Injection molding system, and manufacturing system

Abstract

To realize space saving while increasing a degree of freedom in customizing an injection molding system.SOLUTION: An injection molding unit consists of a main unit in which a first injection molding machine is arranged to mold an integrated product by injecting a first molding material into a cavity which is divided by a lower mold and an upper mold and in which an insert member is placed, and an optional unit. The optional unit includes at least one of the following: a component molding unit in which a second injection molding machine that molds an insert member by injecting a second molding material or a press molding machine that molds an insert member by press molding is arranged; and a robot unit in which a robot that performs a placement operation to place an insert member in a cavity or a transfer operation to transport the integrated product molded by the first injection molding machine is arranged. The main unit is configured to allow the optional unit to be detachable.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to an injection molding system and a manufacturing system.

Background Art

[0002] Regarding an injection molding system, Patent Document 1 discloses a system including a plurality of molding cells connected to a management device via a network. Each molding cell includes an injection molding machine, a temperature control machine for adjusting the temperature of a mold, an imaging device for imaging a molded product, and a robot for taking out the molded product. The configuration of each molding cell is customizable. For example, there may be a configuration including a molded product taking-out device instead of a robot, a configuration including a molded product measuring device, or a configuration not including a molded product imaging device.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Although the above document describes that each device constituting the molding cell is connected by a communication line, it does not particularly mention the physical arrangement of each device. In recent years, downsizing of manufacturing equipment has been demanded. As described above, in an injection molding system including a plurality of devices related to injection molding, a technology capable of realizing space saving while increasing the degree of freedom of customization is required.

Means for Solving the Problems

[0005] According to a first aspect of the present disclosure, an injection molding unit is provided. The injection molding unit includes a main unit in which a first injection molding machine for injecting a first molding material into a cavity partitioned by a lower mold and an upper mold and in which an insert member is disposed to mold an integrated product is disposed, and an option unit. The option unit includes at least one of a member molding unit in which a second injection molding machine for injecting a second molding material to mold the insert member or a press molding machine for molding the insert member by press molding is disposed, and a robot unit in which a robot that performs an arrangement operation of arranging the insert member in the cavity or a transfer operation of transferring the integrated product molded by the first injection molding machine is disposed. The main unit is configured to be detachable from the option unit.

[0006] According to a second aspect of the present disclosure, a manufacturing system is provided. The manufacturing system includes one or more injection molding systems according to the above aspect, an assembly line for assembling a product using the integrated product, and a transfer unit for transferring the integrated product from the injection molding system to the assembly line.

Brief Description of the Drawings

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Embodiments for Carrying Out the Invention

[0008] A. First Embodiment: FIG. 1 is a front view showing the schematic configuration of the injection molding system 5 in the first embodiment. FIG. 2 is a plan view showing the schematic configuration of the injection molding system 5 in the first embodiment. In FIGS. 1 and 2, arrows along the X, Y, and Z directions orthogonal to each other are shown. The X, Y, and Z directions are the directions along the X-axis, Y-axis, and Z-axis, which are three mutually orthogonal spatial axes, and include both the directions on one side along the X-axis, Y-axis, and Z-axis and the opposite directions. The X-axis and Y-axis are axes along the horizontal plane, and the Z-axis is an axis along the vertical line. The -Z direction is the vertical direction, and the +Z direction is the direction opposite to the vertical direction. The -Z direction is also referred to as "down", and the +Z direction is also referred to as "up". In other figures, arrows along the X, Y, and Z directions are also represented as appropriate. The X, Y, and Z directions in FIGS. 1 and 2 represent the same directions as the X, Y, and Z directions in other figures.

[0009] The injection molding system 5 includes a main unit 100 and an option unit 400. In this embodiment, the option unit 400 includes a robot unit 450 and an accessory equipment unit 700. In this embodiment, the robot unit 450 is arranged adjacent to the main unit 100 in the -Y direction of the main unit 100. The accessory equipment unit 700 is arranged adjacent to the robot unit 450 in the -Y direction of the robot unit 450. In the following description, when not particularly distinguishing between the units included in the option unit 400, these units may also be simply referred to as the option unit 400. That is, in this embodiment, the robot unit 450 and the accessory equipment unit 700 are not distinguished, and both may be simply referred to as the option unit 400.

[0010] The main unit 100 is configured to be detachable from the option unit 400. In this embodiment, the robot unit 450 and the accessory unit 700 are detachable from the main unit 100. In this embodiment, as shown in FIG. 2, a plate-like member 6 for connection is bridged between the main unit 100 and the robot unit 450, and the plate-like member 6 is fastened to the main unit 100 and the robot unit 450 with bolts, whereby the robot unit 450 is detachably connected to the main unit 100. The accessory unit 700 is detachably connected to the main unit 100 by connecting pipes and wirings (not shown) provided in the accessory unit 700 to the main unit 100. Further, the accessory unit 700 and the robot unit 450 are connected by the plate-like member 6 in the same manner as the connection between the main unit 100 and the robot unit 450. As the connection means for detachably connecting the option unit 400 to the main unit 100, not limited to the above bolts and pipes, fasteners such as clamps and various metal fittings may be used.

[0011] When the main unit 100 and the accessory unit 700 are arranged adjacent to each other, it is also possible to connect them with the plate-like member 6. For example, the accessory unit 700 may be arranged in the +Y direction of the main unit 100 and connected to the main unit 100. On the other hand, as in this embodiment, by not connecting the option unit 400 in the +Y direction of the main unit 100 and positioning the main unit 100 at the end in the +Y direction of the injection molding system 5, maintenance of the main unit 100 can be easily performed from the +Y direction side of the main unit 100 without moving each unit, so the maintainability of the main unit 100 is improved.

[0012] In this embodiment, the dimensions of each unit in the X direction and the dimensions in the Z direction are unified. More specifically, as shown in FIG. 2, the dimensions of each housing of the main unit 100 and the option unit 400 in the X direction are unified to the dimension Lx, and as shown in FIG. 1, the dimensions of each housing in the Z direction are unified to the dimension Lz. As a result, when the units are arranged along the Y direction as in this embodiment, in the X direction and the Z direction, it is possible to suppress a certain unit from protruding more than other units. Therefore, for example, when swapping the arrangement of the units, the change in the shape of the outer edges of the entire main unit 100 and option unit 400 in the X direction and the Z direction is suppressed, so the possibility that the arrangement of each unit is restricted by the installation space is reduced. Also, for example, when replacing a unit included in the option unit 400 with another unit or adding a new unit to the option unit 400, the possibility that the arrangement of each unit is restricted by the installation space is reduced in the X direction and the Z direction. Therefore, the degree of freedom in arranging each unit in the injection molding system 5 and in selecting the option unit 400 is improved.

[0013] As shown in FIG. 1, each housing of the main unit 100 and the option unit 400 is provided with a wheel 99. In a state where the main unit 100 and the option unit 400 are not connected, each unit can move independently. Also, in the vicinity of the wheel 99 of each unit, a bolt-type stopper 98 is provided. By using the stopper 98, the user can fix each unit or the injection molding system 5 at an arbitrary installation location.

[0014] As shown in FIG. 1, the main unit 100, the robot unit 450, and the accessory equipment unit 700 are each covered by a first cover C1 to a third cover C3 around them. This suppresses the intrusion of foreign substances such as dust into the injection molding system 5. Each cover may be made of, for example, at least partially transparent glass or resin so that the internal working conditions can be visually recognized from the outside. Also, each cover may be provided with, for example, a door for maintenance or an opening for ventilation. Note that FIG. 2 shows a top view of the injection molding system 5 with the covers of each unit removed.

[0015] As shown in FIG. 2, a first injection molding machine 101 is arranged in the main unit 100. A robot 451 is arranged in the robot unit 450. A mold temperature controller 710 and a material feeding device 720 are arranged in the accessory equipment unit 700.

[0016] FIG. 3 is a first diagram showing a schematic configuration of the first injection molding machine 101 in the first embodiment. The first injection molding machine 101 in the present embodiment includes a first control unit 103, an injection device 110, a lower mold support unit 150, a position changing unit 180, a mold clamping device 200, an ejector unit 250, and a base 300. The base 300 is fixed to the housing of the main unit 100.

[0017] The first injection molding machine 101 is configured to be able to install a mold 10. The mold 10 has an upper mold 11 and a lower mold 15. The upper mold 11 and the lower mold 15 define a cavity, which is a space corresponding to the shape of the molded product. More specifically, unevenness for defining the cavity is provided on the lower surface of the upper mold 11 and the upper surface of the lower mold 15. When the upper mold 11 and the lower mold 15 are clamped, a cavity having a shape corresponding to these unevennesses is defined between the upper mold 11 and the lower mold 15. The mold 10 may be made of, for example, metal, resin, or ceramic. The metal mold 10 is sometimes referred to as a die.

[0018] The forming die 10 is installed in the first injection molding machine 101 by being supported by the support part of the first injection molding machine 101. In the present embodiment, the support part refers to the upper die support part 13 that supports the upper die 11 and the lower die support part 150 that supports the lower die 15. The upper die support part 13 is fixed to the lower part of the injection device 110 and is configured as a holder including an upper die clamp 12 for clamping and fixing the upper die 11 in the Y direction. The lower die support part 150 is provided below the upper die support part 13 and is configured as a holder including a lower die clamp 160 for clamping and fixing the lower die 15 in the Y direction. In FIGS. 2, 3, and other figures described later, unless otherwise specified, the state in which the forming die 10 is installed in the first injection molding machine 101 is shown.

[0019] As shown in FIG. 3, in the present embodiment, in the state where the forming die 10 is supported by the support part, that is, in the state where the upper die 11 is supported by the upper die support part 13 and the lower die 15 is supported by the lower die support part 150, the upper die 11 is disposed below the injection device 110, and the lower die 15 is disposed below the upper die 11. That is, in the state where the forming die 10 is supported by the support part, the injection device 110, the upper die 11, and the lower die 15 are arranged in order from above in the vertical direction. In the present embodiment, in the state where the forming die 10 is supported by the support part, both the upper die 11 and the lower die 15 are disposed above the base 300.

[0020] The first injection molding machine 101 is configured as an injection molding machine for performing insert molding. Insert molding is one of the methods for molding a molded product by injection molding, and refers to a method of molding an integrated product in which an insert part and the injection-molded molding material are integrated as a molded product by injecting the molding material into the cavity of the forming die 10 in which the insert member is disposed. In the present embodiment, the insert member is disposed in the cavity of the forming die 10 by being placed on the lower die 15. The insert member may be formed of, for example, metal or resin. The molding material injected by the first injection molding machine 101 may also be referred to as the first molding material.

[0021] The first control unit 103 is composed of a computer including one or more processors, a main storage device, and an input / output interface for inputting and outputting signals to and from the outside. By the processor loading and executing a program on the main storage device, the first control unit 103 in the present embodiment controls the injection device 110 and the mold clamping device 200 of the first injection molding machine 101 to shape an integrated product, and also controls various devices provided in the option unit 400, thereby exerting a function of overall controlling the entire injection molding system 5.

[0022] The mold clamping device 200 in the present embodiment is configured to be able to perform mold clamping and mold opening of the mold 10 by moving the injection device 110 and the upper mold 11 along the Z direction in a state where the mold 10 is supported by a support portion. The mold clamping device 200 includes a mold driving unit 210, a first support column portion 230, and a second support column portion 240. The mold driving unit 210 has a mold clamping motor 212, a speed reducer 214, a ball screw portion 216, a movable platen 218, and a fixed platen 220.

[0023] The first support column portion 230 is composed of four columns extending in the Z direction. A base 300 is fixed to the upper end portion of the first support column portion 230, and the fixed platen 220 of the mold driving unit 210 is fixed to the lower end portion. That is, the base 300 and the fixed platen 220 are fixed to each other by the first support column portion 230. In FIG. 3, only two columns arranged in the -Y direction among the four columns constituting the first support column portion 230 are shown.

[0024] The fixed platen 220 has a flat plate shape. The fixed platen 220 is fixed to the lower end portion of the above-described first support column portion 230 so that its plate surface is parallel to the horizontal direction.

