Injection molding machine and injection molding system

Abstract

To satisfy both suppression of fluctuation of a vulcanized state and shortening of cycle time.SOLUTION: An injection molding machine 1 continuously injection-molds a plurality of rubber products by a plurality of molding dies M. The injection molding machine 1 comprises: a work part 2 which opens / closes the molding dies M; at least one injection part 3 which is constituted as a separate body from the work part 2; a conveying part 10 which conveys the molding dies M between the work part 2 and the injection part 3; and a first temperature regulating part 7 which is arranged at the injection part 3 and regulates the temperature of the molding dies M, wherein the first temperature regulating part 7 consists of a plurality of first heaters 73 and first temperature sensors 74 arranged at different positions from each other so as to individually regulate the temperature of different portions of the molding dies M.SELECTED DRAWING: Figure 8

Description

[Technical Field]

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

[0002] Patent Document 1 discloses a so-called rotary vulcanization molding machine as an example of an injection molding machine. This machine is equipped with an injection station, a heating zone, and a product removal station arranged along a circulating conveying path. In the machine disclosed in this document, part of the circulating conveying path is made into multiple parallel conveying paths that are parallel to each other, and a heating zone is provided in each of the parallel conveying paths.

[0003] According to Patent Document 1, by transporting molding dies using not only one parallel transport path but also other parallel transport paths in combination, even if the transport speed on a specific parallel transport path is slowed, it is possible to suppress a decrease in production capacity, which makes it possible to adjust the length of the vulcanization time without reducing production capacity. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Publication number 6-36893 Summary of the Invention [Problem to be solved by the invention]

[0005] When a single molding machine is configured to perform mold opening / closing, injection molding, and vulcanization of a rubber product, as in conventional molding machines, it is not possible to manufacture the next rubber product until the vulcanization reaction is complete. This is inconvenient when trying to shorten the cycle time when injection molding multiple rubber products continuously.

[0006] Therefore, the inventors of the present application have considered dividing the equipment into stations for performing each process, as in Patent Document 1, so that different processes such as mold opening and closing, injection molding, and vulcanization reaction can proceed in parallel.

[0007] In this case, for example, the mold opening / closing device and the injection molding device are separated into separate work and injection stations, which allows the mold opening / closing and injection molding of rubber products to be separated and each separate process to be carried out simultaneously in parallel.

[0008] However, to realize the above-mentioned configuration, each separate device needs to be connected by a conveying path. In this case, if we focus on the molding machine as a whole, the cycle time will be shortened by the amount of rubber products produced simultaneously. However, the inventors of the present application realized that if we focus on each molding die, inconveniences may arise due to the conveying time when transporting the die from the injection section to the working section.

[0009] In other words, the mold temperature drops while the mold is being transported. The amount of mold temperature drop can vary depending on the contact conditions with the transport section. Variations in the amount of mold temperature drop can lead to variations in the state of vulcanization of the rubber, which can ultimately lead to a decrease in the quality of the final product.

[0010] To address this possibility, it is conceivable to reheat the molding mold in a station other than the injection section, such as in a stationed vulcanization device, but until now, no mechanism has been known that can simultaneously suppress variations in the vulcanization state and shorten the cycle time.

[0011] The present disclosure has been made in view of the above points, and aims to achieve both suppression of variations in the vulcanization state and shortening of the cycle time. [Means for solving the problem]

[0012] A first aspect of the present disclosure relates to an injection molding apparatus for continuously injection-molding a plurality of rubber products using a plurality of molding dies. The injection molding apparatus includes a working unit for opening and closing the molding dies, at least one injection unit configured as a separate unit from the working unit for injecting a rubber material into the molding dies, a transport unit connecting the working unit and the injection unit and transporting the molding dies between the working unit and the injection unit, and a temperature control unit disposed in the injection unit for adjusting the temperature of the molding dies.

[0013] According to the first aspect of the present disclosure, the temperature adjustment unit is configured by a plurality of heaters and temperature sensors arranged at different positions so as to individually adjust the temperatures of different parts of the molding die.

[0014] The "injection unit" referred to here may be integrated with the device that performs the vulcanization reaction, or may be separate from the device that performs the vulcanization reaction, as in the second embodiment described below.

[0015] According to the first aspect, the injection molding apparatus has a working unit and an injection unit that are separate from each other. This separates the steps for injection molding a rubber product, allowing different steps to be carried out in parallel, thereby reducing the cycle time.

[0016] On the other hand, if the devices for performing each process are separate, it becomes necessary to connect each device by a transport unit, as in the first embodiment. In this case, there is a concern that the amount of decrease in mold temperature may vary, for example, when the mold is transported from the injection unit to the working unit.

[0017] In contrast, according to the first aspect, the injection molding apparatus can individually adjust the temperature of different parts of the molding die using a temperature control unit located in the injection unit. This allows the temperature of different parts of the molding die, which has dropped during transport, to be raised evenly and quickly. This reduces variations in the vulcanization state of rubber products.

[0018] Furthermore, according to a second aspect of the present disclosure, the injection molding apparatus may include at least one vulcanizing unit configured as a separate entity from the working unit and the injection unit, which heats the molding mold into which the rubber material is injected to cause a vulcanization reaction of the rubber material, the transport unit interconnects the working unit, the injection unit, and the vulcanizing unit, and transports the molding mold between the working unit, the injection unit, and the vulcanizing unit, and the temperature control unit is disposed in both the injection unit and the vulcanizing unit.

[0019] According to the second aspect, the injection molding apparatus has a vulcanization section as a separate unit in addition to the working section and the injection section. In this case, there is a concern that the amount of mold temperature decrease may vary, for example, when the mold is transported from the injection section to the vulcanization section.

[0020] In contrast, according to the second aspect, the injection molding apparatus can individually adjust the temperature of different parts of the molding die using a temperature control unit located in the vulcanization unit. This allows the temperature of different parts of the molding die, which has dropped during transport, to be raised evenly and quickly. This reduces variations in the vulcanization state of rubber products.

[0021] According to the second aspect, by providing the injection section and the vulcanization section with temperature control sections, the heating time in the vulcanization section can be shortened, which contributes to shortening the cycle time.

[0022] Furthermore, according to a third aspect of the present disclosure, the conveying section may have a pair of rail members supporting both side portions of the molding die, and the different portions may include both side portions of the molding die and a central portion of the molding die located between the both side portions.

[0023] According to the third aspect, by using the pair of rail members as described above, the contact area between the molding die and the conveying section can be reduced, which can suppress the decrease in mold temperature during conveyance, but this may cause variations in the amount of mold temperature decrease between the contact points of the molding die with the peripheral parts (e.g., rollers) of the rail members and other parts of the molding die.

[0024] In contrast, by configuring the contact points between the molding die and the peripheral portion of the rail member and other areas to have separate temperature adjustments, as in the third aspect, it is possible to suppress variations in the amount of mold temperature reduction.

[0025] Furthermore, according to a fourth aspect of the present disclosure, the injection molding apparatus may include a second temperature control unit disposed in the working section for adjusting the temperature of the molding mold in the working section, and the second temperature control unit may be configured with a plurality of heaters and temperature sensors disposed at different positions so as to individually adjust the temperature of different parts of the molding mold.

[0026] According to the fourth aspect, by providing the working section with a second temperature control section, it is possible to suppress a decrease in the mold temperature of the molding die when the mold is opened. Also, by configuring different parts of the molding die to have their temperatures adjusted individually, it is possible to raise the temperature evenly between the different parts. This makes it possible to suppress variations in the vulcanization state of the rubber product.

[0027] Furthermore, according to a fifth aspect of the present disclosure, the molding die may have a flange portion protruding from the molding die, the working unit may have a support portion that supports the flange portion when the molding die is opened or closed, and the contact surface between the flange portion and the support portion may have an uneven shape.

[0028] Here, the uneven shape may be provided on the flange portion, on the support portion, or on both.

