Injection molding equipment

Abstract

To downsize an injection molding apparatus in a vertical direction.SOLUTION: An injection molding apparatus includes a support that supports a mold having an upper mold and a lower mold, and an injection unit that injects a molding material into a cavity defined by the upper mold and the lower mold. An injection unit, an upper mold, and a lower mold are arranged in order from the top in the vertical direction while the mold is supported by the support. The injection unit includes a rotating flat screw having a grooved surface formed with grooves, a barrel having an opposing surface facing the grooved surface and formed with a communication hole through which the molding material flows, and a heater heating the material supplied between the grooved surface and the opposing surface, and plasticizes at least a portion of the material by rotating the flat screw and heating by the heater to produce a molding material. The molding material is delivered to the communication hole.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to an injection molding apparatus. [Background technology]

[0002] Regarding injection molding devices, Patent Document 1 discloses an injection molding machine equipped with an injection unit having an inline screw. Patent Document 1 also describes, as injection molding machines equipped with this injection unit, a so-called horizontal injection molding machine that clamps and opens molds horizontally, as well as a vertical injection molding machine that clamps and opens molds vertically. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-130834 Summary of the Invention [Problem to be solved by the invention]

[0004] By arranging the injection unit and mold of a vertical injection molding machine vertically, the vertical injection molding machine can be made smaller in the horizontal direction. However, when an injection unit with an inline screw and a mold are arranged vertically, the entire injection molding machine becomes long in the vertical direction, which can sometimes impose restrictions on the installation space. [Means for solving the problem]

[0005] According to one aspect of the present disclosure, there is provided an injection molding apparatus. The injection molding apparatus includes a support section that supports a molding die having an upper mold and a lower mold, and an injection unit that injects a molding material toward a cavity defined by the upper mold and the lower mold. With the molding die supported by the support section, the injection unit, the upper mold, and the lower mold are arranged in this order vertically from top to bottom. The injection unit includes a rotating flat screw having a groove-forming surface with grooves formed therein, a barrel having an opposing surface that faces the groove-forming surface and having a communicating hole through which the molding material flows, and a heater that heats the material supplied between the groove-forming surface and the opposing surface. By rotating the flat screw and heating by the heater, at least a portion of the material is plasticized to generate the molding material, and the molding material is then delivered to the communicating hole. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a first diagram showing a schematic configuration of an injection molding apparatus according to a first embodiment. [Figure 2] FIG. 2 is a second diagram showing a schematic configuration of the injection molding apparatus according to the first embodiment. [Figure 3] FIG. 3 is a perspective view showing a lower die support portion and a position changing portion in the first embodiment. [Figure 4] FIG. 3 is a third diagram showing a schematic configuration of the injection molding apparatus according to the first embodiment. [Figure 5] FIG. 2 is a cross-sectional view showing the configuration of an injection unit in the first embodiment. [Figure 6] FIG. 2 is a perspective view showing a schematic configuration of a rotor. [Figure 7] Schematic plan view of the barrel. [Figure 8] FIG. [Figure 9] FIG. 9 is a schematic view showing a cross section taken along the line IX-IX in FIG. 8. [Figure 10] FIG. 4 is a plan view of a first gear and a second gear provided in the reducer, viewed in the −Z direction. [Figure 11] 10 is a graph showing an example of torque value control of a mold clamping motor in an injection process. [Figure 12] FIG. 1 is a first diagram showing a schematic configuration of an injection molding apparatus according to a second embodiment. [Figure 13] FIG. 10 is a plan view showing a schematic configuration of a lower die support part in the second embodiment. [Figure 14] FIG. 2 is a second diagram showing a schematic configuration of the injection molding apparatus according to the second embodiment. [Figure 15] FIG. 10 is a plan view showing a schematic configuration of an injection molding apparatus according to a third embodiment. [Figure 16] FIG. 10 is a plan view showing a schematic configuration of an injection molding apparatus according to a fourth embodiment. [Figure 17] FIG. 10 is a diagram showing a schematic configuration of an injection molding apparatus according to a fifth embodiment. [Figure 18] FIG. 13 is a plan view showing the vicinity of the center of a lower mold in a fifth embodiment. [Figure 19] FIG. 13 is a first diagram schematically showing a cross section of a lower mold in a fifth embodiment. [Figure 20] FIG. 22 is a second diagram schematically showing a cross section of the lower mold in the fifth embodiment. [Figure 21] FIG. 10 is a schematic diagram illustrating an insert detection unit according to another embodiment. [Figure 22] FIG. 10 is a schematic diagram illustrating an insert detection unit according to another embodiment. [Figure 23] FIG. 10 is a schematic diagram illustrating an insert detection unit according to another embodiment. [Figure 24] FIG. 10 is a schematic diagram illustrating an insert detection unit according to another embodiment. [Figure 25] FIG. 10 is a schematic diagram illustrating an insert detection unit according to another embodiment. [Figure 26] FIG. 10 is a schematic diagram illustrating an insert detection unit according to another embodiment. [Figure 27] FIG. 10 is a cross-sectional view of a case according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0007] A. First embodiment: FIG. 1 is a first diagram showing a schematic configuration of an injection molding apparatus 100 according to a first embodiment. In FIG. 1, arrows are shown along the X, Y, and Z directions, which are orthogonal to each other. The X, Y, and Z directions are directions along the X, Y, and Z axes, which are three spatial axes that are orthogonal to each other. Each of the X, Y, and Z directions includes both a direction on one side of the X, Y, and Z axes and a direction opposite the X, Y, and Z axes. The X and Y axes are axes along a horizontal plane, and the Z axis is an axis along a vertical line. The −Z direction is the vertical direction, and the +Z direction is the direction opposite the vertical direction. The −Z direction is also referred to as “down,” and the +Z direction is also referred to as “up.” Arrows along the X, Y, and Z directions are also shown in other figures as appropriate. The X, Y, and Z directions in FIG. 1 and the X, Y, and Z directions in other figures represent the same directions.

[0008] Injection molding apparatus 100 includes injection unit 110, lower mold support section 150, position change section 180, mold clamping device 200, ejector section 250, base 400, and control section 500. Injection molding apparatus 100 of this embodiment is fixed to housing 90 by fixing base 400 to housing 90. Injection molding apparatus 100 is configured so that mold 10 can be installed. Injection molding apparatus 100 molds a molded product by injecting a molding material (described below) from injection unit 110 into the installed mold 10. Mold 10 may be made of metal, resin, or ceramic, for example. A metal mold 10 is sometimes called a metal mold.

[0009] The housing 90 is provided with wheels 99 at the corners of its bottom surface. Therefore, the injection molding apparatus 100 is configured to be freely movable. In this embodiment, a bolt-type stopper 98 is provided on the bottom surface of the housing 90 adjacent to the wheel 99. By using this stopper 98, the user can fix the injection molding apparatus 100 to the installation location.

[0010] The control unit 500 is configured by a computer equipped with one or more processors, a main memory device, and an input / output interface for inputting and outputting signals from and to the outside. The processor loads and executes a program on the main memory device, whereby the control unit 500 controls the injection unit 110 and the mold clamping device 200 to manufacture molded products.

[0011] Mold 10 has an upper mold 11 and a lower mold 15. Upper mold 11 and lower mold 15 define a cavity, which is a space corresponding to the shape of the molded product. More specifically, the lower surface of upper mold 11 and the upper surface of lower mold 15 are provided with irregularities for defining the cavity, and when upper mold 11 and lower mold 15 are clamped together, a cavity having a shape corresponding to these irregularities is defined between upper mold 11 and lower mold 15.

[0012] Mold 10 is installed in injection molding apparatus 100 by being supported by a support portion of injection molding apparatus 100. In this embodiment, the support portions refer to upper mold support portion 13 that supports upper mold 11 and lower mold support portion 150 that supports lower mold 15. Upper mold support portion 13 is fixed to the bottom of injection unit 110 and is configured as a holder equipped with upper mold clamp 12 for clamping and fixing upper mold 11 in the Y direction. Lower mold support portion 150 is provided below upper mold support portion 13 and is configured as a holder equipped with lower mold clamp 160 for clamping and fixing lower mold 15 in the Y direction. Unless otherwise specified, FIG. 1 and other figures described below show mold 10 installed in injection molding apparatus 100.

[0013] As shown in Fig. 1, when molding die 10 is supported by the supports, that is, when upper die 11 is supported by upper die support portion 13 and lower die 15 is supported by lower die support portion 150, upper die 11 is disposed below injection unit 110 and lower die 15 is disposed below upper die 11. In other words, when molding die 10 is supported by the supports, injection unit 110, upper die 11, and lower die 15 are disposed in this order from top to bottom in the vertical direction. As shown in Fig. 1, in this embodiment, when molding die 10 is supported by the supports, upper die 11 and lower die 15 are both disposed above base 400.

[0014] Clamping unit 200 is configured to be able to clamp and open casting mold 10 by moving injection unit 110 and upper mold 11 along the Z direction while casting mold 10 is supported by a support portion. Clamping unit 200 includes a mold drive portion 210, a first support portion 230, and a second support portion 240. Mold drive portion 210 includes a clamping motor 212, a reducer 214, a ball screw portion 216, a movable platen 218, and a fixed platen 220.

[0015] The first support column 230 is composed of four support columns extending in the Z direction. The base 400 is fixed to the upper end of the first support column 230, and the fixed platen 220 of the mold driving unit 210 is fixed to the lower end. In other words, the base 400 and the fixed platen 220 are fixed to each other by the first support column 230. Note that, of the four support columns that make up the first support column 230, only two support columns arranged in the -Y direction are shown in FIG. 1.

[0016] The fixed plate 220 has a flat plate shape and is fixed to the lower end of the first support column 230 so that the plate surface is parallel to the horizontal direction.

[0017] The mold clamping motor 212 in this embodiment is configured as a motor with an electromagnetic brake. The mold clamping motor 212 generates a braking force by the electromagnetic brake when no voltage is applied to the excitation coil, thereby restricting the rotation of the motor shaft, and allows the restriction of the rotation of the motor shaft when no voltage is applied to the excitation coil. The mold clamping motor 212 is disposed below the lower mold 15. More specifically, the mold clamping motor 212 is fixed to the lower part of the fixed platen 220, which is fixed to the lower end of the first support column 230, with its output shaft facing upward. The driving of the mold clamping motor 212 is controlled by the control unit 500.

[0018] The reducer 214 is connected to the output shaft of the mold clamping motor 212. A ball screw portion 216 is connected to the output shaft of the reducer 214. The reducer 214 in this embodiment is a concentric shaft type reducer in which the input shaft and the output shaft are on the same axis. The reducer 214 is fixed to the fixed platen 220 in a state in which the ball screw portion 216 connected to the reducer 214 protrudes upward relative to the fixed platen 220.

[0019] The movable platen 218 has a flat plate shape. The movable platen 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 column portion 230. When the mold clamping motor 212 rotates the ball screw portion 216, the movable platen 218 moves in the Z direction relative to the fixed platen 220, using the first support column portion 230 as a guide, with its lower surface facing the upper surface of the fixed platen 220.

