Method and device for assisting the molding of pulverized mixed materials

Abstract

To eliminate problems such as the risk that quality cannot be guaranteed due to an excessive amount of crushed materials, and the problem of insufficient reuse of crushed materials due to a deficient amount of the crushed materials, by easily obtaining a highly accurate and effective mixing ratio of crushed materials in an actual molded product.SOLUTION: There is provided a method for assisting in molding a crushed material mixture, comprising: measuring a virgin material plasticization time Tv up to a predetermined plasticization end position Xe using only a virgin material Rv, and a crushed material plasticization time Ts up to the predetermined plasticization end position Xe under a plasticization condition using only a crushed material Rs to perform a registration process as a basic time data Do; measuring a plasticization time Tm of the crushed material mixture up to the plasticization end position Xe in a predetermined shot when producing a molded product using a crushed material mixture Rm to obtain actual time data Dp; and calculating a crushed material ratio Px in the crushed material mixture Rm to perform outputting based on the virgin material plasticization time Tv, the crushed material plasticization time Ts, and the crushed material mixture plasticization time Tm.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a molding support method and device for a pulverized material mixture in an injection molding machine that plasticizes and injection molds a pulverized material mixture made by mixing virgin material and pulverized material in a predetermined ratio. [Background technology]

[0002] Generally, in production factories that use injection molding machines, not only virgin materials are used as resin materials for molding, but also unwanted moldings such as spools, runners, and defective moldings that are generated after molding are often reused.In this case, these unwanted moldings are finely crushed to produce crushed material, which is then mixed with virgin material (pellets) at a specified ratio to be used as crushed material mixture.

[0003] Conventionally, molding means for molding using such pulverized mixed materials include the plastic molding mechanism described in Patent Document 1 and the resin molding device with a spool / runner recycling function described in Patent Document 2.

[0004] The plastic molding mechanism described in Patent Document 1 aims to provide a plastic molding mechanism for recycling recovered molded products by stably and efficiently mixing coarsely crushed material with raw material, and specifically, it is configured with a transport means for transporting the recovered molded products removed from the molding die directly to above the material drop outlet of the removal device, a coarse crushing means arranged on the upper surface of the raw material feed rate adjustment means fixed to the top of the material drop outlet and coarsely crushing the transported recovered molded products, and a raw material feed rate adjustment means having a through hole for dropping the recovered molded products coarsely crushed by the coarse crushing means into the material drop outlet, and transporting the raw material to the through hole while adjusting the feed rate, thereby mixing the recovered molded products and raw material.

[0005] Furthermore, the resin molding apparatus described in Patent Document 2 aims to eliminate the need for a separate large-scale device to transport crushed material from spools and runners to the molding machine, simplify the overall configuration of the resin molding apparatus, and make cleaning easier when changing types.Specifically, the resin molding apparatus is equipped with an extraction means for removing spools and runners from the resin molding position of the molding machine, and a crusher for crushing the spools and runners removed by this extraction means, and the crusher has a crushed material discharge port connected to the molding machine so that the crushed material obtained by crushing the spools and runners supplied from the extraction means can be supplied into the molding machine. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2007-125818 [Patent Document 2] Japanese Patent Application Publication No. 7-304038 Summary of the Invention [Problem to be solved by the invention]

[0007] However, the conventional molding method using the above-mentioned pulverized mixed material has the following problems.

[0008] In other words, the crushed material used is not uniform in particle shape or size, but rather random, so when mixed with virgin material, the mixing ratio is likely to vary. Specifically, even if the weight ratio is 70 wt% virgin material (pellets) and 30 wt% crushed material, the molded product will not necessarily be a 70:30 mixture, and variation is likely to occur.

[0009] In this case, if it has been confirmed that there are no problems with quality, including strength, if the crushed material is within, for example, 30 wt%, then if there are molded products that exceed 30 wt% due to variation, there is a risk that the molded product will be inappropriate and quality may no longer be guaranteed, so the important thing is not the ratio at the time of mixing, but the mixing ratio in the actual molded product.

[0010] However, since the mixing ratio in actual molded products is mixed in a molten state, it is not easy to confirm the mixing ratio. Ultimately, if there is too much crushed material, there is a risk that the quality cannot be guaranteed, and conversely, if there is too little crushed material, the crushed material cannot be effectively used (reused). Therefore, there has been a demand for a highly effective and accurate means of confirming the mixing ratio in actual molded products.

[0011] The present invention aims to provide a molding support method and device 1 for a pulverized material mixture Rm that solves the problems present in the background art. [Means for solving the problem]

[0012] The molding support method for pulverized material mixed material Rm according to the present invention involves, when plasticizing and injection molding a pulverized material mixed material Rm obtained by mixing virgin material Rv and pulverized material Rs at a predetermined ratio (Px), a molding machine controller provided in an injection molding machine M that previously sets a virgin material plasticization time Tv up to a predetermined plasticization end position Xe under predetermined plasticization conditions using only the virgin material Rv used in the pulverized material mixed material Rm, and a pulverized material plasticization time Ts up to a predetermined plasticization end position Xe under predetermined plasticization conditions using only the pulverized material Rs used in the pulverized material mixed material Rm. The time measured by the molding machine controller 2 is registered and processed as basic time data Do, and when producing a molded product using the pulverized material mixed material Rm, the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a specified shot is measured by the molding machine controller 2 to obtain actual measured time data Dp, and the ratio Px of pulverized material in the pulverized material mixed material Rm is calculated based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts, and the pulverized material mixed material plasticization time Tm, and is output and processed by the molding machine controller 2.