[0029] According to the fifth aspect, the uneven contact surface reduces the contact area between the flange and the support when the molding die is opened and closed (particularly when the die is opened to remove the rubber product), thereby preventing a decrease in die temperature due to heat conduction.

[0030] Furthermore, according to a sixth aspect of the present disclosure, the conveying section has a pair of rail members supporting both side portions of the molding die, and the pair of rail members are provided with conveying rollers arranged to support the bottom surfaces of the both side portions and support rollers arranged to face the outer surfaces of the both side portions, and the pair of rail members support the both side portions via the conveying rollers, and the conveying rollers receive power from a drive source to rotate around a rotation axis fixed to the pair of rail members.

[0031] According to the sixth aspect, the pair of rail members support both sides of the molding die via the conveying rollers. This reduces the contact area between the pair of rail members and the molding die, and prevents a decrease in mold temperature. Furthermore, by using support rollers in addition to the conveying rollers, it becomes possible to appropriately position the molding die while minimizing the contact area with the molding die.

[0032] Furthermore, according to a seventh aspect of the present disclosure, the injection molding apparatus may be configured as a separate entity from the working unit, the injection unit, and the vulcanizing unit, and may include one or more replacement units for replacing the molding mold, and the replacement units may be positioned adjacent to the vulcanizing unit.

[0033] According to the seventh aspect, by providing an exchange unit separate from the working unit, it becomes possible to simultaneously open and close the molding die in the working unit and exchange the molding die in the exchange unit, which contributes to shortening the cycle time.

[0034] Furthermore, by locating the vulcanization unit and the replacement unit adjacent to each other, as in the seventh aspect, the vulcanization reaction of the rubber material in the vulcanization unit and the mold replacement operation in the replacement unit can be smoothly switched. This allows the mold replacement to be performed using the time reserved for the vulcanization reaction, minimizing the impact on the entire cycle of the injection molding machine, such as the timing of transporting other molds. This also contributes to shortening the cycle time.

[0035] An eighth aspect of the present disclosure relates to an injection molding system including a plurality of the injection molding apparatuses, wherein the working unit of one of the plurality of injection molding apparatuses and the working unit of another of the injection molding apparatuses are arranged adjacent to each other.

[0036] According to the eighth aspect, by providing two working sections adjacent to each other, it is advantageous for one worker to use two devices simultaneously. [Effects of the Invention]

[0037] As described above, according to the present disclosure, it is possible to suppress variations in the vulcanization state and shorten the cycle time at the same time. [Brief explanation of the drawings]

[0038] [Figure 1] FIG. 1 is a plan view illustrating the overall configuration of an injection molding system. [Figure 2A] FIG. 2A is a plan view illustrating the configuration of the injection molding device alone. [Figure 2B] FIG. 2B is a plan view schematically illustrating the configuration of the injection molding device alone. [Figure 3] FIG. 3 is a front view illustrating the configuration of the molding die. [Figure 4A] FIG. 4A is a front view illustrating the configuration of the second working unit. [Figure 4B] FIG. 4B is a front view illustrating the configuration of the second working unit. [Figure 5] FIG. 5 is a diagram illustrating an example of a contact surface between the flange portion and the lifting portion. [Figure 6] FIG. 6 is a perspective view illustrating the configuration of the transport unit. [Figure 7] FIG. 7 is a cross-sectional view illustrating the configuration of the transport unit. [Figure 8] FIG. 8 is a cross-sectional view illustrating the configuration of the first injection section. [Figure 9] FIG. 9 is a cross-sectional view illustrating the configuration of the first vulcanizing section. [Figure 10] FIG. 10 is a block diagram illustrating the configuration of the controller. [Figure 11] The upper part of FIG. 11 shows whether each molding die is present at each station, and the lower part of FIG. 11 shows the process performed for each molding die. [Figure 12A] FIG. 12A is a diagram illustrating the operation of an injection molding system. [Figure 12B] FIG. 12B is a diagram illustrating the operation of the injection molding system. [Figure 12C] FIG. 12C is a diagram illustrating the operation of the injection molding system. [Figure 13] FIG. 13 is a diagram for explaining heater control. DETAILED DESCRIPTION OF THE INVENTION

[0039] Hereinafter, embodiments of the present disclosure will be described. Note that the following description is an example.

[0040] <1. Overall structure> Fig. 1 is a plan view illustrating a schematic example of the overall configuration of an injection molding system S. Fig. 2A is a plan view illustrating a configuration of an injection molding apparatus 1 alone, and Fig. 2B is a plan view illustrating the same. Fig. 3 is a front view illustrating a configuration of a molding die M.

[0041] The injection molding system S according to this embodiment includes multiple (two in the illustrated example) injection molding apparatuses 1. Hereinafter, the "injection molding apparatus 1" will be simply referred to as the "molding apparatus 1." The two molding apparatuses 1 shown in FIG. 1 may also be referred to as the "first molding apparatus 1L" and the "second molding apparatus 1R," respectively.

[0042] Hereinafter, among directions extending along the installation surface (e.g., the factory floor) of the injection molding system S, the direction extending along the arrangement direction of the first molding device 1L and the second molding device 1R will be referred to as the "left-right direction." Similarly, a direction extending along the installation surface and perpendicular to the arrangement direction will be referred to as the "front-rear direction." Furthermore, a direction perpendicular to the installation surface will be referred to as the "up-down direction."

[0043] Next, we will explain the configuration of the first molding device 1L as the molding device 1. As shown in Fig. 1, the following explanation is also common to the second molding device 1R, except that it is mirror symmetrical with respect to an axis of symmetry extending along the front-rear direction.

[0044] As shown in Figure 1, although each element constituting the second molding device 1R is marked with an "'', the configuration of that element is substantially the same as the configuration of each element constituting the first molding device 1L without the "".

[0045] The molding device 1 is configured to continuously injection mold a plurality of resin products using a plurality of molding dies M. In particular, in this embodiment, rubber products are injection molded as the resin products.

[0046] The molding apparatus 1 also performs insert molding. That is, prior to injection molding, different types of parts are accommodated in advance in each molding die M. The different types of parts are parts that include materials other than synthetic rubber.

[0047] As shown in Fig. 3, in this embodiment, a metal fitting Pa is used as the different part. Although only one fitting Pa is shown in the figure, when multiple rubber products are molded using one molding die M, multiple fittings Pa will be housed in one molding die M. The molding device 1 molds a rubber product into which the fitting Pa is embedded. During this molding, the molding device 1 is configured to simultaneously transport multiple (four in this embodiment) molding dies M.

[0048] As shown in Figures 2A and 2B, the four molding dies M may be distinguished from one another by being referred to as the "first molding die M1," the "second molding die M2," the "third molding die M3," and the "fourth molding die M4," respectively.

[0049] 3, each molding die M is configured by stacking a plurality of (e.g., five) mold parts Mp in the vertical direction. In other words, the molding device 1 is configured as a vertical molding machine, and performs so-called vertical insert molding.

[0050] Hereinafter, the lower mold formed by some of the mold parts Mp will be denoted by the symbol Md, and the upper mold formed by the remaining mold parts Mp will be denoted by the symbol Mu. As an example, the five mold parts Mp will be referred to as the "first mold part Mp1," "second mold part Mp2," "third mold part Mp3," "fourth mold part Mp4," and "fifth mold part Mp5," ​​in that order from bottom to top. The "fourth mold part Mp4" and "fifth mold part Mp5" will constitute the upper mold Mu, and the remaining mold parts Mp will constitute the lower mold Md.

[0051] 3, the molding die M has flange portions Mf protruding from the molding die M. In the illustrated example, the flange portions Mf protrude from each of the third mold portion Mp3, the fourth mold portion Mp4, and the fifth mold portion Mp5. Each flange portion Mf protrudes in the horizontal direction (the direction extending along the plane defined by the left-right direction and the front-rear direction).

