold touch time when the movable mold 820 touches the fixed mold 810.

[0038] The mold clamping device 100 has a mold thickness adjustment mechanism 180. The mold thickness adjustment mechanism 180 adjusts the mold thickness by adjusting the distance L between the fixed platen 110 and the toggle support 130. The mold thickness adjustment is performed, for example, between the end of a molding cycle and the start of the next molding cycle. The mold thickness adjustment mechanism 180 has, for example, a screw shaft 181 formed at the rear end of the tie bar 140, a screw nut 182 held rotatably and immovably on the toggle support 130, and a mold thickness adjustment motor 183 that rotates the screw nut 182 screwed onto the screw shaft 181.

[0039] The screw shaft 181 and the screw nut 182 are provided for each tie bar 140. The rotational driving force of the mold thickness adjustment motor 183 may be transmitted to the multiple screw nuts 182 via a rotational driving force transmission unit 185. The multiple screw nuts 182 can be rotated synchronously. Note that by changing the transmission path of the rotational driving force transmission unit 185, it is also possible to rotate the multiple screw nuts 182 individually.

[0040] The rotational drive force transmission unit 185 is composed of, for example, gears. In this case, a driven gear is formed on the outer periphery of each screw nut 182, a drive gear is attached to the output shaft of the mold thickness adjustment motor 183, and an intermediate gear that meshes with the multiple driven gears and the drive gear is rotatably held in the center of the toggle support 130. Note that the rotational drive force transmission unit 185 may be composed of a belt, a pulley, or the like, instead of gears.

[0041] The operation of the mold thickness adjustment mechanism 180 is controlled by a control device 700. The control device 700 drives the mold thickness adjustment motor 183 to rotate the screw nut 182. As a result, the position of the toggle support 130 relative to the tie bar 140 is adjusted, and the interval L between the fixed platen 110 and the toggle support 130 is adjusted. Note that a plurality of mold thickness adjustment mechanisms may be used in combination.

[0042] The distance L is detected using a mold thickness adjustment motor encoder 184. The mold thickness adjustment motor encoder 184 detects the amount of rotation and the direction of rotation of the mold thickness adjustment motor 183, and sends a signal indicating the detection result to the control device 700. The detection result of the mold thickness adjustment motor encoder 184 is used to monitor and control the position of the toggle support 130 and the distance L. Note that the toggle support position detector that detects the position of the toggle support 130 and the distance detector that detects the distance L are not limited to the mold thickness adjustment motor encoder 184, and general types can be used.

[0043] The mold clamping apparatus 100 may have a mold temperature regulator that regulates the temperature of the mold apparatus 800. The mold apparatus 800 has a flow path for a temperature control medium therein. The mold temperature regulator regulates the temperature of the mold apparatus 800 by regulating the temperature of the temperature control medium supplied to the flow path of the mold apparatus 800.

[0044] Although the mold clamping apparatus 100 of this embodiment is of a horizontal type in which the mold opening and closing direction is horizontal, it may be of a vertical type in which the mold opening and closing direction is vertical.

[0045] Although the mold clamping apparatus 100 of the present embodiment has a mold clamping motor 160 as a drive source, it may have a hydraulic cylinder instead of the mold clamping motor 160. Also, the mold clamping apparatus 100 may have a linear motor for opening and closing the mold, and an electromagnet for mold clamping.

[0046] (Ejector device) In describing the ejector unit 200, similar to the description of the mold clamping unit 100, the direction of movement of the movable platen 120 during mold closing (e.g., the positive direction of the X-axis) will be referred to as the forward direction, and the direction of movement of the movable platen 120 during mold opening (e.g., the negative direction of the X-axis) will be referred to as the rearward direction.

[0047] The ejector unit 200 is attached to the movable platen 120 and moves forward and backward together with the movable platen 120. The ejector unit 200 has an ejector rod 210 that ejects a molded product from the mold device 800, and a drive mechanism 220 that moves the ejector rod 210 in the movement direction of the movable platen 120 (X-axis direction).

[0048] The ejector rod 210 is arranged so as to be able to move forward and backward in a through hole of the movable platen 120. The front end of the ejector rod 210 contacts an ejector plate 826 of the movable mold 820. The front end of the ejector rod 210 may or may not be connected to the ejector plate 826.

[0049] The drive mechanism 220 includes, for example, an ejector motor and a motion conversion mechanism that converts the rotational motion of the ejector motor into the linear motion of the ejector rod 210. The motion conversion mechanism includes a screw shaft and a screw nut that screws onto the screw shaft. A ball or roller may be interposed between the screw shaft and the screw nut.

[0050] The ejector unit 200 performs an ejection process under the control of the control unit 700. In the ejection process, the ejector rod 210 advances from the standby position to the ejection position at a set moving speed, thereby advancing the ejector plate 826 and ejecting the molded product. After that, the ejector motor is driven to move the ejector rod 210 backward at the set moving speed, and the ejector plate 826 backward to the original standby position.

[0051] The position and moving speed of the ejector rod 210 are detected, for example, by using an ejector motor encoder. The ejector motor encoder detects the rotation of the ejector motor and sends a signal indicating the detection result to the control device 700. Note that the ejector rod position detector that detects the position of the ejector rod 210 and the ejector rod moving speed detector that detects the moving speed of the ejector rod 210 are not limited to the ejector motor encoder, and general types can be used.

[0052] (injection device) In the description of the injection device 300, unlike the description of the mold clamping device 100 and the description of the ejector device 200, the movement direction of the screw 330 during filling (e.g., the negative X-axis direction) is described as the forward direction, and the movement direction of the screw 330 during metering (e.g., the positive X-axis direction) is described as the rearward direction.

[0053] The injection device 300 is installed on a slide base 301, and the slide base 301 is disposed so as to be movable forward and backward with respect to the injection device frame 920. The injection device 300 is disposed so as to be movable forward and backward with respect to the mold device 800. The injection device 300 touches the mold device 800, and fills the molding material measured in the cylinder 310 into a cavity space 801 in the mold device 800. The injection device 300 has, for example, a cylinder 310 for heating the molding material, a nozzle 320 provided at the front end of the cylinder 310, a screw 330 disposed in the cylinder 310 so as to be movable forward and backward and rotatable, a metering motor 340 for rotating the screw 330, an injection motor 350 for moving the screw 330 forward and backward, and a load detector 360 for detecting a load transmitted between the injection motor 350 and the screw 330.

[0054] Cylinder 310 heats the molding material supplied to the inside from supply port 311. The molding material includes, for example, resin. The molding material is formed, for example, in the shape of pellets, and is supplied to supply port 311 in a solid state. Supply port 311 is formed at the rear of cylinder 310. A cooler 312 such as a water-cooled cylinder is provided on the outer periphery of the rear of cylinder 310. A heater 313 such as a band heater and a temperature detector 314 are provided on the outer periphery of cylinder 310, forward of cooler 312.

[0055] Cylinder 310 is divided into a plurality of zones in the axial direction (e.g., X-axis direction) of cylinder 310. Each of the plurality of zones is provided with heater 313 and temperature detector 314. A set temperature is set for each of the plurality of zones, and control device 700 controls heater 313 so that the detected temperature of temperature detector 314 becomes the set temperature.

[0056] The nozzle 320 is provided at the front end of the cylinder 310, and is pressed against the mold device 800. A heater 313 and a temperature detector 314 are provided on the outer periphery of the nozzle 320. The control device 700 controls the heater 313 so that the detected temperature of the nozzle 320 becomes the set temperature.

[0057] The screw 330 is disposed in the cylinder 310 so as to be rotatable and movable forward and backward. When the screw 330 is rotated, the molding material is sent forward along the spiral groove of the screw 330. As the molding material is sent forward, it is gradually melted by heat from the cylinder 310. As the liquid molding material is sent forward of the screw 330 and accumulates in the front part of the cylinder 310, the screw 330 is moved backward. Thereafter, when the screw 330 is moved forward, the liquid molding material accumulated in front of the screw 330 is injected from the nozzle 320 and filled into the mold device 800.

[0058] A check ring 331 is attached to the front of the screw 330 so as to be movable forward and backward as a check valve for preventing the backflow of molding material from the front to the rear of the screw 330 when the screw 330 is pushed forward.

[0059] When the screw 330 is moved forward, the backflow prevention ring 331 is pushed backward by the pressure of the molding material in front of the screw 330, and moves backward relatively to the screw 330 to a blocking position (see FIG. 2) where the flow path of the molding material is blocked. This prevents the molding material accumulated in front of the screw 330 from flowing backward.

[0060] On the other hand, when the screw 330 is rotated, the backflow prevention ring 331 is pushed forward by the pressure of the molding material sent forward along the spiral groove of the screw 330, and moves forward relatively to the screw 330 to an open position (see FIG. 1) where the flow path of the molding material is opened. As a result, the molding material is sent forward of the screw 330.

[0061] The backflow prevention ring 331 may be either a co-rotating type that rotates together with the screw 330 or a non-co-rotating type that does not rotate together with the screw 330.

[0062] The injection device 300 may have a drive source for moving the backflow prevention ring 331 back and forth between the open position and the closed position relative to the screw 330.

[0063] The metering motor 340 rotates the screw 330. The drive source for rotating the screw 330 is not limited to the metering motor 340, and may be, for example, a hydraulic pump.

[0064] The injection motor 350 advances and retreats the screw 330. A motion conversion mechanism that converts the rotational motion of the injection motor 350 into the linear motion of the screw 330 is provided between the injection motor 350 and the screw 330. The motion conversion mechanism has, for example, a screw shaft and a screw nut that screws onto the screw shaft. A ball or roller may be provided between the screw shaft and the screw nut. The drive source that advances and retreats the screw 330 is not limited to the injection motor 350, and may be, for example, a hydraulic cylinder.

[0065] The load detector 360 detects the load transmitted between the injection motor 350 and the screw 330. The detected load is converted into pressure by the control device 700. The load detector 360 is provided on a load transmission path between the injection motor 350 and the screw 330, and detects the load acting on the load detector 360.

