Injection molding machine, controller

Abstract

Provided is a technique for making it possible to effectively utilize the capabilities of a predetermined machine during normal time, while preventing a situation in which the operation of the machine fails at the time of abnormality. A controller 700 according to an embodiment of the present disclosure is provided with: a request transmission unit 7103 which transmits a data transmission request for having a data output unit 800 transmit data in a control period; and a data reception unit 7104 which receives, in accordance with the data transmission request, the data transmitted from the data output unit 800. The data that can be transmitted from the data output unit 800 include a plurality of types of data having different data amounts. The request transmission unit 7103 varies the timing of transmitting the data transmission request in the control period depending on the type of data among the plurality of types of data that is demanded by the data transmission request.

Description

[Technical field]

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

[0002] For example, industrial machines such as injection molding machines are known (see Patent Document 1, etc.).

[0003] In such a machine, the machine is controlled according to preset conditions. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2017-105136 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, if conditions that require a relatively high performance from the machine are set, it becomes difficult for the machine to perform operations that correspond to the required performance in the event of an abnormality, and there is a possibility that the operation will fail.On the other hand, if conditions that correspond to the performance that the machine can achieve with a margin are set in advance, assuming an abnormality, the machine will only perform operations that correspond to performance that is lower than the performance that the machine can actually achieve in normal times, and there is a possibility that the machine's original performance cannot be effectively utilized.

[0006] In view of the above problems, an object of the present invention is to provide a technology that can effectively utilize the performance of a given machine under normal circumstances while preventing the machine from failing to operate under abnormal conditions. [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 that controls the injection molding machine; Equipped with An abnormality in the control device, an abnormality in a data output unit that transmits data to the control device, or an abnormality in communication between the control device and the data output unit If no abnormality is detected, a predetermined operation corresponding to relatively high performance is performed. The above When an abnormality occurs, the predetermined operation corresponding to a relatively low performance within a range in which the predetermined operation does not fail is performed, thereby A series of steps to obtain Continue operation, An injection molding machine is provided.

[0008] In another embodiment of the present disclosure, On the designated machine A controller for performing control related to the above, An abnormality in the controller, an abnormality in the data output unit that transmits data to the controller, or an abnormality in communication between the controller and the data output unit If no abnormality is occurring, the predetermined machine is caused to perform a predetermined operation corresponding to a relatively high performance; The above When an abnormality occurs, the predetermined machine is made to perform the predetermined operation corresponding to a relatively low performance within a range in which the predetermined operation does not fail, thereby machine of A series of Continue the operation, A controller is provided. Effect of the Invention

[0009] According to the above-described embodiment, in a given machine, it is possible to effectively utilize the performance of the machine under normal circumstances while preventing the machine from failing to operate under abnormal circumstances. [Brief description of the drawings]

[0010] [Figure 1A] FIG. 1 is a diagram illustrating an example of a configuration of an injection molding machine management system including an injection molding machine. [Figure 1B] FIG. 1 is a diagram illustrating an example of a configuration of an injection molding machine management system including an injection molding machine. [Diagram 2] FIG. 2 is a diagram illustrating an example of a configuration for collecting data from an injection molding machine. [Figure 3A] FIG. 2 is a diagram illustrating an example of a communication frame having a relatively short data length. [Figure 3B] FIG. 2 is a diagram illustrating an example of a communication frame having a relatively long data length. [Figure 4] 10 is a flowchart illustrating an example of a request timing setting process performed by a controller. [Diagram 5] 10 is a flowchart illustrating an example of a data acquisition process performed by a controller. [Figure 6A] 4 is a timing chart showing an example of the operation of a controller and a data output unit (encoder) according to the present embodiment in a normal state. [Figure 6B] 10 is a timing chart showing an example of the operation of the controller and the data output unit (encoder) according to the present embodiment when an abnormality occurs in the data output unit (encoder). [Figure 7A] 10 is a timing chart showing an example of the operation of a controller and a data output unit according to a first comparative example when an abnormality occurs. [Figure 7B] 10 is a timing chart showing an example of the operation of a controller and a data output unit according to a second comparative example during normal operation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0012] [Injection molding machine management system configuration] First, with reference to FIG. 1 (FIGS. 1A and 1B), the configuration of an injection molding machine management system (hereinafter simply referred to as the "management system") SYS according to this embodiment will be described.

[0013] Fig. 1 is a diagram showing an example of an injection molding machine management system according to this embodiment. Specifically, Fig. 1A shows a side cross-sectional view showing a state of the injection molding machine 1 when mold opening is completed, and Fig. 1B shows a side cross-sectional view showing a state of the injection molding machine 1 when mold clamping is performed. Hereinafter, in the drawings of this embodiment, 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 the horizontal direction, and the positive and negative directions of the Z-axis (hereinafter simply "Z direction") represent the vertical direction.

[0014] The management system SYS includes a plurality of injection molding machines 1 (three in this example) and a management device 2.

[0015] The management system SYS may include only one injection molding machine 1.

[0016] <Injection molding machine> The injection molding machine 1 performs a series of operations to obtain a molded product.

[0017] The injection molding machine 1 is communicably connected to a management device 2 through a predetermined communication line NW, and transmits (uploads) data on the operating status of the injection molding machine 1 (hereinafter, "operating status data") to the management device 2 (an example of a predetermined external device). 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. The communication line NW may include, for example, a mobile communication network with a base station as a terminal. The communication line NW may also include, for example, a satellite communication network using a communication satellite. The communication line NW may also include, for example, an Internet network. The communication line NW may also include, for example, a LAN (Local Area Network) in a factory where the injection molding machine 1 is installed. The communication line NW may also be, for example, a short-distance communication line compatible with Bluetooth (registered trademark) communication, WiFi communication, etc.

[0018] The injection molding machine 1 (an example of a predetermined machine) includes a clamping device 100, an ejector device 200, an injection device 300, a moving device 400, and a controller 700.

[0019] <<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 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, and a mold thickness adjustment mechanism 180.

[0020] In the following description of the mold clamping device 100, the movement direction of the movable platen 120 when the mold is closed (to the right in Figures 1A and 1B) is defined as the front, and the movement direction of the movable platen 120 when the mold is opened (to the left in Figures 1A and 1B) is defined as the rear.

[0021] The stationary platen 110 is fixed to the frame Fr. The stationary mold 11 is attached to the surface of the stationary platen 110 that faces the movable platen 120.

[0022] 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. The movable mold 12 is attached to the surface of the movable platen 120 facing the fixed platen 110.

[0023] The movable platen 120 is advanced or retreated relative to the fixed platen 110 to perform mold closing, mold clamping, and mold opening.

[0024] The mold device 10 includes a fixed mold 11 corresponding to a fixed platen 110 and a movable mold 12 corresponding to a movable platen 120 .

[0025] The toggle support 130 is connected to the fixed platen 110 at a predetermined distance L, 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, for example. In this case, the guide of the toggle support 130 may be common to the guide 101 of the movable platen 120.