[0020] In this embodiment, the second support column 240 is composed of four support columns extending in the Z direction. The second support column 240 is provided so as to penetrate the base 400 in the Z direction. The movable platen 218 is fixed to the lower end of the second support column 240. The injection unit 110 is fixed to the upper end of the second support column 240. Note that, of the four support columns that make up the second support column 240, only two support columns arranged in the -X direction are shown in FIG. 1.

[0021] FIG. 2 is a second diagram showing a schematic configuration of the injection molding apparatus 100 according to the first embodiment. FIG. 2 shows the state in which the molding die 10 installed in the injection molding apparatus 100 is clamped. As shown in FIGS. 1 and 2, the clamping apparatus 200 clamps and opens the molding die 10 by driving the clamping motor 212 to move the injection unit 110 and the upper die 11 in the vertical direction. More specifically, the driving force of the clamping motor 212 is transmitted to the ball screw portion 216 via the reducer 214, causing the movable platen 218 coupled to the ball screw portion 216 to move in the Z direction along the first support column 230, and the injection unit 110 and the upper die 11 fixed to the movable platen 218 via the second support column 240 to move in the Z direction. By moving the movable platen 218 in the −Z direction, the clamping apparatus 200 can move the injection unit 110 and the upper die 11 in the −Z direction relative to the lower die 15, thereby performing mold clamping. Similarly, the mold clamping device 200 can move the injection unit 110 and the upper mold 11 in the +Z direction relative to the lower mold 15 by moving the movable platen 218 in the +Z direction, thereby performing mold opening. An injection molding device that performs mold opening and mold clamping along the vertical direction, such as the injection molding device 100, is also called a vertical injection molding device or a vertical injection molding machine.

[0022] The injection molding apparatus 100 of this embodiment is equipped with a descent restricting unit configured to restrict movement of the injection unit 110 and the upper mold 11 in a direction toward the lower mold 15. In this embodiment, the mold clamping motor 212 functions as the descent restricting unit. More specifically, the electromagnetic brake of the mold clamping motor 212 restricts rotation of the motor shaft of the mold clamping motor 212 when no voltage is applied to the mold clamping motor 212, thereby preventing the ball screw portion 216 from unintentionally rotating due to downward loads from the injection unit 110, the upper mold 11, or the movable platen 218. This prevents the injection unit 110 and the upper mold 11 from unintentionally moving downward.

[0023] The position changing unit 180 is configured to be able to linearly move the lower mold support unit 150 along a transverse direction that intersects with the vertical direction. In this embodiment, the position changing unit 180 is configured to be able to linearly move the lower mold support unit 150 along the X direction. The position changing unit 180 has a movable unit 186 that supports the lower mold support unit 150 and an electric actuator 181 that moves the movable unit 186. The electric actuator 181 is configured with a ball screw and a motor that rotates the ball screw. In this embodiment, the position changing unit 180 drives the electric actuator 181 to move the movable unit 186 so as to slide in the X direction relative to the base 400. The drive of the electric actuator 181 is controlled by the control unit 500.

[0024] Fig. 3 is a perspective view showing the lower mold support part 150 and the position changing part 180. In Fig. 3, the second support part 240 is omitted. As shown in Fig. 3, the electric actuator 181 of the position changing part 180 is arranged along the X direction in a recess 405 formed in the base 400. The recess 405 is a portion where the upper surface 401 of the base 400 is recessed downward, and is formed along the X direction.

[0025] A linear guide 406 is further provided within the recess 405. The linear guide 406 functions as a guide for the movable part 186 that is moved by the electric actuator 181. The linear guide 406 is configured from a pair of parallel rail-shaped members that are long in the X direction, and is fixed to the bottom surface of the recess 405 via bolts.

[0026] 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 legs 188 that support the plate part 187. The plate part 187 and the legs 188 are fixed to each other via bolts. The legs 188 are connected to the electric actuator 181. The legs 188 have a shape that allows them to engage with the linear guide 406 in the Y direction. The engagement between the legs 188 and the linear guide 406 allows the movable part 186 to move in the X direction and restricts the movable part 186 from moving in the Y direction, so that the movable part 186 can be moved stably in the X direction by driving the electric actuator 181.

[0027] The lower die support portion 150 described above has a pair of blocks 152 arranged facing each other in the Y direction. Each block 152 is fixed to the upper surface of the plate portion 187 via a bolt. Each block 152 has an edge portion 153 on which the lower die 15 is placed. The lower die clamps 160 described above are provided on the upper surfaces of the blocks 152. More specifically, one lower die clamp 160 is provided on the upper surface of each block 152. The lower die clamps 160 clamp and fix the lower die 15 placed on the edge portion 153 of the block 152 in the Y direction.

[0028] FIG. 4 is a third diagram showing a schematic configuration of the injection molding apparatus 100 according to the first embodiment. FIG. 4 illustrates a state in which the lower mold support unit 150 is moved by the position change unit 180 to a position further in the −X direction than in FIG. 1 . The position change unit 180 is configured to be able to switch between a state in which the lower mold 15 is located at injection position P as shown in FIG. 1 and a state in which the lower mold 15 is located at a position different from injection position P as shown in FIG. 4 by moving the lower mold support unit 150. The injection position P refers to a position where the lower mold 15 and the upper mold 11 face each other. In this embodiment, the position change unit 180 moves the lower mold support unit 150 in the X direction to position the lower mold 15 at injection position P or standby position W. The standby position W is located in the −X direction from the injection position P.

[0029] The ejector unit 250 is a member for removing the molded article from the lower mold 15. The ejector unit 250 of this embodiment removes the molded article from the lower mold 15 at the standby position W described above. The ejector unit 250 has a main body unit 260 for pushing the molded article up from the lower mold 15, and an ejector drive unit 270 for operating the main body unit 260. In this embodiment, the main body unit 260 is connected to the lower mold 15, and moves in the X direction together with the lower mold 15 by the position change unit 180. The ejector drive unit 270 is fixed to the base 400.

[0030] The main body 260 has a flat ejector plate 261 and a shaft-like ejector pin 262 fixed to the ejector plate 261. The main body 260 is connected to the lower mold 15 by inserting the ejector pin 262 from below the lower mold 15 into a through-hole formed in the lower mold 15 so as to penetrate a portion defining a cavity in the Z direction. As shown in FIG. 3 , when the lower mold 15 is supported by the lower mold support 150, the ejector plate 261 is disposed between the lower mold 15 and the plate 187 in the Z direction and between the blocks 152 constituting the lower mold support 150 in the Y direction. Also, as shown in FIG. 1 , a hole 189 penetrating the plate 187 in the Z direction is provided in the plate 187 at a position overlapping at least a portion of the ejector plate 261 when viewed along the Z direction. In this embodiment, the hole 189 is provided in the center of the plate 187 in the X and Y directions.

[0031] The ejector driving unit 270 is configured with a ball screw and a motor that rotates the ball screw. As shown in Fig. 1, the ejector driving unit 270 is fixed to the base 400 below the base 400. The driving of the ejector driving unit 270 is controlled by the control unit 500.

[0032] A contact portion 280 is coupled to the ball screw of the ejector driving portion 270. The contact portion 280 is disposed in a hollow portion 407 that passes through the base 400 in the Z direction.

[0033] When the lower mold 15 shown in FIG. 4 is positioned at the standby position W, the ejector driving unit 270 moves the contact portion 280 coupled to the ball screw in the +Z direction, thereby allowing the contact portion 280 to push up the main body portion 260. More specifically, the contact portion 280 protrudes from the hollow portion 407 in the +Z direction by being driven by the ejector driving unit 270, and then passes through the hole 189 formed in the plate portion 187 in the +Z direction, thereby coming into contact with the ejector plate 261. Then, while in contact with the ejector plate 261, the contact portion 280 can push up the main body portion 260 in the +Z direction by further moving in the +Z direction. The ejector pins of the pushed-up main body portion 260 push up the molded product in the +Z direction, and the molded product is removed from the lower mold 15.

[0034] 5 is a cross-sectional view showing the configuration of the injection unit 110 in the first embodiment. The injection unit 110 has a material supply part 20, a rotor 40, a barrel 50, a heater 58, a nozzle 60, and an injection control mechanism 70.

[0035] Injection unit 110 uses rotor 40, barrel 50, and heater 58 to plasticize at least a portion of the material supplied from material supply section 20 between rotor 40 and barrel 50 to generate a molding material, and then injects the molding material from nozzle 60 toward the cavity of mold 10. In this embodiment, "plasticization" refers to the application of heat to a thermoplastic material to melt it. Furthermore, "melting" refers not only to a thermoplastic material being heated to a temperature above its melting point and becoming liquid, but also to a thermoplastic material being softened and becoming fluid by being heated to a temperature above its glass transition point.

[0036] In this embodiment, the material supply unit 20 is configured by a hopper. The material supply unit 20 stores material in the form of pellets, powder, or the like. In this embodiment, ABS resin formed into pellets is used as the material. As shown in FIG. 5, a supply path 22 is provided below the material supply unit 20. The supply path 22 is connected to an introduction path 102 formed in a case 107, which will be described later. The material supply unit 20 supplies material between the rotor 40 and the barrel 50 via the supply path 22 and the introduction path 102.

[0037] The rotor 40 is also called a scroll or a flat screw. The rotor 40 is driven to rotate about a rotation axis RX along the Z direction by a rotor drive unit 31 composed of a drive motor 32 and a rotor reducer 300. The rotation of the rotor 40 by the rotor drive unit 31 is controlled by a control unit 500.

[0038] The rotor 40 and the rotor reducer 300 are housed in a housing 101. The housing 101 has a case 107 and an upper cover 108. The case 107 is a housing portion that surrounds the periphery of the rotor 40 and the periphery of the rotor reducer 300 in the horizontal direction. The upper cover 108 is a portion that is disposed on top of the case 107 so as to cover the rotor 40 and the rotor reducer 300 from above. The drive motor 32 is disposed on top of the upper cover 108 so that its output shaft 33 can be inserted into the housing 101 through an opening provided in the upper cover 108.

[0039] A communication hole 56 through which the produced modeling material flows is formed in the center of the barrel 50. An injection cylinder 71 of an injection control mechanism 70, which will be described later, is connected to the communication hole 56. A check valve 59 is provided in the communication hole 56 upstream of the injection cylinder 71.

[0040] FIG. 6 is a perspective view showing a schematic configuration of the rotor 40. The rotor 40 has a generally cylindrical shape with a height along its central axis that is smaller than its diameter. A spiral groove 45 is formed around a central portion 47 on the groove-forming surface 42 of the rotor 40, which faces the barrel 50. The groove 45 communicates with a material inlet 44 formed on the rotor side surface 43 of the rotor 40. Material supplied from the material supply unit 20 is supplied to the groove 45 through the material inlet 44. The grooves 45 are formed by being separated by a ridge portion 46. While FIG. 6 shows an example in which three grooves 45 are formed, the number of grooves 45 may be one or more. The groove 45 is not limited to a spiral shape, but may also be a spiral shape or an involute curve shape, or may have a shape extending in an arc from the center to the outer periphery.

