Control device for the extraction machine

Abstract

To provide a control device for an extraction machine that can store and manage information about molds. [Solution] The processor 201 of the extraction machine control device 200 receives a mold opening signal from the molding machine 10 indicating the mold opening operation of the mold 33, measures the number of times each mold 33 is opened and closed based on the input mold opening signal, and stores the measured number of times each mold 33 is opened and closed in the storage unit 201. The processor 201 then determines whether the number of times each mold 33 is opened and closed exceeds a threshold, and if it determines that the threshold has been exceeded, it causes the controller 40 to output maintenance information.

Description

Technical Field

[0001] The present invention relates to a control device for a take-out machine.

Background Art

[0002] Conventionally, a maintenance device has been proposed that measures the number of times a mold used in a molding machine is opened and closed, stores the measured number of opening and closing operations, and is configured to be able to transmit the stored number of opening and closing operations to an external device. Such a maintenance device is described in, for example, Patent Document 1.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, a mold is generally a lump of metal and is a heavy object. When attaching it to a molding machine, a crane or the like is used. And a maintenance device composed of electronic components and the like is generally more likely to break than a mold. For this reason, when attaching a mold to a molding machine, there is a possibility that the maintenance device may be damaged, so it has been difficult to directly attach the maintenance device to the mold.

[0005] The present invention has been made in view of the above problems, and an object thereof is to provide a control device for a take-out machine that can store and manage mold information.

Means for Solving the Problems

[0006] A first means for solving the above problem is a control device for an extraction machine that can communicate with a molding machine to which molds are interchangeably attached, comprising: a measuring unit that receives at least one of a mold opening signal indicating the mold opening operation and a mold closing signal indicating the mold closing operation from the molding machine, and measures the number of openings and closings or the usage time for each mold based on the input mold opening signal or mold closing signal; a storage unit that stores the number of openings and closings or the usage time measured by the measuring unit for each mold; a determination unit that determines whether the number of openings and closings or the usage time for each mold exceeds a threshold; and an output unit that, if the determination unit determines that the threshold has been exceeded, causes the extraction machine's notification unit to output maintenance information prompting maintenance.

[0007] This allows the system to measure and store the number of times the mold is opened or closed, or the usage time, based on the mold open signal or mold closed signal. If these exceed a threshold, maintenance information is output. Therefore, the control device of the extraction machine can manage the number of times the mold is opened or closed or the usage time for each mold. [Brief explanation of the drawing]

[0008] [Figure 1] Perspective view of the molding machine and the extraction machine. [Figure 2] Side view of the molding machine and the extraction machine. [Figure 3] A block diagram showing the functions of the molding machine control device and the extraction machine control device. [Figure 4] A flowchart of the manufacturing process. [Figure 5] A schematic diagram of the manufacturing information input screen. [Figure 6] A schematic diagram of the mold information input screen. [Modes for carrying out the invention]

[0009] Hereinafter, embodiments of the "control device for the extraction machine" described herein will be explained with reference to the drawings. Figures 1 and 2 show a molding machine 10 and an extraction machine 20 for extracting molded products from the molding machine 10.

[0010] First, let's describe the molding machine 10. The molding machine 10 has a main body 11 that extends in the X direction, and a fixed platen 12 and a movable platen 13 that are positioned opposite each other at an appropriate distance in the middle of the main body 11. Four tie bars 14 that extend along a predetermined X direction are horizontally mounted at the four corners of the fixed platen 12 and the movable platen 13. A movable platen 15 is supported on the tie bars 14 so as to be able to move relative to the fixed platen 12 in the X direction.

[0011] A fixed mold 31 is attached to the fixed mounting platen 12a provided on the fixed platen 12, and a movable mold 32 is attached to the movable mounting platen 15a provided on the movable platen 15, opposite to the fixed mold 31. The combination of the fixed mold 31 and the movable mold 32 constitutes the mold 33.

[0012] Furthermore, the movable platen 15 is connected to the operating shaft of a clamping member 16, such as a hydraulic cylinder or a reciprocating feed screw member, which is provided on the main body 11. The movable platen 15 is moved as the clamping member 16 operates, causing the movable mold 32 to perform a mold closing or mold opening operation relative to the fixed mold 31.