[0066] The load detector 360 sends a signal of the detected load to the control device 700. The load detected by the load detector 360 is converted into pressure acting between the screw 330 and the molding material, and is used to control and monitor the pressure that the screw 330 receives from the molding material, the back pressure on the screw 330, the pressure that the screw 330 acts on the molding material, and the like.

[0067] The pressure detector for detecting the pressure of the molding material is not limited to the load detector 360, and a general detector may be used. For example, a nozzle pressure sensor or a mold internal pressure sensor may be used. The nozzle pressure sensor is installed in the nozzle 320.

[0068] The injection device 300 performs a metering process, a filling process, a pressure holding process, and the like under the control of the control device 700. The filling process and the pressure holding process may be collectively referred to as the injection process.

[0069] In the metering process, the metering motor 340 is driven to rotate the screw 330 at a set rotation speed, and the molding material is sent forward along the spiral groove of the screw 330. As a result, the molding material is gradually melted. As the liquid molding material is sent forward of the screw 330 and accumulates at the front of the cylinder 310, the screw 330 is moved backward. The rotation speed of the screw 330 is detected, for example, by using a metering motor encoder 341. The metering motor encoder 341 detects the rotation of the metering motor 340 and sends a signal indicating the detection result to the control device 700. Note that the screw rotation speed detector that detects the rotation speed of the screw 330 is not limited to the metering motor encoder 341, and a general one can be used.

[0070] In the metering process, in order to restrict abrupt retraction of the screw 330, a set back pressure may be applied to the screw 330 by driving the injection motor 350. The back pressure on the screw 330 is detected, for example, by using a load detector 360. When the screw 330 retracts to the metering completion position and a predetermined amount of molding material is accumulated in front of the screw 330, the metering process is completed.

[0071] The position and rotation speed of the screw 330 in the metering process are set together as a series of setting conditions. For example, a metering start position, a rotation speed switching position, and a metering completion position are set. These positions are arranged in this order from the front to the rear, and represent the start and end points of the section in which the rotation speed is set. The rotation speed is set for each section. There may be one or more rotation speed switching positions. The rotation speed switching positions do not have to be set. In addition, a back pressure is set for each section.

[0072] In the filling step, the injection motor 350 is driven to move the screw 330 forward at a set moving speed, and the liquid molding material accumulated in front of the screw 330 is filled into the cavity space 801 in the mold device 800. The position and moving speed of the screw 330 are detected, for example, by using an injection motor encoder 351. The injection motor encoder 351 detects the rotation of the injection motor 350 and sends a signal indicating the detection result to the control device 700. When the position of the screw 330 reaches a set position, switching from the filling step to the pressure holding step (so-called V / P switching) is performed. The position where the V / P switching is performed is also called the V / P switching position. The set moving speed of the screw 330 may be changed depending on the position of the screw 330, time, etc.

[0073] The position and movement speed of the screw 330 in the filling process are set together as a series of setting conditions. For example, a filling start position (also called an "injection start position"), a movement speed switching position, and a V / P switching position are set. These positions are arranged in this order from the rear side to the front, and represent the start and end points of the section for which the movement speed is set. The movement speed is set for each section. There may be one or more movement speed switching positions. The movement speed switching positions do not have to be set.

[0074] An upper limit value for the pressure of the screw 330 is set for each section in which the moving speed of the screw 330 is set. The pressure of the screw 330 is detected by a load detector 360. When the pressure of the screw 330 is equal to or lower than the set pressure, the screw 330 is advanced at the set moving speed. On the other hand, when the pressure of the screw 330 exceeds the set pressure, the screw 330 is advanced at a moving speed slower than the set moving speed so that the pressure of the screw 330 is equal to or lower than the set pressure, for the purpose of protecting the mold.

[0075] After the position of the screw 330 reaches the V / P switching position in the filling process, the screw 330 may be temporarily stopped at the V / P switching position, and then the V / P switching may be performed. Immediately before the V / P switching, instead of stopping the screw 330, the screw 330 may be moved forward or backward at a slow speed. Furthermore, the screw position detector that detects the position of the screw 330 and the screw movement speed detector that detects the movement speed of the screw 330 are not limited to the injection motor encoder 351, and general detectors may be used.

[0076] In the holding pressure step, the injection motor 350 is driven to push the screw 330 forward, and the pressure of the molding material at the front end of the screw 330 (hereinafter also referred to as "holding pressure") is maintained at a set pressure, and the molding material remaining in the cylinder 310 is pushed toward the mold device 800. The molding material that is insufficient due to cooling contraction in the mold device 800 can be replenished. The holding pressure is detected, for example, by a load detector 360. The set value of the holding pressure may be changed depending on the elapsed time from the start of the holding pressure step. The holding pressure and the holding time for which the holding pressure is held in the holding pressure step may each be set multiple times, or may be set collectively as a series of setting conditions.

[0077] In the dwelling step, the molding material in the cavity space 801 in the mold device 800 is gradually cooled, and when the dwelling step is completed, the entrance to the cavity space 801 is blocked by the solidified molding material. This state is called a gate seal, and prevents the molding material from flowing back from the cavity space 801. After the dwelling step, the cooling step is started. In the cooling step, the molding material in the cavity space 801 is solidified. A measuring step may be performed during the cooling step in order to shorten the molding cycle time.

[0078] The injection device 300 of this embodiment is of an in-line screw type, but may be of a pre-plastication type or the like. A pre-plastication type injection device supplies molding material molten in a plasticization cylinder to an injection cylinder, and injects the molding material from the injection cylinder into a mold device. A screw is disposed in the plasticization cylinder so as to be rotatable but unable to move forward or backward, or a screw is disposed so as to be rotatable and able to move forward or backward. Meanwhile, a plunger is disposed in the injection cylinder so as to be able to move forward or backward.

[0079] Furthermore, the injection device 300 of this embodiment is a horizontal type in which the axial direction of the cylinder 310 is horizontal, but may be a vertical type in which the axial direction of the cylinder 310 is vertical. A mold clamping device to be combined with the vertical injection device 300 may be either a vertical type or a horizontal type. Similarly, a mold clamping device to be combined with the horizontal injection device 300 may be either a horizontal type or a vertical type.

[0080] (Mobile device) In the description of the moving device 400, similar to the description of the injection device 300, the moving direction of the screw 330 during filling (for example, the negative X-axis direction) is the front, and the moving direction of the screw 330 during metering (for example, the positive X-axis direction) is the rear.

[0081] The moving device 400 moves the injection device 300 forward and backward relative to the mold device 800. In addition, the moving device 400 presses the nozzle 320 against the mold device 800 to generate a nozzle touch pressure. The moving device 400 includes a hydraulic pump 410, a motor 420 as a drive source, a hydraulic cylinder 430 as a hydraulic actuator, and the like.

[0082] The hydraulic pump 410 has a first port 411 and a second port 412. The hydraulic pump 410 is a pump that can rotate in both directions, and by switching the rotation direction of the motor 420, it draws in hydraulic fluid (e.g., oil) from one of the first port 411 and the second port 412 and discharges it from the other, thereby generating hydraulic pressure. Note that the hydraulic pump 410 can also draw in hydraulic fluid from a tank and discharge the hydraulic fluid from one of the first port 411 and the second port 412.

[0083] The motor 420 operates the hydraulic pump 410. The motor 420 drives the hydraulic pump 410 with a rotational direction and rotational torque according to a control signal from the control device 700. The motor 420 may be an electric motor or an electric servo motor.

[0084] The hydraulic cylinder 430 has a cylinder body 431, a piston 432, and a piston rod 433. The cylinder body 431 is fixed to the injection device 300. The piston 432 divides the inside of the cylinder body 431 into a front chamber 435 as a first chamber and a rear chamber 436 as a second chamber. The piston rod 433 is fixed to the fixed platen 110.

[0085] A front chamber 435 of the hydraulic cylinder 430 is connected to a first port 411 of the hydraulic pump 410 via a first flow path 401. The hydraulic fluid discharged from the first port 411 is supplied to the front chamber 435 via the first flow path 401, thereby pushing the injection unit 300 forward. The injection unit 300 is moved forward, and the nozzle 320 is pressed against the fixed die 810. The front chamber 435 functions as a pressure chamber that generates a nozzle touch pressure of the nozzle 320 by the pressure of the hydraulic fluid supplied from the hydraulic pump 410.

[0086] On the other hand, the rear chamber 436 of the hydraulic cylinder 430 is connected to the second port 412 of the hydraulic pump 410 via the second flow path 402. The hydraulic fluid discharged from the second port 412 is supplied to the rear chamber 436 of the hydraulic cylinder 430 via the second flow path 402, thereby pushing the injection unit 300 backward. The injection unit 300 is moved backward, and the nozzle 320 is separated from the fixed mold 810.

[0087] In this embodiment, the moving device 400 includes the hydraulic cylinder 430, but the present invention is not limited to this. For example, instead of the hydraulic cylinder 430, an electric motor and a motion conversion mechanism that converts the rotational motion of the electric motor into the linear motion of the injection device 300 may be used.

[0088] (Control device) The control device 700 is configured, for example, by a computer, and has a CPU (Central Processing Unit) 701, a storage medium 702 such as a memory, an input interface 703, an output interface 704, and a communication interface 705 as shown in Fig. 1 and Fig. 2. The control device 700 performs various controls by causing the CPU 701 to execute a program stored in the storage medium 702. The control device 700 also receives signals from the outside via the input interface 703, and transmits signals to the outside via the output interface 704.

[0089] The control device 700 repeatedly performs a metering process, mold closing process, pressure increase process, mold clamping process, filling process, pressure holding process, cooling process, pressure release process, mold opening process, and ejection process, etc., to repeatedly produce molded products. A series of operations to obtain a molded product, for example, an operation from the start of a metering process to the start of the next metering process, is also called a "shot" or a "molding cycle." The time required for one shot is also called the "molding cycle time" or "cycle time."

[0090] One molding cycle includes, for example, a metering process, a mold closing process, a pressure increase process, a mold clamping process, a filling process, a pressure holding process, a cooling process, a pressure release process, a mold opening process, and an ejection process, in this order. The order here refers to the order in which each process starts. The filling process, the pressure holding process, and the cooling process are performed during the mold clamping process. The start of the mold clamping process may coincide with the start of the filling process. The completion of the pressure release process coincides with the start of the mold opening process.