[0041] The rotor 40 of this embodiment is provided with a retention suppression portion 48 in the central portion 47 that protrudes toward the communication hole 56. In this embodiment, the retention suppression portion 48 has a substantially conical shape, and the central axis of the retention suppression portion 48 substantially coincides with the rotation axis RX of the rotor 40. The tip of the retention suppression portion 48 is disposed inside the communication hole 56 formed in the barrel 50. The retention suppression portion 48 efficiently guides the molding material from the central portion 47 to the communication hole 56, suppressing retention of the molding material in the central portion 47. In other embodiments, the rotor 40 may not be provided with the retention suppression portion 48.

[0042] FIG. 7 is a schematic plan view of barrel 50. Barrel 50 has an opposing surface 52 that faces groove-forming surface 42 of rotor 40. As shown in FIG. 7, the above-mentioned communication hole 56 is formed so as to open in the center of opposing surface 52. In opposing surface 52, a plurality of guide grooves 54 are formed that are connected to communication hole 56 and extend in a spiral shape from communication hole 56 toward the outer periphery. Note that in other embodiments, guide groove 54 does not have to be connected to communication hole 56. Also, guide groove 54 does not have to be provided in the barrel.

[0043] The heaters 58 heat 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. 5 , in this embodiment, four heaters 58 are provided inside the barrel 50. The output of the heaters 58 is controlled by the control unit 500.

[0044] The material supplied to the grooves 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 due to the rotation of the rotor 40 and heating by the heater 58, and is then 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 a communication hole 56 provided in the center of the barrel 50, and further guided from the communication hole 56 to the injection control mechanism 70.

[0045] As shown in FIG. 5 , injection control mechanism 70 includes injection cylinder 71 and plunger 72. Injection control mechanism 70 has the function of injecting molding material in injection cylinder 71 into the cavity of molding die 10. Injection control mechanism 70 controls the amount of molding material injected from nozzle 60 under the control of control unit 500. Injection cylinder 71 is a substantially cylindrical member connected to communication hole 56 of barrel 50. In this embodiment, injection cylinder 71 is disposed along the X direction. Plunger 72 is inserted into injection cylinder 71. Plunger 72 slides inside injection cylinder 71 and pressure-feeds the molding material in injection cylinder 71 to nozzle 60. Plunger 72 is driven by a motor (not shown).

[0046] Fig. 8 is a perspective view of the case 107. Fig. 9 is a schematic view showing a cross section taken along line IX-IX in Fig. 8. Figs. 8 and 9 show the case 107 in a state in which the rotor 40 is not housed therein.

[0047] As shown in Figures 5 and 8, the introduction path 102 described above is formed in the case 107. As shown in Figure 5, the introduction path 102 has a vertical section 105 and an inclined section 106. The vertical section 105 is a section of the introduction path 102 that extends along the vertical direction. The inclined section 106 is a section of the introduction path 102 that extends along an inclined direction D that is inclined between the horizontal and vertical directions. The vertical section 105 is located upstream of the inclined section 106 in the flow direction of the material flowing inside the introduction path 102.

[0048] As shown in FIGS. 5 and 8, the introduction path 102 has an introduction port 103 at one end and an outlet port 104 at the other end. The introduction port 103 forms the beginning of a vertical portion 105, and the outlet port 104 forms the end of an inclined portion 106. The introduction port 103 is provided on the upper surface of a case 107. As shown in FIG. 5, the above-mentioned supply path 22 is connected to the introduction port 103. As shown in FIGS. 5 and 8, the outlet port 104 is provided so as to open toward a space 109 in the case 107 for accommodating the rotor 40. More specifically, the outlet port 104 is provided at a position facing the rotor side surface 43 of the rotor 40 accommodated in the case 107, as shown in FIG. 5.

[0049] As shown in FIG. 9 , the outlet 104 has a rectangular shape that is elongated in the X direction when viewed along the Y direction, which is the direction in which the rotor side surface 43 and the outlet 104 face each other. Because the outlet 104 has a shape that is elongated in the X direction when viewed along the Y direction, the material flowing in the inlet channel 102 is more likely to spread in the X direction at the outlet 104 along the shape of the outlet 104, compared to, for example, a case in which the outlet 104 has a shape that is elongated in the Z direction when viewed along the Y direction. This makes it easier for the material flowing in the inlet channel 102 to flow into the material inlet 44 provided on the rotor side surface 43 of the rotating rotor 40, thereby suppressing clogging of the material in the inlet channel 102. Furthermore, because the outlet 104 has a rectangular shape when viewed along the Y direction, the material flowing in the inlet channel 102 is more likely to spread in the X direction at the outlet 104 along the shape of the outlet 104, compared to, for example, a case in which the outlet 104 has a circular shape when viewed along the Y direction. Therefore, clogging of the introduction passage 102 with material is suppressed.

[0050] 5, the rotor reducer 300 includes a substantially cylindrical eccentric body 301 fixed to the output shaft 33 of the drive motor 32, a first gear 310 configured as a planetary gear, and a second gear 320 configured as an internal sun gear. The rotor reducer 300 in this embodiment is a concentric shaft type reducer in which the input shaft and the output shaft are coaxial.

[0051] The end of the eccentric body 301 on the drive motor 32 side is journaled by a first ball bearing 341 fixed to the upper cover 108. The end of the eccentric body 301 on the rotor 40 side is journaled by a second ball bearing 342 press-fitted into the inner periphery of the second gear 320. The outer periphery of the portion of the eccentric body 301 fixed to the first ball bearing 341 and the outer periphery of the portion of the eccentric body 301 fixed to the second ball bearing 342 are perfectly circular with the output shaft of the drive motor 32 as the center. In contrast, the portion of the eccentric body 301 sandwiched between the first ball bearing 341 and the second ball bearing 342 is perfectly circular with its central axis eccentric with respect to the output shaft of the drive motor 32. Hereinafter, the term "eccentric body 301" simply refers to the portion of the eccentric body 301 sandwiched between the first ball bearing 341 and the second ball bearing 342.

[0052] FIG. 10 is a plan view of the first gear 310 and the second gear 320 provided in the rotor reducer 300, viewed in the -Z direction. The first gear 310 has an annular shape, and a needle bearing 344 is press-fitted and fixed to its inner periphery. As shown in FIG. 10, wavy external teeth 311 are formed on the outer periphery of the first gear 310. A plurality of pins 312 are arranged on the first gear 310 at equal intervals in the circumferential direction when viewed in the -Z direction. Each of these pins 312 is disposed in a pin receiving recess 303. A plurality of pin receiving recesses 303 are formed in an annular pin receiving portion 302 fixed to the periphery of the eccentric body 301 in the upper cover 108. Each pin receiving recess 303 opens toward the -Z direction and has a diameter larger than that of the pin 312. Therefore, the pin 312 can move within the pin receiving recess 303 in the X and Y directions, which are perpendicular to the rotation axis RX.

[0053] As shown in Fig. 5, the second gear 320 has a cylindrical shape with a bottom that opens at the end face on the +Z direction side. A first recess 321 is formed in the end face on the +Z direction side of the second gear 320, and a second recess 323 is further formed at the bottom of the first recess 321. The first recess 321 houses the first gear 310. The first recess 321 has wavy internal teeth 322 formed on its inner periphery that come into contact with the external teeth 311 of the first gear 310 shown in Fig. 10. The second ball bearing 342 described above is press-fitted and fixed in the second recess 323.

[0054] A recess 49 is formed in the end face of the rotor 40 on the +Z direction side, and a bottom 328 of the second gear 320 fits into this recess 49. The recess 49 and the bottom 328 are subjected to anti-spinning processing such as D-cutting. The rotor 40 is fixed to the bottom 328 in the direction of the rotation axis RX by a bolt 324 serving as a fixing part. In other words, the rotor 40 is integrated with the second gear 320. Therefore, when the second gear 320 moves along the rotation axis RX, the rotor 40 also moves along the rotation axis RX accordingly. Note that the second gear 320 and the rotor 40 may be fixed to each other by other fixing parts such as rivets, rather than by a single bolt 324. The number of bolts 324 is not limited to one, and multiple bolts may be used to fix the second gear 320 and the rotor 40.

[0055] A flange-shaped first restricting portion 325 is formed on the outer periphery of second gear 320. Details of this first restricting portion 325 will be described later. A portion of second gear 320 on the +Z direction side of first restricting portion 325 is journaled by a third ball bearing 343 fixed to upper cover 108 on the outer periphery side of pin receiving portion 302. In this embodiment, third ball bearing 343 is configured as a single-row angular bearing that receives a load from rotor 40 in the +Z direction.

[0056] The operation of the rotor reducer 300 described above will be explained. When the drive motor 32 rotates, the eccentric body 301 fixed to the output shaft 33 of the drive motor 32 rotates. As the eccentric body 301 rotates, it partially contacts a needle bearing 344 provided on the inner periphery of the first gear 310. When the eccentric body 301 contacts the needle bearing 344, the first gear 310 receives a driving force from the eccentric body 301, and swings in the X and Y directions intersecting the rotation axis RX with the pin 312 housed in the pin receiving recess 303. Due to this movement of the first gear 310, the external teeth 311 of the first gear 310 come into partial contact with the internal teeth 322 of the second gear 320 in sequence, causing the second gear 320 to rotate at a predetermined reduction ratio determined by the number of external teeth 311 of the first gear 310 and the number of internal teeth 322 of the second gear 320, and as a result, the rotor 40 fixed to the second gear 320 rotates within the case 107.

[0057] As described above, the flange-shaped first restricting portion 325 is formed on the outer periphery of the second gear 320. Since the rotor 40 is fixed to the second gear 320, it can be said that the first restricting portion 325 is indirectly fixed to the rotor 40.

[0058] The case 107 has a second restricting portion 111 that faces the surface of the first restricting portion 325 on the -Z direction side. The first restricting portion 325 is contactable with the second restricting portion 111. "Contactable" means that the rotor 40 can be in either a non-contacting state or a contacting state. The first restricting portion 325 and the second restricting portion 111 restrict movement of the rotor 40 along the rotation axis RX, more specifically, movement in the -Z direction beyond a predetermined amount.

[0059] The groove-forming surface 42 of the rotor 40 is spaced a predetermined distance from the opposing surface 52 when the first restricting portion 325 and the second restricting portion 111 are in contact with each other. This distance is, for example, 0.1 mm. The distance between the groove-forming surface 42 and the opposing surface 52 refers to the shortest distance at a position where the groove 45 and the guide groove 54 are not formed.

[0060] Grease may be applied between the first restriction portion 325 and the second restriction portion 111 to reduce sliding resistance therebetween, or a low-friction coating such as fluororesin may be applied to these surfaces. Alternatively, the first restriction portion 325 or the second restriction portion 111 may be formed from a member with a low friction coefficient.

