Injection molding machine and injection molding system

Abstract

To satisfy both shortening of cycle time and suppression of an installation area.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 plurality of injection parts 3 which respectively inject a rubber material into the molding dies M; a linear conveying part 10 which is shared among the injection parts 3 and reciprocally moves the molding dies M so as to convey the molding dies M to the injection parts 3; and a stopper 16 as a control mechanism which is arranged at an intermediate portion on the conveying part 10 and individually controls conveyance of the molding dies M.SELECTED DRAWING: Figure 2B

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 the steps of mold opening and closing, injection, vulcanization, and the like for resin products (e.g., rubber products), as in conventional molding machines, it is not possible to manufacture the next resin product until one resin product is completed. This is inconvenient in terms of shortening the cycle time when attempting to injection mold a plurality of resin 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 multiple processes such as mold opening and closing, injection, and vulcanization reaction can proceed in parallel.

[0007] In this case, for example, the devices for mold disassembly and injection are organized into separate stations as a disassembly section and an injection section, respectively, which allows the mold disassembly and injection of resin products to be separated and each separate process to be carried out simultaneously in parallel.

[0008] However, when each process is separated, the devices that perform each process must be connected by a circulating conveyance path as in Patent Document 1. However, conventionally known circulating conveyance paths require a large installation area, which is inconvenient when trying to make the injection molding device more compact.

[0009] The present disclosure has been made in consideration of the above points, and its purpose is to achieve both a reduction in cycle time and a reduction in installation area. [Means for solving the problem]

[0010] A first aspect of the present disclosure relates to an injection molding apparatus for continuously injection-molding a plurality of resin products using a plurality of molding dies. The injection molding apparatus includes a plurality of injection sections each for injecting a resin material into the molding dies, a linear transport section shared among the injection sections for reciprocating the molding dies to transport them to the injection sections, and a control mechanism disposed midway on the transport section for individually controlling the transport of the molding dies.

[0011] According to the first aspect, the injection molding apparatus is equipped with multiple injection units. This allows multiple processes (especially injection) to proceed in parallel, contributing to a reduction in cycle time. Furthermore, by connecting the multiple injection units with a transport unit, even if some of the injection units stop due to malfunction, maintenance, etc., the remaining injection units can continue injection molding. This also contributes to a reduction in cycle time.

[0012] Furthermore, by moving the molding dies back and forth along a linear conveyor, the conveyor can be made more compact than conventional circulating conveyor paths, thereby shortening the cycle time and reducing the installation area.

[0013] When multiple devices (injection units) are connected by a linear conveying section, multiple molding dies may be conveyed simultaneously along the conveying path. In such cases, the conveying speed of each molding die may not necessarily be the same. If molding dies are conveyed while touching each other, this may cause problems in conveying them to the corresponding injection units.

[0014] To deal with this possibility, it is conceivable to use a large conveying unit to increase the distance between the molding dies, but this is inconvenient as it contradicts the need to reduce the installation area.

[0015] Therefore, as in the first aspect, a control mechanism is placed on the conveying section. This makes it possible to stop each molding die individually, allowing the conveying section to be made as small as possible. By controlling each molding die individually with the control mechanism, it becomes possible to convey them at different times.

[0016] Furthermore, by locating the control mechanism at a location midway along the conveying section, it becomes possible to connect devices such as the injection section not only to both ends of the conveying section but also to a location midway along the conveying section, which makes it easy to add and connect other devices to the injection molding machine, and increases the degree of freedom in locating each device.

[0017] Furthermore, according to a second aspect of the present disclosure, the control mechanism may be configured by a plurality of stoppers arranged at different positions on the conveying section and operating to restrict or allow the reciprocating movement of the molding die.

[0018] Furthermore, according to a third aspect of the present disclosure, the injection molding device may be arranged at a predetermined location on the conveying section and include a plurality of mold sensors that detect the presence or absence of the molding mold at the predetermined location, and a controller electrically connected to the mold sensors, and the controller may individually control the stoppers based on the detection signals of the mold sensors.