[0025] The clamping motor 212 in this embodiment is composed of a motor with an electromagnetic brake. The clamping motor 212 generates a braking force by the electromagnetic brake to restrict the rotation of the motor shaft when no voltage is applied to the exciting coil, and allows the restriction of the rotation of the motor shaft when no voltage is applied to the exciting coil. The clamping motor 212 is disposed below the lower mold 15. More specifically, the clamping motor 212 is fixed to the lower part of the fixed plate 220 fixed to the lower end of the first support portion 230 with its output shaft facing upward. The drive of the clamping motor 212 is controlled by the first control unit 103.

[0026] The speed reducer 214 is connected to the output shaft of the clamping motor 212. A ball screw portion 216 is connected to the output shaft of the speed reducer 214. The speed reducer 214 in this embodiment is a coaxial type speed reducer in which the input shaft and the output shaft are on the same axis. The speed reducer 214 is fixed to the fixed plate 220 with the ball screw portion 216 connected to the speed reducer 214 protruding upward with respect to the fixed plate 220.

[0027] The movable plate 218 has a flat plate shape. The movable plate 218 is coupled to the ball screw portion 216 so that its plate surface is parallel to the horizontal direction, and is penetrated in the Z direction by the first support portion 230. The movable plate 218 moves in the Z direction with respect to the fixed plate 220 with its lower surface facing the upper surface of the fixed plate 220 by the rotation of the ball screw portion 216 due to the drive of the clamping motor 212, using the first support portion 230 as a guide.

[0028] The second support portion 240 in this embodiment is composed of four columns extending in the Z direction. The second support portion 240 is provided so as to penetrate the base 300 in the Z direction. The movable plate 218 is fixed to the lower end of the second support portion 240. The injection device 110 is fixed to the upper end of the second support portion 240. In FIG. 3, only two columns arranged in the -X direction among the four columns constituting the second support portion 240 are shown.

[0029] FIG. 4 is a second diagram showing the schematic configuration of the first injection molding machine 101. FIG. 4 shows a state in which the mold 10 installed in the first injection molding machine 101 is clamped. As shown in FIGS. 3 and 4, the mold clamping device 200 clamps and opens the mold 10 by moving the injection device 110 and the upper mold 11 along the vertical direction by driving the mold clamping motor 212. More specifically, when the driving force of the mold clamping motor 212 is transmitted to the ball screw portion 216 via the speed reducer 214, the movable platen 218 coupled to the ball screw portion 216 moves in the Z direction along the first support portion 230, and the injection device 110 and the upper mold 11 fixed to the movable platen 218 via the second support portion 240 move in the Z direction. The mold clamping device 200 can perform mold clamping by moving the movable platen 218 in the -Z direction to move the injection device 110 and the upper mold 11 in the -Z direction with respect to the lower mold 15. Similarly, the mold clamping device 200 can perform mold opening by moving the movable platen 218 in the +Z direction to move the injection device 110 and the upper mold 11 in the +Z direction with respect to the lower mold 15. An injection molding machine that performs mold opening and mold clamping along the vertical direction, such as the first injection molding machine 101, is sometimes referred to as a vertical injection molding device or a vertical injection molding machine.

[0030] In addition, in the present embodiment, since the rotation of the motor shaft of the mold clamping motor 212 is restricted in a state where no voltage is applied to the mold clamping motor 212 by the electromagnetic brake of the mold clamping motor 212 described above, the ball screw portion 216 is prevented from rotating unintentionally due to the downward load by the injection device 110, the upper mold 11, and the movable platen 218. Thereby, it is suppressed that the injection device 110 and the upper mold 11 move downward toward the lower mold 15 unintentionally.

[0031] The position changing unit 180 is configured to linearly move the lower mold support unit 150 along an intersecting direction which is a direction intersecting with the vertical direction. In the present embodiment, the position changing unit 180 is configured to linearly move the lower mold support unit 150 along the X direction. The position changing unit 180 includes a movable part 186 that supports the lower mold support unit 150, and an electric actuator 181 that moves the movable part 186. The electric actuator 181 is composed of a ball screw and a motor that rotates the ball screw. The position changing unit 180 of the present embodiment moves the movable part 186 to slide in the X direction with respect to the base 300 by driving the electric actuator 181. The driving of the electric actuator 181 is controlled by the first control unit 103.

[0032] FIG. 5 is a perspective view showing the lower mold support unit 150 and the position changing unit 180. In FIG. 5, the second support column part 240 is omitted. As shown in FIG. 5, the electric actuator 181 of the position changing unit 180 is arranged along the X direction in a recess 305 formed in the base 300. The recess 305 is a part where the upper surface 301 of the base 300 is recessed downward and is formed along the X direction.

[0033] Furthermore, a linear guide 306 is provided in the recess 305. The linear guide 306 functions as a guide for the movable part 186 that is moved by the electric actuator 181. The linear guide 306 is composed of a pair of parallel rail-shaped members that are long in the X direction and is fixed to the bottom surface of the recess 305 via bolts.

[0034] The movable part 186 has a plate part 187 which is a rectangular plate-shaped member that supports the lower mold support part 150, and a leg part 188 that supports the plate part 187. The plate part 187 and the leg part 188 are fixed to each other via bolts. The leg part 188 is coupled to the electric actuator 181. The leg part 188 has a shape that engages with the linear guide 306 in the Y direction. Due to the engagement between the leg part 188 and the linear guide 306, the movement of the movable part 186 along the X direction is allowed, and the movement of the movable part 186 along the Y direction is restricted. Therefore, the movable part 186 can be stably moved along the X direction by driving the electric actuator 181.

[0035] The above-described lower mold support part 150 has a pair of blocks 152 that are arranged facing each other in the Y direction. Each block 152 is fixed to the upper surface of the plate part 187 via bolts. Each block 152 has an edge part 153 for placing the lower mold 15. The above-described lower mold clamp 160 is provided on the upper surface of the block 152. More specifically, one lower mold clamp 160 is provided on the upper surface of each block 152. The lower mold clamp 160 sandwiches and fixes the lower mold 15 placed on the edge part 153 of the block 152 in the Y direction.

[0036] The position changing part 180 is configured to be able to switch between a state where the lower mold 15 is located at the injection position P shown in FIG. 3 and a state where the lower mold 15 is located at a position different from the injection position P by moving the lower mold support part 150. The injection position P refers to the position where the lower mold 15 and the upper mold 11 face each other. The position changing part 180 of the present embodiment positions the lower mold 15 at the injection position P and the standby position W by moving the lower mold support part 150 in the X direction. Note that FIG. 2 shows a state where the lower mold 15 is located at the standby position W, and FIG. 3 shows a state where the lower mold 15 is located at the injection position P. The first injection molding machine 101 may be provided with, for example, a positioning pin or the like for positioning the lower mold 15 at the injection position P or the standby position W.

[0037] The ejector part 250 shown in Fig. 3 is a member for removing the molded product from the lower mold 15. The ejector part 250 of the present embodiment removes the molded product from the lower mold 15 at the standby position W described above. The ejector part 250 has a main body part 260 for pushing up the molded product from the lower mold 15 and an ejector drive part 270 for operating the main body part 260. In the present embodiment, the main body part 260 is connected to the lower mold 15 and moves along the X direction together with the lower mold 15 by the position changing part 180. The ejector drive part 270 is fixed to the base 300.

[0038] The main body part 260 has a flat ejector plate 261 and a shaft-shaped ejector pin 262 fixed to the ejector plate 261. The main body part 260 is connected to the lower mold 15 by inserting the ejector pin 262 into a through hole formed so as to penetrate in the Z direction a portion partitioning the cavity of the lower mold 15 from below the lower mold 15. As shown in Fig. 5, the ejector plate 261 is disposed between the lower mold 15 and the plate part 187 in the Z direction and between the blocks 152 constituting the lower mold support part 150 in the Y direction in a state where the lower mold 15 is supported by the lower mold support part 150. Further, as shown in Fig. 3, a hole part 189 penetrating the plate part 187 in the Z direction is provided at a position where at least a part of the ejector plate 261 overlaps the plate part 187 when viewed along the Z direction. In the present embodiment, the hole part 189 is provided at the central part of the plate part 187 in the X direction and the Y direction.

[0039] The ejector drive part 270 is constituted by a ball screw and a motor for rotating the ball screw. As shown in Fig. 1, the ejector drive part 270 is fixed to the base 300 below the base 300. The drive of the ejector drive part 270 is controlled by the first control part 103.

[0040] A contact part 280 is coupled to the ball screw of the ejector drive part 270. The contact part 280 is disposed in a cavity part 307 penetrating the base 300 in the Z direction.

[0041] When the lower mold 15 is in the standby position W, the ejector drive unit 270 can push up the main body 260 by moving the contact part 280 coupled to the ball screw in the +Z direction. More specifically, the contact part 280 protrudes from the cavity 307 in the +Z direction by the drive of the ejector drive unit 270, and further, by passing through the hole 189 formed in the plate part 187 in the +Z direction, it can contact the ejector plate 261. Then, the contact part 280 can push up the main body 260 in the +Z direction by moving further in the +Z direction in a state of being in contact with the ejector plate 261. The molded product is pushed up in the +Z direction by the ejector pins of the pushed-up main body 260, and the molded product is removed from the lower mold 15.

[0042] FIG. 6 is a cross-sectional view showing the configuration of the injection device 110 provided in the first injection molding machine 101. The injection device 110 includes a material supply unit 20, a rotor 40, a barrel 50, a heater 58, a nozzle 60, and an injection control mechanism 70.

[0043] The injection device 110 plasticizes at least a part of the material supplied between the rotor 40 and the barrel 50 from the material supply unit 20 by the rotor 40, the barrel 50, and the heater 58 to generate a molding material, and injects the molding material from the nozzle 60 toward the cavity of the mold 10. In the present embodiment, "plasticization" means that heat is applied to a thermoplastic material to melt it. Further, "melting" means not only that a thermoplastic material is heated to a temperature equal to or higher than the melting point to become liquid, but also that a thermoplastic material is heated to a temperature equal to or higher than the glass transition point to soften and exhibit fluidity.

[0044] The material supply unit 20 in this embodiment is constituted by a hopper. The material supply unit 20 stores materials in the form of pellets, powders, etc. In this embodiment, ABS resin formed into pellets is used as the material. As shown in FIG. 6, a supply path 22 is provided below the material supply unit 20. The supply path 22 is connected to an introduction path 106 formed in the housing portion 105. The material supply unit 20 supplies the material between the rotor 40 and the barrel 50 via the supply path 22 and the introduction path 106.

[0045] The rotor 40 is also called a scroll or a flat screw. The rotor 40 is rotationally driven about a rotation axis RX along the Z direction by a rotor drive unit 31 constituted by a drive motor 32 and a rotor speed reducer 35. The rotor 40 and the rotor speed reducer 35 are housed in the housing portion 105. The rotation of the rotor 40 by the rotor drive unit 31 is controlled by the first control unit 103.

[0046] A communication hole 56 into which the generated modeling material flows is formed at the center of the barrel 50. An injection cylinder 71 of an injection control mechanism 70 described later is connected to the communication hole 56. A check valve 59 is provided in the communication hole 56 at a position upstream of the injection cylinder 71.

[0047] FIG. 7 is a perspective view showing a schematic configuration of the rotor 40. The rotor 40 has a substantially cylindrical shape in which the height in the direction along its central axis is smaller than the diameter. On the groove forming surface 42 of the rotor 40 facing the barrel 50, spiral grooves 45 are formed centering on the central portion 47. The grooves 45 communicate with a material inlet 44 formed on the rotor side surface 43 of the rotor 40. The material supplied from the material supply unit 20 is supplied to the grooves 45 through the material inlet 44. The grooves 45 are formed by being separated by ridge portions 46. FIG. 7 shows an example in which three grooves 45 are formed, but the number of grooves 45 may be one, or two or more. Note that the grooves 45 are not limited to a spiral shape, and may be a helical shape, an involute curve shape, or a shape extending in an arc from the central portion toward the outer periphery.

