Injection molding machines, industrial machine controllers

Abstract

To provide a technique that can improve convenience for a user when collecting data output by an industrial machinery such as an injection molder within an acceptable range of a processing load of a controlling device.SOLUTION: An injection molder 1 according to an embodiment of the disclosure comprises: a mold clamping device 100 that clamps a mold device 10; an injection device 300 that fills the mold device 10 clamped by the mold clamping device 100 with a molding material; an ejector device 200 that, after the molding material filled by the injection device 300 is cooled and solidified, takes out a molded article from the mold device 10; and a controller 700 that includes a data acquisition section 7003 for acquiring data about an operation state of the injection molder 1, the data being output inside the injection molder 1, and storing the data in a data storage section 7004, and a processing load adjustment section 7002 that adjusts the number of pieces of the data acquired by the data acquisition section 7003 in accordance with a state of a processing load of the controller 700.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to injection molding machines and the like. [Background technology]

[0002] For example, in industrial machines such as injection molding machines, various data outputted from within the machine (e.g., output data from various sensors that detect the operating state of the machine) may be collected (see, for example, Patent Document 1, etc.).

[0003] Patent Document 1 discloses a technique for observing the processing load state of a control device (controller), determining whether or not collection of target data is possible, and notifying the user of the result. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2020 / 213663 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the above-mentioned technology only notifies the user whether the data to be collected can be collected, and in order to collect the necessary types of data within the allowable range of the processing load on the control device, the user must set and input the data to be acquired while referring to the notification content. Therefore, there is room for improvement in terms of user convenience.

[0006] In view of the above problems, an object of the present invention is to provide a technology that can improve user convenience when collecting data output by industrial machinery such as an injection molding machine within the allowable range of the processing load of a control device. [Means for solving the problem]

[0007] In order to achieve the above object, in one embodiment of the present disclosure, a mold clamping device that clamps the mold device; an injection unit that fills the mold unit clamped by the mold clamping unit with a molding material; an ejector device that removes a molded product from the mold device after the molding material filled by the injection device is cooled and solidified; a control device including an acquisition unit that acquires data related to the injection molding machine outputted from inside the injection molding machine and records the data in a storage unit, and an adjustment unit that adjusts the number of types of the data acquired by the acquisition unit in accordance with a processing load state of the control device; An injection molding machine is provided.

[0008] In another embodiment of the present disclosure, an acquisition unit that acquires data related to the industrial machine outputted from inside the industrial machine and records the data in a storage unit; and an adjustment unit that adjusts the number of types of the data acquired by the acquisition unit in accordance with a processing load state of a controller, A controller for an industrial machine is provided. Effect of the Invention

[0009] According to the above-described embodiment, it is possible to improve the convenience for a user when collecting data outputted from an industrial machine such as an injection molding machine within an allowable range of the processing load of a control device. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a diagram illustrating an example of a configuration of an injection molding machine system. [Diagram 2] FIG. 1 is a diagram illustrating an example of a configuration of an injection molding machine system. [Diagram 3] FIG. 2 is a block diagram illustrating an example of a hardware configuration of a management device. [Figure 4] FIG. 2 is a functional block diagram showing an example of a functional configuration related to collection of data related to an injection molding machine in the injection molding machine system. [Diagram 5] FIG. 10 is a diagram illustrating a relationship between a base processing load of a controller and its allowable upper limit. [Figure 6] FIG. 11 is a diagram illustrating an example of a change over time in a base processing load of a controller. [Figure 7] FIG. 13 illustrates an example of a collection data setting screen. [Figure 8] FIG. 13 is a diagram showing another example of the collection data setting screen. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, an embodiment will be described with reference to the drawings.

[0012] Hereinafter, embodiments will be described with reference to the drawings. In each drawing, the same or corresponding components will be denoted by the same or corresponding reference numerals, and the description thereof may be omitted.

[0013] [Outline of injection molding machine system] An outline of an injection molding machine system SYS according to this embodiment will be described with reference to FIGS.

[0014] Figures 1 and 2 are diagrams showing an example of the configuration of an injection molding machine system SYS according to this embodiment. In Figure 1, the injection molding machine 1 is shown in a state when mold opening is completed, and in Figure 2, the injection molding machine 1 is shown in a state when mold clamping is performed. In Figures 1 and 2, the X-axis, Y-axis, and Z-axis are perpendicular to each other, the positive and negative directions of the X-axis (hereinafter simply "X direction") and the positive and negative directions of the Y-axis (hereinafter simply "Y direction") represent horizontal directions, and the positive and negative directions of the Z-axis (hereinafter simply "Z direction") represent vertical directions.

[0015] The injection molding machine system SYS includes an injection molding machine 1, a management device 2, and a user terminal 3.

[0016] In this example, the injection molding machine system SYS includes two injection molding machines 1, but may include one or more than two injection molding machines. The injection molding machine system SYS includes one management device 2 or multiple management devices. The injection molding machine system SYS includes one user terminal 3 or multiple user terminals.

[0017] <Outline of injection molding machine> An injection molding machine 1 (an example of industrial machinery) performs a series of operations for obtaining a molded product by injection molding.

[0018] Moreover, the injection molding machine 1 is communicably connected to a management device 2 and a user terminal 3 through a predetermined communication line NW. Moreover, the injection molding machine 1 may be communicably connected to another injection molding machine 1 through the communication line NW.

[0019] The communication line NW includes, for example, a local network (LAN: Local Area Network) in a factory where the injection molding machine 1 is installed. The local network may be wired or wireless, or may be in a form including both. The communication line NW may also include, for example, a wide area network (WAN: Wide Area Network) outside the factory where the injection molding machine 1 is installed. The wide area network may include, for example, a mobile communication network with a base station as its terminal. The mobile communication network may include, for example, LTE (Long Term Evolution), 4G (4G), etc. th Generation), 5G(5 th Generation) and the like. The wide area network may also include, for example, a satellite communication network that uses a communication satellite. The wide area network may also include, for example, the Internet network. The communication line NW may also include, for example, a short-distance communication line that supports wireless communication methods such as Bluetooth (registered trademark) communication and WiFi communication.

[0020] For example, the injection molding machine 1 sequentially acquires data (hereinafter, "operation data") related to the operating status of the injection molding machine 1 (its own machine) that is periodically output, and transmits (uploads) the data to the management device 2 via the communication line NW. This allows the management device 2 (or its manager or operator, etc.) to grasp the operating status and manage the timing of maintenance of the injection molding machine 1 and the operating schedule of the injection molding machine 1. Furthermore, the management device 2 generates data related to control of the injection molding machine 1 (e.g., molding conditions, etc.) based on the operating data of the injection molding machine 1, and transmits the data to the injection molding machine 1, thereby enabling control of the injection molding machine 1 from outside.

[0021] The operation data includes, for example, data showing a control state regarding the molding operation of the injection molding machine 1 (hereinafter, "control data"). The control data is output by a controller 700 described later. The operation data also includes, for example, data regarding the operation state of a driver 710 (see FIG. 4) that drives various electric actuators that realize the molding operation of the injection molding machine 1 (hereinafter, "driver operation data"). The electric actuators include, for example, a mold clamping motor 160, a mold thickness adjustment motor 183, an ejector motor 210, a metering motor 340, an injection motor 350, a motor 420, and the like, which are described later. The driver operation data is output by the various drivers 710. The operation data also includes various detection data regarding the injection molding machine 1 during operation. The detection data is output by, for example, a sensor 720 (see FIG. 4). The sensor 720 includes, for example, a mold clamping motor encoder 161, a mold thickness adjustment motor encoder 184, an ejector motor encoder 211, a metering motor encoder 341, an injection motor encoder 351, etc., which will be described later. The sensor 720 also includes, for example, a tie bar distortion detector 141, a temperature detector 314, a pressure detector 360, etc., which will be described later. The sensor 720 also includes, for example, various current sensors and voltage sensors that detect currents and voltages of electric actuators, etc. The sensor 720 may also include an AD (Analog-Digital) converter that converts analog output detection data into digital data and outputs the digital data.

[0022] Also, for example, the injection molding machine 1 sequentially acquires operation data of the injection molding machine 1 (its own machine) that is periodically output, and transmits the operation data of the injection molding machine 1 (its own machine) to the user terminal 3 through the communication line NW. This allows the injection molding machine 1 to provide information on the operation status of the injection molding machine 1 to the user through the user terminal 3.

[0023] Also, for example, the injection molding machine 1, as a master machine, may monitor and control the operation of another injection molding machine 1 as a slave machine through the communication line NW. Specifically, the injection molding machine 1 (slave machine) may transmit operation data to the injection molding machine 1 (master machine) through the communication line NW. This allows the injection molding machine 1 (master machine) to monitor the operation of the other injection molding machine 1 (slave machine). Also, the injection molding machine 1 (master machine) may transmit a control command regarding the operation to the other injection molding machine 1 (slave machine) through the communication line NW while grasping the operation state of the other injection molding machine 1 (slave machine) based on the operation data. This allows the injection molding machine 1 (master machine) to control the operation of the other injection molding machine 1 (slave machine). In this case, the injection molding machine 1 (master machine) may control the operation of the other injection molding machine 1 (slave machine) so as to synchronize with the operation of the injection molding machine 1 (master machine).

[0024] <Overview of management device> As described above, the management device 2 is communicatively connected to the injection molding machine 1 through the communication line NW. The management device 2 may also be communicatively connected to the user terminal 3 through the communication line NW.

[0025] The management device 2 is, for example, an on-premise server or a cloud server installed in a remote location such as a management center outside the factory where the injection molding machine 1 is installed. The management device 2 may also be, for example, an edge server installed inside the factory where the injection molding machine 1 is installed or in a location relatively close to the factory (for example, a communication facility such as a wireless base station or station building near the factory). The management device 2 may also be a terminal device (for example, a desktop computer terminal) in the factory where the injection molding machine 1 is installed. The management device 2 may also be a mobile terminal (for example, a smartphone, a tablet terminal, a laptop computer terminal, etc.) that can be carried by the manager of the injection molding machine 1, etc.

[0026] The management device 2 may, for example, grasp the operating state of the injection molding machine 1 based on data transmitted (uploaded) from the injection molding machine 1, and manage (monitor) the operating state of the injection molding machine 1. Furthermore, the management device 2 may perform various diagnoses, such as abnormality diagnosis, of the injection molding machine 1 based on the grasped operating state of the injection molding machine 1.

[0027] Furthermore, the management device 2 may transmit control data (e.g., data related to molding conditions) to the injection molding machine 1 through, for example, the communication line NW. In this way, the management device 2 can control the operation of the injection molding machine 1.

[0028] The management device 2 may also set the injection molding machine 1 in response to a predetermined input from the user received through the input device 2G, which will be described later. The settings for the injection molding machine 1 include, for example, settings for molding conditions of the injection molding machine 1. The settings for the injection molding machine 1 include, for example, settings for collection of data for the injection molding machine 1, which will be described later. Specifically, the management device 2 may set the injection molding machine 1 in response to a predetermined input to a predetermined setting screen of the display device 2H, which is received from the user through the input device 2G. Then, the user terminal 3 may transmit the determined setting contents for the injection molding machine 1 to the target injection molding machine 1. This allows the injection molding machine 1 to set its own machine in response to the received setting contents. Therefore, the management device 2 can reflect the setting contents in response to the user's operation in the injection molding machine 1.

[0029] The management device 2 may provide information about the injection molding machine 1 to a manager of the injection molding machine 1 or a factory, for example, through the display device 2H. The information about the injection molding machine 1 includes, for example, information about the operating state of the injection molding machine 1. Specifically, the management device 2 causes the display device 2H to display information about the injection molding machine 1 based on various data transmitted (uploaded) from the injection molding machine 1, in response to a predetermined input received from a user through the input device 2G, for example. In this way, the management device 2 can provide information about the injection molding machine 1 to a manager of the injection molding machine 1 or a factory, for example, based on the data received from the injection molding machine 1.