[0052] To simplify the following explanation, the various steps involved in injection molding are classified into five steps: an opening / closing step, an injection step, a vulcanization step, a mold exchange step, and a waiting step. The opening / closing step can also be called the disassembly and assembly step of the molding mold M, or the working step.

[0053] The opening and closing process is a general term for the processes of opening and closing the molding die M, removing the rubber product, inserting the metal fittings P, and closing the molding die M. The opening and closing of the molding die M is a general term for the processes of disassembling the molding die M (mold opening) and assembling the molding die M (mold closing).

[0054] The injection process refers to a process of injecting a rubber material as a resin material into the molding die M while heating the molding die M after the opening and closing process. The vulcanization process refers to a process of vulcanizing the rubber material by heating the molding die M after the injection process. The die exchange process is a so-called "changeover" and refers to a process of exchanging the molding die M for another molding die M. The standby process refers to a process of temporarily waiting for the molding die M after the vulcanization process before the opening and closing process.

[0055] The molding apparatus 1 according to this embodiment is devised to allow different processes to proceed in parallel. For example, the molding apparatus 1 is divided into stations in which the devices and equipment for performing each process are independent of each other.

[0056] 2A and 2B, molding apparatus 1 includes a work section (1st Work, 2nd Work) 2 that performs the opening and closing process, an injection section 3 that performs the injection process, a vulcanization section (1st Vul, 2nd Vul) 4 that performs the vulcanization process, an exchange section (1st Ex, 2nd Ex) 5 that performs the mold exchange process, and a standby section 6 that performs the standby process. These sections are interconnected by a conveyance section 10. Hereinafter, these sections may be referred to as "stations."

[0057] Furthermore, the molding apparatus 1 is designed to allow not only different processes but also the same processes to proceed in parallel. For this purpose, the molding apparatus 1 is provided with a plurality of injection sections 3, vulcanization sections 4, and replacement sections 5 (two in this embodiment).

[0058] Hereinafter, one of the two injection units 3 will be referred to as the "first injection unit 31," and the other will be referred to as the "second injection unit 32." Similarly, one of the two vulcanization units 4 will be referred to as the "first vulcanization unit 41," and the other will be referred to as the "second vulcanization unit 42." Similarly, one of the two replacement units 5 will be referred to as the "first replacement unit 51," and the other will be referred to as the "second replacement unit 52."

[0059] As will be described later, the first injection section 31, the first vulcanization section 41, and the first replacement section 51 are used for the first and third molds M1 and M3. The second injection section 32, the first vulcanization section 42, and the second replacement section 52 are used for the second and third molds M2 and M4. The working section 2, the waiting section 6, and the transport section 10 are shared among the four molds P.

[0060] Returning to the relationship between the first molding device 1L and the second molding device 1R, the former working section 2 and the latter working section 2' are disposed adjacent to each other as shown in FIG.

[0061] Additionally, behind the working section 2 of the first molding device 1L are arranged a storage box B1 for the metal fittings P used in the device 1L and a product box B2 for storing finished rubber products. Similarly, behind the working section 2' of the second molding device 1R are arranged a storage box B1' for the metal fittings P used in the device 1R and a product box B2' for storing finished rubber products.

[0062] The first molding apparatus 1L is also provided with a controller 100 that controls each part of the apparatus (see FIG. 10 described later). This controller 100 may be shared with the second molding apparatus 1R, or may be provided individually for each molding apparatus 1.

[0063] Each part of the molding device 1 will be described in turn below.

[0064] <2. Working section> The working unit 2 opens and closes the molding die M. This working unit 2 has a first working unit 21 and a second working unit 22. The first working unit 21 is a device for carrying out the operation of removing a rubber product from the molding die M after molding is completed (hereinafter simply referred to as the "removal operation"), and the operation of placing a new metal fitting P in the molding die M after the removal operation (hereinafter simply referred to as the "preparation operation"). The second working unit 22 is a device that carries out the process of opening and closing the molding die M and the process of moving the lower die Md back and forth between it and the first working unit 21 after opening and closing.

[0065] The first working unit 21 is connected to the transport unit 10 via the second working unit 22. The first working unit 21 is a pedestal-like device on which the removal work and preparation work for the lower mold Md are performed by an operator U as illustrated in FIG. 1. These work may be automated by various devices. The first working unit 21 transports the lower mold Md after the removal work and preparation work have been completed to the second working unit 22, and has a switch (not shown) that causes the second working unit 22 to execute the above-mentioned two steps.

[0066] 4A and 4B are front views illustrating the configuration of the second working unit 22. As shown in Fig. 4A and 4B, the second working unit 22 includes a base unit 23 that supports the lower mold Md from below, a lifting unit 24 that sequentially lifts and lowers each mold part Mp that constitutes the upper mold Mu, and a pushing unit 25 that pushes the upper mold Mu from above. The lifting unit 24 may be an independent device for each mold part Mp.

[0067] For example, when removing a rubber product from the molding die M, the second working unit 22 opens the molding die M by disassembling the molding die M into a lower die Md and an upper die Mu. At that time, the lifting unit 24 supports the flange portion Mf of the fifth mold portion Mp5 from below and lifts the fifth mold portion Mp5 upward. Thereafter, the lifting unit 24 supports the flange portion Mf of the fourth mold portion Mp4 from below and lifts the fourth mold portion Mp4 upward.

[0068] On the other hand, when a new injection molding is performed using the molding die M, the second working unit 22 places the upper die Mu on the lower die Md after the preparation work, thereby closing the molding die M. In particular, when placing the fifth mold part Mp5, in addition to transporting the fifth mold part Mp5 using the lifting unit 24, the pushing part 25 pushes it in from above. As a result, the molding die M is sandwiched vertically between the pedestal part 23 and the pushing part 25. Furthermore, the placement of the fourth and fifth mold parts Mp4 and Mp5 is performed via the flange parts Mf of each mold part Mp, just as when the mold is opened.

[0069] In this way, the lifting / lowering unit 24 of the second working unit 22 functions as a support unit that supports each flange portion Mf when opening or closing the molding die M. During this support, the flange portions Mf inevitably come into contact with the lifting / lowering unit 24. Therefore, in this embodiment, the contact surface Mi between the flange portions Mf and the lifting / lowering unit 24 has an uneven shape to reduce the contact area between the two members.

[0070] 5 is a diagram illustrating the contact surface Mi between the flange portion Mf and the lifting portion 24. This figure corresponds to a view of the flange portion Mf of the fifth mold portion Mp5 as the mold portion Mp, viewed along the left-right direction. As shown in FIG. 5, in this embodiment, the lower surface of the flange portion Mf constitutes the contact surface Mi. This contact surface Mi is recessed upward.

[0071] The base 23 has a slide part 231 that moves back and forth between the first working part 21 and the second working part 22, a first hot plate part 81 that supports the first mold part Mp1 (particularly the lower surface of the first mold part Mp1) from below, and an interposition part 232 that is interposed between the slide part 231 and the first hot plate part 81. The first hot plate part 81 has a thin plate shape that extends horizontally.

[0072] Here, the first hot plate unit 81 and the interposing unit 232 are connected via a fastener 233 extending vertically. The upper surface of the sliding unit 231 contacts the lower surface of the interposing unit 232. This upper surface has an uneven shape as shown in Figs. 4A and 4B.

[0073] On the other hand, the pushing section 25 has a second hot plate section 82 that contacts the fifth mold section Mp5 (particularly the upper surface of the fifth mold section Mp5). The second hot plate section 82 has a thin plate shape that extends horizontally.

[0074] In addition, a first hot plate 81 and a second hot plate 82 are respectively arranged on the base 23 and the pressing portion 25 via a heat insulating material 236. Both the upper and lower heat insulating materials 236 have a sheet shape. The upper and lower heat insulating materials 236 may also have a plate or block shape.

