Control devices, molding machines, and molding systems

Abstract

The present invention provides a user management device that allows for more appropriate information provision to users compared to managing users according to their roles. [Solution] The management device is characterized by comprising a management means for managing users by a first management method for managing the level of users who use the molding device according to their roles, and a second management method for managing the level of users according to their skill level in the work.

Description

Technical Field

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

Background Art

[0002] Patent Document 1 describes a molding machine that groups users according to their job types (such as managers and workers) and grants each group only the operation authorities corresponding to their respective job types. Patent Document 2 describes an injection molding machine that includes a touch panel, and access levels for permitting / forbidding display are set for all screens that can be displayed on the touch panel, and the display is restricted according to the authority of the operator.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a molding machine, the information provided may vary according to the role of the user. For example, when there are functions that can be used and functions that cannot be used depending on the role of the user, only the information on the functions that can be used may be provided to the user. However, regardless of the role of the user, for example, the necessary information may vary depending on the proficiency of the user's work. Even in such a case, it is preferable to manage the user so that the information necessary for the user can be provided.

[0005] An object of the present invention is to provide a management device or the like that can manage a user so as to more appropriately provide information to the user as compared with the case of managing the user according to the role.

Means for Solving the Problems

[0006] One aspect of the present invention is a management device characterized by comprising a management means for managing users by a first management method for managing the level of users who use a molding apparatus according to their roles, and a second management method for managing the level of users according to their skill level in the work. [Effects of the Invention]

[0007] According to one aspect of the present invention, it is possible to provide a management device, etc., that manages users in a way that allows for more appropriate provision of information to users compared to managing users according to their roles. [Brief explanation of the drawing]

[0008] [Figure 1] This diagram shows the configuration of an injection molding machine to which the first embodiment is applied. [Figure 2] This is a diagram showing the configuration of the control device. [Figure 3] This diagram shows the configuration of a data processing device. [Figure 4] This diagram shows the configuration of the control device. [Figure 5] This figure shows an example of a computer hardware configuration for implementing a control device, a data processing device, and a management device. [Figure 6] This diagram shows examples of setting user levels; (a) shows an example of setting levels by role, and (b) shows an example of setting levels by skill level. [Figure 7] This figure shows an example of a table that links user identification information with user level. [Figure 8] This flowchart shows an example of the processing flow when information is provided to users of injection molding machines. [Figure 9] This figure shows an example of a table that links user identification information with the user's work level for each stage of the process. [Modes for carrying out the invention]

[0009] Embodiments of the present invention will be described in detail below with reference to the attached drawings. (First Embodiment) <Device configuration> Figure 1 shows the configuration of an injection molding machine 10 to which the first embodiment is applied. The injection molding machine 10 comprises an injection device 20, a mold clamping device 30, a control device 100, a data processing device 200, a display device 300, and a management device 400. In the following description, the direction from the injection device 20 to the mold clamping device 30 may be referred to as "forward." The injection molding machine 10 is an example of a molding machine. The injection device 20 and the mold clamping device 30 are examples of molding equipment.

[0010] The injection device 20 comprises a cylinder for heating the molding material, a screw that is rotatable within the cylinder and can move axially, a rotary motor that drives the screw in the rotational direction, a motor that drives the screw axially, and the like. The molding material is, for example, resin. The injection device 20 injects the molding material, which has been heated and turned into liquid in the cylinder, by rotating and advancing the screw forward, and fills the mold of the clamping device 30 located in front of the injection device 20. The injection device 20 performs processes such as metering, filling, and holding pressure in the manufacturing process of the molded product. The filling and holding pressure processes are collectively called the injection process.

[0011] The mold clamping device 30 comprises a mold, a clamping mechanism for clamping the mold, and a motor for driving the clamping mechanism. The mold clamping device 30 closes the mold and receives the molding material injected from the injection device 20 into the mold. At this time, the mold clamping device 30 clamps the mold with the clamping mechanism to prevent the mold from opening as the molding material fills it (mold clamping). A molded product is produced when the molding material filled into the mold solidifies. After this, the mold clamping device 30 opens the mold and sends out the produced molded product. In the manufacturing process of a molded product, the mold clamping device 30 performs, for example, a mold closing process, a pressurization process, a mold clamping process, a depressurization process, and a mold opening process.