[0091] In addition, in order to shorten the molding cycle time, a plurality of processes may be performed simultaneously. For example, the metering process may be performed during the cooling process of the previous molding cycle, or during the mold clamping process. In this case, the mold closing process may be performed at the beginning of the molding cycle. The filling process may be started during the mold closing process. The ejection process may be started during the mold opening process. In the case where an opening / closing valve for opening and closing the flow path of the nozzle 320 is provided, the mold opening process may be started during the metering process. This is because even if the mold opening process is started during the metering process, the molding material will not leak from the nozzle 320 as long as the opening / closing valve closes the flow path of the nozzle 320.

[0092] One molding cycle may include steps other than the metering step, mold closing step, pressure increase step, mold clamping step, filling step, pressure holding step, cooling step, pressure release step, mold opening step, and ejection step.

[0093] For example, after the dwelling step is completed, a pre-metering suck-back step may be performed in which the screw 330 is retracted to a preset metering start position before the metering step is started. This can reduce the pressure of the molding material accumulated in front of the screw 330 before the metering step starts, and can prevent the screw 330 from suddenly retracting at the start of the metering step.

[0094] Furthermore, after the metering step is completed, a post-metering suck-back step may be performed in which the screw 330 is moved back to a preset filling start position (also called the "injection start position") before the filling step is started. This can reduce the pressure of the molding material accumulated in front of the screw 330 before the filling step is started, and can prevent the molding material from leaking from the nozzle 320 before the filling step is started.

[0095] The control device 700 is connected to an operation device 750 that accepts input operations by a user and a display device 760 that displays a screen. The operation device 750 and the display device 760 may be configured, for example, by a touch panel 770 and may be integrated. The touch panel 770 as the display device 760 displays a screen under the control of the control device 700. For example, the screen of the touch panel 770 may display information such as the settings of the injection molding machine 10 and the current state of the injection molding machine 10. The touch panel 770 is capable of accepting operations in the displayed screen area. In addition, for example, an operation unit such as a button or an input field that accepts an input operation by a user may be displayed in the screen area of ​​the touch panel 770. The touch panel 770 as the operation device 750 detects an input operation on the screen by the user and outputs a signal corresponding to the input operation to the control device 700. As a result, for example, the user can operate the operation unit provided on the screen while checking the information displayed on the screen to perform settings of the injection molding machine 10 (including input of a setting value), etc. Furthermore, the user can operate an operation unit provided on the screen to perform an operation of the injection molding machine 10 corresponding to the operation unit. The operation of the injection molding machine 10 may be, for example, the operation (including stopping) of the clamping device 100, the ejector device 200, the injection device 300, the moving device 400, etc. The operation of the injection molding machine 10 may be, for example, switching of a screen displayed on the touch panel 770 serving as the display device 760, etc.

[0096] In this embodiment, the operation device 750 and the display device 760 are described as being integrated as the touch panel 770, but they may be provided independently. Also, a plurality of operation devices 750 may be provided. The operation device 750 and the display device 760 are disposed on the operation side (Y-axis negative direction) of the mold clamping unit 100 (more specifically, the fixed platen 110).

[0097] FIG. 3 is a diagram showing an example of the functional configuration of the control device 700 according to the present embodiment. As shown in FIG. 3, FIG. 3 shows components of the control device 700 of the injection molding machine 10 in the form of functional blocks. Each functional block shown in FIG. 3 is conceptual, and does not necessarily have to be physically configured as shown in the figure. All or a part of each functional block can be functionally or physically distributed and integrated in any unit. All or any part of each processing function performed by each functional block is realized by a program executed by the CPU 701. Alternatively, each functional block may be realized as hardware using wired logic. As shown in FIG. 3, the CPU 701 of the control device 700 includes an acquisition unit 711, a determination unit 712, an output control unit 713, an injection molding control unit 714, and a log information storage unit 715. In addition, the control device 700 includes a threshold information storage unit 702A in the storage medium 702.

[0098] The control device 700 according to this embodiment acquires a situation regarding an object discharged from a gap provided in the mold device 800, and judges whether or not an abnormality has occurred in the mold device 800 based on the situation regarding the object discharged from the gap. In this embodiment, a situation regarding the flow of gas (an example of an object) discharged from the gap is used as an example of a situation regarding an object discharged from the gap of the mold device 800. More specifically, an example is used in which the volume of the sound of air (an example of a gas) and gas (an example of a gas) discharged from the gap of the mold device 800 is used.

[0099] Fig. 4 is a cross-sectional view showing a mold apparatus 800 according to this embodiment. In the example shown in Fig. 4, a fixed mold 810 and a movable mold 820 included in the mold apparatus 800 are shown. In the example shown in Fig. 4, a sprue 802 is formed in the fixed mold 810. In addition, a runner (not shown) may be provided between the cavity space 801 and the sprue 802.

[0100] In this embodiment, the injection device 300 injects the liquid molding material, thereby filling the liquid molding material into the cavity space 801. The mold device 800 is provided with an air vent 803 for discharging air that was present in the cavity space 801 before filling and gas that is generated from the flow front of the molding material during filling when the cavity space 801 is filled with the molding material.

[0101] The air vent 803 is a groove provided on the parting line surface of the mold device 800 and has a depth of several μm to several tens of μm.

[0102] Then, the air that was present in the cavity space 801 before filling and the gas generated from the flow front of the molding material during filling are exhausted to the outside of the cavity space 801 through the air vent 803. The air and gas exhausted from the outlet 804 of the air vent 803 are exhausted to the outside of the mold device 800 through the air guide groove 805.

[0103] When the molding material is filled, sound is generated when air and gas pass through air vent 803. Hereinafter, the sound generated when air and gas pass through air vent 803 is referred to as discharge sound. When discharge sound is generated, it can be recognized that air and gas have passed through air vent 803.

[0104] Usually, injection molding is started by injection molding machine 10 in a state where no resin or oil due to gas has adhered to air vent 803. However, when injection molding is repeatedly performed by injection molding machine 10, when gas generated from the flow front in cavity space 801 passes through air vent 803, the resin and oil contained in the discharged gas adheres to and accumulates on the inner wall surface of air vent 803, accumulating as a mold deposit.

[0105] Each time mold deposits accumulate in the air vent 803, the air vent 803 becomes clogged, reducing the cross-sectional area of ​​the air and gas flow passages in the air vent 803. As the cross-sectional area of ​​the flow passages becomes smaller, the exhaust sound becomes louder.

[0106] When the air vent 803 is blocked and the air and gas cannot be discharged, the discharge sound is not generated. In other words, when the discharge sound is not generated, it means that the air and gas cannot be discharged from the mold device 800. When the air and gas cannot be discharged, the gas in the cavity space 801 near the air vent 803 is compressed instantaneously and becomes hot (as a result of becoming in a state close to adiabatic compression), and the molded product may burn. In addition, when the molding material is a molten resin, flammable gas is generated from the flow front (flow front), and when the flammable gas is compressed and becomes hot, the flammable gas burns, and the molded product may burn. In other words, the defective rate of the molded product may increase.

[0107] 5 is a diagram showing the correspondence relationship between the number of shots after the start of injection molding and the volume of the discharge sound. Line 1501 shows the volume of the discharge sound detected for each shot when injection molding is performed using, for example, an arbitrary molding material. Line 1502 shows the volume of the discharge sound detected for each shot when injection molding is performed using, for example, a molding material that generates less gas compared to the molding material of line 1501.

[0108] In line 1501, the discharge sound becomes louder as the number of shots increases. Then, the discharge sound suddenly decreases at shot number S1. Therefore, it can be recognized that at shot number S1, air vent 803 becomes clogged and air and gas can no longer be discharged.

[0109] In line 1502, the discharge sound does not increase as the number of shots increases, but the discharge sound drops sharply at shot number S2. Therefore, it can be recognized that at shot number S2, air vent 803 becomes clogged and air and gas cannot be discharged.

[0110] Therefore, the control device 700 according to the present embodiment judges whether or not an abnormality has occurred in the mold device 800 based on the discharge sound (an example of a situation) of the air and gas (an example of an object) discharged from an air vent (an example of a gap). The abnormality to be judged is, for example, blockage of the air vent 803.

[0111] Returning to FIG. 3, in this embodiment, a case will be described in which a microphone 781 provided in the injection molding machine 10 is used to detect the situation regarding an object discharged through the gap of the mold device 800.

[0112] The microphone (an example of a detection unit) 781 detects surrounding sounds including those of the mold device 800, converts the detected sounds into electrical signals, and outputs the electrical signals to the control device 700.

[0113] The microphone 781 in this embodiment outputs to the control device 700 an electrical signal indicating the exhaust sound (an example of a situation) of air and gas exhausted from the gap in the mold device 800 when molding material is injected from the injection device 300.

[0114] The microphone 781 may be provided at any location where the discharge sound can be detected. In this embodiment, the microphone 781 is provided on the movable platen 120 in Fig. 1 as an example. Note that this embodiment is not limited to providing the microphone 781 on the movable platen 120, and the microphone 781 may be provided at, for example, position 782 on the tie bar 140, or positions 783, 784, 785 on the frame 900 or the mold clamping unit frame 910. In this way, any location where the discharge sound from the mold device 800 can be detected may be used.

[0115] 3, various sensors 790 are a group of sensors provided in the injection molding machine 10. Specific sensors included in various sensors 790 will be described in the embodiments described later.

[0116] The threshold information storage unit 702A stores a threshold for determining whether or not the mold device 800 is abnormal. For example, the threshold information storage unit 702A stores a threshold Tl related to the volume of the discharge sound. The threshold stored in the threshold information storage unit 702A according to this embodiment is set by a user. Note that this embodiment is not limited to a method in which the threshold is set by the user, and the threshold may be automatically set by the injection molding machine 10.

[0117] The acquisition unit 711 acquires detection results by the microphone 781 and various sensors 790 provided in the injection molding machine 10. For example, the acquisition unit 711 acquires an electric signal indicative of a discharge sound from the microphone 781. As another example, the acquisition unit 711 acquires signals indicative of detection results from the various sensors 790. Furthermore, the acquisition unit 711 acquires a threshold value Tl from the threshold value information storage unit 702A. A specific value of the threshold value Tl will be described later.