[0075] As described above, the working unit 2 according to this embodiment is provided with a pair of upper and lower first and second hot plate units 81, 82. The first and second hot plate units 81, 82 constitute a second temperature control unit 8 configured to adjust the temperature of the molding die M. The second temperature control unit 8 is an example of the "second temperature control unit" in this embodiment.

[0076] The second temperature adjustment unit 8 is composed of a plurality of second heaters 83 and second temperature sensors 84 arranged at different positions so as to individually adjust the temperatures of different portions of the molding die M. The plurality of second heaters 83 and second temperature sensors 84 are respectively built into the first and second hot plate units 81, 82. As shown in Figures 3 and 4B, the "different portions" referred to here include both side portions Ms of the molding die M (particularly both side portions in the horizontal direction) and the central portion Mc of the molding die M located between the both side portions.

[0077] 4B, the plurality of second heaters 83 and second temperature sensors 84 are divided into at least a second side device group 8S located on both sides of the molding die M and a second center device group 8C located in the center of the molding die M. The second side device group 8S and the second center device group 8C are each connected to a controller 100 described below, and are individually controlled in response to control signals from the controller 100. Note that it is sufficient that the second temperature sensor 84 is disposed in at least one of the second side device groups 8S located on both sides of the molding die M. The same applies to the first temperature adjustment unit 7 and the third temperature adjustment unit 9 described below.

[0078] <3. Conveyor section> [3-1. Structure of the transport unit] Fig. 6 is a perspective view illustrating the configuration of the transport unit 10, and Fig. 7 is a cross-sectional view thereof. As shown in Fig. 2A and Fig. 2B, the transport unit 10 connects different stations and transports the molding die M between the stations.

[0079] 2B, the transport unit 10 interconnects the working unit (particularly the second working unit 22) 2, the injection unit 3, the vulcanization unit 4, the replacement unit 5, and the standby unit 6. The transport unit 10 transports the molding die M between the working unit 2, the injection unit 3, the vulcanization unit 4, the replacement unit 5, and the standby unit 6.

[0080] As described above, the conveying section 10 is shared among the first and second injection sections 31, 32, the first and second vulcanization sections 41, 42, the first and second exchange sections 51, 52, and the standby section 6. This conveying section 10 reciprocates the molding die M to transport it to each station, including the first and second injection sections 31, 32. The conveying section 10 is linear rather than loop-shaped. Therefore, the reciprocating movement of the molding die M by the conveying section 10 is generally linear.

[0081] More specifically, the conveying section 10 has a pair of rail members 11 that support both side portions Ms shown in Fig. 3. The pair of rail members 11 is composed of two rail portions 12 that are spaced apart in the front-to-rear direction. Each rail portion 12 extends in the direction in which the molding apparatus 1 is arranged, i.e., in the left-to-right direction.

[0082] 6, each rail portion 12 is provided with a conveying roller 13 and a support roller 14. A plurality of conveying rollers 13 and a plurality of support rollers 14 are provided along the direction in which each rail portion 12 extends, i.e., along the left-right direction.

[0083] The conveying rollers 13 are arranged to support the bottom surfaces of both side portions Ms of the molding die M. The transport rollers 13 protrude upward from the upper surface 12a of the rail portion 12. The pair of rail members 11 supports both side portions Ms of the molding die M via the transport rollers 13.

[0084] The conveying rollers 13 receive power from a driving source (not shown) to rotate around a rotation shaft 13a fixed to the pair of rail members 11, respectively.

[0085] That is, the transport rollers 13 are configured to be driven to rotate on the spot, unlike a roller conveyor that is allowed to move (slide) relative to the pair of rail members 11. The rotation direction of the transport rollers 13 is switched in response to a control signal from the controller 100. This switches the movement direction of the molding die M.

[0086] The support rollers 14 are arranged to face the outer surfaces of both side portions Ms of the molding die M. The support rollers 14 protrude from the inner surface 12b of the rail portion 12 inward in the front-rear direction.

[0087] The support rollers 14 each rotate around a rotation shaft 14a fixed to the pair of rail members 11 (see FIG. 6). The support rollers 14 rotate around the rotation shaft 14a in response to the frictional force received from the molding die M.

[0088] Furthermore, the transport unit 10 has a plurality of mold sensors 15 and a plurality of stoppers 16. Both the plurality of mold sensors 15 and the stoppers 16 are electrically connected to the controller 100.

[0089] A plurality of die sensors 15 are arranged at predetermined locations on the transport section 10. Each die sensor 15 is configured to detect the presence or absence of a molding die M at the corresponding predetermined location.

[0090] Specifically, multiple mold sensors 15 are arranged at different positions on the transport section 10 (only one is illustrated in FIG. 7). The mold sensor 75 is, for example, an optical sensor that detects the amount of light. A detection signal from the mold sensor 15 is input to the controller 100. The controller 100 determines the transport status of the forming mold M based on the input detection signal.

[0091] For example, when the molding die M is to be transported to a predetermined position, if the amount of light detected at the predetermined position is less than a predetermined threshold, the controller 100 determines that the molding die M has not been transported normally. In this case, the controller 100 issues a warning to the operator via a display unit, an audio unit, etc. (not shown).

[0092] 2B, the plurality of stoppers 16 are arranged at different positions, including midway along the conveying section 10. Each stopper 16 controls the conveyance of the forming die M individually.

[0093] In detail, each stopper 16 is provided in each of the first branch portion P1, the second branch portion P2, and the third branch portion P3 described below, in addition to the first and second vulcanizing portions 41, 42 and, if necessary, the waiting portion 6.

[0094] The controller 100 controls the plurality of stoppers 16 individually based on the detection signal of the mold sensor 15. Each stopper 16 operates in response to a control signal from the controller 100 to restrict or allow the reciprocating movement of each molding mold M.

[0095] [3-2. Layout of each station relative to the transport section] The working unit 2 is connected to one side (rear) of one end (right end) of the conveying unit 10. A standby unit 6, a first vulcanizing unit 41, and a second vulcanizing unit 42 are arranged in this order on the conveying unit 10 (above the conveying unit 10) from the one end to the other end (left end). The standby unit 6, the first vulcanizing unit 41, and the second vulcanizing unit 42 are arranged at intervals in the direction in which the molding die M is conveyed by the conveying unit 10 (left-right direction).

[0096] The first and second injection units 31, 32 are connected side by side on the other side (front) of the conveying unit 10 so as to be located opposite the working unit 2. The center of the first injection unit 31 is located between the working unit 2 and the first vulcanizing unit 41 in the left-right direction. The center of the second injection unit 32 is located between the first vulcanizing unit 41 and the second vulcanizing unit 42 in the left-right direction.

[0097] The first and second replacement units 51, 52 are connected to the rear of the conveying unit 10 so as to be arranged alongside the working unit 2. The first replacement unit 51 is adjacent to the first vulcanizing unit 41 behind the conveying unit 10. Similarly, the second replacement unit 52 is adjacent to the second vulcanizing unit 42 behind the conveying unit 10.

[0098] 2B, working unit 2 can be considered to branch off from a location (first branching point P1) midway along transport unit 10. Standby unit 6 can be considered to branch off from the same location (first branching point P1) as working unit 2.

[0099] The first injection section 31 can be considered to branch off from another intermediate portion (second branch section P2) in the transport section 10. The second injection section 32 can be considered to branch off from yet another intermediate portion (third branch section P3) in the transport section 10.

[0100] The first replacement section 51 can be considered to branch off from another intermediate portion (first vulcanizing section 41) in the transport section 10. The second replacement section 52 can be considered to branch off from another intermediate portion (second vulcanizing section 42) in the transport section 10.

[0101] In other words, the conveying section 10 branches at the first branching section P1 described above into a path connecting the working section 2 with the injection section 3, the vulcanization section 4 and the replacement section 5, and a path connecting the working section 2 with the waiting section 6.

