Allowable range setting device, injection molding machine, and allowable range setting method

Abstract

The allowable range setting device (14) that sets allowable an range for an operating status value representing the operating status of an injection molding machine (16) has: an adjustment value setting unit (26) that sets an adjustment value that adjusts the magnitude of the allowable range; an analysis value acquisition unit (22) that acquires as an analysis value an operating status value determined based on an analysis result by a flow analysis device (12) that analyzes the flow of a resin inside a mold of the injection molding machine (16); and an allowable range setting unit (28) that sets an allowable range based on the adjustment value set in the adjustment value setting unit (26) and the analysis value acquired in the analysis value acquisition unit (22).

Description

Tolerance setting device, injection molding machine, and tolerance setting method

[0001] The present invention relates to a tolerance setting device, an injection molding machine, and a tolerance setting method.

[0002] Japanese Patent No. 3395542 discloses a molding condition setting method that utilizes a flow analysis simulation technique to calculate analytically optimal molding conditions and sets upper and lower allowable limits for key molding variables during the molding process.

[0003] Japanese Patent No. 3395542 does not disclose a method for setting the above-mentioned upper and lower allowable limits. Therefore, the technique disclosed in Japanese Patent No. 3395542 has a problem in that it is not possible to set an allowable range defined by the upper and lower allowable limits.

[0004] The present invention aims to solve the above-mentioned problems.

[0005] A first aspect of the present invention is a tolerance setting device that sets a tolerance range for an operating state value that indicates the operating state of an injection molding machine, the tolerance setting device having an adjustment value setting unit that sets an adjustment value to adjust the size of the tolerance range, an analysis value acquisition unit that acquires, as an analysis value, the operating state value determined based on an analysis result by a flow analysis device that analyzes the flow of resin inside a mold of the injection molding machine, and a tolerance setting unit that sets the tolerance range based on the adjustment value set in the adjustment value setting unit and the analysis value acquired by the analysis value acquisition unit.

[0006] A second aspect of the present invention is an injection molding machine, which includes the tolerance setting device of the first aspect.

[0007] A third aspect of the present invention is a tolerance setting method for setting a tolerance range for an operating state value indicating the operating state of an injection molding machine, the tolerance setting method comprising: an adjustment value setting step for setting an adjustment value to adjust the size of the tolerance range; an analysis value acquisition step for acquiring, as an analysis value, the operating state value determined based on an analysis result obtained by a flow analysis device that analyzes the flow of resin inside a mold of the injection molding machine; and a tolerance setting step for setting the tolerance range based on the adjustment value set in the adjustment value setting step and the analysis value acquired in the analysis value acquisition step.

[0008] The present invention allows for the setting of acceptable ranges of operating condition values ​​in an injection molding machine.

[0009] FIG. 1 is a block diagram illustrating a configuration of an injection molding machine system. FIG. 2 is a diagram illustrating a method for setting an allowable range for injection pressure. FIG. 3 is a diagram illustrating a method for setting an allowable range for injection pressure. FIG. 4 is a diagram illustrating a method for setting an allowable range for injection pressure. FIG. 5 is a diagram illustrating a method for setting an allowable range for injection pressure. FIG. 6 is a diagram illustrating a method for setting an allowable range for injection pressure. FIG. 7 is a diagram illustrating a method for setting an allowable range for a load during metering. FIG. 8 is a diagram illustrating a method for setting an allowable range for a load during forward movement of an ejector. FIG. 9 is a diagram illustrating an example of display of allowable range information on a display device. FIG. 10 is a flowchart illustrating an allowable range setting process performed in an allowable range setting device. FIG. 11 is a diagram illustrating an allowable range for injection pressure. FIG. 12 is a diagram illustrating an allowable range for injection pressure. FIG. 13 is a diagram illustrating an example of display of options on a display device. FIG. 14 is a diagram illustrating an example of display of a slide bar and a slide on a display device. FIG. 15 is a block diagram illustrating a configuration of an injection molding machine system. FIG. 16 is a block diagram illustrating a configuration of an injection molding machine system. FIG. 17 is a block diagram illustrating a configuration of an injection molding machine system. FIG. 18 is a block diagram showing the configuration of an injection molding machine system.

[0010] 1 is a block diagram showing the configuration of an injection molding machine system 10. The injection molding machine system 10 includes a flow analysis device 12, a tolerance setting device 14, and an injection molding machine 16.

[0011] The flow analysis device 12 is a device that analyzes the flow of resin inside the mold of the injection molding machine 16 during molding. The flow analysis device 12 may also analyze the metering operation of raw material pellets, the ejector operation of the molded product, the opening and closing operation of the movable platen, etc. Based on the analysis results, the flow analysis device 12 calculates an operating state value that indicates the operating state of the injection molding machine 16. Hereinafter, the operating state value calculated by the flow analysis device 12 based on the analysis results may be referred to as an analysis value.

[0012] The molding conditions include, for example, injection speed, injection acceleration, injection pressure, mold clamping force, speed / pressure switching position, dwell pressure, dwell time, cooling time, nozzle temperature, barrel temperature, mold temperature, mold opening speed, mold closing speed, ejector speed, maximum injection time, and maximum injection pressure.