[0118] The determination unit 712 determines whether or not an abnormality has occurred in the mold device 800 based on a change in the volume of the discharge sound indicated by the electrical signal acquired from the microphone 781. Specifically, the determination unit 712 determines whether or not the volume of the discharge sound indicated by the electrical signal acquired from the microphone 781 is smaller than a threshold value Tl acquired from the threshold information storage unit 702A. If it is determined that the volume of the discharge sound is smaller than the threshold value Tl, it determines that the air vent 803 is clogged and gas burning may have occurred in the molded product.

[0119] Furthermore, the determination unit 712 according to this embodiment determines whether or not an abnormality has occurred in the mold device 800 based on the time at which the discharge sound is generated. Specifically, the determination unit 712 determines whether or not there is a delay in the time from when the filling starts until the discharge sound is detected. In other words, if there is a delay in the time until the discharge sound is detected, the temperature of the molding material may be lowered due to the delay in filling, or the surface temperature of the inner wall of the cavity space 801 may be lowered, reducing the fluidity of the molding material, which may result in a short shot in the molded product.

[0120] Therefore, in this embodiment, the threshold value Tt is defined as a value obtained by adding a predetermined margin to the time from the start of filling to the detection of the discharge sound when the molded product is a non-defective product.

[0121] Then, the judgment unit 712 judges whether or not the time from the start of injection molding to the detection of the discharge sound in the current injection of the molding material is longer than the threshold value Tt, in other words, the time from the start of the previous injection molding to the detection of the discharge sound. If the judgment unit 712 judges that the time is longer than the threshold value Tt, it judges that there is a possibility that a short shot has occurred in the molded product.

[0122] The output control unit 713 controls the output of information to one or more of the display device 760, a speaker (not shown), and an external device. The external device may be, for example, a machine for removing molded products, a mobile communication terminal (not shown) carried by a user, or a management device (not shown) for managing the work site.

[0123] Furthermore, the output control unit 713 outputs information based on the determination result of the determination unit 712, in accordance with the settings on a setting screen (described later).

[0124] For example, the output control unit 713 outputs screen information to the display device 760. Fig. 6 is a diagram illustrating a setting screen output by the output control unit 713 according to this embodiment. In the setting screen shown in Fig. 6, the user can set a criterion for determining whether or not there is an abnormality.

[0125] The setting screen 1600 shown in FIG. 6 includes a field 1601 for setting the unit of sound loudness, a field 1602 for the actual normal value of the discharge sound, a field 1603 for setting the threshold value in the event of an abnormality, a field 1604 for setting an alarm in the event of an abnormality, a field 1605 for setting production stop in the event of an abnormality, and a field 1606 for the actual loudness of the discharge sound during the most recent molding.

[0126] A sound loudness unit setting field 1601 switches between "dB" (decibels) and "Pa" (pascals) in response to a user operation. In response to the switching of the sound loudness unit setting field 1601, the display of a normal value performance field 1602 for discharge sound, a threshold value setting field 1603 for when an abnormality occurs, and a production stop setting field 1605 for when an abnormality occurs are switched.

[0127] The actual result column 1602 for the normal value of the discharge sound displays, as the normal value of the discharge sound, the detection result of the volume of the discharge sound detected by the microphone 781 when the injection molding machine 10 is operated immediately after cleaning of the mold device 800 in the injection molding machine 10. The discharge sound caused by injection molding immediately after cleaning is the discharge sound when no mold deposit has accumulated in the air vent 803. The user can set the abnormality threshold setting column 1603 shown below by referring to the normal value of the discharge sound displayed in the actual result column 1602.

[0128] The abnormality threshold setting field 1603 is a field for receiving an input from a user of a threshold Tl for the volume of the discharge sound in an abnormal state. The threshold Tl set in the abnormality threshold setting field 1603 is stored in the threshold information storage unit 702A. The determination unit 712 then determines whether the discharge sound detected by the microphone 781 is smaller than the threshold Tl read from the threshold information storage unit 702A.

[0129] The threshold value Tl of the discharge sound in an abnormal state is set to a value smaller than the normal value shown in the actual result column 1602 of the normal value of the discharge sound so that the normal value shown in the actual result column 1602 is not detected as abnormal. Note that the threshold value Tl of the discharge sound may be automatically set based on the normal value shown in the actual result column 1602.

[0130] As a result, the judgment unit 712 judges that an abnormality has occurred in the mold device 800 if the magnitude of the discharge detected in the current injection of molding material is smaller than the threshold value Tl, in other words, if it is smaller than the magnitude of the sound detected in the previous injection of molding material.

[0131] The abnormality alarm setting field 1604 is a field for receiving a selection from the user as to whether or not to output an alarm sound when the determination unit 712 determines that the discharge sound is low. The abnormality alarm setting field 1604 receives a selection of "on" or "off" from the user. When "on", the output control unit 713 outputs an alarm sound via a speaker (not shown) when the discharge sound becomes low. When "off", the output control unit 713 does not output an alarm sound via a speaker (not shown) when the discharge sound becomes low.

[0132] The setting field 1605 for stopping production when an abnormality occurs is a field for receiving a selection from the user as to whether or not to stop injection molding when the determination unit 712 determines that the discharge sound is low. The setting field 1605 for stopping production when an abnormality occurs receives a selection of "ON" or "OFF" from the user. When "ON", the injection molding control unit 714 (described below) stops injection molding when the discharge sound becomes low. When "OFF", the injection molding control unit 714 continues injection molding even when the injection sound becomes low.

[0133] The actual result column 1606 of the loudness of the discharge sound during the most recent molding displays the detection result of the loudness of the discharge sound detected by the microphone 781 during the most recent injection molding when injection molding is being performed by the injection molding machine 10.

[0134] The injection molding control unit 714 executes processing for producing a molded product with the injection molding machine 10. The injection molding control unit 714 also performs control related to injection molding based on the judgment result of the judgment unit 712, in accordance with the settings on the setting screen described above. For example, when "ON" is set in the setting field 1605 for production stop in case of abnormality, the injection molding control unit 714 stops injection molding when the discharge sound becomes small.

[0135] The log information storage unit 715 stores (saves) log information related to injection molding by the injection molding machine 10 in the storage medium 702. The log information related to injection molding may include setting information set for injection molding by the injection molding machine 10, performance information indicating detection results by various sensors 790 for the injection molding machine 10 to perform injection molding, and judgment results by the judgment unit 712.

[0136] Fig. 7 is a diagram illustrating a log information screen output by the output control unit 713 according to this embodiment. The log information screen shown in Fig. 7 displays log information related to injection molding. Furthermore, the log information screen allows settings for the log information storage unit 715 to store the log information.

[0137] The log information screen 1700 shown in FIG. 7 displays a total number 1711, a number of good items 1712, a number of defective items 1713, a number of rejected items 1714, a logging button 1715, a monitoring settings button 1716, a save button 1717, an update button 1718, a statistics list 1720, and a performance list 1730.

[0138] The statistics list 1720 shows statistical information (for example, average, range, maximum, minimum, standard deviation) for each of the setting fields 1721 to 1727. The contents shown in the setting fields 1721 to 1727 can be set by the operator. In this embodiment, it is possible to display, monitor, and save log information for the items shown in the setting fields 1721 to 1727. Note that monitoring in this embodiment refers to judging whether or not an item is non-defective based on a predetermined standard.

[0139] The statistical information is information calculated based on actual values ​​(one example of parameters) obtained each time a molded product is manufactured by performing injection molding with the injection molding machine 10, and includes, for example, the average, range, maximum, minimum, and standard deviation calculated for each of the setting fields 1721 to 1727 in the statistics list 1720. Note that this embodiment shows an example of statistical information, and statistical information other than the average, range, maximum, minimum, and standard deviation, such as an integral value, may be used. Also, the items for which the statistical information is calculated are not limited to the items set in the setting fields 1721 to 1727, and may be other items.

[0140] The output control unit 713 calculates statistical information based on performance values ​​(one example of parameters) obtained by the various sensors 790 and the microphone 781 during injection molding within the range shown in the performance list 1730. Then, the output control unit 713 displays the calculated statistical information in the statistics list 1720.

[0141] The "monitoring", "monitoring value", and "range" in the statistics list 1720 are information for determining whether or not the molded product in the corresponding setting field is defective.

[0142] When the monitoring in the statistics list 1720 is "OFF", the control device 700 does not perform monitoring, and when it is "ON", the control device 700 performs monitoring. When it is "ON", the control device 700 judges whether or not the measured performance value in the item indicated in the setting field satisfies the criteria indicated by the "monitoring value" and "range" (for example, whether or not it is included in the "range" with the "monitoring value" as the median). As another example, the control device 700 may judge whether or not the criteria based on the set plus tolerance and minus tolerance are satisfied with the set monitoring value as the median, or whether or not the criteria of the set upper limit value and lower limit value are satisfied. Note that the monitoring method of the performance value may be any method, regardless of the above-mentioned method. The monitoring is switched by the monitoring setting button 1716.

[0143] The "Defective" section of the statistics table 1720 indicates the number of molded articles that do not meet the criteria indicated by the "Monitoring Value" and "Range."

[0144] The "Cycle time" in the setting field 1721, the "Filling time" in the setting field 1722, and the "Metering time" in the setting field 1723 are items set to monitor the time required for the cycle, filling, and metering.

[0145] The "VP switching position" in the setting field 1724 is an item set to monitor the position of the screw 330 when switching from the filling process to the pressure holding process (V / P switching position). The "minimum cushion position" in the setting field 1725 is an item set to monitor the position of the screw 330 when it moves to the frontmost position when pressure is applied after filling the molding material into the mold device 800. The "filling peak pressure" in the setting field 1726 is an item set to monitor the peak value of the pressure when the molding material is filled.

[0146] The "volume of discharge noise" in the setting field 1727 is an item set in order to monitor the discharge noise caused by air and gas discharged every time a molded product is molded.

[0147] The setting fields 1721 to 1727 can be changed to items that the operator wishes to monitor. A method for changing the items will not be described here.