[0102] The former path branches at a second branching section P2 into a path toward the first injecting section 31 and a path toward the first vulcanizing section 41. The path toward the first vulcanizing section 41 further branches at a third branching section P3 into a path toward the second injecting section 32 and a path toward the second vulcanizing section 42.

[0103] <4. Injection part> The configuration of the first injection unit 31 will be described below. The following description is common to the configuration of the second injection unit 32. The first injection unit 31 is configured as a separate unit from the working unit 2, the second injection unit 32, the vulcanizing unit 4, the replacing unit 5, and the waiting unit 6. The molding die M is transported from the working unit 2 to the first injection unit 31. The first injection unit 31 injects a rubber material as a resin material into the transported molding die M.

[0104] Specifically, the first injection unit 31 is configured to be an independent device (station) relative to the working unit 2, the second injection unit 32, the vulcanizing unit 4, the replacing unit 5, and the waiting unit 6. The first injection unit 31 is connected to the transport unit 10 via a robot arm and a conveyor extending in the front-rear direction.

[0105] 8 is a front view illustrating the configuration of the first injection unit 31. As shown in the figure, the first injection unit 31 is a vertical injection device. That is, the first injection unit 31 lifts the molding die M using a base part 311 located below, thereby clamping the molding die M from above and below and clamping it. Then, insert molding begins by filling the die with rubber material from a cylinder 312 located above.

[0106] Here, the first injection section 31 has a first hot plate section 71 that supports the first mold section Mp1 (particularly, the lower surface of the first mold section Mp1) from below when clamping the molding die M, and a second hot plate section 72 that abuts the fifth mold section Mp5 (particularly, the upper surface of the fifth mold section Mp5) from above. Both the first and second hot plate sections 71, 72 have a thin plate shape that extends horizontally.

[0107] Before the rubber material starts to be filled, the first and second heating plate sections 71, 72 start heating the molding die M. This heating is carried out for a predetermined period of time.

[0108] That is, the first injection section 31 heats the molding die M into which the rubber material is injected, more specifically, the molding die M before and after the injection of the rubber material, thereby promoting the vulcanization reaction of the rubber material. The first injection section 31 according to this embodiment is configured to perform a part of the vulcanization process in addition to the injection process.

[0109] Moreover, the first injection section 31 according to this embodiment has a pair of upper and lower hot plate sections 71, 72. The pair of hot plate sections 71, 72 constitute a first temperature adjustment section 7 according to this embodiment, which is configured to adjust the temperature of the molding die M. The first temperature adjustment section 7 is an example of the "temperature adjustment section" according to this embodiment.

[0110] The first hot plate unit 71 and the second hot plate unit 72 are disposed in the first injection unit 31 via heat insulating materials 76. The upper and lower heat insulating materials 76 are both in the form of a sheet. The upper and lower heat insulating materials 76 may also be in the form of a plate or a block.

[0111] The first temperature adjustment unit 7 is composed of a plurality of first heaters 73 and first temperature sensors 74 arranged at different positions so as to individually adjust the temperatures of different portions of the molding die M. The first heaters 73 and first temperature sensors 74 are respectively built into the first and second hot plate units 71, 72. As shown in Fig. 8, the "different portions" here include both side portions Ms of the molding die M and the central portion of the molding die M located between the both side portions, similar to the second temperature adjustment unit 8.

[0112] That is, similar to the second temperature adjustment unit 8, the multiple first heaters 73 and first temperature sensors 74 are divided into a first side device group 7S located on both side portions Ms of the molding die M, and a first center device group 7C located in the center portion Mc of the molding die M. The first center device group 7C and the first side device group 7S are each connected to a controller 100, and are individually controlled in response to control signals from the controller 100.

[0113] The molding die M that has been heated by the first injection section 31 is transported to the first vulcanizing section 41. The molding die M that has been heated by the second injection section 32 is transported to the second vulcanizing section 42. The timing at which the molding die M is transported to the first injection section 31 and the timing at which another molding die M is transported to the second injection section 32 are set to be mutually different.

[0114] <5. Vulcanization section> The configuration of the first vulcanizing section 41 will be described below. The following description is common to the configuration of the second vulcanizing section 42. The first vulcanizing section 41 is configured as a separate entity from the working section 2, the injection section 3, the second vulcanizing section 42, the replacement section 5, and the standby section 6. Following heating in the first injection section 31, the first vulcanizing section 41 heats the molding die M into which the rubber material has been injected. In this way, the first vulcanizing section 41 promotes the vulcanization reaction of the rubber material.

[0115] Specifically, the first vulcanizing section 41 is configured to be an independent device (station) relative to the working section 2, the injection section 3, the second vulcanizing section 42, the replacement section 5, and the standby section 6. The first vulcanizing section 41 is connected to the conveying section 10 via a lifting section 43 and a pushing section 44 arranged midway along the conveying section 10.

[0116] 9 is a cross-sectional view illustrating the configuration of the first vulcanizing unit 41. As shown in the figure, the first vulcanizing unit 41 lifts the molding die M with the lifting unit 43 and presses the pushing unit 44 against the molding die M from above, thereby sandwiching the molding die M from above and below.

[0117] Here, the first vulcanizing section 41 has a first hot plate section 91 that supports the first mold section Mp1 (particularly, the lower surface of the first mold section Mp1) from below when clamping the molding die M, and a second hot plate section 92 that abuts the fifth mold section Mp5 (particularly, the upper surface of the fifth mold section Mp5) from above. Both the first and second hot plate sections 91, 92 have a thin plate shape that extends horizontally.

[0118] As described above, the first vulcanizing section 41 according to this embodiment has a pair of upper and lower hot plate sections 91, 92. The pair of hot plate sections 91, 92 constitute a third temperature adjustment section 9 configured to adjust the temperature of the molding die M. The third temperature adjustment section 9 is another example of the "temperature adjustment section" according to this embodiment.

[0119] The first hot plate unit 91 and the second hot plate unit 92 are disposed in the first vulcanizing unit 41 via respective heat insulating materials 96. The upper and lower heat insulating materials 96 are both in the form of a sheet. The upper and lower heat insulating materials 96 may also be in the form of a plate or a block.

[0120] The third temperature control unit 9 is composed of a plurality of third heaters 93 and third temperature sensors 94 arranged at different positions so as to individually control the temperatures of different portions of the molding die M. The third heaters 93 and third temperature sensors 94 are respectively built into the first and second hot plate units 91 and 92. As shown in Fig. 9, the "different portions" here include both side portions Ms of the molding die M and the central portion Mc of the molding die M located between the both side portions, similar to the first and second temperature control units 7 and 8.

[0121] That is, similar to the first and second temperature adjustment units 7 and 8, the plurality of heaters 93 and temperature sensors 94 are divided into a third side device group 9S located on both side portions Ms of the molding die M, and a third center device group 9C located in the center portion Mc of the molding die M. The third center device group 9C and the third side device group 9S are each connected to a controller 100, and are individually controlled by receiving control signals from the controller 100.

[0122] The molding die M that has been heated by the first vulcanizing section 41 is carried into the working section 2 via the standby section 6. The molding die M that has been heated by the second vulcanizing section 42 is carried into the working section 2 via the standby section 6 at a timing different from the transport timing from the first vulcanizing section 41. Because the two timings are different, one standby section 6 is sufficient.

[0123] <6. Exchange section> The configuration of the first replacement section 51 will be described below. The following description is common to the configuration of the second replacement section 52. The first replacement section 51 is configured as a separate entity from the working section 2, the injection section 3, the vulcanizing section 4, the second replacement section 52, and the standby section 6. The first replacement section 51 transports the molding die M that has passed directly through the first vulcanizing section 41 from the first injection section 31. The first replacement section 51 replaces the transported molding die M with another molding die M.

[0124] Specifically, the first replacement section 51 is configured to be an independent device (station) relative to the working section 2, the injection section 3, the vulcanizing section 4, the second replacement section 52, and the waiting section 6. The first replacement section 51 is connected to the transport section 10 and the first vulcanizing section 41 via a robot arm arranged near the first vulcanizing section 41 and a conveyor extending in the front-rear direction.