[0026] Although 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, 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.

[0027] 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 is, for example, a strain gauge. 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 example, to detect the mold clamping force.

[0028] Any clamping force detector that can be used to detect the clamping force may be used instead of or in addition to the tie bar strain detector 141. For example, the clamping force detector is not limited to the strain gauge type, but may be a piezoelectric type, a capacitive type, a hydraulic type, an electromagnetic type, or the like, and the attachment position thereof is not limited to the tie bar 140.

[0029] 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.

[0030] The configuration of the toggle mechanism 150 is not limited to the configuration shown in Figures 1A and 1B. For example, although the number of joints in each link group is five in Figures 1A and 1B, 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.

[0031] 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.

[0032] 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.

[0033] 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 .

[0034] In the mold closing process, the mold clamping motor 160 is driven 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.

[0035] 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 general types can be used. 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 general types can be used.

[0036] In the mold clamping process, the mold clamping motor 160 is further driven to move the crosshead 151 further forward from the mold closing completion position to the mold clamping position, thereby generating a mold clamping force. 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. A molded product is obtained by solidifying the filled molding material. There may be multiple cavity spaces 14, in which case multiple molded products are obtained at the same time.

[0037] In the mold opening process, the mold clamping motor 160 is driven 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.

[0038] 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 (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.

[0039] 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.

[0040] Note 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.

[0041] 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 referred to as the "link angle"). 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.

[0042] 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.

[0043] The mold clamping device 100 has a mold thickness adjustment mechanism 180 that 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] The rotation transmission unit 185 may be configured with a belt, a pulley, or the like, instead of the gears.

[0048] 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.

[0049] 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.

[0050] 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 general detectors may be used.

[0051] 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.

[0052] Incidentally, the mold clamping unit 100 of this embodiment is of a horizontal type in which the mold opening and closing direction is horizontal, but it may be of a vertical type in which the mold opening and closing direction is vertical.

[0053] Furthermore, the clamping apparatus 100 of the present embodiment has a clamping motor 160 as a drive source, but may have a hydraulic cylinder instead of the clamping motor 160. Furthermore, the clamping apparatus 100 may have a linear motor for opening and closing the mold, and an electromagnet for clamping the mold.

[0054] <<Ejector device>> The ejector device 200 ejects a 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.

[0055] In the following description of the ejector unit 200, similar to the description of the mold clamping unit 100, the direction of movement of the movable platen 120 when the mold is closed (to the right in Figures 1A and 1B) is defined as the front, and the direction of movement of the movable platen 120 when the mold is opened (to the left in Figures 1A and 1B) is defined as the rear.

[0056] 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.

[0057] 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 a roller may be interposed between the screw shaft and the screw nut.

[0058] 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.

[0059] The ejector device 200 performs the ejection process under the control of the controller 700 .

[0060] In the ejection process, the ejector motor 210 is driven 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 motor 210 is driven to retreat the ejector rod 230 at a set speed, and the movable member 15 is retreated 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.

[0061] 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 general detectors may be used.

[0062] <<Injection device>> The injection device 300 is mounted on a slide base 301 which is movable forward and backward with respect to the frame Fr, and is movable forward and backward with respect to the mold device 10. The injection device 300 touches the mold device 10 and fills the cavity space 14 in the mold device 10 with molding material. The injection device 300 has, for example, a cylinder 310, a nozzle 320, a screw 330, a metering motor 340, an injection motor 350, and a pressure detector 360.

[0063] In the following description of the injection device 300, the direction in which the injection device 300 is brought closer to the mold device 10 (leftward in Figures 1A and 1B) is defined as the front, and the direction in which the injection device 300 is brought away from the mold device 10 (rightward in Figures 1A and 1B) is defined as the rear.

[0064] 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.

[0065] Cylinder 310 is divided into a plurality of zones in the axial direction of cylinder 310 (left and right direction in FIGS. 1A and 1B). 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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. 1B) 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.

[0070] 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 advances relatively to the screw 330 to an open position (see FIG. 1A) where the flow path of the molding material is opened. As a result, the molding material is sent forward of the screw 330.

[0071] The backflow prevention ring 331 may be either a co-rotating type that rotates together with the screw 330 or a non-co-rotating type that does not rotate together with the screw 330.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] In the metering process, the metering motor 340 is driven to rotate the screw 330 at a set rotation speed, and the molding material is sent 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.

[0079] Incidentally, the screw rotation speed detector for detecting the rotation speed of the screw 330 is not limited to the metering motor encoder 341, and a general one can be used.

[0080] In the metering process, in order to restrict abrupt retraction of the screw 330, the injection motor 350 may be driven to apply a set back pressure to the screw 330. The back pressure on the screw 330 is detected, for example, by 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.

[0081] In the filling step, the injection motor 350 is driven to advance the screw 330 at a set speed, and the liquid molding material accumulated in front of the screw 330 is filled 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.

[0082] After the position of the screw 330 reaches a set position in the filling process, the screw 330 may be temporarily stopped at the set position, and then the V / P switching may be performed. Immediately before the V / P switching, instead of stopping the screw 330, the screw 330 may be moved forward or backward at a slow speed. Furthermore, 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 general detectors may be used.

[0083] In the pressure holding step, the injection motor 350 is driven to push the screw 330 forward, and the pressure of the molding material at the front end of the screw 330 (hereinafter also referred to as "holding pressure") is maintained at a set pressure, and the molding material remaining in the cylinder 310 is pushed toward the mold device 10. This makes it possible 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.

[0084] In the dwelling process, the molding material in the cavity space 14 in the mold device 10 is gradually cooled, and when the dwelling process 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 process, the cooling process is started. In the cooling process, the molding material in the cavity space 14 is solidified. In order to shorten the molding cycle time, a measuring process may be performed during the cooling process.

[0085] The injection device 300 of this embodiment is of an in-line screw type, but may be of a pre-plastication type or the like. A pre-plastication type injection device supplies molding material molten in a plasticization cylinder to an injection cylinder, and injects the molding material from the injection cylinder into a mold device. A screw is disposed in the plasticization cylinder so as to be rotatable or so as to be rotatable and movable forward and backward, and a plunger is disposed in the injection cylinder so as to be movable forward and backward.

[0086] Furthermore, the injection device 300 of this embodiment is a horizontal type in which the axial direction of the cylinder 310 is horizontal, but may be a vertical type in which the axial direction of the cylinder 310 is vertical. A mold clamping device to be combined with the vertical injection device 300 may be either a vertical type or a horizontal type. Similarly, a mold clamping device to be combined with the horizontal injection device 300 may be either a horizontal type or a vertical type.

[0087] <<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.

[0088] In the following description of the moving device 400, similar to the description of the injection device 300, the direction in which the injection device 300 is brought closer to the mold device 10 (leftward in Figures 1A and 1B) is defined as the front, and the direction in which the injection device 300 is brought away from the mold device 10 (rightward in Figures 1A and 1B) is defined as the rear.