[0013] The above-mentioned maximum injection time is the upper limit of the injection time in the injection process. When the time elapsed since the start of the injection process exceeds the maximum injection time, the injection process is switched to the pressure holding process. The above-mentioned maximum injection pressure is the upper limit of the injection pressure in the injection process. In the section of the injection process where the injection pressure is the maximum injection pressure, the injection operation is switched to pressure control that maintains the maximum injection pressure.

[0014] Examples of operating state values ​​include injection pressure, injection time, backflow during injection, load during metering, metering time, resin temperature, load during mold opening, mold opening time, load during mold closing, mold closing time, load when ejector advances, ejector advance time, load when ejector retreats, ejector retreat time, pressure of resin inside the mold, temperature of resin inside the mold, and flow rate of resin inside the mold.

[0015] The backflow during injection refers to the flow rate of resin flowing backward along the axial direction of the screw. If the injection molding machine 16 is electric, the load during metering refers to the load torque of the screw rotation motor during resin metering. The resin temperature refers to the temperature of the resin at a predetermined position inside the nozzle or barrel. If the injection molding machine 16 is electric, the load during mold closing refers to the load torque of the movable platen drive motor during mold closing. If the injection molding machine 16 is electric, the load during mold opening refers to the load torque of the movable platen drive motor during mold opening. If the injection molding machine 16 is electric, the load during ejector advancement refers to the load torque of the ejector rod drive motor during the advancement of the ejector rod. If the injection molding machine 16 is electric, the ejector advancement time refers to the time required for the ejector rod to advance. If the injection molding machine 16 is an electric type, the load when the ejector retracts refers to the load torque of the ejector rod drive motor when the ejector rod retracts. If the injection molding machine 16 is an electric type, the ejector retraction time refers to the time required for the ejector rod to retract. The injection molding machine 16 is not limited to an electric type, but may also be a hydraulic type.

[0016] The pressure of the resin inside the mold is detected by a pressure sensor provided inside the mold. The temperature of the resin inside the mold is detected by a temperature sensor provided inside the mold. The flow rate of the resin inside the mold is detected by a flow rate sensor provided inside the mold. The pressure of the resin detected by the pressure sensor, the temperature of the resin detected by the temperature sensor, and the flow rate of the resin detected by the flow rate sensor are sent to the injection molding machine 16 via communication.

[0017] The tolerance setting device 14 sets a tolerance range for the operating state value during molding in the injection molding machine 16. If the operating state value during molding exceeds the tolerance range, the injection molding machine 16 will take action such as outputting an alarm.

[0018] The tolerance setting device 14 includes a calculation unit 18 and a storage unit 20. The calculation unit 18 is a processor such as a central processing unit (CPU) or a graphics processing unit (GPU). The calculation unit 18 includes an analytic value acquisition unit 22, a display control unit 24, an adjustment value setting unit 26, and an allowable range setting unit 28. The analytic value acquisition unit 22, the display control unit 24, the adjustment value setting unit 26, and the allowable range setting unit 28 are realized by the calculation unit 18 executing a program stored in the storage unit 20. At least a portion of the analytic value acquisition unit 22, the display control unit 24, the adjustment value setting unit 26, and the allowable range setting unit 28 may be realized by an integrated circuit such as an application specific integrated circuit (ASIC) or a field-programmable gate array (FPGA). At least a portion of the analytic value acquisition unit 22, the display control unit 24, the adjustment value setting unit 26, and the allowable range setting unit 28 may be realized by an electronic circuit including discrete devices.

[0019] The storage unit 20 is configured with a volatile memory (not shown) and a non-volatile memory (not shown), which are computer-readable storage media. The volatile memory is, for example, a random access memory (RAM). The non-volatile memory is, for example, a read-only memory (ROM) or a flash memory. Data, for example, is stored in the volatile memory. Programs, tables, maps, for example, are stored in the non-volatile memory. At least a portion of the storage unit 20 may be provided in the above-mentioned processor, integrated circuit, etc. At least a portion of the storage unit 20 may be installed in a device connected to the tolerance range setting device 14 via a network.

[0020] The analytic value acquiring unit 22 acquires, as analytic values, operating state values ​​calculated by the flow analysis device 12. The analytic value acquiring unit 22 may acquire the analytic values ​​from the flow analysis device 12. The analytic value acquiring unit 22 may acquire the analytic values ​​from a data management device 46 (FIG. 18) described below. The data management device 46 is a device that manages data used for analysis in the flow analysis device 12. The data management device 46 is also a device that manages data of the analysis results analyzed in the flow analysis device 12.

[0021] The display control unit 24 controls the display device 30 to display images and the like on the display device 30 .

[0022] The adjustment value setting unit 26 sets an adjustment value based on, for example, at least one of a numerical value input by the user and specification information of the injection molding machine 16. The adjustment value is a value that adjusts the size of the tolerance range.

[0023] The adjustment value setting unit 26 acquires a numerical value from the input device 32. The user inputs a numerical value by operating the input device 32 according to guidance such as an image displayed on the display device 30.

[0024] The adjustment value setting unit 26 acquires specification information of the injection molding machine 16 from the injection molding machine 16. The specification information is, for example, information such as the maximum injection pressure. The specification information may be input by a user. The specification information may also be stored in the storage unit 20 in advance.

[0025] The input device 32 is, for example, a keyboard, a pointing device, etc. The display device 30 is, for example, a liquid crystal display, an organic electroluminescence display, etc. A touch panel display may be used as the input device 32 and the display device 30.