[0061] Even when the rotor 40 moves toward the barrel 50 along the rotation axis RX, the first restricting portion 325 fixed to the rotor 40 contacts the second restricting portion 111 before the rotor 40 contacts the barrel 50. Therefore, even when, for example, the supply of material from the material supply unit 20 is temporarily interrupted during continuous molding or when material clogs the supply path 22 or the introduction path 102, the rotor 40 and the barrel 50 will not come into contact with each other. This prevents the rotor 40 and the barrel 50 from wearing out and reducing in durability.

[0062] 5, the rotor reducer 300 in this embodiment is disposed at a position different from the introduction path 102 provided in the case 107. As a result, the flow of material in the introduction path 102 is less likely to be obstructed than when, for example, a portion of the rotor reducer 300 is disposed within the introduction path 102, and therefore, retention of material in the introduction path 102 is suppressed. On the other hand, in other embodiments, a portion of the rotor reducer 300 may be disposed within the introduction path 102. For example, the outer end portion in the circumferential direction of the first restriction portion 325 may be disposed within the introduction path 102.

[0063] Figure 11 is a graph showing an example of torque value control of mold clamping motor 212 in the injection process of this embodiment. The injection process refers to the process of injecting molding material from injection unit 110 into the cavity of clamped molding die 10. The injection process may also include a pressure holding process in which molding material is replenished into the cavity to compensate for shrinkage of the molding material injected into the cavity. Figure 11 is a graph with time on the horizontal axis and the torque value of mold clamping motor 212 on the vertical axis, showing the change in the torque value of mold clamping motor 212 over elapsed time.

[0064] As shown in FIG. 11 , in this embodiment, during the injection process, control unit 500 first controls the torque value of mold clamping motor 212 to a first torque value Tr1 to press upper mold 11 against lower mold 15 located at injection position P, thereby starting mold clamping of casting mold 10. In the example shown in FIG. 11 , control unit 500 increases the torque value to first torque value Tr1 between times t1 and t2, and then maintains the torque value at first torque value Tr1 between times t2 and t3 to press upper mold 11 against lower mold 15. Note that mold clamping of casting mold 10 is initiated with lower mold 15 and upper mold 11 already in contact with each other. The operation of bringing lower mold 15 and upper mold 11 into contact with each other prior to mold clamping is sometimes referred to as mold closing. Mold closing and mold clamping may be performed consecutively.

[0065] Next, the control unit 500 decreases the torque value of the mold clamping motor 212 from the first torque value Tr1 to the second torque value Tr2, and presses the upper mold 11 against the lower mold 15. Thereafter, the control unit 500 increases the torque value from the second torque value Tr2 to the third torque value Tr3, and presses the upper mold 11 against the lower mold 15. In the example shown in FIG. 11 , the control unit 500 decreases the torque value from the first torque value Tr1 to the second torque value Tr2 between times t3 and t4, and holds the torque value at the second torque value Tr2 between times t4 and t5, and presses the upper mold 11 against the lower mold 15. Thereafter, the control unit 500 again increases the torque value from the second torque value Tr2 to the third torque value Tr3 between times t5 and t6, and holds the torque value at the third torque value Tr3 between times t6 and t7, and presses the upper mold 11 against the lower mold 15. In this embodiment, the control unit 500 injects the molding material from the injection unit 110 into the cavity at time t3, and then maintains pressure until time t7.

[0066] By decreasing the torque value from the first torque value Tr1 to the second torque value Tr2 at time t3, the load on the mold clamping motor 212 can be reduced, for example, compared to maintaining the torque value at the first torque value Tr1 from time t3 to time t5. This allows, for example, a smaller motor to be used as the mold clamping motor 212. Furthermore, by increasing the torque value from the second torque value Tr2 to the third torque value Tr3 at time t5, leakage of molding material from between the upper mold 11 and the lower mold 15 due to insufficient torque is suppressed, for example, compared to maintaining the torque value at the second torque value Tr2 from time t5 to time t7. The third torque value Tr3 may be the same as the first torque value Tr1, for example. However, from the viewpoint of further suppressing the load on the mold clamping motor 212, it is preferable that the third torque value Tr3 be smaller than the first torque value Tr1. Note that after controlling the torque value to the third torque value Tr3, the control unit 500 may repeat the control of increasing or decreasing the torque value once or multiple times. For example, after time t7, the control unit 500 may decrease the torque value again to the second torque value Tr2, and then increase the torque value again to the third torque value Tr3.

[0067] After the injection step, the control unit 500 opens the casting mold 10 by generating a torque in the opposite direction to the torque during mold clamping. In this embodiment, the control unit 500 makes the maximum torque value of the mold clamping motor 212 during the injection step greater than the maximum torque value of the mold clamping motor 212 during mold opening. For example, in the example of FIG. 11 described above, the maximum torque value during the injection step is the first torque value Tr1, so the control unit 500 controls the maximum torque value of the mold clamping motor 212 during mold opening to a value smaller than the first torque value Tr1.

[0068] According to the injection molding apparatus 100 of the present embodiment described above, with the molding die 10 supported by the support portion of the injection molding apparatus 100, the injection unit 110, the upper mold 11, and the lower mold 15 are arranged in this order from top to bottom in the vertical direction. The injection unit 110 includes a flat screw, a barrel 50, and a heater 58. By rotating the flat screw and heating by the heater 58, the material is plasticized at least in part to generate a molding material, and the generated molding material is delivered to the communication hole 56. Therefore, the injection unit 110 includes an inline screw, and the entire injection molding apparatus 100 can be made smaller in the vertical direction compared to a configuration in which the injection unit 110 is equipped with an inline screw and the molding material is generated by the inline screw.

[0069] Furthermore, in this embodiment, the injection molding apparatus 100 includes a mold clamping device 200 that performs mold clamping and mold opening by moving the injection unit 110 and the upper mold 11 in the vertical direction while the molding die 10 is supported on a support portion. With this configuration, mold clamping and mold opening can be performed by moving the injection unit 110 and the upper mold 11 in the vertical direction relative to the lower mold 15 without moving the lower mold 15 in the vertical direction. This allows the molded product to be removed from the lower mold 15 at a fixed position in the vertical direction. Therefore, for example, the molded product removal process can be more easily automated. Furthermore, when performing insert molding in which the molding material and the insert part are molded integrally within the molding die 10, the insert part can be placed on the lower mold 15 at a fixed position in the vertical direction. Therefore, for example, the process of placing the insert part in insert molding can be more easily automated.

[0070] Furthermore, in this embodiment, a descent restricting portion is provided that is configured to restrict movement of the injection unit 110 and the upper mold 11 in a direction toward the lower mold 15. Therefore, the descent restricting portion can prevent the injection unit 110 and the upper mold 11 from unintentionally moving toward the lower mold 15.

[0071] Furthermore, in this embodiment, the mold clamping device 200 moves the injection unit 110 and the upper mold 11 in the Z direction by the mold clamping motor 212 arranged below the lower mold 15. As a result, the arrangement of the members constituting the injection unit 110 is less likely to be restricted by the arrangement of the mold clamping motor 212, compared to an embodiment in which the mold clamping motor 212 is arranged above the lower mold 15. Therefore, the degree of freedom in the configuration of the injection unit 110 can be increased.

[0072] Furthermore, in this embodiment, during the injection process, control unit 500 controls the torque value of mold clamping motor 212 to a first torque value to press upper mold 11 against lower mold 15, then decreases the torque value of mold clamping motor 212 from the first torque value to a second torque value to press upper mold 11 against lower mold 15, and further increases the torque value of mold clamping motor 212 from the second torque value to a third torque value to press upper mold 11 against lower mold 15. Therefore, overload on mold clamping motor 212 can be suppressed, and leakage of molding material from casting mold 10 can be suppressed.

[0073] Furthermore, in this embodiment, the control unit 500 sets the maximum torque value of the mold clamping motor 212 during mold clamping to be greater than the maximum torque value of the mold clamping motor 212 during mold opening. Therefore, the load on the mold clamping motor 212 during mold opening can be reduced.

[0074] B. Second embodiment: 12 is a first diagram showing a schematic configuration of injection molding apparatus 100b in the second embodiment. In this embodiment, injection molding apparatus 100b differs from the first embodiment in that it includes a first support portion 156 that supports first lower mold 16 as the lower mold, and a second support portion 157 that supports second lower mold 17 as the lower mold. Portions of the configuration of injection molding apparatus 100b that are not particularly described are the same as those in the first embodiment.

[0075] FIG. 13 is a plan view showing a schematic configuration of a lower die support portion 150b in the second embodiment. FIG. 13 shows the lower die support portion 150b and the plate portion 187 supporting the lower die support portion 150b, viewed from above. As shown in FIGS. 12 and 13, the lower die support portion 150b has the first support portion 156 and the second support portion 157. In this embodiment, the first support portion 156 is a portion of the edge portion 153b of a pair of blocks 152b constituting the lower die support portion 150b that supports the first lower die 16. Similarly, the second support portion 157 is a portion of the edge portion 153b of the block 152b that supports the second lower die 17. The first support portion 156 is located in the +X direction of the second support portion 157. A pair of first lower die clamps 161 and a pair of second lower die clamps 162 are provided on the upper surface of the block 152b. Similar to the lower die clamp 160 described in the first embodiment, the first lower die clamp 161 clamps and fixes the first lower die 16 supported by the first support portion 156 in the Y direction. Similarly, the second lower die clamp 162 clamps and fixes the second lower die 17 supported by the second support portion 157 in the Y direction.

[0076] The position changer 180b is configured to be able to move the first support part 156 and the second support part 157. In this embodiment, the position changer 180b moves the first support part 156 and the second support part 157 linearly along a direction intersecting the vertical direction. More specifically, as in the first embodiment, the position changer 180b drives the electric actuator 181 to move the movable part 186 supporting the lower die support part 150b so as to slide in the X direction relative to the base 400. As a result, the first support part 156 and the second support part 157 move linearly along the X direction in cooperation with each other.

[0077] FIG. 14 is a second diagram showing a schematic configuration of an injection molding apparatus 100b according to the second embodiment. FIG. 14 illustrates a state in which the lower mold support portion 150b is moved by the position changer 180b, so that the lower mold support portion 150b is positioned further in the +X direction than in the state shown in FIG. 12. The position changer 180b is configured to switch the state of the injection molding apparatus 100b 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 the first lower mold portion 16 is located at injection position P and the second lower mold portion 17 is located at a position different from injection position P, as shown in FIG. 12. The second state refers to a state in which the second lower mold portion 17 is located at injection position P and the first lower mold portion 16 is located at a position different from injection position P, as shown in FIG. 14.

[0078] As shown in FIG. 12, in this embodiment, the position changing unit 180b positions the second lower mold 17 at the first standby position W1 in the first state. Also, as shown in FIG. 14, in the second state, the position changing unit 180b positions the first lower mold 16 at the second standby position W2. The first standby position W1 and the second standby position W2 are both different from the injection position P. The second standby position W2 is located on the opposite side of the first standby position W1 in the X direction, with the injection position P in between. In other words, the first standby position W1 and the second standby position W2 are separated in the X direction by the injection position P. In this 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.