[0089] Although the moving device 400 is disposed on one side of the cylinder 310 of the injection device 300 in FIGS. 1A and 1B, it may be disposed on both sides of the cylinder 310, or may be disposed symmetrically with the cylinder 310 as the center.

[0090] The hydraulic pump 410 has a first port 411 and a second port 412. The hydraulic pump 410 is a pump that 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. The hydraulic pump 410 can also draw in hydraulic fluid from a tank and discharge the hydraulic fluid from one of the first port 411 and the second port 412.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] The moving device 400 is not limited to a configuration including the hydraulic cylinder 430. 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.

[0096] <<Controller>> The controller 700 directly transmits control signals to the clamping unit 100, the ejector unit 200, the injection unit 300, the moving unit 400, and the like, and controls the driving of the injection molding machine 1.

[0097] The controller 700 is mainly configured with a computer having, for example, 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 by making the CPU 701 execute a program installed in the auxiliary storage device 703. The controller 700 also receives external signals and outputs signals to the outside through the interface device 704. For example, the controller 700 is communicably connected to the management device 2 through the interface device 704. The controller 700 may also be communicably connected to another injection molding machine 1 (its controller 700) through the interface device 704.

[0098] The functions of the controller 700 may be shared among multiple controllers.

[0099] The controller 700 causes the injection molding machine 1 to repeatedly perform a mold closing process, a mold clamping process, a mold opening process, etc., to repeatedly manufacture molded products. In addition, the controller 700 causes the injection device 300 to perform a metering process, a filling process, a pressure holding process, etc., during the mold clamping process.

[0100] A series of operations for obtaining a molded product, for example, an operation 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." The time required for one shot is also called a "molding cycle time."

[0101] One molding cycle is, for example, configured in the following order: a metering process, a mold closing process, a mold clamping process, a filling process, a pressure dwell process, a cooling process, a mold opening process, and an ejection process. This order is the order in which each process starts. The filling process, the pressure dwell process, and the 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.

[0102] 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 addition, if 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 as long as the opening / closing valve closes the flow path of the nozzle 320.

[0103] The controller 700 is connected to an operation device 750, a display device 760, and the like.

[0104] The operation device 750 receives operation input from a user regarding the injection molding machine 1, and outputs a signal corresponding to the operation input to the controller 700.

[0105] The display device 760 displays various images under the control of the controller 700 .

[0106] The display device 760 displays, for example, an operation screen related to the injection molding machine 1 in response to an operation input on the operation device 750.

[0107] 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 are prepared, and are switched and displayed on the display device 760, or are displayed overlapping each other. The user can perform settings related to the injection molding machine 1 (including input of set values) and the like by operating the operation device 750 while watching the operation screen displayed on the display device 760.

[0108] Further, under the control of the controller 700, for example, the display device 760 displays an information screen that provides the user with various information corresponding 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.).

[0109] The operation device 750 and the display device 760 may be configured as, for example, a touch panel display and integrated together.

[0110] Although the operation device 750 and the display device 760 in this embodiment are integrated, they may be provided independently. Also, a plurality of operation devices 750 may be provided.

[0111] <Management device> The management device 2 is communicably connected to the injection molding machine 1 through a communication line NW.

[0112] The management device 2 is, for example, a computer (for example, 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 in a location relatively close to the factory where the injection molding machine 1 is installed (for example, a wireless base station or station building near the factory). The management device 2 may also be a 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-type computer terminal, etc.) that can be carried by a manager of the injection molding machine 1, etc.

[0113] The management device 2 can grasp the operating state of the injection molding machine 1 based on, for example, data uploaded from the injection molding machine 1, and manage the operating state of the injection molding machine 1. Furthermore, the management device 2 can 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.

[0114] Furthermore, the management device 2 can transmit control information (eg, information on various setting conditions) to the injection molding machine 1 through, for example, the communication line NW.

[0115] [Injection molding machine control method] Next, a method for controlling the injection molding machine 1 will be described.

[0116] <Outline of injection molding machine control method> First, an overview of the control method for the injection molding machine 1 according to this embodiment will be described.

[0117] In this embodiment, the controller 700 performs control regarding a predetermined operation so that a predetermined operation corresponding to a relatively high performance is performed under normal circumstances (when no abnormality occurs).

[0118] On the other hand, in the event of an abnormality (when an abnormality occurs), the controller 700 performs control related to the predetermined operation so as to perform the predetermined operation corresponding to a relatively low performance within a range in which the predetermined operation does not fail.

[0119] The predetermined operation includes, for example, a molding operation corresponding to a first example described below and an operation related to internal communication corresponding to a second example described below. The abnormality includes, for example, an abnormality related to the predetermined operation. Furthermore, the abnormality may include, for example, an abnormality other than the predetermined operation.

[0120] As a result, the controller 700 can operate the injection molding machine 1 in a relatively high performance manner under normal circumstances, while operating in a relatively low performance manner under abnormal circumstances without causing a breakdown in the operation of the injection molding machine 1. Therefore, the injection molding machine 1 can effectively utilize its performance under normal circumstances while preventing a situation in which its operation breaks down under abnormal circumstances.

[0121] <First example of a method for controlling an injection molding machine> Next, a description will be given of a first example of a control method for the injection molding machine 1. In this example, a control method for the molding operation of the injection molding machine 1 will be described.

[0122] <<Normal operation of injection molding machine>> The controller 700 controls the actuator that drives the driven part (e.g., the screw 330, etc.) so that the torque (hereinafter referred to as "load torque") applied to the driven part related to the molding operation and the operating speed of the driven part become relatively large within the allowable range.

[0123] For example, the controller 700 sets the load torque and operating speed of the driven parts to the maximum values ​​of the allowable range (hereinafter, "maximum allowable values") and performs feedback control while monitoring the actual values ​​(measured values) of the load torque and operating speed of the driven parts.

[0124] In this way, the controller 700, under normal circumstances, controls the load torque and operating speed of the driven parts to be relatively large, thereby achieving relatively high performance in the molding operation of the injection molding machine 1. Therefore, under normal circumstances, the controller 700 can effectively utilize the performance in the molding operation that the injection molding machine 1 has.

[0125] <<Operation of injection molding machine in case of abnormality>> When an abnormality occurs, the controller 700 controls the actuator that drives the driven part so that the set values ​​of the load torque and the operating speed of the driven part are relatively low within a range where the molding operation does not fail. The controller 700 may determine that an abnormality has occurred, for example, when a deviation has occurred between the set values ​​of the load torque and the operating speed of the driven part and the actual values ​​(measured values) that exceeds a predetermined standard. The controller 700 may also determine that an abnormality has occurred, for example, when the actual values ​​of the load torque and the operating speed exceed their expected upper limits.