[0013] An injection unit 17 is provided on the main body 11 on the fixed platen 12 side. When the movable mold 32 is closed, the injection unit 17 injects molten synthetic resin into the mold 33 from an injection cylinder 17a that is pressed against the back surface of the fixed mold 31, thereby forming a molded resin product.

[0014] As shown in Figure 3, the molding machine 10 includes a molding machine control device 100. The molding machine control device 100 includes a processor 101 as hardware, a storage unit 102 such as memory and storage, and a communication bus 103 connecting the processor 101 and the storage unit 102. The storage unit 102 provides, for example, a work area for temporary use when the processor 101 is performing processing. The storage unit 102 also stores various programs and data for the processor 101 to read and execute.

[0015] Next, the extraction machine 20 will be described. As shown in Figures 1 and 2, the extraction machine 20 is fixed to the upper surface of the fixed platen 12 of the molding machine 10. The extraction machine 20 in this embodiment is, for example, a gantry loader. More specifically, the travel frame 21 of the extraction machine 20 is provided in a straight line so as to extend in the Y direction perpendicular to the X direction. A first traveling body 22 is supported on the upper part of the travel frame 21 so as to be movable in the Y direction. The first traveling body 22 is configured to reciprocate in the Y direction by a first moving mechanism 23 (see Figure 3), such as a feed screw mechanism, a belt mechanism, or a rack and pinion mechanism. The first moving mechanism 23 has a first electric motor 23a, such as a numerically controllable servo motor, and is driven by the first electric motor 23a.

[0016] The first traveling body 22 is provided with front and rear frames 24 that extend linearly in the X direction. The front and rear frames 24 have a length such that their ends reach the open movable mold 32. The second traveling body 25 is supported on the front and rear frames 24 so as to be movable in the X direction. The second traveling body 25 is configured to reciprocate in the X direction by a second moving mechanism 26 (see Figure 3), such as a lead screw mechanism, belt mechanism, or rack and pinion mechanism. The second moving mechanism 26 has a second electric motor 26a, such as a numerically controllable servo motor, and is driven by the second electric motor 26a.

[0017] The second traveling body 25 is provided with upper and lower frames 27 that extend linearly in the Z direction (vertical direction). The upper and lower frames 27 are supported on the second traveling body 25 so as to move up and down. The upper and lower frames 27 have a length such that when lowered, their lower ends reach between the open molds 33. The upper and lower frames 27 are configured to reciprocate in the Z direction by a third moving mechanism 28 (see Figure 3), such as a feed screw mechanism, belt mechanism, or rack and pinion mechanism. The third moving mechanism 28 has a third electric motor 28a, such as a numerically controllable servo motor, and is driven by the third electric motor 28a.

[0018] At the lower end of the upper and lower frames 27, a chuck 29 having a plurality of suction pads, gripping claws that open and close, etc. is attached. The chuck 29 is provided with an operating mechanism 30 (see FIG. 3) such as an air cylinder or an electric motor. By operating a plurality of suction pads, gripping claws that open and close, etc. (suction operation, opening and closing operation) by these operating mechanisms 30, one or a plurality of molded products can be gripped by the chuck 29.

[0019] As shown in FIG. 3, the take-out machine 20 has a take-out machine control device 200. The take-out machine control device 200 includes a processor 201 as hardware, a storage unit 202 such as a memory and a storage, and a communication bus 203 that connects the processor 201 and the storage unit 202. The storage unit 202 provides, for example, a work area for temporary use when the processor 201 performs processing. In addition, the storage unit 202 stores various programs and data for the processor 201 to read and execute.

[0020] Further, the take-out machine 20 has a controller 40 as an information input unit and a notification unit. The controller 40 has a touch panel 40a that outputs (displays) various information and can input various instructions. The controller 40 is connected to the take-out machine control device 200 by wire or the like and is configured to be able to input and output various information with the take-out machine control device 200.

[0021] Next, the functions of the molding machine control device 100 and the take-out machine control device 200 will be described. First, the function of the take-out machine control device 200 will be described. The processor 201 of the take-out machine control device 200 has a function as a take-out control unit that performs take-out control of the molded product.