[0148] For example, "time until discharge sound is detected" may be set in the setting field 1727. Then, the determination unit 712 may determine whether or not the time from the start of injection molding until the discharge sound is detected is longer than a threshold value Tt, based on the settings of the "monitoring value" and "range" in the setting field 1727.

[0149] The result list 1730 shows a list of setting information (e.g., setting values) for the items set in the setting fields 1721 to 1727 or result values ​​measured by various sensors for each shot. The items set in the setting fields 1721 to 1727 are set to "CH1" to "CH7". In addition, each shot is associated with a "shot number", "time" of injection molding, and "identification" of injection molding as information indicating the shot.

[0150] The logging button 1715 is a button for accepting a selection of whether or not to save as log information the performance values ​​shown in the performance list 1730. When the logging button 1715 is pressed ("DATA LOGGING ON" is displayed), the log information saving unit 715 saves the information shown in the performance list 1730 (for example, performance values ​​from various sensors) and the like in the storage medium 702 as log information.

[0151] That is, in this embodiment, the volume of the discharge sound for each shot and the like can be stored in the storage medium 702 as log information.

[0152] The monitoring setting button 1716 is a button for accepting whether or not to monitor according to the monitoring items in the statistics list 1720. When the monitoring setting button 1716 is pressed (displaying "Monitoring On"), each shot is monitored for defects and the monitoring results are included in the log information. When the monitoring setting button 1716 is pressed, it becomes possible to switch the monitoring for each of the setting fields 1721 to 1727 in the statistics list 1720 to "Off" or "On".

[0153] The save button 1717 is a button for accepting whether or not to save the statistical values ​​(for example, average, range, maximum, minimum, standard deviation, etc.) for each of the setting fields 1721 to 1727. When the save button 1717 is pressed, the log information saving unit 715 saves the statistical values ​​for each of the setting fields 1721 to 1727 and the performance values ​​shown in the performance list 1730 as log information in the storage medium 702. In this embodiment, an example of saving the statistical values ​​and the performance values ​​will be described, but the present invention is not limited to saving the statistical values ​​and the performance values. For example, when a setting is shown in the performance list 1730, the log information saving unit 715 may save the setting value together. Furthermore, even if the setting value is not shown in the performance list 1730, the log information saving unit 715 may save the setting value in association with the performance value shown in the performance list 1730.

[0154] The update button 1718 is a button for accepting whether or not to update the statistics list 1720 and the performance list 1730 every time injection molding is completed by the injection molding machine 10. When the update button 1718 is pressed (displays "Always"), the statistics list 1720 and the performance list 1730 are updated every time injection molding is completed by the injection molding machine 10.

[0155] Total number 1711 indicates the number of molded products molded by the injection molding machine 10. Number of good products 1712 indicates the number of molded products that are determined to be good products based on "Monitoring", "Monitoring value", and "Range". Number of defective products 1713 indicates the number of molded products that are determined to be defective products based on "Monitoring", "Monitoring value", and "Range". Number of rejected products 1714 indicates the number of rejected molded products.

[0156] As described above, when a molded product is produced from a molding material by the injection molding machine 10, the output control unit 713 of the control device 700 displays, for each molded product, actual values ​​(an example of detection results) detected by various sensors in the process of producing the molded product in the actual result list 1730 of the display device 760.

[0157] For example, "CH7" corresponds to "volume of discharge sound" in the result list 1730. That is, in the "CH7" column of the result list 1730, the volume of the discharge sound detected by the microphone 781 for each shot is displayed as a result value.

[0158] Furthermore, when the logging button 1715 is pressed, the log information storage unit 715 stores information shown in the results list 1730 (e.g., results values ​​from various sensors) as log information in the storage medium 702, and the loudness of the discharge sound generated each time a molded product is molded is stored as log information in the storage medium 702. Therefore, the loudness of the discharge sound generated when molding the molded product can be managed for each molded product. Also, when "time until discharge sound is detected" is set for any channel in the results list 1730, the time until discharge sound generated when molding the molded product can be managed for each molded product.

[0159] Next, a description will be given of a procedure of processing based on the discharge sound from the mold device 800, which is executed by the control device 700 according to this embodiment. Fig. 8 is a flowchart showing a procedure of processing based on the discharge sound from the mold device 800, which is executed by the control device 700 according to this embodiment.

[0160] First, the determination unit 712 determines whether or not "ON" is selected in the setting field 1605 for stopping production when an abnormality occurs, in other words, whether or not a selection has been made to stop operation when an abnormality is detected in the volume of the discharge sound (S1801). Note that in the processing procedure shown in Fig. 8, the description will be made assuming that "ON" is set in the setting field 1604 for the alarm when an abnormality occurs, and that the log information storage unit 715 is set to store log information.

[0161] When the determination unit 712 determines that the selection to stop the operation has been made (S1801: YES), the injection molding control unit 714 performs molding processing to produce a molded product by the injection molding machine 10 (S1802).

[0162] Then, the acquisition unit 711 acquires, from the microphone 781, the discharge sound from the mold device 800 during the filling of the molding material (S1803).

[0163] Then, the determination unit 712 determines whether the time until the discharge sound is detected is equal to or greater than the threshold value Tt (S1804). When the determination unit 712 determines that the time until the discharge sound is detected is equal to or greater than the threshold value Tt, the output control unit 713 determines that there is a possibility that a short shot has occurred in the current molded product, and outputs an instruction to the take-out machine to discard the current molded product (S1805).

[0164] When the determining unit 712 determines that the time until the discharge sound is detected is less than the threshold value Tt, the process proceeds to S1806 without performing any particular process.

[0165] Then, the determination unit 712 determines whether the volume of the discharge sound is smaller than the threshold value Tl read from the threshold value information storage unit 702A (S1806). If it is determined that the volume of the discharge sound is equal to or larger than the threshold value Tl (S1806: YES), the shaping process is performed again from S1802.

[0166] On the other hand, if the judgment unit 712 determines that the volume of the discharge sound is smaller than the threshold value Tl (S1806: NO), the output control unit 713 outputs an alarm sound from a speaker (not shown) indicating that an abnormality has occurred in the mold device 800 (S1807).

[0167] Then, the log information storage unit 715 stores, in the storage medium 702, as log information, the fact that the volume of the discharge sound has become smaller than the threshold value Tl and that an abnormality has occurred in the mold device 800 (S1808).

[0168] Then, the injection molding control unit 714 stops the molding process for producing a molded product in the injection molding machine 10 (S1809).

[0169] On the other hand, if the judgment unit 712 determines that a selection to stop the operation has not been made (S1801: NO), the injection molding control unit 714 performs molding processing to produce a molded product in the injection molding machine 10 (S1810).

[0170] Then, the acquisition unit 711 acquires, from the microphone 781, the discharge sound from the mold device 800 during the filling of the molding material (S1811).

[0171] Then, the determination unit 712 determines whether the time until the discharge sound is detected is equal to or greater than the threshold value Tt (S1812). When the determination unit 712 determines that the time until the discharge sound is detected is equal to or greater than the threshold value Tt, the output control unit 713 determines that there is a possibility that a short shot has occurred in the current molded product, and outputs an instruction to the take-out machine to discard the current molded product (S1813).

[0172] When the determining unit 712 determines that the time until the discharge sound is detected is less than the threshold value Tt, the process proceeds to S1814 without performing any particular process.

[0173] Then, the determination unit 712 determines whether the volume of the discharge sound is smaller than the threshold value Tl read from the threshold value information storage unit 702A (S1814). If it is determined that the volume of the discharge sound is equal to or larger than the threshold value Tl (S1814: YES), the forming process is performed again from S1810.

[0174] On the other hand, if the judgment unit 712 determines that the volume of the discharge sound is smaller than the threshold value Tl (S1814: NO), the output control unit 713 outputs an alarm sound from a speaker (not shown) indicating that an abnormality has occurred in the mold device 800 (S1807).

[0175] Then, the log information storage unit 715 stores, in the storage medium 702, as log information, the fact that the volume of the discharge sound has become smaller than the threshold value Tl and that an abnormality has occurred in the mold device 800 (S1816).

[0176] The injection molding control unit 714 continues the molding process for producing a molded product by the injection molding machine 10 (S1817). During this molding process, the output of the alarm sound may continue and the processes of S1811 to S1813 may also be performed.

[0177] In this embodiment, whether or not there is an abnormality in the mold device 800 is determined based on the discharge sound detected by a microphone 781 provided outside the mold device 800. In other words, there is no need to provide a sensor in the mold device 800 to detect an abnormality in the mold device 800. In other words, since processing of the mold device 800 is not required, the workload can be reduced. In addition, there is no need to attach a sensor to each mold device 800, which can reduce costs.

[0178] Conventionally, a technology has been proposed to predict the quality of a molded product by installing sensors that detect temperature and pressure in the cavity, but this technology requires a sensor hole to be provided in the mold device to install the sensor. Depending on the position where the measurement is to be performed, there are cases where the sensor cannot be inserted into the mold device, or where the sensor cannot be installed because the sensor marks will remain on the molded product that will become the appearance part.

[0179] In contrast, in this embodiment, whether or not there is an abnormality in the mold device 800 is determined based on the discharge sound detected by a microphone 781 installed outside the mold device 800. Therefore, since there is no need to provide a sensor hole or the like in the mold device 800, the workload is reduced, and since no sensor marks are left, the accuracy of the molded product can be improved.

[0180] In addition, when installing a sensor in an existing mold device that does not have a sensor, a large-scale modification may be required. In addition, when disassembling and cleaning a mold device with a built-in sensor, the disassembly and reassembly work must be done carefully so as not to damage the sensor, so that the disassembly and cleaning takes time and the workload is large.

[0181] In contrast, in the present embodiment, whether or not there is an abnormality in the mold device 800 is determined based on the discharge sound detected by a microphone 781 installed outside the mold device 800, thereby shortening the time required for disassembly and cleaning and reducing the workload.

[0182] (Modification of the first embodiment) In the above-described embodiment, an example has been described in which the microphone 781 is provided outside the mold apparatus 800. However, the above-described embodiment is not limited to an example in which the microphone 781 is provided outside the mold apparatus 800, and the microphone 781 may be provided in the mold apparatus 800.