[0126] For example, when an abnormality occurs, the controller 700 performs feedback control while monitoring the actual values ​​(measured values) of the load torque and operating speed of the driven part, setting the set values ​​of the load torque and operating speed of the driven part as lower limit values ​​at which the molding operation can be continued, which are predetermined.

[0127] In this way, the controller 700 controls the load torque and the operating speed of the driven parts to be relatively small within a range in which the molding operation does not fail during an abnormality, so that the controller 700 can prevent the molding operation of the injection molding machine 1 from failing during an abnormality.

[0128] In this example, the above control method is adopted for both the load torque and the operating speed of the driven part, but the above control method may be adopted for only one of them.

[0129] <Second example of injection molding machine control method> Next, a second example of the control method for the injection molding machine will be described with reference to Figures 2 to 8. In this example, a control method for operations related to internal communication of the injection molding machine 1 will be described.

[0130] <<Configuration for collecting data from injection molding machines>> FIG. 2 is a diagram showing an example of a configuration for collecting data from the injection molding machine 1. As shown in FIG.

[0131] The injection molding machine 1 includes a controller 700 and a data output unit 800 as components related to data collection.

[0132] The controller 700 includes a CPU 701 and a field programmable gate array (FPGA) 710.

[0133] As described above, the CPU 701 realizes various processes by starting and executing various programs installed in the auxiliary storage device 703 of the controller 700. In this example, the CPU 701 accesses a memory built in the FPGA 710 and acquires (reads) data acquired (received) from the data output unit 800. The CPU 701 also performs various control processes related to the injection molding machine 1 using the input device data acquired from the FPGA 710.

[0134] The FPGA 710 includes a start trigger output unit 7101 , a counter 7102 , a request transmission unit 7103 , and a data reception unit 7104 .

[0135] The start trigger output unit 7101 outputs a start trigger for a process (program) that controls the injection molding machine 1, that is, an interrupt request, to the CPU 701 at each predetermined processing cycle (hereinafter, "control cycle").

[0136] The counter 7102 performs counting (time counting) processing by hardware.

[0137] A request transmitting unit 7103 (an example of a transmitting unit) transmits to the data output unit 800 a request signal requesting the transmission of data (hereinafter, a “data transmission request”).

[0138] The data receiving unit 7104 (an example of a receiving unit) receives data transmitted from the data output unit 800 in response to a data transmission request, and stores the data in the memory of the FPGA 710.

[0139] The data output unit 800 acquires various data relating to the operating state of the injection molding machine 1. Signals are exchanged between the data output unit 800 and the FPGA 710 of the controller 700 by serial communication.

[0140] The controller 700 acquires data from the data output unit 800 for each control cycle, and by using the acquired data, can appropriately control the injection molding machine 1. Therefore, if the controller 700 fails to acquire data from the data output unit 800 in a certain control cycle, the controller 700 cannot appropriately control the operation of the injection molding machine 1, and the operation of the injection molding machine 1 may fail. Therefore, while performing a process (an example of a predetermined process) related to internal communication for acquiring data from the data output unit 800, the controller 700 (for example, the FPGA 710) disables other processes or prioritizes the process related to the internal communication over other processes.

[0141] The data output unit 800 includes, for example, various encoders. The encoders acquire and output digital data (hereinafter, "encoder data") such as the rotational position (rotational angle) of an electric motor used in a driven unit of the injection molding machine 1. The encoders may include, for example, at least one of the mold clamping motor encoder 161, the mold thickness adjustment motor encoder 184, the ejector motor encoder 211, the metering motor encoder 341, and the injection motor encoder 351.

[0142] Furthermore, for example, a pressure sensor (pressure detector) is included in the data output section 800. The pressure sensor may include, for example, the pressure detector 360.

[0143] Furthermore, for example, a temperature sensor (temperature detector) is included in the data output section 800. The temperature sensor may include, for example, the temperature detector 314.

[0144] Furthermore, the data output section 800 includes, for example, a strain detector. The strain detector may include, for example, the tie bar strain detector 141.

[0145] The data output section 800 also includes, for example, a current sensor and a voltage sensor.

[0146] The data output section 800 also includes, for example, a torque sensor.

[0147] The data output unit 800 also includes, for example, an AD (Analog-Digital) converter. The AD converter acquires and outputs value data (hereinafter, "AD value data") obtained by converting output signals (analog signals) of various sensors that output analog signals into digital signals. The AD converter may acquire and output AD value data of values ​​obtained by converting analog signals, such as predetermined voltage values ​​and current values ​​in electric motors used in driven parts of the injection molding machine 1 and drive circuits that drive the electric motors, into digital signals.

[0148] In the following, in this example, the explanation will be continued on the assumption that the data output unit 800 is an encoder.

[0149] <<Examples of data output from the data output unit>> 3 (FIGS. 3A and 3B) are diagrams showing specific examples of communication frames corresponding to data output from data output section 800. Fig. 3A is a diagram for explaining an example (communication frame 31) of a communication frame having a relatively short data length (hereinafter simply referred to as a "short communication frame"), and Fig. 3B is a diagram for explaining an example (communication frame 32) of a communication frame having a relatively long data length (hereinafter simply referred to as a "long communication frame").

[0150] As shown in FIG. 3A, the communication frame 31 output from the data output unit 800 includes position data 31A and abnormality notification data 31B.

[0151] The position data 31A indicates the rotational position of the electric motor obtained by an encoder. The position data 31A includes data indicating the rotational position (rotation angle) during one rotation of the electric motor (hereinafter, "single rotation position data"). The position data 31A may also include data indicating the number of rotations and in which direction the electric motor has rotated based on the initial position of the electric motor (hereinafter, "multiple rotation position data").

[0152] The abnormality notification data 31B is 1-bit data that indicates whether or not an abnormality occurs in the encoder. For example, when the abnormality notification data 31B has a value of "0", it indicates that the encoder is normal, and when the abnormality notification data 31B has a value of "1", it indicates that an abnormality has occurred.

[0153] As shown in FIG. 3B, the communication frame 32 includes position data 32A, abnormality notification data 32B, and abnormality detail data 32C.

[0154] The position data 32A and the abnormality notification data 32B respectively represent the same contents as the position data 31A and the abnormality notification data 31B of the communication frame 31.

[0155] The abnormality details data 32C indicates details of an abnormality occurring in the encoder. For example, the abnormality details data 32C indicates which type of abnormality has occurred among a plurality of types of abnormalities. When the 1-bit data corresponding to each type is "0", it indicates that the abnormality of that type has not occurred, and when it is "1", it indicates that the abnormality of that type has occurred.

[0156] In this way, the data output section 800 (encoder) is configured to be able to output two types of communication frames 31 and 32 having different data lengths.

[0157] The data output unit 800 may be configured to be capable of outputting three or more types of communication frames having different data lengths. For example, the data output unit 800 (encoder) may be configured to be capable of outputting two types of communication frames 31: a communication frame 31 in which the position data 31A includes only a one-rotation position, and a communication frame 31 in which the position data 31A includes both a one-rotation position and a multiple-rotation position.