[0048] The rotor 40 of this embodiment is provided with a residence suppression portion 48 that protrudes toward the communication hole 56 at the central portion 47. In this embodiment, the residence suppression portion 48 has a substantially conical shape, and the central axis of the residence suppression portion 48 substantially coincides with the rotation axis RX of the rotor 40. The tip of the residence suppression portion 48 is disposed inside the communication hole 56 formed in the barrel 50. The residence suppression portion 48 efficiently guides the molding material from the central portion 47 to the communication hole 56, and suppresses the residence of the molding material at the central portion 47. In other embodiments, the rotor 40 may not be provided with the residence suppression portion 48.

[0049] FIG. 8 is a schematic plan view of the barrel 50. The barrel 50 has an opposing surface 52 that opposes the groove forming surface 42 of the rotor 40. As shown in FIG. 8, the above-described communication hole 56 is formed so as to open at the central portion of the opposing surface 52. A plurality of guide grooves 54 that are connected to the communication hole 56 and extend in a spiral shape from the communication hole 56 toward the outer periphery are formed in the opposing surface 52. Note that in other embodiments, the guide grooves 54 may not be connected to the communication hole 56. Further, the barrel may not be provided with the guide grooves 54.

[0050] The heater 58 heats the material supplied between the groove forming surface 42 of the rotor 40 and the opposing surface 52 of the barrel 50. As shown in FIG. 6, in this embodiment, four heaters 58 are provided in the barrel 50. The output of the heater 58 is controlled by the first control unit 103.

[0051] The material supplied to the groove 45 of the rotor 40 is plasticized between the groove forming surface 42 of the rotor 40 and the opposing surface 52 of the barrel 50 by the rotation of the rotor 40 and the heating by the heater 58, and is guided to the central portion 47 of the rotor 40 by the rotation of the rotor 40. The material that has flowed into the central portion 47 is sent out to the communication hole 56 provided at the center of the barrel 50, and is further guided from the communication hole 56 to the injection control mechanism 70.

[0052] As shown in FIG. 6, the injection control mechanism 70 includes an injection cylinder 71 and a plunger 72. The injection control mechanism 70 has a function of injecting the molding material in the injection cylinder 71 into the cavity of the mold 10. The injection control mechanism 70 controls the injection amount of the molding material from the nozzle 60 under the control of the first control unit 103. The injection cylinder 71 is a substantially cylindrical member connected to the communication hole 56 of the barrel 50. In the present embodiment, the injection cylinder 71 is arranged along the X direction. The plunger 72 is inserted into the injection cylinder 71. The plunger 72 slides inside the injection cylinder 71 and pumps the molding material in the injection cylinder 71 to the nozzle 60. The plunger 72 is driven by a motor (not shown).

[0053] The mold temperature regulator 710 arranged in the accessory equipment unit 700 shown in FIG. 2 circulates a heat medium through a cooling pipe provided in the mold 10 via a pipe (not shown) to adjust the temperature of the mold 10. The material feeding device 720 is composed of a dryer that stores the material used in the first injection molding machine 101 while dehumidifying and drying it, and a loader that sends the material stored in the dryer to the material supply unit 20, and sends the material to the material supply unit 20 via a tube (not shown) or the like. In the present embodiment, the mold temperature regulator 710 and the material feeding device 720 are controlled by the first control unit 103.

[0054] The robot 451 arranged in the robot unit 450 is composed of a horizontal articulated robot and includes an arm and a second control unit 455. An end effector is attached to the arm of the robot 451. In the present embodiment, an adsorption pad for adsorbing a molded product or an insert member is attached to the arm as the end effector. The robot 451 is installed on a robot base 452 fixed to the housing of the robot unit 450. In other embodiments, the robot 451 may not be a horizontal articulated robot, and may be, for example, a Cartesian robot or a vertical articulated robot.

[0055] Similar to the first control unit 103, the second control unit 455 is constituted by a computer. By the processor executing programs and instructions loaded onto the main memory device, the second control unit 455 controls the operations of the arm and the end effector, enabling the robot 451 to exhibit various functions. In the present embodiment, the operation of the robot 451 is controlled by the first control unit 103 via the second control unit 455.

[0056] In the present embodiment, the robot 451 disposed in the robot unit 450 functions as a feeding robot and a conveying robot. The feeding robot refers to a robot that performs an arrangement operation of arranging an insert member in the cavity of the mold 10. In the present embodiment, the robot 451 functioning as a feeding robot arranges the insert member in the cavity of the mold 10 by placing the insert member on the lower mold 15 located at the standby position W.

[0057] The conveying robot refers to a robot that performs a conveying operation of conveying the integrated product molded by the first injection molding machine 101. In the present embodiment, the robot 451 functioning as a conveying robot adsorbs the integrated product molded by the first injection molding machine 101 and removed from the lower mold 15 by the ejector unit 250 at the standby position W, and conveys the adsorbed integrated product to an inspection device (not shown) installed on the robot base 452 to perform an appearance inspection of the integrated product. Thereafter, the robot 451 conveys the integrated product to a packing device (not shown) installed on the robot base 452 and performs packing of the integrated product.

[0058] The end effector attached to the arm of the robot 451 may have, for example, a portion for adsorbing a molded product and a portion for adsorbing an insert member. In such a configuration, when the robot 451 functions as a transfer robot and a material supply robot as in the present embodiment, the robot 451 can adsorb the molded product removed from the lower mold 15 while adsorbing the insert member. Therefore, the movement distance of the arm from when the molded product removed from the lower mold is adsorbed until the insert member is placed on the lower mold 15 can be made smaller. As a result, injection molding can be performed more efficiently. Further, the end effector may be configured by a gripper that grips the molded product and the insert member, for example, instead of an adsorption pad. In this case, the end effector may have, for example, a portion for gripping the molded product and a portion for gripping the insert member.

[0059] According to the injection molding system 5 of the present embodiment described above, the main unit 100 is configured to be detachable from the option unit 400. Therefore, while increasing the degree of freedom in customizing the injection molding system 5, it is possible to save space compared to installing each unit or each device separately.

[0060] Further, in the present embodiment, in a state where the upper mold 11 and the lower mold 15 are installed in the first injection molding machine 101, the injection device 110, the upper mold 11, and the lower mold 15 are arranged in order from above in the vertical direction. The injection device 110 includes a flat screw, a barrel 50, and a heater 58, and at least a part of the material is plasticized by the rotation of the flat screw and the heating by the heater 58 to generate a molding material. Thereby, for example, compared with the case where the injection device 110, the upper mold 11, and the lower mold 15 are arranged along the horizontal direction, the first injection molding machine 101 can be miniaturized in the horizontal direction, so that the main unit 100 can be miniaturized in the horizontal direction. Further, for example, compared with the case where the injection device 110 includes an in-line screw instead of a flat screw, the first injection molding machine 101 can be miniaturized, so that the main unit 100 can be miniaturized. Therefore, it becomes easier to realize space saving of the injection molding system 5. Further, for example, since a larger number of option units 400 or a larger option unit 400 can be attached as the main unit 100 is miniaturized, the degree of freedom in customizing the injection molding system 5 can be increased.

[0061] Further, in the present embodiment, a mold clamping device 200 is provided that performs mold clamping and mold opening by moving the injection device 110 and the upper mold 11 along the vertical direction. In such a configuration, mold clamping and mold opening can be performed by moving the injection device 110 and the upper mold 11 in the vertical direction with respect to the lower mold 15 without moving the lower mold 15 in the vertical direction. Thereby, removal of the integral part from the lower mold 15 and placement of the insert part on the lower mold 15 can be executed at a fixed position in the vertical direction. Therefore, the process of removing the integral part from the lower mold 15 and the process of placing the insert part on the lower mold 15 can be more easily automated.

[0062] B. Second Embodiment: FIG. 9 is a plan view showing a schematic configuration of the injection molding system 5b in the second embodiment. FIG. 10 is a first diagram showing a schematic configuration of the first injection molding machine 101b disposed in the main unit 100b in the present embodiment. In FIG. 9, as in FIG. 2 described in the first embodiment, a state in which each cover of each unit is removed from the injection molding system 5b is shown as viewed from above. As shown in FIG. 10, in the present embodiment, unlike the first embodiment, the first injection molding machine 101b includes a first support portion 156 that supports the first lower mold 16 as a lower mold, and a second support portion 157 that supports the second lower mold 17 as a lower mold. In FIG. 9, the first lower mold 16 and the first support portion 156 are located below the injection device 110 and are not shown. Regarding the parts of the injection molding system 5b that are not particularly described, they are the same as those in the first embodiment.

[0063] FIG. 11 is a plan view showing a schematic configuration of the lower mold support portion 150b in the second embodiment. In FIG. 11, a state in which the lower mold support portion 150b and the plate portion 187 that supports the lower mold support portion 150b are viewed from above is shown. As shown in FIGS. 10 and 11, the lower mold support portion 150b has the above-described first support portion 156 and second support portion 157. The first support portion 156 in the present embodiment is a portion for supporting the first lower mold 16 among the edge portions 153b of a pair of blocks 152b that constitute the lower mold support portion 150b. Similarly, the second support portion 157 is a portion for supporting the second lower mold 17 among the edge portions 153b of the block 152b. The first support portion 156 is located in the +X direction of the second support portion 157. On the upper surface of the block 152b, a pair of first lower mold clamps 161 and a pair of second lower mold clamps 162 are provided. Similar to the lower mold clamp 160 described in the first embodiment, the first lower mold clamp 161 sandwiches and fixes the first lower mold 16 supported by the first support portion 156 in the Y direction. Similarly, the second lower mold clamp 162 sandwiches and fixes the second lower mold 17 supported by the second support portion 157 in the Y direction.

[0064] The position changing unit 180b is configured to be able to move the first support portion 156 and the second support portion 157. In the present embodiment, the position changing unit 180b linearly moves the first support portion 156 and the second support portion 157 along an intersecting direction intersecting the vertical direction. More specifically, similar to the first embodiment, the position changing unit 180b moves the movable portion 186 that supports the lower mold support portion 150b in the X direction with respect to the base 300 by driving the electric actuator 181. As a result, the first support portion 156 and the second support portion 157 move linearly along the X direction in conjunction with each other.

[0065] FIG. 12 is a second diagram showing a schematic configuration of the first injection molding machine 101b in the second embodiment. FIG. 12 shows a state in which the lower mold support portion 150b is positioned in the +X direction more than in the case shown in FIG. 10 due to the movement of the lower mold support portion 150b by the position changing unit 180b. The position changing unit 180b is configured to be able to switch the state of the first injection molding machine 101b between a first state and a second state by moving the first support portion 156 and the second support portion 157. The first state refers to a state in which, as shown in FIG. 10, the first lower mold 16 is positioned at the injection position P and the second lower mold 17 is positioned at a position different from the injection position P. The second state refers to a state in which, as shown in FIG. 12, the second lower mold 17 is positioned at the injection position P and the first lower mold 16 is positioned at a position different from the injection position P.

[0066] As shown in FIG. 10, in the present embodiment, the position changing unit 180b positions the second lower mold 17 at the first standby position W1 in the first state. Further, as shown in FIG. 12, the position changing unit 180b positions the first lower mold 16 at the second standby position W2 in the second state. Both the first standby position W1 and the second standby position W2 are positions different from the injection position P. The second standby position W2 is located on the opposite side of the first standby position W1 across the injection position P in the X direction. That is, the first standby position W1 and the second standby position W2 are separated by the injection position P in the X direction. In the present embodiment, the first standby position W1 is located in the -X direction of the injection position P, and the second standby position W2 is located in the +X direction of the injection position P. Note that also in FIG. 9 described above, as in FIG. 10, in the first state, the state where the first lower mold 16 is located at the injection position P and the second lower mold 17 is located at the first standby position W1 is shown. In other embodiments, the first injection molding machine 101b may include, for example, positioning pins or the like for positioning the first lower mold 16 at the injection position P or the second standby position W2, or for positioning the second lower mold 17 at the injection position P or the first standby position W1.