[0183] 4, the microphone 781 may be provided, for example, at a position 791 near an air vent 803 of the mold apparatus 800. As another example, the microphone 781 may be provided at a position 792 near an outlet 804 of the air vent 803. Furthermore, the microphone 781 may be provided at a position 793 on the outer periphery side of the outlet 804 of the air vent 803. Furthermore, the microphone 781 may be provided at positions 794 and 795 on the outer periphery of the mold apparatus 800.

[0184] In this modification, by providing the microphone 781 near the air vent 803 of the mold device 800, it is possible to suppress the influence of other sounds or the operating sound of the injection molding machine 10 when the microphone 781 collects the discharge sound. Therefore, this modification can realize an improvement in the detection accuracy of the discharge sound.

[0185] Second Embodiment In the above-described embodiment and modified example, a case where the air vent 803 of the mold device 800 is completely blocked, in other words, where the discharge of gas from the gap is suppressed, has been described as an abnormality of the mold device 800. However, in this embodiment, the abnormality of the mold device is not limited to a case where the air vent 803 is completely blocked, and for example, the mold device 800 may be determined to be abnormal at a stage where mold deposits have accumulated in the air vent 803.

[0186] In the above-mentioned embodiment and modified example, an example of judging whether or not the discharge sound has become smaller than the threshold value Tl has been described. However, the above-mentioned embodiment and modified example are not limited to a method of judging whether or not the discharge sound has become smaller than the threshold value Tl. Therefore, in the second embodiment, an example of using the frequency of the discharge sound as an example of a state related to an object discharged from an air vent (an example of a gap) 803 of a mold device 800 will be described. The control device 700 according to this embodiment judges whether or not a gas burn is imminent based on the frequency of the discharge sound detected by the microphone 781.

[0187] Conventionally, a user would check whether or not gas burns have occurred by referring to a molded product produced by an injection molding machine. If gas burns have occurred, the user would stop production using the injection molding machine and clean the mold device. In some cases, the mold device would need to be disassembled and cleaned, which requires time and manpower.

[0188] The number of shots from cleaning until gas burns occur varies depending on many factors, such as the lot of the molding material (subtle differences in components), the moisture content of the molding material, the condition of the parting line surface of the mold device, the surface condition of the mold device, how well the mold device is cleaned, the degree of gas generation from the molding material (variation in plasticization), the temperature and dimensions of the mold device, the mold clamping force, etc. For this reason, it is difficult to calculate the number of shots that will prevent gas burns from occurring.

[0189] Therefore, in order to prevent gas burns from occurring, users would repeat injection molding several times from cleaning until gas burns occurred, and count the number of shots until gas burns occurred. Then, among the multiple shots until gas burns occurred, users would stop injection molding and clean the mold device when the number of shots was less than the minimum number of shots. Furthermore, there was a tendency to set the number of shots for cleaning with a certain margin from the minimum number of shots.

[0190] For example, if gas burns occurred after 10,000 shots the first time, after 6,000 shots the second time, and after 13,000 shots the third time, then from the fourth time onwards, the die equipment was cleaned after 5,000 shots, taking into account a certain margin.

[0191] In this case, injection molding is stopped at 5,000 shots to clean the mold device, but gas burns may not occur until around 13,000 shots. In other words, the mold device needs to be cleaned more frequently, which may result in a decrease in production efficiency.

[0192] In this embodiment, a method for determining whether or not gas burning is imminent will be described.

[0193] The acquisition unit 711 according to this embodiment acquires the discharge sound from the microphone 781. The discharge sound can also be regarded as vibration. Furthermore, the acquisition unit 711 calculates the frequency of the acquired discharge sound from the discharge sound. Note that in this embodiment, the frequency of the discharge sound may be acquired from a vibration sensor or the like instead of the microphone 781.

[0194] As described above, every time the injection molding machine 10 repeats injection molding, mold deposits accumulate in the air vent 803, and the cross-sectional area of ​​the air vent 803 becomes narrower. Therefore, the acquisition unit 711 according to this embodiment calculates the cross-sectional area of ​​the air vent 803 from the frequency of the discharge sound. The frequency of the discharge sound is shown in the following formula (1). The variables shown in formula (1) are a positive integer n, a sound speed v, a resonating tube length L, and a tube diameter d.

[0195] f = nv / (2 (L + 0.8 × d) ... (1)

[0196] The length L of the resonating tube corresponds to the length of air vent 803, and the area derived from the diameter d of the tube corresponds to the cross-sectional area of ​​air vent 803. Next, the dimensions of air vent 803 will be described.

[0197] Fig. 9 is a diagram illustrating the dimensions of an air vent 803 of a mold apparatus 800 according to this embodiment. In a part of the mold apparatus 800 shown in Fig. 9, an air vent 803 and an air guide groove 805 for discharging gas and air from a cavity space 801 to the outside are shown. The air guide groove 805 is provided on the outer periphery side of the air vent 803 and is formed to have a larger cross-sectional area than the air vent 803.

[0198] The air vent 803 is formed with a land length La, a depth da, and a width wa. The land length La corresponds to the length L of the tube in formula (1), and the area calculated from the depth da and the width wa corresponds to the area derived from the diameter d of the tube.

[0199] Then, when air vent 803 begins to be clogged by mold deposits, the cross-sectional area of ​​air vent 803, which corresponds to the area of ​​the pipe diameter d, becomes smaller. It can be seen from equation (1) that when the cross-sectional area of ​​air vent 803 becomes smaller, the frequency of the exhaust sound becomes larger.

[0200] Therefore, in this embodiment, a threshold value Tf of the frequency of the discharge sound is stored in the threshold information storage unit 702A. The threshold value Tf may be determined based on the frequency of the discharge sound detected by the microphone 781 at the timing before the air vent 803 is completely blocked during a test run, for example.

[0201] Then, the determination unit 712 determines whether or not an abnormality has occurred in the mold device 800 based on a change in the frequency of the discharge sound (an example of vibration) calculated by the acquisition unit 711. Specifically, the determination unit 712 determines whether or not the frequency of the discharge sound (an example of vibration) calculated by the acquisition unit 711 is greater than the threshold Tf stored in the threshold information storage unit 702A. If it is determined that the frequency is greater than the threshold Tf stored in the threshold information storage unit 702A, it determines that the air vent 803 is blocked and gas burning is about to occur. Then, the output control unit 713 displays on the display device 760 a message that gas burning is about to occur. The user can recognize that gas burning is about to occur. Therefore, the user can stop the injection molding machine 10 and clean the mold device 800 before gas burning occurs.

[0202] Furthermore, the output control unit 713 may display the actual value of the frequency of the discharge sound in a setting field (for example, setting field 1727) of the log information screen. Furthermore, the log information screen can also accept settings for monitoring the frequency of the discharge sound. This makes it possible to determine that a molded product is defective when the frequency of the discharge sound is greater than a threshold value Tf. Furthermore, the actual value of the frequency of the discharge sound can be stored as log information.

[0203] In addition, in this embodiment, the method of determining whether or not gas burning is imminent is not limited to determining the frequency of the discharge sound. As shown in Fig. 5, as gas burning approaches, the discharge sound becomes louder. Therefore, the determination unit 712 may determine whether or not gas burning is imminent based on whether or not the volume of the discharge sound has become larger than a predetermined threshold value.

[0204] In this embodiment, the output control unit 713 notifies the user that gas burning is imminent, so that the mold device 800 can be cleaned before gas burning occurs. This can improve production efficiency. The judgment according to this embodiment may be combined with the judgment according to the above-mentioned embodiment.

[0205] In this embodiment, production of molded products can be continued until just before gas burns occur in the molded products, so that the frequency of cleaning the mold device 800 can be minimized, thereby improving productivity.

[0206] (Third embodiment) In the above-mentioned embodiment, an example of detecting the discharge sound of gas and air discharged from the mold device 800 using the microphone 781 has been described. However, in the above-mentioned embodiment, the method is not limited to the method of using the microphone 781. Therefore, in the third embodiment, an example of detecting the flow rate of gas and air discharged from the mold device 800 will be described as an example of detecting the situation regarding an object discharged from the air vent (an example of a gap) 803 of the mold device 800. That is, in the above-mentioned embodiment, an example of determining whether or not a gas burn is imminent or whether or not the air vent 803 of the mold device 800 is completely blocked based on the frequency of the discharge sound or the volume of the discharge sound as an example of the situation in which gas is discharged from the gap has been described. However, in the above-mentioned embodiment, the situation in which gas is discharged from the gap is not limited to the frequency of the discharge sound or the volume of the discharge sound. In this embodiment, as an example of the situation in which gas is discharged from the gap, determining whether or not a gas burn is imminent based on the flow rate of gas and air.

[0207] In this embodiment, a flow meter is included as one of various sensors 790 of the injection molding machine 10. The flow meter according to this embodiment may be provided at a position 791 near an air vent 803 of a mold device 800 shown in FIG. 4, or may be provided at a position 792 near an outlet 804 of the air vent 803.

[0208] The acquisition unit 711 calculates the flow velocity by dividing the flow rate detected by the flow meter by the measurement time.

[0209] In the case where the mold assembly 800 has multiple air vents 803, when one air vent 803 is filled with mold deposits, the air and gas discharged from the other air vents 803 is concentrated. Therefore, the flow rate and flow velocity of the air and gas discharged from the other air vents 803 increases.

[0210] In this embodiment, the flow velocity threshold value Tr is stored in the threshold information storage unit 702A. The threshold value Tr may be determined based on the flow rate detected by the flow meter at the time when one air vent 803 is filled with mold deposits during a test run, for example.

[0211] Then, the determination unit 712 determines whether or not the flow velocity calculated by the acquisition unit 711 is greater than the threshold value Tr stored in the threshold information storage unit 702A. If it is determined that the flow velocity is greater than the threshold value Tr stored in the threshold information storage unit 702A, it determines that gas burning is about to occur due to blockage of any one of the multiple air vents 803, etc. Then, the output control unit 713 displays on the display device 760 a message that gas burning is about to occur. The user can recognize that gas burning is about to occur. Therefore, the user can stop the injection molding machine 10 and clean the mold device 800 before gas burning occurs.