[0079] 12 and 14, the injection molding apparatus 100b in this embodiment includes a first positioning unit 190 that positions the second lower mold 17 at the first standby position W1 and a second positioning unit 193 that positions the first lower mold 16 at the second standby position W2. In this embodiment, the first positioning unit 190 and the second positioning unit 193 also function as injection positioning units that position the first lower mold 16 or the second lower mold 17 at the injection position P. More specifically, the first positioning unit 190 positions the first lower mold 16 at the injection position P and the second lower mold 17 at the first standby position W1 in the first state. The second positioning unit 193 positions the second lower mold 17 at the injection position P and the first lower mold 16 at the second standby position W2 in the second state.

[0080] The first positioning part 190 has a first positioning hole 191 formed in the plate part 187 of the movable part 186 and a first positioning pin 192 provided in the base 400. The first positioning hole 191 is formed as a portion where the lower surface of the plate part 187 is recessed upward. In this embodiment, the first positioning hole 191 is formed at the end of the plate part 187 in the -X direction. The first positioning pin 192 is biased upward by a spring (not shown) and is fixed to the end of the base 400 in the -X direction with its upper end protruding above the upper surface 401 of the base 400. By fitting the first positioning pin 192 into the first positioning hole 191, the plate part 187 is positioned with respect to the base 400 with the first lower mold 16 positioned at the injection position P and the second lower mold 17 positioned at the first standby position W1. Similarly, the second positioning portion 193 includes a second positioning hole 194 formed at the end of the plate portion 187 in the +X direction, and a second positioning pin 195 fixed to the end of the base 400 in the +X direction. By fitting the second positioning pin 195 into the second positioning hole 194, the plate portion 187 is positioned with respect to the base 400 in a state where the second lower mold 17 is located at the injection position P and the first lower mold 16 is located at the second standby position W2.

[0081] 12 and 14, the injection molding apparatus 100b in this embodiment has a first ejector section 251 and a second ejector section 252. The first ejector section 251 is a member for removing a molded product from the second lower mold 17 at the first standby position W1. The second ejector section 252 is a member for removing a molded product from the first lower mold 16 at the second standby position W2.

[0082] The configurations of the first ejector unit 251 and 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 unit 263 connected to the second lower mold 17 for pushing up the molded product from the second lower mold 17, and a first ejector driver 271 for operating the first main body unit 263. Similarly, the second ejector unit 252 includes a second main body unit 264 connected to the first lower mold 16 for pushing up the molded product from the first lower mold 16, and a second ejector driver 272 for operating the second main body unit 264.

[0083] The injection molding apparatus 100b of this embodiment described above also allows the entire injection molding apparatus 100b to be more compact in the vertical direction than when the injection unit 110 is equipped with an inline screw and produces molding material using the inline screw. In particular, this embodiment includes a position changer 180b configured to move 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 changer 180b moves the first support portion 156 and the second support portion 157 to switch between a first state in which the first lower mold 16 is located at injection position P and the second lower mold 17 is located at a position different from injection position P, and a second state in which the second lower mold 17 is located at injection position P and the first lower mold 16 is located at a position different from injection position P. This allows a molded product to be removed from one lower mold located at injection position P while the other lower mold located at a position different from injection position P is being molded. Therefore, a molded product can be efficiently molded using the first lower mold 16 and the second lower mold 17. Furthermore, when insert molding is performed, insert molding can be performed using one lower mold positioned at injection position P, while an insert member can be placed on the other lower mold positioned at a position different from injection position P. Therefore, insert molding can be efficiently performed using the first lower mold 16 and the second lower mold 17.

[0084] Furthermore, in this embodiment, injection molding apparatus 100b is equipped with an injection positioning unit that positions first lower mold 16 or second lower mold 17 at injection position P. Therefore, first lower mold 16, which moves in accordance with the movement of first support portion 156, or second lower mold 17, which moves in accordance with the movement of second support portion 157, can be positioned at injection position P by the injection positioning unit, thereby enabling efficient injection molding.

[0085] Furthermore, in this embodiment, the position changing unit 180b moves the first support unit 156 and the second support unit 157 linearly along the X direction, and in the first state, positions the second lower mold 17 at the first standby position W1, and in the second state, positions the first lower mold 16 at the second standby position W2, which is on the opposite side of the injection position P in the X direction from the first standby position W1. Therefore, by moving the first support unit 156 and the second support unit 157 linearly along the X direction using the position changing unit 180b, it is possible to easily switch between the first state and the second state.

[0086] Furthermore, in this embodiment, the injection molding apparatus 100b includes a first positioning unit 190 that positions the second lower mold 17 at the first standby position W1, and a second positioning unit 193 that positions the first lower mold 16 at the second standby position W2. As a result, when either the first lower mold 16 or the second lower mold 17 is positioned at the injection position P, the other is positioned at the respective standby position. Therefore, for example, at each standby position, it is possible to more efficiently remove a molded product from the first lower mold 16 or the second lower mold 17, and to more efficiently place an insert part on the first lower mold 16 or the second lower mold 17. Furthermore, the processes of removing a molded product and placing an insert part can be more easily automated.

[0087] Furthermore, in this embodiment, injection molding apparatus 100b is equipped with a first ejector unit 251 for removing a molded article from second lower mold 17 at first standby position W1, and a second ejector unit 252 for removing a molded article from first lower mold 16 at second standby position W2. Therefore, in either the first state or the second state, by using first ejector unit 251 or second ejector unit 252, the molded article can be easily removed from first lower mold 16 or second lower mold 17.

[0088] C. Third embodiment: Fig. 15 is a plan view showing a schematic configuration of an injection molding apparatus 100c according to the third embodiment. Fig. 15 shows the injection molding apparatus 100c as viewed from above. In Fig. 15, the second lower mold 17 and the second support portion 157 are located below the injection unit 110 and are not shown. Unlike the second embodiment, the injection molding apparatus 100c of this embodiment is equipped with a robot 450. Portions of the configuration of the injection molding apparatus 100c of this embodiment that are not particularly described are the same as those of the second embodiment.

[0089] The robot 450 in this embodiment is configured as a horizontal articulated robot and includes an arm and a robot control unit 460. An end effector is attached to the arm of the robot 450. In this embodiment, a suction pad for adsorbing a molded product or an insert member is attached to the arm as the end effector. The robot 450 is installed on a robot base 452 fixed to the housing 90b. In other embodiments, the robot 450 does not have to be a horizontal articulated robot, and may be, for example, a Cartesian robot or a vertical articulated robot.

[0090] The robot control unit 460 is configured by a computer similar to the control unit 500. The robot control unit 460 controls the operations of the arms and end effectors by having a processor execute programs and instructions loaded onto a main storage device, thereby causing the robot 450 to perform various functions. In this embodiment, the robot 450 is controlled by the control unit 500 via the robot control unit 460.

[0091] In this embodiment, the robot 450 functions as a transport robot and a material supply robot. The transport robot refers to a robot that transports a molded product removed from the first lower mold 16 at the second standby position W2 and a molded product removed from the second lower mold 17 at the first standby position W1. The material supply robot refers to a robot that places an insert member on the first lower mold 16 located at the second standby position W2 and the second lower mold 17 located at the first standby position W1. In this embodiment, the robot 450 transports the molded product and places the insert member on the lower mold by sucking and transporting the molded product and the insert member using a suction pad.

[0092] The molded product removed from the first lower mold 16 or the second lower mold 17 is transported by a robot 450 functioning as a transport robot to a location where, for example, the appearance inspection and packaging of the molded product are performed. The appearance inspection and packaging of the molded product may be performed on, for example, a robot base 452. In this case, for example, an inspection device and a packaging device may be disposed on the robot base 452.

[0093] The end effector attached to the arm of the robot 450 may have, for example, a portion for suctioning a molded product and a portion for suctioning an insert member. In this configuration, when the robot 450 functions as a transport robot and a material supply robot as in this embodiment, the robot 450 can suction a molded product removed from a lower mold while still holding the insert member. This reduces the arm's travel distance between suctioning the molded product removed from the lower mold and placing the insert member on the lower mold. This allows for more efficient injection molding. Furthermore, the end effector may be configured, for example, with a gripper for gripping a molded product or an insert member, rather than a suction pad. In this case, the end effector may have, for example, a portion for gripping a molded product and a portion for gripping an insert member.

[0094] The injection molding apparatus 100c of this embodiment described above also allows the entire injection molding apparatus 100c to be made smaller in the vertical direction than when the injection unit 110 is equipped with an in-line screw and the molding material is produced by the in-line screw. In particular, in this embodiment, the injection molding apparatus 100c is equipped with a transfer robot that transfers the molded product removed from the first lower mold 16 at the second standby position W2 and the molded product removed from the second lower mold 17 at the first standby position W1. This allows the process of transferring the molded products removed from the first lower mold 16 and the second lower mold 17 to the next process to be automated, thereby enabling more efficient molding of molded products.

[0095] Furthermore, in this embodiment, the injection molding apparatus 100c is equipped with a material supply robot that places insert members on the first lower mold 16 located at the second standby position W2 and the second lower mold 17 located at the first standby position W1. This makes it possible to automate the process of placing insert members on the first lower mold 16 and the second lower mold 17, thereby enabling more efficient insert molding.

[0096] D. Fourth embodiment: Fig. 16 is a plan view showing a schematic configuration of an injection molding apparatus 100d according to the fourth embodiment. Similar to Fig. 15 described above, Fig. 16 shows the injection molding apparatus 100d as seen from above. The injection molding apparatus 100d of this embodiment includes a first robot 470 and a second robot 480. Portions of the configuration of the injection molding apparatus 100d that are not particularly described are the same as those of the third embodiment.

[0097] The first robot 470 is installed on a first robot base 472 fixed to the housing 90c. The second robot 480 is installed on a second robot base 482 fixed to the housing 90c. In this embodiment, the first robot 470 functions as a transport robot and a material supply robot, similar to the robot 450 described in the third embodiment. The second robot 480 is a robot that acts as an intermediary between the first robot 470, which functions as a transport robot, and the inspection process and the packaging process.

[0098] The first robot 470 is configured as a three-axis orthogonal robot. The first robot 470 has a first robot control unit 475 and an arm configured with three slide axes along the X-axis, Y-axis, and Z-axis. An end effector is attached to the arm of the first robot 470. In this embodiment, a suction pad is attached to the arm of the first robot 470 as the end effector. The first robot control unit 475 is configured by a computer, similar to the robot control unit 460 described in the third embodiment, and controls the operation of the arm and end effector of the first robot 470, causing the first robot 470 to function as a transport robot and a material supply robot. In this embodiment, the first robot 470 is controlled by the control unit 500 via the first robot control unit 475.