[0022] When an operator inputs the number of molded products to be manufactured to the controller 40 via the touch panel 40a, the controller 40 inputs the number of products to be manufactured to the extraction machine control device 200. The processor 201 of the extraction machine control device 200 stores the input number of products in the storage unit 202. The processor 201 also notifies the molding machine control device 100 of this number of products and has it store it in its storage unit 102. Note that the manufacturing time may be used instead of the number of products manufactured.

[0023] Furthermore, if the number of products manufactured is stored, the processor 201 reads the control information for the extraction machine 20 stored in the storage unit 202. The control information for the extraction machine 20 includes information necessary to control the extraction machine 20, such as the stopping position of the chuck 29, the moving speed, and the timing of the start of movement. More specifically, it includes information such as the drive sequence of the first to third electric motors 23a, 26a, and 28a, rotational speed, output torque, acceleration time, constant speed time, deceleration time, drive start timing, drive stop timing, and the gripping and release timing of the molded product by the operating mechanism 30.

[0024] The control information for the extraction machine 20 is determined by operator teaching and stored in the memory unit 202. The control information for the extraction machine 20 is determined for each mold 33 attached to the molding machine 10, and the control information for the extraction machine 20 is stored in the memory unit 202 for each mold 33. Each mold 33 is assigned an identification number as mold information to identify the mold 33, which is attached to the surface of the mold 33. The memory unit 202 stores the control information associated with this identification number.

[0025] The identification number of the mold 33 attached to the molding machine 10 is set (stored) in the memory units 102 and 202 as the identification number indicating the current mold 33 when the mold 33 is attached to the molding machine 10 (during replacement, etc.). The processor 201 reads the control information of the extraction machine 20 associated with the identification number currently set in the memory unit 202. In the following, the identification number currently set (stored) in the memory units 102 and 202 as the identification number indicating the mold 33 attached to the molding machine 10 may simply be referred to as the "currently set identification number".

[0026] The processor 201 of the extraction machine control device 200 controls the extraction machine 20 to extract the molded product from the mold 33 based on the control information of the extraction machine 20 that it has read, once it receives a mold opening signal from the molding machine control device 100 indicating the completion of the mold opening operation, until the input production quantity becomes zero.

[0027] Next, the functions of the molding machine control device 100 will be described. The processor 101 of the molding machine control device 100 has functions such as controlling the opening and closing operation of the mold 33 and controlling the injection unit 17. The processor 101 of the molding machine control device 100 reads control information for the molding machine 10 from the storage unit 102 if the stored number of production units is 1 or more. The control information for the molding machine 10 includes information necessary for opening and closing control of the mold 33 and injection control. More specifically, the control information for the molding machine 10 includes information related to opening and closing control, such as the opening and closing speed of the mold 33, the opening and closing timing, and the stopping position of the movable mold 32 (i.e., stroke length). In addition, the control information for the molding machine 10 includes information related to injection control, such as the amount of resin to be injected, the injection timing, and the injection speed.

[0028] The control information for the molding machine 10, like the control information for the extraction machine 20, is determined by teaching by an operator and stored in the memory unit 102. The control information for the molding machine 10 is determined for each mold 33 attached to the molding machine 10, and the control information for the molding machine 10 is stored in the memory unit 102 in association with the identification number of the mold 33.

[0029] The processor 101 of the molding machine control device 100 controls the mold clamping member 16 to close the mold 33 according to the control information of the molding machine 10 corresponding to the currently set identification number, if the number of products to be manufactured is 1 or more. When the mold closing operation is completed, the processor 101 inputs a mold closing signal to the extraction machine control device 200. After the mold closing operation is completed, the processor 101 controls the injection unit 17 to inject resin into the mold 33 according to the control information of the molding machine 10. After the injection is completed, the processor 101 of the molding machine control device 100 controls the mold clamping member 16 to open the mold 33 according to the control information of the molding machine 10. Then, when the mold opening operation is completed, the processor 101 of the molding machine control device 100 inputs a mold opening signal to the extraction machine control device 200 to notify it of this. As a result, the resin molded product is removed from the mold 33 by the extraction machine 20 as described above.

