Manufacturing method and injection molding system

Abstract

A manufacturing system including an injection molding machine and a conveying device injects into a mold at a molding operation position within the injection molding machine to cool the mold, removes a molded product from the mold at the molding operation position, conveys the mold to a path of the conveying device, and heats the mold on the path.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 62 / 849,664, filed May 17, 2019.

[0002] The present disclosure relates to an injection molding system. [Background technology]

[0003] The production of molded products using an injection molding machine includes injecting resin into a mold after it has been clamped, forcing the resin into the mold at high pressure to compensate for the volume loss caused by the resin solidifying, holding the molded product in the mold until the resin solidifies, and then removing the molded product from the mold.

[0004] In the above-mentioned molding method, a method of using two molds for one injection molding machine has been proposed to increase productivity. For example, U.S. Patent No. 2018 / 0009146 / Japan Patent Publication No. 2018-001738 / VN20160002505 discusses a system in which conveying devices 3A and 3B are arranged on both sides of an injection molding machine 2. In this system, molded products are manufactured for one injection molding machine 2 while multiple molds are replaced by the conveying devices 3A and 3B. Figures 1 to 4 show the injection molding system of U.S. Patent No. 2018 / 0009146 / Japan Patent Publication No. 2018-001738 / VN20160002505.

[0005] In this system, cooling of mold 100A or 100B is performed on transfer device 3A or 3B outside of injection molding machine 2. While one mold 100A / 100B is being cooled, processes such as molded product removal → mold clamping → injection / pressure holding are performed for the other mold 100A / 100B by injection molding machine 2. Because mold opening and molded product removal are performed by injection molding machine 2, transfer devices 3A and 3B do not require mold opening and molded product removal functions.

[0006] This makes it possible to manufacture a molded product P by replacing a plurality of molds with one injection molding machine 2. This makes it possible to reduce the cost of the entire system.

[0007] If the time required for cooling one mold can be contained within the time required for all processes from the start of the mold change process, to the removal process, injection process, and pressure holding process of the other mold, and then to the completion of the mold change process again, productivity can be improved up to twice as much as with normal molding. In other words, in addition to suppressing cost increases, there is the advantage of being able to achieve high productivity.

[0008] A heat and cool molding technique is known. In this technique, the mold is heated in advance to a temperature higher than the thermal deformation temperature of the resin, and the mold is cooled after the resin is injected into the mold. This technique can prevent defects in the appearance of molded products, but requires forced heating and cooling equipment. In addition, it has the disadvantage that the molding process is longer than general molding methods.

[0009] In the system of Japanese Patent Publication H7-119012, since the molded product is removed outside the injection molding machine, it is necessary to provide a mold opening / closing mechanism for each removal device. Also, it is necessary to provide a molded product removal mechanism for each removal device. Therefore, multiple mold opening / closing mechanisms and molded product removal mechanisms are required, which increases the cost of the entire system.

[0010] Although the system of Japanese Patent Publication H7-119012 can increase productivity compared to normal molding by performing cooling processes both inside and outside the injection molding machine, there is room for further improvement. For example, productivity can be maximized by allocating the process time inside and outside the injection molding machine to half of the total molding process.

[0011] Japanese Patent Publication No. H10-180797 discloses a technique for insert molding. Insert molding is a widely known technique in which a part is transferred into a mold and then injection molded to integrally mold the part with resin. However, most insert parts are prepared in advance.

[0012] What is needed is heat and cool molding technology in an injection molding system that switches between multiple molds. Summary of the Invention

[0013] According to at least one aspect of the present disclosure, a method for a manufacturing system including an injection molding machine and a conveying device includes a first step of injecting into a mold at a molding operation position in the injection molding machine and cooling the mold, a second step of removing a molded product from the mold at the molding operation position, and a third step of conveying the mold to a path of the conveying device and heating the mold on the path.

[0014] These and other embodiments, features and advantages of the present disclosure will become apparent from the following detailed description of exemplary embodiments of the present disclosure, taken in conjunction with the accompanying drawings and the claims set forth below. [Brief description of the drawings]

[0015] [Figure 1] 1 shows an injection molding system.

[0016] [Diagram 2] FIG.

[0017] [Diagram 3] 3 is an end view of the stationary platen, as viewed from the direction of the arrow II in FIG. 2.

[0018] [Figure 4] FIG. 4 is a partial perspective view for explaining a configuration around a molding operation position.

[0019] [Diagram 5] The configuration for controlling the temperature of a mold is shown.

[0020] [Figure 6] 1 is a list showing conditions for heat and cool molding.

[0021] [Figure 7] 1 is a flow chart illustrating an injection molding process in which the heating process is performed external to the injection molding machine.

[0022] [Figure 8] 1 is a graph showing the transition of temperatures of both mold 100A and mold 100B.

[0023] [Figure 9] 4 is a flow chart of an injection molding process in which the heating process is performed inside an injection molding machine.

[0024] [Figure 10] 1 is a graph showing the transition of temperatures of both mold 100A and mold 100B.

[0025] Throughout the drawings, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components, or portions of the illustrated embodiments. Moreover, while the present disclosure will now be described in detail with reference to the drawings, it is done so in connection with the exemplary embodiments for purposes of illustration. It is intended that changes and modifications can be made to the exemplary embodiments described without departing from the true scope and spirit of the present disclosure as defined by the appended claims. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] This disclosure describes some exemplary embodiments and relies on patents, patent applications, and other references for details known to those skilled in the art. Thus, when patents, patent applications, or other references are cited or repeated in this specification, they should be understood to be incorporated by reference in their entirety for all purposes, not just as proposed herein.