[0099] The second robot 480 is configured by a horizontal articulated robot similar to the robot 450 described in the third embodiment, and includes an arm to which an end effector is attached, and a second robot control unit 485. The second robot 480 is controlled by the control unit 500 via the second robot control unit 485.

[0100] In this embodiment, the molded article removed from the first lower mold 16 or the second lower mold 17 is transported by a first robot 470, which functions as a transport robot, onto a temporary table 476 provided on a first robot base 472. A second robot 480 transports the molded article placed on the temporary table 476 by the first robot 470 to a location where the appearance of the molded article is inspected and packaged.

[0101] In other embodiments, the first robot 470 does not have to be a Cartesian robot and may be another robot. Similarly, the second robot 480 does not have to be a horizontal articulated robot and may be another robot. The first robot 470 and the second robot 480 may be the same robot. Furthermore, the end effector attached to the arm of the first robot 470 may have, for example, a portion for adsorbing the molded product and a portion for adsorbing the insert member, as in the case of the robot 450 described in the third embodiment, or may be composed of a gripper.

[0102] As in the third embodiment, the injection molding apparatus 100d of this embodiment described above automates the process of transporting a molded product removed from the lower mold to the next process and the process of placing an insert member in the lower mold, thereby enabling efficient injection molding. In particular, in this embodiment, the injection molding apparatus 100d includes a first robot 470 and a second robot 480. Therefore, for example, by arranging the first robot 470 and the second robot 480 so that the movable ranges of the arms of each robot complement each other, the possibility of more efficient injection molding is increased.

[0103] In other embodiments, the injection molding apparatus 100d may not include a transport robot or a material supply robot. For example, an injection molding system for manufacturing molded products may be configured using an injection molding apparatus 100 without a robot and a transport robot or a material supply robot. Even in such a configuration, as described in the third and fourth embodiments, the process of transporting a molded product removed from the lower mold to the next process and the process of placing an insert member on the lower mold can be automated, allowing for efficient injection molding. Furthermore, the injection molding apparatus 100 may include, for example, only one of a transport robot and a material supply robot. Similarly, the injection molding system may include only one of a transport robot and a material supply robot.

[0104] E. Fifth embodiment: 17 is a diagram showing a schematic configuration of an injection molding apparatus 100e in a fifth embodiment. Unlike the third embodiment, the injection molding apparatus 100e of this embodiment includes an insert detection unit 510 that detects whether an insert member has been placed at the insert position of the lower mold 15e. The insert position is a predetermined position in the lower mold 15e where the insert member is to be placed. Portions of the configuration of the injection molding apparatus 100e that are not specifically described are the same as those in the first embodiment.

[0105] FIG. 18 is a plan view showing the vicinity of the center in the X and Y directions of the lower mold 15e in the fifth embodiment. FIG. 19 is a first diagram schematically showing a cross section of the lower mold 15e. FIG. 18 shows the vicinity of the center in the X and Y directions of the lower mold 15e as viewed from above. FIG. 19 also shows the state in which an insert member M is placed at an insert position S. The insert member M may be, for example, a member made of metal or a member made of a resin different from the molding material injected from the injection unit 110. Hereinafter, the state in which the insert member M is placed at the insert position S may also be referred to as a normal installation state.

[0106] 18 and 19, in this embodiment, the insert position S is determined as a position within the opening of a recess Dn formed in the lower mold 15e. The recess Dn is a portion that defines the cavity of the molding die 10. For example, the recess Dn may be provided with a step for positioning the insert member M at the insert position S.

[0107] Air holes 520 are formed at the insert position S. In this embodiment, four air holes 520 are formed at the insert position S. The air holes 520 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 520 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. 19, the air holes 520 are blocked by the insert member M placed at the insert position S.

[0108] As shown in FIG. 17 , the insert detection unit 510 in this embodiment includes a suction unit 511, a measurement unit 512, and a detection unit 513. The suction unit 511 is a member configured to suck air from the insertion position S through the air hole 520 shown in FIGS. 18 and 19 . In this embodiment, the suction unit 511 is configured as a suction pump and sucks air from the insertion position S to the suction unit 511 through the air hole 520 and a tube (not shown) connected to the air hole 520. The measurement unit 512 measures the flow rate or pressure of the air sucked by the suction unit 511. In this embodiment, the measurement unit 512 is configured as a flow meter that measures the air flow rate. In other embodiments, the measurement unit 512 may be configured as, for example, a pressure meter that measures the air pressure. The detection unit 513 detects whether the insert detection unit 510 is properly installed based on the air flow rate or pressure measured by the measurement unit 512. In this embodiment, the control unit 500 functions as the detection unit 513.

[0109] FIG. 20 is a second diagram schematically illustrating a cross section of the lower mold 15e. FIG. 20 illustrates an example of the state of the lower mold 15e and the insert member M in an "incorrect installation state," in which the insert member M is placed in a position different from the insert position S of the lower mold 15e. In the state illustrated in FIG. 20, the air hole 520 is not blocked by the insert member M, and therefore the air flow rate sucked by the suction unit 511 and measured by the measurement unit 512 is greater than that in the correct installation state illustrated in FIG. 19. Furthermore, even when the insert member M is not placed on the lower mold 15e or in an incorrect installation state, for example, when only a portion of the air hole 520 is covered by the insert member M, the air flow rate measured by the measurement unit 512 is similarly greater. Therefore, the control unit 500, functioning as the detection unit 513, can detect whether the correct installation state is present based on the difference between the air flow rate measured by the measurement unit 512 and the air flow rate in the correct installation state. The air flow rate in the correct installation state is determined in advance, for example, through experiments. Furthermore, even if the measurement unit 512 is configured as a pressure gauge that measures air pressure, the detection unit 513 can similarly detect whether or not the installation state is correct based on the difference between the measured pressure and the pressure in the correct installation state.

[0110] When the control unit 500, functioning as the detection unit 513, detects that the insert member M is not in the correct installation state, it may notify the user of the incorrect installation state, for example, via an alarm unit (not shown). In this case, the alarm unit may be, for example, a display unit configured with an LCD panel or the like that displays visual information, or a speaker or the like that emits audio information. Furthermore, when the injection molding apparatus 100 includes a material supply robot, as in the third and fourth embodiments, the control unit 500 may control the material supply robot to perform air suction and measurement immediately after placing the insert member M on the lower mold 15e. If the control unit 500 detects that the insert member M is not in the correct installation state, it may control the material supply robot to adjust the position of the insert member M so that the insert member M is in the correct installation state. This allows the insert member M to be placed on the lower mold 15e at the first standby position W1 or the second standby position W2, and the position of the insert member M to be adjusted. Therefore, injection molding can be performed more efficiently compared to when detecting whether the insert member M is in the incorrect installation state or adjusting the position of the insert member M at a position other than the first standby position W1 or the second standby position W2.

[0111] The injection molding apparatus 100e of the present embodiment described above also allows the entire injection molding apparatus 100e to be more compact in the vertical direction than when the injection unit 110 is equipped with an inline screw and molding material is produced by the inline screw. In particular, the present embodiment includes an insert detection unit 510 that detects whether the insert member M has been placed at the insert position S. This configuration allows the insert detection unit 510 to detect whether the insert member M has been placed at the insert position S. This prevents, for example, insert molding from being performed without the insert member M being placed at the insert position S, thereby reducing the risk of defective molded products. Furthermore, preventing injection molding from being performed with the insert member M placed at a position other than the insert position S reduces damage to the molding die 10, the injection unit 110, and the like.

[0112] Furthermore, in this embodiment, the insert detection unit 510 includes a suction unit 511 configured to be able to suck air from the insert position S through an air hole 520 formed at the insert position S, and a measurement unit 512 that measures the flow rate or pressure of the sucked air, and a detection unit 513 that detects whether or not an insert member M has been placed at the insert position S based on the measured air flow rate or pressure. Therefore, with a simple configuration, it is possible to detect whether or not an insert member M has been placed at the insert position S based on the air flow rate or pressure.

[0113] 21 to 26 are schematic diagrams illustrating insert detectors 510b to 510g in other embodiments. Similar to FIG. 19, FIGS. 21 to 23, 25, and 26 show an insert member M placed at the insert position S. FIG. 24 shows an example of the state of the insert member M in an incorrect installation state. Similar to FIG. 20, the insert detectors 510b to 510g shown in FIGS. 21 to 26 do not include the suction unit 511, the measurement unit 512, and the detection unit 513, respectively, unlike the fifth embodiment. In the configuration shown in FIGS. 24 to 26, the injection molding apparatus 100 includes a first robot 470 that functions as a transport robot and a material supply robot, similar to the fourth embodiment.

[0114] The insert detection unit 510b shown in FIG. 21 includes a contact-type displacement sensor 514 configured to detect the amount of depression of its upper end. The contact-type displacement sensor 514 is inserted into a through-hole formed to penetrate the lower mold 15e in the Z direction at the insert position S, with its upper end protruding from the top of the through-hole. As shown in FIG. 21, the upper end of the contact-type displacement sensor 514 is pressed downward by the insert member M placed at the insert position S. The contact-type displacement sensor 514 detects the amount of depression, which is the amount by which the upper end is depressed, using a differential transformer. In the embodiment shown in FIG. 21, the control unit 500 detects the normal installation state when the amount of depression of the upper end of the contact-type displacement sensor 514 is within a predetermined range. This range of depression is determined, for example, based on the amount of depression in the normal installation state measured through experiments.

[0115] The insert detection unit 510c shown in FIG. 22 includes an optical sensor 515 that measures the distance to the lower mold 15 and other components using a triangulation method. The optical sensor 515 includes a transmitter that emits a laser beam and a light-receiving unit that detects the laser beam emitted by the transmitter and reflected by the lower mold 15 and other components. In the embodiment shown in FIG. 22, the control unit 500 controls the optical sensor 515 to cause the light-receiving unit to detect the laser beam emitted by the transmitter and reflected by the lower mold 15 and other components, thereby measuring the distance between the recess Dn formed in the lower mold 15 and the optical sensor 515. The control unit 500 detects the correct installation state when the measured distance value is within a predetermined range. This range of distance values ​​is determined based on the distance between the insert member M and the optical sensor 515 in the correct installation state measured through experiments.

[0116] The insert detection unit 510d shown in Fig. 23 includes a camera 516 that captures an image of the vicinity of the recess Dn of the lower mold 15. In the embodiment shown in Fig. 23, the control unit 500 analyzes the image captured by the camera 516 to detect whether or not the insert is in a normal installation state.

[0117] The optical sensor 515 described in FIG. 22 and the camera 516 described in FIG. 23 are disposed, for example, at a position facing the lower mold 15 located at the standby position W. The optical sensor 515 and the camera 516 may be fixed, for example, to the housing 90, the base 400, the injection unit 110, or the like. Note that, as in the second to fourth embodiments, when the injection molding apparatus 100 is configured to be switchable between the first state and the second state, it is more preferable that the optical sensor 515 and the camera 516 be 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. This allows the insert detection unit 510c and the insert detection unit 510d to detect whether the insert member M has been placed at the insert position S at both the first standby position W1 and the second standby position W2.