[0030] As described above, the user terminal 3 is communicably connected to the injection molding machine 1 and the management device 2 through the communication line NW.

[0031] The user terminal 3 is used by users of the injection molding machine system SYS. The users of the injection molding machine system SYS include users of the injection molding machine 1, such as an operator who operates the injection molding machine 1 and a serviceman who maintains the injection molding machine 1. The users of the injection molding machine system SYS also include users of the management device 2, such as an administrator of the injection molding machine 1 and a factory where the injection molding machine 1 is installed.

[0032] The user terminal 3 is, for example, a portable terminal device (i.e., a mobile terminal) such as a smartphone, a tablet terminal, a laptop PC (Personal Computer), etc. The user terminal 3 may also be, for example, a stationary terminal device such as a desktop PC.

[0033] The user terminal 3 may have a display device such as a liquid crystal display or an organic EL display, and may provide information about the injection molding machine 1 to the user through the display device. The information about the injection molding machine 1 includes, for example, information about the operating state of the injection molding machine 1. Specifically, the user terminal 3 may have an input device such as an operation input device, a voice input device, a gesture input device, and may transmit a request signal for providing information to the injection molding machine 1 or the management device 2 in response to a predetermined input (i.e., a request from the user) received from the user through the input device. Then, in response to the request signal received from the user terminal 3, the injection molding machine 1 or the management device 2 may deliver data including the target information (for example, operation data corresponding to information about the operating state, etc.) to the user terminal 3 that is the sender of the request signal. In this way, the user terminal 3 can provide the user with information about the injection molding machine 1 based on the data received from the injection molding machine 1 or the management device 2.

[0034] The user terminal 3 may also set the injection molding machine 1 in response to a predetermined input from the user received through the input device. The settings for the injection molding machine 1 include, for example, settings for molding conditions of the injection molding machine 1. The settings for the injection molding machine 1 include, for example, settings for collection of data for the injection molding machine 1, which will be described later. Specifically, the user terminal 3 may set the injection molding machine 1 in response to, for example, a predetermined input received from the user through the input device on a predetermined setting screen of the display device. Then, the user terminal 3 may transmit the determined setting contents for the injection molding machine 1 to the target injection molding machine 1. This allows the injection molding machine 1 to set its own machine in response to the received setting contents. Therefore, the user terminal 3 can reflect the setting contents in response to the user's operation in the injection molding machine 1.

[0035] [Basic configuration of injection molding machine] Next, the basic configuration of the injection molding machine 1 will be described with reference to FIGS.

[0036] The injection molding machine 1 includes a clamping device 100, an ejector device 200, an injection device 300, a moving device 400, a controller 700, an input device 750, and a display device 760.

[0037] <Mold clamping device> The mold clamping device 100 performs mold closing, mold clamping, and mold opening of the mold device 10. The mold clamping device 100 is, for example, a horizontal type, and the direction in which the mold device 10 is opened and closed (hereinafter, "mold opening and closing direction") is horizontal. The mold clamping device 100 has a fixed platen 110, a movable platen 120, a toggle support 130, a tie bar 140, a toggle mechanism 150, a mold clamping motor 160, a motion conversion mechanism 170, a mold thickness adjustment mechanism 180, and the like.

[0038] In the following description of the mold clamping device 100, the moving direction of the movable platen 120 when the mold apparatus 10 is closed (to the right in FIGS. 1 and 2) is defined as the front, and the moving direction of the movable platen 120 when the mold apparatus 10 is opened (to the left in FIGS. 1 and 2) is defined as the rear. The same applies to the description of the ejector device 200 described later.

[0039] The mold apparatus 10 includes a fixed mold 11 and a movable mold 12 .

[0040] The stationary platen 110 is fixed to the frame Fr. A stationary mold 11 is attached to the surface of the stationary platen 110 that faces the movable platen 120.

[0041] The movable platen 120 is movable relative to the frame Fr in the mold opening / closing direction. A guide 101 is disposed on the frame Fr to guide the movable platen 120. A movable mold 12 is attached to the surface of the movable platen 120 facing the fixed platen 110.

[0042] The movable platen 120 is advanced or retreated relative to the fixed platen 110 to perform mold closing, mold clamping, and mold opening.

[0043] The toggle support 130 is connected to the fixed platen 110 at a distance, and is placed on the frame Fr so as to be movable in the mold opening and closing direction. The toggle support 130 may be movable along a guide laid on the frame Fr. In this case, the guide of the toggle support 130 may be common to the guide 101 of the movable platen 120.

[0044] In this embodiment, the fixed platen 110 is fixed to the frame Fr, and the toggle support 130 is movable relative to the frame Fr in the mold opening / closing direction, but the toggle support 130 may be fixed to the frame Fr, and the fixed platen 110 may be movable relative to the frame Fr in the mold opening / closing direction.

[0045] The tie bar 140 connects the fixed platen 110 and the toggle support 130 at an interval L in the mold opening / closing direction. A plurality of tie bars 140 (for example, four) may be used. Each tie bar 140 is parallel to the mold opening / closing direction and extends according to the mold clamping force. At least one tie bar 140 is provided with a tie bar strain detector 141 that detects strain of the tie bar 140. The tie bar strain detector 141 sends a signal indicating the detection result to the controller 700. The detection result of the tie bar strain detector 141 is used for detecting the mold clamping force, etc.

[0046] In this embodiment, the tie bar strain detector 141 is used as the clamping force detector for detecting the clamping force, but it may be replaced with other devices based on known technology. For example, the clamping force detector is not limited to the strain gauge type, but may be a piezoelectric type, a capacitance type, a hydraulic type, an electromagnetic type, or the like, and the attachment position thereof is not limited to the tie bar 140.

[0047] The toggle mechanism 150 is disposed between the movable platen 120 and the toggle support 130, and moves the movable platen 120 in the mold opening / closing direction relative to the toggle support 130. The toggle mechanism 150 is composed of a crosshead 151, a pair of link groups, etc. Each link group has a first link 152 and a second link 153 that are connected to bendable and extendable by a pin or the like. The first link 152 is attached to the movable platen 120 by a pin or the like so as to be swingable, and the second link 153 is attached to the toggle support 130 by a pin or the like so as to be swingable. The second link 153 is attached to the crosshead 151 via a third link 154. When the crosshead 151 is advanced or retreated relative to the toggle support 130, the first link 152 and the second link 153 are bent or retreated, and the movable platen 120 advances or retreats relative to the toggle support 130.

[0048] The configuration of the toggle mechanism 150 is not limited to the configuration shown in Figures 1 and 2. For example, although the number of joints in each link group is five in Figures 1 and 2, it may be four, and one end of the third link 154 may be connected to a joint between the first link 152 and the second link 153.

[0049] The mold clamping motor 160 is attached to the toggle support 130 and operates the toggle mechanism 150. The mold clamping motor 160 moves the crosshead 151 forward and backward relative to the toggle support 130, thereby bending and extending the first link 152 and the second link 153 and moving the movable platen 120 forward and backward relative to the toggle support 130. The mold clamping motor 160 is directly connected to the motion conversion mechanism 170, but may also be connected to the motion conversion mechanism 170 via a belt, a pulley, or the like.

[0050] The motion conversion mechanism 170 converts the rotational motion of the mold clamping motor 160 into the linear motion of the crosshead 151. The motion conversion mechanism 170 includes a screw shaft 171 and a screw nut 172 that screws onto the screw shaft 171. A ball or a roller may be interposed between the screw shaft 171 and the screw nut 172.

[0051] The mold clamping device 100 performs a mold closing process, a mold clamping process, a mold opening process, and the like under the control of a controller 700 .

[0052] In the mold closing process, the mold clamping device 100 drives the mold clamping motor 160 to advance the crosshead 151 to a mold closing completion position at a set speed, thereby advancing the movable platen 120 and bringing the movable mold 12 into contact with the fixed mold 11. The position and speed of the crosshead 151 are detected, for example, by using a mold clamping motor encoder 161. The mold clamping motor encoder 161 detects the rotation of the mold clamping motor 160 and sends a signal indicating the detection result to the controller 700.

[0053] Incidentally, the crosshead position detector that detects the position of the crosshead 151 and the crosshead speed detector that detects the speed of the crosshead 151 are not limited to the mold clamping motor encoder 161, and may be replaced with other devices based on known technology. Also, the movable platen position detector that detects the position of the movable platen 120 and the movable platen speed detector that detects the speed of the movable platen 120 are not limited to the mold clamping motor encoder 161, and may be replaced with other devices based on known technology.

[0054] In the mold clamping process, the mold clamping device 100 generates a mold clamping force by further driving the mold clamping motor 160 to move the crosshead 151 further forward from the mold closing completion position to the mold clamping position. During mold clamping, a cavity space 14 is formed between the movable mold 12 and the fixed mold 11, and the injection device 300 fills the cavity space 14 with liquid molding material. The filled molding material is cooled and solidified to obtain a molded product. The number of cavity spaces 14 in the mold device 10 may be multiple. In this case, multiple molded products are obtained at the same time.

[0055] In the mold opening process, the mold clamping unit 100 drives the mold clamping motor 160 to move the crosshead 151 backward at a set speed to a mold opening completion position, thereby moving the movable platen 120 backward and separating the movable mold 12 from the fixed mold 11. After that, the ejector unit 200 ejects the molded product from the movable mold 12.

[0056] The setting conditions in the mold closing process and the mold clamping process are set together as a series of setting conditions. For example, the speed and position of the crosshead 151 in the mold closing process and the mold clamping process (specifically, including the mold closing start position, the speed switching position, the mold closing completion position, and the mold clamping position), the mold clamping force, etc. are set together as a series of setting conditions. The mold closing start position, the speed switching position, the mold closing completion position, and the mold clamping position are arranged in this order from the rear side to the front, and represent the start and end points of the section in which the speed is set. The speed is set for each section. There may be one or more speed switching positions. The speed switching position does not have to be set. Only one of the mold clamping position and the mold clamping force may be set.

[0057] The setting conditions for the mold opening process are also set in a similar manner. For example, the speed and position of the crosshead 151 in the mold opening process (including the mold opening start position, the speed switching position, and the mold opening completion position) are set together as a series of setting conditions. The mold opening start position, the speed switching position, and the mold opening completion position are arranged in this order from the front to the rear, and represent the start and end points of the section in which the speed is set. The speed is set for each section. There may be one or more speed switching positions. The speed switching position does not have to be set. The mold opening start position and the mold clamping position may be the same position. Furthermore, the mold opening completion position and the mold closing start position may be the same position.

[0058] It should be noted that the speed, position, etc. of the movable platen 120 may be set instead of the speed, position, etc. of the crosshead 151. Also, the clamping force may be set instead of the position of the crosshead (e.g., clamping position) or the position of the movable platen.

[0059] The toggle mechanism 150 amplifies the driving force of the mold clamping motor 160 and transmits it to the movable platen 120. The amplification ratio is also called the toggle ratio. The toggle ratio changes according to the angle θ between the first link 152 and the second link 153 (hereinafter also referred to as the "link angle θ"). The link angle θ is determined from the position of the crosshead 151. When the link angle θ is 180°, the toggle ratio is maximum.

[0060] When the thickness of the mold device 10 changes due to replacement of the mold device 10 or a change in temperature of the mold device 10, the mold thickness is adjusted so that a predetermined clamping force is obtained during mold clamping. In the mold thickness adjustment, for example, the distance L between the fixed platen 110 and the toggle support 130 is adjusted so that the link angle θ of the toggle mechanism 150 becomes a predetermined angle at the time of mold touch when the movable mold 12 touches the fixed mold 11.