[0125] The first exchange section 51 is a changeover device that automatically exchanges the molding die M by operating a button or the like. Even when exchanging the molding die M in the first exchange section 51, the molding die M passes through the corresponding injection section 3 and vulcanization section 4 in order after being carried out from the work section 2.

[0126] In this case, the molding die M to be replaced stays in the work section 2 and the injection section 3 for a predetermined time, but the preparation work and injection of the rubber material in each section are omitted. Thereafter, the molding die M to be replaced passes through the first vulcanization section 41 and is carried into the first exchange section 51.

[0127] <7.Waiting section> The standby section 6 is arranged as a separate entity from the working section 2, the injection section 3, the vulcanization section 4, and the replacement section 5. The standby section 6 allows the molding die M to wait after the vulcanization reaction in the vulcanization section 4 before being sent back to the working section 2.

[0128] 2B, the standby section 6 is arranged in the conveying section 10 so as to branch off from the path connecting the vulcanizing section 4 and the working section 2. Furthermore, the standby section 6 according to this embodiment is arranged in the conveying section 10 so as to branch off from the path connecting the injection section 3 and the working section 2.

[0129] In detail, at the first branching section P1 mentioned above, the conveying section 10 branches into a path connecting the working section 2 with the injection section 3, the vulcanization section 4 and the replacement section 5, and a path connecting the working section 2 with the waiting section 6.

[0130] The former path branches at a second branching section P2 into a path toward the first injecting section 31 and a path toward the first vulcanizing section 41. The path toward the first vulcanizing section 41 further branches at a third branching section P3 into a path toward the second injecting section 32 and a path toward the second vulcanizing section 42.

[0131] <8. Controller> Fig. 10 is a block diagram illustrating the configuration of the controller 100. As shown in Fig. 10, the controller 100 has a CPU 101, a memory 102, and an input / output bus 103. The controller 100 controls the actuators of each station constituting the working unit 2, the injection unit 3, the vulcanizing unit 4, the replacement unit 5, and the transport unit 10 based on detection signals from various sensors.

[0132] Here, the sensors connected to the controller 100 include a plurality of mold sensors 15, a plurality of first temperature sensors 74, a plurality of second temperature sensors 84, and a plurality of third temperature sensors 94.

[0133] The actuators controlled by the controller 100 include a plurality of first heaters 73, a plurality of second heaters 83, and a plurality of third heaters 93.

[0134] In addition, the actuators controlled by the controller 100 include a plurality of conveying rollers 13 , a plurality of stoppers 16 , an elevator 24 , a base 311 , a cylinder 312 , and an elevator 43 .

[0135] <9. Operation of each molding device> Next, the operating procedure of the injection molding system S realized by the controller 100 will be described in detail with reference to Fig. 11 and Figs. 12A to 12C. Here, the upper part of Fig. 11 shows the presence or absence of each molding die M at each station, and the lower part of Fig. 11 shows each molding die M and the molding apparatus 1 where the worker U is located. Also, Figs. 12A to 12C are diagrams illustrating the operation of the injection molding system S.

[0136] The horizontal axis of Fig. 11 represents the passage of time. For example, at time t1, the first molding die M1 is placed in the working section 2, the second molding die M2 is placed in the second vulcanizing section 42, the third molding die M3 is placed in the first injection section 31, and the fourth molding die M4 is placed in the second injection section 32. This state corresponds to the upper part of Fig. 12A.

[0137] The only difference between the upper and lower sections of FIG. 11 is whether each station is shown as the main focus or each molding die M is shown as the main focus, but the meaning is essentially the same.

[0138] [9-1. Time t1] At the top of Fig. 12A, the removal and preparation work for the first molding die M1 has been completed. The worker U operates buttons, switches, etc. in the working section 2 to instruct the first molding die M1 to be transported from the first working section 21 to the second working section 22. This button operation is input to the controller 100. The worker U moves to the first working section 21 of the second molding device 1R.

[0139] Furthermore, in parallel with the above process, in the first injection section 31, a vulcanization process is carried out by the first temperature adjustment section 7 on the third molding die M3 after the rubber material has been injected. In the second injection section 32, a rubber material is injected into the fourth molding die M4. In the second vulcanization section 42, a vulcanization process is carried out by the third temperature adjustment section 9 on the second molding die M2 transferred from the second injection section 32.

[0140]

[0000] [9-2. Time t2] At the next time t2, as shown in the middle part of FIG. 12A, the worker starts the removal operation and preparation operation for the first molding die M1' of the second molding apparatus 1R in the first working section 21' of the same apparatus 1R.

[0141] At the same time, in the working section 2 of the first molding apparatus 1L, the first molding die M1 is automatically transported from the first working section 21 to the second working section 22 of the apparatus 1L.

[0142] Furthermore, in parallel with the above process, in the first injection section 31, the third molding die M3 after the injection of the rubber material is subjected to a vulcanization process by the first temperature adjustment section 7. In the second injection section 32, the rubber material is injected into the fourth molding die M4. In the second vulcanization section 42, the second molding die M2 transferred from the second injection section 32 is subjected to a vulcanization process by the third temperature adjustment section 9, which is then completed.

[0143] [9-3. Time t3] At subsequent time t3, as shown in the lower part of FIG. 12A, worker U proceeds with the removal work and preparation work for first molding die M1' in first working section 21' of second molding apparatus 1R.

[0144] At the same time, in the working section 2 of the first molding device 1L, the transport of the first molding mold M1 from the first working section 21 of the device 1L to the second working section 22 is completed, and in the second working section 22, the upper mold Mu is mounted on the lower mold Md.

[0145] Furthermore, in parallel with the above process, in the first injection section 31, the vulcanization process by the first temperature adjustment section 7 is completed for the third molding die M3 after the rubber material has been injected. In the second injection section 32, the process of injecting the rubber material into the fourth molding die M4 proceeds.

[0146] Furthermore, the second molding die M2, for which the vulcanization process in the second vulcanization section 42 has been completed, is transported from the second vulcanization section 42 to the waiting section 6. The third and fourth molding dies M3, M4 are located in the corresponding injection sections 3, and each injection section 3 is connected to the side of the transport section 10, so that the transport section 10 is not blocked by the third and fourth molding dies M3, M4, and the second molding die M2 can be transported smoothly.

[0147] [9-4. Time t4] At subsequent time t4, as shown in the upper part of FIG. 12B, the worker U proceeds with the removal work and preparation work for the first molding die M1' in the first working section 21( of the second molding apparatus 1R.

[0148] At the same time, in the first molding device 1L, the first molding die M1 is carried out from the working section 2 of the device 1L to the first branch section P1. At that time, since the second molding die M2 after vulcanization is staying in the branched standby section 6 as described above, the second molding die M2 does not block the conveying section 10, and the first molding die M1 can be carried out smoothly.

[0149] Furthermore, in parallel with the above process, the third molding die M3 is transported from the first injection section 31 to the second branch section P2. In the second injection section 32, the injection process for the fourth molding die M4 is completed, and the vulcanization process for the fourth molding die M4 is started by the first temperature adjustment section 7 of the second injection section 32.

[0150] In this way, by performing the first half of the vulcanization process in the first and second injection sections 31, 32, the molding die M stays longer in the first or second injection section 31, 32. This is effective in preventing other molding dies M from blocking the transport section 10 when the molding die M is transported from the vulcanization section 4 to the standby section 6.

[0151] [9-5.Time t5] At subsequent time t5, as shown in the middle part of FIG. 12B, worker U completes the removal work and preparation work for first molding die M1' in first working section 21' of second molding apparatus 1R.