[0026] The tolerance setting unit 28 sets the tolerance based on the analysis value and the adjustment value, and outputs the tolerance to the injection molding machine 16.

[0027] [Methods for Setting the Allowable Range] Five methods for setting the allowable range will be described below. As an example, a method for setting the allowable range for injection pressure will be described below.

[0028] (First Method) FIG. 2 is a diagram for explaining a method for setting an allowable range for injection pressure. A first method for setting an allowable range will be explained using FIG. 2. "R" in FIG. 2 indicates an allowable range. "PA" in FIG. 2 indicates the maximum value of injection pressure calculated by the flow analysis device 12. Hereinafter, the maximum value of injection pressure calculated by the flow analysis device 12 may be referred to as the maximum value of injection pressure in analysis. "D" in FIG. 2 indicates an adjustment value. "α" in FIG. 2 indicates a numerical value input by the user. "R," "PA," "D," and "α" in other figures have the same meanings.

[0029] In the first method, the user inputs a positive value as the value α. The adjustment value setting unit 26 sets the adjustment value D based on the value α input by the user. Specifically, the adjustment value setting unit 26 sets D=α. This formula may be stored in the storage unit 20.

[0030] The allowable range setting unit 28 sets the lower limit of the allowable range R for the injection pressure to 0 [MPa]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the injection pressure based on a preset formula using the maximum injection pressure PA in the analysis and the adjustment value D. The allowable range setting unit 28 sets the upper limit of the allowable range R to PA+D [MPa]. This formula may be stored in the storage unit 20. As shown in FIG. 2 , the allowable range R is a range that changes according to the numerical value α input by the user.

[0031] (Second Method) Fig. 3 is a diagram for explaining a method for setting the allowable range for injection pressure. A second method for setting the allowable range will be explained using Fig. 3.

[0032] In the second method, the user inputs a value in the range of 0≦α≦1 as the value α. The adjustment value setting unit 26 sets the adjustment value D based on a preset formula using the value α input by the user and the maximum injection pressure PA in the analysis. Specifically, the adjustment value setting unit 26 sets D = PA × α. This formula may be stored in the storage unit 20.

[0033] The allowable range setting unit 28 sets the lower limit of the allowable range R for the injection pressure to 0 [MPa]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the injection pressure to PA+D [MPa]. As shown in Fig. 3, the allowable range R is a range that changes depending on the value α input by the user.

[0034] (Third Method) Figure 4 is a diagram for explaining a method for setting an allowable range for injection pressure. A third method for setting an allowable range will be explained using Figure 4. "PS" shown in Figure 4 is the maximum injection pressure in the specifications of the injection molding machine 16. Hereinafter, the maximum injection pressure in the specifications of the injection molding machine 16 may be referred to as the maximum injection pressure in the specifications. The same meaning is also shown for "PS" shown in other figures.

[0035] In the third method, the user inputs a value in the range of 0≦α≦1 as the value α. The adjustment value setting unit 26 sets the adjustment value D based on a preset formula using the value α input by the user, the analytical maximum injection pressure PA, and the specification maximum injection pressure PS. Specifically, the adjustment value setting unit 26 sets D = (PS - PA) × α. This formula may be stored in the storage unit 20.

[0036] The allowable range setting unit 28 sets the lower limit of the allowable range R for the injection pressure to 0 [MPa]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the injection pressure to PA+D [MPa]. As shown in Fig. 4, the allowable range R is a range that changes according to the value α input by the user.

[0037] (Fourth Method) FIG. 5 is a diagram illustrating a method for setting an allowable range for injection pressure. A fourth method for setting an allowable range will be described using FIG. 5. "PS_a" shown in FIG. 5 is the maximum injection pressure in the specifications of the injection molding machine 16 of model a. Hereinafter, the maximum injection pressure in the specifications of the injection molding machine 16 of model a may be referred to as the maximum injection pressure in the specifications of model a. "PS_b" shown in FIG. 5 is the maximum injection pressure in the specifications of the injection molding machine 16 of model b. Hereinafter, the maximum injection pressure in the specifications of the injection molding machine 16 of model b may be referred to as the maximum injection pressure in the specifications of model b. Model a and model b are different models. "PS_a" and "PS_b" shown in other figures have the same meaning.

[0038] The adjustment value setting unit 26 sets an adjustment value D for the model a based on the maximum injection pressure PA in the analysis and the maximum injection pressure PS_a in the specifications of the model a. The adjustment value setting unit 26 sets the adjustment value D for the model a in the range of 0≦D≦(PS_a−PA).

[0039] The adjustment value setting unit 26 sets an adjustment value D for the model b based on the maximum injection pressure PA in the analysis and the maximum injection pressure PS_b in the specifications of the model b. The adjustment value setting unit 26 sets the adjustment value D for the model b in the range of 0≦D≦(PS_b−PA).

[0040] The allowable range setting unit 28 sets the lower limit of the allowable range R for the injection pressure to 0 [MPa]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the injection pressure to PA+D [MPa]. As shown in Fig. 5, the allowable range R is a range that changes depending on the model of the injection molding machine 16.

[0041] (Fifth Method) Fig. 6 is a diagram for explaining a method for setting the allowable range for injection pressure. A fifth method for setting the allowable range will be explained using Fig. 6.