[0061] The mold thickness adjustment mechanism 180 adjusts the mold thickness by adjusting the distance L between the fixed platen 110 and the toggle support 130. The mold thickness adjustment mechanism 180 has a screw shaft 181 formed at the rear end of the tie bar 140, a screw nut 182 rotatably held by the toggle support 130, and a mold thickness adjustment motor 183 that rotates the screw nut 182 screwed onto the screw shaft 181.

[0062] The screw shaft 181 and the screw nut 182 are provided for each tie bar 140. The rotation of the mold thickness adjustment motor 183 may be transmitted to the multiple screw nuts 182 via a rotation transmission unit 185. The multiple screw nuts 182 can rotate synchronously.

[0063] In addition, by changing the transmission path of the rotation transmission unit 185, it is also possible to rotate the multiple screw nuts 182 individually.

[0064] The rotation transmission unit 185 is composed of, for example, gears, etc. In this case, a passive gear is formed on the outer periphery of each screw nut 182, a drive gear is attached to the output shaft of the mold thickness adjustment motor 183, and an intermediate gear that meshes with the multiple passive gears and the drive gear is rotatably held in the center of the toggle support 130.

[0065] The rotation transmission unit 185 may be configured with a belt, a pulley, or the like, instead of the gears.

[0066] The operation of the mold thickness adjustment mechanism 180 is controlled by a controller 700. The controller 700 drives the mold thickness adjustment motor 183 to rotate the screw nut 182, thereby adjusting the position of the toggle support 130, which rotatably holds the screw nut 182, relative to the fixed platen 110, and adjusting the distance L between the fixed platen 110 and the toggle support 130.

[0067] The distance L is detected using a mold thickness adjustment motor encoder 184. The mold thickness adjustment motor encoder 184 detects the amount of rotation and the direction of rotation of the mold thickness adjustment motor 183, and sends a signal indicating the detection result to the controller 700. The detection result of the mold thickness adjustment motor encoder 184 is used to monitor and control the position of the toggle support 130 and the distance L.

[0068] Incidentally, the toggle support position detector that detects the position of the toggle support 130 and the gap detector that detects the gap L are not limited to the mold thickness adjustment motor encoder 184, and may be replaced with other devices based on known technology.

[0069] The mold thickness adjustment mechanism 180 adjusts the gap L by rotating one of a screw shaft 181 and a screw nut 182 that are screwed together. A plurality of mold thickness adjustment mechanisms 180 may be used, and a plurality of mold thickness adjustment motors 183 may be used.

[0070] In this example, the mold clamping apparatus 100 is a horizontal type in which the mold opening and closing direction is horizontal, but it may be a vertical type in which the mold opening and closing direction is vertical. In this example, the mold clamping apparatus 100 has a mold clamping motor 160 as a drive source, but it may have a hydraulic cylinder instead of the mold clamping motor 160. The mold clamping apparatus 100 may have a linear motor for mold opening and closing, and an electromagnet for mold clamping.

[0071] <Ejector device> After the molding material filled in the mold device 10 by the injection device 300 is cooled and solidified, the ejector device 200 ejects (removes) the molded product from the mold device 10. The ejector device 200 includes an ejector motor 210, a motion conversion mechanism 220, an ejector rod 230, and the like.

[0072] The ejector motor 210 is attached to the movable platen 120. The ejector motor 210 is directly connected to the motion conversion mechanism 220, but may be connected to the motion conversion mechanism 220 via a belt, a pulley, or the like.

[0073] The motion conversion mechanism 220 converts the rotational motion of the ejector motor 210 into the linear motion of the ejector rod 230. The motion conversion mechanism 220 includes a screw shaft and a screw nut that screws onto the screw shaft. A ball or roller may be interposed between the screw shaft and the screw nut.

[0074] The ejector rod 230 is movable forward and backward in a through hole of the movable platen 120. The front end of the ejector rod 230 contacts the movable member 15 disposed inside the movable mold 12 so as to be movable forward and backward. The front end of the ejector rod 230 may or may not be connected to the movable member 15.

[0075] The ejector device 200 performs the ejection process under the control of the controller 700 .

[0076] In the ejection process, the ejector unit 200 drives the ejector motor 210 to advance the ejector rod 230 from the standby position to the ejection position at a set speed, thereby advancing the movable member 15 and ejecting the molded product. Thereafter, the ejector unit 200 drives the ejector motor 210 to retract the ejector rod 230 at a set speed, thereby retracting the movable member 15 to its original standby position. The position and speed of the ejector rod 230 are detected, for example, by using an ejector motor encoder 211. The ejector motor encoder 211 detects the rotation of the ejector motor 210 and sends a signal indicating the detection result to the controller 700.

[0077] Incidentally, the ejector rod position detector that detects the position of the ejector rod 230 and the ejector rod speed detector that detects the speed of the ejector rod 230 are not limited to the ejector motor encoder 211, and may be replaced with other devices based on known technology.

[0078] <Injection device> The injection device 300 fills the molding material into the mold device 10 clamped by the mold clamping device 100. Specifically, the injection device 300 is mounted on a slide base 301 that can move forward and backward with respect to the frame Fr, and can move forward and backward with respect to the mold device 10. The injection device 300 touches the mold device 10 and fills the molding material into the cavity space 14 in the mold device 10. The injection device 300 has, for example, a cylinder 310, a nozzle 320, a screw 330, a metering motor 340, an injection motor 350, a pressure detector 360, and the like.

[0079] In the following description of the injection unit 300, the direction in which the injection unit 300 approaches the mold device 10 (leftward in Figs. 1 and 2) is defined as the front, and the direction in which the injection unit 300 moves away from the mold device 10 (rightward in Figs. 1 and 2) is defined as the rear. The same applies to the description of the moving unit 400 described later.

[0080] Cylinder 310 heats the molding material supplied to the inside from supply port 311. The molding material includes, for example, resin. The molding material is formed, for example, in the form of pellets, and is supplied to supply port 311 in a solid state. Supply port 311 is formed at the rear of cylinder 310. A cooler 312 such as a water-cooled cylinder is provided on the outer periphery of the rear of cylinder 310. A heater 313 such as a band heater and a temperature detector 314 are provided on the outer periphery of cylinder 310 forward of cooler 312.

[0081] Cylinder 310 is divided into a plurality of zones in the axial direction of cylinder 310 (left and right direction in Figs. 1 and 2). Each zone is provided with heater 313 and temperature detector 314. For each zone, controller 700 controls heater 313 so that the temperature detected by temperature detector 314 becomes the set temperature.

[0082] The nozzle 320 is provided at the front end of the cylinder 310 and is pressed against the mold device 10. A heater 313 and a temperature detector 314 are provided on the outer periphery of the nozzle 320. A controller 700 controls the heater 313 so that the detected temperature of the nozzle 320 becomes the set temperature.

[0083] The screw 330 is disposed in the cylinder 310 so as to be rotatable and movable forward and backward. When the screw 330 is rotated, the molding material is sent forward along the spiral groove of the screw 330. As the molding material is sent forward, it is gradually melted by heat from the cylinder 310. As the liquid molding material is sent forward of the screw 330 and accumulates in the front part of the cylinder 310, the screw 330 is moved backward. Thereafter, when the screw 330 is moved forward, the liquid molding material accumulated in front of the screw 330 is injected from the nozzle 320 and filled into the mold device 10.

[0084] A check ring 331 is attached to the front of the screw 330 so as to be movable back and forth as a check valve for preventing the backflow of molding material from the front to the rear of the screw 330 when the screw 330 is pushed forward.

[0085] When the screw 330 is moved forward, the backflow prevention ring 331 is pushed backward by the pressure of the molding material in front of the screw 330, and moves backward relatively to the screw 330 to a blocking position (see FIG. 2) where the flow path of the molding material is blocked. This prevents the molding material accumulated in front of the screw 330 from flowing backward.

[0086] On the other hand, when the screw 330 is rotated, the backflow prevention ring 331 is pushed forward by the pressure of the molding material sent forward along the spiral groove of the screw 330, and moves forward relatively to the screw 330 to an open position (see FIG. 1) where the flow path of the molding material is opened. As a result, the molding material is sent forward of the screw 330.

[0087] The backflow prevention ring 331 may be of a co-rotating type that rotates together with the screw 330 , or of a non-co-rotating type that does not rotate together with the screw 330 .

[0088] The injection device 300 may have a drive source for moving the backflow prevention ring 331 back and forth between the open position and the closed position relative to the screw 330.

[0089] The metering motor 340 rotates the screw 330. The drive source for rotating the screw 330 is not limited to the metering motor 340, and may be, for example, a hydraulic pump or the like.

[0090] The injection motor 350 advances and retreats the screw 330. A motion conversion mechanism that converts the rotational motion of the injection motor 350 into the linear motion of the screw 330 is provided between the injection motor 350 and the screw 330. The motion conversion mechanism has, for example, a screw shaft and a screw nut that screws onto the screw shaft. A ball, a roller, or the like may be provided between the screw shaft and the screw nut. The drive source that advances and retreats the screw 330 is not limited to the injection motor 350, and may be, for example, a hydraulic cylinder, or the like.

[0091] The pressure detector 360 detects the pressure transmitted between the injection motor 350 and the screw 330. The pressure detector 360 is provided on a force transmission path between the injection motor 350 and the screw 330, and detects the pressure acting on the pressure detector 360.

[0092] The pressure detector 360 sends a signal indicating the detection result to the controller 700. The detection result of the pressure detector 360 is used to control and monitor the pressure that the screw 330 receives from the molding material, the back pressure on the screw 330, the pressure that the screw 330 exerts on the molding material, etc.

[0093] The injection device 300 performs a measuring process, a filling process, a pressure holding process, and the like under the control of the controller 700.

[0094] In the metering process, the injection device 300 drives the metering motor 340 to rotate the screw 330 at a set rotation speed, and sends the molding material forward along the spiral groove of the screw 330. As a result, the molding material is gradually melted. As the liquid molding material is sent forward of the screw 330 and accumulates at the front of the cylinder 310, the screw 330 is moved backward. The rotation speed of the screw 330 is detected, for example, by using a metering motor encoder 341. The metering motor encoder 341 detects the rotation of the metering motor 340 and sends a signal indicating the detection result to the controller 700.

[0095] Incidentally, the screw rotation speed detector that detects the rotation speed of the screw 330 is not limited to the metering motor encoder 341, and may be replaced with other devices based on known technology.

[0096] In the metering process, the injection device 300 may apply a set back pressure to the screw 330 by driving the injection motor 350 in order to limit abrupt retraction of the screw 330. The back pressure on the screw 330 is detected, for example, by using a pressure detector 360. The pressure detector 360 sends a signal indicating the detection result to the controller 700. When the screw 330 retracts to the metering completion position and a predetermined amount of molding material is accumulated in front of the screw 330, the metering process is completed.

[0097] In the filling step, the injection device 300 drives the injection motor 350 to advance the screw 330 at a set speed, and fills the liquid molding material accumulated in front of the screw 330 into the cavity space 14 in the mold device 10. The position and speed of the screw 330 are detected, for example, by using an injection motor encoder 351. The injection motor encoder 351 detects the rotation of the injection motor 350 and sends a signal indicating the detection result to the controller 700. When the position of the screw 330 reaches a set position, switching from the filling step to the pressure holding step (so-called V / P switching) is performed. The position at which the V / P switching is performed is also referred to as a V / P switching position. The set speed of the screw 330 may be changed depending on the position of the screw 330, time, etc.