[0158] <<Request timing setting process>> 4 is a flowchart outlining an example of a process (hereinafter, "request timing setting process") for setting the transmission timing (hereinafter, "request timing") of a data transmission request to the data output unit 800 (encoder) by the controller 700. This flowchart is executed, for example, during the initial process of the controller 700. The initial process of the controller 700 is executed, for example, when the power supply of the injection molding machine 1 is turned on and the controller 700 starts up, or when the controller 700 is restarted for some reason.

[0159] 4, in step S102, the FPGA 710 transmits a data transmission request for a short communication frame, and measures the communication time from the transmission of the data transmission request to the completion of reception of the data of the short communication frame. After completing the process of step S102, the FPGA 710 proceeds to step S104.

[0160] In step S104, the FPGA 710 calculates the request timing of the short communication frame within the control period from when the start trigger is output to the CPU 701 until when the next start trigger is output based on the communication time (measured value) of the short communication frame. Specifically, the FPGA 710 calculates the request timing of the data transmission request so that the data of the short communication frame can be completely received within the control period. For example, the FPGA 710 calculates a waiting time Tw from when the start trigger is output to the CPU 701 until when the data transmission request is transmitted (hereinafter, "request waiting time"). Since the communication time of a short communication frame is relatively short, the request waiting time Tw is relatively long. When the FPGA 710 completes the process of step S104, the FPGA 710 proceeds to step S106.

[0161] In step S106, the FPGA 710 transmits a data transmission request for a long communication frame, and measures the communication time from the transmission of the data transmission request to the completion of reception of the data of the long communication frame. After completing the process of step S106, the FPGA 710 proceeds to step S108.

[0162] In step S108, the FPGA 710 calculates the request timing of the long communication frame within the control period from when the start trigger is output to the CPU 701 to when the next start trigger is output, based on the communication time (measured value) of the long communication frame. Specifically, the FPGA 710 calculates the request timing of the data transmission request (e.g., request waiting time Tw) so that reception of the data of the long communication frame can be completed within the control period. Since the communication time of a long communication frame is relatively long, the request waiting time Tw is relatively short. After completing the process of step S108, the FPGA 710 proceeds to step S110.

[0163] In step S110, the FPGA 710 sets request timing (request waiting time Tw) corresponding to both the short communication frame and the long communication frame in an internal memory. When the FPGA 710 completes the process of step S110, it ends the current process of this flowchart.

[0164] <<Data acquisition process>> 5 is a flowchart outlining an example of a process (hereinafter, "data acquisition process") for acquiring data output from the data output unit 800 by the controller 700. This flowchart is repeatedly executed for each control period, specifically, each time a start trigger is output to the CPU 701, after the initial process of the controller 700 is completed.

[0165] 5, in step S202, the FPGA 710 reads out from the memory the setting contents of the type of data (communication frame) requested by the data transmission request. The setting of the type of data in the memory is performed by software processing executed by the CPU 701.

[0166] Specifically, the CPU 701 acquires data received from the data output unit 800 from the memory of the FPGA 710 in response to a start trigger, and checks the contents of the abnormality notification data (abnormality notification data 31B or abnormality notification data 32B) included in the acquired data. When the abnormality notification data indicates that there is no abnormality in the data output unit 800 (encoder), the CPU 701 sets the type of data requested in the data transmission request to a short communication frame. This is because, when there is no abnormality in the data output unit 800, the controller 700 does not need the abnormality detail data 32C. On the other hand, when the abnormality notification data indicates that there is an abnormality in the data output unit 800, the CPU 701 sets the type of data requested in the data transmission request to a long communication frame. This is because, when there is an abnormality in the data output unit 800, the controller 700 needs to grasp the details of the abnormality in the data output unit 800 using the abnormality detail data 32C.

[0167] When the FPGA 710 completes the process of step S202, the process proceeds to step S204.

[0168] In step S204, the FPGA 710 determines whether the type of data requested by the data transmission request is a short communication frame. If the type of data requested by the data transmission request is a short communication frame, the FPGA 710 proceeds to step S206, and if the type of data requested by the data transmission request is a long communication frame, the FPGA 710 proceeds to step S208.

[0169] In step S206, the FPGA 710 sets a request timing corresponding to a short communication frame (for example, a request waiting time Tw1 corresponding to a short communication frame). After completing the process of step S206, the FPGA 710 proceeds to step S210.

[0170] On the other hand, in step S208, the FPGA 710 sets a request timing corresponding to a long communication frame (for example, a request waiting time Tw2 corresponding to a long communication frame). After completing the process of step S208, the FPGA 710 proceeds to step S210.

[0171] In step S210, the FPGA 710 determines whether or not a request timing has arrived. For example, the FPGA 710 determines whether or not a request waiting time Tw (request waiting time Tw1 or request waiting time Tw2) has elapsed, starting from the output of an activation trigger. At this time, the FPGA 710 uses the counter 7102 to determine whether or not the request waiting time Tw has elapsed. If the request timing has arrived, the FPGA 710 proceeds to step S212, and if the request timing has not arrived, the FPGA 710 waits until the request timing arrives (repeats the processing of this step).

[0172] In step S212, the FPGA 710 transmits a data transmission request to the data output unit (encoder) 800. When the FPGA 710 completes the process of step S212, the process proceeds to step S214.

[0173] In step S214, the FPGA 710 receives the data transmitted from the data output unit 800 (encoder) in response to the data transmission request. When the FPGA 710 completes the process of step S214, it ends the current process of this flowchart.

[0174] <<Example of normal operation of an injection molding machine>>

[0175] Fig. 6A is a timing chart showing an example of the operation of the controller 700 and the data output unit 800 under normal circumstances (specifically, a state in which there is no abnormality in the data output unit 800). Fig. 6A includes a timing chart 61 showing the operation of the CPU 701, a timing chart 62 showing the operation of the FPGA 710, and a timing chart 63 showing the operation of the data output unit 800 (encoder).

[0176] As shown in FIG. 6A, in step S601, the FPGA 710 (activation trigger output unit 7101) outputs a activation trigger to the CPU 701.

[0177] In step S602, the CPU 701 accesses the memory of the FPGA 710 in response to a start trigger from the FPGA 710, and acquires the latest data received from the data output unit 800 (encoder).

[0178] In step S603, the CPU 701 sets the type of data requested in the data transmission request in the memory of the FPGA 710 according to the content of the abnormality notification data included in the most recently acquired data. In this example, since no abnormality has occurred in the data output unit 800, a short communication frame is set as the type of data requested in the data transmission request.

[0179] When a request waiting time Tw1 corresponding to a short communication frame has elapsed since the output of the activation trigger, the FPGA 710 (request transmission unit 7103) performs processing for transmitting a data transmission request to the data output unit 800 in step S604.

[0180] In step S605, the data output unit 800 acquires data in response to the data transmission request received from the FPGA 710, and transmits the data to the FPGA 710.

[0181] In step S606, the FPGA 710 (data receiving unit 7104) performs a process of receiving the data transmitted from the data output unit 800.

[0182] After the reception of the data transmitted from the data output unit 800 is completed, the FPGA 710 (activation trigger output unit 7101) outputs a activation trigger corresponding to the next control cycle to the CPU 701 in step S607.

[0183] Then, in step S608, the CPU 701 acquires from the memory of the FPGA 710 the latest data of the data output unit 800 received in step S606.

[0184] In this way, during normal operation when there is no abnormality in the data output unit 800, the request waiting time Tw is set relatively long. That is, the time allocated to the communication process is set relatively short. This makes it possible to relatively lengthen the time that can be allocated to the control process for realizing the molding operation of the injection molding machine 1 within the control cycle. Therefore, the control performance of the injection molding machine 1 can be improved.

[0185] <<Examples of injection molding machine behavior when an abnormality occurs>> Fig. 6B is a timing chart showing an example of the operation of the controller 700 and the data output unit 800 when an abnormality occurs in the data output unit 800. Fig. 6B includes a timing chart 64 showing the operation of the CPU 701, a timing chart 65 showing the operation of the FPGA 710, and a timing chart 66 showing the operation of the data output unit 800 (encoder).

[0186] As shown in FIG. 6B, in step S611, the FPGA 710 (activation trigger output unit 7101) outputs a activation trigger to the CPU 701.

[0187] In step S612, the CPU 701 accesses the memory of the FPGA 710 in response to a start trigger from the FPGA 710, and acquires the latest data received from the data output unit 800 (encoder).

[0188] In step S613, the CPU 701 sets the type of data requested in the data transmission request in the memory of the FPGA 710 according to the content of the abnormality notification data included in the most recently acquired data. In this example, since an abnormality has occurred in the data output unit 800, a long communication frame is set as the type of data requested in the data transmission request.

[0189] When the request waiting time Tw2 corresponding to the long communication frame has elapsed since the output of the activation trigger, the FPGA 710 (request sending unit 7103) performs processing for sending a data transmission request to the data output unit 800 in step S614.

[0190] In step S615, the data output section 800 acquires data in response to the data transmission request received from the FPGA 710, and performs processing to transmit the data to the FPGA 710.

[0191] In step S616, the FPGA 710 (data receiving unit 7104) performs a process of receiving the data transmitted from the data output unit 800.

[0192] After the reception of the data transmitted from the data output unit 800 is completed, the FPGA 710 (activation trigger output unit 7101) outputs a activation trigger corresponding to the next control cycle to the CPU 701 in step S617.

[0193] Then, in step S618, the CPU 701 acquires from the memory of the FPGA 710 the latest data of the data output unit 800 received in step S616.

[0194] In this way, when an abnormality occurs in the data output unit 800, the request waiting time Tw is set relatively short. That is, the time allocated to communication processing is set relatively long (request waiting time Tw2). As a result, even if an abnormality occurs in the data output unit 800 and the amount of data to be acquired from the data output unit 800 increases, the controller 700 can complete data reception within the control period and appropriately use the latest data in the next control period.

[0195] <<Effect>> 7A and 7B are timing charts showing the operation of the controller and the data output unit according to the comparative example. Specifically, FIG. 7A is a timing chart showing the operation of the controller (CPU, FPGA) and the data output unit according to the first comparative example when the data output unit is abnormal. FIG. 7A includes a timing chart 71 showing the operation of the CPU, a timing chart 72 showing the operation of the FPGA, and a timing chart 73 showing the operation of the data output unit. Also, FIG. 8B is a timing chart showing the operation of the controller (CPU, FPGA) and the data output unit according to the second comparative example under normal conditions (i.e., when the data output unit is not abnormal). FIG. 7B includes a timing chart 74 showing the operation of the CPU, a timing chart 75 showing the operation of the FPGA, and a timing chart 76 showing the operation of the data output unit.

[0196] It should be noted that steps S701 to S708 in Fig. 7A are the same processes as steps S611 to S618 in Fig. 6B, respectively, and steps S711 to S718 in Fig. 7B are the same processes as steps S601 to S608 in Fig. 6A, respectively.

[0197] In the controller according to the first comparative example, the request waiting time Tw is fixed to a relatively long value, that is, a request waiting time Tw1 corresponding to a short communication frame. Therefore, in normal times when there is no abnormality in the data output unit, data reception from the data output unit can be completed within the control period, as in the case of FIG. 6A described above. Therefore, in the next control period, the CPU can access the memory of the FPGA and obtain the latest data from the data output unit.

[0198] On the other hand, when the data output unit 800 is abnormal, the controller needs to obtain a long communication frame. Therefore, as shown in FIG. 7A, it takes a relatively long time for the FPGA to receive the data transmitted from the data output unit (step S706), and the FPGA cannot complete the reception of the data by the time it outputs the start trigger (step S707). Therefore, even if the CPU accesses the memory of the FPGA in step S708, it cannot obtain the latest data from the data output unit. As a result, the controller cannot appropriately control the injection molding machine, and the operation of the injection molding machine may fail.

[0199] In addition, in the controller according to the second comparative example, the request waiting time Tw is fixed to a relatively short value, that is, a request waiting time Tw2 corresponding to a long communication frame. Therefore, when an abnormality occurs in the data output unit, the controller can complete data reception within a control period and appropriately use the latest data in the next control period even in a situation where the amount of data increases relatively, as in the case of Fig. 6B described above.

[0200] On the other hand, in normal times when there is no abnormality in the data output unit, the controller only needs to obtain a short communication frame. Therefore, as shown in FIG. 7B, the process of receiving data transmitted from the data output unit within a control cycle ends early, and thereafter, the time allocated to the communication process is largely left over (see "surplus time" in FIG. 7B). As described above, from the viewpoint of the necessity of appropriately controlling the operation of the injection molding machine 1, data acquisition from the data output unit is essential for each control cycle, so that in the time allocated to the communication process, the communication process either occupies that time or takes priority over other processes. Therefore, even if the communication process for data acquisition ends early, that time cannot be used for other processes, and resources that can be used for control processes for realizing the molding operation of the injection molding machine 1 are wasted.

[0201] If the request timing is fixed in this way, the latest data may not be acquired if the data output unit is abnormal, or the time allocated to communication processing within the control period may be unused if the data output unit is normal.

[0202] In contrast, in this example, the injection molding machine 1 (controller 700) allocates a relatively short amount of time to internal communication processing when no abnormality occurs, and allocates a relatively long amount of time to internal communication processing when an abnormality occurs.

[0203] This allows the injection molding machine 1 to vary the time allocated to the communication process that should be completed within a predetermined processing cycle in accordance with the increase or decrease in the amount of data to be communicated depending on the presence or absence of an abnormality. Therefore, the injection molding machine 1 (controller 700) can improve the control performance of the injection molding machine 1 while suppressing a situation in which the communication process cannot be completed within the control cycle.

[0204] Furthermore, in this example, when an abnormality occurs, the injection molding machine 1 (controller 700) processes internal communication so as to prioritize response to the abnormality over the performance of the injection molding machine 1. Specifically, when an abnormality occurs, the controller 700 shortens the time allocated to other processes and relatively lengthens the time allocated to communication processing compared to normal times so as to obtain a communication frame 32 with a relatively large amount of data including the abnormality detail data 32C.

[0205] This allows the injection molding machine 1 to perform at its maximum potential under normal circumstances, while prioritizing response to an abnormality when an abnormality occurs, and to respond appropriately to the abnormality.

[0206] Furthermore, in this example, the data output section 800 (an example of a transmitting device) transmits data within a control period, and the controller 700 (an example of a receiving device) receives data within a control period. When an abnormality occurs, the data output unit 800 transmits information notifying the occurrence of the abnormality (for example, abnormality notification data set to "1") to the controller 700, and when the controller 700 receives this information, it relatively lengthens the time allocated to communication processing with the data output unit 800 within the control period.

[0207] This allows the controller 700 to grasp the presence or absence of an abnormality using information from the data output unit 800, and to vary the time allocated to communication processing in accordance with the increase or decrease in the amount of data to be communicated depending on the presence or absence of an abnormality. Therefore, the injection molding machine 1 (controller 700) can improve the control performance of the injection molding machine 1 while suppressing a situation in which the communication processing between the controller 700 and the data output unit 800 cannot be completed within the control period.

[0208] In addition, in this example, the injection molding machine 1 varies the amount of data for internal communication depending on a predetermined flag (e.g., the value of abnormality notification data), and varies the time allocated to communication processing within the control period in which internal communication is performed depending on the change in the amount of data.

[0209] As a result, even if the amount of data to be communicated increases or decreases, the injection molding machine 1 can vary the time allocated to the communication process within the control period in accordance with the increase or decrease. Therefore, the injection molding machine 1 (controller 700) can improve the control performance of the injection molding machine 1 while suppressing a situation in which the communication process between the controller 700 and the data output unit 800 cannot be completed within the control period.

[0210] In this example, multiple types of data with different data amounts are included in the data that can be transmitted from the data output unit 800. The request transmission unit 7103 then varies the timing of transmitting a data transmission request within a control period depending on the type of data requested in the data transmission request among the multiple types of data.

[0211] As a result, when the amount of data requested from the data output unit 800 is relatively large, the controller 700 can make the request timing relatively earlier within the control cycle and ensure time to complete reception of the data within the control cycle. Also, when the amount of data requested from the data output unit 800 is relatively small, the controller 700 can make the request timing relatively later within the control cycle and reduce the time allocated to communication processing. Therefore, the injection molding machine 1 (controller 700) can improve the control performance of the injection molding machine 1 while suppressing a situation in which communication processing between the controller 700 and the data output unit 800 cannot be completed within the control cycle.

[0212] Furthermore, in this example, the counter 7102 (an example of a measurement unit) may measure the time required from transmission of a data transmission request by the request transmission unit 7103 to completion of reception of the data by the data reception unit for each of the multiple types of data during initial processing of the controller 700. Then, the request transmission unit 7103 may determine the timing to transmit a data transmission request based on the measurement results of the time required for each of the multiple types of data.

[0213] This allows the controller 700 to use actual measurement values ​​required for communication processing for each of a plurality of types of data with different data amounts, and therefore allows the controller 700 to set the request timing more appropriately.

[0214] In addition, in this example, the CPU 701 (an example of a judgment unit) may determine the type of data requested by the request signal in the current control cycle based on the contents of the data (e.g., abnormality notification data) received by the data receiving unit 7104 in the previous control cycle.

[0215] This allows the controller 700 to switch the type of data to be transmitted from the data output section, for example, using the contents of the data received from the data output section 800 as a trigger.

[0216] Furthermore, in this example, each of the multiple types of data transmittable from the data output unit 800 may include information regarding the presence or absence of an abnormality in the data output unit 800 (for example, abnormality notification data). Furthermore, some types of data among the multiple types of data transmittable from the data output unit 800 may include information regarding details of the abnormality in the data output unit 800 (for example, abnormality detail data). Then, the CPU 701 may determine the presence or absence of an abnormality in the data output unit 800 based on information regarding the presence or absence of an abnormality in the data output unit 800 included in the data received by the data receiving unit 7104 in the previous control cycle, and if there is no abnormality in the data output unit 800, may request a type of data that does not include information regarding the details of the abnormality in the data output unit 800 in a data transmission request, and if there is an abnormality in the data output unit 800, may request a type of data that includes information regarding the details of the abnormality in the data output unit 800 in a data transmission request.

[0217] This allows the controller 700 to grasp whether or not there is an abnormality in the data output section 800, and to switch the type of data to be transmitted from the data output section depending on whether or not there is an abnormality in the data output section 800.

[0218] In this example, the data output section 800 may be an encoder.

[0219] This enables the controller 700 to improve the control performance of the injection molding machine 1 while suppressing a situation in which the communication process with the encoder cannot be completed within a control period.

[0220] In this example, the FPGA 710 is configured to be able to communicate with the encoder, and may include a request sending unit 7103 and a data receiving unit 7104.

[0221] As a result, the controller 700 can realize a function that improves the control performance of the injection molding machine 1, while suppressing a situation in which communication processing with the encoder cannot be completed within the control period, for example, by using an FPGA attached to the encoder.

[0222] [Transformation, modification] Although the embodiments have been described in detail above, the present disclosure is not limited to the above-described embodiments, and various modifications and variations are possible within the scope of the gist described in the claims.

[0223] For example, in the above-described embodiment, the abnormality of the injection molding machine 1 may include a communication abnormality between the controller 700 (FPGA 710) and the data output unit 800, in addition to the abnormality of the data output unit 800 described above. In this case, the controller 700 monitors the communication state with the data output unit 800, and when a communication abnormality occurs, the controller 700 may operate the injection molding machine 1 by lowering the performance to a relatively low level within a range in which the molding operation of the injection molding machine 1 does not fail. This is because there is a possibility that the controller 700 cannot acquire the data output from the data output unit 800. Specifically, the controller 700 may extrapolate data in the current control cycle from past data, and use the extrapolated data to control the driven parts of the injection molding machine 1. In addition, the controller 700 may control an actuator that drives the driven parts so that the set values ​​of the load torque and operating speed of the driven parts are relatively low within a range in which the molding operation does not fail. In other words, when a communication abnormality occurs, the controller 700 may relatively lower the performance related to control using the data acquired from the data output section 800 compared to normal times.

