Injection molding machine, controller

Abstract

Provided is a technology capable of more appropriately achieving a real-time property of a control process related to the operation of an industrial machine such as an injection molding machine. An injection molding machine 1 according to one embodiment of the present disclosure is provided with a mold clamping device 100, an injection device 300, an ejector device 200, and a controller 700. Specifically, the mold clamping device 100 clamps a mold device 10. The injection device 300 fills the mold device 10 clamped by the mold clamping device 100 with a molding material. The ejector device 200 removes a molded article from the mold device 10 after the molding material supplied by the injection device 300 has cooled and solidified. The controller 700 outputs an interrupt request every prescribed control period, and carries out a control process related to the operation of the injection molding machine 1 in accordance with the interrupt request. The controller 700 outputs the interrupt request before the preparation for data required for the control process is completed, and starts the control process after the preparation for the required data has been completed.

Description

Technical Field

[0001] The present disclosure relates to an injection molding machine and the like.

Background Art

[0002] For example, in industrial machines such as injection molding machines, control processing regarding their operations is performed at each predetermined control cycle using various data such as data output by various sensors (see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in a control device (controller) of an industrial machine, an interrupt request is output at each predetermined control cycle, and control processing regarding the operation of the industrial machine is executed in response to the interrupt request.

[0005] However, due to the overhead of the interrupt processing, the situation of cache hits in the interrupt processing, etc., there may be variations in the required time of the interrupt processing. Therefore, for example, when this required time becomes relatively long, the timing of the start of the control processing based on the completion of the preparation of the data required for the control processing may become relatively late, and it may affect the real - time performance of the control processing.

[0006] Therefore, in view of the above problems, an object is to provide a technology that can more appropriately realize the real - time performance of control processing regarding the operation of industrial machines such as injection molding machines.

Means for Solving the Problems

[0007] To achieve the above objective, in one embodiment of this disclosure, A clamping device for clamping the mold equipment, An injection device for filling the mold device, which has been clamped by the clamping device, After the molding material filled by the injection device has cooled and solidified, an ejector device removes the molded product from the mold device, The system includes a control device that outputs an interrupt request at predetermined intervals and performs control processing related to the operation of the injection molding machine in response to the interrupt request, The control device outputs the interrupt request before the occurrence of the trigger that serves as the basis for starting the control process, and starts the control process after the occurrence of the trigger. An injection molding machine is provided.

[0008] In other embodiments of this disclosure, An interrupt request output unit that outputs an interrupt request at predetermined intervals, The system includes a control processing unit that performs control processing related to the operation of an industrial machine in response to the aforementioned interrupt request, The interrupt request output unit outputs the interrupt request before the occurrence of the trigger that serves as the basis for starting the control process. The control processing unit starts the control processing after the occurrence of the trigger. A controller is provided. [Effects of the Invention]

[0009] According to the above-described embodiment, real-time control processing related to the operation of industrial machinery such as injection molding machines can be more appropriately realized. [Brief explanation of the drawing]

[0010] [Figure 1] This figure shows an example of the configuration of an injection molding machine management system, including an injection molding machine. [Figure 2] This figure shows an example of the configuration of an injection molding machine management system, including an injection molding machine. [Figure 3]It is a diagram showing an example of the hardware configuration of the control system of an injection molding machine. [Figure 4] It is a block diagram showing an example of the functional configuration of a controller. [Figure 5] It is a timing chart showing an example of the operation of a controller. [Figure 6] It is a flowchart schematically showing an example of the setting process regarding an interrupt request. [Figure 7] It is a diagram showing an example of a setting screen displayed on a display device. [Figure 8] It is a timing chart showing the operation of a controller of an injection molding machine according to a comparative example. [Mode for Carrying Out the Invention]

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

[0012] [Overview of Injection Molding Machine Management System] First, referring to FIGS. 1 and 2, the overview of the injection molding machine management system SYS according to the present embodiment will be described.

[0013] FIGS. 1 and 2 are diagrams showing an example of the injection molding machine management system according to the present embodiment. Specifically, in FIG. 1, a side cross-sectional view showing the state at the completion of mold opening of the injection molding machine .

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

[0015] Note that the injection molding machine 1 included in the injection molding machine management system SYS may be one.

[0016] <Injection molding machine> The injection molding machine 1 (an example of industrial machinery) performs a series of operations to obtain a molded product.

[0017] Furthermore, the injection molding machine 1 is connected to the management device 2 via a predetermined communication line NW. The injection molding machine 1 may also be connected to other injection molding machines 1 via the communication line NW.

[0018] The communication line NW may be, for example, a one-to-one communication line. The communication line NW may also include the local network (LAN) of the facility (factory) where the injection molding machine 1 is installed. The local network may be constructed using wired connections, wireless connections, or a combination of both. Furthermore, the communication line NW may also include a wide area network (WAN) outside the facility (factory) where the injection molding machine 1 is installed. The wide area network may include, for example, a mobile communication network with base stations as its endpoints. The mobile communication network may include, for example, 4G (4G) including LTE (Long Term Evolution). th Generation) and 5G (5 th It may support (Generation) etc. Furthermore, the wide area network may include, for example, a satellite communication network that utilizes communication satellites. Furthermore, the wide area network may include, for example, the Internet network. Furthermore, the communication line NW may include, for example, a short-range communication line that supports wireless communication standards such as Bluetooth® communication and WiFi communication.

[0019] For example, the injection molding machine 1 transmits (uploads) data related to the operating status of the injection molding machine 1 (hereinafter referred to as "operating status data") and data related to the production status (hereinafter referred to as "production status data") to the management device 2 via a communication line NW. The operating status data may include, for example, measurement data and control data related to the operating status of the driven parts of the injection molding machine 1 (e.g., position, velocity, angular velocity, acceleration, etc.). The operating status data may also include, for example, measurement data and control data related to the operating status of the electrically driven parts of the injection molding machine 1 (e.g., current, voltage, etc.). The operating status data may also include, for example, measurement data and control data related to the operating status of the hydraulic driven parts (e.g., hydraulic fluid pressure, etc.). The operating status data may also include, for example, data related to the temperature status of a predetermined part of the injection molding machine 1. As a result, the management device 2 can automatically or manually grasp the operating status in response to input from an administrator or operator, and manage the timing of maintenance and the operating schedule of the injection molding machine 1. Furthermore, the production status data includes, for example, data on the number of molded products produced (number of shots) from a predetermined point in time. This allows the control device 2 to grasp the production status of molded products by the injection molding machine 1.

[0020] Furthermore, for example, injection molding machine 1, acting as a master machine, may monitor and control the operation of other injection molding machines 1 acting as slave machines via a communication line NW. Specifically, injection molding machine 1 (slave machine) may transmit operating status data to injection molding machine 1 (master machine) via a communication line NW. This allows injection molding machine 1 (master machine) to monitor the operation of other injection molding machines 1 (slave machines). In addition, injection molding machine 1 (master machine) may, based on the operating status data, understand the operating status of other injection molding machines 1 (slave machines) and transmit control commands related to their operation to other injection molding machines 1 (slave machines) via a communication line NW. This allows injection molding machine 1 (master machine) to control the operation of other injection molding machines 1 (slave machines).

[0021] <Management device> The management device 2 is connected to the injection molding machine 1 via a communication line NW and manages the operating status and other conditions of the injection molding machine 1. The management device 2 may, for example, automatically manage the operating status and other conditions of the injection molding machine 1 according to predetermined rules or autonomously. Alternatively, the management device 2 may manage the operating status and other conditions of the injection molding machine 1 in response to various inputs received from users of the injection molding machine 1, such as administrators or operators. In other words, the management device 2 may support the management of the operating status and other conditions of the injection molding machine 1 by users of the injection molding machine 1, such as administrators or operators.

[0022] The functions of the management device 2 can be realized by any hardware or any combination of hardware and software. For example, the management device 2 is an information processing device that includes a CPU (Central Processing Unit), a memory device such as RAM (Read Only Memory), a non-volatile auxiliary storage device such as ROM (Read Only Memory), and an interface device for input / output with the outside world. The management device 2 may realize various functions by loading a program to be installed in the auxiliary storage device into the memory device and executing it on the CPU. The management device 2 may, for example, obtain a program to be installed in the auxiliary storage device from a predetermined recording medium through the interface device. The predetermined recording medium includes, for example, a flexible disk, CD (Compact Disc), DVD (Digital Versatile Disc), BD (Blu-ray® Disc), SD memory card, USB (Universal Serial Bus) memory, etc. The management device 2 may also, for example, obtain (download) a program to be installed in the auxiliary storage device from an external computer through the interface device.