[0098] In the filling process, after the position of the screw 330 reaches a set position, the screw 330 may be temporarily stopped at the set position, and then V / P switching may be performed. Also, immediately before V / P switching, instead of stopping the screw 330, the screw 330 may be moved forward or backward at a slow speed. Also, the screw position detector that detects the position of the screw 330 and the screw speed detector that detects the speed of the screw 330 are not limited to the injection motor encoder 351, and may be replaced with other devices based on known technology.

[0099] In the pressure holding step, the injection device 300 drives the injection motor 350 to push the screw 330 forward, maintains the pressure of the molding material at the front end of the screw 330 (hereinafter, "holding pressure") at a set pressure, and pushes the molding material remaining in the cylinder 310 toward the mold device 10. This allows the injection device 300 to replenish the molding material that is insufficient due to cooling contraction in the mold device 10. The holding pressure is detected, for example, by a pressure detector 360. The pressure detector 360 sends a signal indicating the detection result to the controller 700. The set value of the holding pressure may be changed depending on the elapsed time from the start of the pressure holding step, etc.

[0100] In the dwelling step, the molding material in the cavity space 14 in the mold device 10 is gradually cooled, and when the dwelling step is completed, the entrance to the cavity space 14 is blocked by the solidified molding material. This state is called a gate seal, and prevents the molding material from flowing back from the cavity space 14. After the dwelling step, the cooling step is started. In the cooling step, the molding material in the cavity space 14 is solidified. In order to shorten the molding cycle time, a measuring step may be performed during the cooling step.

[0101] In this example, the injection device 300 is of an in-line screw type, but may be of a pre-plastication type or the like. The pre-plastication type injection device supplies the molding material melted in the plasticization cylinder to the injection cylinder, and injects the molding material from the injection cylinder into the mold device. A screw is disposed in the plasticization cylinder so as to be rotatable or rotatable and movable forward and backward, and a plunger is disposed in the injection cylinder so as to be movable forward and backward. In this example, the injection device 300 is of a horizontal type in which the axial direction of the cylinder 310 is horizontal, but may be of a vertical type in which the axial direction of the cylinder 310 is vertical. The mold clamping device combined with the vertical injection device 300 may be of a vertical type or a horizontal type. Similarly, the mold clamping device combined with the horizontal injection device 300 may be of a horizontal type or a vertical type.

[0102] <Mobile device> The moving device 400 moves the injection device 300 forward and backward relative to the mold device 10. In addition, the moving device 400 presses the nozzle 320 against the mold device 10 to generate a nozzle touch pressure. The moving device 400 has a hydraulic pump 410, a motor 420 as a drive source, a hydraulic cylinder 430 as a hydraulic actuator, and the like.

[0103] Although the moving device 400 is disposed on one side of the cylinder 310 of the injection device 300 in FIG. 2, it may be disposed on both sides of the cylinder 310, or may be disposed symmetrically with the cylinder 310 as the center.

[0104] The hydraulic pump 410 has a first port 411 and a second port 412. The hydraulic pump 410 can rotate in both directions, and by switching the rotation direction of the motor 420, the hydraulic pump 410 draws in hydraulic fluid (e.g., oil) from one of the first port 411 and the second port 412 and discharges it from the other port, thereby generating hydraulic pressure.

[0105] The hydraulic pump 410 can also suck hydraulic fluid from a tank and discharge the hydraulic fluid from either the first port 411 or the second port 412.

[0106] The motor 420 operates the hydraulic pump 410. The motor 420 drives the hydraulic pump 410 with a rotational direction and rotational torque according to a control signal from the controller 700. The motor 420 may be an electric motor or an electric servo motor.

[0107] The hydraulic cylinder 430 has a cylinder body 431, a piston 432, and a piston rod 433. The cylinder body 431 is fixed to the injection device 300. The piston 432 divides the inside of the cylinder body 431 into a front chamber 435 as a first chamber and a rear chamber 436 as a second chamber. The piston rod 433 is fixed to the fixed platen 110.

[0108] A front chamber 435 of the hydraulic cylinder 430 is connected to a first port 411 of the hydraulic pump 410 via a first flow path 401. The hydraulic fluid discharged from the first port 411 is supplied to the front chamber 435 via the first flow path 401, thereby pushing the injection unit 300 forward. The injection unit 300 is moved forward, and the nozzle 320 is pressed against the fixed die 11. The front chamber 435 functions as a pressure chamber that generates a nozzle touch pressure of the nozzle 320 by the pressure of the hydraulic fluid supplied from the hydraulic pump 410.

[0109] On the other hand, the rear chamber 436 of the hydraulic cylinder 430 is connected to the second port 412 of the hydraulic pump 410 via the second flow path 402. The hydraulic fluid discharged from the second port 412 is supplied to the rear chamber 436 of the hydraulic cylinder 430 via the second flow path 402, thereby pushing the injection unit 300 backward. The injection unit 300 is moved backward, and the nozzle 320 is separated from the fixed mold 11.

[0110] In this example, the moving device 400 includes the hydraulic cylinder 430, but is not limited to this configuration. For example, instead of the hydraulic cylinder 430, an electric motor and a motion conversion mechanism that converts the rotational motion of the electric motor into the linear motion of the injection device 300 may be used.

[0111] <Controller> The controller 700 (an example of a control device) directly transmits control signals to the clamping device 100, the ejector device 200, the injection device 300, the moving device 400, and the like, and controls the driving of the injection molding machine 1.

[0112] The functions of the controller 700 are realized by any hardware or a combination of any hardware and software. The controller 700 is configured, for example, with a computer as its core, and includes a CPU (Central Processing Unit) 701, a memory device 702, an auxiliary storage device 703, and an interface device 704 for input / output. The controller 700 performs various controls related to the injection molding machine 1, for example, by loading a program installed in the auxiliary storage device 703 into the memory device 702 and having the CPU 701 execute the program. The controller 700 also receives external signals and outputs signals to the outside through the interface device 704. The interface device 704 may include a plurality of different types of interface devices according to the communication lines to be connected.

[0113] The functions of the controller 700 may be shared and realized by a plurality of controllers. For example, the functions of the controller 700 may be shared and realized by a motion controller that controls the operations of various actuators of the injection molding machine 1, a sequence controller that controls the entire sequence of the injection molding machine 1, etc.

[0114] The programs, various files, and data used by the controller 700 are read from the recording medium 5 to the auxiliary storage device 703 of the controller 700 through the interface device 704 and stored (installed). The recording medium 5 is, for example, a general-purpose recording medium such as an SD card, a USB (Universal Serial Bus) memory, a CD (Compact Disc), or a DVD (Digital Versatile Disc). The recording medium 5 may also be a dedicated tool communicatively connected to the injection molding machine 1 (the interface device 704 of the controller 700) via a predetermined communication cable in the final inspection process of the manufacturing line of the injection molding machine 1. The programs, various files, and data used by the controller 700 may also be downloaded to the controller 700 from an external computer (for example, the management device 2, etc.) through, for example, a communication line NW.

[0115] The controller 700 causes the injection molding machine 1 (such as the clamping device 100) to repeatedly perform a mold closing process, a mold clamping process, a mold opening process, etc., to repeatedly manufacture molded products. The controller 700 also causes the injection device 300 to perform a metering process, a filling process, a pressure holding process, etc., during the mold clamping process.

[0116] Incidentally, a series of operations of the injection molding machine 1 to obtain a molded product, for example, operations from the start of a metering process by the injection unit 300 to the start of a metering process by the next injection unit 300, is also called a "shot" or a "molding cycle." Also, the time required for one shot is also called a "molding cycle time."

[0117] One molding cycle includes, for example, a metering process by the injection device 300, a mold closing process, a mold clamping process, a filling process by the injection device 300, a pressure holding process by the injection device 300, a cooling process, a mold opening process, and an ejection process, and these processes are started in this order. The filling process, pressure holding process, and cooling process are performed from the start of the mold clamping process to the end of the mold clamping process. The end of the mold clamping process coincides with the start of the mold opening process.

[0118] In addition, in order to shorten the molding cycle time, a plurality of processes may be performed simultaneously. For example, the metering process may be performed during the cooling process of the previous molding cycle, and in this case, the mold closing process may be performed at the beginning of the molding cycle. The filling process may be started during the mold closing process. The ejection process may be started during the mold opening process. In the case where an opening / closing valve for opening and closing the flow path of the nozzle 320 of the injection device 300 is provided, the mold opening process may be started during the metering process. This is because even if the mold opening process is started during the metering process, the molding material will not leak from the nozzle 320 and the nozzle 520 as long as the opening / closing valve closes the flow paths of the nozzle 320 and the nozzle 520.

[0119] The controller 700 is communicatively connected to an input device 750 and a display device 760 via, for example, a one-to-one communication line, a local network, or a short-distance communication line.

[0120] The input device 750 receives input related to the injection molding machine 1 from the user, and a signal corresponding to the input is input to the controller 700.

[0121] For example, the input device 750 includes an operation input device that accepts operation input from a user using a hand, etc. The operation input device is, for example, a button, a toggle, a lever, a joystick, a keyboard, a mouse, a touch pad, a touch panel mounted on the display device 760, etc.

[0122] Furthermore, for example, the input device 750 may include a voice input device or a gesture input device that accepts voice input or gesture input from the user.

[0123] Furthermore, for example, the input device 750 may include a biometric input device that accepts biometric input from a user. The biometric input includes, for example, voiceprint input, iris input, fingerprint input, and the like.

[0124] The display device 760 displays various information screens related to the injection molding machine 1 under the control of the controller 700. For example, the display device 760 displays an operation screen related to the injection molding machine 1 according to the input contents received by the input device 750.

[0125] The operation screen displayed on the display device 760 is used for settings related to the injection molding machine 1. The settings related to the injection molding machine 1 include, for example, settings of molding conditions related to the injection molding machine 1 (specifically, input of set values). The settings also include, for example, settings related to selection of types of detection values ​​of various sensors and the like related to the injection molding machine 1 to be recorded as logging data during molding operations. The settings also include, for example, settings of display specifications (for example, types of actual values ​​to be displayed and display manner, etc.) on the display device 760 of detection values ​​(actual values) of various sensors and the like related to the injection molding machine 1 during molding operations. A plurality of operation screens may be prepared and displayed by switching between them on the display device 760 or by overlapping them. The user can perform settings related to the injection molding machine 1 (including input of set values) and the like by operating the input device 750 while watching the operation screen displayed on the display device 760.

[0126] Moreover, under the control of the controller 700, the display device 760 displays various information (information screens) in response to operations on the operation screen. A plurality of information screens are prepared, and are switched and displayed on the display device 760, or are displayed overlapping each other. For example, the display device 760 displays the setting contents related to the injection molding machine 1 (for example, the setting contents related to the molding conditions of the injection molding machine 1). Also, for example, the display device 760 displays management information (for example, information related to the operation record of the injection molding machine 1, etc.).

[0127] [Hardware configuration of management device] Next, the hardware configuration of the management device 2 will be described with reference to FIG.

[0128] FIG. 3 is a block diagram showing an example of a hardware configuration of the management device 2. As shown in FIG.

[0129] The functions of the management device 2 are realized by any hardware or a combination of any hardware and software. For example, as shown in Fig. 3, the management device 2 includes an external interface 2A, an auxiliary storage device 2B, a memory device 2C, a CPU 2D, a high-speed calculation device 2E, a communication interface 2F, an input device 2G, and a display device 2H. The external interface 2A, the auxiliary storage device 2B, the memory device 2C, the CPU 2D, the high-speed calculation device 2E, the communication interface 2F, the input device 2G, and the display device 2H are connected by a bus B.

[0130] The user terminal 3 may have the same hardware configuration as the management device 2. Therefore, hereinafter, illustrations and detailed descriptions of the hardware configuration of the user terminal 3 will be omitted.