[0067] As shown in FIGS. 10 and 12, the first injection molding machine 101b in the present embodiment has a first ejector unit 251 and a second ejector unit 252. The first ejector unit 251 is a member for removing the molded product from the second lower mold 17 at the first standby position W1. The second ejector unit 252 is a member for removing the molded product from the first lower mold 16 at the second standby position W2.

[0068] The configuration of the first ejector unit 251 and the configuration of the second ejector unit 252 are the same as the configuration of the ejector unit 250 described in the first embodiment. That is, the first ejector unit 251 includes a first main body 263 connected to the second lower mold 17 for pushing up the molded product from the second lower mold 17, and a first ejector drive unit 271 for operating the first main body 263. Similarly, the second ejector unit 252 includes a second main body 264 connected to the first lower mold 16 for pushing up the molded product from the first lower mold 16, and a second ejector drive unit 272 for operating the second main body 264.

[0069] Also in this embodiment, the robot 451 arranged in the robot unit 450 functions as a feeding robot that performs an arranging operation and a conveying robot that performs a conveying operation, in the same manner as in the first embodiment. More specifically, in this embodiment, the robot 451 that functions as a feeding robot executes, as an arranging operation, the placement of the insert member on the second lower mold 17 located at the first standby position W1 and the first lower mold 16 located at the second standby position W2. Further, the robot 451 that functions as a conveying robot executes, as a conveying operation, the conveyance of the integrated product removed from the second lower mold 17 at the first standby position W1 and the integrated product removed from the first lower mold 16 at the second standby position W2.

[0070] The robot 451 in this embodiment continuously executes the above-described conveying operation and placement operation. More specifically, in the first state, the robot 451 first adsorbs the integrated product removed from the second lower mold 17 by the first ejector unit 251 at the first standby position W1, and conveys the integrated product from the second lower mold 17. Next, the robot 451 places an insert member for molding the integrated product using the second lower mold 17 on the second lower mold 17 located at the first standby position W1. Similarly, in the second state, the robot 451 adsorbs the integrated product removed from the first lower mold 16 by the second ejector unit 252 at the second standby position W2, conveys the integrated product from the first lower mold 16, and places the insert member on the first lower mold 16 located at the second standby position W2. The first control unit 103 can more efficiently mold the integrated product by, for example, performing insert molding using the lower mold located at the injection position P while the above-described conveying operation and placement operation by the robot 451 are being executed.

[0071] Also, with the injection molding system 5b of this embodiment described above, while increasing the degree of freedom in customizing the injection molding system 5b, space saving can be achieved compared to installing each unit or each device separately. In particular, in this embodiment, a position changing unit 180b is provided, which is configured to be movable and includes a first support portion 156 that supports the first lower mold 16 and a second support portion 157 that supports the second lower mold 17. The position changing unit 180b switches between a first state in which the first lower mold 16 is located at the injection position P and the second lower mold 17 is located at a position different from the injection position P, and a second state in which the second lower mold 17 is located at the injection position P and the first lower mold 16 is located at a position different from the injection position P, by moving the first support portion 156 and the second support portion 157. As a result, for example, while molding the integrated product using one of the lower molds located at the injection position P, the integrated product can be removed from the other lower mold located at a position different from the injection position P, and the insert member can be placed on the other lower mold. Therefore, the integrated product can be efficiently molded using the first lower mold 16 and the second lower mold 17.

[0072] In addition, in the present embodiment, the position changing unit 180b moves the first support portion 156 and the second support portion 157 along the X direction, positions the second lower mold 17 at the first standby position W1 in the first state, and positions the first lower mold 16 at the second standby position W2 on the side opposite to the first standby position W1 across the injection position P in the X direction in the second state. Further, the first injection molding machine 101b includes a first ejector portion 251 for removing an integrated product from the second lower mold 17 at the first standby position W1 and a second ejector portion 252 for removing an integrated product from the first lower mold 16 at the second standby position W2. Therefore, by linearly moving the first support portion 156 and the second support portion 157 along the X direction by the position changing unit 180b, the first state and the second state can be easily switched. Also, in either the first state or the second state, the integrated product can be easily removed from the lower mold by using the first ejector portion 251 or the second ejector portion 252.

[0073] In addition, in the present embodiment, the robot 451 disposed in the robot unit 450 included in the option unit 400 performs, as a placement operation, placement of an insert member on the second lower mold 17 located at the first standby position W1 and the first lower mold 16 located at the second standby position W2. Further, the robot 451 performs, as a transfer operation, transfer of the integrated product removed from the second lower mold 17 at the first standby position W1 and the integrated product removed from the first lower mold 16 at the second standby position W2. Thereby, a process of transferring the integrated product removed from the other lower mold while insert molding is being performed using one lower mold, and a process of similarly placing an insert member on the other lower mold can be automated. Therefore, in the injection molding system 5, an integrated product can be manufactured more efficiently.

[0074] C. Third Embodiment: FIG. 13 is a plan view showing a schematic configuration of the injection molding system 5c in the third embodiment. In FIG. 13, as in FIG. 9 described in the second embodiment, a state in which each cover of each unit is removed from the injection molding system 5c is shown as viewed from above. The optional unit 400c of the injection molding system 5c, unlike the second embodiment, includes a first robot unit 450A and a second robot unit 450B as robot units. Regarding the parts not particularly described in the injection molding system 5c, they are the same as those in the second embodiment.

[0075] The first robot unit 450A is arranged between the main unit 100b and the accessory equipment unit 700 in the Y direction, similarly to the robot unit 450 in the first and second embodiments. The second robot unit 450B is arranged adjacent to the main unit 100b in the +Y direction of the main unit 100b. That is, the first robot unit 450A and the second robot unit 450B are arranged so as to sandwich the main unit 100b in the Y direction. Adjacent units are connected by a plate-like member 6.

[0076] A first robot 451A is arranged in the first robot unit 450A. A second robot 451B is arranged in the second robot unit 450B. In this embodiment, the first robot 451A and the second robot 451B are constituted by robots similar to the robot 451 of the robot unit 450 in the first and second embodiments. The operation of the first robot 451A is controlled by the first control unit 103 via the third control unit 456 provided in the first robot 451A. The operation of the second robot 451B is controlled by the first control unit 103 via the fourth control unit 457 provided in the second robot 451B.

[0077] The first robot 451A is installed on a first robot base 452A fixed to the housing of the first robot unit 450A. The second robot 451B is arranged on a second robot base 452B fixed to the housing of the second robot unit 450B. In the present embodiment, inspection devices and packaging devices (not shown) are installed on the first robot base 452A, similar to the robot base 452 in the first and second embodiments.

[0078] In the present embodiment, the first robot 451A functions as a transfer robot, and the second robot 451B functions as a feeding robot. By interacting with each other, the first robot 451A and the second robot 451B continuously execute a transfer operation by the first robot 451A and a placement operation by the second robot 451B. More specifically, in the first state, first, the first robot 451A adsorbs the integrated product removed from the second lower mold 17 at the first standby position W1 and transfers the integrated product from the second lower mold 17. Next, the second robot 451B places the insert member on the second lower mold 17 located at the first standby position W1. Similarly, in the second state, after the first robot 451A adsorbs the integrated product removed from the first lower mold 16 and transfers the integrated product from the first lower mold 16, the second robot 451B places the insert member on the first lower mold 16 located at the second standby position W2.

[0079] The first robot 451A and the second robot 451B may be constituted by robots other than the horizontal articulated robot, similar to the robot 451 in the first and second embodiments. The first robot 451A and the second robot 451B may be constituted by different robots. For example, the first robot 451A may be constituted by a horizontal articulated robot as in the present embodiment, and the second robot 451B may be constituted by a vertical articulated robot.

[0080] Also with the injection molding system 5c of the present embodiment described above, similar to the second embodiment, it is possible to automate the process of conveying an integrated product removed from one lower mold while performing insert molding using the other lower mold, and similarly the process of placing an insert member on the other lower mold. Therefore, in the injection molding system 5c, an integrated product can be efficiently manufactured. In particular, in the present embodiment, since the robots respectively arranged in the two robot units cooperate with each other to execute the conveying operation and the feeding operation, there is a higher possibility of manufacturing an integrated product more efficiently while easily controlling each robot.

[0081] D. Fourth Embodiment: FIG. 14 is a plan view showing a schematic configuration of an injection molding system 5d in the fourth embodiment. FIG. 14 shows, as in FIG. 9 described in the second embodiment, a state in which each cover of each unit has been removed, as seen from above, of the injection molding system 5d. The optional unit 400d of the injection molding system 5d, unlike the third embodiment, includes, as robot units, the first robot unit 450A and the third robot unit 450C described in the third embodiment. Regarding parts of the injection molding system 5d that are not particularly described, they are the same as those in the third embodiment.

[0082] The third robot unit 450C is arranged adjacent to the main unit 100b in the -Y direction of the main unit 100b. The first robot unit 450A is arranged adjacent to the third robot unit 450C in the -Y direction of the third robot unit 450C. That is, the third robot unit 450C is arranged between the main unit 100b and the first robot unit 450A in the Y direction. In the -Y direction of the first robot unit 450A, an auxiliary equipment unit 700 is arranged as in the third embodiment. Adjacent units are connected by a plate-like member 6.

[0083] The third robot unit 450C is provided with a third robot 451C. The third robot 451C is composed of a three-axis orthogonal robot. The third robot 451C has a fifth control unit 458 and an arm composed of three slide axes along the X-axis, Y-axis, and Z-axis respectively. An end effector is attached to the arm of the third robot 451C. In the present embodiment, a suction pad is attached to the arm of the third robot 451C as an end effector. The fifth control unit 458 is composed of a computer including a main storage device and an input / output interface for inputting and outputting signals to and from the outside. The fifth control unit 458 controls the operations of the arm and the end effector of the third robot 451C. In the present embodiment, the operation of the third robot 451C is controlled by the first control unit 103 via the fifth control unit 458.

[0084] The third robot 451C is installed on a third robot base 452C fixed to the housing of the third robot unit 450C. In the present embodiment, the third robot 451C functions as a transfer robot and a feeding robot in the same manner as the robot 451 in the first embodiment and the second embodiment. The first robot 451A functions as a transfer robot for relaying between the third robot 451C functioning as a transfer robot and the inspection process and the packing process.

[0085] In the present embodiment, the integrated product removed from the lower mold is conveyed by the third robot 451C functioning as a transfer robot onto a temporary placement table Ts provided on the third robot base 452C. The first robot 451A conveys the integrated product placed on the temporary placement table Ts by the third robot 451C to an inspection device or a packing device.

[0086] In other embodiments, the third robot 451C may not be an orthogonal robot, and for example, may be a horizontal articulated robot or a vertical articulated robot. The first robot 451A and the third robot 451C may be the same robot. Further, the end effector attached to the arm of the third robot 451C may have, for example, a portion for adsorbing a molded product and a portion for adsorbing an insert member, similar to the case of the robot 451 in the first embodiment and the second embodiment, or may be constituted by a gripper.

[0087] Also, with the injection molding system 5d of the present embodiment described above, similar to the second embodiment and the third embodiment, a process of transporting an integrated product removed from one lower mold while insert molding is being performed using the other lower mold, and a process of similarly placing an insert member on the other lower mold can be automated. Therefore, in the injection molding system 5d, an integrated product can be efficiently manufactured. In particular, in the present embodiment, the first robot 451A disposed in the first robot unit 450A functions as a transfer robot that relays between the third robot 451C that functions as a transfer robot and a feeding robot, and inspection processes, packing processes, etc. that are executed after insert molding. Therefore, there is an increased possibility of manufacturing an integrated product more efficiently while simply controlling each robot.

[0088] In other embodiments, the optional unit 400d of the injection molding system 5d may further include, for example, the second robot unit 450B described in the third embodiment. In this case, for example, in the injection molding system 5d, the second robot unit 450B, the main unit 100b, the third robot unit 450C, the first robot unit 450A, and the accessory equipment unit 700 are arranged in this order along the Y direction.