[0118] The insert detection unit 510e shown in FIG. 24 is configured with a contact detection sensor 517 that detects contact with the lower mold 15. The contact detection sensor 517 is fixed to the arm Am of the first robot 470. The contact detection sensor 517 is disposed in a position that does not come into contact with the insert member M in the normal installation state when the contact detection sensor 517 scans a position that overlaps with the insert position S when viewed along the Z direction. In the embodiment shown in FIG. 24, the control unit 500 detects that the state is the normal installation state when no contact is detected by the contact detection sensor 517.

[0119] The insert detection unit 510f shown in Fig. 25 is configured with the optical sensor 515 described in Fig. 22. In the configuration shown in Fig. 25, the optical sensor 515 is fixed to the arm Am of the first robot 470, similar to the contact detection sensor 517 described in Fig. 24. In the configuration shown in Fig. 25, the control unit 500 detects that the insert detection unit 510f is in the normal installation state, similar to the configuration described in Fig. 22.

[0120] The insert detection unit 510g shown in Fig. 26 is configured with the camera 516 described in Fig. 23. In the configuration shown in Fig. 26, the camera 516 is fixed to the arm Am of the first robot 470. In the configuration shown in Fig. 26, the control unit 500 detects that the insert detection unit 510g is in the normal installation state, similar to the configuration described in Fig. 23.

[0121] As described above, in the configurations shown in FIGS. 24 to 26 , the various sensors and other components constituting each insert detection unit are fixed to the arm Am of the first robot 470. In this configuration, the control unit 500 controls the robot 450 to place the insert member M on the lower mold 15 using the end effector Ef attached to the arm Am, and then detects whether the insert member M is properly installed based on the detection results of the sensors and other components attached to the arm Am. If it is determined that the insert member M is not properly installed, the control unit 500 again adjusts the position of the insert member M using the end effector Ef. This allows for more efficient insert molding while reducing defects in molded products and damage to the molding die 10 and injection unit 110. Furthermore, even if the injection molding apparatus 100 is configured to be switchable between the first and second states as in the second to fourth embodiments, it is possible to detect whether the insert member M has been placed at the insert position S at both the first standby position W1 and the second standby position W2 without providing multiple sensors and other components constituting each insert detection unit.

[0122] F. Other Embodiments: (F-1) In the above embodiment, the outlet 104 of the introduction channel 102 has a rectangular shape when viewed along the Y direction. However, the outlet 104 does not have to have a rectangular shape when viewed along the Y direction. FIG. 27 is a diagram showing a cross section of a case 107b in another embodiment. Unlike the outlet 104 described in FIG. 9, the outlet 104b shown in FIG. 27 has an asymmetric shape in the X direction when viewed along the Y direction. More specifically, when viewed along the Y direction, the portion of the outlet 104b located in the −X direction of the bisector L that bisects the outlet 104b in the X direction has a semi-elliptical shape, and the portion located in the +X direction of the bisector L has a rectangular shape. Meanwhile, the outlet 104b has a shape that is elongated in the X direction as a whole when viewed along the Y direction, similar to the outlet 104 described in FIG. 9. Even with this configuration, clogging of the material in the introduction channel 102 is suppressed. Furthermore, the outlet 104 may have other shapes, such as a circular shape or an elliptical shape, when viewed along the Y direction.

[0123] (F-2) In the above embodiment, the mold clamping device 200 performs mold clamping and mold opening by vertically moving the injection unit 110 and the upper mold 11. Alternatively, the mold clamping device 200 may perform mold clamping and mold opening by vertically moving the lower mold 15.

[0124] (F-3) In the above embodiment, the mold clamping motor 212 is disposed below the lower mold 15. However, the mold clamping motor 212 may be disposed at the same position as the lower mold 15 in the vertical direction, or may be disposed above the lower mold 15.

[0125] (F-4) In the above embodiment, mold clamping motor 212 functions as a descent restriction unit. However, mold clamping motor 212 does not have to function as a descent restriction unit. For example, the descent restriction unit may be configured with a stopper or clamp that supports injection unit 110 when molding die 10 is in the mold open state, or may be configured with a hook that lifts and secures injection unit 110. Furthermore, injection molding apparatus 100 does not have to be equipped with a descent restriction unit.

[0126] (F-5) In the above embodiment, during mold clamping, the control unit 500 controls the torque value of the mold clamping motor 212 to a first torque value to press the upper mold 11 against the lower mold 15, then decreases the torque value of the mold clamping motor 212 from the first torque value to a second torque value to press the upper mold 11 against the lower mold 15, and further increases the torque value of the mold clamping motor 212 from the second torque value to a third torque value to press the upper mold 11 against the lower mold 15. In contrast, the control unit 500 does not have to control the torque value of the mold clamping motor 212 in this manner during mold clamping. For example, the control unit 500 may decrease the torque value from the first torque value to the second torque value, maintain it at the second torque value, and then open the molds without increasing the torque value.

[0127] (F-6) In the above embodiment, the control unit 500 sets the maximum torque value of the mold clamping motor 212 during mold clamping to be greater than the maximum torque value of the mold clamping motor 212 during mold opening. In contrast, the control unit 500 may set the maximum torque value during mold opening to be smaller than the maximum torque value during mold clamping, or may set the maximum torque value during mold opening to be the same as the maximum torque value during mold clamping.

[0128] (F-7) In the above embodiment, the position changing unit 180 moves the lower mold support unit 150 linearly along the X direction. However, the position changing unit 180 does not have to move the lower mold support unit 150 linearly. For example, the position changing unit 180 may be configured by a so-called rotary table that moves the lower mold support unit 150 so that the trajectory of the movement of the lower mold support unit 150 describes a circle when viewed along the vertical direction.

[0129] (F-8) In the above embodiment, the first support portion 156 and the second support portion 157 are configured as part of a pair of blocks 152b that configure the lower mold support portion 150b. However, the first support portion 156 and the second support portion 157 do not have to be configured as part of the block 152b. For example, the first support portion 156 and the second support portion 157 may be configured separately as holders for holding the first lower mold 16 and the second lower mold 17, respectively. In this case, the position changer 180 may be configured to be able to move the first support portion 156 and the second support portion 157 individually, and may switch between the first state and the second state by moving the first support portion 156 and the second support portion 157 individually.

[0130] (F-9) In the above embodiment, first positioning unit 190 and second positioning unit 193 function as injection positioning units. However, first positioning unit 190 and second positioning unit 193 do not have to function as injection positioning units. For example, injection molding apparatus 100 may be provided with first positioning unit 190 or second positioning unit 193 that do not position the lower mold at the injection position, and an injection positioning unit. Furthermore, injection molding apparatus 100 does not have to be provided with all of first positioning unit 190, second positioning unit 193, and an injection positioning unit, and may be provided with, for example, only one of them.

[0131] G. Other forms: The present disclosure is not limited to the above-described embodiments and can be realized in various forms without departing from the spirit thereof. For example, the present disclosure can also be realized in the following forms. The technical features in the above embodiments corresponding to the technical features in each form described below can be appropriately replaced or combined to solve some or all of the problems of the present disclosure or to achieve some or all of the effects of the present disclosure. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted.

[0132] (1) According to one aspect of the present disclosure, there is provided an injection molding apparatus. The injection molding apparatus includes a support section that supports a molding die having an upper die and a lower die, and an injection unit that injects a molding material toward a cavity defined by the upper die and the lower die. With the molding die supported by the support section, the injection unit, the upper die, and the lower die are arranged in this order vertically from top to bottom. The injection unit includes a rotating flat screw having a groove-forming surface with grooves formed therein, a barrel having an opposing surface that faces the groove-forming surface and having a communicating hole through which the molding material flows, and a heater that heats the material supplied between the groove-forming surface and the opposing surface. The rotation of the flat screw and the heating by the heater plasticize at least a portion of the material to generate the molding material, and the molding material is then delivered to the communicating hole. According to this configuration, the injection molding apparatus as a whole can be made smaller in size in the vertical direction than when the injection unit is equipped with an inline screw and the molding material is produced by the inline screw.

[0133] (2) The above embodiment may include a mold clamping device that clamps and opens the upper mold and the lower mold by moving the injection unit and the upper mold along the vertical direction while the molding mold is supported by the support portion. According to this embodiment, the injection unit and the upper mold can be moved vertically relative to the lower mold to clamp and open the mold without moving the lower mold vertically. This allows the molded product to be removed from the lower mold at a fixed position in the vertical direction, making it easier to automate, for example, the molded product removal process. Furthermore, when performing insert molding, the insert part can be placed on the lower mold at a fixed position in the vertical direction, making it easier to automate, for example, the insert part placement process in insert molding.

[0134] (3) In the above embodiment, a descent restricting portion may be provided that is configured to restrict movement of the injection unit and the upper mold toward the lower mold. According to this embodiment, the descent restricting portion can prevent the injection unit and the upper mold from unintentionally moving toward the lower mold.

[0135] (4) In the above embodiment, the mold clamping device has a mold clamping motor disposed below the lower mold, moves the injection unit and the upper mold along the vertical direction by driving the mold clamping motor, and further includes a control unit that controls the driving of the mold clamping motor. According to this embodiment, the injection unit and the upper mold can be moved along the vertical direction by controlling the mold clamping motor, and the arrangement of the components that make up the injection unit is less likely to be restricted by the arrangement of the mold clamping motor compared to an embodiment in which the mold clamping motor is disposed above the lower mold. Therefore, the degree of freedom in the configuration of the injection unit can be increased.

[0136] (5) In the above embodiment, in the injection step of injecting the molding material from the injection unit into the cavity, the control unit may control the torque value of the mold clamping motor to a first torque value to press the upper mold against the lower mold, then decrease the torque value from the first torque value to a second torque value to press the upper mold against the lower mold, and further increase the torque value from the second torque value to a third torque value to press the upper mold against the lower mold. According to this embodiment, it is possible to prevent overload of the mold clamping motor and to prevent leakage of molding material from the mold.

[0137] (6) In the above embodiment, the control unit may set the maximum torque value of the mold clamping motor during mold clamping to be greater than the maximum torque value of the mold clamping motor during mold opening. According to this embodiment, the load on the mold clamping motor during mold opening can be reduced.

[0138] (7) The above embodiment may include a first support section supporting a first lower mold as the lower mold, a second support section supporting a second lower mold as the lower mold, and a position change section configured to move the first support section and the second support section. The position change section may 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 by moving the first support section and the second support section, and switch between 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 this embodiment, while a molded product is being molded using one lower mold located at the injection position, the molded product can be removed from the other lower mold located at a position different from the injection position. Therefore, molded products can be efficiently molded using the first lower mold and the second lower mold. Furthermore, when insert molding is performed, one lower mold is positioned at the injection position, and the insert member can be placed on the other lower mold positioned at a position different from the injection position, so that insert molding can be performed efficiently using the first lower mold and the second lower mold.