[0224] Also, for example, the control method for communication processing between the controller 700 and the data output unit 800 in the above-mentioned embodiment and the examples of modifications and changes may be applied to communication processing between the upper controller and the lower controller included in the controller 700. In this case, data may be periodically transmitted from one to the other, or data may be periodically exchanged between them. Specifically, when either the upper controller or the lower controller periodically acquires data from the other, the time allocated to communication processing related to data acquisition may be set to be short under normal circumstances and relatively long under abnormal circumstances. Also, the time allocated to communication processing related to data acquisition may be changed so as to be longer as the amount of data to be acquired increases. Also, when the communication state between the upper controller and the lower controller is monitored by the data acquisition side and a communication abnormality is detected, the performance of one of the data acquisition sides regarding control using data may be relatively lower than normal.

[0225] Also, for example, the control method for communication processing between the controller 700 and the data output unit 800 in the above-mentioned embodiment and modifications may be applied to communication processing between the injection molding machine 1 and the management device 2. In this case, data may be periodically transmitted from one to the other, or data may be periodically exchanged between them. Specifically, when either the injection molding machine 1 or the management device 2 periodically acquires data from the other, the time allocated to communication processing related to data acquisition may be set to be short in normal times and relatively long in abnormal times. Also, the time allocated to communication processing related to data acquisition may be changed so as to be longer as the amount of data to be acquired increases. Also, when the communication state between the injection molding machine 1 and the management device 2 is monitored by the data acquisition side, and a communication abnormality is detected, the performance of one of the data acquisition sides regarding control using the data may be relatively lower than normal times.

[0226] Furthermore, for example, in the above-described embodiments and examples of modifications and variations, the controller 700 that controls the injection molding machine 1 has been described, but similar content may be adopted in a controller that controls other specific machines (for example, industrial machines, industrial robots, etc.).

[0227] Finally, this application claims priority based on Japanese Patent Application No. 2019-184036, filed on October 4, 2019, the entire contents of which are incorporated herein by reference. [Explanation of symbols]

[0228] 1. Injection molding machine (prescribed machine) 100 Mold clamping device 200 Ejector device 300 Injection device 400 Mobile Device 700 Controller 701 CPU (judgment section) 710 FPGA 750 Operating device 760 Display device 800 Data Output Unit 7101 Start trigger output section 7102 Counter 7103 Request sending unit (sending unit) 7104 Data receiving unit (receiving unit) SYS Injection molding machine management 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 that controls the injection molding machine, When no abnormality occurs in the control device, in a data output unit that transmits data to the control device, or in communication between the control device and the data output unit, a predetermined operation corresponding to relatively high performance is performed, and when the abnormality occurs, a predetermined operation corresponding to relatively low performance within a range in which the predetermined operation does not fail is performed, thereby continuing a series of operations to obtain a molded product. Injection molding machine.

2. While performing a predetermined process corresponding to the predetermined operation, other processes cannot be performed, or the predetermined process is prioritized over other processes.

2. The injection molding machine according to claim 1.

3. When the abnormality occurs, the predetermined process is performed so as to prioritize response to the abnormality over the performance of the injection molding machine.

3. The injection molding machine according to claim 2.

4. When the abnormality does not occur, a time allocated to the internal communication processing as the predetermined processing is relatively short, and when the abnormality occurs, a time allocated to the internal communication processing as the predetermined processing is relatively long.

4. The injection molding machine according to claim 2 or 3.

5. a transmitting device that transmits data within a predetermined processing period; a receiving device for receiving data within the processing period, The sending device and the receiving device are the data output unit and the control device, or a first control unit and a second control unit included in the control device, the abnormality is an abnormality in the data output unit or the first control unit serving as the transmitting device, When the abnormality occurs, the transmitting device transmits information notifying the occurrence of the abnormality to the receiving device; when the receiving device receives the information, the receiving device relatively lengthens a time allocated to a communication process with the transmitting device as the predetermined process within the processing cycle; 5. An injection molding machine according to claim 2 .

6. The amount of data in the internal communication is varied according to a predetermined flag indicating the presence or absence of the abnormality, and a time allocated to a communication process as the predetermined process within a predetermined processing period in which the internal communication is performed is varied according to the change in the amount of data.

6. An injection molding machine according to any one of claims 2 to 5.

7. When no abnormality occurs, a molding operation is performed so that at least one of the torque applied to the driven part and the speed of the driven part becomes relatively large, and when the abnormality occurs, a molding operation is performed so that the torque and the speed become relatively small within a range that does not cause the molding operation to fail.

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

8. A controller for controlling a predetermined machine, When no abnormality occurs in the controller, the data output unit that transmits data to the controller, or the communication between the controller and the data output unit, the specified machine is caused to perform a predetermined operation corresponding to a relatively high performance, and when the abnormality occurs, the specified machine is caused to perform a predetermined operation corresponding to a relatively low performance within a range in which the predetermined operation does not fail, thereby allowing the specified machine to continue a series of operations. controller.

9. While performing a predetermined process corresponding to the predetermined operation, other processes cannot be performed, or the predetermined process is prioritized over other processes. The controller of claim 8.

10. When the abnormality occurs, the predetermined process is performed so as to prioritize the response to the abnormality over the performance of the predetermined machine. The controller of claim 9.

11. a transmission unit that transmits a request signal to the data output unit to transmit data within a predetermined processing period as the predetermined processing; a receiving unit that receives data transmitted from the data output unit in response to the request signal as the predetermined process, The data that can be transmitted from the data output unit includes a plurality of types of data each having a different data amount, the transmission unit varies a timing for transmitting the request signal within the processing cycle depending on a type of data requested by the request signal among the plurality of types of data. A controller according to claim 9 or 10.

12. a measurement unit that measures a required time from transmission of the request signal by the transmission unit to completion of reception of the data by the reception unit for each of the plurality of types of data during an initial process of the controller, the transmitting unit determines the timing to transmit the request signal based on the required time for each of the plurality of types of data measured by the measuring unit. The controller of claim 11.

13. a determination unit that determines a type of data requested by the request signal in the current processing cycle based on the content of the data received by the receiving unit in the previous processing cycle, 13. A controller according to claim 11 or 12.

14. Each of the plurality of types of data includes information regarding the presence or absence of the abnormality in the data output unit, Some types of data among the plurality of types of data include information regarding details of the abnormality of the data output unit, the determination unit determines the presence or absence of an abnormality in the data output unit based on information regarding the presence or absence of an abnormality in the data output unit, which is included in data received by the receiving unit within the previous processing cycle, and when there is no abnormality in the data output unit, causes a request signal to be sent for a type of data that does not include information regarding details of the abnormality in the data output unit, and when there is an abnormality in the data output unit, causes a request signal to be sent for a type of data that includes information regarding details of the abnormality in the data output unit. The controller of claim 13.

15. The data output unit is an encoder. A controller according to any one of claims 11 to 14.

16. An FPGA capable of communicating with the encoder; The FPGA includes the transmitting unit and the receiving unit.

16. The controller of claim 15.

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