[0012] The control device 100 is a device that controls the operation of the injection device 20 and the clamping device 30. The data processing device 200 is a device that processes data obtained as the injection device 20 and the clamping device 30 operate. The display device 300 displays information related to the control of the injection device 20 and the clamping device 30 by the control device 100, data acquired by the data processing device 200, and the processing results of the data processing device 200. The display device 300 also displays an operation screen for inputting commands and data to the control device 100 and the data processing device 200. The display device 300 also displays information on advice provided to the user. The management device 400 is a device that manages the level of the user using the injection molding machine 10. The user level managed by the management device 400 is used, for example, to determine the information on functions and advice provided to the user.

[0013] <Configuration of control device 100> Figure 2 shows the configuration of the control device 100. The control device 100 controls the operation of the injection device 20 and the clamping device 30. The control device 100 is implemented, for example, by a computer. The control device 100 comprises a control information acquisition unit 110, a control unit 120, and a storage unit 130. The control device 100 controls the injection device 20 and the clamping device 30 to repeatedly manufacture molded products by repeatedly performing the processes related to the manufacture of molded products. The processes related to the manufacture of molded products include a metering process, a mold closing process, a pressurizing process, a mold clamping process, a filling process, a holding pressure process, a cooling process, a depressurizing process, a mold opening process, and an ejection process. Hereinafter, these manufacturing processes may be collectively referred to as the "manufacturing process." Also, a series of operations to obtain a molded product, for example, the operations from the start of one metering process to the start of the next metering process in the above manufacturing process, may be referred to as a "shot," "molding cycle," etc. Note that the above processes for manufacturing molded products are merely examples. For example, other processes not included above may be included as processes performed in one shot.

[0014] The control information acquisition unit 110 acquires control information used to control the injection device 20 and the mold clamping device 30. The control information is conditions set by the user and is input by the user using, for example, an input device not shown in the figure. The control information includes, for example, molding conditions such as resin temperature, mold temperature (cylinder temperature), injection holding pressure time, metering value, V-P switching position, holding pressure, injection speed (filling speed), screw rotation speed, screw back pressure, and mold clamping force. A plurality of combinations of these molding conditions are determined according to the molded product and the mold. The combination data of these molding conditions is hereinafter also referred to as molding condition data set. The control information acquisition unit 110 stores the acquired control information in the storage unit 130 as a molding condition data set.

[0015] The control unit 120 controls the injection device 20 and the mold clamping device 30 using the above-described molding condition data set, and performs processes related to the production (shot) of a molded product including the above-described respective processes. At the start of the production of the molded product or the like, the control unit 120 reads out from the storage unit 130 the molding condition data set corresponding to the molded product to be produced. Then, the control unit 120 controls the operations of the injection device 20 and the mold clamping device 30 based on the read control information. Specifically, the control unit 120 controls the injection device 20 and the mold clamping device 30 so that the data obtained from the injection device 20 and the mold clamping device 30 in the production process matches the set values of the molding condition data set. Further, the control unit 120 may display the molding condition data set read from the storage unit 130 on the display device 300. The user may refer to the data of the molding conditions displayed on the display device 300 and perform operations such as correcting the values as necessary.

[0016] The storage unit 130 holds the control information 131 acquired by the control information acquisition unit 110. The molding condition data set included in the control information 131 is prepared in association with the molded product to be manufactured and the mold. The storage unit 130 holds the molding condition data set for each molded product to be manufactured and mold. Also, although not shown, the storage unit 130 holds a program for the control unit 120 to control the injection device 20 and the mold clamping device 30. As will be described in detail later, the function of the control unit 120 is realized by the processor in the control device 100 reading and executing the program held in the storage unit 130.

[0017] <Configuration of data processing device 200> FIG. 3 is a diagram showing the configuration of the data processing device 200. The data processing device 200 acquires and processes data obtained as the injection device 20 and the mold clamping device 30 execute operations in the process related to the manufacture of the above-mentioned molded product. The data processing device 200 is realized by, for example, a computer. The data processing device 200 includes an acquisition unit 210, a processing unit 220, a storage unit 230, and a display control unit 240.