[0030] From this point onward, the molding machine control device 100 repeatedly performs a series of processes (opening / closing control and injection control) until the input (stored) production quantity becomes zero. Note that the above-described process flow is just one example, and the order and content of the processes may be changed as appropriate, as long as molding and removal of molded products are performed continuously until the production quantity becomes zero.

[0031] By the way, if the number of times the mold 33 is opened and closed exceeds a predetermined number, or if the usage time exceeds a predetermined time, the mold 33 requires maintenance (inspection, parts replacement, servicing, etc.). However, the mold 33 itself is a solid block of metal and generally does not have electronic equipment to store such information. The molding machine 10 and the extraction machine 20 have control devices 100 and 200, which are configured to store the number of times the mold is opened and closed, etc., but the mold 33 is configured to be replaceable, and it is not guaranteed that the same mold 33 will be installed. Also, since the molding machine 10 and the extraction machine 20 continuously manufacture a predetermined number of molded products, the operator does not always check the controller 40. For this reason, even if maintenance information is displayed, it may not be seen by the operator depending on the timing.

[0032] Therefore, in this embodiment, the extraction device control unit 200 stores the number of times the mold 33 is opened and closed, and when the number of openings and closings reaches a predetermined number, it outputs maintenance information at an appropriate timing. This will be explained in detail below.

[0033] First, the manufacturing process flow during the production of molded products will be explained with reference to Figure 4. In the manufacturing process shown in Figure 4, the number of products to be manufactured is input and stored in the storage unit 202, and then the processor 201 of the extraction device control device 200 repeatedly executes the process. When the manufacturing process starts, the processor 201 determines whether the number of products to be manufactured stored in the storage unit 202 is "1" or greater (step S100). If this determination result is negative, the process is terminated.

[0034] Meanwhile, after processing in step S100, the processor 201 of the extraction machine control device 200 determines whether or not it has received a mold open signal from the molding machine control device 100 (step S101). That is, the processor 101 of the molding machine control device 100 determines whether or not it has molded the product according to the control information of the molding machine 10 associated with the identification number being set, as described above, and has received a mold open signal from the extraction machine control device 200.

[0035] If the result of this determination is negative, after a predetermined time has elapsed, the processor 201 executes the process of step S101 again. On the other hand, if the result of the determination of step S101 is positive, the processor 201 controls the remover 20 to remove the molded product from the mold 33 based on the control information of the remover 20 associated with the identification number being set, as described above (step S102). At the same time, when the processor 201 receives a mold open signal, it adds 1 to the number of open / close operations stored in the storage unit 202 associated with the identification number being set, and updates the number of open / close operations stored in the storage unit 202 associated with the identification number (step S103). For this reason, in this embodiment, the processor 201 functions as a measurement unit.

[0036] Furthermore, when a molded product is removed, the processor 201 subtracts the number of products removed from the number of products stored in the memory unit 102 and updates the number of products stored in the memory unit 202 (step S104). After that, the process from steps S100 to S104 is repeatedly executed until the number of products becomes zero.

[0037] Next, I will explain the timing for displaying maintenance information. When manufacturing molded products, the touch panel 40a of the controller 40 displays a manufacturing information input screen, and the operator inputs the number of products to be manufactured. The extraction machine 20 and the molding machine 10 then enter an automatic operation state until the number of products manufactured reaches zero, continuously manufacturing and extracting molded products.

[0038] Therefore, when the operator inputs the number of units to be manufactured, the processor 201 reads the number of openings and closings associated with the currently set identification number, that is, the identification number of the mold 33 attached to the molding machine 10, and determines whether the read number of openings and closings exceeds the threshold number. The threshold number is predetermined for each type of mold 33, and for example, a value of 10,000 to 300,000 is set. In this embodiment, it is set to 20,000. The threshold number is determined based on experiments, simulations, or empirical rules. If this determination result is positive, the processor 201 controls the controller 40 to display maintenance information on the manufacturing information input screen. For example, as shown in Figure 5, maintenance information 302 is displayed on the manufacturing information input screen 301 displayed on the touch panel 40a. This maintenance information 302 is displayed until maintenance is performed and the number of openings and closings is reset by the operator.