[0019] According to the third aspect, the controller can control each stopper based on the transport status of each molding die, thereby enabling more accurate control of each stopper.

[0020] According to a fourth aspect of the present disclosure, the injection units each inject a rubber material as the resin material into the molding die, and the injection molding device includes a working unit configured as a separate entity from the injection unit and for opening and closing the molding die, and a plurality of vulcanizing units configured as separate entities from the working unit and the injection unit and 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 between the working unit, the injection unit, and the vulcanizing unit, and at least one of the working unit, the injection unit, and the vulcanizing unit may be positioned at the midpoint.

[0021] As in the fourth aspect, at least one of the working unit, the injection unit, and the vulcanizing unit is disposed in a portion of the conveying unit, which makes it possible to arrange a plurality of devices in the conveying unit while avoiding an increase in the length of the conveying unit.

[0022] Furthermore, in order to place the device at an intermediate location, it is necessary to stop the molding die at that location, and by using a control mechanism such as that of the first aspect, it is possible to meet such needs.

[0023] Furthermore, according to a fifth aspect of the present disclosure, the working unit may be connected to one side of the conveying unit, the vulcanizing unit may be positioned on the conveying unit, and the injection unit may be connected to the other side of the conveying unit so as to be located opposite the working unit.

[0024] According to the fifth aspect, it is possible to lay out the injection units and the working unit at separate locations across the conveying unit. This makes it possible to increase the safety of workers even when various tasks are performed by the workers in the working unit. Furthermore, although each injection unit is likely to be larger than other devices because it is connected to supply pipes for resin material, it is possible to lay out the injection units without increasing the length of the conveying unit or interfering with the working unit. This makes it possible to make the injection molding device as compact as possible.

[0025] Furthermore, according to a sixth aspect of the present disclosure, the injection molding apparatus may include an exchange unit that is arranged separately from the working unit, the injection unit, and the vulcanizing unit and that exchanges the molding mold, and the transport unit connects the working unit, the injection unit, the vulcanizing unit, and the exchange unit, and transports the molding mold between the working unit, the injection unit, the vulcanizing unit, and the exchange unit, and the exchange unit may be connected to one side so as to be arranged alongside the working unit.

[0026] According to the sixth aspect, it is possible to lay out the injection units and the replacement unit at separate locations across the transport unit. This makes it possible to increase the safety of workers even when various tasks are performed by the workers in the replacement unit. Furthermore, although each injection unit is likely to be larger than other devices because it is connected to supply pipes for resin material, it is possible to lay out the injection units without interfering with the replacement unit without increasing the length of the transport unit. This makes it possible to make the injection molding apparatus as compact as possible.

[0027] According to a seventh aspect of the present disclosure, the replacement portion may be adjacent to the vulcanized portion on the one side.

[0028] According to the seventh aspect, by arranging the two devices adjacent to each other, it is possible to smoothly switch between the process in the vulcanization section and the process in the replacement section. This reduces the impact on the various processes for other molding dies, and ultimately on the cycle time of the entire injection molding device. This contributes to shortening the cycle time.

[0029] Furthermore, according to an eighth 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 vulcanization unit, and may include a waiting unit in which the molding mold waits after the vulcanization reaction in the vulcanization unit before being sent back to the working unit, the conveying unit connects the working unit, the injection unit, the vulcanization unit, and the waiting unit, and moves the molding mold back and forth between the working unit, the injection unit, the vulcanization unit, and the waiting unit, and the waiting unit may be arranged in the conveying unit so as to branch off from a path connecting the vulcanization unit and the working unit.

[0030] According to the eighth aspect, by providing a standby section as in this aspect, even when other molding dies are positioned in the working section, it is possible to configure so that there is no hindrance to the removal of the other molding dies, which is convenient for molding multiple molding dies simultaneously and is advantageous in shortening the cycle time without increasing the length of the conveying section.

[0031] A ninth 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.

[0032] According to the ninth 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]

[0033] As described above, according to the present disclosure, it is possible to achieve both a reduction in cycle time and a reduction in installation area. [Brief explanation of the drawings]

[0034] [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 perspective view illustrating the configuration of the transport unit. [Figure 6] FIG. 6 is a cross-sectional view illustrating the configuration of the transport unit. [Figure 7] FIG. 7 is a plan view illustrating the configuration of the stopper. [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

[0035] Hereinafter, embodiments of the present disclosure will be described. Note that the following description is an example.

[0036] <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.

[0037] 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.

[0038] 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."

[0039] 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.

[0040] 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 "".

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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).

[0048] 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.

[0049] 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).

[0050] 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.

[0051] 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.

[0052] 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."

[0053] 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).

[0054] 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."

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] Each part of the molding device 1 will be described in turn below.

[0060] <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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] On the other hand, the pushing section 25 has a second hot plate section 82 that comes into contact with 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.

[0068] 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.

[0069] 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.

[0070] The second temperature adjustment unit 8 is composed of a plurality of second heaters 83 and second temperature sensors 84. The plurality of second heaters 83 and second temperature sensors 84 are respectively built into the first and second hot plate units 81, 82. The second temperature adjustment units 8 are connected to a controller 100 (described later) and are individually controlled by receiving control signals from the controller 100.

[0071] <3. Conveyor section> [3-1. Structure of the transport unit] Fig. 5 is a perspective view illustrating the configuration of the transport unit 10, and Fig. 6 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 5, 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] Furthermore, the conveying 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. Each of the plurality of stoppers 16 constitutes a "control mechanism" in this embodiment.

[0082] 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.

[0083] 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.

[0084] 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).

[0085] 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.

[0086] 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.

[0087] 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.

[0088] Fig. 7 is a plan view illustrating the configuration of the stopper 16. As shown in Fig. 7, the stopper 16 is made up of a first stopper 161 and a second stopper 162 that are aligned in the front-rear direction.

[0089] The first stopper 161 rises upward in response to a control signal from the controller 100, thereby allowing linear movement from right to left, but restricting linear movement from left to right.

[0090] The second stopper 162 rises upward in response to a control signal from the controller 100, thereby allowing linear movement from left to right, but restricting linear movement from right to left.

[0091] By raising one of the first and second stoppers 161, 162, it is possible to restrict or allow linear movement of each molding die M. Furthermore, by arranging the first and second stoppers 161, 162 side by side in the front-to-rear direction, it is possible to shorten the dimension of the conveying section 10 in the left-to-right direction.

[0092] [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 conveying direction (left-right direction) of the molding die M by the conveying unit 10. The first and second vulcanizing units 41, 42 are arranged in a midway position on the conveying unit 10.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] The first injection section 31 can be considered to branch off from another intermediate portion (second connecting section P2) in the conveying section 10. The second injection section 32 can be considered to branch off from yet another intermediate portion (third connecting section P3) in the conveying section 10.

[0097] The first replacement section 51 can be considered to branch off from another intermediate section (first vulcanizing section 41) in the transport section 10. The second replacement section 52 can be considered to branch off from another intermediate section (second vulcanizing section 42) in the transport section 10.

[0098] 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.

[0099] The former path branches at a second branching portion P2 into a path toward the first injecting portion 31 and a path toward the first vulcanizing portion 41. The path toward the first vulcanizing portion 41 further branches at a third branching portion P3 into a path toward the second injecting portion 32 and a path toward the second vulcanizing portion 42.

[0100] 2A, the distance D1 between the first injection section 31 and the second injection section 32 in the conveying direction (left-right direction) of each molding die M is shorter than the dimension D2 of the first vulcanizing section 41 in the same direction. By reducing the distance D1 between the first injection section 31 and the second injection section 32, the molding device 1 can be made more compact.

[0101] Such a configuration can be achieved by placing at least one of the first injection section 31, the second injection section 32 and the first vulcanization section 41 (in this embodiment, the first vulcanization section 41) on the conveying section 10, rather than connecting all of them to the side of the conveying section 10.

[0102] <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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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 the first temperature adjustment section 7 according to this embodiment, which is configured to adjust the temperature of the molding die M.

[0109] 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.

[0110] The first temperature adjustment unit 7 is composed of a plurality of first heaters 73 and a first temperature sensor 74. The plurality of first heaters 73 and the first temperature sensor 74 are respectively built into the first and second hot plate units 71, 72. The first temperature adjustment unit 7 is connected to a controller 100 (described later) and is controlled by receiving a control signal from the controller 100.

[0111] 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.

[0112] <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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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 the third temperature adjustment section 9 according to this embodiment, which is configured to adjust the temperature of the molding die M.

[0117] 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.

[0118] The third temperature adjustment unit 9 is composed of a plurality of third heaters 93 and a third temperature sensor 94. The plurality of third heaters 93 and the third temperature sensor 94 are respectively built into the first and second hot plate units 91, 92. The third temperature adjustment unit 9 is connected to a controller 100 (described later) and is controlled by receiving a control signal from the controller 100.

[0119] 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.

[0120] <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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] <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.

[0125] 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.

[0126] 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.

[0127] The former path branches at a second branching portion P2 into a path toward the first injecting portion 31 and a path toward the first vulcanizing portion 41. The path toward the first vulcanizing portion 41 further branches at a third branching portion P3 into a path toward the second injecting portion 32 and a path toward the second vulcanizing portion 42.

[0128] <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.

[0129] 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.

[0130] 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.

[0131] 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 .

[0132] <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.

[0133] 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.

[0134] 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.

[0135] [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.

[0136] 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.

[0137] [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.

[0138] 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.

[0139] 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.

[0140] [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.

[0141] 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.

[0142] 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.

[0143] 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.

[0144] [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.

[0145] 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.

[0146] 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.

[0147] 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 the transfer section 10 from being blocked by other molding dies M when the molding die M is transferred from the vulcanization section 4 to the standby section 6.

[0148] Furthermore, by arranging the first injection section 31 and the first vulcanizing section 41 adjacent to each other in the left-right direction, and by arranging the second injection section 32 and the second vulcanizing section 42 adjacent to each other, the molding die M can be smoothly transported from the first injection section 31 to the first vulcanizing section 41 regardless of whether the molding die M is located in the second vulcanizing section 42. Similarly, the molding die M can be smoothly transported from the second injection section 32 to the second vulcanizing section 42 regardless of whether the molding die M is located in the first vulcanizing section 41.

[0149] [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.

[0150] 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.

[0151] 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.

[0152] 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.

[0153] [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.

[0154] 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.

[0155] 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.

[0156] 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.

[0157] [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.

[0158] 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.

[0159] 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.

[0160] [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'.

[0161] 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'.

[0162] 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.

[0163] [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'.

[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] [9-9. 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.

[0166] 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.

[0167] 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.

[0168] 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.

[0169] 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.

[0170] The first and third molding dies M1 and M3 include a first injection section 31 and a first vulcanization section 41.

[0171] The second and fourth molding dies M2 and M4 include a second injection section 32 and a second vulcanization section 42.

[0172] 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.

[0173] 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.

[0174] 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.

[0175] <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.

[0176] Although these heating controls are basically PID controls, the introduction of adaptive control allows each PID value (each parameter such as a coefficient that governs PID control) to be automatically adjusted. As a result, even if there is a delay in the heater reaching 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.

[0177] 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.

[0178] <11. Significance of this embodiment> As explained above, the molding apparatus 1 according to this embodiment is equipped with multiple injection units 3, as illustrated in Figures 2A and 2B. This allows multiple processes (especially injection) to proceed in parallel, contributing to a reduction in cycle time. Furthermore, by connecting the multiple injection units 3 with the conveying unit 10, even if some of the injection units 31 stop due to a malfunction, maintenance, or the like, injection molding can continue using the remaining injection units 32. This also contributes to a reduction in cycle time.

[0179] 2A and 2B, by reciprocating the molding die M using the linear conveying section 10, the conveying section 10 can be made more compact than a conventional circulating conveying path, thereby shortening the cycle time and reducing the installation area.

[0180] Incidentally, when multiple devices (injection units 3) are connected by a linear conveying unit 10, multiple molding dies M may be conveyed simultaneously along the conveying path. In such cases, the conveying speed of each molding die M may not necessarily be the same. If molding dies M are conveyed while in contact with each other, this may cause problems in conveying each molding die M to the corresponding injection unit 3.

[0181] To address this possibility, it may be possible to use a large conveying unit 10 to increase the distance between the molding dies M, but this would be inconvenient as it would run counter to the need to reduce the installation area.

[0182] Therefore, as shown in Fig. 2B, multiple stoppers 16 are arranged on the conveying section 10. This makes it possible to stop each molding die M individually, making it possible to make the conveying section 10 as small as possible. By controlling each molding die M individually with the stoppers 16, it becomes possible to convey them at different times.

[0183] Furthermore, by locating stopper 16 at a midpoint on conveying section 10, it becomes possible to connect devices such as injection section 3 not only to both ends of conveying section 10 but also to that midpoint. This makes it easy to add and connect other devices such as exchange section 5 to molding apparatus 1, increasing the degree of freedom in locating each device.

[0184] 6, the controller 100 can control each stopper 16 based on the transport status of each molding die M. This makes it possible to control each stopper 16 more accurately.

[0185] 2A and 2B, at least one of the working section 2, the injection section 3, and the vulcanization section 4 is disposed at a midpoint of the conveying section 10. This makes it possible to arrange multiple devices in the conveying section 10 while avoiding the conveying section 10 from becoming too long.

[0186] Furthermore, in order to place the device at an intermediate location, it is necessary to stop the molding die M at that location, and by using the stopper 16 as described above, it is possible to meet such needs.

[0187] 2A and 2B, it is possible to lay out each injection unit 3 and working unit 2 at separate locations with the conveying unit 10 in between. This makes it possible to improve the safety of the worker U even when various tasks are performed by the worker U in the working unit 2. Furthermore, although each injection unit 3 is concerned to be larger than other devices because it must be connected to supply pipes for the resin material, it is possible to lay out the injection unit 3 without increasing the length of the conveying unit 10 or interfering with the working unit 2. This makes it possible to make the molding apparatus 1 as compact as possible.

[0188] 2A and 2B, it is possible to lay out the injection units 3 and the replacement unit 5 at separate locations with the transport unit 10 in between. This makes it possible to increase the safety of the worker U even when various tasks are performed by the worker U in the replacement unit 5. Furthermore, although there is a concern that each injection unit 3 will be larger than other devices because it will need to connect supply pipes for the resin material, etc., it is possible to lay out the injection units 3 without increasing the length of the transport unit 10 or interfering with the replacement unit 5. This makes it possible to make the molding apparatus 1 as compact as possible.

[0189] 1, by placing the vulcanizing unit 4 and the replacement unit 5 adjacent to each other, it is possible to smoothly switch between the process in the vulcanizing unit 4 and the process in the replacement unit 5. This makes it possible to suppress the impact on various processes for other molding dies M, and ultimately on the cycle time of the entire molding apparatus 1. This contributes to shortening the cycle time.

[0190] 2A and 2B, even when other molding dies M are positioned in the working section 2, the standby section 6 can be configured to not interfere with the removal of the other molding dies M. This is convenient for molding a plurality of molding dies M simultaneously, and is advantageous in shortening the cycle time without increasing the length of the conveying section 10.

[0191] 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.

[0192] 2A, the distance D1 between the first injecting section 31 and the second injecting section 32 in the left-right direction is shorter than the dimension D2 of the first vulcanizing section 31 in the left-right direction. This makes it possible to make the injection device 1 more compact in the left-right direction.

[0193] <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.

[0194] Furthermore, it is not essential to provide the vulcanizing unit 4 and the replacement unit 5. When the vulcanizing unit 4 is omitted, the present disclosure can be used to mold resin products other than rubber products, in which a cooling process of the resin material is performed instead of the vulcanization process. In other words, it is not essential to use a rubber material as the resin material. [Explanation of symbols]

[0195] 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 3 Injection part 31 1st injection part 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) 8 Second temperature control unit (second temperature control unit) 9 Third temperature control section (temperature control section) 10 Conveying section 11 Pair of rail members 13 Conveyor roller 14 Support roller 15 Mold Sensor 16 Stopper (control mechanism) M molding die

Claims

1. An injection molding apparatus that continuously injection molds a plurality of resin products using a plurality of molding dies, a plurality of injection units each configured to inject a resin material into the molding die; a linear transport unit shared between the injection units and configured to reciprocate the molding die so as to transport the molding die to the injection units; a control mechanism that is disposed midway on the transport section and that individually controls the transport of the molding dies. An injection molding apparatus characterized by:

2. 2. The injection molding apparatus according to claim 1, The control mechanism is configured by a plurality of stoppers that are arranged at different positions on the conveying section and operate to restrict or allow the reciprocating movement of the molding die. An injection molding apparatus characterized by:

3. 3. The injection molding apparatus according to claim 2, a plurality of mold sensors disposed at predetermined locations on the conveying section and detecting the presence or absence of the molding mold at the predetermined locations; a controller electrically connected to the mold sensor; The controller controls the stoppers individually based on the detection signal of the mold sensor. An injection molding apparatus characterized by:

4. 2. The injection molding apparatus according to claim 1, The injection units each inject a rubber material as the resin material into the molding die, a working unit configured as a separate unit from the injection unit and configured to open and close the molding die; a plurality of vulcanizing units configured as separate entities from the working unit and the injection unit, which heat 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; At least one of the working section, the injection section, and the vulcanizing section is disposed in the intermediate portion. An injection molding apparatus characterized by:

5. 5. The injection molding apparatus according to claim 4, the working unit is connected to one side of the transport unit, The vulcanizing unit is disposed on the conveying unit, The injection unit is connected to the other side of the transport unit so as to be located on the opposite side of the working unit. An injection molding apparatus characterized by:

6. 6. The injection molding apparatus according to claim 5, an exchange unit that is disposed separately from the working unit, the injection unit, and the vulcanizing unit and that exchanges the molding die; the transport unit connects the working unit, the injection unit, the vulcanizing unit, and the replacement unit, and transports the molding die between the working unit, the injection unit, the vulcanizing unit, and the replacement unit; The replacement unit is connected to the one side of the working unit so as to be arranged side by side with the working unit. An injection molding apparatus characterized by:

7. 7. The injection molding apparatus according to claim 6, The replacement portion is adjacent to the vulcanized portion on the one side. An injection molding apparatus characterized by:

8. 5. The injection molding apparatus according to claim 4, a standby unit configured as a separate unit from the working unit, the injection unit, and the vulcanizing unit, for allowing the molding die to wait after the vulcanization reaction in the vulcanizing unit before being sent back to the working unit; the transport unit connects the working unit, the injection unit, the vulcanization unit, and the standby unit, and moves the molding die back and forth between the working unit, the injection unit, the vulcanization unit, and the standby unit; The waiting section is arranged in the conveying section so as to branch off from a path connecting the vulcanizing section and the working section. An injection molding apparatus characterized by:

9. An injection molding system including a plurality of injection molding apparatuses according to any one of claims 1 to 8, 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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