[0023] The management device 2 is, for example, a cloud server or on-premise server installed in a remote location such as a management center outside the factory where the injection molding machine 1 is installed. Alternatively, the management device 2 may be an edge server installed inside the factory where the injection molding machine 1 is installed or in a location relatively close to the factory (for example, a wireless base station or station building near the factory). The management device 2 may also be a terminal device (user terminal) used by users of the injection molding machine 1, such as administrators or operators. The user terminal may be a management terminal device within the factory where the injection molding machine 1 is installed or a terminal device (user terminal) used by users of the injection molding machine 1. The management terminal device and user terminal may be a stationary terminal device such as a desktop PC (Personal Computer). Alternatively, the management terminal device and user terminal may be a portable terminal device that can be carried by users such as administrators or operators of the injection molding machine 1. Portable terminal devices may include, for example, smartphones, tablet devices, and laptop PCs.

[0024] For example, the management device 2 may understand the operating status of the injection molding machine 1 based on the operating status data transmitted (uploaded) from the injection molding machine 1 and manage the operating status of the injection molding machine 1. In addition, the management device 2 may perform various diagnoses, such as abnormality diagnosis of the injection molding machine 1, based on the operating status of the injection molding machine 1 as understood from the operating status data.

[0025] Furthermore, the management device 2 may manage the production status of the injection molding machine 1 based on production status data transmitted (uploaded) from the injection molding machine 1, for example.

[0026] Furthermore, for example, the control device 2 may transmit control signals to the injection molding machine 1 via a communication line NW, including control information (e.g., information regarding various setting conditions). This allows the control device 2 to control the operation of the injection molding machine 1.

[0027] [Configuration of an injection molding machine] Next, we will continue to explain the configuration of the injection molding machine with reference to Figures 1 and 2.

[0028] As shown in Figures 1 and 2, the injection molding machine 1 includes a clamping device 100, an ejector device 200, an injection device 300, a moving device 400, and a controller 700.

[0029] <<Mold clamping device>> The mold clamping device 100 performs mold closing, mold clamping, and mold opening of the mold device 10. The mold clamping device 100 is, for example, a horizontal type, and the mold opening and closing direction is horizontal. The mold clamping device 100 has a fixed platen 110, a movable platen 120, a toggle support 130, a tie bar 140, a toggle mechanism 150, a mold clamping motor 160, a motion conversion mechanism 170, and a mold thickness adjustment mechanism 180.

[0030] In the following description of the mold clamping device 100, the direction of movement of the movable platen 120 when the mold is closed (right direction in Figures 1 and 2) will be described as forward, and the direction of movement of the movable platen 120 when the mold is open (left direction in Figures 1 and 2) will be described as backward.

[0031] The fixed platen 110 is fixed to the frame Fr. A fixed mold 11 is attached to the surface of the fixed platen 110 facing the movable platen 120.

[0032] The movable platen 120 is movable relative to the frame Fr in the mold opening and closing direction. A guide 101 is laid on the frame Fr to guide the movable platen 120. The movable mold 12 is attached to the surface of the movable platen 120 that faces the fixed platen 110.

[0033] The mold is closed, clamped, and opened by moving the movable platen 120 forward and backward relative to the fixed platen 110.

[0034] The mold apparatus 10 is comprised of a fixed mold 11 corresponding to a fixed platen 110 and a movable mold 12 corresponding to a movable platen 120.

[0035] The toggle support 130 is connected to the fixed platen 110 at a predetermined distance L and is mounted on the frame Fr so as to be movable in the mold opening and closing direction. The toggle support 130 may be movable along a guide laid on the frame Fr, for example. In this case, the guide of the toggle support 130 may be the same as the guide 101 of the movable platen 120.

[0036] Furthermore, while the fixed platen 110 is fixed to the frame Fr and the toggle support 130 is movable relative to the frame Fr in the mold opening and closing direction, the toggle support 130 may be fixed to the frame Fr and the fixed platen 110 may be movable relative to the frame Fr in the mold opening and closing direction.

[0037] The tie bars 140 connect the fixed platen 110 and the toggle support 130 at a distance L in the mold opening and closing direction. Multiple tie bars 140 (for example, four) may be used. Each tie bar 140 is parallel to the mold opening and closing direction and stretches in accordance with the clamping force. At least one tie bar 140 is provided with a tie bar strain detector 141 that detects the strain of the tie bar 140. The tie bar strain detector 141 is, for example, a strain gauge. The tie bar strain detector 141 sends a signal indicating its detection result to the controller 700. The detection result of the tie bar strain detector 141 is used, for example, to detect the clamping force.

[0038] Furthermore, any clamping force detector available for detecting clamping force may be used instead of, or in addition to, the tie bar strain detector 141. For example, the clamping force detector is not limited to strain gauge type, but may be piezoelectric, capacitive, hydraulic, electromagnetic, etc., and its mounting position is not limited to the tie bar 140.

[0039] The toggle mechanism 150 is positioned between the movable platen 120 and the toggle support 130, and moves the movable platen 120 in the mold opening and closing direction relative to the toggle support 130. The toggle mechanism 150 consists of a crosshead 151, a pair of link groups, etc. Each link group has a first link 152 and a second link 153 that are flexibly connected by pins or the like. The first link 152 is pivotably attached to the movable platen 120 by pins or the like, and the second link 153 is pivotably attached to the toggle support 130 by pins or the like. The second link 153 is attached to the crosshead 151 via a third link 154. When the crosshead 151 is moved forward and backward relative to the toggle support 130, the first link 152 and the second link 153 flex and extend, and the movable platen 120 moves forward and backward relative to the toggle support 130.

[0040] Furthermore, the configuration of the toggle mechanism 150 is not limited to the configuration shown in Figures 1 and 2. For example, in Figures 1 and 2, each link group has five nodes, but it may also have four, and one end of the third link 154 may be connected to the node between the first link 152 and the second link 153.

[0041] The clamping motor 160 is attached to the toggle support 130 and operates the toggle mechanism 150. The clamping motor 160 moves the crosshead 151 forward and backward relative to the toggle support 130, thereby bending and extending the first link 152 and the second link 153, and moving the movable platen 120 forward and backward relative to the toggle support 130. The clamping motor 160 is directly connected to the motion conversion mechanism 170, but it may also be connected to the motion conversion mechanism 170 via a belt, pulley, or the like.

[0042] The motion conversion mechanism 170 converts the rotational motion of the clamping motor 160 into the linear motion of the crosshead 151. The motion conversion mechanism 170 includes a screw shaft 171 and a screw nut 172 that screws onto the screw shaft 171. A ball or roller may be interposed between the screw shaft 171 and the screw nut 172.

[0043] The mold clamping device 100 performs mold closing, mold clamping, mold opening, etc., under the control of the controller 700.

[0044] In the mold closing process, the clamping motor 160 is driven to advance the crosshead 151 at a set speed to the mold closing completion position, thereby advancing the movable platen 120 and bringing the movable mold 12 into contact with the fixed mold 11. The position and speed of the crosshead 151 are detected, for example, using a clamping motor encoder 161. The clamping motor encoder 161 detects the rotation of the clamping motor 160 and sends a signal indicating the detection result to the controller 700.

[0045] Furthermore, the crosshead position detector for detecting the position of the crosshead 151 and the crosshead speed detector for detecting the speed of the crosshead 151 are not limited to the clamping motor encoder 161, and general-purpose devices can be used. Similarly, the movable platen position detector for detecting the position of the movable platen 120 and the movable platen speed detector for detecting the speed of the movable platen 120 are not limited to the clamping motor encoder 161, and general-purpose devices can be used.

[0046] In the clamping process, the clamping motor 160 is further driven to advance the crosshead 151 from the closed position to the clamping position, thereby generating clamping force. During clamping, a cavity space 14 is formed between the movable mold 12 and the fixed mold 11, and the injection unit 300 fills the cavity space 14 with liquid molding material. As the filled molding material solidifies, a molded product is obtained. There may be multiple cavity spaces 14, in which case multiple molded products can be obtained simultaneously.

[0047] In the mold opening process, the clamping motor 160 is driven to retract the crosshead 151 to the mold opening completion position at a set speed, thereby retracting the movable platen 120 and separating the movable mold 12 from the fixed mold 11. Subsequently, the ejector device 200 ejects the molded product from the movable mold 12.

[0048] The setting conditions for the mold closing process and the mold clamping process are set together as a series of setting conditions. For example, the speed and position of the crosshead 151 (including the mold closing start position, speed switching position, mold closing completion position, and mold clamping position) and the mold clamping force in the mold closing process and the mold clamping process are set together as a series of setting conditions. The mold closing start position, speed switching position, mold closing completion position, and mold clamping position are arranged in this order from rear to front and represent the start and end points of the sections in which the speed is set. The speed is set for each section. There may be one speed switching position or multiple speed switching positions. There may be no speed switching positions. The mold clamping position and the mold clamping force may be set individually or individually.