[0212] Furthermore, the determination unit 712 determines whether the flow velocity calculated by the acquisition unit 711 has become "0". When the flow velocity has become "0", the determination unit 712 determines that the air vent 803 is completely blocked. The control when the air vent 803 is completely blocked is the same as in the above-mentioned embodiment, and the description thereof will be omitted.

[0213] Furthermore, the output control unit 713 may display the actual value of the flow rate in a setting field (for example, setting field 1727) on the log information screen. Furthermore, the log information screen can also accept settings for monitoring the flow rate. This makes it possible to determine that a molded product is defective when the flow rate is greater than a threshold value Tr. Furthermore, the actual value of the flow rate can be stored as log information.

[0214] (Fourth embodiment) In the fourth embodiment, an example of detecting the temperature of gas and air discharged from a mold device 800 will be described as an example of detecting the condition of an object discharged from an air vent (an example of a gap) 803 of the mold device 800.

[0215] If the air vent 803 of the mold device 800 becomes clogged and the flow path cross-sectional area of ​​the air vent 803 becomes smaller, the air and gas in the cavity space 801 become difficult to discharge, and are instantaneously compressed, causing the air and gas to become hot (in other words, a state close to adiabatic compression occurs).

[0216] In this embodiment, the various sensors 790 of the injection molding machine 10 include a temperature sensor. The temperature sensor may be a radiation thermometer or a thermocouple. The temperature sensor according to this embodiment may be provided at a position 791 near an air vent 803 of a mold device 800 shown in FIG. 4, or at a position 792 near an outlet 804 of the air vent 803.

[0217] The acquisition unit 711 acquires the temperatures of the air and gas detected by the temperature sensors.

[0218] In this embodiment, the temperature threshold Tte is stored in the threshold information storage unit 702A. The threshold Tte may be determined based on the temperature detected by the temperature sensor before the air vent 803 is completely blocked during a test run, for example.

[0219] Then, the determination unit 712 determines whether or not the flow velocity calculated by the acquisition unit 711 is greater than the threshold value Tte stored in the threshold information storage unit 702A. If it is determined that the flow velocity is greater than the threshold value Tte stored in the threshold information storage unit 702A, it determines that the air vent 803 is clogged and gas burning is about to occur. Then, the output control unit 713 displays on the display device 760 a message indicating that gas burning is about to occur. The user can recognize that gas burning is about to occur. Therefore, the user can stop the injection molding machine 10 and clean the mold device 800 before gas burning occurs.

[0220] Furthermore, the output control unit 713 may display the actual temperature value in a setting field (for example, setting field 1727) on the log information screen. Furthermore, the log information screen can also accept settings for monitoring the temperature. This makes it possible to determine that a molded product is defective when the temperature exceeds a threshold value Tte. Furthermore, the temperature can be stored as log information.

[0221] Fifth embodiment In the fifth embodiment, as an example of detecting the condition of an object discharged from an air vent (an example of a gap) 803 of the mold apparatus 800, an example of detecting one or more of the concentration of components of the gas and air discharged from the mold apparatus 800 (when gas burns, the concentration of the components changes after combustion) and the amount of moisture (humidity) is described.

[0222] If the air vent 803 of the mold device 800 becomes clogged and the flow path cross-sectional area of ​​the air vent 803 becomes smaller, the air and gas in the cavity space 801 become difficult to discharge, and are instantaneously compressed, causing the air and gas to become hot (in other words, a state close to adiabatic compression occurs).

[0223] The gas generated from the flow front of the molding material varies depending on the type of molding material, but it often contains flammable gases such as methane and ethylene. If flammable gas is included, it may exceed the ignition point and burn.

[0224] When methane is present, combustion results in the following changes in composition: In case of complete combustion: CH4 + 2O2 → CO2 + 2H2O Incomplete combustion: 2CH4+3O2→2CO+4H2O

[0225] When ethylene is present, the following changes in composition occur upon combustion: C2H4+3O2→2H2O+2CO2

[0226] In other words, if the air vent 803 is not clogged with mold deposits, combustible gases do not burn, so large amounts of methane, ethylene, and oxygen are detected. On the other hand, if the air vent 803 becomes clogged with mold deposits, combustible gases burn, so the amounts of methane, ethylene, and oxygen decrease, and large amounts of carbon dioxide, carbon monoxide, and water are detected.

[0227] Therefore, in this embodiment, an example is taken in which a gas detection sensor capable of detecting changes in the concentration of components such as methane, ethylene, oxygen, carbon dioxide, and carbon monoxide, or in the amount of moisture is included as the various sensors 790 of the injection molding machine 10. The gas detection sensor may be provided at a position 791 near an air vent 803 of a mold device 800 shown in FIG. 4, or at a position 792 near an outlet 804 of the air vent 803.

[0228] In the present embodiment, an example is shown in which the flammable gas generated from the molding material includes methane and ethylene, but molding materials that generate other flammable gases may also be used.

[0229] The acquisition unit 711 acquires the concentration of the component methane, ethylene, oxygen, carbon dioxide, or carbon monoxide, or the amount of moisture, detected by the gas detection sensor.

[0230] In this embodiment, the threshold value Tc related to the concentration or moisture content of the gas component described above is stored in the threshold value information storage unit 702A. The threshold value Tc may be determined based on the concentration or moisture content of the component detected by the gas detection sensor before the air vent 803 is completely blocked during a test run, for example.

[0231] Then, the determination unit 712 performs a determination using the threshold value Tc stored in the threshold information storage unit 702A as a determination criterion. For example, the determination unit 712 determines whether the concentration or moisture content of the above-mentioned gas component acquired by the acquisition unit 711 is within a predetermined range based on the threshold value Tc. The determination unit 712 may determine whether the concentration or moisture content of the first component is greater than the threshold value Tc, or may determine whether the concentration of the second component is less than the threshold value Tc. The first component is, for example, a component that increases due to gas burning, and the second component is, for example, a component that decreases due to gas burning. If the determination unit 712 determines that the concentration or moisture content of the first component is greater than the threshold value Tc stored in the threshold information storage unit 702A, the determination unit 712 may determine that the air vent 803 is blocked and gas burning has occurred. Then, the output control unit 713 displays the fact that gas burning has occurred on the display device 760. The user can recognize that gas burning has occurred and that the air vent 803 is close to being completely blocked. Therefore, the user can stop the injection molding machine 10 and perform cleaning of the mold device 800, etc., before the air vent 803 is completely blocked.

[0232] Furthermore, the output control unit 713 may display the actual values ​​of the concentration or moisture content of the above-mentioned gas components in a setting field (for example, setting field 1727) on the log information screen. Furthermore, the log information screen can also accept settings for monitoring the concentration or moisture content of the above-mentioned gas components. This makes it possible to determine that a molded product is defective when the concentration or moisture content of the above-mentioned gas components exceeds a threshold value Tc. Furthermore, the actual value of the frequency of the discharge sound can be stored as log information.

[0233] In this embodiment, the above-mentioned determination based on the concentration or moisture content of the gas component may be performed for one type of gas, or may be performed in combination for a plurality of types of gas.

[0234] Sixth embodiment In the sixth embodiment, an example of detecting the odor of gas and air discharged from a mold device 800 will be described as an example of detecting the condition of an object discharged from an air vent (an example of a gap) 803 of the mold device 800.

[0235] If the air vent 803 of the mold device 800 becomes clogged and the flow path cross-sectional area of ​​the air vent 803 becomes smaller, the air and gas in the cavity space 801 become difficult to discharge, and are instantaneously compressed, causing the air and gas to become hot (in other words, a state close to adiabatic compression occurs).

[0236] The gas generated from the flow front of the molding material varies depending on the type of molding material, but it often contains flammable gases such as methane and ethylene. If flammable gas is contained, it will burn if it exceeds the ignition point.

[0237] When combustible gases or the like are burned, gas burns also occur in the molded product. When gas burns occur in the molded product, part of the molded product is carbonized, giving off a burnt odor.

[0238] Therefore, in this embodiment, an odor sensor is included as one of the various sensors 790 of the injection molding machine 10. The odor sensor is capable of detecting the intensity of a burnt odor. As the odor sensor, for example, a sensor capable of detecting odor intensity by a semiconductor method (when an odorous gas comes into contact with a metal oxide semiconductor, the electrical conductivity increases and the detection value changes) is used. The odor sensor may be provided at a position 791 near an air vent 803 of a mold device 800 shown in FIG. 4, or at a position 792 near an outlet 804 of the air vent 803.

[0239] The acquisition unit 711 acquires the intensity of the odor of the burnt molded product detected by the odor sensor.

[0240] In this embodiment, a threshold value Ts indicating the intensity of the odor of the burnt molded product is stored in the threshold information storage unit 702A. The threshold value Ts may be determined based on the intensity of the odor detected by the odor sensor when the molded product is burnt before the air vent 803 is completely blocked during a test run, for example.

[0241] Then, the determination unit 712 determines whether or not the odor intensity acquired by the acquisition unit 711 is greater than the threshold value Ts stored in the threshold information storage unit 702A. If it is determined that the odor intensity is greater than the threshold value Ts stored in the threshold information storage unit 702A, it determines that the air vent 803 is clogged and gas burning has occurred. Then, the output control unit 713 displays the fact that gas burning has occurred on the display device 760. The user can recognize that gas burning has occurred and that the air vent 803 is close to being completely clogged. Therefore, the user can stop the injection molding machine 10 and clean the mold device 800 before the air vent 803 is completely clogged.

[0242] Furthermore, the output control unit 713 may display the above-mentioned odor intensity performance value in a setting field (e.g., setting field 1727) on the log information screen. Furthermore, the log information screen can also accept settings for monitoring odor intensity. This makes it possible to determine that a molded product is defective if the odor intensity exceeds a threshold value Ts. Furthermore, the odor intensity performance value can be stored as log information.

[0243] The above-described first to sixth embodiments and modifications are not limited to a method of control using any one of them, and a combination of the methods may be used for control.