[0131] The external interface 2A functions as an interface for reading data from the recording medium 2AA and writing data to the recording medium 2AA. The recording medium 2AA includes, for example, a flexible disk, a CD, a DVD, an SD memory card, a USB memory, etc. This allows the management device 2 to read various data used in processing through the recording medium 2AA, store it in the auxiliary storage device 2B, and install programs that realize various functions.

[0132] The management device 2 may obtain various data and programs from external devices through the communication interface 2F.

[0133] The auxiliary storage device 2B stores various installed programs, as well as files and data necessary for various processes. The auxiliary storage device 2B includes, for example, a hard disc drive (HDD), a solid state drive (SSD), a flash memory, and the like.

[0134] When an instruction to start a program is received, the memory device 2C reads out and stores the program from the auxiliary storage device 2B. The memory device 2C includes, for example, a dynamic random access memory (DRAM) or a static random access memory (SRAM).

[0135] The CPU 2D executes various programs loaded from the auxiliary storage device 2B to the memory device 2C, and realizes various functions related to the management device 2 in accordance with the programs.

[0136] The high-speed calculation device 2E works in conjunction with the CPU 2D to perform calculation processing at a relatively high speed. The high-speed calculation device 2E includes, for example, a graphics processing unit (GPU), an application specific integrated circuit (ASIC), or a field-programmable gate array (FPGA).

[0137] Incidentally, the high speed calculation device 2E may be omitted depending on the required calculation processing speed.

[0138] The communication interface 2F is used as an interface for connecting to an external device so as to be able to communicate with the external device. This allows the management device 2 to communicate with the external device, such as the injection molding machine 1 or the user terminal 3, through the communication interface 2F. The communication interface 2F may have multiple types of communication interfaces depending on the communication method between the connected device and the like.

[0139] The input device 2G accepts various inputs from the user.

[0140] The input device 2G includes, for example, an operation input device that accepts mechanical operation input from a user using a hand, etc. The operation input device includes, for example, a button, a toggle, a lever, a joystick, a mouse, a keyboard, etc. In addition, the operation input device includes, for example, a touch panel mounted on the display device 2H, a touch pad provided separately from the display device 2H, etc.

[0141] The input device 2G also includes, for example, a voice input device capable of receiving voice input from the user. The voice input device includes, for example, a microphone capable of collecting the user's voice.

[0142] The input device 2G includes, for example, a gesture input device capable of receiving a gesture input from a user. The gesture input device includes, for example, a camera capable of capturing an image of a user's gesture.

[0143] The input device 2G includes, for example, a biometric input device capable of receiving biometric input from a user. The biometric input device includes, for example, a camera capable of acquiring image data including information related to a user's fingerprint or iris.

[0144] The display device 2H displays an information screen and an operation screen to the user. The display device 2H includes, for example, a liquid crystal display, an organic EL (Electroluminescence) display, etc.

[0145] [Function configuration for collecting operation data of injection molding machines] Next, a functional configuration related to collection of operation data of the injection molding machine 1 in the injection molding machine system SYS will be described with reference to FIGS.

[0146] Fig. 4 is a functional block diagram showing an example of a functional configuration related to collection of data related to the injection molding machine 1 in the injection molding machine system SYS. Fig. 5 is a diagram showing a schematic diagram of the relationship between the base processing load of the controller 700 and a predetermined allowable upper limit (hereinafter, "allowable upper limit") PL_lim.

[0147] <Functional configuration of injection molding machine (controller)> 4, the controller 700 of the injection molding machine 1 includes, as functional units, a processing load estimation unit 7001, a processing load adjustment unit 7002, a data acquisition unit 7003, a data storage unit 7004, and a data transmission unit 7005. The functions of the processing load estimation unit 7001, the processing load adjustment unit 7002, the data acquisition unit 7003, and the data transmission unit 7005 are realized, for example, by loading a program installed in the auxiliary storage device 703 into the memory device 702 and executing the program by the CPU 701. The function of the data storage unit 7004 is realized, for example, by a storage area defined in the memory device 702 or the auxiliary storage device 703.

[0148] The controller 700 executes the processes of the processing load estimating unit 7001, the processing load adjusting unit 7002, and the data acquiring unit 7003 in this order as a series of processes for each predetermined processing cycle. In this case, the acquired operational data (specifically, the operational data accumulated in the data storage unit 7004) is transmitted to the management device 2 collectively after the fact at a predetermined timing. The controller 700 may also execute the processes of the processing load estimating unit 7001, the processing load adjusting unit 7002, the data acquiring unit 7003, and the data transmitting unit 7005 in this order as a series of processes for each predetermined processing cycle. In this case, the acquired operational data is basically transmitted to the management device 2 in real time.

[0149] The processing load estimating unit 7001 (an example of an estimating unit) predicts the load state (hereinafter, "processing load") due to processing executed by the controller 700. The processing load of the controller 700 corresponds to the load state due to processing in the CPU 701 of the controller 700, for example, and may be expressed as a ratio (load rate) to the maximum value of the processing load of the controller 700 (CPU 701) (hereinafter, "maximum processing load"). Specifically, the processing load estimating unit 7001 may estimate the base processing load (hereinafter, "base processing load") of the controller 700 for each predetermined processing cycle.

[0150] The base processing load of the controller 700 means, for example, a portion of the processing load (total) of the controller 700 that does not include (excludes) a processing load for collecting operation data of the injection molding machine 1 (own machine) (hereinafter, "data collection processing load"). The processing for collecting operation data of the injection molding machine 1 (own machine) includes, for example, a processing by a data acquisition unit 7003 described later, i.e., a processing for acquiring operation data and recording it in a data storage unit 7004. In addition, when the respective processing by the data acquisition unit 7003 and the data transmission unit 7005 is performed as a series of processing, the processing for collecting operation data of the injection molding machine 1 may include, for example, a processing by the data transmission unit 7005, i.e., a processing for transmitting the operation data to the management device 2.

[0151] For example, the processing load estimation unit 7001 estimates the base processing load of the controller 700 based on information on the base processing load of the controller 700 for each of the multiple processes of the injection molding machine 1 and information on the current process of the injection molding machine 1. This is because the injection molding machine 1 repeatedly executes a molding cycle consisting of multiple processes, and the processing load of the controller 700 in the same process is usually considered to be at a similar level (within a certain range). As described above, the multiple processes of the injection molding machine 1 include a measuring process, a mold closing process, a mold clamping process, a filling process, a pressure holding process, a cooling process, a mold opening process, and an ejection process. The base processing load of the controller 700 for each of the multiple processes of the injection molding machine 1 may be determined in advance, for example, through an experiment using an actual machine equivalent to the injection molding machine 1 or a computer simulation related to the injection molding machine 1 (controller 700). The information may be stored, for example, in a predetermined storage area of ​​the auxiliary storage device 703 of the controller 700. The information on the current process of the injection molding machine 1 may be acquired, for example, based on control data related to sequence control for sequentially executing a plurality of processes of the injection molding machine 1. This allows the processing load estimation unit 7001 to estimate the base processing load of the controller 700 by referring to information on the base processing load corresponding to the current process among information on the base processing load of the controller 700 for each of the plurality of processes.

[0152] Also, for example, the processing load estimating unit 7001 predicts the base processing load of the controller 700 based on the tendency of time-dependent change in the base processing load of the controller 700 over a predetermined period of time in the most recent past.

[0153] Specifically, the processing load estimating unit 7001 may measure the base processing load of the controller 700 in a time series as background processing of the above-mentioned series of processes. The measurement period of the base processing load by the background processing may be set longer than the processing period of the above-mentioned series of processes. This makes it possible to make the load state of the controller 700 by the background processing (measurement process of the base processing load) relatively small (low). Then, the processing load estimating unit 7001 may predict the base processing load of the controller 700 by extrapolation based on the tendency of change in time series of measurement data for a predetermined time period most recently in the past during the above-mentioned series of processes.

[0154] Furthermore, for example, the processing load estimation unit 7001 may predict the base processing load of the controller 700 based on a measurement result of a pattern of periodic time change of the base processing load of the controller 700. The pattern of time change of the processing load of the controller 700 represents, for example, a pattern of time change of the base processing load of the controller 700 for each molding cycle time Tc (see FIG. 5).

[0155] Specifically, the processing load estimation unit 7001 may measure the processing load of the controller 700 in a time series and record the measurement data in the memory device 702 or the auxiliary storage device 703 in a manner that correlates it with the operating state of the injection molding machine 1 at that time. The operating state of the injection molding machine 1 includes the process of the injection molding machine 1 and the elapsed time from the start of the process. The measurement of the base processing load of the controller 700 is performed, for example, during an inspection operation in a final inspection process during the manufacture of the injection molding machine 1. In addition, the measurement of the base processing load of the controller 700 may be performed, for example, during normal operation between the start (power on) and the stop (power off) of the injection molding machine 1 as background processing of the above-mentioned series of processes. The measurement period of the base processing load by the background processing may be set to be longer than the processing period of the above-mentioned series of processes, as in the above-mentioned case. In this case, the measurement of the base processing load of the controller 700 may be performed, for example, constantly from the start to the stop of the injection molding machine 1, or may be selectively performed during a part of the period from the start to the stop of the injection molding machine 1. Then, the processing load estimation unit 7001 may perform machine learning of the time change of the processing load of the controller 700 based on the time change of the measurement data and the time change of the operating state of the injection molding machine 1, and obtain information on the pattern of the time change of the processing load of the controller 700. As a result, the processing load estimation unit 7001 can estimate the processing load of the controller 700 based on the pattern of the time change of the processing load of the controller 700 and the current operating state of the injection molding machine 1 during the above-mentioned series of processes. The current operating state of the injection molding machine 1 may be determined based on, for example, control data related to sequence control for sequentially executing a plurality of processes corresponding to the molding cycle of the injection molding machine 1.

[0156] The processing load adjusting unit 7002 (an example of an adjusting unit) adjusts the processing load for collecting operational data by the controller 700 (hereinafter, "data collection processing load") so that the processing load of the controller 700 does not exceed a predetermined allowable upper limit (tolerable upper limit) PL_lim. For example, as shown in Fig. 5, the processing load adjusting unit 7002 adjusts the data collection processing load of the controller 700 so that the data collection processing load falls within a range of the difference between the allowable upper limit PL_lim and the base processing load 501 of the controller 700 (the matte part in Fig. 5). The allowable upper limit PL_lim may be, for example, specified in advance, or may be set by the setting unit 22 of the management device 2 in response to a predetermined input (request) from the user.

[0157] For example, the processing load adjusting unit 7002 adjusts the number of pieces of operational data to actually be collected (acquired) out of all the operational data candidates for collection, thereby adjusting the data collection processing load of the controller 700. This is because the processing load (processing time) of the data acquiring unit 7003 and the processing load (processing time) of the data transmitting unit 7005 increase as the number of pieces of data to be collected increases.

[0158] The number of operational data that is actually collected (operational data to be collected) refers to the number of operational data that is collected (acquired) at the same timing (that is, within the same processing cycle).

[0159] The processing load adjusting unit 7002 determines the number of collectable operation data based on, for example, the base processing load estimated by the processing load estimating unit 7001 and the allowable upper limit PL_lim. Specifically, the processing load adjusting unit 7002 may determine the number of operation data that the controller 700 can collect at a processing load equivalent to the difference between the allowable upper limit PL_lim and the estimated value of the base processing load based on information on the relationship between the number of data to be collected and the data collection processing load. The relationship between the number of data to be collected and the data collection processing load is predefined, for example, through an experiment on an actual machine equivalent to the injection molding machine 1 or a computer simulation on the injection molding machine 1 (controller 700), and the information may be stored in the auxiliary storage device 703. The information on the relationship between the number of data to be collected and the data collection processing load may be, for example, table information indicating the data collection processing load for each number of data to be collected.