[0039] Furthermore, when the mold 33 is replaced, a mold information input screen is displayed on the touch panel 40a, and the operator is prompted to input an identification number indicating the mold 33 attached to the molding machine 10. When the identification number is entered by the operator, the processors 101 and 201 set it in the memory units 102 and 202 as the identification number of the current mold 33.

[0040] Therefore, when the operator inputs an identification number indicating the replacement mold 33, the processor 201 reads the number of times the mold has been opened and closed, which is stored in association with that identification number. This number of times the mold has been opened and closed is the number of times it was measured the last time the mold 33 identified by the identification number was attached to the molding machine 10 to manufacture a molded product.

[0041] The processor 201 then determines whether the read number of open / close cycles exceeds a threshold. If the number of open / close cycles exceeds the threshold, the processor 201 displays maintenance information on the mold information input screen. Specifically, as shown in Figure 6, it displays maintenance information 304 on the mold information input screen 303 displayed on the touch panel 40a. Therefore, in this embodiment, the processor 201 functions as both a determination unit and an output unit.

[0042] If the identification number indicating the mold 33 attached to the molding machine 10 is not stored, that is, if the mold 33 is attached to the molding machine 10 for the first time, the number of openings and closings will be zero, and maintenance information will not be displayed. Incidentally, in this case, the processor 201 prompts the user to set the control information for the take-out machine 20 and the molding machine 10 corresponding to the identification number. If the control information is set, the processor 201 sets the number of openings and closings stored in association with the identification number to zero. Also, if maintenance is performed on the mold 33 according to the maintenance information, the number of openings and closings will be reset to zero.

[0043] According to the above embodiment, the following effects are achieved. (1) The number of times the mold 33 is opened and closed is measured and stored based on the mold opening signal, and maintenance information is output if the number of openings and closings exceeds a threshold. Therefore, the extraction machine control device 200 can manage the number of openings and closings for each mold 33.

[0044] (2) The system stores the number of times the mold 33 identified by the identification number was opened and closed when it was attached to the molding machine 10, and when the identification number is entered, it determines whether the number of times the mold has been opened and closed associated with that identification number exceeds a threshold. Therefore, when the mold 33 is replaced, simply by entering the identification number, it is possible to determine whether the number of times the mold has been opened and closed exceeds the threshold, that is, whether maintenance is required.

[0045] (3) The system stores control information associated with the identification number when the mold 33 identified by the identification number is attached to the molding machine 10. When the identification number is entered, the system controls the extraction machine 20 and the molding machine 10 based on the control information associated with the identification number. Therefore, when the mold 33 is replaced, the control information can be easily set and maintenance can be determined simply by entering the identification number.

[0046] (4) When manufacturing molded products, the number of molded products to be manufactured is entered via the controller 40. Therefore, by outputting maintenance information on the manufacturing information input screen, the maintenance information can be reliably visually checked by the worker, and they can understand that maintenance is required.

[0047] (5) When replacing the mold 33, if it is determined that the number of times the replaced mold 33 has been opened and closed exceeds a threshold, maintenance information will be output on the mold information input screen. This allows the user to confirm whether maintenance is required when entering the identification number during replacement.

[0048] (modified version) Some of the configurations in the above embodiment may be modified. The following describes some modified examples with altered configurations. In the above embodiment, the number of opening and closing cycles was measured based on the mold opening signal, but the number of opening and closing cycles may also be measured based on the mold closing signal.

[0049] In the above embodiment, the determination of whether the number of openings and closings exceeds the threshold was made after the number of units to be manufactured was entered on the manufacturing information input screen. However, at any time while the manufacturing information input screen is displayed, the determination of whether the number of openings and closings exceeds the threshold may be made before the number of units to be manufactured is entered, and if it does, maintenance information may be displayed.