[0018] The acquisition unit 210 acquires data to be processed from the injection device 20 and the mold clamping device 30. Various sensors and detectors are attached to the injection device 20 and the mold clamping device 30. The data acquired by these sensors and detectors (hereinafter referred to as "acquired data") is information representing the molding result by the injection device 20 and the mold clamping device 30 and is used for quality control of the molded product. Specifically, for example, it includes the weight of the molded product, the dimensions of the molded product, the in-mold pressure, the minimum cushion position, the characteristic amount of the filling pressure waveform, and the like. These acquired data are actual values obtained in the manufacturing process of the molded product. The acquisition unit 210 receives the acquired data transmitted from the sensors and detectors and stores it in the storage unit 230.

[0019] The processing unit 220 processes the acquired data stored in the storage unit 230. Specifically, the processing unit 220 extracts representative values ​​from the acquired data in each process and generates time-series data by serializing the acquired data in each process. In extracting representative values, the processing unit 220 performs statistical processing on the acquired data, such as calculating the average value, identifying the range of values, and identifying the maximum and minimum values.

[0020] The storage unit 230 stores representative values, time-series data, statistical data, etc., processed by the processing unit 220. These data are associated with the original acquired data, for example. Specifically, these data may be stored in the data file of the corresponding original acquired data. Alternatively, the data file containing these data may be associated with the data file of the original data. In this way, each data generated by the processing unit 220 is also stored in association with the molded product or mold that was manufactured in the shot from which the original acquired data was obtained. The data format of the data file stored in the storage unit 230 may include, for example, CSV (Comma Separated Values), XML (Extensible Markup Language), JSON (JavaScript Object Notation), etc.

[0021] Although not shown in the diagram, the storage unit 230 also holds a program for the processing unit 220 to perform data processing. As will be explained in more detail later, the processing unit 220's functions are realized when the processor in the data processing device 200 reads and executes the program held in the storage unit 230.

[0022] The display control unit 240 displays acquired data and data resulting from processing by the processing unit 220 on the display device 300. The data to be displayed includes setting information in the control information used by the control device 100 to control the injection device 20 and the clamping device 30. The setting information (setting values) can be acquired from the control device 100. The display control unit 240 acquires this data from the storage unit 230 and the storage unit 130 of the control device 100 and displays it on the display device 300.

[0023] <Configuration of the control device 400> Figure 4 shows the configuration of the management device 400. The management device 400 comprises a user information receiving unit 410, a level acquisition unit 420, a provision information determination unit 430, a display control unit 440, and a storage unit 450. The management device 400 is an example of a management means.

[0024] The user information receiving unit 410 acquires the identification information of users who use the injection molding machine 10. Users are managed by assigning identification information such as an ID and password to each individual or group they belong to. The user's identification information is stored in the storage unit 450, linked to the user's level. The user information receiving unit 410 acquires the user's ID, for example, by RFID (Radio Frequency Identification). Alternatively, the user's ID may be acquired by other methods such as password input, USB authentication key, or biometric authentication. The level acquisition unit 420 acquires the user's level from the storage unit 450, which is linked to the user identification information acquired by the user information receiving unit 410.

[0025] The information provision determination unit 430 determines the information to be provided to the user. The information provision determination unit 430 determines the information to be provided to the user based on the user's level acquired by the level acquisition unit 420. The information provided to the user here is, for example, information on the functions that the user can use. It is also, for example, information on advice provided regarding functions that can be used by both users with relatively high work proficiency and users with relatively low work proficiency. The information provision determination unit 430 changes the information on advice provided according to the user's level.

[0026] The display control unit 440 causes the information to be provided to the user, as determined by the information provision determination unit 430, to be displayed on the display device 300. The information to be provided to the user may be displayed on the display device 300 as a pop-up, for example, or the information may be displayed based on the user's selection. Alternatively, the information to be provided to the user may be displayed on a display screen other than the display device 300. For example, the information to be provided to the user may be transmitted to a terminal owned by the user and displayed on the terminal.