[0160] Then, the processing load adjusting unit 7002 selects the determined number of operation data from the operation data of the collection candidates. The operation data of the collection candidates may be all operation data output inside the injection molding machine 1 and obtainable by the controller 700, or may be a part of the operation data selected from all the operation data. In the latter case, the operation data of the collection candidates selected from all the operation data obtainable by the controller 700 is set, for example, by the setting unit 22 of the management device 2. The method of selecting the determined number of operation data from the operation data of the collection candidates may be arbitrary.

[0161] The processing load adjusting unit 7002 selects a determined number of historical data to be collected from among the historical data candidates for collection, based on, for example, list information of a predetermined selection order.

[0162] Further, the processing load adjusting unit 7002 selects a determined number of operation data to be collected from among the operation data of the collection candidates based on the priority of data collection, which is defined for each operation data of the collection candidates, for example. Specifically, the processing load adjusting unit 7002 may select operation data to be acquired in order from the operation data of the collection candidates with the highest priority. The priority of each operation data of the collection candidates may be defined in advance, or may be set by the setting unit 22 of the management device 2 in response to a predetermined input (request) from the user. For example, the priority of operation data whose contents (values) are updated relatively frequently according to the operating state of the injection molding machine 1, such as control data such as command values, detection data indicating an abnormality, driver operation data of the driver 710, and detection data of the sensor 720, may be set higher. On the other hand, the priority of operation data whose contents (values) are updated relatively less frequently, such as data related to the profile (waveform) of command values, which is unlikely to be changed during the operation of the injection molding machine 1 once set, may be set lower.

[0163] Also, for example, in the case where the processes of the data acquisition unit 7003 and the data transmission unit 7005 are assumed to be performed as a series of processes, the processing load adjustment unit 7002 may switch between holding or releasing the assumption in accordance with the base processing load of the controller 700. Specifically, the processing load adjustment unit 7002 may switch between a case where the process of the data transmission unit 7005 is performed as the series of processes described above, and a case where the process of the data transmission unit 7005 is separated from the series of processes and performed at a later timing than the series of processes. In this way, the processing load adjustment unit 7002 can adjust the data collection processing load of the controller 700 in accordance with the base processing load of the controller 700 so that the entire processing load of the controller 700 does not exceed the allowable upper limit PL_lim. For example, in the case where the base processing load of the controller 700 estimated by the processing load estimation unit 7001 exceeds a predetermined standard that is smaller than the allowable upper limit PL_lim, the processing load adjustment unit 7002 causes only the processing of the data acquisition unit 7003 to be performed. On the other hand, the processing load adjusting unit 7002 may cause both the data acquiring unit 7003 and the data transmitting unit 7005 to perform processing when the base processing load of the controller 700 predicted by the processing load estimating unit 7001 is equal to or less than the predetermined standard. Thereby, when the base processing load becomes relatively large, the controller 700 suspends the transmission of the operational data to suppress the data collection processing load, and as a result, the processing load of the controller 700 can be suppressed to the allowable upper limit PL_lim or less. Then, when the base processing load becomes relatively small, the controller 700 resumes the transmission of the operational data, and can transmit (add) the unsent operational data in addition to the latest operational data to the management device 2. The predetermined standard is variable, for example, according to the number of data to be collected. Specifically, the predetermined standard may be set smaller (lower) as the number of data to be collected increases. This is because the processing load (processing time) required for the data acquiring unit 7003 to acquire all the data to be collected increases as the number of data to be collected increases.

[0164] Also, for example, the processing load adjusting unit 7002 adjusts both the number of data to be collected and the processing of the data transmitting unit 7005 in accordance with the processing load of the controller 700 estimated by the processing load estimating unit 7001, thereby adjusting the data collection load of the controller 700. For example, the processing load adjusting unit 7002 adjusts the number of data to be collected within a range equal to or greater than a predetermined lower limit in accordance with the processing load of the controller 700 in a manner similar to that described above. Then, when the processing load adjusting unit 7002 cannot adjust the overall processing load of the controller 700 to be equal to or less than the allowable upper limit PL_lim even if the number of data to be collected is adjusted to the predetermined lower limit, the processing load adjusting unit 7002 may further separate the processing of the data transmitting unit 7005 from the series of processing described above. The predetermined lower limit of the number of data to be collected may be, for example, predetermined, or may be set by the setting unit 22 of the management device 2 in response to a predetermined input (request) from the user.

[0165] The processing load adjusting unit 7002 may adjust the data collection processing load of the controller 700 based on the measured value of the current base processing load of the controller 700 instead of using the prediction result of the processing load estimating unit 7001. In this case, the processing load estimating unit 7001 is omitted. The controller 700 may also urge the user to manually adjust the data collection processing load instead of automatically adjusting the data collection processing load so that the processing load does not exceed the allowable upper limit PL_lim. For example, the controller 700 may estimate the processing load of the controller 700 for each of the multiple processes of the injection molding machine 1 when the operation data to be acquired that is to be set in the management device 2 is adopted, and present the relationship with the allowable upper limit PL_lim to the user through the management device 2. For example, the controller 700 may also present to the user through the management device 2 the number (range) of operation data that can be acquired within a range in which the processing load of the controller 700 does not exceed the allowable upper limit PL_lim, specific names of the operation data, and the like, for each of the multiple processes of the injection molding machine 1. This allows the user to use the functions of the setting unit 22 described below to set the operational data to be acquired for each of the multiple processes in the management device 2, and manually adjust the data collection processing load in accordance with changes in the processing load for each of the multiple processes.

[0166] The data acquisition unit 7003 (an example of an acquisition unit) acquires the operational data of the acquisition target and records it in the data storage unit 7004. For example, when the processing load adjustment unit 7002 adjusts the number of operational data of the acquisition target, the data acquisition unit 7003 acquires the operational data of the acquisition target selected by the processing load adjustment unit 7002. For example, when the operational data of the acquisition target is input from the outside to the controller 700, such as the output of the driver 710 or the output of the sensor 720, the data acquisition unit 7003 acquires the latest operational data already received by the interface device 704 from the reception buffer. Also, when the operational data of the acquisition target is output inside the controller 700, such as control data, the data acquisition unit 7003 acquires the latest operational data from the memory device 702 or the like.

[0167] The data storage unit 7004 (an example of a storage unit) historically stores the operational data acquired by the data acquisition unit 7003. The operational data in the data storage unit 7004 may be continuously held even after it is transmitted to the management device 2 by the data transmission unit 7005, or may be deleted after it is transmitted to the management device 2 by the data transmission unit 7005.

[0168] The data transmission unit 7005 (an example of a transmission unit) transmits the operational data stored in the data storage unit 7004 to the management device 2. For example, the data transmission unit 7005 transmits the operational data to the management device 2 in real time as a series of processes starting from the acquisition of the operational data by the data acquisition unit 7003. Also, for example, the data transmission unit 7005 may collectively transmit the operational data acquired by the data acquisition unit 7003 and accumulated in the data storage unit 7004 to the management device 2 after the fact.

[0169] <Functional configuration of management device> 4, the management device 2 includes, as functional units, a setting screen display processing unit 21, a setting unit 22, a data acquisition unit 23, a data storage unit 24, and a data display processing unit 25. The functions of the setting screen display processing unit 21, the setting unit 22, the data acquisition unit 23, and the data display processing unit 25 are realized, for example, by loading a program installed in the auxiliary storage device 2B into the memory device 2C and executing the program by the CPU 2D. Also, the function of the data storage unit 24 is realized, for example, by a storage area defined in the auxiliary storage device 2B or the like.

[0170] The setting screen display processing unit 21 displays a setting screen (hereinafter, “data collection setting screen”) that supports various settings related to the collection of operational data in the controller 700 on the display device 2H in response to a predetermined input received through the input device 2G.

[0171] The setting unit 22 performs settings related to data collection in the controller 700 in response to a predetermined input on a data collection setting screen received through the input device 2G. This allows the user to cause the management device 2 to perform settings related to data collection in the injection molding machine 1 (controller 700) through the input device 2G. Specifically, the setting unit 22 may perform settings related to data collection in the controller 700 and transmit a command signal including the settings. This allows the management device 2 to reflect the settings specified by the command signal in the processing related to data collection in the controller 700.

[0172] For example, as described above, the setting unit 22 sets the allowable upper limit PL_lim in response to a predetermined input on the data collection setting screen that is received via the input device 2G.

[0173] Also, for example, the setting unit 22 sets the priority of each piece of operational data that is a collection candidate in response to a predetermined input on the data collection setting screen that is received via the input device 2G, as described above.

[0174] Also, for example, the setting unit 22 sets the operational data to be collected in response to a predetermined input on the data collection setting screen that is received via the input device 2G, as described above.

[0175] Also, for example, the setting unit 22 sets a predetermined lower limit for the number of data to be collected in response to a predetermined input on the data collection setting screen received via the input device 2G, as described above.

[0176] The functions of the setting screen display processing unit 21 and the setting unit 22 may be added or transferred to the injection molding machine 1 (for example, the controller 700). This allows the user to perform various inputs on the data collection setting screen displayed on the display device 760 through the input device 750 (one example of the first input unit, the second input unit, and the third input unit) of the injection molding machine 1. Then, the user can cause the setting unit (one example of the first setting unit to the third setting unit) of the injection molding machine 1 to perform settings related to data collection of the controller 700 through the data collection setting screen of the display device 760. Similarly, the functions of the setting screen display processing unit 21 and the setting unit 22 may be added or transferred to the user terminal 3. This allows the user to perform various inputs on the data collection setting screen displayed on the display device of the user terminal 3 through the input device of the user terminal 3, and cause the setting unit of the user terminal 3 to perform settings related to data collection of the controller 700.

[0177] The data acquiring unit 23 acquires the operation data that has been transmitted from the injection molding machine 1 (data transmitting unit 7005) and received by the communication interface 2F from a receiving buffer or the like, and registers it in the data storage unit 24.

[0178] The data storage unit 24 historically stores the operation data of the injection molding machine 1 acquired by the data acquisition unit 23. For example, a record group (a database of operation data) consisting of records for each acquisition timing of the operation data of the injection molding machine 1 is constructed in the data storage unit 24. Also, for example, when the injection molding machine system SYS includes multiple injection molding machines 1, a database of operation data for each of the multiple injection molding machines 1 is constructed in the data storage unit 24.

[0179] The data display processing unit 25 causes the display device 2H to display the operation data in the data storage unit 24 in response to a predetermined input from the user received by the input device 2G. The operation data may be displayed, for example, in a chronological list format or in a chronological graph format. In addition, in a mode in which the operation data is transmitted to the management device 2 in real time, the display of the operation data on the display device 2H is updated successively every time new operation data is registered in the data storage unit 24. This allows the user to monitor the operation status of the injection molding machine 1 in real time.

[0180] The function of the data display processing unit 25 may be added or transferred to the injection molding machine 1 (for example, the controller 700). In this case, the operation data is accumulated in the data storage unit 7004, and a database of the operation data may be constructed, for example, as in the case of the data storage unit 24 described above. This allows the user to check the operation data through the display device 760 of the injection molding machine 1. The function of the data display processing unit 25 may be added or transferred to the user terminal 3. In this case, for example, the user terminal 3 transmits a request signal for displaying the operation data in response to a predetermined input from the user received through its input device. This allows the user terminal to receive data for the display screen of the operation data from the management device 2, and to display the display screen on its display device, allowing the user to check the operation data through the user terminal 3.

[0181] [Example of time-dependent changes in the controller's base processing load] Next, a specific example of a change over time in the base processing load of the controller 700 will be described with reference to FIG.