[0050] In the above embodiment, the usage time may be measured instead of the number of opening and closing cycles. For example, in the case of continuous manufacturing, the time for one cycle from the previous mold opening signal (or mold closing signal) to the input of the current mold opening signal is predetermined. Therefore, the usage time can be measured by adding the time of one cycle to the usage time each time a mold opening signal is input. In the above embodiment, if the number of openings and closings (or usage time) does not exceed the threshold, the number of openings and closings (or usage time) for each mold 33 is compared with the threshold, the remaining number of openings and closings (or remaining time) until the threshold is reached is calculated, and the calculated remaining number of openings or remaining time is output to the controller 40. Alternatively, the remaining number of openings and closings may be multiplied by the time of one cycle to convert it to remaining time and output, or the remaining number of openings and closings may be calculated from the remaining time and output.

[0051] In the above embodiment, maintenance information may be output to the controller 40 at any time when the number of openings and closings (or usage time) exceeds a threshold during manufacturing. In the above embodiment, the mold information is not limited to an identification number, but may also be the name of the mold 33, a string of alphanumeric characters, etc. Furthermore, it may be input via a barcode or the like. Image recognition may also be used. In the above embodiment, the touch panel 40a of the controller 40 was used as the notification unit, but maintenance information may also be notified using a speaker or the like. The controller 40 does not have to be a touch panel type; it may also have button input. In the above embodiment, various information was input and output to the molding machine 10 by using the controller 40 of the extraction machine 20 through communication with the molding machine 10, but information may also be input and output using the controller of the molding machine 10. [Explanation of Symbols]

[0052] 10... Molding machine, 20... Extraction machine, 33... Mold, 40... Controller, 100... Molding machine control device, 101... Processor for molding machine control device, 200... Extraction machine control device, 201... Processor for extraction machine control device.

Claims

1. In a control device for a molding machine that can communicate with a mold that can be fitted with replaceable molds, A measuring unit receives at least one of the mold opening signal and the mold closing signal from the molding machine, and measures the number of openings and closings or the usage time for each mold based on the input mold opening signal or mold closing signal. A storage unit that stores the number of opening and closing cycles or the usage time measured by the measurement unit for each mold, A determination unit for each mold that determines whether the number of openings and closings or the usage time exceeds a threshold, A control device for an extraction device, comprising: an output unit that, when the determination unit determines that a threshold has been exceeded, outputs maintenance information prompting maintenance from the extraction device's notification unit.

2. The storage unit stores the number of openings and closings or the usage time measured by the measurement unit when the mold identified by the mold information is attached to the molding machine, in association with the mold information. The control device for an extraction machine according to claim 1, wherein the determination unit determines from the storage unit whether the number of openings and closings or the usage time associated with the mold information, when the mold information indicating a mold attached to the molding machine is input via the information input unit of the extraction machine, exceeds a threshold value.

3. The storage unit stores control information for the removal machine when the mold identified by the mold information is attached to the molding machine, in association with the mold information. The control device for an extraction machine according to claim 2, comprising: when mold information indicating a mold attached to the molding machine is input via the information input unit of the extraction machine, the extraction control unit reads the control information associated with the mold information from the storage unit and thereafter controls the extraction machine based on the control information.

4. The information input unit and the notification unit are implemented by a controller having a touch panel. When the number of molded products to be manufactured or the manufacturing time is input via the controller, the extraction control unit continuously controls the extraction machine until the number of molded products molded by the molding machine reaches the input number of products to be manufactured, or until the operating time of the molding machine reaches the manufacturing time. The control device for an extraction machine according to claim 3, wherein the output unit, when determined by the determination unit, causes maintenance information to be output on the manufacturing information input screen for inputting the number of units manufactured or the manufacturing time.

5. It has a controller with a touch panel, The controller displays a mold information input screen that accepts input of mold information to identify the mold installed after replacement when the mold attached to the molding machine is replaced. The control device for an extraction machine according to any one of claims 1 to 4, wherein the output unit outputs maintenance information when the mold information is input to the mold information input screen and the determination unit determines that the number of openings and closings or the usage time of the replaced mold exceeds a threshold.

6. If the number of openings and closings or the usage time does not exceed the threshold, the determination unit compares the number of openings and closings or the usage time for each mold with the threshold, and calculates the remaining number of openings or remaining time until the threshold is reached. The control device for a retrieval machine according to any one of claims 1 to 4, wherein the output unit outputs the calculated remaining number of times or remaining time.

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