[0139] (8) In the above embodiment, an injection positioning unit may be provided that positions the first lower mold or the second lower mold at the injection position. According to this embodiment, the first lower mold, which moves in accordance with the movement of the first support unit, or the second lower mold, which moves in accordance with the movement of the second support unit, can be positioned at the injection position by the injection positioning unit, thereby enabling efficient injection molding.

[0140] (9) In the above embodiment, the position changer may linearly move the first support member and the second support member along an intersecting direction intersecting the vertical direction, and in the first state, position the second lower mold at a first standby position different from the injection position, and in the second state, position the first lower mold at a second standby position opposite the first standby position across the injection position in the intersecting direction. According to this embodiment, the first state and the second state can be easily switched by linearly moving the first support member and the second support member along the intersecting direction using the position changer.

[0141] (10) The above embodiment may further include a first positioning unit that positions the second lower mold at the first standby position and a second positioning unit that positions the first lower mold at the second standby position. According to this embodiment, when either the first lower mold or the second lower mold is positioned at the injection position, the other is positioned at the respective standby positions. Therefore, for example, at each standby position, it is possible to more efficiently remove a molded product from the first lower mold or the second lower mold, and to more efficiently place an insert part on the first lower mold or the second lower mold. Furthermore, it is possible to more easily automate the processes of removing a molded product and placing an insert part.

[0142] (11) In the above embodiment, a first ejector unit for removing the molded article from the second lower mold at the first standby position and a second ejector unit for removing the molded article from the first lower mold at the second standby position may be provided. According to this embodiment, in either the first state or the second state, the molded article can be easily removed from the first lower mold or the second lower mold by using the first ejector unit or the second ejector unit.

[0143] (12) In the above embodiment, a transport robot may be provided to transport the molded product removed from the first lower mold at the second standby position and the molded product removed from the second lower mold at the first standby position. According to this embodiment, the process of transporting the molded products removed from the first lower mold and the second lower mold to the next process can be automated, thereby making it possible to more efficiently mold molded products.

[0144] (13) In the above embodiment, a material supply robot may be provided that places an insert member on the first lower mold located at the second standby position and the second lower mold located at the first standby position. According to this embodiment, the process of placing the insert member on the first lower mold and the second lower mold can be automated, thereby making it possible to perform insert molding more efficiently.

[0145] (14) In the above embodiment, an insert detection unit may be provided that detects whether an insert member is placed at a predetermined insert position of the lower mold. According to this embodiment, the insert detection unit can detect whether an insert member M is placed at the insert position S. This, for example, can prevent injection molding from being performed without an insert member placed at the insert position when insert molding is performed, thereby reducing defects in molded products. Furthermore, it can prevent injection molding from being performed with an insert member placed at a position other than the insert position, thereby reducing damage to the molding mold, injection unit, etc.

[0146] (15) In the above embodiment, the insert position may have an air hole formed therein that is blocked by the insert member placed at the insert position, and the insert detection unit may include a suction unit configured to suck air from the insert position through the air hole, a measurement unit that measures the flow rate or pressure of the air sucked by the suction unit, and a detection unit that detects whether the insert member is placed at the insert position based on the air flow rate or pressure measured by the measurement unit. According to this embodiment, it is possible to detect whether the insert member is placed at the insert position based on the air flow rate or pressure with a simple configuration.

[0147] The present disclosure can be realized in various forms other than the injection molding apparatus described above, for example, an injection molding system. [Explanation of symbols]

[0148] 10...Mold, 11...Upper mold, 12...Upper mold clamp, 13...Upper mold support portion, 15, 15e...Lower mold, 16...First lower mold, 17...Second lower mold, 20...Material supply portion, 22...Supply path, 31...Rotor drive portion, 32...Drive motor, 33...Output shaft, 40...Rotor, 42...Groove forming surface, 43...Rotor side surface, 44...Material inlet, 45...Groove, 46...Convex rib portion, 47...Central portion, 48...Retention prevention portion, 50...Barrel, 52...Opposite surface, 54...Guide groove, 56...Communicating hole, 58...Heater, 59...Check valve, 60...Nozzle, 70...Injection control mechanism, 71...Injection cylinder, 72...Plunger, 90, 90b, 90c ...housing, 98...stopper, 99...wheel, 100, 100b, 100c, 100d, 100e...injection molding apparatus, 101...accommodation section, 102...introduction path, 103...introduction port, 104, 104b...exit port, 105...vertical section, 106...inclined section, 107, 107b...case, 108...upper cover, 109...space section, 110...injection unit, 111...second regulating section, 150, 150b...lower mold support section, 152, 152b...block, 153, 153b...edge section, 156...first support section, 157...second support section, 160...lower mold clamp, 161...first lower mold clamp, 162...second lower mold clamp, 180,180b...position change portion, 181...electric actuator, 186...movable portion, 187...plate portion, 188...leg portion, 189...hole portion, 190...first positioning portion, 191...first positioning hole, 192...first positioning pin, 193...second positioning portion, 194...second positioning hole, 195...second positioning pin, 200...mold clamping device, 210...mold drive portion, 212...mold clamping motor, 214...reduction gear, 216...ball screw portion, 218...movable platen, 220...fixed platen, 230...first support portion, 240...second support portion, 250...ejector portion, 251...first ejector portion, 252...second ejector portion, 260...main body portion, 261...ejector plate, 262...ejector pin, 263...first main body portion, 264...second main body portion, 270...ejector drive portion, 271...first ejector drive portion, 272...second ejector drive portion, 280...contact portion, 300...rotor reducer, 301...eccentric body, 302...pin receiving portion, 303...pin receiving recess, 309...gear A housing portion, 310...first gear, 311...external teeth, 312...pin, 320...second gear, 321...first recess, 322...internal teeth, 323...second recess, 324...bolt, 325...first restricting portion, 328...bottom, 341...first ball bearing, 342...second ball bearing, 343...third ball bearing, 344...needle bearing, 400...base, 401...upper surface, 405...recess, 406...linear guide, 407...hollow portion, 450...robot, 460...robot control portion , 470...First robot, 472...First robot base, 475...First robot control unit, 480...Second robot, 482...Second robot base, 485...Second robot control unit, 500...Control unit, 510, 510b, 510c, 510d, 510e, 510f, 510g...Insert detection unit, 511...Suction unit, 512...Measurement unit, 513...Detection unit, 514...Contact displacement sensor, 515...Optical sensor, 516...Camera, 517...Contact detection sensor, 520...Air vent,

Claims

1. a support portion for supporting a molding die having an upper die and a lower die; an injection unit that injects a molding material toward a cavity defined by the upper mold and the lower mold, With the molding die supported by the support portion, the injection unit, the upper die, and the lower die are arranged in this order from top to bottom in the vertical direction, The injection unit comprises: a rotating flat screw having a groove forming surface on which grooves are formed; a barrel having an opposing surface facing the groove forming surface and having a communication hole through which the molding material flows; a heater that heats the material supplied between the groove forming surface and the opposing surface, By rotating the flat screw and heating by the heater, at least a portion of the material is plasticized to generate the molding material, and the molding material is sent to the communicating holes; a mold clamping device that clamps and opens the upper mold and the lower mold by moving the injection unit and the upper mold along the vertical direction while the molding mold is supported by the support section, the mold clamping device has a mold clamping motor disposed below the lower mold, and the injection unit and the upper mold are moved along the vertical direction by driving the mold clamping motor; Further, a control unit that controls the driving of the mold clamping motor is provided. In an injection process in which the molding material is injected from the injection unit toward the cavity, the control unit controls the torque value of the clamping motor to a first torque value to press the upper mold against the lower mold, then decreases the torque value from the first torque value to a second torque value to press the upper mold against the lower mold, and further increases the torque value from the second torque value to a third torque value to press the upper mold against the lower mold, in an injection molding apparatus.

2. a support portion for supporting a molding die having an upper die and a lower die; an injection unit that injects a molding material toward a cavity defined by the upper mold and the lower mold, With the molding die supported by the support portion, the injection unit, the upper die, and the lower die are arranged in this order from top to bottom in the vertical direction, The injection unit comprises: a rotating flat screw having a groove forming surface on which grooves are formed; a barrel having an opposing surface facing the groove forming surface and having a communication hole through which the molding material flows; a heater that heats the material supplied between the groove forming surface and the opposing surface, By rotating the flat screw and heating by the heater, at least a portion of the material is plasticized to generate the molding material, and the molding material is sent to the communicating holes; a mold clamping device that clamps and opens the upper mold and the lower mold by moving the injection unit and the upper mold along the vertical direction while the molding mold is supported by the support section, the mold clamping device has a mold clamping motor disposed below the lower mold, and the injection unit and the upper mold are moved along the vertical direction by driving the mold clamping motor; Further, a control unit that controls the driving of the mold clamping motor is provided. The control unit sets a maximum torque value of the mold clamping motor during mold clamping to be greater than a maximum torque value of the mold clamping motor during mold opening.

3. 3. The injection molding apparatus according to claim 1 or 2, a first support portion that supports a first lower mold as the lower mold; a second support portion that supports a second lower mold as the lower mold; a position change unit configured to be able to move the first support unit and the second support unit, The position change unit By moving the first support portion and the second support portion, the first lower mold or the second lower mold is moved to an injection position where the lower mold and the upper mold face each other; An injection molding apparatus that switches between 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.

4. 4. The injection molding apparatus according to claim 3, an injection positioning unit that positions the first lower mold or the second lower mold at the injection position;

5. 5. The injection molding apparatus according to claim 3 or 4, The position change unit The first support portion and the second support portion are moved linearly along an intersecting direction intersecting the vertical direction, In the first state, the second lower mold is positioned at a first standby position different from the injection position, and in the second state, the first lower mold is positioned at a second standby position on the opposite side of the injection position from the first standby position in the intersecting direction. Injection molding equipment.

6. 6. The injection molding apparatus according to claim 5, an injection molding apparatus comprising: a first positioning unit that positions the second lower mold at the first standby position; and a second positioning unit that positions the first lower mold at the second standby position.

7. 7. The injection molding apparatus according to claim 5 or 6, an injection molding apparatus comprising: a material supply robot that places an insert member on the first lower mold positioned at the second standby position and the second lower mold positioned at the first standby position;

8. 8. An injection molding apparatus according to any one of claims 1 to 7, An injection molding apparatus comprising: a descent restricting section configured to restrict movement of the injection unit and the upper mold in a direction toward the lower mold.

9. 9. An injection molding apparatus according to any one of claims 1 to 8, An injection molding apparatus comprising an insert detector for detecting whether an insert member is placed at a predetermined insert position in the lower mold.

10. 10. The injection molding apparatus according to claim 9, an air hole that is blocked by the insert member placed at the insert position is formed at the insert position; The insert detection unit a suction section configured to be able to suck air from the insert position through the air hole; a measuring unit that measures the flow rate or pressure of the air sucked by the suction unit; a detection unit that detects whether the insert member is placed at the insert position based on the flow rate or pressure of the air measured by the measurement unit, Injection molding equipment.

Images