[0027] The memory unit 450 stores user identification information and user levels in association. User levels include levels based on roles and levels based on work proficiency. Levels based on roles are levels such as job title and the level of responsibility for the processes performed. Levels based on work proficiency indicate the degree of skill and understanding the user has regarding the tasks they perform. The memory unit 450 may also store user levels based on other parameters of roles or work proficiency.

[0028] The skill level for each task may be managed by assigning a single level to each user, or it may be managed by managing the skill level for each work process. Users are ranked and managed based on their proficiency in tasks such as setting molding conditions. Alternatively, their skill level may be determined and managed based on factors such as the time it takes to set molding conditions and the screens they review during the setting process. Furthermore, the user's skill level may be managed based on their proficiency in tasks related to the maintenance of the injection molding machine 10, their proficiency in tasks related to the setup of the injection molding machine 10, etc. For example, the user's skill level may be determined and managed based on the time it takes to maintain the injection molding machine 10, the screens they check during maintenance, etc. Also, for example, the user's skill level may be determined and managed based on the time it takes to set up the injection molding machine 10, the screens they check during setup, etc.

[0029] Furthermore, the memory unit 450 stores information to be provided for each user level. For example, the memory unit 450 stores the user level and the operation authority associated with it. The information provision determination unit 430 obtains the user's operation authority from the user level and determines the information to be provided to the user based on the operation authority.

[0030] For example, the memory unit 450 stores information linking the user's level with advice provided regarding functions that can be used by both users with relatively high and relatively low skill levels. The information provision determination unit 430 acquires the advice information corresponding to the user's level and determines it to be provided to the user.

[0031] <Hardware configuration of the computer that implements the control device 100, data processing device 200, and management device 400> Figure 5 shows an example of the hardware configuration of a computer 500 that implements a control device 100, a data processing device 200, and a management device 400. The computer 500 shown in Figure 5 includes a processor 501 as an arithmetic means, and a main memory 502 and an auxiliary memory 503 as storage means. Various arithmetic circuits such as a CPU (Central Processing Unit), GPU (Graphics Processing Unit), ASIC (Application Specific Integrated Circuit), and FPGA (Field-Programmable Gate Array) can be used as the processor 501. The processor 501 reads programs stored in the auxiliary memory 503 into the main memory 502 and executes them. For example, RAM (Random Access Memory) can be used as the main memory 502. For example, a magnetic disk drive or SSD (Solid State Drive) can be used as the auxiliary memory 503.

[0032] Furthermore, the computer 500 includes a display device (display) 504 and an input device 505 on which the user performs input operations. For example, a keyboard or mouse can be used as the input device 505. Alternatively, a touch panel integrated with the display device 504 may be used as the input device 505. The display device 504 may be implemented using the display device 300 shown in Figure 1. Note that the configuration of the computer 500 shown in Figure 5 is merely an example, and the computer 500 used in the first embodiment is not limited to the configuration shown in Figure 5. For example, it may be configured to include non-volatile memory such as flash memory or ROM (Read Only Memory) as a storage device.

[0033] When the control device 100 is implemented by the computer shown in Figure 5, the control information acquisition unit 110 is implemented, for example, by a processor 501 that reads and executes a program and an input device 505. The functions of the control unit 120 are implemented, for example, by the processor 501 reading and executing a program. The storage unit 130 is implemented, for example, by an auxiliary storage device 503.

[0034] When the data processing device 200 is implemented by the computer shown in Figure 5, the functions of the acquisition unit 210 and the processing unit 220 are implemented, for example, by the processor 501 reading and executing a program. The storage unit 230 is implemented, for example, by the auxiliary storage device 503. The display control unit 240 is implemented by the processor 501 which reads and executes a program.

[0035] When the management device 400 is implemented by the computer 500 shown in Figure 5, the functions of the user information receiving unit 410, the level acquisition unit 420, the provided information determination unit 430, and the display control unit 440 are implemented, for example, by the processor 501 reading and executing a program. The storage unit 450 is implemented, for example, by the auxiliary storage device 503.

[0036] <Level Management> The method for managing user levels in the first embodiment will be explained using Figures 6 and 7. Tables 610, 620, and 700 shown in Figures 6 and 7 are stored in the storage unit 450. Figure 6 shows examples of setting user levels, where (a) shows an example of setting levels by role, and (b) shows an example of setting levels by skill level.