[0042] The adjustment value setting unit 26 sets the adjustment value D based on information about the mold or information about the resin. For example, the adjustment value setting unit 26 sets the magnitude of the adjustment value D when the mold has a sliding part to be smaller than the magnitude of the adjustment value D when the mold does not have a sliding part. For example, the adjustment value setting unit 26 sets the magnitude of the adjustment value D to be smaller the higher the viscosity of the resin.

[0043] The adjustment value setting unit 26 may acquire information about the mold and information about the resin from the flow analysis device 12. The adjustment value setting unit 26 may acquire information about the mold and information about the resin from information input by the user. The adjustment value setting unit 26 may acquire information about the mold and information about the resin from a centralized control device 44 ( FIG. 17 ) described later. The centralized control device 44 centrally controls a plurality of injection molding machines 16. The adjustment value setting unit 26 may acquire information about the mold and information about the resin from a data management device 46 ( FIG. 18 ) described later. The data management device 46 is a device that manages data used for analysis in the flow analysis device 12. The data management device 46 is also a device that manages data of analysis results analyzed in the flow analysis device 12.

[0044] The information about the mold is, for example, the field for which the mold is intended, the likelihood of the mold breaking down, etc. The information about the resin is, for example, the range of set temperatures, flowability, etc.

[0045] The allowable range setting unit 28 sets the lower limit of the allowable range R for the injection pressure to 0 [MPa]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the injection pressure to PA+D [MPa].

[0046] For example, the injection pressure limit must be set more strictly when the mold has a sliding part than when the mold does not have a sliding part. The stricter the injection pressure limit, the smaller the allowable range R. As shown in Figure 6, the allowable range R is a range that changes depending on the strictness of the injection pressure limit.

[0047] The method for setting the allowable range for the injection pressure has been described above. However, the allowable ranges for other operating state values ​​may also be set in the same manner as described above. Below, as examples, the method for setting the allowable ranges for the load during metering and the load during ejector forward movement will be described.

[0048] (Method of setting the allowable range of load during metering) FIG. 7 is a diagram for explaining a method of setting the allowable range of load during metering. Using FIG. 7, a method of setting the allowable range of load during metering will be explained. The setting method explained here is the same as the second method described above. "TA" written in FIG. 7 indicates the maximum value of load during metering calculated by the flow analysis device 12. Hereinafter, the maximum value of load during metering calculated by the flow analysis device 12 may be referred to as the maximum value of load during analytical metering.

[0049] The user inputs a value in the range of 0≦α≦1 as the value α. The adjustment value setting unit 26 sets the adjustment value D based on the value α input by the user and the maximum value TA of the load during analytical measurement. Specifically, the adjustment value setting unit 26 sets D = TA × α.

[0050] The allowable range setting unit 28 sets the lower limit of the allowable range R for the load during measurement to 0 [%]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the load during measurement to TA+D [%]. As shown in Fig. 7 , the allowable range R is a range that changes depending on the value α input by the user.

[0051] In the same way as the method for setting the allowable range of the load during metering, it is also possible to set the allowable range of the metering completion time.

[0052] (Method for setting the allowable range of the load when the ejector advances) FIG. 8 is a diagram for explaining a method for setting the allowable range of the load when the ejector advances. A method for setting the allowable range of the load when the ejector advances will be explained using FIG. 8. The setting method explained here is the same as the second method described above. "SA" written in FIG. 8 indicates the maximum value of the load when the ejector advances, calculated by the flow analysis device 12. Hereinafter, the maximum value of the load when the ejector advances, calculated by the flow analysis device 12, may be referred to as the analytical maximum value SA of the load when the ejector advances.

[0053] The user inputs a value in the range of 0≦α≦1 as the value α. The adjustment value setting unit 26 sets the adjustment value D based on the value α input by the user and the analytical maximum value SA of the load when the ejector is moving forward. Specifically, the adjustment value setting unit 26 sets D=SA×α.

[0054] The allowable range setting unit 28 sets the lower limit of the allowable range R for the load when the ejector is moving forward to 0 [%]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the load when the ejector is moving forward to SA+D [%]. As shown in FIG. 8 , the allowable range R is a range that changes depending on the value α input by the user.

[0055] The allowable range of the ejector completion time can be set in the same way as the allowable range of the load when the ejector advances. Also, the allowable range of the load when the mold is opened and the allowable range of the load when the mold is closed can be set in the same way as the allowable range of the load when the ejector advances.

[0056] [Display on Display Device] The display control unit 24 controls the display device 30 to display information about the allowable ranges on the display device 30. Fig. 9 is a diagram showing an example of how information about the allowable ranges is displayed on the display device 30. As shown in Fig. 9, the display control unit 24 displays a list of information about the allowable ranges for each item of the operating state value.

[0057] 10 is a flowchart showing the tolerance setting process performed by the tolerance setting device 14. The tolerance setting process is executed each time the flow analysis device 12 sets molding conditions for the injection molding machine 16.

[0058] In step S1, the analytical value acquisition unit 22 acquires analytical values ​​from the flow analysis device 12. Then, the process proceeds to step S2.

[0059] In step S2, the display control unit 24 controls the display device 30. As a result, a display related to a guide prompting the user to input a numerical value is displayed on the display device 30. Then, the process proceeds to step S3.