[0089] E. Fifth Embodiment: FIG. 15 is a plan view showing a schematic configuration of an injection molding system 5e in the fifth embodiment. As in FIG. 2 described in the first embodiment, FIG. 15 shows a state in which each cover of each unit of the injection molding system 5e with the cover removed is seen from above. Different from the first embodiment, the injection molding system 5e in the present embodiment includes an insert detection unit 730 that detects whether or not an insert member is placed at the insert position of the lower mold 15e. The insert position is a position predetermined as a position where the insert member is placed in the lower mold 15e. Regarding parts of the configuration of the injection molding system 5e that are not particularly described, they are the same as those in the first embodiment.

[0090] FIG. 16 is a plan view showing the vicinity of the central portion of the lower mold 15e in the X and Y directions in the fifth embodiment. FIG. 16 shows a state in which the vicinity of the central portion of the lower mold 15e in the X and Y directions is seen from above. FIG. 17 is a diagram for explaining the correct installation state. The correct installation state refers to a state in which the insert member M is placed at the insert position S of the lower mold 15e. FIG. 17 schematically shows a cross section of the lower mold 15e and the insert member M, and the arm Am and the end effector Ef of the robot 451 arranged in the robot unit 450.

[0091] As shown in FIGS. 16 and 17, in the present embodiment, the insert position S is defined as a position within the opening of the recess Dn formed in the lower mold 15e. The recess Dn is a part that partitions the cavity of the mold 10. The recess Dn may be provided with, for example, a step for positioning the insert member M at the insert position S.

[0092] At the insert position S, air holes HL are formed. In the present embodiment, four air holes HL are formed at the insert position S. The air holes HL are formed so as to penetrate the lower mold 15e in the Z direction at the insert position S. As shown in FIG. 18, the air holes HL are formed at positions that do not overlap with the through holes into which the ejector pins 262 are inserted when viewed from above. As shown in FIG. 17, the air holes HL are blocked by the insert member M disposed at the insert position S.

[0093] As shown in FIG. 15, in the present embodiment, the insert detection unit 730 is provided in the first injection molding machine 101e of the main unit 100e. The insert detection unit 730 in the present embodiment includes a suction unit 731, a measurement unit 732, and a detection unit 733. The suction unit 731 is a member configured to be able to suck air from the insert position S through the air holes HL shown in FIGS. 16 and 17. In the present embodiment, the suction unit 731 is constituted by a suction pump, and sucks air from the insert position S to the suction unit 731 through the air holes HL and a tube (not shown) connected to the air holes HL. The measurement unit 732 measures the flow rate or pressure of the air sucked by the suction unit 731. In the present embodiment, the measurement unit 732 is constituted by a flow meter that measures the flow rate of air. In other embodiments, the measurement unit 732 may be constituted by a pressure gauge that measures the pressure of air, for example. The detection unit 733 detects whether or not it is in the correct installation state based on the flow rate or pressure of the air measured by the measurement unit 732. In the present embodiment, the first control unit 103 functions as the detection unit 733.

[0094] FIG. 18 is a diagram for explaining the misinstallation state. The misinstallation state refers to a state in which the insert member M is disposed at a position different from the insert position S in the lower mold 15e. In FIG. 18, similarly to FIG. 17, the cross sections of the lower mold 15e and the insert member M, and the arm Am and the end effector Ef of the robot 451 are schematically shown.

[0095] In the state shown in FIG. 18, since the air holes HL are not blocked by the insert member M, the flow rate of the air sucked by the suction unit 731 and measured by the measurement unit 732 becomes larger compared to the case in the normal installation state shown in FIG. 17. Also, for example, even when only a part of the air holes HL is covered by the insert member M, the flow rate of the air measured by the measurement unit 732 similarly becomes larger. Therefore, the first control unit 103 functioning as the detection unit 733 can detect whether it is in the normal installation state based on the difference between the flow rate of the air measured by the measurement unit 732 and the flow rate of the air in the normal installation state. The flow rate of the air in the normal installation state is determined in advance by experiments, for example. Note that even when the measurement unit 732 is configured by a pressure gauge that measures the pressure of the air, the detection unit 733 can similarly detect whether it is in the normal installation state based on the difference between the measured pressure and the pressure in the normal installation state.

[0096] In this embodiment, the robot 451 functioning as a feeding robot places the insert member M at the insert position S based on the detection result by the insert detection unit 730 in the placement operation. More specifically, the robot 451 in this embodiment operates the arm Am to place the insert member M adsorbed to the end effector Ef on the lower mold 15e. Then, if it is detected by the insert detection unit 730 that the insert member M is not in the correct placement state, the robot 451 moves the insert member M placed on the lower mold 15e to adjust the position of the insert member M. Thereafter, for example, if it is detected again by the insert detection unit 730 that the insert member M is not in the correct placement state, the robot 451 adjusts the position of the insert member M again. The robot 451 repeatedly executes such position adjustment of the insert member M until it is detected by the insert detection unit 730 that the insert member M is in the correct placement state. As a result, the insert member M is placed at the insert position S. Note that the first control unit 103 may start detecting whether the insert member M is in the correct placement state after the insert member M is placed on the lower mold 15e by the robot 451, for example. Or, for example, while constantly detecting whether the insert member M is in the correct placement state, the first control unit 103 may control the robot 451 so that the position adjustment of the insert member M by the robot 451 is not executed until the next placement operation is started after the placement operation is completed. Further, the arm Am of the robot 451 may be provided with, for example, a contact sensor, a non-contact laser sensor, a camera, etc. for detecting the insert member M placed on the lower mold 15e. Thereby, the robot 451 can execute the position adjustment of the insert member M more efficiently.

[0097] Also, when the first control unit 103 detects that the insert member M is not in the correct placement state, it may notify the user that the insert member M is not in the correct placement state via, for example, a notification unit (not shown). In this case, the notification unit may be, for example, a display unit constituted by a liquid crystal panel or the like that displays visual information, or a speaker or the like that emits voice information.

[0098] Also, with the injection molding system 5e of the present embodiment described above, it is possible to increase the degree of freedom in customizing the injection molding system 5e and achieve space savings compared to installing each unit or each device separately. In particular, in the present embodiment, the injection molding system 5e includes an insert detection unit 730 that detects whether or not the insert member M is placed at the insert position S. Thereby, using the insert detection unit 730, it is possible to detect whether or not the insert member M is placed at the insert position S. Therefore, it is possible to suppress injection molding from being performed in a state where the insert member M is placed at a position different from the insert position S, and thus it is possible to suppress damage to the mold 10, the injection device 110, etc. installed in the first injection molding machine 101e, and the occurrence of defective products.

[0099] Further, in the present embodiment, the robot 451 disposed in the robot unit 450 places the insert member M at the insert position S based on the detection result by the insert detection unit 730 in the placement operation. Thereby, in the placement operation, the robot 451 can adjust the position of the insert member M so that the insert member M is located at the insert position S while placing the insert member M on the lower mold 15e. Therefore, after the placement operation, for example, the insert member M can be placed at the insert position S without adjusting the position of the insert member M using another robot, device, etc. different from the robot 451, so that an integral product can be manufactured more efficiently in the injection molding system 5e.

[0100] FIG. 19 is a schematic diagram for explaining the insert detection unit 730b in another embodiment. In FIG. 19, as in FIG. 17, a cross section of the lower mold 15 and the insert member M, and the arm Am and the end effector Ef of the robot 451 are schematically shown. The insert detection unit 730b shown in FIG. 19 does not include a suction unit 731, a measurement unit 732, and a detection unit 733, but includes a camera 736 that images the vicinity of the recess Dn of the lower mold 15. In the form shown in FIG. 19, the first control unit 103 detects whether it is in the correct installation state by analyzing the image captured by the camera 736. The camera 736 is disposed, for example, at a position facing the lower mold 15 located at the standby position W. The camera 736 may be fixed to the housing of the main unit 100, or may be fixed to the base 300, the injection device 110, or the like. Note that, as in the second to fourth embodiments, when the first injection molding machine 101 is configured to be able to switch between the first state and the second state, it is more preferable that the camera 736 is disposed at both a position facing the second lower mold 17 located at the first standby position W1 and a position facing the first lower mold 16 located at the second standby position W2. Thereby, in either the first standby position W1 or the second standby position W2, it can be detected by the insert detection unit 730b whether the insert member M is placed at the insert position S.

[0101] FIG. 20 is a schematic diagram for explaining the insert detection unit 730c in another embodiment. As in FIGS. 17 and 19, FIG. 20 schematically shows a cross-section of the lower mold 15 and the insert member M, and the arm Am and the end effector Ef of the robot 451. The insert detection unit 730c includes a camera 736. In the form shown in FIG. 20, the camera 736 is fixed to the arm Am of the robot 451. In the form shown in FIG. 20, as in the form shown in FIG. 19, it is detected whether it is in the correct placement state by image analysis. The image analysis may be executed, for example, by the first control unit 103 or by the second control unit 455. In such a form, in the placement operation, the first control unit 103 controls the robot 451, and after placing the insert member M on the lower mold 15 by the end effector Ef attached to the arm Am, based on the detection result by a sensor or the like attached to the arm Am, etc., it is detected whether it is in the correct placement state. If it is determined that it is not in the correct placement state, the position of the insert member M can be adjusted again by the end effector Ef. Therefore, while suppressing damage to the mold 10 and the injection device 110 and the occurrence of defective products, an integrated product can be manufactured more efficiently. Further, even when the first injection molding machine 101 is configured to be able to switch between the first state and the second state as in the second to fourth embodiments, without arranging a plurality of sensors or the like constituting each insert detection unit, it is possible to detect whether the insert member M is placed at the insert position S at either the first standby position W1 or the second standby position W2.

[0102] Further, the insert detection unit 730 does not necessarily have the form of sucking the above-described air or the form including the camera 736. For example, it may be a contact or non-contact sensor that measures the distance from the lower mold 15, a contact detection sensor that detects contact with the lower mold 15, etc., and may be configured to detect whether it is in the correct installation state based on the detection value of each sensor. In this case, each sensor may be fixed to the housing of the main unit 100, may be fixed to the base 300, the injection device 110, etc., or may be provided on the robot 451 of the robot unit 450 like the camera 736 described in FIG. 20.

[0103] F. Sixth Embodiment: FIG. 21 is a front view showing a schematic configuration of an injection molding system 5f according to the sixth embodiment. FIG. 22 is a plan view showing a schematic configuration of the injection molding system 5f. As in FIG. 1 described in the first embodiment, FIG. 22 shows a state in which each cover of each unit is removed and the injection molding system 5f is viewed from above. The optional unit 400f of the injection molding system 5f in the present embodiment includes a member molding unit 500, which is different from the first embodiment. Regarding the parts not particularly described in the configuration of the injection molding system 5f, they are the same as those in the first embodiment.

[0104] As shown in FIG. 21, the optional unit 400f includes the above-described member molding unit 500, and includes a robot unit 450 and an accessory device unit 700 in the same manner as in the first embodiment. In FIG. 21, the periphery of the member molding unit 500 is covered by a fourth cover C4, similar to the periphery of other units being covered by a cover.

[0105] In this embodiment, the robot unit 450 is arranged adjacent to the main unit 100 in the +Y direction of the main unit 100. The member forming unit 500 is arranged adjacent to the robot unit 450 in the +Y direction of the robot unit 450. The accessory equipment unit 700 is arranged adjacent to the main unit 100 in the -Y direction of the main unit 100. As shown in FIG. 22, adjacent units are connected by a plate-like member 6. Incidentally, when the main unit 100 and the member forming unit 500 are arranged adjacent to each other, it is also possible to connect the two with a plate-like member 6.

[0106] As shown in FIG. 22, a second injection molding machine 510 is arranged in the member forming unit 500 in this embodiment. The second injection molding machine 510 injects a second molding material to mold the insert member. The second molding material is generated, for example, by plasticizing a resin material having a color or composition different from that of the material for generating the first molding material. The second injection molding machine 510 in this embodiment is different from the first injection molding machine 101 in that it injects the second molding material and molds the insert member, but the configuration of each part of the second injection molding machine 510 is the same as that of the first injection molding machine 101. The second injection molding machine 510 is controlled by the first control unit 103 via a sixth control unit 511 provided in the second injection molding machine 510. Incidentally, in the accessory equipment unit 700, for example, a device for feeding the material to the second injection molding machine 510 and adjusting the temperature of the mold used in the second injection molding machine 510 may be arranged.

[0107] Unlike the robot in the first embodiment, the robot 451 disposed in the robot unit 450 of this embodiment does not function as a transfer robot but only functions as a material supply robot. As an arrangement operation, the robot 451 in this embodiment performs an operation of placing the insert member formed by the member molding unit 500 on the lower mold 15. More specifically, the robot 451 adsorbs the insert member formed by the second injection molding machine 510 of the member molding unit 500 and transports it to the lower mold 15 located at the standby position W in the first injection molding machine 101 of the main unit 100 and places it on the lower mold 15.

[0108] Also, with the injection molding system 5f of this embodiment described above, while increasing the degree of freedom in customizing the injection molding system 5f, it is possible to achieve space savings compared to installing each unit or each device separately. In particular, in this embodiment, the robot unit 450 is disposed adjacent to the main unit 100, the member molding unit 500 is disposed adjacent to the robot unit 450, and the robot 451 performs an operation of placing the insert member formed by the member molding unit 500 on the lower mold 15 as an arrangement operation. As a result, since the robot unit 450 is disposed adjacent to the main unit 100 and the member molding unit 500, the insert member formed by the member molding unit 500 can be efficiently transported to the lower mold 15 installed in the first injection molding machine 101 of the main unit 100 and placed on the lower mold 15 by the robot 451 disposed in the robot unit 450. Therefore, in the injection molding system 5f, the process from molding the insert member to molding the integrated product using the molded insert member can be automated and efficiently executed, so that the integrated product can be manufactured more efficiently.

[0109] In other embodiments, for example, instead of the second injection molding machine 510, a press molding machine that molds the insert member by press molding may be disposed in the member molding unit 500. Further, the optional unit 400f may include, for example, a robot unit in which a transfer robot that transfers the integrated product molded by the main unit 100 is disposed.

[0110] G. Seventh Embodiment: FIG. 23 is a front view showing a schematic configuration of an injection molding system 5g according to the seventh embodiment. FIG. 24 is a plan view showing a schematic configuration of the injection molding system 5g. As in FIG. 1 described in the first embodiment, FIG. 24 shows a state in which each cover of each unit of the injection molding system 5g with the covers removed is seen from above. The optional unit 400g of the injection molding system 5g according to the present embodiment includes a member molding unit 500b, unlike the first embodiment. For parts of the injection molding system 5g that are not particularly described, they are the same as those in the first embodiment.

[0111] As shown in FIG. 23, the optional unit 400g includes the above-described member molding unit 500b, an accessory equipment unit 700, and an inspection unit 800, and does not include a robot unit 450, unlike the first embodiment. In FIG. 21, the periphery of the member molding unit 500b is covered by a fifth cover C5, and the periphery of the inspection unit 800 is covered by a sixth cover C6.

[0112] In the present embodiment, the member molding unit 500b is arranged adjacent to the main unit 100g in the +Y direction of the main unit 100g. The inspection unit 800 is arranged adjacent to the main unit 100g in the -Y direction of the main unit 100g. The accessory equipment unit 700 is arranged adjacent to the inspection unit 800 in the -Y direction of the inspection unit 800. Adjacent units are connected by a plate-like member 6.

[0113] As shown in FIG. 24, a press molding machine 520 for molding an insert member by press molding is arranged in the member molding unit 500b in the present embodiment. The press molding machine 520 is arranged on a press base 521 fixed to the housing of the member molding unit 500b. The press molding machine 520 in the present embodiment forms a plurality of insert members in the sheet material MS such that the plurality of insert members are continuous along the longitudinal direction of the sheet material MS by punching a part of the sheet material MS having a sheet shape. In the present embodiment, the sheet material MS is formed of a metal material. The press molding machine 520 includes a seventh control unit 522 configured by a computer in the same manner as the first control unit 103. The operation of the press molding machine 520 is controlled by the first control unit 103 via the seventh control unit 522.

[0114] The first injection molding machine 101g arranged in the main unit 100g in the present embodiment performs insert molding by injecting a first molding material into a cavity in which an insert member formed in the sheet material MS is arranged, thereby molding an integrated product in which the insert member and the first molding material are integrated. Thereby, a plurality of integrated products are formed in the sheet material MS such that the plurality of integrated products are continuous along the longitudinal direction of the sheet material MS. Hereinafter, the sheet material MS before the insert member is formed is referred to as the first sheet MS1, the sheet material MS after the insert member is formed and before the integrated product is formed is referred to as the second sheet MS2, and the sheet material after the integrated product is formed may be referred to as the third sheet MS3. The sheet material MS may also be referred to as a hoop material. A method of performing insert molding using the hoop material in which the insert member is formed is sometimes referred to as hoop molding or chain mold molding.

[0115] Unlike the first embodiment, the first injection molding machine 101g in this embodiment does not include a position changing unit 180, and the lower mold 15 installed in the first injection molding machine 101g is always located at the injection position P. Further, the ejector unit in this embodiment is configured to be able to remove an integrated product from the lower mold 15 located at the injection position P. In FIG. 24, the lower mold 15 installed in the first injection molding machine 101g is located under the injection device 110 and is indicated by a dashed line.

[0116] In the lower mold 15 in this embodiment, for example, positioning pins for positioning an insert member with respect to the mold 10 may be provided. In this case, the positioning pins are configured to be insertable into positioning holes formed at positions corresponding to portions where the insert members of the sheet material MS are formed. The positioning holes are formed, for example, by the press molding machine 520 at positions that do not overlap with the insert members in the sheet material MS at the same time as the molding of the insert members.

[0117] An inspection device (not shown) is arranged in the inspection unit 800. The inspection device performs an appearance inspection of the integrated product under the control of the first control unit 103. In other embodiments, for example, an inspection robot for performing an appearance inspection of the integrated product may be arranged in the inspection unit 800. Further, an inspection device or an inspection robot may be arranged in a unit different from the inspection unit 800, or neither an inspection device nor an inspection robot may be arranged in any unit, and the appearance inspection of the integrated product may not be performed in the injection molding system 5g.

[0118] As shown in FIG. 23, in addition to the units described above, the injection molding system 5g in this embodiment includes an unwinding device FM that rotates and unwinds a first sheet MS1 wound in a roll shape, and a winding device FW that rotates and winds up a third sheet MS3 in a roll shape. The unwinding device FM and the winding device FW are arranged in the Y direction such that the main unit 100g and the option unit 400g are sandwiched between them. A contact type deflection sensor DS1 for detecting the deflection of the sheet material MS is provided between the unwinding device FM and the main unit 100g and the option unit 400g by two bars (not shown). A deflection sensor DS2 similar to the deflection sensor DS1 is provided between the winding device FW and the main unit 100g and the option unit 400g. In this embodiment, by driving the winding device FW, unwinding of the first sheet MS1 from the unwinding device FM and winding of the third sheet MS3 onto the winding device FW are realized. The driving of the winding device FW is controlled by the first control unit 103. In this embodiment, the first control unit 103 refers to the deflection of the first sheet MS1 detected by the deflection sensor DS1 and the deflection of the third sheet MS3 detected by the deflection sensor DS2, and adjusts the winding amount of the third sheet MS3 wound by the winding device FW. Note that in FIG. 24, the unwinding device FM, the winding device FW, and the deflection sensors DS1 and DS2 are omitted. In other embodiments, the deflection sensors DS1 and DS2 may be configured by, for example, non-contact type deflection sensors, or the deflection sensors DS1 and DS2 may not be provided in the injection molding system 5g.

[0119] As shown in FIG. 24, in this embodiment, the manufacturing of the integrated component is continuously performed while the sheet material MS is conveyed in the +Y direction from the unwinding device FM toward the winding device FW. First, the first sheet MS1 unwound from the unwinding device FM is sent to the press forming machine 520 arranged in the member forming unit 500b. An insert member is formed on the first sheet MS1 sent to the press forming machine 520 by the press forming machine 520. Next, the second sheet MS2 with the insert member formed thereon is sent to the first injection molding machine 101g of the main unit 100g. An integrated component is formed on the insert member formed on the second sheet MS2 sent to the first injection molding machine 101g by the first injection molding machine 101g. Then, the third sheet MS3 with the integrated component formed thereon is sent to the inspection unit 800, and after undergoing an appearance inspection, it is wound up by the winding device FW.

[0120] In other embodiments, the unwinding of the first sheet MS1 from the unwinding device FM and the winding up of the third sheet MS3 to the winding device FW may be realized, for example, by driving the unwinding device FM or by driving both the unwinding device FM and the winding device FW. Also, the winding device FW may not be provided. For example, a cutting machine for cutting the third sheet MS3 to cut out individual integrated components may be provided, and the sheet material MS may be conveyed from the unwinding device FM toward the cutting machine. In this case, the sheet material MS may be conveyed from the unwinding device FM toward the cutting machine, for example, by driving the unwinding device FM, or may be conveyed from the unwinding device FM toward the cutting machine by an air-type or motor-type feeder. Further, when the option unit 400g of the injection molding system 5g includes the robot unit 450 as in the first embodiment, for example, the integrated components cut by the cutting machine may be conveyed to an inspection device or the like by the robot 451 functioning as a transfer robot.

[0121] The member forming unit 500b and the main unit 100g do not necessarily have to be arranged adjacent to each other. For example, other units may be arranged between the member forming unit 500b and the main unit 100g. In this case, the unit arranged between the member forming unit 500b and the main unit 100g is preferably a unit that does not inhibit the movement of the sheet material MS conveyed from the member forming unit 500b toward the main unit 100g.

[0122] Also, with the injection molding system 5g of the present embodiment described above, while increasing the degree of freedom in customizing the injection molding system 5g, it is possible to achieve space savings compared to installing each unit or each device separately. In particular, in the present embodiment, adjacent to the main unit 100g, a member forming unit 500b in which a press molding machine 520 is arranged is provided. The press molding machine 520 forms a plurality of the insert members in the sheet material MS by punching out a part of the sheet material MS. Thereby, while sending the sheet material MS in which the insert member is formed by the press molding machine 520 from the press molding machine 520 to the first injection molding machine 101g, the first injection molding machine 101g forms an integrated product of the insert member formed in the sheet material MS and the first molding material, so that a plurality of integrated products can be continuously molded. Therefore, in the injection molding system 5g, since the process from forming the insert member to forming the integrated product using the formed insert member can be efficiently executed, the integrated product can be manufactured more efficiently.

[0123] FIG. 25 is a plan view showing a schematic configuration of an injection molding system 5h in another embodiment. As in FIG. 24 described above, FIG. 25 shows a top view of the injection molding system 5h with the covers of each unit removed. Note that in FIG. 25, the accessory equipment unit 700 is omitted. The optional unit 400h of the injection molding system 5h includes, in addition to the units included in the optional unit 400g described in the seventh embodiment, a molding unit 550. The molding unit 550 is arranged adjacent to the main unit 100g in the -Y direction of the main unit 100g. In the molding unit 550, a third injection molding machine 551 for performing insert molding with the integrated product molded by the main unit 100g as an insert part is arranged. The third injection molding machine 551 is constituted by, for example, an injection molding machine similar to the first injection molding machine 101g. In the third injection molding machine 551, for example, a mold having a cavity larger than the cavity of the mold 10 used in the first injection molding machine 101g is used, and a molding material having a color and composition different from those of the material for generating the first molding material is plasticized and the generated molding material is injected under the control of the first control unit 103. Even in such a form, in the injection molding system 5h, from the step of molding the insert member to the step of molding the integrated product using the molded insert member can be efficiently executed, so that the integrated product can be manufactured more efficiently. Note that the molding unit 550 may be included in the optional unit of the injection molding system described in the first to sixth embodiments, for example.

[0124] H. Eighth Embodiment: FIG. 26 is a diagram showing a schematic configuration of a manufacturing system 8 as an eighth embodiment. The manufacturing system 8 in the present embodiment includes the injection molding system 5 described above, an assembly line 900 for assembling a production product using an integrated part, and a transfer unit 910 for transferring the integrated part manufactured by the injection molding system 5 from the injection molding system 5 to the assembly line 900. In the present embodiment, the manufacturing system 8 includes four injection molding systems 5 and four transfer units 910 for transferring the integrated parts from each injection molding system 5. In the present embodiment, the assembly line 900 is constituted by a belt conveyor for conveying the integrated parts. That is, in the present embodiment, the production product is manufactured while being conveyed by the belt conveyor constituting the assembly line 900. The assembly of the production product on the assembly line 900 may be performed, for example, by a robot or manually.

[0125] In the present embodiment, the transfer unit 910 is constituted by a belt conveyor connecting each injection molding system 5 and the assembly line 900. On the transfer unit 910, for example, an integrated part that has passed through an appearance inspection is placed by the robot unit 450 or the like described in FIG. 2. Then, the integrated part placed on the transfer unit 910 is transferred to the assembly line 900 by driving the belt conveyor constituting the transfer unit 910. In other embodiments, the transfer unit 910 may be included, for example, in the optional unit 400 of the injection molding system 5, or may be constituted by a robot such as an autonomous mobile robot that transfers the integrated part to the assembly line 900.

[0126] The number of injection molding systems 5 provided in the manufacturing system 8 may be one, two or three, or five or more. Also, as the form of the injection molding system 5, each form described in the first to seventh embodiments can be adopted. When the manufacturing system 8 includes a plurality of injection molding systems 5 as in the present embodiment, the configurations of each injection molding system 5 may be partly or entirely the same, or may be different from each other.

[0127] Even with the manufacturing system 8 of the present embodiment described above, it is possible to increase the degree of freedom in customizing the injection molding system 5 while achieving space savings compared to installing each unit or each device separately. Further, in the manufacturing system 8, the integrated parts manufactured by the injection molding system 5 are aggregated to the assembly line 900, and the products using the integrated parts can be efficiently manufactured.

[0128] I. Other Embodiments: (I-1) In the above embodiment, the first injection molding machine 101 plasticizes the material by a flat screw to generate the first molding material. In contrast, the first injection molding machine 101 may generate a molding material by plasticizing the material by rotating, for example, an in-line screw.

[0129] (I-2) In the above embodiment, in the first injection molding machine 101, the injection device 110, the upper mold 11, and the lower mold 15 are arranged in this order from above in the vertical direction. In contrast, in the first injection molding machine 101, the injection device 110, the upper mold 11, and the lower mold 15 do not have to be arranged in this order from above in the vertical direction. For example, along the horizontal direction, the injection device 110, the upper mold 11, and the lower mold 15 may be arranged in this order. Further, with respect to the upper mold 11 and the lower mold 15 arranged along the vertical direction, the injection device 110 may be arranged along the vertical direction or a direction intersecting the vertical direction and the horizontal direction. When the upper mold 11 and the lower mold 15 are arranged along the horizontal direction, the insert member is arranged, for example, in a recess or a depression formed in a portion partitioning the cavity of the upper mold 11 or the lower mold 15. In this case, as an arrangement operation, the robot 451 functioning as a material supply robot performs an operation of installing the insert member in a recess or a depression formed in the upper mold 11 or the lower mold 15.

[0130] (I-3) In the above embodiment, the mold clamping device 200 performs mold clamping and mold opening by moving the injection device 110 and the upper mold 11 along the vertical direction. In contrast, the mold clamping device 200 may perform mold clamping and mold opening by moving the lower mold 15 along the vertical direction.

[0131] (I-4) In the above embodiment, the position changing unit 180 linearly moves the lower mold support part 150 along the X direction. In contrast, the position changing unit 180 does not necessarily linearly move the lower mold support part 150. For example, the position changing unit 180 may be constituted by a so-called rotary table that moves the lower mold support part 150 such that the locus of the movement of the lower mold support part 150 draws a circle when viewed along the vertical direction.

[0132] (I-5) In the above embodiment, the first support part 156 and the second support part 157 are constituted as a part of a pair of blocks 152b that constitute the lower mold support part 150b. In contrast, the first support part 156 and the second support part 157 do not necessarily have to be constituted as a part of the block 152b. For example, the first support part 156 and the second support part 157 may be separately constituted as holders for holding the first lower mold 16 and the second lower mold 17, respectively. In this case, the position changing unit 180 may be configured to be able to move the first support part 156 and the second support part 157 individually, and may switch between the first state and the second state by moving the first support part 156 and the second support part 157 individually.

[0133] (I-6) In the above embodiment, the second injection molding machine 510 and the third injection molding machine 551 are constituted by injection molding machines similar to the first injection molding machine 101. In contrast, the configurations of the second injection molding machine 510 and the third injection molding machine 551 may be different from the configuration of the first injection molding machine 101. For example, in the first injection molding machine 101, the upper mold 11 and the lower mold 15 are arranged along the vertical direction, and in the second injection molding machine 510 and the third injection molding machine 551, the upper mold and the lower mold may be arranged along the horizontal direction. Also, the first injection molding machine 101 may be configured as an injection molding machine equipped with a flat screw, and the second injection molding machine 510 and the third injection molding machine 551 may be configured as injection molding machines equipped with an in-line screw instead of a flat screw.

[0134] (I-7) In the above embodiment, the option unit 400 includes the accessory equipment unit 700. In contrast, the option unit 400 may not include the accessory equipment unit 700. In this case, the mold temperature regulator 710, the material delivery device 720, etc. may be provided in other units such as the main unit 100.

[0135] (I-8) In the above embodiment, the dimensions in the X direction and the dimensions in the Z direction of each unit are unified. For example, in addition to this, the dimensions in the Y direction may be unified among each unit or between some of the units. As a result, when swapping the arrangements of the units with unified dimensions in the Y direction, the possibility of being restricted by the installation space is further reduced. Also, the dimensions may be unified only between some of the units, or the dimensions of each unit may not be unified. For example, the dimensions in the X direction, Y direction, and Z direction of the plurality of robot units included in the option unit 400 may be unified, and the dimensions in the X direction, Y direction, and Z direction of other units may not be unified. Even in this case, when swapping or exchanging the arrangements of the units with unified dimensions, the possibility of being restricted by the installation space is reduced.

[0136] (I-9) The option unit 400 may include, for example, other units different from each of the units described in the above embodiment, or may include a plurality of the same units. Each unit does not have to be arranged in a line, and may be arranged in an L shape, a cross shape, a rectangular shape, etc. when viewed along the Z direction. Also, the devices etc. arranged in each unit described in the above embodiment may be arranged in other units. For example, the robot 451 that functions as a feeding robot or a transfer robot may be arranged in the main unit 100 or the member forming unit 500.

[0137] In the above-described embodiment, the first control unit 103 provided in the first injection molding machine 101 exhibits a function of comprehensively controlling the entire injection molding system 5. On the other hand, the first control unit 103 does not necessarily have to comprehensively control the entire injection molding system 5. For example, a control unit of a device included in the optional unit 400 or the like may comprehensively control the entire injection molding system 5, or a control unit that only performs comprehensive control of the entire injection molding system 5 may be provided. Further, a control unit that comprehensively controls the entire injection molding system 5 may not be provided. For example, control units provided in various devices arranged in the first control unit 103 and the optional unit 400 may refer to measured values by a timer, various sensors, etc., and control the first injection molding machine 101 and various devices so that the operations of the first injection molding machine 101 and various devices are interlocked with each other.

[0138] J. Other forms: The present disclosure is not limited to the above-described embodiments, and can be realized in various forms without departing from the gist thereof. For example, the present disclosure can also be realized by the following forms. The technical features in the above-described embodiments corresponding to the technical features in each of the following forms can be appropriately replaced or combined in order to solve part or all of the problems of the present disclosure or to achieve part or all of the effects of the present disclosure. Further, if the technical feature is not described as essential in this specification, it can be appropriately deleted.

[0139] (1) According to a first aspect of the present disclosure, an injection molding unit is provided. The injection molding unit includes a main unit in which a first injection molding machine for injecting a first molding material into a cavity partitioned by a lower mold and an upper mold and in which an insert member is disposed to form an integrated product is disposed, and an option unit. The option unit includes at least one of: a member molding unit in which a second injection molding machine for injecting a second molding material to mold the insert member or a press molding machine for molding the insert member by press molding is disposed; and a robot unit in which a robot that performs an arrangement operation of arranging the insert member in the cavity or a transfer operation of transferring the integrated product molded by the first injection molding machine is disposed. The main unit is configured to be detachable from the option unit. According to such an aspect, it is possible to increase the degree of freedom in customizing the injection molding system and to save space as compared with separately installing each unit or each device.

[0140] (2) In the above-described embodiment, the first injection molding machine includes an injection device that injects a molding material toward the cavity. In a state where the upper mold and the lower mold are installed on the first injection molding machine, the injection device, the upper mold, and the lower mold are arranged in order from above in the vertical direction. The injection device has a groove-forming surface on which a groove is formed, a flat screw that rotates, a barrel having an opposing surface that faces the groove-forming surface and in which a communication hole through which the first molding material flows is formed, a heater that heats the material supplied between the groove-forming surface and the opposing surface, and a nozzle that communicates with the communication hole and injects the first molding material toward the cavity. By rotating the flat screw and heating by the heater, at least a part of the material may be plasticized to generate the molding material, and the first molding material may be sent to the communication hole. According to such an embodiment, for example, compared with a case where the injection device, the upper mold, and the lower mold are arranged along the horizontal direction, the first injection molding machine can be miniaturized in the horizontal direction, so that the main unit can be miniaturized in the horizontal direction. Further, for example, compared with a case where the injection device includes an in-line screw instead of a flat screw, the first injection molding machine can be miniaturized, so that the main unit can be miniaturized. Therefore, it is easy to realize space saving of the injection molding system. Further, since a larger number of option units or larger option units can be attached as the main unit is miniaturized, the degree of freedom in customizing the injection molding system can be increased.

[0141] (3) In the above-described embodiment, the first injection molding machine may include a mold clamping device that performs mold clamping and mold opening between the upper mold and the lower mold by moving the injection device and the upper mold along the vertical direction. According to such an embodiment, at a fixed position in the vertical direction, it is possible to remove an integrated product from the lower mold and place an insert part on the lower mold. Therefore, the process of removing the integrated product from the lower mold and the process of placing the insert part on the lower mold can be more easily automated.

[0142] (4) In the above-described embodiment, the first injection molding machine includes a first support portion that supports the first lower mold as the lower mold, a second support portion that supports the second lower mold as the lower mold, and a position changing portion configured to be capable of moving the first support portion and the second support portion. The position changing portion moves the first support portion and the second support portion to move the first lower mold or the second lower mold to an injection position where the lower mold and the upper mold face each other. There may be a first state in which the first lower mold is located at the injection position and the second lower mold is located at a position different from the injection position, and a second state in which the second lower mold is located at the injection position and the first lower mold is located at a position different from the injection position. According to such an embodiment, for example, while molding an integrated product using one of the lower molds located at the injection position, the integrated product can be removed from the other lower mold located at a position different from the injection position, and an insert member can be placed on the other lower mold. Therefore, in the main unit, an integrated product can be efficiently molded using the first lower mold and the second lower mold.

[0143] (5) In the above-described embodiment, the position changing portion linearly moves the first support portion and the second support portion along an intersecting direction intersecting the vertical direction. In the first state, the second lower mold is located at a first standby position different from the injection position. In the second state, the first lower mold is located at a second standby position on the opposite side of the first standby position across the injection position in the intersecting direction. The first injection molding machine may further include a first ejector portion for removing the integrated product from the second lower mold at the first standby position and a second ejector portion for removing the integrated product from the first lower mold at the second standby position. According to such an embodiment, by linearly moving the first support portion and the second support portion along the X direction by the position changing portion, the first state and the second state can be easily switched. Also, in either the first state or the second state, the integrated product can be easily removed from the lower mold by using the first ejector portion or the second ejector portion.