[0037] Figure 6(a) shows the level settings based on the user's role. Table 610 in Figure 6(a) is a table that associates levels with user roles and corresponding abilities. When the user's role is "Operator," the user's level is "1," and the corresponding ability is "Able to adjust production conditions under instruction." When the user's role is "Engineer," the user's level is "2," and the corresponding ability is "Able to launch new models." When the user's role is "Maintenance," the user's level is "3," and the corresponding ability is "Able to handle problems when they occur."

[0038] Figure 6(b) shows the level settings based on the user's work proficiency. Table 620 in Figure 6(b) is a table that associates levels with the user's work proficiency and corresponding abilities. If the user's proficiency is "beginner," the user's level is "1," and the corresponding ability is "understands basic settings." If the user's proficiency is "experienced," the user's level is "2," and the corresponding ability is "can deal with phenomena that have been experienced." If the user's proficiency is "expert," the user's level is "3," and the corresponding ability is "can make correct situational judgments about phenomena that occur and implement optimal countermeasures." The level assignments and corresponding abilities shown in Figure 6 may be changed as appropriate by the user.

[0039] Figure 7 shows an example of Table 700, which links user identification information with user levels. Table 700 is a table that associates user IDs with levels based on roles and levels based on work proficiency. For example, user ID "A" has a role level of "3" and a work proficiency level of "2". From the correspondence with Tables 610 and 620 shown in Figure 6, user ID "A" has the role of "Maintenance" and a work proficiency level of "Experienced".

[0040] Thus, in the first embodiment, users are managed by a first management method that manages user levels by role, and a second management method that manages user levels by work proficiency. This makes it possible to provide users with different necessary functions depending on their role, as well as provide them with different necessary information depending on their work proficiency resulting from differences in experience, etc. Note that table 700 is not stored in the storage unit 450, but may be stored, for example, in an RFID tag such as a card held by each user.

[0041] <Information processing flow> Figure 8 is a flowchart showing an example of the processing flow when information is provided to a user of the injection molding machine 10. In Figure 8, first, the user information receiving unit 410 acquires the user's identification information (step 1001). Here, it is assumed that the user information receiving unit 410 has acquired the user's ID "A" via RFID (Radio Frequency Identification) (see Figure 7).

[0042] Next, the level acquisition unit 420 acquires the user's level from the storage unit 450 (step 1002). The level acquisition unit 420 acquires from the table 700 stored in the storage unit 450 that the user with ID "A" has a role-based level of "3" and a work proficiency level of "2" (see Figure 7).

[0043] Next, the information provision determination unit 430 determines the information to be provided to the user based on the level acquired by the level acquisition unit 420 (step 1003). The information provision determination unit 430 acquires the information provision for each level stored in the storage unit 450 and determines the information to be provided to the user. For example, the information provision determination unit 430 acquires the user's operational authority based on the level by role and determines the information to be provided to the user based on the operational authority. It also determines, for example, that information to be provided is advice regarding functions that can be used by both users with relatively high operational proficiency and users with relatively low operational proficiency, based on the level by work proficiency. In this way, the level by work proficiency is used as an indicator for determining the information to be provided as advice to the user.

[0044] Then, the display control unit 440 causes the display device 300 to display the determined information (step 1004). In the first embodiment, the user level managed by the management device 400 was used as an indicator for determining the information to be provided to the user, but is not limited to this. The user level managed by the management device 400 may be used for other purposes.

[0045] (Second embodiment) The injection molding machine 10 according to the second embodiment includes, similar to the first embodiment, an injection device 20, a mold clamping device 30, a control device 100, a data processing device 200, a display device 300, and a management device 400. The management device 400 also includes, similar to the first embodiment, a user information receiving unit 410, a level acquisition unit 420, a provided information determination unit 430, a display control unit 440, and a storage unit 450. In the second embodiment, the user's level is managed in the storage unit 450 for each work process, which is different from the first embodiment. In the following description, components identical to those in the first embodiment are denoted by the same reference numerals, and detailed explanations are omitted.