[0244] In the above-described embodiment and modified examples, examples of detecting the state of gas and air discharged from the air vent 803 of the mold device 800 have been described. However, the above-described embodiment and modified examples are not limited to the method of detecting the state of gas and air discharged from the air vent 803. The object to be detected may be any object discharged from a gap in the mold device 800, and may be discharged from, for example, a gap occurring on the parting line surface.

[0245] The above-mentioned embodiment and modified examples have been described with respect to examples of detecting the state of gas and air discharged from the mold device 800. However, the above-mentioned embodiment and modified examples do not limit the detection target to gas and air, and may be any gas such as gas or air, or may be an object other than gas, such as a molding material discharged from the mold device 800.

[0246] Seventh embodiment In the above-described embodiment, an example has been described in which the control device 700 of the injection molding machine 10 performs an abnormality determination for the mold device 800 based on the state of an object discharged from the mold device 800. However, the above-described embodiment is not limited to a method in which the control device 700 of the injection molding machine 10 performs an abnormality determination for the mold device 800. Therefore, in the seventh embodiment, an example is given in which a management device that controls the injection molding machine 10 performs an abnormality determination for the mold device 800.

[0247] Fig. 10 is a conceptual diagram showing a management system according to the seventh embodiment. In the example shown in Fig. 10, four injection molding machines 10 are installed in a factory 2100.

[0248] In the factory 2100, a management system is formed by connecting a management device 2011 and four injection molding machines 10 via a communication line. The management device 2011 may be connected to an external device via a communication network (not shown). Meanwhile, the four injection molding machines 10 are capable of communicating with the management device 2011 but are not capable of connecting to external devices. This maintains the safety of the four injection molding machines 10.

[0249] In this embodiment, an example is taken in which the injection molding machine 10 does not store a threshold information storage unit 702A, but the threshold information storage unit 702A is stored in the storage device 2012 of the management device 2011.

[0250] The management device 2011 receives log information related to the injection molding performed by each of the four injection molding machines 10 from the injection molding machines 10, and registers the log information in the storage device 2012. In this way, the management device 2011 can store the log information related to the injection molding performed by each of the four injection molding machines 10.

[0251] The control device 700 of the injection molding machine 10 transmits one or more detection results of the microphone 781 and the various sensors 790 to a management device 2011. The management device 2011 includes at least the determination unit 712 and the output control unit 713 shown in the above-described embodiment and modified example.

[0252] Then, the judgment unit 712 of the management device 2011 identifies the situation regarding the object (e.g., air or gas) discharged from the air vent 803 based on one or more detection results of the microphone 781 and the various sensors 790, and judges whether or not an abnormality has occurred in the mold device 800 based on the situation regarding the object (e.g., air or gas).

[0253] The determination by the determining unit 712 of the management apparatus 2011 according to this embodiment may be any one of the determinations in the above-mentioned embodiments and modifications, or may be a combination of the determinations shown in the above-mentioned embodiments and modifications.

[0254] The output control unit 713 outputs to a display device or speaker (not shown) of the management device 2011 a message that an abnormality has occurred in the mold device 800. The output control unit 713 also outputs to a display device 760 or speaker of the injection molding machine 10 to be monitored a message that an abnormality has occurred in the mold device 800. Furthermore, the output control unit 713 may output an instruction to the injection molding machine 10 to be monitored to stop injection molding.

[0255] The management device 2011 according to this embodiment may include a log information storage unit 715. The log information storage unit 715 of the management device 2011 may store, in the storage device 2012, information based on one or more detection results of the microphone 781 and the various sensors 790, transmitted from the injection molding machine 10.

[0256] <effect> Conventionally, in order to check the state of the molding material during injection molding, a sensor (such as a temperature sensor or pressure sensor) was often installed in the cavity space where the molding material flows. Because the pressure and temperature inside the cavity space are high, the load on the sensor was high, and there was a high possibility of the sensor malfunctioning.

[0257] In contrast, in the above-described embodiment and modified example, the sensor is provided outside the cavity space. Since the sensor is provided outside the cavity space, the load on the sensor is low, and the possibility of a malfunction occurring in the sensor can be reduced.

[0258] In the above-mentioned embodiment and modified example, when mold deposits accumulate and block the air vent 803, making it difficult for objects (e.g., air and gas) to be discharged from the cavity space 801, the state of the object (e.g., any one or more of the following: the volume of the discharge sound (vibration), the frequency of the vibration caused by the discharge, the flow rate or flow speed of the object being discharged, the temperature of the object being discharged, the concentration of each component of the object being discharged, the moisture content (humidity), and the odor intensity) changes. Therefore, in the above-mentioned embodiment and modified example, the control device 700 or the management device 2011 judges the state of the object based on a predetermined threshold value. This judgment makes it possible to recognize whether or not any one or more of gas burns and short shots of the molded product may have occurred. The judgment result is output to the display device 760 or the like, so that the user can recognize the change in the molded product.

[0259] That is, in the above-described embodiment and modified example, whether or not an abnormality has occurred in the mold device 800 is determined based on the volume of the discharge sound (vibration), the frequency of the vibration due to the discharge, the flow rate or flow speed of the discharged gas, the temperature of the discharged gas, the concentration of each component of the discharged gas, the moisture content (humidity), and the intensity of the odor, as examples of the situation in which gas is discharged from the gap. In the determination based on the situation in which gas is discharged from the gap, a sensor (for example, a microphone 781 or various sensors 790) for detecting the situation can be provided outside the cavity space 801, so that the degree of freedom in the installation location can be improved compared to the conventional case. In addition, since the sensor does not need to withstand the pressure in the cavity space 801, an inexpensive sensor can be used.

[0260] Among the examples of situations in which gas is discharged from a gap, it is easier to install a sensor to detect the volume of the discharge sound (vibration) and the frequency of the vibration due to the discharge, compared to the flow rate or flow velocity of the discharged gas, the temperature of the discharged gas, the concentration of each component of the discharged gas, the moisture content (humidity), and the intensity of the odor. In other words, in the case of the flow rate or flow velocity of the discharged gas, the temperature of the discharged gas, the concentration of each component of the discharged gas, the moisture content (humidity), and the intensity of the odor, it is necessary to install a pipe or the like so that the gas discharged from air vent 803 does not mix with the surrounding gas or is not altered based on the surrounding gas, or to install a sensor (e.g., various sensors 790) near the outlet 804 of air vent 803 and directly detect the gas discharged from outlet 804.

[0261] On the other hand, when the magnitude of the discharge sound (vibration) and the frequency of the vibration due to discharge are used, a sensor (e.g., microphone 781) can be provided at a position away from the clamping device 100, so that it is possible to provide the sensor (e.g., microphone 781) on the frame 900 side, for example. In other words, since it is not necessary to process the mold device 800 in order to determine whether or not an abnormality has occurred in the mold device 800 in a situation where gas is discharged from a gap, the cost for detecting an abnormality can be reduced. Furthermore, since the sensor (e.g., microphone 781) can be easily installed, the workload can be reduced.

[0262] In the above-described embodiment and modified example, it is possible to detect the possibility that one or more of gas burns and short shots will occur in the molded product. Depending on the detection result, the user can stop the injection molding of the injection molding machine 10 and clean it. Therefore, the frequency of cleaning the mold device 800 can be minimized, and productivity can be improved.

[0263] Although the embodiments of the injection molding machine, management device, and management system according to the present invention have been described above, the present invention is not limited to the above-mentioned embodiments. Various changes, modifications, substitutions, additions, deletions, and combinations are possible within the scope of the claims. Naturally, these also fall within the technical scope of the present invention. [Explanation of symbols]

[0264] 10 injection molding machine 700 Control device 701 CPU 702 Storage medium 702A Threshold information storage unit 705 Communication Interface 711 Acquisition Department 712 Judgment section 713 Output control section 714 Injection Molding Control Unit 715 Log Information Storage Unit 760 Display device 2011 management device 2012 storage device

Claims

1. a mold device into which a molding material is injected by an injection device; a detection unit that detects a state regarding an object discharged from a gap provided in the mold device when the molding material is injected; a control device that determines whether or not an abnormality has occurred in the die device based on a state related to the object discharged from the gap; An injection molding machine comprising:

2. the control device determines whether or not an abnormality has occurred in the mold device based on a state related to the flow of gas discharged from the gap.

2. The injection molding machine according to claim 1.

3. The detection unit detects a discharge sound generated when the material is discharged through the gap, The control device determines whether or not an abnormality has occurred in the mold device based on a change in the volume of the discharge sound or a time when the discharge sound has occurred.

3. The injection molding machine according to claim 2.

4. the control device determines that an abnormality has occurred in the mold device when the loudness of the sound detected in the current injection of the molding material is smaller than the loudness of the sound detected in the previous injection of the molding material.

4. The injection molding machine according to claim 3.

5. the control device determines that an abnormality has occurred in the mold device when the time from the start of injection molding to the detection of the discharge sound in the current injection of the molding material is longer than the time from the start of the previous injection molding to the detection of the discharge sound.

4. The injection molding machine according to claim 3.

6. The detection unit detects vibrations generated when the gas is discharged from the gap, The control device determines whether or not an abnormality has occurred in the mold device based on the change in the frequency of the vibration.

3. The injection molding machine according to claim 2.

7. The detection unit detects a speed, a temperature, a concentration of a predetermined component, an odor intensity, or moisture contained in the object discharged through the gap, The control device determines whether or not an abnormality has occurred in the mold device by using a predetermined threshold value as a judgment criterion for the speed, temperature, concentration of a predetermined component, odor intensity, or moisture contained in the object of the object.

2. The injection molding machine according to claim 1.

8. When it is determined that an abnormality has occurred in the mold device, the control device stops the injection of the molding material into the mold device, or outputs a message indicating that an abnormality has occurred in the mold device.

2. The injection molding machine according to claim 1.

9. The detection unit is installed outside the mold device, or near an air vent provided in the mold device or outside the air vent.

2. The injection molding machine according to claim 1.

10. an acquisition unit that acquires, from a detection unit provided in the injection molding machine, a status of an object discharged through a gap provided in a mold device when a molding material is injected into the mold device by the injection molding machine; a control device that determines whether or not a defect has occurred in the die device based on a state related to the object discharged from the gap; A management device comprising:

11. The management device according to claim 10; The injection molding machine; A management system equipped with

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