[0144] (6) In the above-described embodiment, the option unit includes the robot unit, and the robot, as the placement operation, places the insert member on the second lower mold located at the first standby position and the first lower mold located at the second standby position, or, as the transfer operation, transfers the integrated product removed from the second lower mold at the first standby position and the integrated product removed from the first lower mold at the second standby position. According to such an embodiment, the process of transferring the integrated product removed from the other lower mold while insert molding is being performed using one lower mold, and similarly, the process of placing the insert member on the other lower mold can be automated. Therefore, in the injection molding system, integrated products can be manufactured more efficiently.

[0145] (7) In the above-described embodiment, an insert detection unit for detecting whether or not the insert member is disposed at a predetermined insert position of the lower mold may be provided. According to such an embodiment, using the insert detection unit, it is possible to detect whether or not the insert member is placed at the insert position. Therefore, it is possible to suppress injection molding from being performed in a state where the insert member is placed at a position different from the insert position, and thus, it is possible to suppress damage to the upper mold and the lower mold installed in the first injection molding machine, damage to the injection device, and the occurrence of defective products.

[0146] (8) In the above-described embodiment, the option unit includes the robot unit, and the robot, as the placement operation, executes the placement of the insert member on the lower mold, and in the placement operation, based on the detection result by the insert detection unit, the insert member may be placed at the insert position. According to such an embodiment, the robot can adjust the position of the insert member so that the insert member is located at the insert position while placing the insert member on the lower mold in the placement operation. Therefore, after the placement operation, the insert member can be placed at the insert position without adjusting the position of the insert member using, for example, another robot or device different from the robot, and thus, in the injection molding system, integrated products can be manufactured more efficiently.

[0147] (9) In the above-described embodiment, the option unit includes the robot unit and the member molding unit. The robot unit is arranged adjacent to the main unit, and the member molding unit is arranged adjacent to the robot unit. The robot may execute, as the placement operation, an operation of placing the insert member molded by the member molding unit on the lower mold. According to such an embodiment, since the robot unit is arranged adjacent to the main unit and the member molding unit, the robot arranged in the robot unit can efficiently convey the insert member molded by the member molding unit to the lower mold installed in the first injection molding machine of the main unit and place it on the lower mold. Therefore, in the injection molding system, the process from molding the insert member to molding the integrated product using the molded insert member can be automated and efficiently executed, so that the integrated product can be manufactured more efficiently.

[0148] (10) In the above-described embodiment, the option unit includes the member molding unit in which the press molding machine is arranged. The press molding machine may form a plurality of the insert members on the sheet material by punching out a part of the sheet material having a sheet shape. According to such an embodiment, while feeding the sheet material on which the insert members are formed by the press molding machine from the press molding machine to the first injection molding machine, the first injection molding machine forms an integrated product of the insert members formed on the sheet material and the first molding material, so that a plurality of integrated products can be continuously molded. Therefore, in the injection molding system, the process from molding the insert member to molding the integrated product using the molded insert member can be efficiently executed, so that the integrated product can be manufactured more efficiently.

[0149] (11) According to the second embodiment of the present disclosure, a manufacturing system is provided. This manufacturing system includes one or more injection molding systems of the above-described embodiment, an assembly line for assembling a production product using the integrated product, and a transfer unit for transferring the integrated product from the injection molding system to the assembly line. According to such a form, while increasing the degree of freedom in customizing the injection molding system, it is possible to achieve space savings compared to installing each unit or each device separately. Also, in the manufacturing system, the integrated parts manufactured by the injection molding system can be aggregated to the assembly line, and the production products can be efficiently manufactured.

Explanation of Signs

[0150] 5, 5b, 5c, 5d, 5e, 5f, 5g, 5h... injection molding system, 6... plate-like member, 8... manufacturing system, 10... mold, 11... upper mold, 12... upper mold clamp, 13... upper mold support part, 15, 15e... lower mold, 16... first lower mold, 17... second lower mold, 20... material supply part, 22... supply path, 31... rotor drive part, 32... drive motor, 35... rotor reducer, 40... rotor, 42... groove forming surface, 43... rotor side surface, 44... material inlet, 45... groove, 46... rib part, 47... central part, 48... retention suppression part, 50... barrel, 52... opposing surface, 54... guide groove, 56... communication hole, 58... heater, 59... check valve, 60... nozzle, 70... injection control mechanism, 71... injection cylinder, 72... plunger, 98... stopper, 99... wheel, 100, 100b, 100e, 100g... main unit, 101, 101b, 101e, 101g... first injection molding machine, 103... first control part, 105... housing part, 106... introduction path, 110... injection device, 150, 150b... lower mold support part, 152, 152b... block, 153... edge part, 153b... edge part, 156... first support part, 157... second support part, 160... lower mold clamp, 161... first lower mold clamp, 162... second lower mold clamp, 180, 180b... position changing part, 181... electric actuator, 186... movable part, 187... plate part, 188... leg part, 189... hole part, 200... mold clamping device, 210... mold drive part, 212... mold clamping motor, 214... reducer, 216... ball screw part, 218... movable platen, 220... fixed platen, 230... first support column part, 240... second support column part, 250... ejector part, 251... first ejector part, 252... second ejector part, 260... main body part, 261... ejector plate, 262... ejector pin, 263... first main body part, 264... second main body part, 270... ejector drive part, 271... first ejector drive part, 272... second ejector drive part, 280... contact part, 300... base, 301... upper surface, 305... depression, 306... linear guide, 307... cavity part, 400, 400c, 400d, 400f, 400g,400h... Option unit, 450... Robot unit, 450A... First robot unit, 450B... Second robot unit, 450C... Third robot unit, 451... Robot, 451A... First robot, 451B... Second robot, 451C... Third robot, 452... Robot base, 455... Second control unit, 456... Third control unit, 457... Fourth control unit, 458... Fifth control unit, 500... Member forming unit, 510... Second injection molding machine, 511... Sixth control unit, 520... Press molding machine, 522... Seventh control unit, 550... Forming unit, 551... Third injection molding machine, 700... Auxiliary equipment unit, 710... Mold temperature controller, 720... Material feeding device, 730, 730b, 730c, 730d... Insert detection unit, 731... Suction unit, 732... Measuring unit, 733... Detection unit, 736... Camera, 800... Inspection unit, 900... Assembly line, 910... Transfer unit,

Claims

1. A main unit in which a first injection molding machine for injecting a first molding material to form an integrated product is arranged in a cavity partitioned by a lower mold and an upper mold and in which an insert member is arranged; An option unit, and The option unit includes: A member molding unit in which a second injection molding machine for injecting a second molding material to mold the insert member or a press molding machine for molding the insert member by press molding is arranged; At least one of: a robot unit in which a robot that performs an arrangement operation of arranging the insert member in the cavity or a transfer operation of transferring the integrated product molded by the first injection molding machine is arranged, The main unit is configured to be detachable from the option unit, The option unit includes the robot unit and the member molding unit, The robot unit is arranged adjacent to the main unit, The member molding unit is arranged adjacent to the robot unit, The robot, as the arrangement operation, executes an operation of placing the insert member molded by the member molding unit on the lower mold. An injection molding system.

2. A main unit in which a first injection molding machine for injecting a first molding material to form an integrated product is arranged in a cavity partitioned by a lower mold and an upper mold and in which an insert member is arranged; An option unit, and The option unit includes: A member molding unit in which a second injection molding machine for injecting a second molding material to mold the insert member or a press molding machine for molding the insert member by press molding is arranged; At least one of: a robot unit in which a robot that performs an arrangement operation of arranging the insert member in the cavity or a transfer operation of transferring the integrated product molded by the first injection molding machine is arranged, The main unit is configured to be detachable from the option unit, The option unit includes the member molding unit in which the press molding machine is arranged, The press molding machine forms a plurality of the insert members in the sheet material by punching out a part of the sheet material having a sheet shape. An injection molding system.

3. A main unit in which a first injection molding machine for injecting a first molding material into a cavity partitioned by a lower mold and an upper mold and in which an insert member is disposed to mold an integrated product is disposed; an option unit; and the option unit includes: a member molding unit in which a second injection molding machine for injecting a second molding material to mold the insert member or a press molding machine for molding the insert member by press molding is disposed; a robot unit in which a robot for performing an arrangement operation of arranging the insert member in the cavity or a transfer operation of transferring the integrated product molded by the first injection molding machine is disposed, including at least one of them; the main unit is configured to be detachable from the option unit; the first injection molding machine includes an injection device for injecting the first molding material toward the cavity; in a state where the upper mold and the lower mold are installed in the first injection molding machine, the injection device, the upper mold, and the lower mold are arranged in order from above in the vertical direction; the injection device includes: a flat screw having a groove formation surface formed with grooves and rotating; a barrel having an opposing surface opposing the groove formation surface and formed with a communication hole into which the first molding material flows; a heater for heating the material supplied between the groove formation surface and the opposing surface; a nozzle communicating with the communication hole and injecting the first molding material toward the cavity; and by rotation of the flat screw and heating by the heater, at least a part of the material is plasticized to generate the first molding material, and the first molding material is sent to the communication hole; the first injection molding machine includes a mold clamping device for performing mold clamping and mold opening between the upper mold and the lower mold by moving the injection device and the upper mold along the vertical direction; the first injection molding machine includes: a first support portion for supporting a first lower mold as the lower mold; a second support portion for supporting a second lower mold as the lower mold; a position changing portion configured to be capable of moving the first support portion and the second support portion; and the position changing portion: moves the first lower mold or the second lower mold to an injection position where the lower mold and the upper mold face each other by moving the first support portion and the second support portion. Switch between a first state in which the first lower mold is positioned at the injection position and the second lower mold is positioned at a position different from the injection position, and a second state in which the second lower mold is positioned at the injection position and the first lower mold is positioned at a position different from the injection position. Injection molding system.

4. The injection molding system according to claim 3, wherein the position changing unit linearly moves the first support part and the second support part along an intersecting direction intersecting with the vertical direction, in the first state, positions the second lower mold at a first standby position different from the injection position, and in the second state, positions the first lower mold at a second standby position on the opposite side of the first standby position across the injection position in the intersecting direction, The first injection molding machine further includes a first ejector part for removing the integrated product from the second lower mold at the first standby position and a second ejector part for removing the integrated product from the first lower mold at the second standby position. Injection molding system.

5. The injection molding system according to claim 4, wherein the option unit includes the robot unit, the robot As the arranging operation, placing the insert member on the second lower mold positioned at the first standby position and the first lower mold positioned at the second standby position, or As the conveying operation, conveying the integrated product removed from the second lower mold at the first standby position and the integrated product removed from the first lower mold at the second standby position. Injection molding system.

6. The injection molding system according to claim 1 or 2, wherein the first injection molding machine includes an injection device for injecting the first molding material toward the cavity, In a state where the upper mold and the lower mold are installed on the first injection molding machine, the injection device, the upper mold, and the lower mold are arranged in order from above in the vertical direction, The injection device has a groove forming surface formed with grooves and a rotating flat screw, has an opposing surface facing the groove forming surface, and a barrel formed with a communication hole into which the first molding material flows, a heater for heating the material supplied between the groove forming surface and the opposing surface, and a nozzle communicating with the communication hole and injecting the first molding material toward the cavity. By rotating the flat screw and heating with the heater, at least a part of the material is plasticized to generate the first molding material, and the first molding material is sent to the communication hole. Injection molding system. **Claim 7** An injection molding system according to claim 6, wherein the first injection molding machine includes a clamping device that clamps and unclamps the upper mold and the lower mold by moving the injection device and the upper mold along the vertical direction. **Claim 8** An injection molding system according to any one of claims 3 to 7, comprising an insert detection unit for detecting whether the insert member is disposed at a predetermined insert position of the lower mold. **Claim 9** An injection molding system according to claim 8, wherein the optional unit includes the robot unit, and the robot performs, as the placement operation, placing the insert member on the lower mold, and in the placement operation, places the insert member at the insert position based on the detection result by the insert detection unit. **Claim 10** One or more injection molding systems according to any one of claims 1 to 9, an assembly line for assembling a product using the integral part, and a transfer unit for transferring the integral part from the injection molding system to the assembly line.

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