[0182] Fig. 6 is a diagram showing an example of the change over time of the base processing load of the controller 700. Specifically, Fig. 6 shows a specific example of the change over time of the base processing load of the controller 700 in one molding cycle starting from the start of the mold closing process of the injection molding machine 1 and ending at the end of the ejection process.

[0183] In this embodiment, the mold closing step and the mold clamping step are described as a series of steps. Also, in this embodiment, a measuring step for the molding material to be used in the next molding cycle is carried out during the cooling step.

[0184] As shown in FIG. 6, at time t0, the mold closing process starts.

[0185] When the mold closing process is started, the base processing load of the controller 700 increases suddenly (in a pulse-like manner) from a very low level in response to the start of control of the mold closing operation and the mold clamping operation of the mold clamping apparatus 100 (see arrow A1 in the figure). Thereafter, during a series of operations of the mold closing operation and the mold clamping operation of the mold clamping apparatus 100 from the mold closing process to the mold clamping process, the base processing load of the controller 700 changes at a predetermined level lower than the pulse-like maximum value at the start of control, with some fluctuation. Then, when the mold clamping operation of the mold clamping apparatus 100 is completed, the mold clamping process ends at time t1, and the process moves to the filling process. At this time, the base processing load of the controller 700 temporarily drops to a very low level.

[0186] When the filling process is started, the base processing load of the controller 700 increases suddenly (in a pulse-like manner) from a very low level in response to the start of control of the filling operation of the injection unit 300 and the moving unit 400 (see arrow A2 in the figure). The maximum value of the base processing load of the controller 700 at this time corresponds to the maximum value of the base processing load of the controller 700 in the entire molding cycle. Thereafter, during the filling process, the base processing load of the controller 700, while fluctuating to a certain extent, remains at a predetermined level lower than the pulse-like maximum value at the start of control. Then, when the filling operation of the injection unit 300 and the moving unit 400 is completed, the filling process ends at time t2 and the process proceeds to the pressure holding process.

[0187] When the pressure holding process is started, in response to the start of control of the pressure holding operation of the injection unit 300, the base processing load of the controller 700 increases suddenly (in a pulse-like manner) from the level at the end of the filling process (see arrow A3 in the figure). Thereafter, in the pressure holding process, the base processing load of the controller 700 remains at the same level as in the filling process, with some fluctuation. Then, when the pressure holding operation is completed at time t3, the pressure holding process ends and the process moves to the cooling process and the measuring process. At this time, the base processing load of the controller 700 temporarily drops to a very low level.

[0188] When the metering process is started, the base processing load of the controller 700 increases suddenly (in a pulse-like manner) from a very low level in response to the start of control of the metering operation of the injection unit 300 (see arrow A4 in the figure). Thereafter, in the metering process, the base processing load of the controller 700, while fluctuating to some extent, remains at a predetermined level lower than the pulse-like maximum value at the start of control. Then, when the metering operation of the injection unit 300 is completed, the pressure holding process ends at time t4.

[0189] The cooling process continues even after the pressure dwell process is completed. During the cooling process, since the actuators of the injection molding machine 1 are not operating, the base processing load of the controller 700 remains at a very low level with some fluctuation. Then, at time t5, the cooling process ends and the mold opening process begins.

[0190] When the mold opening process is started, the base processing load of the controller 700 increases suddenly (in a pulse-like manner) from a very low level in response to the start of control of the mold opening operation of the mold clamping unit 100 (see arrow A5 in the figure). After that, the base processing load of the controller 700 decreases to a predetermined level lower than the pulse-like maximum value at the start of control. Then, when the mold opening operation is completed, at time t6, the mold opening process ends and the ejection process begins. At this time, the base processing load of the controller 700 decreases to a very low level once.

[0191] When the ejection process is started, the base processing load of the controller 700 increases suddenly (in a pulse-like manner) from a very low level in response to the start of control of the ejection operation of the ejector unit 200 (see arrow A6 in the figure). After that, the base processing load of the controller 700 decreases to a predetermined level that is lower than the pulse-like maximum value at the start of control. Then, when the ejection operation is completed, the base processing load of the controller 700 decreases once to a very low level.

[0192] When the ejection operation is completed, the ejector unit 200 transitions to an operation of returning to the standby state. In response to the start of control for the operation of returning the ejector unit 200 to the standby state, the base processing load of the controller 700 increases suddenly (in a pulse-like manner) from a very low level (see arrow A7 in the figure). Thereafter, the base processing load of the controller 700 decreases to a predetermined level lower than the pulse-like maximum value at the start of control. Then, when the operation of returning to the standby state of the ejector unit 200 is completed, the ejection process ends and the molding cycle is completed. At this time, the base processing load of the controller 700 decreases to a very low level.

[0193] For example, the processing load adjusting unit 7002 may adjust the data collection processing load of the controller 700 in a time series manner so that the data collection processing load falls within the range of the difference between the allowable upper limit PL_lim and the base processing load of the controller 700 (the matte patterned area in Figure 6).

[0194] Furthermore, for example, the processing load estimating unit 7001 may predict the base processing load of the controller 700 based on a pattern (measurement result) of a time change in the base processing load of the controller 700 as in this example (FIG. 6).

[0195] [Data collection setting screen] Next, a specific example of the data collection setting screen will be described with reference to FIGS.

[0196] 7 and 8 are diagrams showing an example (data collection setting screen 70) and another example (data collection setting screen 80) of a data collection setting screen displayed on the display device 2H. Specifically, Fig. 7 is a specific example of a data collection setting screen for setting operational data to be acquired and its priority, and Fig. 8 is a specific example of a data collection setting screen for setting the allowable upper limit PL_lim.

[0197] The display contents of the data collection setting screen 70 in FIG. 7 and the display contents of the data collection setting screen 80 in FIG. 8 may be simultaneously displayed as one data collection setting screen. For example, the data collection setting screen may be divided into two display areas vertically or horizontally, and the display contents of the data collection setting screen 70 and the display contents of the data collection setting screen 80 may be displayed in each display area. In this case, at least one of the two display areas may be scrollable so that all display contents can be displayed as necessary. This allows the user to set operational data as candidates for acquisition, set the priority of each operational data as candidates for acquisition, and set the allowable upper limit PL_lim through one data collection setting screen.

[0198] <Setting the operational data to be acquired and its priority> As shown in Figure 7, in this example, each operational data that can be set as an acquisition candidate is classified into relatively large categories (hereinafter, "major categories") and relatively small categories (hereinafter, "minor categories") included in the major categories, and is displayed hierarchically linked to the major categories and minor categories.

[0199] In this example, major categories such as "command log", "diagnosis data", "clamping device", "ejector device", "moving device", and "injection device" are predefined. "Command log" is a major category corresponding to data related to a log of command exchange between a control device (e.g., controller 700) and a controlled device (e.g., driver 710 and sensor 720). "Diagnostic data" is a major category corresponding to data related to the results of self-diagnosis during operation of various devices such as the controller 700, driver 710, and sensor 720. "Clamping device" is a major category corresponding to operation data related to the clamping device 100. "Ejector device" is a major category corresponding to operation data related to the ejector device 200. "Moving device" is a major category corresponding to operation data related to the moving device 400. "Injection device" is a major category corresponding to operation data related to the injection device 300.

[0200] Within the broad category of "injection device", subcategories such as "injection motor", "metering motor", and "holding pressure" are predefined.

[0201] The "injection motor" is a subcategory corresponding to operation data related to the injection motor 350. As shown in FIG. 6, the subcategory of "injection motor" includes, as settable operation data, position command value data, position actual value data, speed command value data, speed actual value data, current command value data, and current actual value data. The subcategory of "injection motor" may also include, as settable operation data, voltage actual value data and PWM (Pulse Width Modulation) command value data. The position command value data and the speed command value data are data representing command values ​​related to the rotational position (rotational angle) and rotational speed of the injection motor 350, respectively, and may be output from the controller 700. The position actual value data and the speed actual value data are data representing actual values ​​(detected values) of the rotational position and rotational speed of the injection motor 350, respectively, and may be output from a sensor 720 (injection motor encoder 351) that detects the position and speed of the injection motor 350. The current command value data is data representing a command value related to the current of the injection motor 350, and may be output from the controller 700. The current actual value data is data representing an actual value (detected value) of the current of the injection motor 350, and may be output from the sensor 720 that detects the current of the injection motor 350. The voltage actual value data is data representing an actual value (detected value) of the voltage of the injection motor 350, and may be output from the sensor 720 that detects the applied voltage of the injection motor 350. The PWM command value data is data representing a command value for driving a switching element included in the driver 710, and may be output from the driver 710.

[0202] "Metering motor" is a subcategory corresponding to operation data related to the metering motor 340. The subcategory of "metering motor" may include, for example, position command value data, actual position value data, speed command value data, actual speed value data, current command value data, actual current value data, actual voltage value data, PWM command value data, and the like related to the metering motor 340.

[0203] "Holding pressure" is a subcategory related to the pressure (holding pressure) of the molding material at the front end of the screw 330. The subcategory of "holding pressure" may include, for example, command value data related to the holding pressure and actual value data related to the holding pressure.

[0204] On the data collection setting screen 70, the user can use the input device 2G to operate the icon (a square containing a "+" or "-" symbol) adjacent to the left of the text information representing the major category. This allows the user to expand and display the hierarchical levels (subcategories) below the major category, or collapse and hide them. In this example, only the major category of "ejection device" is expanded, and its subordinate subcategories are displayed.

[0205] Similarly, on the data collection setting screen 70, the user can use the input device 2G to operate an icon adjacent to the left of the character information representing the expanded small category. This allows the user to expand and display the lower hierarchical levels of the small category (operational data included in the small category) or collapse and hide them.

[0206] In the data collection setting screen 70, a check box 61 is arranged adjacent to the right of the expanded operational data. In the data collection setting screen 70, the user can use the input device 2G to operate the check box 71 adjacent to the right of the expanded operational data to input or delete a check mark. This allows the user to input a check mark in the check box 71 for each of one or more pieces of operational data included in the expanded small classification, and set (add) the data as an acquisition candidate operational data. In addition, the user can delete the check mark in the check box 71 for each of one or more pieces of operational data included in the expanded small classification, and exclude the data from the acquisition candidate operational data. In addition, the user can understand which type of operational data is set as an acquisition candidate operational data by checking the contents of the check box 71 for each of one or more pieces of operational data included in the expanded small classification.

[0207] In this example, the check boxes 61 corresponding to the position command data, actual position value data, speed command value data, actual speed value data, current command value, and actual current value included in the subcategory of “injection motor” are checked, and the data are set as candidate operating data to be acquired.

[0208] Furthermore, on the data collection setting screen 70, adjacent to the further right of the check box 61 to the right of the expanded operational data, radio buttons 72 representing three options for the priority of the operational data of the acquisition candidate ("high", "medium", "low") are arranged. The priority of the operational data increases in the order of "low", "medium", and "high". On the data collection setting screen 70, the user can set the priority of the operational data for which a check mark has been entered in the check box by selecting any one of the three radio buttons 72 using the input device 2G. Furthermore, the user can grasp the setting contents of the priority for each of the operational data of the acquisition candidate by checking the selection contents of the radio button 72 for one or more pieces of operational data included in the expanded minor classification.

[0209] In this example, the “High” radio button is selected for the position command data, actual position value data, speed command value data, and actual speed value data included in the “injection motor” subcategory, and the “Medium” radio button is selected for the current command value and actual current value.

[0210] In this example, the priority is set in three stages, but the priority may be set in more than three stages or in a manner that allows for continuous change by inputting a numerical value or sliding an input on a bar graph, etc.

[0211] <Setting the maximum allowable processing load for the controller> 8, in this example, a time-series graph 81 simulating the time change of the base processing load of the controller 700 is displayed, and an input box 82 and an icon 83 representing the allowable upper limit are arranged on the vertical axis representing the processing load of the graph 81. This allows the user to check the setting status of the allowable upper limit PL_lim from the value in the input box 82 and the vertical position of the icon 83.