[0152] At the same time, in the first molding device 1L, the first molding die M1 is transported from the first branch section P1 to the second branch section P2 of the device 1L. Subsequently, the second molding die M2 is transported from the standby section 6 to the first branch section P1. By transporting the first molding die M1 first, the first molding die M1 does not get in the way when the second molding die M2 is transported.

[0153] Furthermore, since the movement directions of the first molding die M1 and the second molding die M2 are both the same (leftward), the control logic of the transport unit 10 by the controller 100 becomes simple. Such control logic is realized by introducing the stopper 16 as described above.

[0154] Furthermore, in parallel with the above process, the third molding die M3 is transported from the second branch section P2 to the first vulcanizing section 41. The first vulcanizing section 41 starts the latter half of the vulcanizing process for the third molding die M3 by the third temperature adjustment section 9. In the second injection section 32, the vulcanizing process for the fourth molding die M4 progresses.

[0155] [9-6.Time t6] At subsequent time t6, as shown in the lower part of FIG. 12B, the worker U starts moving from the first working unit 21' of the second forming apparatus 1R to the first working unit 21 of the first forming apparatus 1L.

[0156] At the same time, in the transport section 10 of the first molding device 1L, the first molding die M1 is transported from the second branch section P2 to the first injection section 31. In the first injection section 31, the process of injecting the rubber material into the first molding die M1 begins.

[0157] Furthermore, in the same transport section 10, the second molding die M2 is transported from the first branch section P1 to the second working section 22. In the second working section 22, disassembly of the second molding die M2 (removal of the upper die Mu) begins. During this disassembly work, the second molding die M2 is heated by the second temperature adjustment section 8.

[0158] Furthermore, in parallel with the above steps, a vulcanization step for the third molding die M3 is carried out in the first vulcanization section 41. In the second injection section 32, a vulcanization step for the fourth molding die M4 is carried out.

[0159] [9-7.Time t7] At the following time t7, the first molding die M1' begins to be conveyed from the first working section 21' to the second working section 22' of the second molding apparatus 1R.

[0160] Meanwhile, in the first molding apparatus 1L, as shown in the upper part of FIG. 12C, an operator U starts the work of removing the mold from the second molding die M2 and the preparation work in the first working section 21 of the apparatus 1L.

[0161] Furthermore, in parallel with the above steps, the first injection section 31 carries out a step of injecting a rubber material into the first molding die M1. The first vulcanization section 41 carries out a step of vulcanizing the third molding die M3. The second injection section 32 carries out a step of vulcanizing the fourth molding die M4.

[0162] [9-8.Time t8] At subsequent time t8, the first molding die M1' is transported from the first working section 21' to the second working section 22' of the second molding apparatus 1R. In the second working section 22', the upper die Mu is mounted on the lower die Md of the first molding die M1'.

[0163] Furthermore, as shown in the middle of FIG. 12C, in the second molding apparatus 1R, the second molding die M2' is transported from the second vulcanizing section 42' of the apparatus 1R shown in FIG. 1 to the standby section 6'.

[0164] Meanwhile, in the first molding device 1L, removal and preparation work for the second molding die M2 is carried out. In the first injection section 31, the process of injecting rubber material into the first molding die M1 is carried out. In addition, in the first vulcanization section 41, the process of vulcanization for the third molding die M3 is carried out. In addition, in the second injection section 32, the process of vulcanization for the fourth molding die M4 is carried out.

[0165] [9-8.Time t9] At subsequent time t9, as shown in the lower part of FIG. 12C, the first molding die M1' is transported from the second working section 22' of the second molding apparatus 1R to the first branch section P1'.

[0166] Meanwhile, in the first molding device 1L, removal and preparation work for the second molding die M2 is carried out. In the first injection section 31, the process of injecting rubber material into the first molding die M1 is carried out. In addition, in the first vulcanization section 41, the process of vulcanization for the third molding die M3 is carried out. In addition, in the second injection section 32, the process of vulcanization for the fourth molding die M4 is carried out.

[0167] [9-9. After time t9] As shown in FIG. 11, the processing after time t9 in the first molding device 1L can be considered to be the same as the processing from time t1 to time t9 by making the following changes.

[0168] Specifically, in the process from time t1 to time t9, The first molding die M1 is read in the order of the second molding die M2, the third molding die M3, and the fourth molding die M4.

[0169] In parallel with the above-mentioned replacement, the second molding die M2 is replaced with the third molding die M3, the fourth molding die M4, and the first molding die M1 in that order.

[0170] In parallel with the above-mentioned replacement, the third molding die M3 is replaced with the fourth molding die M4, the first molding die M1, and the second molding die M2 in that order.

[0171] In parallel with the above-mentioned replacement, the fourth molding die M4 is replaced with the first molding die M1, the second molding die M2, and the third molding die M3 in that order.

[0172] The first and third molding dies M1 and M3 include a first injection section 31 and a first vulcanization section 41.

[0173] The second and fourth molding dies M2 and M4 include a second injection section 32 and a second vulcanization section 42.

[0174] For example, after time t9, the second molding die M2 is transported from the working section 2 to the second injection section 32. At that time, the third molding die M3 is transported from the first vulcanization section 41 to the standby section 6 and waits for a predetermined time in the standby section 6. After the second molding die M2 is transported out of the working section 2 and passes through the first branch section P1, the third molding die M3 is transported from the standby section 6 into the working section 2.

[0175] Furthermore, the fourth molding die M4 is transported from the second injection section 32 to the second vulcanizing section 42 and the standby section 6 in this order, and then is carried into the working section 2 after the third molding die M3 has been carried out of the working section 2. The first molding die M1 is transported from the first injection section 31 to the first vulcanizing section 41 and the standby section 6 in this order, and then is carried into the working section 2 after the fourth molding die M4 has been carried out of the working section 2.

[0176] On the other hand, the second molding device 1R uses four molding dies M', just like the first molding device 1L, but as shown in Figures 12A to 12C, by making the transport timing of the first molding die M1' different from the transport timing of the first molding die M1 of the first molding device 1L, even a single worker U can operate two molding devices 1 simultaneously.

[0177] <10. Heater Control> As described above, in the first and second injection sections 31, 32, heating is performed by the first temperature adjustment section 7 before and after injection of the rubber material. In the second working section 22, heating is performed by the second temperature adjustment section 8 when the molding die M is disassembled (opened). In the first and second vulcanization sections 41, 42, heating by the first and second injection sections 31, 32 is followed by heating by the third temperature adjustment section 9.

[0178] As mentioned above, these heating operations are performed separately for the side portions Ms and the center portion Mc of the molding die M. Furthermore, although the heating control is basically PID control, by introducing adaptive control, each PID value (each parameter such as a coefficient governing PID control) is automatically adjusted. As a result, even if a delay occurs before the heater reaches the target temperature due to changes in the molding device 1, as shown by the dashed line in Figure 13, the delay can be automatically corrected as shown by the solid line in the same figure.

[0179] Furthermore, even when the molding die M is not present, the controller 100 controls at least one of the first temperature adjustment unit 7, the second temperature adjustment unit 8, and the third temperature adjustment unit 9 to heat the first and second hot plate units of the temperature adjustment units 7, 8, and 9. This allows the temperature of the molding die M to be raised quickly.

[0180] <11. Significance of this embodiment> As described above, the molding apparatus 1 according to this embodiment is configured such that the working section 2, the injection section 3, and the vulcanization section 4 are all separate entities. This separates the steps for injection molding a rubber product, making it possible to carry out different steps in parallel, thereby achieving a reduction in cycle time.

[0181] On the other hand, if the devices for performing each process are separate, it is necessary to connect the separate devices via the transport unit 10. In this case, there is a concern that the amount of decrease in mold temperature may vary when the mold is transported, for example, from the injection unit 3 to the working unit 2.

[0182] 8 and 10, the molding apparatus 1 can individually adjust the temperatures of the different regions Ms, Mc of the molding die M by using the first temperature adjustment unit 7 disposed in the injection unit 3. This allows the temperature of the molding die M, whose temperature has dropped during transport, to be raised evenly and quickly between the different regions Ms, Mc. This makes it possible to suppress variations in the vulcanization state of the rubber product.