[0013] Furthermore, the molding support device 1 for the pulverized material mixture Rm according to the present invention is configured as a molding support device for an injection molding machine M that plasticizes the pulverized material mixture Rm, which is a mixture of virgin material Rv and pulverized material Rs at a predetermined ratio (Px), and performs injection molding. The molding support device 1 includes a plasticization condition setting function unit Fs that sets predetermined plasticization conditions, and a function unit that measures a virgin material plasticization time Tv up to a predetermined plasticization end position Xe under plasticization conditions using only the virgin material Rv used in the pulverized material mixture Rm, and a pulverized material plasticization time Ts up to a predetermined plasticization end position Xe under plasticization conditions using only the pulverized material Rs used in the pulverized material mixture Rm, and calculates a basic time The molding machine controller 2 is characterized by having a basic time data acquisition function unit Fo that registers and processes the time data Do as interval data Do, an actual time data acquisition function unit Fp that measures the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a specified shot when producing a molded product using the pulverized material mixed material Rm and acquires it as actual measured time data Dp, a pulverized material ratio calculation function unit Fa that calculates the pulverized material ratio Px in the pulverized material mixed material Rm based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts and the pulverized material mixed material plasticization time Tm, and an output processing function unit Fe that outputs and processes the obtained pulverized material ratio Px.

[0014] On the other hand, in a preferred embodiment of the present invention, when implementing the molding support method, the pulverized material ratio Px can be calculated by Px = [(Tm - Tv) / (Ts - Tv)] × 100 [wt%] (Equation 1), where Px [wt%] is the pulverized material ratio, Tm [seconds] is the pulverized material mixed material plasticization time, Tv [seconds] is the virgin material plasticization time, and Ts [seconds] is the pulverized material plasticization time. The pulverized material ratio Px can be calculated for each shot or for each shot at a predetermined interval and output. The pulverized material ratio Px can also be calculated by calculating the delay time Td from the pulverized material mixed material plasticization time Tm until it is reflected in the molded product, including at least the capacity of the screw 3, and linking the pulverized material ratio Px to the molded product based on this delay time Td. Furthermore, an upper limit value Pxu and / or a lower limit value Pxd can be set for the pulverized material ratio Px, and a quality determination process can be performed in which molded products below the upper limit value Pxu and / or above the lower limit value Pxd are determined to be good products.

[0015] On the other hand, when implementing the molding support device 1, the plasticization condition setting function unit Fs can include one or more setting items: the rotation speed of the screw 3, the back pressure on the screw, the set temperature of the heating barrel, and the plasticization end position Xe of the screw. The molding machine controller 2 can also be provided with a pass / fail judgment processing function unit Fj that sets an upper limit Pxu and / or a lower limit Pxd for the pulverized material ratio Px obtained by the pulverized material ratio calculation function unit Fa and judges molded products that are less than the upper limit Pxu and / or greater than the lower limit Pxd as pass / fail. Furthermore, the molding machine controller 2 can be provided with an output processing function unit Fe that displays the pulverized material ratio Px numerically and / or graphically. The molding machine controller 2 can also be provided with an output processing function unit Fe that judges molded products that exceed the upper limit Pxu and / or are less than the lower limit Pxd as pass / fail and performs predetermined output processing, including displaying an alarm on the display 2d. [Effects of the Invention]

[0016] The molding support method and device 1 for the pulverized material mixture Rm according to the present invention provides the following significant effects.

[0017] (1) The virgin material plasticization time Tv up to the predetermined plasticization end position Xe using only virgin material Rv and the pulverized material plasticization time Ts up to the predetermined plasticization end position Xe under plasticization conditions using only pulverized material Rs are measured and registered as basic time data Do. Furthermore, the pulverized material mixed material plasticization time Tm up to the predetermined plasticization end position Xe for a predetermined shot during production of a molded product using the pulverized material mixed material Rm is measured to obtain actual measured time data Dp. Based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts, and the pulverized material mixed material plasticization time Tm, the pulverized material ratio Px in the pulverized material mixed material Rm is calculated and output. This makes it easy to obtain a highly accurate and effective pulverized material Rs mixture ratio Px for actual molded products. This eliminates, for example, problems such as the risk of quality being compromised due to too much pulverized material Rs or the inability to fully reuse the pulverized material Rs due to too little pulverized material Rs.

[0018] (2) In a preferred embodiment, when calculating the pulverized material ratio Px using the molding support method, if the pulverized material ratio is Px [wt%], the pulverized material mixed material plasticization time is Tm [seconds], the virgin material plasticization time is Tv [seconds], and the pulverized material plasticization time is Ts [seconds], then Px can be calculated using Px = [(Tm - Tv) / (Ts - Tv)] × 100 [wt%], which is a relatively simple calculation formula, and therefore the accurate pulverized material ratio Px can be obtained quickly and easily.

[0019] (3) In a preferred embodiment, when calculating the crushed material ratio Px, if the output processing is performed by calculating it for each shot or for each shot at a predetermined interval, the crushed material ratio Px can be calculated for any shot or shot interval.Therefore, it is possible to obtain the crushed material ratio Px according to the purpose, for example, by calculating it for each shot when the crushed material Rs has a large variation, and by calculating it for each multiple shots when the crushed material Rs has a small variation, which provides excellent flexibility and convenience.

[0020] (4) In a preferred embodiment, when calculating the crushed material ratio Px, after the crushed material mixed material plasticization time Tm is calculated, the delay time Td until it is reflected in the molded product is calculated, including at least the capacity of the screw 3, and the crushed material ratio Px and the molded product are linked based on this delay time Td.This allows the crushed material ratio Px to match the molded product based on it, thereby further improving the accuracy and reliability of the crushed material ratio Px.

[0021] (5) In a preferred embodiment, the molding machine controller 2 is provided with an upper limit value Pxu and / or a lower limit value Pxd for the crushed material ratio Px obtained by the crushed material ratio calculation function unit Fa, and a pass / fail judgment processing function unit Fj is provided which judges molded products that are below the upper limit value Pxu and / or above the lower limit value Pxd as pass / fail products.This makes it possible to easily and accurately judge the pass / fail of molded products, thereby further improving the quality and reliability of molded products.

[0022] (6) In a preferred embodiment, when configuring the plasticization condition setting function unit Fs, if one or more setting items are included, such as the rotation speed of the screw 3, the back pressure on the screw 3, the set temperature of the heating barrel, and the plasticization end position Xe of the screw 3, it becomes possible to set plasticization conditions at the same level as in the actual production process, thereby obtaining a rational and reliable crushed material ratio Px.

[0023] (7) In a preferred embodiment, when configuring the output processing function unit Fe, a display 2d is provided that displays the crushed material ratio Px numerically and / or graphically, so that the operator can easily check the crushed material ratio Px by visual means, thereby quickly and reliably checking the actual status of the crushed material ratio Px.

[0024] (8) In a preferred embodiment, when configuring the molding machine controller 2, if an output processing function unit Fe is provided that determines that a molded product that exceeds the upper limit value Pxu and / or is below the lower limit value Pxd is an improper molded product and performs predetermined output processing including displaying an alarm on the display 2d, it becomes possible to easily and reliably know that an improper molded product has occurred, and therefore to promptly take necessary error response measures, such as discarding the relevant molded product or changing the plasticization conditions. [Brief explanation of the drawings]

[0025] [Figure 1] 1 is a flowchart showing a basic time data acquisition process of a pulverized material mixed material forming support method according to a preferred embodiment of the present invention; [Figure 2] A flowchart showing the procedure for acquiring actual measurement time data during production in the molding support method. [Figure 3] FIG. 2 is a diagram showing the mechanical structure of an injection molding machine that can implement the molding support method; [Figure 4] A block diagram of a processing system (control system) in an injection molding machine that can implement the molding support method. [Figure 5] A graph showing the ratio of crushed material used in the molding support method versus the average plasticization time. [Figure 6] 10 is a graph showing the calculated value of the crushed material ratio for the shot number when the molding support method is implemented; [Figure 7] 1 is a diagram showing an example of a display on a display provided in a molding support device for a pulverized mixed material according to a preferred embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0026] Next, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0027] First, an outline of an injection molding machine M that can utilize the molding support method for a pulverized material mixture according to this embodiment will be described with reference to FIGS. 3 and 4. FIG.

[0028] 3 shows an injection molding machine M, particularly an injection unit Mi without a mold clamping device. In the injection unit Mi, reference numeral 6 denotes a heating barrel, and a nozzle 6n is provided at the front end of the heating barrel 6 via a head portion 6s. The nozzle 6n has the function of injecting molten resin inside the heating barrel 6 into a mold C, shown by an imaginary line.

[0029] Meanwhile, a hopper 6h is provided at the upper part near the rear end of the heating cylinder 6. The lower end opening of this hopper 6h is connected to the inside of the heating cylinder 6 through a material drop port 6d formed through the heating cylinder 6. As a result, the pulverized material mixed material Rm in the hopper 6h is supplied to the inside of the heating cylinder 6 through the material drop port 6d. The pulverized material mixed material Rm is a mixed resin material obtained by mixing virgin material Rv and pulverized material Rs at a predetermined ratio Px.

[0030] In FIG. 3, 7h denotes a heater attached to the outer peripheral surface of the hopper 6h for heating the resin material Rm contained inside the hopper 6h, and 8j denotes a water jacket formed on the heating barrel 6 around the material drop port 6d. The heater 7h is connected to a power supply circuit 8e in the temperature control driver 8d, and the water jacket 8j is connected to a temperature-controlled water circulation circuit 8w in the temperature control driver 8d. The temperature-controlled water circulation circuit 8w circulates a temperature-controlled aqueous medium (hot water or cooling water) through the water jacket 8j, thereby controlling (heating or cooling) the temperature of the resin material Rm passing through the material drop port 6d. Furthermore, the power supply circuit 8e and the temperature-controlled water circulation circuit 8w are each connected to a controller main body 20. As a result, the controller main body 20 issues control commands for the power supply circuit 8e and the temperature-controlled water circulation circuit 8w to the temperature control driver 8d.

[0031] The screw 3 is loaded inside the heating barrel 6 so that it can rotate and move forward and backward. The screw surface is coated with a predetermined surface material (metal) for durability and other reasons. The screw 3 has, from front to rear, a metering zone Zm, a compression zone Zc, and a feed zone Zf. The rear end of the screw 3 is connected to a screw driver 13. The screw driver 13 includes a screw rotation mechanism 13r that rotates the screw 3 and a screw advance / retract mechanism 13m that advances and retracts the screw 3. While the screw rotation mechanism 13r and the screw advance / retract mechanism 13m are driven electrically using an electric motor in the illustrated example, they may also be driven hydraulically using a hydraulic circuit, and any drive system is acceptable. The screw rotation mechanism 13r and the screw advance / retract mechanism 13m are connected to a power supply driver 13d, which is in turn connected to a controller main body 20. As a result, control commands for the screw rotation mechanism 13r and the screw advance / retract mechanism 13m are given to the power supply driver 13d from the controller body 20. Furthermore, physical quantities such as the speed and position of the screw 3 are detected by a speed sensor, a position sensor, etc. (not shown), and these detection signals are given to the power supply driver 13d.

[0032] Furthermore, the heating barrel 6 has, from front to rear, a heating barrel front section 6f, a heating barrel middle section 6m, and a heating barrel rear section 6r, and a front heating section 7f, a middle heating section 7m, and a rear heating section 7r are attached to the outer peripheral surfaces of each section 6f, 6m, and 6r, respectively. Similarly, a head heating section 7s is attached to the outer peripheral surface of the head section 6s, and a nozzle heating section 7n is attached to the outer peripheral surface of the nozzle 6n. These heating sections 7f, 7m, 7r, 7s, and 7n can be configured using band heaters or the like. Therefore, the nozzle heating section 7n, head heating section 7s, front heating section 7f, middle heating section 7m, and rear heating section 7r constitute a heating group section 7 (Figure 4). This heating group section 7 is connected to a heater driver 7d, and the heater driver 7d is connected to the controller main body 20. As a result, the controller main body 20 issues control commands for each heating section 7f, 7m, 7r, 7s, and 7n to the heater driver 7d, and the heating temperature is detected by a temperature sensor (such as a thermocouple) not shown, and this detection signal is sent to the heater driver 7d.

[0033] Meanwhile, FIG. 4 shows the molding machine controller 2 that is responsible for the overall control of the injection molding machine M. The molding machine controller 2 includes the aforementioned controller main body 20 having computer functions incorporating hardware such as a CPU and internal memory 20m, and a display 2d is connected to the controller main body 20. The display 2d includes a display unit 2dd that displays necessary information and is also provided with a touch panel 2dt, which can be used to perform various input operations such as input, setting, and selection. The controller main body 20 is also connected to a driver group 24 that drives (operates) various actuators. The driver group 24 includes a temperature control driver 8d including the power supply circuit 8e and temperature-controlled water circulation circuit 8w described above, a power supply driver 13d, and a heater driver 7d, all of which are shown in FIG. 3.

[0034] Therefore, the molding machine controller 2 includes an HMI control system and a PLC control system, and the internal memory 20m stores a PLC program and an HMI program. The PLC program executes the sequence operations of various processes in the injection molding machine M and monitors the injection molding machine M, while the HMI program executes the setting and display of operating parameters of the injection molding machine M and the display of operation monitoring data of the injection molding machine M. In addition, the internal memory 20m stores a flow analysis processing program as well as a pulverized material processing program Pi.

[0035] The internal memory 20m of the controller main body 20 also stores an application program related to the present invention that realizes the molding support method according to this embodiment, namely, a pulverized material support processing program Pi, as well as a flow analysis processing program Ps. The flow analysis processing program Ps can utilize a molding support device for an injection molding machine already proposed by the applicant (see JP 2020-1183 A and JP 2021-121959 A). In other words, the estimation processing function can numerically estimate accurate information (data) about the melting state of the resin material.

[0036] As a result, the molding machine controller 2 is a main functional part related to the molding support device 1, and includes a plasticization condition setting function part Fs for setting predetermined plasticization conditions, a basic time data acquisition function part Fo for measuring the virgin material plasticization time Tv up to the predetermined plasticization end position Xe under the plasticization conditions using only the virgin material Rv used in the pulverized material mixed material Rm, and the pulverized material plasticization time Ts up to the predetermined plasticization end position Xe under the plasticization conditions using only the pulverized material Rs used in the pulverized material mixed material Rm, and registering and processing the data as basic time data Do, and a production of molded products using the pulverized material mixed material Rm. The device is equipped with an actual time data acquisition function unit Fp that measures the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a specified shot at a time and acquires it as actual time data Dp, a pulverized material ratio calculation function unit Fa that calculates the pulverized material ratio Px in the pulverized material mixed material Rm based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts and the pulverized material mixed material plasticization time Tm, and an output processing function unit Fe that outputs and processes the obtained pulverized material ratio Px, and the molding support method for the pulverized material mixed material Rm of this embodiment is executed based on the above-mentioned pulverized material support processing program Pi.

[0037] Next, the principle of the molding support method (molding support device 1) according to this embodiment will be described with reference to FIGS.

[0038] In production factories that use injection molding machines M, unwanted molded articles such as spools, runners, and defective molded articles are usually generated after molding. Therefore, particularly when high mechanical strength and quality are not required for the molded articles, it is not uncommon to reuse not only virgin materials such as pellets as the resin material for molding, but also the unwanted molded articles mentioned above.

[0039] When recycling unwanted moldings, they are finely crushed to obtain crushed material, which is then mixed with virgin material in a predetermined ratio to form a crushed material mixture. Crushed material is typically obtained by crushing unwanted moldings in a crusher, but the resulting crushed material Rs has a random shape and size. As a result, voids form in the molten resin inside the heating cylinder 6 during plasticization, leading to insufficient melting of the resin or variations in the melting state, which can lead to a decrease in molding quality and even an increase in molding defects, making it difficult to achieve stable molding and production.

[0040] Specifically, even if the crushed material ratio Px is set to 30 wt% (crushed material: 30 wt%, virgin material: 70 wt%) as a molding condition during production, the content of crushed material Rs in the actual molded product varies, resulting in problems such as, for example, there being too much crushed material Rs and the quality cannot be guaranteed, or there being too little crushed material Rs and the crushed material Rs cannot be fully reused.

[0041] For this reason, in the present invention, the properties of the pulverized material Rs may affect the plasticization time due to voids in the resin that occur within the heating barrel 6 during plasticization or the behavior of the pulverized material Rs relative to the heating barrel 6 and the screw 3, that is, the more pulverized material Rs there is, the longer the plasticization time will be, and the less pulverized material Rs there is, the shorter the plasticization time will be.We focused on this and verified this.

[0042] Figure 5 shows the average plasticization time (seconds) when the pulverized material ratio Px, i.e., the mixing ratio of pulverized material Rs (wt%) to virgin material Rv (wt%), is changed. Specifically, the average plasticization time (seconds) was measured for the pulverized material mixture Rm1 (100 wt% virgin material Rv and 0 wt% pulverized material Rs), the pulverized material mixture Rm2 (70 wt% virgin material Rv and 30 wt% pulverized material Rs), the pulverized material mixture Rm3 (30 wt% virgin material Rv and 70 wt% pulverized material Rs), and the pulverized material mixture Rm4 (0 wt% virgin material Rv and 100 wt%).

[0043] As is clear from Figure 5, there is a clear correlation between the pulverized material ratio (mixing ratio) Px and the average plasticization time (seconds), and the plasticization time varies almost linearly with the amount of pulverized material. In other words, if the plasticization time is actually measured, the pulverized material ratio Px corresponding to the measured time can be estimated.

[0044] Therefore, the estimation formula (calculation formula) is as follows: when the crushed material ratio is Px (wt%), the crushed material mixed material plasticization time is Tm (seconds), the virgin material plasticization time is Tv (seconds), and the crushed material plasticization time is Ts (seconds), Px=[(Tm-Tv) / (Ts-Tv)]×100[wt%] The calculation process using this formula can be performed by the crushed material ratio calculation function unit Fa. In this way, the crushed material ratio Px can be calculated using a relatively simple calculation formula, so that the accurate crushed material ratio Px can be obtained quickly and easily.

[0045] FIG. 6 shows a graph of the variation of the calculated pulverized material ratio value versus shot number. While FIG. 6 shows a graph of variation calculated for each shot, in actual production, it may be calculated for each shot at a predetermined interval. In this way, the pulverized material ratio Px can be calculated for any shot or shot interval. Therefore, it is possible to obtain the pulverized material ratio Px according to the purpose, for example, for pulverized material Rs with large variation, it can be calculated for each shot, and for pulverized material Rs with small variation, it can be calculated for each multiple shots, providing excellent flexibility and convenience. In FIG. 6, two types of pulverized material mixture Rm were used, with the pulverized material ratio Px (set ratio) set to 30 wt% and 70 wt%. As is clear from FIG. 6, it can be confirmed that variation occurs for each shot.

[0046] Therefore, for example, in the variation graph of 30 [wt%] shown in Figure 6, an upper limit value Pxu and a lower limit value Pxd can be set, and a pass / fail judgment can be made by the pass / fail judgment processing function unit Fj provided in the molding machine controller 2. That is, for the pulverized material ratio Px obtained by the pulverized material ratio calculation function unit Fa, either the upper limit value Pxu or the lower limit value Pxd, or both the upper limit value Pxu and the lower limit value Pxd, can be set in the molding machine controller 2, and molded products that are less than the upper limit value Pxu and / or greater than the lower limit value Pxd can be judged as pass / fail. By providing such a pass / fail judgment processing function unit Fj, pass / fail judgment for molded products can be made easily and accurately, thereby further improving the quality and reliability of molded products.

[0047] Furthermore, since the molding machine controller 2 includes an output processing function unit Fe, the display 2d is provided with a display screen Vm, an example of which is shown in FIG. 7, which can display information related to the pulverized material ratio Px in real time. The exemplary display screen Vm includes a graphic display unit Vmg at the top that graphically displays the pulverized material ratio Px. The pulverized material ratio Px is displayed as a horizontal bar graph, and the upper limit value Pxu and lower limit value Pxd are indicated by triangular pointer marks. FIG. 7 shows a state in which the pulverized material ratio Px is 30 wt%, with the upper limit value Pxu set to 35 wt% and the lower limit value Pxd set to 25 wt%. Below the graphic display unit Vmg, a numerical display unit Vmn is provided that displays the measured pulverized material ratio Px, the set upper limit value Pxu, and the set lower limit value Pxd. An alarm display unit Vma is provided at the bottom, below the numerical display unit Vmn. This alarm display unit Vma has a normal state indicator light 4s located in the center, an upper limit alarm indicator light 4u located to the right of the normal state indicator light 4s, and a lower limit alarm indicator light 4d located to the left of the normal state indicator light 4s. Figure 7 shows the state when the normal state indicator light 4s is lit.

[0048] On this display screen Vm, the crushed material ratio Px is displayed in real time using the graphic display section Vmg and the numerical display section Vmn, and when the ratio does not deviate from the upper limit value Pxu and the lower limit value Pxd set in the numerical display section Vmn, the normal indicator light 4s is turned on, as shown in Figure 7. On the other hand, when the ratio deviates from the upper limit value Pxu or the lower limit value Pxd, the corresponding upper limit alarm indicator light 4u or lower limit alarm indicator light 4d can be turned on.

[0049] In this way, when configuring the output processing function unit Fe, if a display screen Vm having a numerical display unit and / or a graphic display unit for the crushed material ratio Px is provided on the display 2d, the operator can easily confirm the crushed material ratio Px by visual means, and therefore the actual status of the crushed material ratio Px can be quickly and reliably confirmed.

[0050] Furthermore, if the display screen Vm of the output processing function unit Fe determines that molded products that exceed the upper limit value Pxu and / or are below the lower limit value Pxd are improper molded products, and an alarm display unit is provided on the display 2d to perform the specified output processing, it becomes possible to easily and reliably know that an improper molded product has occurred, and therefore necessary error response processing such as discarding the relevant molded product or changing the plasticization conditions can be carried out promptly.

[0051] In addition, when calculating the pulverized material ratio Px, after calculating the pulverized material mixed material plasticization time Tm, the delay time Td until it is reflected in the molded product can be calculated, including at least the capacity of the screw 3, and the pulverized material ratio Px and the molded product can be linked based on this delay time Td. In this way, the molded product based on the pulverized material ratio Px can be matched, so the accuracy and reliability of the pulverized material ratio Px can be further improved.

[0052] Next, the operation of the molding support device 1 including the molding support method for the pulverized material mixture Rm according to this embodiment will be described according to the flowcharts shown in FIGS. 1 and 2 with reference to the respective drawings.

[0053] First, a preparatory process before carrying out a production process using the molding support method according to this embodiment will be described with reference to the flowchart shown in FIG.

[0054] First, the basic time data acquisition function unit Fo provided in the molding machine controller 2 performs a process for acquiring the virgin material plasticization time Tv for the virgin material Rv related to a predetermined resin material. In this case, the virgin material Rv, such as pellets, is prepared (step S1). Then, the plasticization condition setting function unit Fs in the molding machine controller 2 sets predetermined plasticization conditions (step S2). Specific plasticization conditions can include one or more setting items, such as the rotation speed of the screw 3, the back pressure on the screw 3, the set temperature of the heating barrel, and the plasticization end position Xe of the screw 3. By including such setting items, it becomes possible to set plasticization conditions at the same level as those in the actual production process, thereby obtaining a rational and reliable pulverized material ratio Px.

[0055] Then, only virgin material Rv, i.e., 100% virgin material Rv, is charged into the hopper 6h (step S3). Once preparation for the plasticization process is complete, the plasticization process is carried out based on the set plasticization conditions (step S4). The plasticization process begins by setting the screw 3 to its most forward position (or a predetermined set position), and the plasticization process is carried out from this position. During the plasticization process, the screw 3 rotates, and the plasticized molten resin accumulates in front of the screw 3, while the screw 3 gradually retreats in response. When the screw 3 retreats and reaches the set plasticization end position Xe, the plasticization process is terminated (step S5). Furthermore, upon completion of the plasticization process, the virgin material plasticization time Tv from the start of the plasticization process to the time when the plasticization end position Xe is reached is recorded (step S6).

[0056] On the other hand, a similar process is performed to obtain the pulverized material plasticization time Ts. In this case, only the pulverized material Rs is prepared (step S7). The pulverized material Rs is obtained by pulverizing unwanted moldings, such as spools, runners, and defective moldings, generated after the production (molding) of molded products using the above-mentioned specified resin material using a pulverizer (not shown). The size and shape of the obtained pulverized material Rs are random. In addition, the plasticization condition setting function unit Fs sets predetermined plasticization conditions (step S8). In this case, the same conditions as those used in the process of obtaining the virgin material plasticization time Tv are basically set.

[0057] Then, only the pulverized material Rs, i.e., 100% pulverized material Rs, is loaded into the hopper 6h (step S9). Once preparation for the plasticization process is complete, the plasticization process is carried out based on the set plasticization conditions (step S10). The plasticization process begins by setting the screw 3 to its most advanced position (or a predetermined set position), and the plasticization process is carried out from this position. As with the virgin material Rv, the screw 3 then retreats, and the plasticization process is terminated when it reaches the set plasticization end position Xe (step S11). Furthermore, upon completion of the plasticization process, the pulverized material plasticization time Ts from the start of the plasticization process to the time it reaches the plasticization end position Xe is recorded (step S12).

[0058] The above import process obtains the virgin material plasticization time Tv and the pulverized material plasticization time Ts, which are then registered in the database in the internal memory 20m by the basic time data acquisition function unit Fo of the molding machine controller 2 (step S13). Figure 4 shows an example of a database, with a database DB1 for pulverized material Rsa, a database DB2 for pulverized material Rsb, etc. This completes the acquisition of basic time data related to the specified resin material. Therefore, if there are other resin materials, basic time data can be acquired using a similar procedure (step S14). Furthermore, even if the virgin material plasticization time Tv and the pulverized material plasticization time Ts are changed, for example, by changing the plasticization conditions, basic time data can be acquired using a similar procedure, and the registered items in the database can be updated (step S15). Once the preparatory process prior to the production process based on the flowchart of Figure 1 is completed, the specified production process is carried out (step SP).

[0059] Next, the processing of the production process using the molding support method according to this embodiment will be described with reference to the flowchart shown in FIG.

[0060] Now, assume that a production process is being carried out using a pulverized material mixed material Rm, which is a mixture of virgin material Rv and pulverized material Rs made of a predetermined resin material, by an injection molding machine M (step SP). Note that the pulverized material mixed material Rm as a molding condition can be set in advance using the pulverized material weight input section 34s and the virgin material weight input section 34v of the material input section 34 shown in FIG.

[0061] Meanwhile, during the production process, the molding machine controller 2 monitors the molding cycle of the molding process (step S21). Then, when the molding cycle shifts to the plasticizing process and the plasticizing end position Xe is confirmed, the actual measured time data of the plasticizing time in that shot, i.e., the actual measured time data Dp is acquired by the actual measured time data acquisition function Fp (steps S22, S23, S24).

[0062] When the molding machine controller 2 obtains the actual measurement time data Dp, the pulverized material ratio calculation function unit Fa performs an estimation process (calculation process) of the pulverized material ratio Px (step S25). Specifically, using the virgin material plasticization time Tv and the pulverized material plasticization time Ts, which are the basic time data Do registered in the database, and the pulverized material mixed material plasticization time Tm, which is the actual measurement time data Dp, the pulverized material ratio Px is calculated by Px = [(Tm - Tv) / (Ts - Tv)] × 100 [wt%].

[0063] The obtained pulverized material ratio Px is then subjected to predetermined output processing by the output processing function unit Fe provided in the molding machine controller 2. Specifically, the obtained pulverized material ratio Px is displayed on the display screen Vm of Fig. 7 using the graphic display unit Vmg and the numerical display unit Vmn (step S26). After this, if the next shot continues, the same monitoring process is continued (steps S27, S21, ...).

[0064] The molding machine controller 2 also performs a judgment process using the pass / fail judgment processing function unit Fj (step S28). That is, the judgment process is performed on the pulverized material ratio Px based on the set upper limit value Pxu and lower limit value Pxd. As a result, when the pulverized material ratio Px is equal to or less than the upper limit value Pxu or equal to or greater than the lower limit value Pxd, it is judged to be normal, and the normal indicator light 4s is turned on. On the other hand, when the pulverized material ratio Px exceeds the upper limit value Pxu or is less than the lower limit value Pxd, the obtained molded product is judged to be an improper molded product, and the alarm display unit Vma provided on the display 2d performs the necessary error response process (steps S9, S30).

[0065] Thus, according to the molding support method (molding support device 1) of this embodiment, the basic configuration is to measure the virgin material plasticization time Tv up to the predetermined plasticization end position Xe using only the virgin material Rv, and the pulverized material plasticization time Ts up to the predetermined plasticization end position Xe under plasticization conditions using only the pulverized material Rs, and register and process them as basic time data Do.In addition, when producing a molded product using the pulverized material mixed material Rm, the pulverized material mixed material plasticization time Tm up to the plasticization end position Xe in a predetermined shot is measured to obtain actual time data Dp, and the pulverized material ratio Px in the pulverized material mixed material Rm is calculated and output based on the virgin material plasticization time Tv, the pulverized material plasticization time Ts, and the pulverized material mixed material plasticization time Tm, so that a highly accurate and effective mixing ratio Px of the pulverized material Rs in the actual molded product can be easily obtained. This makes it possible to eliminate, for example, the problem that there is too much pulverized material Rs and the quality cannot be guaranteed, or the problem that there is too little pulverized material Rs and the pulverized material Rs cannot be sufficiently reused.

[0066] Although the preferred embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the detailed configuration, shape, material, quantities, values, methods, etc. can be changed, added, or deleted as desired without departing from the spirit of the present invention.

[0067] For example, the plasticization condition setting function unit Fs has been described as including one or more setting items, such as the rotation speed of the screw 3, the back pressure on the screw 3, the set temperature of the heating barrel 6, and the plasticization end position Xe of the screw 3. However, other plasticization conditions may also be included. Furthermore, while the case where both an upper limit value Pxu and a lower limit value Pxd are set for the pulverized material ratio Px has been described, this does not exclude the case where only one of the upper limit value Pxu and the lower limit value Pxd is set. In particular, only the upper limit value Pxu may be set. Furthermore, the upper limit value Pxu and the lower limit value Pxd may each be set in multiple stages. For example, the upper limit value Pxu may be set to a first upper limit value (preliminary upper limit value) and a second upper limit value (main upper limit value), thereby enabling more detailed judgment, such as issuing a preliminary alarm. On the other hand, although the case where the virgin material plasticization time Tv and the pulverized material plasticization time Ts are respectively registered as basic time data Do has been shown, they may also be registered as an arithmetic formula for calculating the pulverized material ratio Px, and the pulverized material ratio Px may be calculated from this arithmetic formula and the actual measured time data Dp. Also, the pass / fail judgment processing function unit Fj provided in the molding machine controller 2 is not an essential component and does not necessarily have to be provided. Furthermore, it is desirable to provide an alarm display provided in the output processing function unit Fe, but it is not necessarily a required component. [Industrial Applicability]

[0068] The present invention can be used as a molding support method and device for pulverized material mixtures in various injection molding machines that plasticize and injection mold pulverized material mixtures made by mixing virgin material and pulverized material in a predetermined ratio. [Explanation of symbols]

[0069] 1: Molding support device, 2: Molding machine controller, 2d: Display, 3: Screw, Rm: Crushed material mixed material, Rv: Virgin material, Rs: Crushed material, Px: Crushed material ratio, Fs: Plasticization condition setting function unit, Fo: Basic time data acquisition function unit, Fp: Actual time data acquisition function unit, Fa: Crushed material ratio calculation function unit, Fe: Output processing function unit, Fj: Good / bad judgment processing function unit, Pxu: Upper limit value, Pxd: Lower limit value, Vmn: Numerical display unit, Vmg: Graphic display unit, Vma: Alarm display unit

Claims

1. A method for supporting the molding of pulverized material mixtures in an injection molding machine that plasticizes and injection molds a pulverized material mixture, which is a mixture of virgin material and pulverized material at a predetermined ratio, comprising: measuring, in advance, a virgin material plasticization time up to a predetermined plasticization end position under predetermined plasticization conditions using only the virgin material used in the pulverized material mixture; and a pulverized material plasticization time up to a predetermined plasticization end position under the plasticization conditions using only the pulverized material used in the pulverized material mixture, using a molding machine controller provided in the injection molding machine, and registering and processing these as basic time data; and when producing a molded product using the pulverized material mixture, measuring the pulverized material plasticization time up to a plasticization end position in a predetermined shot using the molding machine controller to obtain actual measured time data; and calculating the pulverized material ratio in the pulverized material mixture based on the virgin material plasticization time, the pulverized material plasticization time, and the pulverized material mixture plasticization time, and outputting this data using the molding machine controller.

2. The pulverized material ratio is calculated by the following formula, when the pulverized material ratio is Pm [wt%], the pulverized material mixed material plasticization time is Tm [seconds], the virgin material plasticization time is Tv [seconds], and the pulverized material plasticization time is Ts [seconds]. The forming support method for pulverized material mixed material according to claim 1, characterized in that Pm=[(Tm-Tv) / (Ts-Tv)]×100 [wt%]

3. 2. The molding support method for a pulverized material mixture according to claim 1, wherein the pulverized material ratio is calculated for each shot or for each shot at a predetermined interval and output.

4. The molding support method for pulverized mixed material described in claim 1, characterized in that the pulverized material ratio is calculated by calculating the delay time from when the pulverized mixed material plasticization time is determined until it is reflected in the molded product, including at least the screw capacity, and the pulverized material ratio is linked to the molded product based on this delay time.

5. A molding support method for pulverized mixed material as described in claim 1, characterized in that an upper limit and / or lower limit value is set for the pulverized material ratio, and a pass / fail judgment process is performed in which molded products below the upper limit and / or above the lower limit value are judged to be good products.

6. A molding support device for pulverized material mixed in an injection molding machine that performs injection molding by plasticizing a pulverized material mixed in a predetermined ratio, the molding support device comprising: a plasticization condition setting function unit that sets predetermined plasticization conditions; a basic time data register that measures a virgin material plasticization time up to a predetermined plasticization end position under the plasticization conditions using only the virgin material used in the pulverized material mixed in the pulverized material, and a basic time data register that measures a pulverized material plasticization time up to a predetermined plasticization end position under the plasticization conditions using only the pulverized material used in the pulverized material mixed in the pulverized material, and registers the measured data as basic time data. a data acquisition function unit that measures the pulverized material mixed material plasticization time up to the plasticization end position in a specified shot when producing a molded product from the pulverized material mixed material and acquires it as actual measured time data; a pulverized material ratio calculation function unit that calculates the pulverized material ratio in the pulverized material mixed material based on the virgin material plasticization time, the pulverized material plasticization time, and the pulverized material mixed material plasticization time; and an output processing function unit that outputs the obtained pulverized material ratio.

7. The molding support device for crushed mixed material described in claim 6, characterized in that the plasticization condition setting function unit includes one or more setting items: screw rotation speed, back pressure on the screw, set temperature of the heating barrel, and plasticization end position of the screw.

8. The molding support device for pulverized mixed material described in claim 6, characterized in that the molding machine controller is equipped with a pass / fail judgment processing function unit that sets an upper limit and / or a lower limit for the pulverized material ratio obtained by the pulverized material ratio calculation function unit, and judges molded products that are below the upper limit and / or above the lower limit to be good products.

9. The molding support device for pulverized mixed material according to claim 6, characterized in that the molding machine controller is provided with a display as the output processing function unit for displaying the pulverized material ratio numerically and / or graphically.

10. The molding support device for pulverized mixed material described in claim 8, characterized in that the molding machine controller is equipped with an output processing function unit that determines that molded products that exceed the upper limit value and / or are below the lower limit value are inappropriate molded products and performs predetermined output processing including displaying an alarm on the display.

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