[0027] With reference to the drawings, arrows X and Y in each drawing indicate horizontal directions that are perpendicular to each other, and arrow Z indicates a vertical (upright) direction relative to the ground.

[0028] 1-4 show an injection molding system 1 of U.S. Patent No. 2018 / 0009146 / JP Patent Publication No. 2018-001738 / VN20160002505 and are provided herein for informational / illustrative purposes only.

[0029] The injection molding system 1 includes an injection molding machine 2, conveying devices 3A and 3B, and a control device 4. The injection molding system 1 uses conveying devices 3A and 3B for one injection molding machine 2 to manufacture molded products while replacing multiple molds. Two molds 100A and 100B are used.

[0030] The molds 100A / 100B are a set of a fixed mold 101 and a movable mold 102 that opens and closes relative to the fixed mold 101. A molded product is formed by injecting molten resin into a cavity formed between the fixed mold 101 and the movable mold 102. Mounting plates 101a and 102a are fixed to the fixed mold 101 and the movable mold 102, respectively. The mounting plates 101a and 102a are used to fix the molds 100A / 100B to a molding operation position 11 (mold clamping position) of an injection molding machine.

[0031] The mold 100A / 100B is provided with a self-closing portion 103 that maintains the space between the fixed mold 101 and the movable mold 102 in a closed state. The self-closing portion 103 makes it possible to prevent the mold 100A / 100B from opening even after the mold 100A / 100B is removed from the injection molding machine 2. The self-closing portion 103 maintains the mold 100A / 100B in a closed state by utilizing a magnetic force. The self-closing portion 103 is disposed at a plurality of locations along the opposing surfaces of the fixed mold 101 and the movable mold 102. The self-closing portion 103 is a combination of an element on the fixed mold 101 side and an element on the movable mold 102 side. Usually, two or more sets of self-closing portions 103 are provided for each of the molds 100A and 100B.

[0032] The conveying device 3A carries the mold 100A into and out of the molding operation position 11 of the injection molding machine 2. The conveying device 3B carries the mold 100B into and out of the molding operation position 11. The conveying device 3A, the injection molding machine 2, and the conveying device 3B are arranged in this order in the X-axis direction. In other words, the conveying device 3A and the conveying device 3B are arranged laterally with respect to the injection molding machine 2 so as to sandwich the injection molding machine 2 in the X-axis direction. The conveying devices 3A and 3B are arranged opposite each other, with the conveying device 3A being adjacent to one of the left and right sides of the injection molding machine 2 and the conveying device 3B being adjacent to the other side. The molding operation position 11 is located between the conveying device 3A and the conveying device 3B. Each of the conveying devices 3A and 3B includes a frame 30, a conveying unit 31, a plurality of rollers 32, and a plurality of rollers 33.

[0033] The frame 30 is the skeleton of the transport devices 3A and 3B, and supports the transport unit 31 and a number of rollers 32 and 33. The transport unit 31 is a device that moves the mold 100A / 100B back and forth in the X-axis direction and ejects and inserts the mold 100A / 100B into and from the molding operation position 11.

[0034] The transport unit 31 is an electric cylinder driven by a motor, and includes a rod that advances and retreats relative to the cylinder. The cylinder is fixed to the frame 30, and the fixed mold 101 is fixed to the end of the rod. The transport unit 31 can be either a fluid actuator or an electric actuator, but the electric actuator can improve the control accuracy of the position and speed of the mold 100A / 100B when transporting it. Examples of the fluid actuator include a hydraulic cylinder and an air cylinder. Examples of the electric actuator include, in addition to the electric cylinder, a rack and pinion mechanism driven by a motor, a ball screw mechanism driven by a motor, and the like.

[0035] The transport unit 31 is disposed independently for each of the transport devices 3A and 3B. However, a common support member may be used to support the molds 100A and 100B, and a single common transport unit 31 may be disposed for this support member. When the transport unit 31 is disposed independently for each of the transport devices 3A and 3B, it becomes possible to deal with cases where the movement strokes of the molds 100A and 100B during transport are different. For example, there are cases where the molds cannot be transported simultaneously because their widths (width in the X direction) or thicknesses (width in the Y direction) are different.

[0036] The rollers 32 form a roller row arranged in the X-axis direction, and are arranged in two rows spaced apart in the Y-axis direction. The rollers 32 rotate around a rotation axis in the Z-axis direction, and contact the side surfaces (side surfaces of the mounting plates 101a and 102a) of the mold 100A / 100B to support the mold 100A / 100B from the side and guide the movement of the mold 100A / 100B in the X-axis direction. The rollers 33 form a roller row arranged in the X-axis direction, and are arranged in two rows spaced apart in the Y-axis direction. The rollers 33 rotate around a rotation axis in the Y-axis direction, and support the bottom surface (bottom surfaces of the mounting plates 101a and 102a) of the mold 100A / 100B to support the mold 100A / 100B from below, smoothing the movement of the mold 100A / 100B in the X-axis direction.

[0037] The control device 4 includes a controller 41 for controlling the injection molding machine 2, a controller 42A for controlling the conveying device 3A, and a controller 42B for controlling the conveying device 3B. Each of the controllers 41, 42A, and 42B includes, for example, a processor such as a CPU, a storage device such as a RAM, a ROM, and a hard disk, and an interface (not shown) connected to a sensor or an actuator. The processor executes a program stored in the storage device. An example of a program (control) executed by the controller 41 will be described later. The controller 41 is communicably connected to the controllers 42A and 42B, and instructs the controllers 42A and 42B regarding the conveyance of the molds 100A / 100B. When the loading or unloading of the molds 100A / 100B is completed, the controllers 42A and 42B transmit an operation completion signal to the controller 41. Furthermore, the controllers 42A and 42B transmit an emergency stop signal to the controller 41 when an abnormality occurs.

[0038] A controller is provided for each of the injection molding machine 2, the conveying device A, and the conveying device B, but one controller may control all three devices. To ensure more reliable cooperative operation, the conveying devices A and B may be controlled by a single controller.

[0039] Fig. 2 is a side view of the injection molding machine 2. Fig. 3 is an end view of the fixed platen 61, as seen from the direction of the arrow II in Fig. 2. Fig. 4 is a partial perspective view for explaining the configuration around the molding operation position 11.

[0040] 1 and 2, injection molding machine 2 includes an injection device 5, a mold clamping device 6, and a remover 7 that removes a molded product. Injection device 5 and mold clamping device 6 are arranged on frame 10 in the Y-axis direction.

[0041] The injection device 5 includes an injection cylinder 51 arranged to extend in the Y-axis direction. The injection cylinder 51 includes a heating device (not shown) such as a band heater, and melts the resin introduced from a hopper 53. A screw 51a is built into the injection cylinder 51, and the resin introduced into the injection cylinder 51 is plasticized and measured by rotating the screw 51a. The molten resin can be injected from the injection nozzle 52 by moving the screw 51a in the axial direction (Y-axis direction).

[0042] Fig. 2 shows an example of a shutoff nozzle as the nozzle 52. A pin 56a that opens and closes the discharge port 52a is arranged as the opening and closing mechanism 56 in Fig. 2. The pin 56a is connected to an actuator (cylinder) 56c via a link 56b, and the discharge port 52a is opened and closed by the operation of the actuator 56c.

[0043] The injection cylinder 51 is supported by a drive unit 54. The drive unit 54 includes a motor that rotates the screw 51a to plasticize and measure the resin, and a drive motor that moves the screw 51a forward and backward in the axial direction. The drive unit 54 can move forward and backward in the Y-axis direction along rails 12 on the frame 10. The drive unit 54 also includes an actuator (e.g., an electric cylinder) 55 that moves the injection device 5 forward and backward in the Y-axis direction.

[0044] The mold clamping device 6 clamps and opens / closes the mold 100A / 100B. In the mold clamping device 6, a fixed platen 61, a movable platen 62, and a movable platen 63 are arranged in this order in the Y-axis direction. A plurality of tie bars 64 pass through the platens 61 to 63. Each tie bar 64 is a shaft extending in the Y-axis direction, and one end of the tie bar 64 is fixed to the fixed platen 61. Each tie bar 64 is inserted into a through hole formed in the movable platen 62. The other end of each tie bar 64 is fixed to the movable platen 63 via an adjustment mechanism 67. The movable platens 62 and 63 are movable in the Y-axis direction along rails 13 on the frame 10, and the fixed platen 61 is fixed to the frame 10.

[0045] A toggle mechanism 65 is disposed between the movable platen 62 and the movable platen 63. The toggle mechanism 65 moves the movable platen 62 forward and backward in the Y-axis direction relative to the movable platen 63 (in other words, relative to the fixed platen 61). The toggle mechanism 65 includes links 65a to 65c. The link 65a is rotatably connected to the movable platen 62. The link 65b is rotatably connected to the movable platen 63. The links 65a and 65b are rotatably connected to each other. The links 65c and 65b are rotatably connected to each other. The link 65c is rotatably connected to an arm 66c.

[0046] The arm 66c is fixed to a ball nut 66b. The ball nut 66b engages with a ball screw shaft 66a extending in the Y-axis direction, and moves forward and backward in the Y-axis direction by rotation of the ball screw shaft 66a. The ball screw shaft 66a is supported by the movable platen 63 so as to be rotatable, and the motor 66 is supported by the movable platen 63. The motor 66 rotates the ball screw shaft 66a while detecting the amount of rotation of the motor 66. By driving the motor 66 while detecting the amount of rotation of the motor 66, it is possible to clamp and open / close the mold 100A / 100B.

[0047] The injection molding machine 2 includes sensors 68 for measuring the clamping force. Each sensor 68 is, for example, a strain gauge provided on the tie bar 64, and detects the strain of the tie bar 64 to calculate the clamping force.

[0048] The adjustment mechanism 67 includes a nut 67b rotatably supported on the movable platen 63, a motor 67a serving as a drive source, and a transmission mechanism that transmits the drive force of the motor 67a to the nut 67b. Each tie bar 64 passes through a hole formed in the movable platen 63 and engages with the nut 67b. By rotating the nut 67b, the engagement position between the nut 67b and the tie bar 64 in the Y-axis direction changes. In other words, the fixed position of the movable platen 63 relative to the tie bar 64 changes. This makes it possible to change the gap between the movable platen 63 and the fixed platen 61, thereby making it possible to adjust the mold clamping force, etc.

[0049] The forming operation position 11 is the area between a fixed platen 61 and a movable platen 62 .

[0050] The molds 100A / 100B introduced into the molding operation position 11 are sandwiched between a fixed platen 61 and a movable platen 62, thereby clamping the molds. By the movement of the movable platen 62, the movable mold 102 is opened and closed based on its movement.

[0051] 3 shows an opening 61a at the center of the fixed platen 61, through which the nozzle 52 advances and retreats. A plurality of rollers BR are supported rotatably on the surface (called the inner surface) of the fixed platen 61 facing the movable platen 62. The rollers BR rotate about their rotation axes in the Y-axis direction, support the bottom surfaces (bottom surfaces of the mounting plate 101a) of the molds 100A / 100B, and support the molds 100A / 100B from below to facilitate the movement of the molds 100A / 100B in the X-axis direction. Roller supports 620 are fixed to both sides of the fixed platen 61 in the X-axis direction, and the roller supports 620 support the rollers BR.

[0052] The fixed platen 61 has an inner surface formed with a groove 61b extending in the X-axis direction.

[0053] The grooves 61b are formed in two rows spaced apart from each other vertically. A roller unit 640 is disposed in each groove 61b. A plurality of rollers SR are supported in the roller unit 640 so as to be rotatable. The rollers SR rotate in the Z-axis direction around a rotation axis and contact the outer surface (the outer surface of the mounting plate 101a) of the mold 100A / 100B to support the mold 100A / 100B from the side and guide the movement of the mold 100A / 100B in the X-axis direction. As shown in the cross-sectional view of line II-II, the roller unit 640 is biased by a spring 641 to a position where the rollers SR protrude from the groove 61b, while when the mold is clamped, the rollers SR retract into the groove 61b to a position where they do not protrude from the groove 61b. The roller unit 640 prevents contact between the mold 100A / 100B and the inner surface of the fixed platen 61, which could cause damage to the inner surface, when the mold 100A / 100B is replaced, and does not prevent close contact between the inner surface of the fixed platen 61 and the mold 100A / 100B when the mold is clamped.

[0054] Roller supports 630 are fixed to both sides of the fixed platen 61 in the X-axis direction, and the roller supports 630 support a plurality of rollers SR.

[0055] A plurality of fixing mechanisms (clamps) 610 for fixing the stationary mold 101 to the stationary platen 61 are arranged on the stationary platen 61. Each fixing mechanism 610 includes an engagement portion 610a that engages with the mounting plate 101a, and a built-in actuator (not shown) that moves the engagement portion 610a between an engaged position and a disengaged position.

[0056] As with the fixed platen 61, the movable platen 62 also includes a plurality of rollers BR, roller supports 620 and 630, a roller unit 640, and a fixing mechanism 610 for fixing the movable mold 102.

[0057] 4, the clamping device 6 is surrounded by a cover (exterior plate) 60 for safety, but in order to replace the molds 100A / 100B, an opening 60a through which the molds 100A / 100B pass is formed on the side of the molding operation position 11. Each opening 60a is basically always open, allowing the molds 100A / 100B to be freely ejected and inserted into the molding operation position 11.

[0058] Returning to FIG. 2, the extractor 7 will now be described. The extractor 7 includes a rail 71 extending in the X-axis direction and a movable rail 72 movable on the rail 71 in the X-axis direction. The movable rail 72 is disposed so as to extend in the Y-axis direction, and a slider 73 is disposed on the movable rail 72. The slider 73 moves in the Y-axis direction while being guided by the movable rail 72, and raises and lowers the lifting shaft 73a in the Z-axis direction. A vacuum head 74 is disposed on the lower end of the lifting shaft 73a, and a chuck plate 75 specialized for molded products is attached to the vacuum head 74.

[0059] After the mold is opened, the remover 7 moves the vacuum head 74 between the fixed mold 101 and the movable mold 102, as shown by the dashed lines in Figure 2, using the rails 71, movable rails 72, and slider 73, adsorbs the molded product, and transports it out of the molds 100A / 100B.

[0060] The configuration for controlling the temperature of the mold 100 will be described with reference to FIG. 5. In this exemplary embodiment, high temperature regulators 80A and 80B and low temperature regulators 81A and 81B are provided for heat and cool molding. The high temperature regulator 80A and the low temperature regulator 81A are connected to the mold 100A, and the high temperature regulator 80B and the low temperature regulator 81B are connected to the mold 100B. In another exemplary embodiment, a single high temperature regulator can increase the temperatures of both the mold 100A and the mold 100B, and a single low temperature regulator can decrease the temperatures of both the mold 100A and the mold 100B.

[0061] In another exemplary embodiment using hot runners, a hot runner regulator is included to regulate the temperature of the hot runners. The hot runners maintain the temperature of the molding material injected into the mold at a desired temperature. This can prevent unnecessary waste of molding material. A hot runner regulator may be provided for each of the molds 100A and 100B. A single hot runner regulator may regulate the temperature of both the molds 100A and 100B. In yet another exemplary embodiment using cold runners, the temperature of the cold runners is approximately the same as the temperature of the molds. In this exemplary embodiment, no additional temperature regulator is required for the injection molding system.

[0062] In this exemplary embodiment, whether to perform the heating process while the mold is outside the injection molding machine 2 or while the mold is inside the injection molding machine 2 depends on the length of the heating time and the cooling time. When the heating time is longer than the cooling time, the heating process is performed outside the injection molding machine 2. When the heating time is shorter than the cooling time, the heating process is performed inside the injection molding machine 2. The longer of the heating time and the cooling time is included in the waiting time during which the mold waits outside the injection molding machine 2. Therefore, the productivity of the injection molding system 1 is improved. The injection molding system 1 can select which of the two sequences to execute. The control device 4 can automatically select one of the sequences based on the length of the heating time and the cooling time. The user can select one of the sequences from an operation panel (not shown).

[0063] 6 shows an exemplary list of conditions for heat and cool molding. The conditions listed are merely examples and may be replaced with items that enable the implementation of the present embodiment, or additional items may be added to the exemplary list.

[0064] In an example where the heating process is performed outside the injection molding machine 2, oil or hot water is used as the heating medium, and cooling water is used as the cooling medium. An exemplary molding material is ABS resin, and exemplary molding objects are TV frames and printer frames. In an example where the heating process is performed inside the injection molding machine 2, an electromagnetic induction device is used as the heating medium, and cooling water is used as the cooling medium. An exemplary molding material is PC (polycarbonate) with GF (glass fiber), and an exemplary molding object is a PC frame.

[0065] Comparing the two examples, the heating time when using oil or hot water is longer than the heating time when using an electromagnetic induction device. As a result, the heating time when using oil or hot water is longer than the cooling time, so it is better to perform the heating process outside the injection molding machine 2. The equipment cost for using oil or hot water is usually cheaper than the equipment cost for using an electromagnetic induction device.

[0066] The maximum temperature of the mold 100A / 100B when oil or hot water is used is usually about 100 degrees. The maximum temperature of the mold 100A / 100B when an electromagnetic induction device is used is usually about 160 degrees. Based on this difference, there is a restriction on the molding material that the injection molding machine 2 can perform injection molding. ABS resin melts at 88 degrees, and PC+GF melts at 147 degrees. If the injection molding system 1 cannot raise the temperature of the mold higher than the temperature at which the molding material melts, it is difficult to perform heat and cool molding. Therefore, when PC+GF is used as the molding material, an electromagnetic induction device should be installed. When ABS resin is used as the molding material, oil or hot water, or an electromagnetic induction device can be used as the heating medium.

[0067] FIG. 7 is a flowchart showing an injection molding process in which the heat treatment is performed outside the injection molding machine 2. The control based on the flowchart of FIG. 7 is executed by the CPU included in the control device 4 based on a program stored in the ROM. FIG. 8 is a graph showing the transition of the temperatures of both the mold 100A and the mold 100B. The step numbers in FIG. 7 correspond to the step numbers in FIG. 8. As shown in FIG. 8, some steps of the heat treatment for the mold 100B are completed at a timing related to the start of the flowchart of FIG. 7. At the start of the flowchart of FIG. 7, the mold 100A is located outside the injection molding machine 2, and the mold 100B is located inside the injection molding machine 2 (molding operation position 11).

[0068] First, the control device 4 controls the high-temperature regulator 80A to raise the temperature of the mold 100A located outside the injection molding machine 2 (S301). While the mold 100A is being heated, the control device 4 performs a treatment of the mold 100B located inside the injection molding machine 2.

[0069] The motor 66 is driven to drive the toggle mechanism 65, thereby clamping the mold 100B between the fixed platen 61 and the movable platen 62 (S401). The actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100B. Molten resin is injected into the mold 100B and pressure is maintained (S402). More specifically, the injection unit 5 is driven to fill the cavity in the mold 100B with molten resin from the nozzle 52, and the resin in the cylinder 51 is forced into the mold 100B at high pressure to compensate for the volume reduction caused by the solidification of the resin.

[0070] The mold 100B is cooled inside the injection molding machine 2. After the mold 100B is cooled, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. Since the fixed mold 101 is fixed to the fixed platen 61 by the fixing mechanism 610 and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610, the movable mold 102 is separated from the fixed mold 101 and the mold 100B is opened.

[0071] The remover 7 is driven to remove the molded product remaining on the movable mold 102 side of the mold 100B, and transport it to the outside of the mold 100B (S405).

[0072] Next, the mold 100B is closed (S406). The fixing mechanism 610 is released, and the lock on the mold 100B is released (S407). After a predetermined delay from step S402, the motor 66 is driven to drive the toggle mechanism 65. This causes the mold clamping force to disappear, and the movable platen 62 moves slightly away from the fixed platen 61, forming a space that allows the mold to be replaced.

[0073] Next, the molds 100A and 100B are switched (S302, S408). The mold 100B is carried out from the molding operation position 11 to the transport device 3B, and the mold 100A is carried in from the transport device 3A to the molding operation position 11. The controller 41 transmits an instruction to the controller 42B to carry out the mold 100B, and the controller 42B drives the transport unit 31 to carry out the mold 100B from the molding operation position 11. When the carrying out is completed, the controller 42B transmits a signal indicating the carrying out completion to the controller 41.

[0074] Next, the control device 4 controls the high-temperature regulator 80B to increase the temperature of the mold 100B located outside the injection molding machine 2 (S409).

[0075] While the mold 100B is being heated, the control device 4 processes the mold 100A located inside the injection molding machine 2. The motor 66 is driven to drive the toggle mechanism 65, thereby clamping the mold 100A between the fixed platen 61 and the movable platen 62 (S303). The actuator 55 is driven to move the injection unit 5, and the nozzle 52 is brought into contact with the mold 100A.

[0076] Next, the molten resin is injected into the mold 100A and pressure is maintained (S304). More specifically, the injection device 5 is driven to fill the cavity in the mold 100A with the molten resin from the nozzle 52, and the resin in the cylinder 51 is forced into the mold 100A at high pressure to compensate for the volume reduction caused by the solidification of the resin. The mold 100A is cooled in the injection molding machine 2.

[0077] After cooling the mold 100A, the motor 66 is driven to separate the movable platen 62 from the fixed platen 61. Since the fixed mold 101 is fixed to the fixed platen 61 by the fixing mechanism 610 and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610, the movable mold 102 is separated from the fixed mold 101, and the mold 100A is opened.

[0078] The remover 7 is driven to remove the molded product remaining on the movable mold 102 side of the mold 100A, and transport it to the outside of the mold 100A (S307).

[0079] Next, the mold 100A is closed (S308). The fixing mechanism 610 is released, and the lock on the mold 100A is released (S309). After a predetermined delay from step S304, the motor 66 is driven to drive the toggle mechanism 65. This causes the mold clamping force to disappear, and the movable platen 62 moves slightly away from the fixed platen 61, forming a space that allows the mold to be replaced.

[0080] The molds 100A and 100B are switched again (S310, S410). The mold 100A is carried out from the molding operation position 11 to the transfer device 3A, and the mold 100B is carried into the molding operation position 11 from the transfer device 3B.

[0081] The controller 41 transmits an instruction to the controller 42A to carry out the mold 100A, and the controller 42A drives the transport unit 31 to carry out the mold 100A from the molding operation position 11. When the carrying out is completed, a signal indicating the carrying out is completed is transmitted from the controller 42A to the controller 41. By repeating the above-mentioned process, the heat and cool molding of the mold 100A and the mold 100B is efficiently performed.

[0082] FIG. 9 is a flowchart of an injection molding process in which a heating process is performed inside the injection molding machine 2. Control based on the flowchart of FIG. 9 is executed by a CPU included in the control device 4 based on a program stored in a ROM. FIG. 10 is a graph showing the transition of temperatures of both the mold 100A and the mold 100B. The step numbers in FIG. 9 correspond to the step numbers in FIG. 10. At the start of the flowchart of FIG. 9, the mold 100A is located inside the injection molding machine 2 (molding operation position 11), and the mold 100B is located outside the injection molding machine 2.

[0083] First, the control device 4 controls the high-temperature regulator 80A to increase the temperature of the mold 100A (S101). The actuator 55 is driven to move the injection device 5, and the nozzle 52 is brought into contact with the mold 100A. Next, the molten resin is injected into the mold 100A and pressure is maintained (S102). More specifically, the injection device 5 is driven to fill the cavity in the mold 100A with the molten resin from the nozzle 52, and the resin in the cylinder 51 is forced into the mold 100A at high pressure to compensate for the volume reduction caused by the solidification of the resin.

[0084] Next, the fixing mechanism 610 is released, and the metal mold 100A is unlocked (S103).

[0085] After a predetermined delay from step S102, the motor 66 is driven to drive the toggle mechanism 65. As a result, the mold clamping force disappears and the movable platen 62 moves slightly away from the fixed platen 61, forming a space that allows the mold to be replaced.

[0086] Next, the mold 100 is replaced (S104, S201). The mold 100A is carried out from the molding operation position 11 to the transport device 3A, and the mold 100B is carried from the transport device 3B into the molding operation position 11. The controller 41 transmits an instruction to the controller 42A to carry out the mold 100A, and the controller 42A drives the transport unit 31 to carry out the mold 100A from the molding operation position 11. When the carrying out is completed, the controller 42A transmits a signal indicating the carrying out completion to the controller 41.

[0087] The mold 100A is cooled on the conveying device 3A (S105). While the mold 100A is being cooled, the control device 4 processes the mold 100B. The motor 66 is driven to drive the toggle mechanism 65, thereby clamping the mold 100B between the stationary platen 61 and the movable platen 62 (S202). The motor 66 is driven to separate the movable platen 62 from the stationary platen 61. Since the stationary mold 101 is fixed to the stationary platen 61 by the fixing mechanism 610 and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610, the movable mold 102 is separated from the stationary mold 101, and the mold 100B is opened (S203). The ejector 7 is driven to remove the molded product remaining on the movable mold 102 side of the mold 100B and transport it to the outside of the mold 100B (S204). Next, the mold 100B is closed and clamped (S205).

[0088] Next, the control device 4 controls the high-temperature regulator 80B to increase the temperature of the mold 100B (S206). The actuator 55 is driven to move the injection device 5, and the nozzle 52 is brought into contact with the mold 100B. Next, the molten resin is injected into the mold 100B and pressure is maintained (S207). More specifically, the injection device 5 is driven to fill the cavity in the mold 100B with the molten resin from the nozzle 52, and the resin in the cylinder 51 is forced into the mold 100B at high pressure to compensate for the volume reduction caused by the solidification of the resin.

[0089] The fixing mechanism 610 is released, and the lock on the mold 100B is released (S208). After a predetermined delay from step S207, the motor 66 is driven to drive the toggle mechanism 65. This causes the mold clamping force to disappear, and the movable platen 62 moves slightly away from the fixed platen 61, forming a space that allows the mold to be replaced.

[0090] Next, the mold 100 is replaced (S106, S209). The mold 100B is carried out from the molding operation position 11 to the transport device 3B, and the mold 100A is carried from the transport device 3A into the molding operation position 11. The controller 41 transmits an instruction to the controller 42B to carry out the mold 100B, and the controller 42B drives the transport unit 31 to carry out the mold 100B from the molding operation position 11. When the carrying out is completed, the controller 42B transmits a signal indicating the carrying out completion to the controller 41.

[0091] The mold 100B is cooled on the conveying device 3B. While the mold 100B is being cooled, the control device 4 processes the mold 100A. The motor 66 is driven to drive the toggle mechanism 65, thereby clamping the mold 100A between the stationary platen 61 and the movable platen 62 (S107). The motor 66 is driven to separate the movable platen 62 from the stationary platen 61. Since the stationary mold 101 is fixed to the stationary platen 61 by the fixing mechanism 610 and the movable mold 102 is fixed to the movable platen 62 by the fixing mechanism 610, the movable mold 102 is separated from the stationary mold 101, and the mold 100A is opened (S108). The ejector 7 is driven to remove the molded product remaining on the movable mold 102 side of the mold 100A and transport it to the outside of the mold 100A (S109). Next, the metal mold 100A is closed and clamped (S110). By repeating the above-mentioned process, the heat-and-cool molding of the metal mold 100A and the metal mold 100B is efficiently performed.

[0092] In the embodiments described above, either the heating or cooling process is performed while the mold 100A / 100B is outside the injection molding machine 2. In another exemplary embodiment, both the heating and cooling processes can be performed while the mold 100A / 100B is outside the injection molding machine 2.

[0093] For example, one injection molding operation is divided into four processes: a heating process, an injection / pressure-holding process, a cooling process, and an ejection process. While the heating process of the mold 100A is being performed, the ejection process of the mold 100B is performed. Next, the molds 100A / 100B are switched. While the injection / pressure-holding process of the mold 100A is being performed, the heating process of the mold 100B is performed. Next, the molds 100A / 100B are switched. While the cooling process of the mold 100A is being performed, the injection / pressure-holding process of the mold 100B is performed. Next, the molds 100A / 100B are switched. While the ejection process of the mold 100A is being performed, the cooling process of the mold 100B is performed.

[0094] [Definition] In the description, specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. In other instances, well-known methods, procedures, components, and circuits have not been described in detail to avoid unnecessarily lengthening the present disclosure.

[0095] As used herein, when an element or portion is referred to as being "on," "on," "connected," or "coupled" to another element or portion, it is understood that it may be "on," "on," "connected," or "coupled" directly to that other element or portion, or there may be intervening elements or portions. In contrast, when an element is referred to as being "directly on," "directly connected," or "directly coupled" to another element or portion, there are no intervening elements or portions. When the term "and / or" is used, it includes any and all combinations of one or more of the associated listed items, if any.

[0096] Spatially relative terms such as "under," "beneath," "below," "lower," "above," "upper," "proximal," "distal," and the like may be used herein for ease of description in describing the relationship of an element or feature shown in the various figures to another element or feature(s). However, it should be understood that these spatially relative terms are intended to encompass various orientations of the device in use or operation in addition to the orientation shown in the figures. For example, if the device in the figures were inverted, elements described as "below" or "beneath" other elements or features would be oriented "above" those other elements or features. Thus, a relative spatial term such as "below" can encompass both an orientation above and below. The device may be otherwise oriented (rotated 90 degrees or to other orientations) and the spatially relative descriptors used herein should be interpreted accordingly. Similarly, the relative spatial terms "proximal" and "distal" may be interchangeable where applicable.

[0097] As used herein, the term "about" means, for example, within 10%, within 5%, or less. In some embodiments, the term "about" can also mean within the error of measurement.

[0098] In this specification, terms such as first, second, third, etc. may be used to describe various elements, components, regions, portions, and / or sections. It is to be understood that these elements, components, regions, portions, and / or sections are not limited by these terms. These terms are merely used to distinguish one element, component, region, portion, or section from another region, portion, or section. Thus, a first element, component, region, portion, or section discussed below can also be referred to as a second element, component, region, portion, or section without departing from the teachings of this specification.

[0099] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting. The use of the terms "a," "an," "the," and similar referents in the context of describing the present disclosure (especially in the context of the appended claims) shall be construed to include both the singular and the plural, unless otherwise indicated herein or otherwise clear from the context. The terms "comprising," "having," "includes," "including," and "containing" shall be construed as open-ended terms (i.e., meaning "including, but not limited to"), unless otherwise stated. In particular, when these terms are used herein, they specify the presence of the described features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof not expressly stated. The description of ranges of values ​​herein is merely intended to serve as a shorthand notation for referring individually to each separate value falling within the range, and each separate value is incorporated herein as if it were individually set forth herein, unless otherwise indicated herein. For example, if a range of 10-15 is disclosed, 11, 12, 13, and 14 are also disclosed. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clear from the context. The use of any examples or exemplary language (e.g., "such as") provided herein is intended merely to make the disclosure more clear, and does not limit the scope of the disclosure unless otherwise stated in the claims. No language in this specification should be construed as indicating that any element not recited in the claims is essential to the practice of the disclosure.

[0100] It should be understood that the methods and configurations of the present disclosure can be incorporated in the form of various embodiments, only a few of which are disclosed herein. Variations of those embodiments will be apparent to those skilled in the art upon reading the above description. The inventors anticipate that those skilled in the art will adopt such variations as necessary, and intend that the present disclosure be practiced otherwise than as specifically described herein. Accordingly, the present disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, the present disclosure encompasses any combination of the above-described elements in all possible variations thereof, unless otherwise indicated herein or otherwise apparent from the context.

[0101] Any combination of the exemplary embodiments disclosed above is included as an embodiment of the present disclosure. The exemplary embodiments described above are discussed for illustrative purposes, but are not limited to these embodiments.

Claims

1. A method for a manufacturing system including an injection molding machine and a conveying device, comprising: a first step of injecting a mold at a molding operation position within the injection molding machine and cooling the mold; a second step of removing the molded article from the mold at the molding operation position; a third step of conveying the mold to a path of the conveying device and heating the mold on the path; Including, While the first step and the second step are performed on a first mold in the injection molding machine, the third step is performed on a second mold in the transfer device; While the first step and the second step are performed on the second mold in the injection molding machine, the third step is performed on the first mold in the transfer device; The method of the manufacturing system, wherein the first mold and the second mold are alternately exchanged.

2. A method for a manufacturing system including an injection molding machine and a conveying device, comprising: a first step of heating and injecting a mold at a molding operation position within the injection molding machine; a second step of transporting the mold to a path of the transport device outside the molding operation position and cooling the mold on the path; a third step of transporting the mold to the molding operation position and removing a molded product from the mold at the molding operation position; Including, the conveying device includes a first conveying device and a second conveying device disposed on one side and the other side of the lateral direction of the injection molding machine at the molding operation position, respectively, and the molding operation position is located between the first conveying device and the second conveying device; While the third step and the first step are performed on a first mold in the injection molding machine, the second step is performed on a second mold in the transfer device; While the third step and the first step are performed on the second mold in the injection molding machine, the second step is performed on the first mold in the transfer device; The time for heating the mold and the time for cooling the mold are controlled based on a program; The heating time is shorter than the cooling time, The first conveying device is arranged to carry the first mold into and out of the molding operation position, and the second conveying device is arranged to carry the second mold into and out of the molding operation position, whereby the first mold and the second mold are alternately exchanged. Manufacturing system methods.

3. An injection molding machine; a transport device configured to transport a mold to the injection molding machine; A control device configured to control the injection molding machine and the conveying device; An injection molding system comprising: the control device is configured to select one of the first molding process and the second molding process based on the length of the heating time and the cooling time of the mold controlled based on a program, and is configured to execute the selected process; the first molding step includes heating the mold on a path of the conveying device, conveying the mold to a molding operation position in the injection molding machine, injecting the mold at the molding operation position, and cooling the mold at the molding operation position, and in the first molding step, the heating is performed on a second mold while the conveying, injecting, and cooling are performed on a first mold, and the heating is performed on the first mold while the conveying, injecting, and cooling are performed on the second mold; the second molding step includes heating the mold at the molding operation position, injecting the mold at the molding operation position, transporting the mold to the path of the transport device, and cooling the mold on the path; In the second molding step, the conveying, the injecting, and the heating are performed on a first mold while the cooling is performed on a second mold, and the conveying, the injecting, and the heating are performed on the second mold while the cooling is performed on the first mold; When the heating time is longer than the cooling time, the control device selects and executes the first molding process, and when the heating time is shorter than the cooling time, the control device selects and executes the second molding process. Injection molding system.

4. 4. The injection molding system of claim 3, further comprising a first temperature regulator configured to set a temperature of the first mold to a first temperature higher than a temperature at which a molding material melts, and a second temperature regulator configured to set a temperature of the second mold to a second temperature higher than the temperature at which the molding material melts.

5. A method for a manufacturing system including an injection molding machine and a conveying device, comprising: a setting step in which molding conditions are set by a control device based on the length of time for heating and cooling a mold controlled based on a program, and a molding process to be performed is selected by the control device from among a plurality of molding processes based on the molding conditions set in the setting step; One of the molding steps among the plurality of molding steps includes heating a mold on a path of the conveying device, conveying the mold to a molding operation position in the injection molding machine, injecting into the mold at the molding operation position, and cooling the mold at the molding operation position, and in one molding step, the heating is performed on a second mold while the conveying, injecting, and cooling are performed on a first mold, and the heating is performed on the first mold while the conveying, injecting, and cooling are performed on the second mold, Another molding step among the plurality of molding steps includes heating a mold at a molding operation position, injecting the mold at the molding operation position, transporting the mold to a path of the transport device, and cooling the mold on the path, and in the another molding step, the cooling is performed on a second mold while the transporting, injecting, and heating are performed on a first mold, and the cooling is performed on the first mold while the transporting, injecting, and heating are performed on the second mold; When the heating time is longer than the cooling time, the control device selects and executes the one molding process, and when the heating time is shorter than the cooling time, the control device selects and executes the other molding process. Manufacturing system methods.

6. A heating time for heating the mold in the third step is longer than a cooling time for cooling the mold in the first step; The heating time and the cooling time are controlled based on a program. The method of claim 1.

7. In the third step, the heating of the mold includes heating the mold with one of oil and hot water. The method of claim 1.

8. In the first step, the injecting into the mold includes injecting ABS resin into the mold. The method of claim 1.

9. the first step includes injecting a molding material into the mold, and heating the mold in the third step includes heating the mold to a temperature higher than a temperature at which the molding material melts.

9. The method according to any one of claims 1, 6, 7 and 8.

10. 1. A conveying apparatus configured to be coupled to an injection molding machine forming a manufacturing system, the conveying apparatus comprising: A first conveying device; A second conveying device; a controller configured to control the first transport device and the second transport device and to control a step of transporting a mold to a path of the transport device and on the path for heating the mold, The step of transporting is performed to transport a second mold by the second transport device while a step of injecting a molding material into a first mold, cooling the first mold, and then removing a molded product from the first mold at a molding operation position is performed in the injection molding machine; The step of transporting is performed to transport a first mold by the first transport device while a step of injecting the molding material into the second mold, cooling the second mold, and then removing a molded product from the second mold at the molding operation position is performed in the injection molding machine; The first mold and the second mold are alternately exchanged. A controller, Conveying device.

11. 1. An injection molding machine configured to be coupled to a conveying device forming a manufacturing system, the injection molding machine comprising: a first step of injecting into a mold in the injection molding machine and cooling the mold in a molding operation position; a second step of removing the molded article from the mold at the molding operation position; a third step of conveying the mold to a path of the conveying device and heating the mold on the path; A controller configured to execute while the first step and the second step are performed for a first mold in the injection molding machine, the third step is performed for a second mold in the path; While the first step and the second step are performed for the second mold in the injection molding machine, the third step is performed for the first mold in the conveying device; The first mold and the second mold are alternately exchanged. A controller is provided. Injection molding machine.

12. heating the mold in the first step includes heating the mold with an electromagnetic induction device. The method of claim 2.

13. Injecting into the mold in the first step includes injecting polycarbonate with glass fibers into the mold. The method of claim 2.

14. the first step includes injecting a molding material into the mold, and heating the mold in the first step includes heating the mold to a temperature higher than a temperature at which the molding material melts; 14. The method of any one of claims 2, 12 and 13.

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