[0046] Figure 9 shows an example of a table 900 that links user identification information with the user's work process level. The table 900 is stored in the storage unit 450. Table 900 is a table that associates user IDs with work processes and user levels. In the example shown in Figure 9, user ID "A" has a work process "startup" level of "2" and a work process "molding condition setting" level of "3". User ID "B" has a work process "startup" level of "3" and a work process "molding condition setting" level of "1". The level may be based on a role or on the level of proficiency in a task. Furthermore, when managing levels based on multiple parameters, the management method may differ for each parameter. For example, the level based on a role may not be managed per work process, while the level based on the level of proficiency in a task may be managed per work process.

[0047] In the second embodiment, the process of providing information to the user is carried out according to the flow shown in Figure 8, similar to the first embodiment. Here, in the second embodiment, the user's level is managed for each work process. Therefore, the user's level may differ for each work process, and in step 1003, the information provision determination unit 430 determines the information to be provided to the user based on the level for each work process. Thus, in the second embodiment, the user's level is associated with the work process, which allows, for example, the user to be provided with information tailored to their level for each work process.

[0048] Although embodiments of the present invention have been described above, the technical scope of the present invention is not limited to the above embodiments. For example, the information stored in the storage unit 450 may be managed on an external server that is communicatively connected to the management device 400. The server may be a so-called local server, or it may be a virtual server (for example, a cloud server) constructed using resources on a network. Furthermore, the processing performed by the management device 400 may also be performed by external devices such as smartphones, PCs, or servers. Each of the functional configurations shown in Figure 4 may be provided on the external device, and each function may be executed in a distributed manner across multiple devices or servers. When executed in a distributed manner across multiple devices or servers, any of the devices may execute any of the processes.

[0049] For example, user management may be performed on an external PC, server, or cloud, and the system may be configured to query these external devices for the user's ID and user level when a user logs into the injection molding machine 10. Alternatively, user login may be performed on an external device such as a PC. In this case, user management may be performed on a server or cloud, and the system may be configured to query the server or cloud for the user's ID and user level when a user logs into their PC. In this case, for example, the logged-in user's level and information to be provided to the user may be transmitted from the external device to the injection molding machine 10. Furthermore, it is clear from the claims that combinations of two or more of the above embodiments, as well as various modifications or improvements to the above embodiments, are also included within the technical scope of this disclosure. [Explanation of symbols]

[0050] 10…Injection molding machine, 20…Injection device, 30…Clamping device, 100…Control device, 110…Control information acquisition unit, 120…Control unit, 130…Storage unit, 200…Data processing device, 210…Acquisition unit, 220…Processing unit, 230…Storage unit, 240…Display control unit, 300…Display device, 400…Management device

Claims

1. A management device characterized by comprising a management means for managing a user by a first management method for managing the level of a user using a molding apparatus according to their role, and a second management method for managing the level of a user according to their skill level in the work.

2. The management device according to claim 1, characterized in that the management means manages the user's authority to operate the molding apparatus by the first management method and the second management method.

3. The management device according to claim 1, characterized in that the level of proficiency in the aforementioned work is used as an indicator for determining the information of advice to be provided to the user.

4. The management device according to claim 1, wherein the management means manages the user based on their skill level in setting molding conditions in the second management method.

5. The management device according to claim 1, wherein the management means manages the user based on their skill level in maintaining the molding apparatus in the second management method.

6. The management device according to claim 1, wherein the management means manages the user based on their skill level regarding the setup of the molding apparatus in the second management method.

7. The management device according to claim 1, wherein the management means manages the user for each work process performed by the user in the second management method.

8. A management device characterized by having a management means for managing users according to their skill level for each work process performed by a user using a molding machine.

9. The management device according to claim 8, characterized in that the level is an indicator of the level of proficiency in the work.

10. A control device according to any one of claims 1 to 9, The molding apparatus and, A molding machine characterized by being equipped with the following features.

11. A molding system characterized by comprising a management means for managing a user by a first management method for managing the level of a user using a molding apparatus according to their role, and a second management method for managing the level of a user according to their skill level in the work.

12. A molding system characterized by having a management means for managing users according to their skill level for each work process performed by a user using a molding apparatus.

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