[0060] In step S3, the adjustment value setting unit 26 acquires a numerical value input by the user from the input device 32. Then, the process proceeds to step S4.

[0061] In step S4, the adjustment value setting unit 26 acquires specification information from the injection molding machine 16. After that, the process proceeds to step S5.

[0062] In step S5, the adjustment value setting unit 26 sets the adjustment value, and then the process proceeds to step S6.

[0063] In step S6, the tolerance setting unit 28 sets the tolerance, and then the process proceeds to step S7.

[0064] In step S7, the tolerance setting unit 28 outputs the tolerance to the injection molding machine 16. After that, the process proceeds to step S8.

[0065] In step S8, the display control unit 24 controls the display device 30. As a result, information on the allowable range is displayed on the display device 30. Thereafter, the allowable range setting device 14 ends the allowable range setting process.

[0066] The set adjustment value may be stored in the storage unit 20. If the adjustment value is stored in the storage unit 20, the tolerance setting unit 28 may read the adjustment value from the storage unit 20 instead of the processes of steps S3 to S5.

[0067] As in the fifth method described above, when the adjustment value setting unit 26 sets the adjustment value D based on information about the mold or information about the resin, instead of processing steps S2 to S3, the adjustment value setting unit 26 may acquire the information about the mold and the information about the resin from the flow analysis device 12, etc.

[0068] [Effects] If the actual flow of resin inside the mold of the injection molding machine 16 differs from the analysis results of the flow analysis device 12, the operating state values ​​of the injection molding machine 16 during molding may differ significantly from the analytical values. For example, if the actual injection pressure is higher than the analytical injection pressure, there is a risk of flash occurring in the product, damage to the mold, etc. Therefore, if the actual operating state value exceeds the allowable range, the injection molding machine 16 will take action such as issuing an alarm.

[0069] The size of this tolerance range can preferably be adjusted according to the user's judgment and the specifications of the injection molding machine 16.

[0070] Therefore, in the tolerance setting device 14 of this embodiment, the adjustment value setting unit 26 sets an adjustment value that adjusts the size of the tolerance range. The tolerance setting unit 28 sets the tolerance range based on the analysis value and the adjustment value. This allows the tolerance setting device 14 to adjust the size of the tolerance range.

[0071] In addition, in the tolerance setting device 14 of this embodiment, the adjustment value setting unit 26 sets the adjustment value based on a numerical value input by the user, thereby allowing the tolerance setting device 14 to adjust the size of the tolerance range according to the user's judgment.

[0072] Furthermore, in tolerance setting device 14 of this embodiment, adjustment value setting unit 26 sets the adjustment value based on the specification information of injection molding machine 16. This allows tolerance setting device 14 to adjust the size of the tolerance range in accordance with the specifications of injection molding machine 16.

[0073] Furthermore, the tolerance setting device 14 of this embodiment sets the adjustment value based on information about the mold, thereby enabling the tolerance setting device 14 to adjust the size of the tolerance depending on the mold.

[0074] Furthermore, the tolerance setting device 14 of this embodiment sets the adjustment value based on information about the resin, thereby enabling the tolerance setting device 14 to set the size of the tolerance range depending on the resin.

[0075] Furthermore, in the tolerance setting device 14 of this embodiment, the tolerance setting unit 28 sets the tolerance according to the adjustment value based on a preset formula, thereby reducing the calculation load required for setting the tolerance.

[0076] Furthermore, in the tolerance setting device 14 of this embodiment, the tolerance setting unit 28 sets the tolerance based on the adjustment value stored in the storage unit 20. This allows the tolerance setting device 14 to reduce the calculation load required to set the tolerance.

[0077] The operating state values ​​for which the tolerance setting device 14 of this embodiment sets tolerances are at least one of the injection pressure, injection time, load during metering, backflow during injection, metering time, resin temperature, load during mold opening, mold opening time, load during mold closing, mold closing time, load during ejector advancement, ejector advancement time, load during ejector retreatment, ejector retreatment time, resin pressure inside the mold, resin temperature inside the mold, and resin flow velocity inside the mold. This allows the tolerance setting device 14 to set tolerances for these operating state values.

[0078] Second Embodiment In the allowable range setting device 14 in the first embodiment, for example, the allowable range for the injection pressure is set based on the maximum value of the injection pressure in the analysis. In contrast to this, for example, the allowable range for the injection pressure may be set based on the injection pressure calculated by the flow analysis device 12. Hereinafter, the injection pressure calculated by the flow analysis device 12 may be referred to as the injection pressure in the analysis.

[0079] Fig. 11 is a diagram illustrating the allowable range for injection pressure. "Pa" in Fig. 11 indicates the injection pressure based on analysis. "Pa" in other figures has the same meaning.

[0080] The allowable range setting unit 28 sets the lower limit of the allowable range R for the injection pressure to 0 [MPa]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the injection pressure based on the analytical injection pressure pa at each of time t0, time t1, time t2, time t3, and time t4. As shown in Fig. 11, the allowable range R is a range that changes at a given time.

[0081] 12 is a diagram illustrating the allowable range for injection pressure, showing an example different from that shown in FIG.