[0183] Furthermore, the molding apparatus 1 is configured with a vulcanization section 4 as a separate entity in addition to the working section 2 and injection section 3. In this case, there is a concern that the amount of decrease in mold temperature may vary, for example, when the mold is transported from the injection section 3 to the vulcanization section 4.

[0184] 9 and 10, the molding apparatus 1 can individually adjust the temperatures of the different regions Ms, Mc of the molding die M by using the third temperature adjustment unit 9 arranged in the vulcanization unit 4. This allows the molding die M, whose temperature has dropped during transport, to be heated evenly and quickly in the different regions Ms, Mc. This makes it possible to suppress variations in the vulcanization state of the rubber product.

[0185] 8 and 10, by providing the first temperature adjustment section 8 in the injection section 3, it is possible to shorten the heating time in the vulcanization section 4. This contributes to shortening the cycle time.

[0186] 6 and 7, the contact area between the molding die M and the conveying section 10 can be reduced. While this can reduce the decrease in mold temperature during conveyance, there is a possibility that variations in the amount of decrease in mold temperature may occur between the contact points (side portions Ms) of the molding die M with the peripheral portions of the rail members 11 (e.g., the conveying rollers 13) and other portions of the molding die M (e.g., the center portion Mc).

[0187] In contrast, as illustrated in Figures 3 and 8 to 10, by configuring the temperature to be adjusted separately between the contact point between the molding die M and the peripheral part of the rail member 11 and other parts, it is possible to suppress variation in the amount of mold temperature decrease.

[0188] Furthermore, by using the support rollers 14 in addition to the conveying rollers 13, it is possible to stabilize the positioning (centering) of the molding die M in the front-rear direction while minimizing the contact area with the molding die M as much as possible.

[0189] 4A and 4B, by providing the working unit 2 with the second temperature adjustment unit 8, it is possible to prevent a decrease in the mold temperature of the molding die M when the mold is opened. Similarly to the first temperature adjustment unit 7 and the third temperature adjustment unit 9, by configuring different parts of the molding die M to adjust their temperatures individually, it is possible to raise the temperature evenly between the different parts. This makes it possible to prevent variations in the vulcanization state of the rubber product.

[0190] 5, the contact surface Mi has an uneven shape, which reduces the contact area between the flange portion Mf and the lifting portion 24 when opening and closing the molding die M (particularly when opening the die to remove the rubber product). This makes it possible to prevent a decrease in die temperature due to heat conduction.

[0191] 1, 2A, and 2B, by providing the replacement unit 5 separate from the working unit 2, it becomes possible to simultaneously open and close the molding die M in the working unit 2 and replace the molding die M in the replacement unit 5. This contributes to shortening the cycle time.

[0192] Furthermore, by locating the vulcanizing section 4 and the replacement section 5 adjacent to each other, it is possible to smoothly switch between the vulcanization reaction of the rubber material in the vulcanizing section 4 and the replacement of the molding die M in the replacement section 5. This makes it possible to replace the molding die M using the time that would have been reserved for the vulcanization reaction, minimizing the impact on the overall cycle of the molding apparatus 1, such as the transport timing of other molding dies M. This also contributes to shortening the cycle time.

[0193] Furthermore, as illustrated in FIG. 1 and other figures, by arranging the two work sections 2, 2' adjacent to each other, it is advantageous for one operator U to use the two molding devices 1L, 1R simultaneously.

[0194] <12. Other embodiments> In the above embodiment, the molding apparatus 1 that performs insert molding on the premise that the metal fitting P is inserted is illustrated, but the insertion of the metal fitting P, and therefore insert molding, is not essential.

[0195] Furthermore, it is not essential to provide two or more injection units 3 and vulcanization units 4. It is sufficient to provide one or more of these devices. It is not essential to provide the replacement unit 5.

[0196] Furthermore, the vulcanizing unit 4 is not essential in the first place. The vulcanizing unit 4 may be an apparatus integrated with the injection unit 3. [Explanation of symbols]

[0197] S Injection Molding System 1 Injection molding equipment 1L 1st molding device 1R 2nd molding device 2 Working section 21 First Working Section 22 Second Working Section 224 Lifting unit (support unit) 3 Injection part 31 1st injection section 32 2nd injection part 4. Vulcanization section 41 First Vulcanization Section 42 Second vulcanization section 5 Exchange part 51 1st Exchange Department 52 2nd exchange section 6 Waiting section 7 1st temperature control section (temperature control section) 73 First heater (heater) 74 First temperature sensor (temperature sensor) 8 Second temperature control unit (second temperature control unit) 83 Second heater (heater) 84 Second temperature sensor (temperature sensor) 9 Third temperature control section (temperature control section) 93 Third heater (heater) 94 Third temperature sensor (temperature sensor) 10 Conveying section 11 Pair of rail members 13 Conveyor roller 14 Support roller M molding die Ms Both sides of the molding die Mc Center of the molding die Mf flange Mi contact surface

Claims

1. An injection molding apparatus for continuously injection-molding a plurality of rubber products using a plurality of molding dies, a working unit that opens and closes the molding die; at least one injection unit configured as a separate unit from the working unit and configured to inject a rubber material into the molding die; a transport unit that connects the working unit and the injection unit to each other and transports the molding die between the working unit and the injection unit; a temperature control unit disposed in the injection unit and controlling the temperature of the molding die; The temperature control unit is composed of a plurality of heaters and temperature sensors arranged at different positions so as to individually control the temperatures of different parts of the molding die. An injection molding apparatus characterized by:

2. 2. The injection molding apparatus according to claim 1, and at least one vulcanizing unit configured as a separate unit from the working unit and the injection unit, for heating the molding die into which the rubber material is injected, thereby causing a vulcanization reaction of the rubber material; the transport unit interconnects the working unit, the injection unit, and the vulcanizing unit, and transports the molding die among the working unit, the injection unit, and the vulcanizing unit; The temperature control unit is disposed in both the injection unit and the vulcanization unit. An injection molding apparatus characterized by the above.

3. 2. The injection molding apparatus according to claim 1, the conveying section has a pair of rail members that support both sides of the molding die, The different portions include both side portions of the molding die and a central portion of the molding die located between the both side portions. An injection molding apparatus characterized by:

4. 2. The injection molding apparatus according to claim 1, a second temperature control unit disposed in the working unit and controlling the temperature of the molding die in the working unit; The second temperature control unit is composed of a plurality of heaters and temperature sensors arranged at different positions so as to individually control the temperatures of different parts of the molding die. An injection molding apparatus characterized by:

5. 2. The injection molding apparatus according to claim 1, the molding die has a flange portion protruding from the molding die, the working unit has a support unit that supports the flange unit when the molding die is opened or closed, The contact surface between the flange portion and the support portion has an uneven shape. An injection molding apparatus characterized by:

6. 2. The injection molding apparatus according to claim 1, the conveying section has a pair of rail members that support both sides of the molding die, The pair of rail members include: Conveying rollers arranged to support the bottom surfaces of the both side portions; support rollers arranged to face the outer surfaces of the both side portions, the pair of rail members support the both side portions via the conveying rollers, The conveying roller receives power from a driving source and rotates around a rotation axis fixed to the pair of rail members. An injection molding apparatus characterized by:

7. 3. The injection molding apparatus according to claim 2, one or more replacement units configured as separate units from the working unit, the injection unit, and the vulcanization unit, for replacing the molding die; The replacement portion is disposed adjacent to the vulcanized portion. An injection molding apparatus characterized by:

8. An injection molding system including a plurality of injection molding apparatuses according to any one of claims 1 to 7, The working unit in one of the plurality of injection molding apparatuses and the working unit in another of the injection molding apparatuses are arranged adjacent to each other. An injection molding system comprising:

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