[0212] The positions of the input box 82 and the icon 83 move up and down depending on the value set as the allowable upper limit PL_lim. Specifically, when a value larger than the current value is set as the allowable upper limit PL_lim, the positions of the input box 82 and the icon 83 move up, and when a value smaller than the current value is set as the allowable upper limit PL_lim, they move down.

[0213] For example, the user can use the input device 2G to input a percentage value that the user wants to set as the allowable upper limit PL_lim in the input box 82, thereby causing the management device 2 to set the allowable upper limit PL_lim. Also, for example, the user may be able to use the input device 2G to move the icon 83 up and down, thereby causing the management device 2 to set the allowable upper limit PL_lim.

[0214] [Effect] Next, the operation of the injection molding machine system SYS according to this embodiment will be described.

[0215] In this embodiment, the injection molding machine 1 includes a clamping device 100, an injection device 300, an ejector device 200, and a controller 700. Specifically, the clamping device 100 clamps the mold device 10. The injection device 300 fills the mold device 10 clamped by the clamping device 100 with molding material. The ejector device 200 removes the molded product from the mold device 10 after the molding material filled by the injection device 300 is cooled and solidified. The controller 700 also includes a data acquisition unit 7003 and a processing load adjustment unit 7002. The data acquisition unit 7003 also acquires operation data of the injection molding machine 1 outputted inside the injection molding machine 1 and records it in a data storage unit 7004. The processing load adjustment unit 7002 adjusts the number of operation data acquired by the data acquisition unit 7003 according to the processing load of the controller 700.

[0216] Thus, the controller 700 can automatically adjust the data collection processing load by automatically adjusting the number of operation data to be collected in accordance with the processing load of the controller 700. Therefore, the controller 700 can collect only operation data with a relatively high collection priority when there is no room for the processing load, and can also collect data with a relatively low collection priority when there is room for the processing load. Therefore, the injection molding machine system SYS can improve the user's convenience when collecting data output by the injection molding machine 1 within the allowable range of the processing load of the controller 700.

[0217] Furthermore, in this embodiment, the processing load adjusting unit 7002 may adjust the amount of operational data acquired by the data acquiring unit 7003 so that the processing load of the controller 700 does not exceed the allowable upper limit PL_lim.

[0218] As a result, the injection molding machine system SYS can automatically adjust the data collection processing load of the controller 700 by adjusting the number of operational data to be collected, thereby preventing the processing load of the controller 700 from exceeding the allowable upper limit PL_lim.

[0219] Furthermore, in this embodiment, the management device 2 may include a setting unit 22. Specifically, the setting unit 22 may set the allowable upper limit PL_lim in response to a predetermined input received by the input device 2G.

[0220] This allows the injection molding machine system SYS to have the user determine the allowable upper limit PL_lim.

[0221] In addition, in this embodiment, the processing load adjustment unit 7002 may adjust the number of operational data items acquired by the data acquisition unit 7003 in accordance with the processing load of the controller 700, so that data acquired by the data acquisition unit 7003 is prioritized from among the operational data items that are candidates for acquisition, starting with data with a relatively high priority defined for each operational data item.

[0222] This allows the injection molding machine system SYS to specifically adjust the number of data to be acquired in accordance with the processing load of the controller 700, and also allows the injection molding machine system SYS to collect data with a relatively high acquisition priority even in a situation where the processing load is tight.

[0223] In the present embodiment, the management device 2 may include a setting unit 22. Specifically, the setting unit 22 may set a priority for each of the data items to be acquired in response to a predetermined input received by the input device 2G.

[0224] This allows the injection molding machine system SYS to have the user determine the acquisition priority for each of the acquisition candidate data.

[0225] In the present embodiment, the management device 2 may include a setting unit 22. Specifically, the setting unit 22 may set candidate operational data to be acquired by the data acquiring unit 7003 from among a plurality of operational data in response to a predetermined input received by the input device 2G. Then, the processing load adjusting unit 7002 may adjust the number of operational data to be acquired by the data acquiring unit 7003 within the range of the candidate operational data to be acquired set by the setting unit 22.

[0226] This allows the injection molding machine system SYS to have the user determine the operation data to be acquired.

[0227] Furthermore, in this embodiment, the controller 700 may have a processing load estimating unit 7001. Specifically, the processing load estimating unit 7001 may estimate a processing load of the controller 700. Then, the processing load adjusting unit 7002 may adjust the number of operational data acquired by the data acquiring unit 7003 based on a result of estimation by the processing load estimating unit 7001.

[0228] As a result, the injection molding machine system SYS can adjust the number of operation data items in accordance with the processing load of the controller 700 by utilizing the estimated result of the processing load of the controller 700.

[0229] Furthermore, in this embodiment, the processing load estimating unit 7001 may measure the processing load of the controller 700, and estimate the state of the processing load of the controller 700 based on the measurement results in time series.

[0230] This allows the injection molding machine system SYS (controller 700) to estimate the processing load from the time-series measurement results of the controller 700 processing load by, for example, finding trends and patterns in the time-varying changes in the processing load.

[0231] In addition, in this embodiment, the processing load estimation unit 7001 may learn the pattern of time-dependent changes in the processing load of the controller 700 based on the measurement results in a time series, and estimate the state of the processing load of the controller 700 based on the pattern of the learned results.

[0232] This allows the injection molding machine system SYS (controller 700) to specifically estimate the processing load of the controller 700.

[0233] In addition, in this embodiment, the processing load estimation unit 7001 may estimate the processing load state of the controller 700 based on information regarding the operation pattern of the injection molding machine 1, which is composed of multiple processes, and information regarding the current process among the multiple processes.

[0234] This allows the injection molding machine system SYS (controller 700) to estimate the processing load of the controller 700 in the current process, for example, by using information based on experimental or simulation results regarding the processing load for each of the multiple processes of the injection molding machine 1.

[0235] Furthermore, in this embodiment, the controller 700 may include a data transmission unit 7005. Specifically, the data transmission unit 7005 may transmit data acquired by the data acquisition unit 7003 and recorded in the data storage unit 7004 to the management device 2 as a series of processes following the process by the data acquisition unit 7003. Then, the processing load adjustment unit 7002 may adjust, in accordance with the processing load of the controller 700, whether to cause the data transmission unit 7005 to transmit the operational data as a series of processes or to cause the data transmission unit 7005 to transmit the operational data at a later timing than when the transmission is performed as a series of processes after the acquisition of the operational data by the data acquisition unit 7003.

[0236] As a result, under the premise that the operation data is transmitted to the management device 2 in real time in conjunction with the acquisition of the operation data, in a situation where there is no room for processing load, the controller 700 can, as an exception, delay the transmission of the operation data until there is room for processing load. Therefore, the injection molding machine system SYS (controller 700) can further increase the degree of freedom in adjusting the data collection processing load, and can, for example, maintain the number of operation data to be acquired at or above a certain level. Therefore, the injection molding machine system SYS can more appropriately adjust the data collection processing load.

[0237] [Transformation / Change] Although the embodiments have been described above, the present disclosure is not limited to the above-mentioned embodiments, and various modifications and changes are possible within the scope of the gist described in the claims.

[0238] For example, in the above-described embodiment, a method for collecting data related to the injection molding machine 1 has been described, but a similar method may be applied to other industrial machines. Examples of other industrial machines include stationary machines installed in a factory, such as machine tools and production robots. Examples of other industrial machines include mobile work machines. Examples of mobile work machines include construction machines such as shovels and bulldozers, agricultural machines such as combine harvesters, and transport machines such as mobile cranes and forklifts. [Explanation of symbols]

[0239] 1. Injection molding machine (industrial machinery) 2 Management device (external device) 2A External Interface 2B Auxiliary storage 2C memory device 2D CPU 2E High-speed calculation unit 2F Communication Interface 2G Input Device 2H display device 3. User terminal 21 Setting screen display processing unit 22 Setting section 23 Data Acquisition Section 24 Data storage unit 25 Data display processing section 100 Mold clamping device 200 Ejector device 300 Injection device 400 Mobile Device 700 Controller 701 CPU 702 Memory device 703 Auxiliary storage 704 Interface Device 710 Driver 720 Sensors 750 Input device (first input unit, second input unit, third input unit) 760 Display device 7001 Processing load estimation unit (estimation unit) 7002 Processing load adjustment unit (adjustment unit) 7003 Data Acquisition Department (Acquisition Department) 7004 Data storage unit (storage unit) 7005 Data transmission unit (transmission unit) SYS Injection molding machine system

Claims

1. a mold clamping device that clamps the mold device; an injection unit that fills the mold unit clamped by the mold clamping unit with a molding material; an ejector device that removes a molded product from the mold device after the molding material filled by the injection device is cooled and solidified; A control device including an acquisition unit that acquires data related to the injection molding machine outputted from inside the injection molding machine and records the data in a storage unit, and an adjustment unit that adjusts the number of the data acquired by the acquisition unit according to a load state of the processing of the control device. Injection molding machine.

2. The adjustment unit adjusts the number of pieces of data acquired by the acquisition unit so that the load state of the processing of the control device does not exceed a predetermined upper limit.

2. The injection molding machine according to claim 1.

3. a first input unit that accepts an input from a user; a first setting unit that sets the predetermined upper limit in response to a predetermined input received by the first input unit, 3. The injection molding machine according to claim 2.

4. The adjustment unit adjusts the number of pieces of data acquired by the acquisition unit in accordance with a load state of processing of the control device so that data having a relatively high priority defined for each piece of data is preferentially included in the data acquired by the acquisition unit.

4. An injection molding machine according to claim 1.

5. a second input unit that accepts an input from a user; a second setting unit that sets the priority for each of the data items in response to a predetermined input received by the second input unit; 5. The injection molding machine according to claim 4.

6. a third input unit that accepts an input from a user; a third setting unit that sets the candidate data to be acquired by the acquisition unit from among the plurality of data in response to a predetermined input received by the third input unit, The adjustment unit adjusts the number of the data items acquired by the acquisition unit within the range of the data items of the candidates set by the third setting unit.

6. The injection molding machine according to claim 4 or 5.

7. The control device has an estimation unit that estimates a load state of a process of the control device, The adjustment unit adjusts the number of pieces of data acquired by the acquisition unit based on the estimation result of the estimation unit.

7. An injection molding machine according to any one of claims 1 to 6.

8. The estimation unit measures a processing load state of the control device and estimates a processing load state of the control device based on a time-series measurement result.

8. The injection molding machine according to claim 7.

9. The estimation unit learns a pattern of time change of a processing load state of the control device based on the time-series measurement results, and estimates a processing load state of the control device based on the learned pattern.

9. The injection molding machine according to claim 8.

10. the estimation unit estimates a state of a processing load of the control device based on information about an operation pattern of the injection molding machine that is configured with a plurality of processes and information about a current process among the plurality of processes; 8. The injection molding machine according to claim 7.

11. the control device includes a transmission unit that transmits the data acquired by the acquisition unit and recorded in the storage unit to an external device as a series of processes starting from the process by the acquisition unit; The adjustment unit adjusts whether to cause the transmission unit to transmit the data as part of the series of processes or to cause the transmission unit to transmit the data at a later timing than when the transmission is performed as part of the series of processes after the acquisition unit acquires the data, in accordance with a load state of the processing of the control device.

11. An injection molding machine according to any one of claims 1 to 10.

12. an acquisition unit that acquires data related to an operating state of the industrial machine outputted from inside the industrial machine and records the data in a storage unit; and an adjustment unit that adjusts the number of pieces of data acquired by the acquisition unit in accordance with a load state of processing of a controller. Industrial machinery controller.

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