[0082] The allowable range setting unit 28 sets the lower limit of the allowable range R for the injection pressure to 0 [MPa]. The allowable range setting unit 28 sets the upper limit of the allowable range R for the injection pressure based on the injection pressure pa in the analysis. As shown in Fig. 12, the allowable range R is a range that changes in accordance with the change over time of the injection pressure pa in the analysis.

[0083] In the tolerance setting device 14 of this embodiment, the tolerance setting unit 28 sets a tolerance that changes over time, which allows the tolerance setting device 14 to set a tolerance that corresponds to the change over time of the operating state value analyzed by the flow analysis device 12.

[0084] Third Embodiment In the tolerance setting device 14 of the first embodiment, the user inputs a numerical value by operating the input device 32 in accordance with guidance such as an image displayed on the display device 30. The adjustment value setting unit 26 sets an adjustment value according to the numerical value input by the user.

[0085] Alternatively, the adjustment value setting unit 26 may set the adjustment value in accordance with information input by the user using another input method. Two input methods will be described below with reference to Figs. 13 and 14 .

[0086] 13 is a diagram showing an example of how options 34 are displayed on the display device 30. As shown in FIG. 13, the display control unit 24 causes the display device 30 to display a plurality of options 34a to 34e corresponding to each item of the operating state value. The plurality of options 34a to 34e indicate candidates for setting the size of the tolerance range for each item of the operating state value. By operating the input device 32, the user can select one of the plurality of options 34a to 34e for each item of the operating state value.

[0087] The size of the allowable range changes depending on the adjustment value set by the adjustment value setting unit 26. The size of the allowable range when the user selects option 34a is smaller than the size of the allowable range when the user selects option 34b. Moreover, the size of the allowable range when the user selects option 34c is larger than the size of the allowable range when the user selects option 34b.

[0088] If the user selects option 34d, the adjustment value setting unit 26 may set the adjustment value based on the specifications of the injection molding machine 16, as in the fourth method described in the first embodiment.

[0089] If the user selects option 34e, the adjustment value setting unit 26 may set the adjustment value based on the value input by the user, as in the first to third methods described in the first embodiment.

[0090] The tolerance setting unit 28 may set the operation of the injection molding machine 16 when the operating state value exceeds the tolerance range.

[0091] 13, the display control unit 24 causes the display device 30 to display a pull-down menu 36 for each item of the operating state value. The pull-down menu 36 displays options for the operation of the injection molding machine 16 when the operating state value exceeds the allowable range.

[0092] If the user selects "Alarm Output", the injection molding machine 16 outputs an alarm when the operating state value exceeds the allowable range. If the user selects "Instant Stop", the injection molding machine 16 stops molding when the operating state value exceeds the allowable range. If the user selects "One Cycle Stop", the injection molding machine 16 stops molding after one molding cycle is completed when the operating state value exceeds the allowable range.

[0093] 14 is a diagram showing an example of how the slide bar 38 and slide 40 are displayed on the display device 30. As shown in FIG. 14, the display control unit 24 causes the display device 30 to display the slide bar 38 and slide 40 for each item of the operating state value. The user can move the slide 40 along the slide bar 38 by operating the input device 32.

[0094] The size of the allowable range changes depending on the adjustment value set by the adjustment value setting unit 26. The more the user moves the slide 40 to the right, the smaller the size of the allowable range becomes.

[0095] The display control unit 24 may cause the display device 30 to display buttons 42 corresponding to each item of the operation status value. The user can switch the display of the buttons 42 between "ON" and "OFF" by operating the input device 32. When the display of the button 42 is "ON," the display control unit 24 causes the display device 30 to display a slide bar 38 and a slide 40 for the corresponding item of the operation status value. When the display of the button 42 is "OFF," the display control unit 24 does not cause the display device 30 to display the slide bar 38 and the slide 40 for the corresponding item of the operation status value.

[0096] In the two input methods described above with reference to Figures 13 and 14, information regarding the setting of the magnitude of the allowable range for each item of the actuation state value is input individually. Alternatively, information regarding the setting of the magnitude of the allowable range for each of multiple items of the actuation state value may be input all at once.

[0097] [Effects] In the tolerance range setting device 14 of this embodiment, the display control unit 24 causes the display device 30 to display a plurality of options 34 regarding the size of the tolerance range. The adjustment value setting unit 26 sets an adjustment value based on the option 34 selected by the user. In this way, the tolerance range setting device 14 can reduce the burden of input operations on the user.

[0098] In tolerance setting device 14 of this embodiment, display control unit 24 causes display device 30 to display slide bar 38 and slide 40 that can be moved by the user along slide bar 38. Adjustment value setting unit 26 sets an adjustment value based on the position of slide 40 on slide bar 38 moved by the user. In this way, tolerance setting device 14 can reduce the burden of input operations on the user.

[0099] In the tolerance setting device 14 of this embodiment, the tolerance setting unit 28 sets a tolerance for the operating state value of the item selected by the user, thereby allowing the tolerance setting device 14 to set a tolerance only for the operating state value of the item selected by the user.

[0100] In the tolerance setting device 14 of this embodiment, the tolerance setting unit 28 sets the operation of the injection molding machine 16 when the operating state value exceeds the tolerance range, based on the operation of the injection molding machine 16 input by the user operating the input device 32. This allows the tolerance setting device 14 to set the operation of the injection molding machine 16 when the operating state value exceeds the tolerance range.