[0049] Similarly, the setting conditions for the mold opening process are also set. For example, the speed and position of the crosshead 151 in the mold opening process (including the mold opening start position, speed switching position, and mold opening completion position) are set together as a series of setting conditions. The mold opening start position, speed switching position, and mold opening completion position are arranged in this order from front to back and represent the start and end points of the sections in which the speed is set. The speed is set for each section. There may be one speed switching position or multiple speed switching positions. Speed ​​switching positions do not have to be set. The mold opening start position and the mold closing position may be the same position. Also, the mold opening completion position and the mold closing start position may be the same position.

[0050] Furthermore, instead of setting the speed and position of the crosshead 151, the speed and position of the movable platen 120 may be set. Also, instead of setting the position of the crosshead (for example, the clamping position) or the position of the movable platen, the clamping force may be set.

[0051] The toggle mechanism 150 amplifies the driving force of the clamping motor 160 and transmits it to the movable platen 120. This amplification ratio is also called the toggle ratio. The toggle ratio changes depending on the angle θ between the first link 152 and the second link 153 (hereinafter referred to as the "link angle"). The link angle θ can be determined from the position of the crosshead 151. The toggle ratio is maximized when the link angle θ is 180°.

[0052] If the thickness of the mold device 10 changes due to replacement of the mold device 10 or a change in the temperature of the mold device 10, the mold thickness is adjusted so that a predetermined clamping force is obtained during mold clamping. In mold thickness adjustment, for example, the distance L between the fixed platen 110 and the toggle support 130 is adjusted so that the link angle θ of the toggle mechanism 150 becomes a predetermined angle at the time of mold touch when the movable mold 12 touches the fixed mold 11.

[0053] The mold clamping device 100 has a mold thickness adjustment mechanism 180 that adjusts the mold thickness by adjusting the distance L between the fixed platen 110 and the toggle support 130. The mold thickness adjustment mechanism 180 has a screw shaft 181 formed at the rear end of the tie bar 140, a screw nut 182 that is rotatably held by the toggle support 130, and a mold thickness adjustment motor 183 that rotates the screw nut 182 that is screwed onto the screw shaft 181.

[0054] A screw shaft 181 and screw nut 182 are provided for each tie bar 140. The rotation of the mold thickness adjustment motor 183 may be transmitted to multiple screw nuts 182 via a rotation transmission unit 185. Multiple screw nuts 182 can rotate synchronously.

[0055] Furthermore, by changing the transmission path of the rotation transmission unit 185, it is also possible to rotate multiple screw nuts 182 individually.

[0056] The rotation transmission section 185 is composed of, for example, gears. In this case, a passive gear is formed on the outer circumference of each screw nut 182, a drive gear is attached to the output shaft of the mold thickness adjustment motor 183, and an intermediate gear that meshes with the multiple passive gears and drive gear is rotatably held in the center of the toggle support 130.

[0057] Furthermore, the rotational transmission section 185 may be composed of a belt, pulley, or the like instead of gears.

[0058] The operation of the mold thickness adjustment mechanism 180 is controlled by the controller 700. The controller 700 drives the mold thickness adjustment motor 183 to rotate the screw nut 182, thereby adjusting the position of the toggle support 130, which rotatably holds the screw nut 182, relative to the fixed platen 110, and adjusting the distance L between the fixed platen 110 and the toggle support 130.

[0059] The interval L is detected using the mold thickness adjustment motor encoder 184. The mold thickness adjustment motor encoder 184 detects the amount and direction of rotation of the mold thickness adjustment motor 183 and sends a signal indicating the detection result to the controller 700. The detection result of the mold thickness adjustment motor encoder 184 is used to monitor and control the position and interval L of the toggle support 130.

[0060] Furthermore, the toggle support position detector for detecting the position of the toggle support 130 and the interval detector for detecting the interval L are not limited to the mold thickness adjustment motor encoder 184, but general-purpose ones can be used.

[0061] The mold thickness adjustment mechanism 180 adjusts the gap L by rotating one of the screw shafts 181 and screw nuts 182 that are screwed together. Multiple mold thickness adjustment mechanisms 180 may be used, and multiple mold thickness adjustment motors 183 may be used.

[0062] In this embodiment, the mold clamping device 100 is a horizontal type in which the mold opening and closing direction is horizontal, but it may also be a vertical type in which the mold opening and closing direction is vertical.

[0063] Furthermore, although the clamping device 100 of this embodiment has a clamping motor 160 as a drive source, it may have a hydraulic cylinder instead of the clamping motor 160. Also, the clamping device 100 may have a linear motor for opening and closing the mold and an electromagnet for clamping the mold.

[0064] <<Ejector device>> The ejector device 200 ejects the molded product from the mold device 10 after the molding material filled into the mold device 10 by the injection device 300 has cooled and solidified. The ejector device 200 includes an ejector motor 210, a motion conversion mechanism 220, and an ejector rod 230, etc.

[0065] In the following description of the ejector device 200, similar to the description of the clamping device 100, the direction of movement of the movable platen 120 when the mold is closed (right direction in Figures 1 and 2) will be considered forward, and the direction of movement of the movable platen 120 when the mold is open (left direction in Figures 1 and 2) will be considered backward.

[0066] The ejector motor 210 is attached to the movable platen 120. The ejector motor 210 is directly connected to the motion conversion mechanism 220, but it may also be connected to the motion conversion mechanism 220 via a belt, pulley, or the like.

[0067] The motion conversion mechanism 220 converts the rotational motion of the ejector motor 210 into the linear motion of the ejector rod 230. The motion conversion mechanism 220 includes a screw shaft and a screw nut that screws onto the screw shaft. A ball or roller may be interposed between the screw shaft and the screw nut.

[0068] The ejector rod 230 is designed to move back and forth within a through-hole in the movable platen 120. The front end of the ejector rod 230 contacts a movable member 15, which is arranged to move back and forth inside the movable mold 12. The front end of the ejector rod 230 may or may not be connected to the movable member 15.

[0069] The ejector device 200 performs the ejection process under the control of the controller 700.

[0070] In the ejection process, the ejector motor 210 is driven to advance the ejector rod 230 from the standby position to the ejection position at a set speed, thereby advancing the movable member 15 and ejecting the molded product. Subsequently, the ejector motor 210 is driven to retract the ejector rod 230 at a set speed, retracting the movable member 15 back to its original standby position. The position and speed of the ejector rod 230 are detected, for example, using an ejector motor encoder 211. The ejector motor encoder 211 detects the rotation of the ejector motor 210 and sends a signal indicating the detection result to the controller 700.

[0071] Furthermore, the ejector rod position detector, which detects the position of the ejector rod 230, and the ejector rod speed detector, which detects the speed of the ejector rod 230, are not limited to the ejector motor encoder 211, but can be general-purpose ones.

[0072] <<Injection device>> The injection device 300 is mounted on a slide base 301 that can move back and forth relative to the frame Fr, and is also able to move back and forth relative to the mold device 10. The injection device 300 touches the mold device 10 and fills the cavity space 14 within the mold device 10 with molding material. The injection device 300 includes, for example, a cylinder 310, a nozzle 320, a screw 330, a metering motor 340, an injection motor 350, and a pressure detector 360.

[0073] In the following description of the injection device 300, the direction in which the injection device 300 approaches the mold device 10 (left direction in Figures 1 and 2) will be referred to as the front, and the direction in which the injection device 300 moves away from the mold device 10 (right direction in Figures 1 and 2) will be referred to as the rear.

[0074] The cylinder 310 heats the molding material supplied to its interior from the supply port 311. The molding material includes, for example, resin. The molding material is formed, for example, into pellets and supplied to the supply port 311 in a solid state. The supply port 311 is formed at the rear of the cylinder 310. A cooler 312, such as a water-cooled cylinder, is provided on the outer circumference of the rear of the cylinder 310. In front of the cooler 312, a heater 313, such as a band heater, and a temperature detector 314 are provided on the outer circumference of the cylinder 310.

[0075] The cylinder 310 is divided into multiple zones along its axial direction (left-right direction in Figures 1 and 2). A heater 313 and a temperature detector 314 are provided in each zone. For each zone, the controller 700 controls the heater 313 so that the temperature detected by the temperature detector 314 reaches the set temperature.

[0076] The nozzle 320 is located at the front end of the cylinder 310 and is pressed against the mold device 10. A heater 313 and a temperature detector 314 are provided on the outer circumference of the nozzle 320. The controller 700 controls the heater 313 so that the detected temperature of the nozzle 320 reaches a set temperature.

[0077] The screw 330 is rotatably and reciprocally positioned within the cylinder 310. When the screw 330 is rotated, the molding material is fed forward along the helical groove of the screw 330. As the molding material is fed forward, it is gradually melted by the heat from the cylinder 310. As the liquid molding material is fed forward to the screw 330 and accumulates at the front of the cylinder 310, the screw 330 is retracted. Then, when the screw 330 is advanced, the liquid molding material accumulated in front of the screw 330 is injected from the nozzle 320 and filled into the mold device 10.

[0078] A backflow prevention ring 331 is mounted on the front of the screw 330 so as to be able to move back and forth, acting as a backflow prevention valve to prevent backflow of the molding material from the front to the rear of the screw 330 when the screw 330 is pushed forward.

[0079] When the screw 330 is advanced, the backflow prevention ring 331 is pushed backward by the pressure of the molding material in front of the screw 330, and retracts relative to the screw 330 to a closed position (see Figure 2) that blocks the flow path of the molding material. This prevents the molding material accumulated in front of the screw 330 from flowing backward.

[0080] On the other hand, when the screw 330 is rotated, the backflow prevention ring 331 is pushed forward by the pressure of the molding material being sent forward along the helical groove of the screw 330, and moves relative to the screw 330 to an open position (see Figure 1) that opens the flow path of the molding material. As a result, the molding material is sent forward of the screw 330.

[0081] The backflow prevention ring 331 may be either a co-rotating type that rotates together with the screw 330, or a non-co-rotating type that does not rotate together with the screw 330.

[0082] Furthermore, the injection device 300 may have a drive source that moves the backflow prevention ring 331 back and forth between an open position and a closed position relative to the screw 330.

[0083] The metering motor 340 rotates the screw 330. The drive source for rotating the screw 330 is not limited to the metering motor 340; for example, a hydraulic pump or the like may also be used.

[0084] The injection motor 350 moves the screw 330 forward and backward. Between the injection motor 350 and the screw 330, there is a motion conversion mechanism that converts the rotational motion of the injection motor 350 into the linear motion of the screw 330. The motion conversion mechanism has, for example, a screw shaft and a screw nut that screws onto the screw shaft. Balls or rollers may be provided between the screw shaft and the screw nut. The drive source for moving the screw 330 forward and backward is not limited to the injection motor 350, but may be, for example, a hydraulic cylinder.

[0085] The pressure detector 360 detects the pressure transmitted between the injection motor 350 and the screw 330. The pressure detector 360 is installed in the force transmission path between the injection motor 350 and the screw 330 and detects the pressure acting on the pressure detector 360.

[0086] The pressure detector 360 sends a signal indicating its detection result to the controller 700. The detection result from the pressure detector 360 is used for controlling and monitoring the pressure the screw 330 receives from the molding material, the back pressure on the screw 330, and the pressure acting from the screw 330 on the molding material.

[0087] The injection device 300 performs metering, filling, and holding pressure processes, etc., under the control of the controller 700.

[0088] In the weighing process, the weighing motor 340 is driven to rotate the screw 330 at a set rotational speed, and the molding material is fed forward along the helical groove of the screw 330. As this occurs, the molding material is gradually melted. As the liquid molding material is fed forward by the screw 330 and accumulates at the front of the cylinder 310, the screw 330 is retracted. The rotational speed of the screw 330 is detected, for example, using the weighing motor encoder 341. The weighing motor encoder 341 detects the rotation of the weighing motor 340 and sends a signal indicating the detection result to the controller 700.

[0089] Furthermore, the screw rotation speed detector used to detect the rotation speed of screw 330 is not limited to the metering motor encoder 341, but a general-purpose detector can be used.

[0090] In the metering process, the injection motor 350 may be driven to apply a set back pressure to the screw 330 in order to limit the rapid retraction of the screw 330. The back pressure on the screw 330 is detected, for example, using a pressure detector 360. The pressure detector 360 sends a signal indicating the detection result to the controller 700. The metering process is completed when the screw 330 has retracted to the metering completion position and a predetermined amount of molding material has accumulated in front of the screw 330.

[0091] In the filling process, the injection motor 350 is driven to advance the screw 330 at a set speed, filling the cavity space 14 in the mold device 10 with the liquid molding material accumulated in front of the screw 330. The position and speed of the screw 330 are detected, for example, using the injection motor encoder 351. The injection motor encoder 351 detects the rotation of the injection motor 350 and sends a signal indicating the detection result to the controller 700. When the position of the screw 330 reaches the set position, a switch from the filling process to the holding pressure process (so-called V / P switching) is performed. The position at which the V / P switching occurs is also called the V / P switching position. The set speed of the screw 330 may be changed according to the position and time of the screw 330.

[0092] Furthermore, during the filling process, after the screw 330 reaches the set position, the screw 330 may be temporarily stopped at that set position, and then the V / P switching may be performed. Immediately before the V / P switching, instead of stopping the screw 330, the screw 330 may be moved forward or backward at a slow speed. In addition, the screw position detector that detects the position of the screw 330 and the screw speed detector that detects the speed of the screw 330 are not limited to the injection motor encoder 351, but general-purpose ones can be used.

[0093] In the holding pressure process, the injection motor 350 is driven to push the screw 330 forward, maintaining the pressure of the molding material at the front end of the screw 330 (hereinafter also referred to as "holding pressure") at a set pressure, and pushing the molding material remaining in the cylinder 310 toward the mold device 10. This allows for the replenishment of molding material lost due to cooling shrinkage within the mold device 10. The holding pressure is detected, for example, using a pressure detector 360. The pressure detector 360 sends a signal indicating its detection result to the controller 700. The set value of the holding pressure may be changed according to the elapsed time from the start of the holding pressure process, etc.

[0094] During the holding pressure process, the molding material in the cavity space 14 within the mold device 10 is gradually cooled, and upon completion of the holding pressure process, the entrance to the cavity space 14 is sealed with solidified molding material. This state is called a gate seal, and prevents backflow of molding material from the cavity space 14. After the holding pressure process, the cooling process begins. During the cooling process, the molding material in the cavity space 14 is solidified. To shorten the molding cycle time, a metering process may be performed during the cooling process.

[0095] In this embodiment, the injection device 300 is an in-line screw type, but a pre-plasticization type or the like may also be used. In a pre-plasticization injection device, the molding material molten in a plasticizing cylinder is supplied to the injection cylinder, and the molding material is injected from the injection cylinder into the mold device. A screw is rotatably or rotatably and reciprocally arranged in the plasticizing cylinder, and a plunger is rotatably arranged in the injection cylinder.

[0096] Furthermore, although the injection device 300 in this embodiment is a horizontal type with the axial direction of the cylinder 310 being horizontal, it may also be a vertical type with the axial direction of the cylinder 310 being vertical. The clamping device combined with the vertical injection device 300 may be vertical or horizontal. Similarly, the clamping device combined with the horizontal injection device 300 may be horizontal or vertical.

[0097] <<Mobile device>> The moving device 400 moves the injection device 300 forward and backward relative to the mold device 10. The moving device 400 also presses the nozzle 320 against the mold device 10, generating nozzle touch pressure. The moving device 400 includes a hydraulic pump 410, a motor 420 as a drive source, and a hydraulic cylinder 430 as a hydraulic actuator, etc.

[0098] In the following description of the moving device 400, similar to the description of the injection device 300, the direction in which the injection device 300 approaches the mold device 10 (left direction in Figures 1 and 2) will be referred to as the front, and the direction in which the injection device 300 moves away from the mold device 10 (right direction in Figures 1 and 2) will be referred to as the rear.

[0099] In Figures 1 and 2, the moving device 400 is positioned on one side of the cylinder 310 of the injection device 300, but it may also be positioned on both sides of the cylinder 310, or symmetrically around the cylinder 310.

[0100] The hydraulic pump 410 has a first port 411 and a second port 412. The hydraulic pump 410 is a bidirectional rotatable pump, and by switching the rotation direction of the motor 420, it can draw in working fluid (e.g., oil) from either the first port 411 or the second port 412 and discharge it from the other to generate hydraulic pressure. The hydraulic pump 410 can also draw working fluid from a tank and discharge it from either the first port 411 or the second port 412.

[0101] Motor 420 operates the hydraulic pump 410. Motor 420 drives the hydraulic pump 410 with a rotational direction and rotational torque corresponding to the control signal from the controller 700. Motor 420 may be an electric motor or an electric servo motor.

[0102] The hydraulic cylinder 430 comprises a cylinder body 431, a piston 432, and a piston rod 433. The cylinder body 431 is fixed to the injection device 300. The piston 432 divides the inside of the cylinder body 431 into a front chamber 435 as a first chamber and a rear chamber 436 as a second chamber. The piston rod 433 is fixed to the fixed platen 110.

[0103] The front chamber 435 of the hydraulic cylinder 430 is connected to the first port 411 of the hydraulic pump 410 via the first passage 401. The hydraulic fluid discharged from the first port 411 is supplied to the front chamber 435 via the first passage 401, pushing the injection device 300 forward. As the injection device 300 moves forward, the nozzle 320 is pressed against the fixed mold 11. The front chamber 435 functions as a pressure chamber that generates nozzle touch pressure on the nozzle 320 by the pressure of the hydraulic fluid supplied from the hydraulic pump 410.

[0104] Meanwhile, the rear chamber 436 of the hydraulic cylinder 430 is connected to the second port 412 of the hydraulic pump 410 via the second passage 402. The working fluid discharged from the second port 412 is supplied to the rear chamber 436 of the hydraulic cylinder 430 via the second passage 402, pushing the injection device 300 backward. The injection device 300 is retracted, and the nozzle 320 is separated from the fixed mold 11.

[0105] Furthermore, the moving device 400 is not limited to a configuration including a hydraulic cylinder 430. For example, instead of the hydraulic cylinder 430, an electric motor and a motion conversion mechanism that converts the rotational motion of the electric motor into the linear motion of the injection device 300 may be used.

[0106] <<Controller>> The controller 700 (an example of a control device) directly transmits control signals to the clamping device 100, ejector device 200, injection device 300, and moving device 400, etc., and performs various controls related to the injection molding machine 1.

[0107] The controller 700 may be implemented using any hardware, or any combination of hardware and software. For example, the controller 700 is centered around a computer having a CPU 701, a memory device 702, an auxiliary storage device 703, and an interface device 704 for external input / output. The controller 700 performs various controls by loading a program installed in the auxiliary storage device 703 into the memory device 702 and having the CPU 701 execute it. The controller 700 also receives and outputs external signals through the interface device 704. For example, the controller 700 is connected to the management device 2 via a communication line NW using the interface device 704. The controller 700 may also be connected to another injection molding machine 1 (or its controller 700) via a communication line NW using the interface device 704. Furthermore, the controller 700 may obtain a program to be installed on itself (the auxiliary storage device 703) from a predetermined recording medium via the interface device 704. The specified recording media include, for example, flexible disks, CDs (Compact Discs), DVDs (Digital Versatile Discs), BDs (Blu-ray® Discs), SD memory cards, USB (Universal Serial Bus) memory, etc. The controller 700 may also obtain (download) programs from an external computer (e.g., management device 2) via the interface device 704.

[0108] The functions of controller 700 may be implemented by a single controller 700, or they may be shared among multiple controllers (for example, a higher-level controller 700A and a lower-level controller 700B, etc.), as described later (see Figure 2).

[0109] The controller 700 causes the injection molding machine 1 to repeatedly perform processes such as mold closing, mold clamping, and mold opening, thereby repeatedly manufacturing molded products. In addition, the controller 700 causes the injection device 300 to perform processes such as metering, filling, and holding pressure during the mold clamping process.

[0110] A series of operations to obtain a molded product, such as the operation from the start of the metering process by the injection device 300 to the start of the metering process by the next injection device 300, is also called a "shot" or "molding cycle." The time required for one shot is also called the "molding cycle time."

[0111] A single molding cycle consists of, for example, a weighing process, a mold closing process, a mold clamping process, a filling process, a holding pressure process, a cooling process, a mold opening process, and an ejection process, in that order. This order is the order in which each process begins. The filling process, the holding pressure process, and the cooling process take place between the start and end of the mold clamping process. The end of the mold clamping process coincides with the start of the mold opening process.

[0112] Furthermore, in order to shorten the molding cycle time, multiple processes may be performed simultaneously. For example, the metering process may be performed during the cooling process of the previous molding cycle, in which case the mold closing process may be performed at the beginning of the molding cycle. Also, the filling process may be started during the mold closing process. Also, the ejection process may be started during the mold opening process. In addition, if an on-off valve is provided to open and close the flow path of the nozzle 320 of the injection device 300, the mold opening process may be started during the metering process. This is because even if the mold opening process is started during the metering process, if the on-off valve closes the flow path of the nozzle 320, the molding material will not leak from the nozzle 320.

[0113] The controller 700 is connected to the operating device 750 and the display device 760, etc.

[0114] The operating device 750 (an example of an input device) receives input from the user regarding the injection molding machine 1 and outputs a signal corresponding to the input to the controller 700. This allows the user to operate the injection molding machine 1.

[0115] Furthermore, the injection molding machine 1 (controller 700) may be configured to accept input from the user via an external device. This allows the user to remotely operate the injection molding machine 1, for example. In this case, image data from an imaging device capable of capturing the operating status of the injection molding machine 1 may be transmitted to the external device. This allows the external device to operate the injection molding machine 1 while checking its operating status remotely.

[0116] For example, the controller 700 may be able to receive user input from the management device 2 or other injection molding machines 1 via a communication line NW. The controller 700 may also be able to receive user input from a terminal device via a communication line NW. The terminal device may be a stationary terminal device such as a desktop PC, or a portable terminal device such as a smartphone, tablet, or laptop PC.

[0117] The display device 760 displays various images under the control of the controller 700.

[0118] The display device 760 displays, for example, an operation screen related to the injection molding machine 1 corresponding to the operation input in the operating device 750.

[0119] The operation screen displayed on the display device 760 is used for settings related to the injection molding machine 1. Settings related to the injection molding machine 1 include, for example, setting the molding conditions for the injection molding machine 1 (specifically, inputting setting values). These settings also include, for example, settings for selecting the types of detected values ​​from various sensors related to the injection molding machine 1 that are recorded as logging data during molding operations. These settings also include, for example, settings for the display specifications of the detected values ​​(actual values) from various sensors related to the injection molding machine 1 during molding operations on the display device 760 (for example, the types of actual values ​​to display and how they are displayed). Multiple operation screens are provided and can be switched between or overlaid on the display device 760. The user can perform settings related to the injection molding machine 1 (including inputting setting values) by operating the control device 750 while viewing the operation screen displayed on the display device 760.

[0120] Furthermore, the display device 760 displays an information screen that provides the user with various information corresponding to operations on the operation screen, for example, under the control of the controller 700. Multiple information screens are available and can be switched between or overlaid on the display device 760. For example, the display device 760 displays settings related to the injection molding machine 1 (for example, settings related to the molding conditions of the injection molding machine 1). Also, for example, the display device 760 displays management information (for example, information related to the operating performance of the injection molding machine 1).

[0121] The operating device 750 and the display device 760 may be configured as, for example, a touch panel type display and integrated together.

[0122] In this embodiment, the operating device 750 and the display device 760 are integrated, but they may be provided separately. Furthermore, multiple operating devices 750 may be provided.

[0123] [Hardware configuration of the control system for injection molding machines] Next, with reference to Figure 3, the hardware configuration of the control system for injection molding machine 1 will be described.

[0124] Figure 3 shows an example of the hardware configuration of the control system for injection molding machine 1.

[0125] As shown in Figure 3, the control system of the injection molding machine 1 includes a controller 700, a driver 710, and a sensor 720.

[0126] The controller 700 includes a CPU 701 and an FPGA (Field Programmable Gate Array) 705.

[0127] The CPU 701 (an example of a control processing unit) performs control processing related to the operation of the injection molding machine 1 (hereinafter referred to as "motion control processing") based on data acquired from the driver 710 and sensor 720, for example, through the FPGA 705. Motion control processing includes servo control processing for electric motors. Specifically, the CPU 701 activates control functions related to the operation of the injection molding machine 1 (functions of the control unit 7001 described later) in response to predetermined interrupt requests (hereinafter simply referred to as "interrupt requests") periodically output from the FPGA 705, and executes control processing related to the operation of the injection molding machine 1. The CPU 701 then outputs data corresponding to control commands to the driver 710, etc., through the FPGA 705.

[0128] The interrupt requests dealt with in this example are so-called hardware interrupt requests output from hardware outside the CPU 701 (FPGA 705 in this example). The CPU 701 performs relatively low-priority processes (hereinafter referred to as "low-priority processes") in the background of relatively high-priority processes (hereinafter referred to as "high-priority processes"), such as actuator motion control processes and servo control processes performed as motion control processes. While performing low-priority processes, when the CPU 701 receives an interrupt request for a high-priority process from FPGA 705, it calls the interrupt handler corresponding to the interrupt request. The CPU 701 then uses the interrupt handler to start the high-priority process corresponding to the interrupt request. In this way, the CPU 701 can perform low-priority processes while appropriately executing periodically high-priority processes at predetermined control cycles (an example of a predetermined cycle).

[0129] FPGA 705 (an example of a request output unit) functions as an input / output interface to the outside of the controller 700. That is, the interface device 704 includes FPGA 705.

[0130] FPGA705 receives control data for the actuator from driver710 (hereinafter referred to as "control data") and transmits data equivalent to control commands to driver710 in response to requests from CPU701.

[0131] Furthermore, FPGA 705 receives measurement data regarding the status of the injection molding machine 1 from sensor 720, and transmits data equivalent to control commands regarding the measurement operation of sensor 720 in response to requests from CPU 701.

[0132] Furthermore, the FPGA 705 periodically outputs interrupt requests to the CPU 701 to activate control functions related to the operation of the injection molding machine 1. Specifically, the FPGA 705 may repeatedly set a timer to terminate at predetermined control cycles and output an interrupt request when the timer terminates.

[0133] The driver 710 drives the actuators in response to control commands from the controller 30. The actuators are, for example, electric motors, and the driver 710 outputs a drive current to the electric motors in response to control commands from the controller 30. This allows the controller 700 (CPU 701) to control the electric motors through the driver 710 and achieve the desired operation of the injection molding machine 1. The electric motors include, for example, a clamping motor 160, a mold thickness adjustment motor 183, an ejector motor 210, a metering motor 340, an injection motor 350, and a motor 420.

[0134] Sensor 720 outputs measurement data regarding the state of the injection molding machine 1. Sensor 720 includes, for example, an encoder capable of measuring the rotational position of an electric motor. The encoders include, for example, a clamping motor encoder 161, a mold thickness adjustment motor encoder 184, an ejector motor encoder 211, a metering motor encoder 341, and an injection motor encoder 351. Sensor 720 also includes current sensors and voltage sensors that detect voltages and currents in the power system, including the current and voltage of the electric motor. Furthermore, sensor 720 includes various sensors (for example, a tie bar strain detector 141, a temperature detector 314, and a pressure detector 360, etc.) capable of measuring forces, temperatures, and pressures acting on predetermined locations of the injection molding machine 1.

[0135] [Controller Functional Configuration] Next, the functional configuration of the controller 700 will be described with reference to Figure 4.

[0136] Figure 4 is a block diagram showing an example of the functional configuration of the controller 700.

[0137] As shown in Figure 4, the controller 700 includes a control unit 7001, a display processing unit 7002, a storage unit 7003, a setting unit 7004, and a storage unit 7005. The functions of the control unit 7001, the display processing unit 7002, and the setting unit 7004 are realized, for example, by loading a program installed in the auxiliary storage device 703 into the memory device 702 and executing it on the CPU 701. The functions of the storage units 7003, 7005, and others are realized, for example, by a storage area defined in the auxiliary storage device 703 of the controller 700.

[0138] The control unit 7001 controls the operation of the injection molding machine 1 based on data input from the driver 710 and sensor 720. As described above, the functions of the control unit 7001 are activated and executed by interrupt requests periodically output from the FPGA 705.

[0139] The display processing unit 7002 displays an information screen on the display device 760 in response to user input received through the operating device 750. Specifically, the display processing unit 7002 displays a screen (hereinafter referred to as the "settings screen") for the user to configure settings related to the interrupt request described above using the operating device 750.

[0140] The settings related to interrupt requests include settings for the timing of interrupt request output from FPGA705 (for example, the setting of the correction time T1 described later). The settings related to interrupt requests also include settings for the timing of the start of motion control processing in response to the interrupt request (for example, the setting of the waiting time T2 described later).

[0141] The memory unit 7003 stores (registers) the settings related to the interrupt request described above (for example, the settings for the correction time T1 and waiting time T2 described later).

[0142] The setting unit 7004 performs the settings related to the interrupt request described above. For example, the setting unit 7004 automatically performs the settings related to the interrupt request when triggered by a predetermined input from the user received through the operating device 750, or when conditions other than predetermined inputs are met. Conditions other than predetermined inputs (hereinafter referred to as "automatic setting start conditions") may include, for example, the first startup (power-on) of the injection molding machine 1 in the inspection process before factory shipment, and the first startup after initialization of the controller 700 of the injection molding machine 1. The automatic setting start conditions may also include the first startup after changes (updates) of predetermined hardware such as actuators of the injection molding machine 1 or predetermined software such as programs related to motion control processing. Furthermore, for example, the setting unit 7004 may perform the settings related to the interrupt request in response to user input received through the operating device 750, i.e., input corresponding to the settings desired by the user. In other words, the settings related to the interrupt request may be performed manually.

[0143] Furthermore, the setting unit 7004 may restrict the function of automatically or manually configuring settings related to interrupt requests in response to user input. This prevents situations where the content of the interrupt request settings is unnecessarily changed, which could adversely affect the operation of the injection molding machine 1.

[0144] For example, the setting unit 7004 identifies the user operating the injection molding machine 1 and determines whether to allow or disallow the function to configure interrupt requests in response to input from the operating device 750, depending on the user. This prevents situations where, for example, a user with little knowledge of interrupt requests might accidentally change the settings related to interrupt requests. Specifically, a registration information database may be constructed that links the permission or disallowance of interrupt request settings to identification information defined for each user (hereinafter referred to as "user identification information") (for example, a user's ID (Identifier) ​​or image data for facial recognition). This allows the setting unit 7004 to identify the user using the operating device 750 based on the ID input from the operating device 750 or the image data acquired during facial recognition.

[0145] Furthermore, for example, the setting unit 7004 may restrict the function of setting interrupt requests when input from a user is received through an external device of the injection molding machine 1. Specifically, the function of setting interrupt requests in response to input from some or all of the external device may be prohibited. For example, if the settings for interrupt requests are changed in response to input from a user using an external device, where it is difficult to relatively grasp the operating status of the injection molding machine 1, there is a possibility that a delay in addressing the issue may occur if the change negatively affects the operation of the injection molding machine 1. Also, for example, if the settings for interrupt requests can be changed in response to input through an external device, there is a possibility of security problems.

[0146] The memory unit 7005 stores various data used by the setting unit 7004. For example, the aforementioned registration information database may be constructed in the memory unit 7005.

[0147] [Specific examples of controller operation] Next, with reference to Figure 5, a specific example of the operation of the controller 700 will be described.

[0148] Figure 5 is a timing chart showing an example of the operation of the controller 700. Specifically, Figure 5 shows the "data output", "data preparation", and "interrupt timer" in the controller. This is a timing chart showing the status of "interrupt processing" and "motion control processing".

[0149] "Data output" indicates the output status of data (for example, control data to the driver 710) resulting from motion control processing by the controller 700 (control unit 7001).

[0150] "Data preparation" indicates the preparation status of data used for motion control processing by the controller 700 (control unit 7001) (for example, data received from the driver 710 and sensor 720, or output data from the motion control processing in the previous control cycle). The data used for motion control processing is stored in the internal memory of the FPGA 705, and the CPU 701 can access the internal memory of the FPGA 705 and use this data to execute motion control processing.

[0151] The "interrupt timer" indicates the operating state of the timer that the FPGA705 sets up to output interrupt requests. In the diagram, the rising edge of the timer's operating state represents the timer start, and the falling edge represents the timer end. The interrupt request is output when the timer ends.

[0152] "Interrupt handling" indicates the status (whether or not it is performed) of the pre-processing (interrupt handling) that causes motion control processing to be executed by interrupting low-priority processing in response to an interrupt request output from FPGA705.

[0153] "Motion control processing" indicates the status (whether or not it is being performed) of the motion control processing executed by CPU 701.

[0154] In this example, the interrupt request setting has been modified from its initial state, i.e., a predetermined reference state. The reference state means that the timing of the interrupt request is aligned with the reference timing that triggers the start of motion control processing. In this example, the reference state means that the timing of the interrupt request is aligned with the timing at which the data used in motion control processing is expected to be ready.

[0155] Specifically, assuming that the interrupt request output cycle, i.e., the control cycle of the motion control process, remains unchanged, the timing of the interrupt request is advanced by a correction time T1 from the reference state. More specifically, the end timing of the timer for the FPGA705's interrupt request is advanced by a correction time T1 from the reference state.

[0156] Therefore, as shown in Figure 5, the timer ends before the data is ready, and FPGA 705 outputs an interrupt request to CPU 701 (time t11).

[0157] Furthermore, when the FPGA705 outputs an interrupt request, it starts the next timer (around time t12).

[0158] CPU701 starts interrupt processing in response to the interrupt request output from FPGA705 (time t12).

[0159] In this example, the setting for interrupt requests has been changed from its initial state, specifically regarding the timing of the start of motion control processing in response to an interrupt request. The initial state is, for example, one where the start timing of motion control is synchronized with the completion of the interrupt processing. In other words, in the initial state, motion control processing starts immediately after the interrupt processing is completed.

[0160] Specifically, the timing of the start of motion control processing has been changed to the later of the following two timings: the timing when interrupt processing is completed, and the timing when a waiting time T2 has elapsed since the start of interrupt processing.

[0161] This interrupt handling process takes a relatively long time, and the timing of the end of the waiting time T2 and the completion of the interrupt handling process are approximately the same (time t13). Therefore, CPU 701 starts the motion control process at that time.

[0162] In this example, the waiting time T2 is set so that the start of the motion control process is approximately simultaneous with (for example, immediately after) the timing when the preparation of the data used for the motion control process in FPGA 705 is expected to be completed. Therefore, the motion control process starts immediately after the data is ready. This allows CPU 701 to start the motion control process after the latest data is ready. As a result, CPU 701 can appropriately control the operation of injection molding machine 1. Also, because motion control starts immediately after the data used for the motion control process is ready, controller 700 can more easily ensure real-time performance for the motion control process.

[0163] Furthermore, the waiting time T2 may be set arbitrarily, as long as the motion control processing starts after the timing at which it is expected that the data used for the motion control processing has been prepared.

[0164] Once the CPU 701 completes the motion control processing for the current control cycle, it then outputs data related to the execution results of the motion control processing for that cycle (time t14). The output data is stored (written) to the internal memory of the FPGA 705, for example.

[0165] After CPU701 has finished outputting data and the timer that started after the previous interrupt request has finished, FPGA705 outputs an interrupt request to CPU701 (time t15).

[0166] CPU701 starts interrupt processing in response to the interrupt request output from FPGA705 (time t16).

[0167] This interrupt processing was completed in a relatively short time (time t17). Therefore, after the interrupt processing was completed, CPU 701 waited for the waiting time T2 from the start of the interrupt processing to elapse before starting the motion control processing (time t18). As a result, even if the interrupt processing is completed relatively quickly, if the waiting time T2 is set appropriately, CPU 701 can start the motion control processing after the data used for the motion control processing has been prepared.

[0168] Once the motion control processing for the current control cycle is complete, CPU701 outputs data related to the execution results of the motion control processing for that control cycle (time t19).

[0169] In both the previous and current control cycles, the motion control processing begins after a waiting time T2 has elapsed since the start of the interrupt processing. Therefore, the controller 700 can set the timing of data output related to the execution result of the motion control processing (data output time T0), which is based on the completion of preparation of the data used for the motion control processing, to be approximately the same. Thus, the controller 700 can more appropriately ensure real-time performance for the motion control processing.

[0170] Alternatively, instead of setting a waiting time T2, FPGA705 may output a notification to CPU701 indicating that the data used for motion control processing is ready. In this case, the timing of the start of motion control processing will be changed to the later of the timing when the interrupt processing is completed and the timing when the data is ready. This allows controller700 to start motion control processing in accordance with the completion of data preparation.

[0171] [Configuration process related to interrupt requests] Next, referring to Figure 6, the configuration process for interrupt requests by the controller 700 will be explained.

[0172] Figure 6 is a flowchart illustrating an example of the configuration process for interrupt requests by the controller 700. This flowchart may be executed, for example, when a predetermined input is received from the user via the operating device 750 or the like. This flowchart may also be executed, for example, when the above-mentioned automatic configuration start conditions are met.

[0173] As shown in Figure 6, in step S102, the setting unit 7004 determines whether the function for automatically configuring settings related to interrupt requests (hereinafter referred to as the "automatic setting function") is enabled.

[0174] The automatic setting function may be configured to be selectable by the user, for example, through an operating device 750. Furthermore, when the above-mentioned automatic setting start conditions are met, the automatic setting start conditions may be set to an active state as the initial state, or they may be set to an active or inactive state as the initial state according to the specifications of each customer to whom the injection molding machine 1 is delivered.

[0175] If the automatic setting function is enabled, the setting unit 7004 proceeds to step S104; otherwise, it terminates this flowchart.

[0176] In step S104, the setting unit 7004 actually operates the functions of the control unit 7001 and measures the time required from the output (occurrence) of the interrupt request to the start of the motion control processing in the initial state of the correction time T1 and waiting time T2. That is, the setting unit 7004 measures the time required from the output of the interrupt request to the completion of the interrupt processing.

[0177] Once the processing in step S104 is complete, the controller 700 proceeds to step S106.

[0178] In step S106, the setting unit 7004 determines whether the number of measurements taken for the time required from the output (occurrence) of an interrupt request to the start of motion control processing is equal to or greater than the set number Nth (an integer greater than or equal to 1). If the number of measurements is not equal to or greater than the set number Nth, the setting unit 7004 returns to step S104 and repeats the processes in steps S104 and S106 in the control cycle of the next motion control processing. On the other hand, if the number of measurements is equal to or greater than the set number Nth, the setting unit 7004 stops the actual operation of the control unit 7001 and proceeds to step S108.

[0179] Furthermore, during the normal operation of the injection molding machine 1, the time required from the output of an interrupt request to the completion of the interrupt processing may be measured as background processing, and the measurement results may be used. In this case, the processing in steps S104 and S106 is omitted.

[0180] In step S108, the setting unit 7004 sets the correction time T1 and the waiting time T2 based on the measurement result of the setting count Nth.

[0181] For example, the setting unit 7004 may set the correction time T1 based on the maximum value among the measurement results for the setting count Nth. Specifically, the setting unit 7004 may set the correction time T1 to the maximum value or a value greater than or equal to the measurement result for the setting count Nth. This allows the interrupt processing to be terminated before the timing at which the preparation of data used for motion control processing is expected to be completed. Therefore, the controller 700 can start the motion control processing in accordance with the completion of data preparation by appropriately setting the waiting time T2. Specifically, the setting unit 7004 should set the expected time required from the output of the interrupt request to the start of the interrupt processing to a value greater than or equal to the determined correction time T1 minus the value obtained.

[0182] Furthermore, for example, the setting unit 7004 may set the correction time T1 and waiting time T2 based on the average value of the measurement results for the number of setting attempts Nth.

[0183] When the processing in step S108 is completed, the controller 700 terminates the processing of this flowchart.

[0184] Thus, in this example, the controller 700 can set the correction time T1 and waiting time T2 based on the actual time required from the output of the interrupt request to the completion of the interrupt processing.

[0185] [Specific example of a settings screen] Next, with reference to Figure 7, we will explain the settings screen for configuring interrupt requests.

[0186] Figure 7 shows an example of a settings screen (settings screen 70) displayed on the display device 760.

[0187] Furthermore, a similar settings screen may be displayed on an external management device 2 or the aforementioned terminal device, which is connected to the injection molding machine 1 via a communication line NW. This allows users of the injection molding machine 1, such as administrators and operators, to check the settings related to interrupt requests and to make settings related to interrupt requests through the management device 2 or the aforementioned terminal device.

[0188] As shown in Figure 7, the settings screen 70 includes a processing content display unit 71, a correction time display unit 72, a waiting time display unit 73, and icons 74 to 77.

[0189] The processing content display unit 71 displays the processing flow from the output of the interrupt request to the start of the motion control processing as a timing chart, and shows the time intervals corresponding to the correction time T1 and waiting time T2. This allows the user to understand the processing flow from the output of the interrupt request to the start of the motion control processing, and to specifically confirm the time intervals corresponding to the correction time T1 and waiting time T2 within that flow.

[0190] The correction time display unit 72 displays the current setting value of the correction time T1.

[0191] The waiting time display unit 73 displays the current setting value of the waiting time T2.

[0192] Icon 74 indicates whether the automatic setting function is enabled or disabled, that is, whether settings related to interrupt requests can be configured automatically or manually. In this example, the automatic correction function is enabled.

[0193] Icon 75 is the target of operation for initiating the setting of the correction time T1 and waiting time T2 by the automatic setting function. By operating icon 750 via the operating device 750, the user can have the controller 700 automatically set the correction time T1 and waiting time T2 based on the flowchart in Figure 6 described above.

[0194] Icon 76 is the target of operation for switching to a control state in which settings related to interrupt requests can be manually configured. When icon 76 is operated via the operating device 750 or the like, it may be possible to input values ​​into the input boxes for correction time T1 and waiting time T2 in the correction time display unit 72 and the waiting time display unit 73.

[0195] Furthermore, as described above, if settings related to interrupt requests in response to user input received by the operating device 750, etc., are restricted (prohibited), icons 75 and 76 may be displayed in an inoperable state (for example, grayed out). Also, the values ​​that can be entered for the correction time T1 and waiting time T2 may, of course, be limited in advance to a range that does not adversely affect the motion control process.

[0196] Icon 77 is the target of an operation to return to a specific screen (for example, the home screen).

[0197] In this way, the user can check the settings related to interrupt requests (the settings for correction time T1 and waiting time T2) through the settings screen 70. Furthermore, the user can have the controller 700 configure (change) the settings related to interrupt requests, either using the automatic configuration function or manually, through the settings screen 70.

[0198] [Effect] Next, with reference to Figure 8, the operation of the injection molding machine 1 (controller 700) according to this embodiment will be explained.

[0199] Figure 8 is a timing chart showing the operation of the controller of the injection molding machine in the comparative example. Hereafter, components similar to those in the controller 700 in the comparative example will be described using the same names without reference numerals.

[0200] In this example, the timer is set to terminate at the time when it is expected that the data used for motion control processing in the FPGA is ready.

[0201] As shown in Figure 8, the FPGA outputs an interrupt request in conjunction with the end of the timer (time t21).

[0202] Furthermore, when the FPGA outputs an interrupt request, it starts the next timer (around time t22).

[0203] The CPU starts interrupt processing in response to the interrupt request output from the FPGA (time t22).

[0204] The CPU starts motion control processing once the interrupt request is completed (time t23). In this control cycle, the interrupt processing is completed in a relatively short time.

[0205] The CPU outputs data regarding the execution results of the motion control process for the current control cycle (time t24). This output data is stored (written) to the FPGA's internal memory, for example.

[0206] After the CPU has finished outputting data, and the timer that started after the previous interrupt request has finished, the FPGA, as before, outputs an interrupt request to the CPU when the data to be used for motion control processing is ready (time t25).

[0207] CPU701 has started interrupt processing in response to the interrupt request output from FPGA (time t26).

[0208] CPU701 starts motion control processing after interrupt processing is complete (time t27). In this control cycle, interrupt processing takes relatively longer than in the previous control cycle (dotted line in the figure). This is because the time required for interrupt processing can vary due to factors such as interrupt processing overhead and cache hits during interrupt processing.

[0209] Once the motion control processing for the current control cycle is complete, CPU 701 outputs data related to the execution results of the motion control processing for that control cycle (time t28).

[0210] In the comparative example, as described above, an interrupt request is output in conjunction with the completion of preparation of the data used for motion control processing. Therefore, the timing of data output related to the execution result of motion control processing (data output time T0c), based on the completion of preparation of the data used for motion control processing, is affected by the length of the interrupt processing time. In other words, if the interrupt processing time is relatively long, the start timing of motion control processing, based on the completion of preparation of the data required for motion control processing, will be relatively delayed, which may affect the real-time nature of motion control processing.

[0211] In contrast, in this embodiment, the controller 700 outputs an interrupt request before the occurrence of a trigger that serves as the basis for starting motion control processing (hereinafter referred to as the "start trigger"), and starts the control processing after the occurrence of the trigger. Specifically, the start trigger may be the completion of preparation of the data necessary for motion control processing.

[0212] This allows the controller 700 to perform interrupt processing before the start trigger. Therefore, it is possible to suppress the impact of variations in the time required for interrupt processing on the start timing of motion control processing. Furthermore, even if the interrupt processing finishes relatively early, the motion control processing will start after the start trigger, so motion control processing will not be performed before the start trigger. Thus, the controller 700 can more appropriately achieve real-time control processing related to the operation of the injection molding machine 1.

[0213] Furthermore, the same technology may be employed for other control processes in the injection molding machine 1 besides motion control processing. In this case, the timing of the interrupt request output (correction time T1) and the timing of the start of the other control processes (waiting time T2) may be appropriately set in accordance with the trigger that serves as the basis for starting the other control processes.

[0214] Furthermore, in this embodiment, if the controller 700 has completed preparations to start the motion control process after outputting an interrupt request but before the start trigger occurs, it may wait for the trigger to occur and then start the motion control process.

[0215] This allows the controller 700 to initiate motion control processing in conjunction with the occurrence of a start trigger. As a result, the controller 700 can more effectively achieve real-time control of the injection molding machine 1's operation.

[0216] Furthermore, in this embodiment, the controller 700 may start motion control processing after a predetermined time (waiting time T2) has elapsed since the start of interrupt processing based on the interrupt request.

[0217] As a result, the controller 700 can start motion control processing after the start trigger occurs, by setting the waiting time T2 appropriately.

[0218] Furthermore, in this embodiment, the controller 700 may measure the time required from the output of an interrupt request to the completion of the interrupt processing multiple times, and set the output timing of the interrupt request (correction time T1) and the waiting time T2 based on the measurement results.

[0219] This allows the controller 700 to more appropriately set the interrupt request output timing (correction time T1) and the waiting time T2, taking into account the actual variation in the time required from the output of the interrupt request to the completion of the interrupt processing.

[0220] Furthermore, it is also acceptable to set only the interrupt request output timing (correction time T1) and the waiting time T2. As mentioned above, if a notification of data readiness is output from FPGA705 to CPU701, motion control processing can be started in accordance with the data readiness. Also, if no notification of data readiness is output, the correction time T1 can be set to a relatively small value, ensuring that the timing of interrupt processing completion is always after the start trigger (data readiness).

[0221] Furthermore, in this embodiment, when a predetermined input is received by the operating device 750, the display device 760 may display settings related to the start of motion control processing based on the output of an interrupt request, including the timing of the output of the interrupt request.

[0222] This allows the injection molding machine 1 to allow the user to confirm the settings related to the start of motion control processing based on the output of an interrupt request (for example, the settings for correction time T1 and waiting time T2).

[0223] [Transformation, modification] While embodiments of the injection molding machine management system SYS, etc. have been described above, this disclosure is not limited to the embodiments described above, and various modifications and changes are possible within the scope of the gist described in the claims.

[0224] For example, the timing of the output of the interrupt request and the timing of the start of the control processing based on the interrupt request in the above-described embodiment may be adopted for control of the operation of other control machines. Other machines are, for example, industrial machines or industrial robots used in factories.

[0225] Finally, this application claims priority based on Japanese Patent Application No. 2021-060659, filed on 31 March 2021, and the entire contents of the Japanese Patent Application are incorporated herein by reference. [Explanation of Symbols]

[0226] 1. Injection molding machine (industrial machinery) 2 Management device 100 Mold clamping device 200 Ejector Devices 300 Injection device 400 Mobile device 700 Controller (Control Device) 701 CPU (Control Unit) 702 Memory Device 703 Auxiliary storage 704 Interface device 705 FPGA (Request Output Section) 710 Driver 720 sensors 750 Operating device (input device) 760 Display device 7001 Control Unit 7002 Display Processing Unit 7003 Storage section 7004 Settings Section 7005 Storage section SYS Injection Molding Machine Management System

Claims

1. A clamping device for clamping the mold equipment, An injection device for filling the mold device, which has been clamped by the clamping device, After the molding material filled by the injection device has cooled and solidified, an ejector device removes the molded product from the mold device, The system includes a control device that outputs an interrupt request at predetermined intervals and performs control processing related to the operation of the injection molding machine in response to the interrupt request, The control device outputs the interrupt request before the occurrence of the trigger that serves as the basis for starting the control process, and starts the control process after the occurrence of the trigger. Injection molding machine.

2. The trigger indicates that the data necessary for the control process is ready. The injection molding machine according to claim 1.

3. If the control device completes preparation for starting the control process after the output of the interrupt request but before the occurrence of the trigger, it waits for the occurrence of the trigger and then starts the control process. The injection molding machine according to claim 1 or 2.

4. The control device starts the control process after a predetermined time has elapsed since the start of the interrupt processing based on the interrupt request. An injection molding machine according to any one of claims 1 to 3.

5. The control device measures the time required from the output of the interrupt request to the completion of the interrupt processing based on the interrupt request multiple times, and sets the output timing of the interrupt request based on the measurement results. An injection molding machine according to any one of claims 1 to 3.

6. The control device measures the time required from the output of the interrupt request to the completion of the interrupt processing based on the interrupt request multiple times, and sets the output timing of the interrupt request and the predetermined time based on the measurement results. The injection molding machine according to claim 4.

7. An input device that accepts user input, The system includes a display device that, when a predetermined input is received by the input device, displays the settings related to the start of the control process based on the output of the interrupt request, including the timing of the output of the interrupt request. An injection molding machine according to any one of claims 1 to 6.

8. An interrupt request output unit that outputs an interrupt request at predetermined intervals, The system includes a control processing unit that performs control processing related to the operation of an industrial machine in response to the aforementioned interrupt request, The interrupt request output unit outputs the interrupt request before the occurrence of the trigger that serves as the basis for starting the control process. The control processing unit starts the control processing after the occurrence of the trigger. controller.

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