[0101] 15 is a block diagram showing the configuration of an injection molding machine system 10. In the first embodiment, the tolerance setting device 14 is a device separate from the injection molding machine 16. However, as shown in FIG. 15, the tolerance setting device 14 may be provided in the injection molding machine 16.

[0102] Fig. 16 is a block diagram showing the configuration of the injection molding machine system 10. In the first embodiment, the tolerance setting device 14 is a device separate from the flow analysis device 12. Alternatively, as shown in Fig. 16, the tolerance setting device 14 may be provided in the flow analysis device 12.

[0103] Fig. 17 is a block diagram showing the configuration of the injection molding machine system 10. As shown in Fig. 17, the tolerance setting device 14 may be provided in a centralized control device 44. The centralized control device 44 is a device that controls a plurality of injection molding machines 16.

[0104] Fig. 18 is a block diagram showing the configuration of the injection molding machine system 10. As shown in Fig. 18, the tolerance setting device 14 may be provided in a data management device 46. The data management device 46 is a device that manages data used for analysis in the flow analysis device 12. The data management device 46 is also a device that manages data of the analysis results analyzed in the flow analysis device 12.

[0105] [Operation and Effect] The tolerance setting device 14 of this embodiment is provided in the injection molding machine 16. This makes it possible to provide the user with an injection molding machine 16 incorporating the functions of the tolerance setting device 14.

[0106] The tolerance setting device 14 of this embodiment is provided in the flow analysis device 12. This makes it possible to provide the user with a flow analysis device 12 incorporating the functions of the tolerance setting device 14.

[0107] The tolerance setting device 14 of this embodiment is provided in a centralized control device 44. This makes it possible to provide a centralized control device 44 incorporating the functions of the tolerance setting device 14 to a user.

[0108] The tolerance setting device 14 of this embodiment is provided in the data management device 46. This makes it possible to provide the user with a data management device 46 incorporating the functions of the tolerance setting device 14.

[0109] [Inventions Obtained from the Embodiments] Inventions that can be grasped from the above-described embodiments will be described below.

[0110] A tolerance setting device (14) that sets a tolerance for an operating state value that indicates the operating state of an injection molding machine (16), the tolerance setting device having: an adjustment value setting unit (26) that sets an adjustment value that adjusts the size of the tolerance range; an analysis value acquisition unit (22) that acquires, as an analysis value, the operating state value determined based on an analysis result by a flow analysis device (12) that analyzes the flow of resin inside a mold of the injection molding machine; and a tolerance setting unit (28) that sets the tolerance based on the adjustment value set by the adjustment value setting unit and the analysis value acquired by the analysis value acquisition unit. This allows the tolerance setting device to adjust the size of the tolerance range.

[0111] In the tolerance range setting device, the adjustment value setting unit may set the adjustment value based on a numerical value input by a user operating an input device (32), thereby enabling the tolerance range setting device to adjust the size of the tolerance range in accordance with the user's judgment.

[0112] In the tolerance setting device, the adjustment value setting unit may set the adjustment value based on specification information of the injection molding machine, thereby enabling the tolerance setting device to adjust the size of the tolerance range in accordance with the specifications of the injection molding machine.

[0113] In the tolerance setting device, the adjustment value setting unit may set the adjustment value based on information about the mold, thereby enabling the tolerance setting device to adjust the size of the tolerance in accordance with the mold.

[0114] In the tolerance setting device, the adjustment value setting unit may set the adjustment value based on information about the resin, thereby enabling the tolerance setting device to set the size of the tolerance range depending on the resin.

[0115] In the above-described tolerance setting device, the tolerance setting unit may calculate the tolerance corresponding to the adjustment value based on a predetermined formula, thereby reducing the calculation load required for setting the tolerance.

[0116] The tolerance setting device may further include a storage unit (20) that stores the adjustment value set by the adjustment value setting unit, and the tolerance setting unit may set the tolerance range based on the adjustment value stored in the storage unit. This reduces the calculation load required for setting the tolerance range.

[0117] In the above-described tolerance setting device, the tolerance setting unit may set the tolerance that changes over time, thereby enabling the tolerance setting device to set the tolerance according to the change over time of the operating state value analyzed by the flow analysis device.

[0118] In the above tolerance setting device, the operating state value may be at least one of injection pressure, injection time, backflow during injection, load during metering, metering time, temperature of the resin, load during mold opening, mold opening time, load during mold closing, mold closing time, load when an ejector advances, ejector advance time, load when an ejector retreats, ejector retreat time, pressure of the resin inside the mold, temperature of the resin inside the mold, and flow velocity of the resin inside the mold. This allows the tolerance setting device to set tolerances for these operating state values.

[0119] The tolerance range setting device may further include a display control unit (24) that causes a display device (30) to display a plurality of options (34) regarding the size of the tolerance range, and the adjustment value setting unit may set the adjustment value based on the option selected by a user operating an input device. This allows the tolerance range setting device to reduce the burden of input operations on the user.

[0120] The tolerance range setting device may further include a display control unit that causes a display device to display a slide bar (38) and a slide (40) that can be moved by a user along the slide bar, and the adjustment value setting unit may set the adjustment value based on the position of the slide on the slide bar that is moved by the user operating an input device. This allows the tolerance range setting device to reduce the burden of input operations on the user.

[0121] In the tolerance setting device, the tolerance setting unit may set the tolerance ranges for the operating state values ​​of a plurality of items regarding the operating state of the injection molding machine, and the tolerance setting unit may set the tolerance range for the operating state value of the item selected by a user operating an input device, thereby allowing the tolerance setting device to set the tolerance range only for the operating state value of the item selected by the user.

[0122] In the above tolerance range setting device, the tolerance range setting unit may set the operation of the injection molding machine when the operating state value exceeds the tolerance range, based on the operation of the injection molding machine input by a user operating an input device, thereby enabling the tolerance range setting device to set the operation of the injection molding machine when the operating state value exceeds the tolerance range.

[0123] The injection molding machine includes the tolerance setting device, and thus, an injection molding machine incorporating the functionality of the tolerance setting device can be provided to the user.

[0124] A tolerance setting method for setting a tolerance for an operating state value indicating an operating state of an injection molding machine, the tolerance setting method comprising: an adjustment value setting step for setting an adjustment value to adjust the size of the tolerance range; an analysis value acquisition step for acquiring, as an analysis value, the operating state value determined based on an analysis result obtained by a flow analysis device that analyzes the flow of resin inside a mold of the injection molding machine; and a tolerance setting step for setting the tolerance based on the adjustment value set in the adjustment value setting step and the analysis value acquired in the analysis value acquisition step. This allows the tolerance setting method to adjust the size of the tolerance range.

[0125] The present invention is not limited to the above disclosure, and various configurations can be adopted without departing from the gist of the present invention.

[0126] 14: Tolerance range setting device 16: Injection molding machine 22: Analysis value acquisition unit 24: Display control unit 26: Adjustment value setting unit 28: Tolerance range setting unit 30: Display device 34: Choices 38: Slide bar 40: Slide

Claims

1. 1. A tolerance setting device for setting a tolerance for an operation state value indicating an operation state of an injection molding machine, an adjustment value setting unit that sets an adjustment value for adjusting the size of the tolerance range; an analysis value acquisition unit that acquires, as an analysis value, the operating state value calculated based on an analysis result by a flow analysis device that analyzes a flow of resin inside a mold of the injection molding machine; an allowable range setting unit that sets the allowable range based on the adjustment value set by the adjustment value setting unit and the analytic value acquired by the analytic value acquiring unit; A tolerance setting device comprising:

2. 2. The tolerance setting device according to claim 1, The adjustment value setting unit sets the adjustment value based on a numerical value input by a user operating an input device.

3. 3. The tolerance setting device according to claim 1, The adjustment value setting unit is a tolerance setting device that sets the adjustment value based on specification information of the injection molding machine.

4. 3. The tolerance setting device according to claim 1, The adjustment value setting unit sets the adjustment value based on information about the mold.

5. 3. The tolerance setting device according to claim 1, The adjustment value setting unit sets the adjustment value based on information about the resin.

6. 3. The tolerance setting device according to claim 1, The tolerance setting unit calculates the tolerance corresponding to the adjustment value based on a preset formula.

7. 3. The tolerance setting device according to claim 1, a storage unit that stores the adjustment value set by the adjustment value setting unit, The tolerance setting unit sets the tolerance based on the adjustment value stored in the storage unit.

8. 3. The tolerance setting device according to claim 1, The tolerance setting unit is configured to set the tolerance, which varies with time.

9. 3. The tolerance setting device according to claim 1, The operating state value is at least one of injection pressure, injection time, backflow during injection, load during metering, metering time, temperature of the resin, load at mold opening, mold opening time, load at mold closing, mold closing time, load when ejector advances, ejector advance time, load when ejector retreats, ejector retreat time, pressure of the resin inside the mold, temperature of the resin inside the mold, and flow velocity of the resin inside the mold, a tolerance setting device.

10. 3. The tolerance setting device according to claim 1, a display control unit that causes a display device to display a plurality of options regarding the size of the tolerance range, The adjustment value setting unit sets the adjustment value based on the option selected by a user operating an input device.

11. 3. The tolerance setting device according to claim 1, a display control unit that causes a display device to display a slide bar and a slide that can be moved by a user along the slide bar; The adjustment value setting unit sets the adjustment value based on a position of the slide on the slide bar that is moved by a user operating an input device.

12. 3. The tolerance setting device according to claim 1, the tolerance setting unit sets tolerances for the operation state values ​​of a plurality of items regarding the operation state of the injection molding machine; The tolerance setting unit sets the tolerance for the operating state value of the item selected by a user operating an input device.

13. 3. The tolerance setting device according to claim 1, The tolerance setting unit sets the operation of the injection molding machine when the operating state value exceeds the tolerance range based on the operation of the injection molding machine input by a user operating an input device.

14. 3. An injection molding machine comprising the tolerance range setting device according to claim 1 or 2.

15. 1. A tolerance setting method for setting a tolerance for an operation state value indicating an operation state of an injection molding machine, comprising: an adjustment value setting step of setting an adjustment value for adjusting the size of the tolerance range; an analysis value acquisition step of acquiring, as an analysis value, the operating state value obtained based on an analysis result by a flow analysis device that analyzes a flow of resin inside a mold of the injection molding machine; a tolerance setting step of setting the tolerance based on the adjustment value set in the adjustment value setting step and the analytical value acquired in the analytical value acquiring step; The tolerance setting method includes: