Molding condition adjustment method and molding condition adjustment device

Abstract

[Problem] To provide a molding condition adjustment method that makes it possible to appropriately adjust a molding condition in blow molding. [Solution] This molding condition adjustment method performed by a molding condition adjustment device 3 adjusts a molding condition when manufacturing a hollow molded body by blow-molding an object to be molded by means of a molded body manufacturing device that operates according to a plurality of device setting values. The molding condition adjustment method comprises a plurality of adjustment steps S20-S50 for adjusting a plurality of adjustment items pertaining to an object to be molded and a molded body according to a predetermined adjustment order with respect to the plurality of adjustment items. Each of the plurality of adjustment steps S20-S50 adjusts an adjustment item by setting a device setting value pertaining to the adjustment item by at least one setting method among a plurality of setting methods.

Description

Molding condition adjustment method and molding condition adjustment device

[0001] The present invention relates to a molding condition adjusting method and a molding condition adjusting device.

[0002] Conventionally, molded body manufacturing apparatuses have been used as apparatuses for blow-molding a molded body (preform, parison, etc.) to manufacture a hollow molded body (bottle, etc.). The molded body manufacturing apparatus is an apparatus for manufacturing a molded body from a molded body by, for example, performing a heating process, a stretching process, and a blow-molding process on the molded body (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2007-045119

[0004] The shape and quality of the molded body produced through each process, such as heating the molded body, stretching, and blow molding, are affected by various molding conditions in each process, such as temperature, pressure, and time. Therefore, in order to obtain the target shape and quality of the molded body with respect to multiple adjustment items, it is necessary to adjust the molding conditions for each process before producing the molded body. However, since there are various combinations of molding conditions, this is a very difficult task that relies heavily on the experience and intuition of skilled workers.

[0005] The present invention has been made to solve the above-mentioned problems, and aims to provide a molding condition adjustment method and molding condition adjustment device that enable appropriate adjustment of molding conditions in blow molding.

[0006] In order to achieve the above-mentioned object, one aspect of the present invention provides a molding condition adjustment method that uses a computer to adjust molding conditions when a molded body is blow molded to produce a hollow molded body using a molded body manufacturing device that operates according to a plurality of device setting values, and includes a plurality of adjustment steps that adjust a plurality of adjustment items related to the molded body and the molded body according to a predetermined adjustment order for the plurality of adjustment items, and each of the plurality of adjustment steps adjusts the adjustment item by setting the device setting value related to the adjustment item using at least one of a plurality of setting methods.

[0007] According to the molding condition adjustment method and molding condition adjustment device of the present invention, when each of the plurality of adjustment steps adjusts a plurality of adjustment items according to a predetermined adjustment order, the adjustment items are adjusted by setting the device setting values ​​for the adjustment items using at least one of the plurality of setting methods, thereby making it possible to appropriately adjust the molding conditions for blow molding.

[0008] 1 is a schematic diagram showing an example of a bottle manufacturing management system 1.

[0023] FIG. 1 is a schematic front view showing an example of a preform heating device 20d.

[0024] FIG. 2 is a block diagram showing an example of a preform heating device 20d.

[0025] FIG. 3 is a schematic plan view showing an example of a blow molding device 20f.

[0026] FIG. 4 is a schematic configuration diagram showing an example of a molding unit 25.

[0027] FIG. 5 is a block diagram showing an example of a blow molding device 20f.

[0028] FIG. 6 is a flowchart showing the flow of a bottle manufacturing process.

[0029] FIG. 7 is a data configuration diagram showing an example of a database 310.

[0030] FIG. 8 is a block diagram showing an example of a molding condition adjustment device 3.

[0031] FIG. 9 is a hardware configuration diagram showing an example of a computer 900 constituting each device.

[0032] FIG. 10 is a flowchart showing an example of a molding condition adjustment method by the molding condition adjustment device 3.

[0033] FIG. 11 is a flowchart showing details of an adjustment step (step S20) for adjusting the temperature of the preform 10.

[0034] FIG. 12 is a flowchart showing details of an adjustment step (step S30) for adjusting the mass distribution of the bottle 11.

[0035] FIG. 13 is a flowchart showing details of an adjustment step (step S40) for adjusting the height of the bottle 11.

[0036] FIG. 14 is a flowchart showing details of an adjustment step (step S50) for adjusting the internal volume of the bottle 11.

[0009] Hereinafter, an embodiment for carrying out the present invention will be described with reference to the drawings. The scope necessary for the explanation to achieve the object of the present invention will be schematically shown, and the scope necessary for explaining the relevant parts of the present invention will be mainly explained, and the parts that are omitted from the explanation will be based on publicly known techniques.

[0010] (Configuration of Bottle Manufacturing Management System 1) Fig. 1 is a schematic diagram showing an example of the bottle manufacturing management system 1. The bottle manufacturing management system 1 functions as a system for manufacturing hollow molded bodies by blow molding a molded body. The bottle manufacturing management system 1 is also a system for managing various information related to the molded body, the molded body, molding conditions, etc.

[0011] In this embodiment, a case will be described in which a hollow bottle 11 (e.g., a PET bottle), which is one type of molded body, is produced from a preform 10, which is one type of molded body, by biaxial stretch blow molding. Note that the molded body is not limited to the bottle 11, and may have any shape as long as it is blow molded from a molded body.

[0012] As shown in Fig. 1, the bottle production management system 1 mainly comprises a bottle production device 2, a molding condition adjustment device 3, and a user terminal device 4. Each of the devices 2 to 4 is configured, for example, as a general-purpose or dedicated computer (see Fig. 10 described below), and is connected to a wired or wireless network 5 so that various data can be transmitted and received between them. Note that the number of the devices 2 to 4 and the connection configuration of the network 5 are not limited to the example shown in Fig. 1 and may be changed as appropriate.

[0013] The bottle manufacturing apparatus 2 is an apparatus that uses a mold 200 and operates in accordance with adjusted molding conditions to blow mold the preform 10 into a bottle 11. The molding conditions include various device setting values ​​when each part of the bottle manufacturing apparatus 2 operates.

[0014] The bottle manufacturing apparatus 2 includes an injection molding apparatus 20a that injection-moldes the raw material synthetic resin into preforms 10, a preform removal apparatus 20b that removes the preforms 10 from the injection molding apparatus 20a and transfers them to a preform transport conveyor 20c, a preform transport conveyor 20c that transports the preforms 10, a preform heating apparatus 20d that is provided midway along the preform transport conveyor 20c and heats the preforms 10, a preform supplying apparatus 20e that receives the preforms 10 from the preform transport conveyor 20c and supplies them to a blow molding apparatus 20f, a blow molding apparatus 20f that molds the heated preforms 10 into bottles 11, a molded body removal apparatus 20g that removes the bottles 11 from the blow molding apparatus 20f and transfers them to a molded body transport conveyor 20h, and a molded body transport conveyor 20h that transports the molded bottles 11. The configuration of the bottle manufacturing apparatus 2 is not limited to the example shown in FIG. 1 and may be modified as appropriate.

[0015] The molding condition adjustment device 3 is a device that works in conjunction with the bottle manufacturing device 2 and the user terminal device 4 to adjust molding conditions (specifically, various device setting values) for multiple adjustment items related to the preform 10 and bottle 11.

[0016] The molding condition adjustment device 3 includes a database 310 in which molding condition information A indicating molding conditions and adjustment item information B indicating target values ​​and adjustment results for a plurality of adjustment items can be registered in association with each other. The molding condition information A and adjustment item information B registered in the database 310 are referenced by the bottle manufacturing device 2 and the user terminal device 4 and used in the manufacture of the bottles 11.

[0017] The user terminal device 4 is a device used by a user such as a production manager of the bottle 11. Programs such as application programs and a web browser are installed on the user terminal device 4, and the user terminal device 4 accepts various input operations and outputs various information via a display screen or voice. The user terminal device 4 is used when the user inputs instructions to the molding condition adjustment device 3, outputs the processing results of the molding condition adjustment device 3, and edits the database 310.

[0018] (Preform heating device 20d) Fig. 2 is a schematic front view showing an example of the preform heating device 20d. Fig. 3 is a block diagram showing an example of the preform heating device 20d. The preform heating device 20d performs a preform heating process to heat the preforms 10 sequentially transported by the preform transport conveyor 20c. The preforms 10 are held upright by, for example, a rotatable mandrel (not shown) and transported at a predetermined transport speed by the preform transport conveyor 20c.

[0019] The preform heating apparatus 20d includes, as its main components, a plurality of preform heating units 21 that heat the preforms 10, and a control unit 22 that controls each part of the preform heating apparatus 20d. As shown in Fig. 1, the plurality of preform heating units 21 are arranged at predetermined intervals along the direction in which the preforms 10 are transported by the preform transport conveyor 20c.

[0020] Each of the multiple preform heating units 21 includes multiple preform heating modules 210 that respectively heat various portions of the preform 10, a local preform heating module 211 that locally heats a portion of the preform 10, and a temperature sensor 212. The multiple preform heating modules 210 are arranged at predetermined intervals in the vertical direction and each includes an infrared heater or the like. The local preform heating module 211 is arranged, for example, at a position where it can locally heat the neck portion of the preform 10 and each includes an infrared heater or the like. In this case, the local preform heating module 211 may also serve as the preform heating module 210. The number and arrangement of the preform heating modules 210, the local preform heating modules 211, and the temperature sensor are not limited to the example shown in FIG. 2 and may be changed as appropriate. The preform heating unit 21 may further include a heating module arranged inside the preform 10 to heat the inside of the preform 10. The preform heating unit 21 may further include a blower module that supplies air at a predetermined temperature to the preforms 10 .

[0021] The control unit 22 is electrically connected to the module groups and sensor groups included in the multiple preform heating units 21, and functions as a control unit that comprehensively controls the multiple preform heating units 21. Note that Fig. 3 illustrates the preform heating module 210 and the local preform heating module 211 as part of the module group, and the temperature sensor 212 as part of the sensor group, but does not illustrate the other module groups and sensor groups.

[0022] The control unit 22 is configured by, for example, a general-purpose or dedicated computer (see FIG. 10 described later). The control unit 22 includes, as its main components, a control unit 220, a communication unit 221, an input unit 222, an output unit 223, and a storage unit 224.

[0023] The storage unit 224 stores various programs (such as an operating system (OS) and a preform heating program 2240) and data (such as apparatus setting information 2241) used in the operation of the preform heating apparatus 20d. The apparatus setting information 2241 is information that can register various apparatus setting values ​​when the preform heating apparatus 20d executes a preform heating process, and is configured to be editable by the apparatus user via a display screen (setting interface), for example.

[0024] The control unit 220 is configured by, for example, an arithmetic processing device (a processor such as a CPU, MPU, or GPU) and a sequencer. The control unit 220 functions as a preform heating control unit 2200 by, for example, executing a preform heating program 2240 stored in the storage unit 224.

[0025] The preform heating control section 2200 operates the modules included in each preform heating unit 21. At that time, the preform heating control section 2200 operates each preform heating module 210 in accordance with the apparatus setting values ​​registered in the apparatus setting information 2241, thereby heating each part of the preform 10.

[0026] The communication unit 221 is connected to a communication network and functions as a communication interface for transmitting and receiving various data not only with the molding condition adjustment device 3 and the user terminal device 4, but also with a terminal device (not shown) used by an apparatus user of the preform heating device 20d, and a manufacturing management device (not shown) that performs manufacturing management for the bottle manufacturing management system 1. The input unit 222 accepts various input operations by the user of the preform heating device 20d, and the output unit 223 functions as a user interface by outputting various information to the apparatus user through a screen display, lighting up a signal tower, and sounding a buzzer.

[0027] (Blow Molding Apparatus 20f) FIG. 4 is a schematic plan view showing an example of the blow molding apparatus 20f. FIG. 5 is a schematic configuration diagram showing an example of the molding unit 25. FIG. 6 is a block diagram showing an example of the blow molding apparatus 20f. The blow molding apparatus 20f is an apparatus that uses a plurality of molds 200 (12 in this embodiment), supplies a blow fluid into the preforms 10 held between the molds 200, and repeatedly performs a blow molding process for each mold 200, in which a hollow bottle 11 is blown out of the preforms 10. Note that in this embodiment, the blow fluid is described as air, but it may be any gas other than air or a liquid.

[0028] The blow molding apparatus 20f has, as its main components, a rotary unit 24, a plurality of molding units 25 (12 in this embodiment) arranged at predetermined intervals on the circumferential orbit of the rotary unit 24, and a control unit 26 that controls each part of the blow molding apparatus 20f.

[0029] The rotary unit 24 includes, for example, a disk-shaped rotary support portion 240 that supports a plurality of molding units 25, and a rotation mechanism portion 241 that rotates the rotary support portion 240 at a predetermined rotation speed (rotation period).

[0030] Each of the multiple molding units 25 includes a mold support unit 250 that supports the mold 200 so that it can be opened and closed, a holding unit 251 that holds the preform 10 clamped between the mold 200 in a sealed state, a stretching unit 252 that stretches the preform 10 supported by the holding unit 251, a blow unit 253 that supplies or discharges blow fluid (air) to or from the preform 10 supported by the holding unit 251, and a mold heating unit 254 that heats the mold 200.

[0031] The stretching unit 252 includes a stretch rod 2520 to be inserted into the preform 10, and a stretch rod support mechanism 2521 that supports the stretch rod 2520 so that the stretch rod 2520 can move back and forth.

[0032] The blow unit 253 includes a main pipe 2530 connected to the stretch rod 2520 via the holding unit 251, three branch pipes 2531A to 2531C branched from the main pipe 2530, a pre-blow valve 2532 provided in the branch pipe 2531A connected to a low-pressure pre-blow air supply source, a main blow valve 2533 provided in the branch pipe 2531B connected to a high-pressure main blow air supply source, an exhaust valve 2534 provided in the branch pipe 2531C connected to an exhaust system, and a pressure sensor 2535, a flow rate sensor 2536, and a temperature sensor 2537 provided in the main pipe 2530 or the holding unit 251. The pressure sensor 2535, the flow rate sensor 2536, and the temperature sensor 2537 each function as a measuring unit capable of measuring the pressure, flow rate, and temperature of the blow fluid (pre-blow air, main blow air, blow air exhaust) supplied into the preform 10 at predetermined measurement time intervals, and outputting the measured value at each time point as the measurement result.

[0033] 4 and 5 omit specific configurations of the rotation mechanism 241, mold support unit 250, holding unit 251, and stretching unit 252, but they are configured by appropriately combining, for example, modules for generating driving force such as servo motors and cylinders, driving force transmission mechanisms such as linear guides, ball screws, gears, cams, belts, couplings, and bearings, and sensors such as linear sensors, encoder sensors, and limit sensors. Also, while Figures 4 and 5 omit specific configurations of the mold heating unit 254, they are configured by appropriately combining, for example, modules such as electric heaters and sensors such as temperature sensors.

[0034] The control unit 26 is electrically connected to the module groups and sensor groups provided in the rotary unit 24 and the plurality of molding units 25, and functions as a control unit that comprehensively controls the rotary unit 24 and the plurality of molding units 25. Note that Fig. 6 illustrates a pre-blow valve 2532, a main blow valve 2533, and an exhaust valve 2534 as part of the module group, and a pressure sensor 2535, a flow rate sensor 2536, and a temperature sensor 2537 as part of the sensor group, but does not illustrate the other module groups and sensor groups.

[0035] The control unit 26 is configured, for example, by a general-purpose or dedicated computer (see FIG. 10 described later). The control unit 26 includes, as its main components, a control unit 260, a communication unit 261, an input unit 262, an output unit 263, and a storage unit 264.

[0036] The storage unit 264 stores various programs (such as an operating system (OS) and a blow molding program 2640) and data (such as device setting information 2641) used in the operation of the blow molding apparatus 20f. The device setting information 2641 is information that can register various device setting values ​​when the blow molding apparatus 20f executes the blow molding process, and is configured to be editable by the device user via a display screen (setting interface), for example.

[0037] The control unit 260 is configured by, for example, an arithmetic processing unit (a processor such as a CPU, an MPU, or a GPU) and a sequencer. The control unit 260 functions as a blow molding control unit 2600 by, for example, executing a blow molding program 2640 stored in the storage unit 264.

[0038] The blow molding control unit 2600 operates the module group included in the rotary unit 24 and the module group included in each molding unit 25. At that time, the blow molding control unit 2600 operates the rotary unit 24 and each molding unit 25 in accordance with the apparatus setting values ​​registered in the apparatus setting information 2641, thereby stretching the preform 10 and supplying blowing fluid into the preform 10, thereby blow-molding a hollow bottle 11 from the preform 10.

[0039] The communication unit 261 is connected to a communication network and functions as a communication interface for transmitting and receiving various data not only with the molding condition adjustment device 3 and the user terminal device 4, but also with a terminal device (not shown) used by a device user of the blow molding device 20f and a production management device (not shown) that performs production management for the bottle production management system 1. The input unit 262 accepts various input operations by the user of the blow molding device 20f, and the output unit 263 functions as a user interface by outputting various information to the device user by displaying a screen, lighting a signal tower, and sounding a buzzer.

[0040] 7 is a flowchart showing the flow of the bottle manufacturing process. The bottle manufacturing process is a process for manufacturing a bottle 11 by heating a preform 10, setting the heated preform 10 in a mold 200, and blow molding the set preform 10. The bottle manufacturing process includes a preform heating step (step S100), a pre-blow step (steps S110 to S114), and a main blow step (steps S120 to S124).

[0041] First, in step S100, when the preforms 10 transported by the preform transport conveyor 20c pass through the heating section of the preform heating device 20d, the preform heating device 20d heats the preforms 10 to a predetermined temperature using each preform heating module 210. Then, the preform supply device 20e supplies the heated preforms 10 to the blow molding device 20f.

[0042] Next, in step S110, the blow molding apparatus 20f holds the heated preform 10 using the holding unit 251. In step S111, the blow molding apparatus 20f closes the mold 200 using the mold support unit 250. At that time, the mold 200 is heated to a predetermined temperature using the mold heating unit 254. In step S112, the blow molding apparatus 20f advances the stretch rod 2520 along the central axis of the preform 10, thereby stretching the preform 10. In step S113, the blow molding apparatus 20f opens the pre-blow valve 2532. In step S114, the blow molding apparatus 20f maintains the pre-blow pressure at the target pressure by continuing to supply pre-blow air for the pre-blow time while advancing the stretch rod 2520.

[0043] Next, in step S120, the blow molding apparatus 20f closes the pre-blow valve 2532 to stop the supply of pre-blow air, and opens the main blow valve 2533 to increase the main blow pressure. In step S121, the blow molding apparatus 20f continues the supply of main blow air for the main blow time, thereby maintaining the main blow pressure at the target pressure. In step S122, the blow molding apparatus 20f closes the main blow valve 2533 and opens the exhaust valve 2534 to discharge the blow fluid to the outside through the main pipe 2530. In step S123, the blow molding apparatus 20f opens the mold 200 using the mold support unit 250 while retracting the stretch rod 2520 from inside the preform 10. In step S124, the blow molding apparatus 20f releases the bottle 11 from the holding unit 251. Then, the molded body removal device 20g removes the blow-molded bottle 11 from the mold 200.

[0044] 8 is a data configuration diagram showing an example of database 310. Database 310 has multiple records for each bottle management ID for associating various information handled by bottle production management system 1. Bottle management ID is information for identifying bottle 11 (product number, model number, etc.). Each record has fields in which multiple device setting values ​​included in molding condition information A and target values ​​and measurement results for multiple adjustment items included in adjustment item information B can be registered, for example.

[0045] The molding condition information A and adjustment item information B registered in the database 310 can be referenced from the molding condition adjustment device 3 and the user terminal device 4. Editing operations such as adding, deleting, and correcting each piece of data may be performed on the display screen of the user terminal device 4.

[0046] The molding condition information A is information indicating molding conditions in the bottle manufacturing process shown in Fig. 7. The molding condition information A includes, for example, device setting values ​​for the preform heating unit 21 of the preform heating apparatus 20d, and device setting values ​​for the stretching unit 252, blow unit 253, and mold heating unit 254 of the blow molding apparatus 20f.

[0047] The apparatus setting values ​​for the preform heating unit 21 include an apparatus setting value for increasing or decreasing the overall heating amount of the multiple preform heating modules 210, an apparatus setting value for increasing or decreasing the heating amount of the multiple preform heating modules 210 individually, an apparatus setting value for increasing or decreasing the heating amount of the local preform heating module 211 individually, and an apparatus setting value for increasing or decreasing the air volume and air pressure of the blower module. The apparatus setting values ​​for the preform heating module 210 and the local preform heating module 211 are set by specifying one of multiple heating levels. The apparatus setting value for the blower module is set by specifying one of multiple air volume levels or multiple air pressure levels.

[0048] The device setting values ​​for the stretching unit 252 include the stretch amount by the stretch rod 2520, device setting values ​​for increasing or decreasing the stretching speed, etc. The device setting values ​​for the stretching unit 252 are set by specifying numerical values ​​corresponding to the stretch amount and stretching speed.

[0049] The device setting values ​​for the blow unit 253 include device setting values ​​for increasing or decreasing the pre-blow pressure, pre-blow time, pre-blow flow rate, main blow pressure, main blow time, device setting values ​​for increasing or decreasing the main blow flow rate, etc. The device setting values ​​for the blow unit 253 are set by specifying a numerical value equivalent to the pre-blow pressure or main blow pressure, specifying a time equivalent to the pre-blow time or main blow time, or specifying a numerical value equivalent to the pre-blow flow rate or main blow flow rate.

[0050] The device setting values ​​for the mold heating unit 254 include device setting values ​​for increasing or decreasing the amount of heat applied to the mold 200. The device setting values ​​for the mold heating unit 254 are set by specifying one of a plurality of heating levels.

[0051] The adjustment item information B is information indicating target values ​​for multiple adjustment items related to the preform 10 and the bottle 11. The target values ​​are values ​​determined during the design and inspection stages of the preform 10 and the bottle 11, and correspond to design values ​​and standard values. The multiple adjustment items include at least one of the temperature of the preform 10, the mass distribution of the bottle 11, the height of the bottle 11, and the internal volume of the bottle 11. In particular, the multiple adjustment items preferably include the temperature of the preform 10, the mass distribution of the bottle 11, and at least one of the height and internal volume of the bottle 11. In this embodiment, a case will be described in which the multiple adjustment items are the temperature of the preform 10, the mass distribution of the bottle 11, the height of the bottle 11, and the internal volume of the bottle 11. Note that the adjustment items may be any adjustment items related to the shape and quality of the preform 10 and the bottle 11, and adjustment items other than those described above may also be used. Furthermore, the adjustment items may vary depending on the product number or model number of the bottle 11.

[0052] The "temperature of the preform 10" as an adjustment item is, for example, the temperature of the preform 10 at the point in time after the preform 10 has been heated in step S100 and before the preform 10 is held by the holding unit 251 in step S110. The adjustment item information B includes a target value for the temperature of the preform 10 at that time and the measurement result of the temperature of the preform 10.

[0053] The "mass distribution of the bottle 11" as an adjustment item is, for example, the mass distribution of the bottle 11 at the time after it is removed from the mold 200 in S124. The adjustment item information B includes a target value for the mass distribution of the bottle 11 at that time and the measurement result of the mass distribution of the bottle 11.

[0054] The "height of the bottle 11" as an adjustment item is, for example, the height of the bottle 11 at the time after it is removed from the mold 200 in S124. The adjustment item information B includes a target value for the height of the bottle 11 at that time and the measurement result of the height of the bottle 11.

[0055] The "internal volume of the bottle 11" as an adjustment item is, for example, the internal volume of the bottle 11 at the time after it is removed from the mold 200 in S124. The adjustment item information B includes a target value for the internal volume of the bottle 11 at that time and the measurement result of the internal volume of the bottle 11.

[0056] (Molding condition adjustment device 3) Figure 9 is a block diagram showing an example of the molding condition adjustment device 3. The molding condition adjustment device 3 includes a control unit 30 configured with a processor or the like, a storage unit 31 configured with an HDD, SSD, memory or the like, a communication unit 32 which is a communication interface with the network 5 and external devices, an input unit 33 configured with a keyboard, mouse or the like, and an output unit 34 configured with a display or the like. Note that the input unit 33 and the output unit 34 may be omitted.

[0057] The storage unit 31 stores a database 310 and a molding condition adjustment program 311, as well as an operating system, other programs, data, and the like.

[0058] The control unit 30 executes the molding condition adjustment program 311 stored in the storage unit 31, thereby functioning as a plurality of adjustment processing units 300A to 300D.

[0059] The plurality of adjustment processing units 300A-300D adjust a plurality of adjustment items related to the preforms 10 and bottles 11 in a predetermined adjustment order. The plurality of adjustment processing units 300A-300D then adjust the adjustment items by setting the apparatus setting values ​​related to the adjustment items using at least one of the plurality of setting methods. In doing so, the plurality of adjustment processing units 300A-300D refer to a database 310 and register the adjustment results of the apparatus setting values ​​in the database 310.

[0060] The adjustment order of the adjustment items is predetermined for multiple adjustment items. For example, the adjustment order for the temperature of the preform 10 is determined earlier than the adjustment order for the other adjustment items. More specifically, the adjustment order for the temperature of the preform 10 is determined earlier than the adjustment order for the mass distribution of the bottle 11, and the adjustment order for the mass distribution of the bottle 11 is determined earlier than the adjustment order for the height of the bottle 11 and the adjustment order for the internal volume of the bottle 11. In this embodiment, a case will be described in which the first adjustment processing unit 300A adjusts the temperature of the preform 10, the second adjustment processing unit 300B adjusts the mass distribution of the bottle 11, the third adjustment processing unit 300C adjusts the height of the bottle 11, and the fourth adjustment processing unit 300D adjusts the internal volume of the bottle 11, as the adjustment order of the adjustment items. The adjustment order of the adjustment items is not limited to the above example and can be changed as appropriate.

[0061] The following setting methods are used for setting the device setting values: (a) Overall preform heating conditions: Device setting values ​​related to the overall heating of the preforms 10 are set, such as device setting values ​​for increasing or decreasing the overall heat amount of the multiple preform heating modules 210. (b) Individual preform heating conditions: Device setting values ​​related to the individual heating of the preforms 10 are set, such as device setting values ​​for each individual heating of the multiple preform heating modules 210. (c) Local preform heating conditions: Device setting values ​​related to the local heating of the preforms 10 are set, such as device setting values ​​for each individual heating of the local preform heating module 211. (d) Pre-blow conditions: Device setting values ​​related to pre-blow are set, such as device setting values ​​for increasing or decreasing the stretching amount and stretching speed by the stretching unit 252, and device setting values ​​for increasing or decreasing the pre-blow pressure, pre-blow time, and pre-blow flow rate by the blowing unit 253. (e) Main blow conditions: Set device settings related to the main blow, such as the main blow pressure, main blow time, and device settings for increasing or decreasing the main blow flow rate by the blow unit 253. (f) Bottle cooling conditions: Set device settings related to cooling the bottle 11, such as the device setting for increasing or decreasing the amount of heating of the mold 200 by the mold heating unit 254.

[0062] The method for setting the device settings is not limited to the above example and can be modified as appropriate. For example, if (a) overall preform heating conditions, (b) individual preform heating conditions, and (c) local preform heating conditions are classified as preform heating conditions that set device settings related to the heating of the preform 10, the preform heating conditions may further include setting device settings for increasing or decreasing the air volume and air pressure of the blower module. Furthermore, the above-described single setting method may be divided into multiple setting methods. For example, (d) pre-blow conditions may be divided into a first pre-blow condition that sets device settings for the stretch amount and stretch speed, and a second pre-blow condition that sets device settings for the pre-blow pressure, pre-blow time, and pre-blow flow rate. Furthermore, the above-described multiple setting methods may be combined into a single setting method. For example, a setting method that combines (a) overall preform heating conditions and (d) pre-blow conditions may be performed as a single setting method. Furthermore, a single setting method may set multiple device settings, or a single device setting value. For example, in (e) the main blow conditions, the device setting values ​​for the main blow pressure and the main blow flow rate may be set, or only the device setting value for the main blow pressure may be set, or only the device setting value for the main blow flow rate may be set.

[0063] Each of the multiple adjustment processing units 300A-300D may perform multiple setting processes to set device setting values ​​for adjustment items using multiple setting methods. In this case, each of the multiple adjustment processing units 300A-300D sequentially performs the multiple setting processes according to a predetermined setting order. Each of the multiple adjustment processing units 300A-300D then determines whether the target value for the adjustment item is met by the device setting value set by the setting process performed in ascending order of the setting order. If the target value is met, the adjustment of the adjustment item ends. If the target value is not met, the adjustment of the adjustment item continues by proceeding to the setting process using the next setting method in the setting order. In this way, the setting process using multiple setting methods is performed stepwise for each adjustment item, allowing the molding conditions for blow molding to be appropriately adjusted.

[0064] In this case, the setting order for the multiple setting methods is predetermined for the multiple setting methods. For example, the setting order for the multiple setting methods may be determined so that the setting method for performing coarse adjustments on the adjustment items is determined earlier, and the setting method for performing fine adjustments on the adjustment items is determined later. This allows the priority order for each adjustment item when performing setting processing using the multiple setting methods to be appropriately set, making it easier for the device setting values ​​to converge, and thus enabling appropriate adjustment of the molding conditions for blow molding. The setting method may be different for each adjustment item, and the setting order may also be different for each adjustment item.

[0065] The output processing unit 301 performs output processing to output the adjustment results obtained by the adjustment processing units 300A to 300D to an external device. As an example of the output processing, the output processing unit 301 transmits the adjustment results obtained by the adjustment processing units 300A to 300D to the bottle manufacturing device 2, the user terminal device 4, etc.

[0066] 10 is a hardware configuration diagram showing an example of a computer 900 that constitutes each device. Each of the devices 2 to 4 that constitute the bottle production management system 1 is configured by a general-purpose or dedicated computer 900.

[0067] 10 , the computer 900 includes, as its main components, a bus 910, a processor 912, a memory 914, an input device 916, an output device 917, a display device 918, a storage device 920, a communication I / F (interface) unit 922, an external device I / F unit 924, an I / O (input / output) device I / F unit 926, and a media input / output unit 928. Note that the above components may be omitted as appropriate depending on the application of the computer 900.

[0068] The processor 912 is composed of one or more arithmetic processing devices (such as a CPU (Central Processing Unit), an MPU (Micro-processing unit), a DSP (Digital Signal Processor), or a GPU (Graphics Processing Unit)), and operates as a control unit that controls the entire computer 900. The memory 914 stores various data and programs 930, and is composed of, for example, a volatile memory (DRAM, SRAM, etc.) that functions as a main memory, a non-volatile memory (ROM), a flash memory, etc.

[0069] The input device 916 is composed of, for example, a keyboard, a mouse, a numeric keypad, an electronic pen, etc., and functions as an input unit. The output device 917 is composed of, for example, a sound (audio) output device, a vibration device, etc., and functions as an output unit. The display device 918 is composed of, for example, a liquid crystal display, an organic EL display, electronic paper, a projector, etc., and functions as an output unit. The input device 916 and the display device 918 may be integrated into one device, such as a touch panel display. The storage device 920 is composed of, for example, an HDD, an SSD, etc., and functions as a storage unit. The storage device 920 stores various data necessary for executing the operating system and the program 930.

[0070] The communication I / F unit 922 is connected to a network 940 such as the Internet or an intranet (which may be the same as the network 5 in FIG. 1) by wire or wirelessly, and functions as a communication unit that transmits and receives data to and from other computers in accordance with a predetermined communication standard. The external device I / F unit 924 is connected to an external device 950 such as a camera, printer, scanner, or reader / writer by wire or wirelessly, and functions as a communication unit that transmits and receives data to and from the external device 950 in accordance with a predetermined communication standard. The I / O device I / F unit 926 is connected to I / O devices 960 such as various sensors and actuators, and functions as a communication unit that transmits and receives various signals and data, such as detection signals from sensors and control signals to actuators, to and from the I / O devices 960. The media input / output unit 928 is composed of, for example, a drive device such as a DVD (Digital Versatile Disc) drive or a CD (Compact Disc) drive, a memory card slot, and a USB connector, and reads and writes data from and to media (non-temporary storage media) 970 such as a DVD, CD, memory card, or USB memory.

[0071] In the computer 900 having the above configuration, the processor 912 loads the program 930 stored in the storage device 920 into the memory 914, executes the program, and controls each unit of the computer 900 via the bus 910. The program 930 may be stored in the memory 914 instead of the storage device 920. The program 930 may be recorded on the medium 970 in an installable file format or an executable file format, and provided to the computer 900 via the media input / output unit 928. The program 930 may be provided to the computer 900 by downloading it via the communication I / F unit 922 over the network 940. In addition, the computer 900 may realize the various functions realized by the processor 912 executing the program 930 using hardware such as an FPGA (field-programmable gate array) or an ASIC (application specific integrated circuit).

[0072] The computer 900 is an electronic device of any type, such as a desktop computer or a portable computer. The computer 900 may be a client computer, a server computer, a cloud computer, or an embedded computer such as a control panel or a controller (including a microcomputer, a programmable logic controller, or a sequencer).

[0073] 11 is a flowchart showing an example of a molding condition adjustment method by the molding condition adjustment device 3. The following describes a case where a manufacturing manager performs various input operations on the user terminal device 4 to adjust molding conditions for a bottle 11 whose specific product number is identified by a bottle management ID.

[0074] First, in step S20 (adjustment step) shown in FIG. 11, the first adjustment processing unit 300A adjusts the "temperature of the preform 10" as the first adjustment item.

[0075] 12 is a flowchart showing details of the adjustment step (step S20) of adjusting the temperature of the preform 10. In the adjustment step of adjusting the temperature of the preform 10, a plurality of setting processes are performed to set the device setting values ​​for the preform heating device 20d using a plurality of setting methods. The setting methods used in this process include one or more of (a) overall preform heating conditions, (b) individual preform heating conditions, and (c) local preform heating conditions. For example, (a) overall preform heating conditions and (b) individual preform heating conditions are used.

[0076] In FIG. 12, a case will be described in which any two of the above setting methods are used as a first setting method and a second setting method.

[0077] In step S200, the first adjustment processing unit 300A sets initial values ​​for device setting values ​​related to the temperature of the preform 10. The initial values ​​are set, for example, for the multiple preform heating modules 210 of the preform heating unit 21. At this time, if device setting values ​​used in the past to manufacture bottles 11 of the same product number are stored in the molding condition information A of the database 310, those device setting values ​​or device setting values ​​similar to those device setting values ​​are set as the initial values. Note that the initial values ​​may also be set by the first adjustment processing unit 300A accepting device setting values ​​input by the manufacturing manager via the display screen of the user terminal device 4.

[0078] In step S201, the first adjustment processing unit 300A measures the temperature of the preform 10 when the preform 10 is heated at the device setting values ​​set for the preform heating unit 21 in step S200, and acquires the measurement result. The temperature of the preform 10 is measured by, for example, the temperature sensor 212 and acquired from the preform heating device 20d. Alternatively, the temperature of the preform 10 can be measured by an external measuring device, and the first adjustment processing unit 300A can acquire the measurement result by accepting the measurement result of the measuring device input by the manufacturing manager via the display screen of the user terminal device 4.

[0079] In step S202, the first adjustment processing unit 300A determines whether the measurement result of the temperature of the preform 10 measured in step S201 satisfies the target value of the temperature of the preform 10. The target value of the temperature of the preform 10 is expressed, for example, as a temperature distribution showing the temperatures at multiple locations on the preform 10. Whether the target value is satisfied is determined, for example, based on whether the measurement result of the temperature of the preform 10 is within a predetermined range based on the target value. The target value is acquired by referencing adjustment item information B in the database 310. Alternatively, the first adjustment processing unit 300A can acquire the target value by accepting the target value input by the manufacturing manager via the display screen of the user terminal device 4.

[0080] If the result of determination in step S202 is that the measurement result of the temperature of the preform 10 satisfies the target value (step S202: Yes), the process proceeds to step S230, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the temperature of the preform 10 is normally completed. On the other hand, if the target value is not satisfied (step S202: No), the process proceeds to step S210.

[0081] In step S210, the first adjustment processing unit 300A performs a setting process to set an apparatus setting value related to the temperature of the preform 10 using a first setting method. When the above (a) entire preform heating condition is used as the first setting method, the apparatus setting value is an overall heating level, and when the above (b) individual preform heating condition is used, the apparatus setting value is an individual heating level. The apparatus setting value is set, for example, according to the difference between the measurement result of the temperature of the preform 10 and the target value. The first adjustment processing unit 300A can also set the apparatus setting value by accepting the apparatus setting value input by the manufacturing manager via the display screen of the user terminal device 4.

[0082] In step S211, the first adjustment processing unit 300A measures the temperature of the preform 10 when the preform 10 is heated using the device setting values ​​set by the first setting method in step S210, and obtains the measurement results, as in step S201.

[0083] In step S212, the first adjustment processing unit 300A determines whether the measurement result of the temperature of the preform 10 measured in step S211 satisfies the target value of the temperature of the preform 10, in the same manner as in step S202.

[0084] If the result of determination in step S212 is that the measurement result of the temperature of the preform 10 meets the target value (step S212: Yes), the process proceeds to step S230, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the temperature of the preform 10 is normally completed. On the other hand, if the target value is not met (step S212: No), the process proceeds to step S220.

[0085] In step S220, the first adjustment processing unit 300A performs a setting process to set an apparatus setting value related to the temperature of the preform 10 using a second setting method. When the above (a) preform overall heating condition is used as the second setting method, the apparatus setting value is an overall heating level, and when the above (b) preform individual heating condition is used, the apparatus setting value is an individual heating level. The apparatus setting value is set, for example, according to the difference between the measurement result of the temperature of the preform 10 and the target value. Alternatively, the first adjustment processing unit 300A can set the apparatus setting value by accepting the apparatus setting value input by the manufacturing manager via the display screen of the user terminal device 4.

[0086] In step S221, the first adjustment processing unit 300A measures the temperature of the preform 10 when the preform 10 is heated at the device setting value set by the second setting method in step S220, and obtains the measurement results, as in steps S201 and S211.

[0087] In step S222, the first adjustment processing unit 300A determines whether the measurement result of the temperature of the preform 10 measured in step S221 satisfies the target value of the temperature of the preform 10, in the same manner as in steps S202 and S212.

[0088] If the result of the determination in step S222 is that the measurement result of the temperature of the preform 10 meets the target value (step S222: Yes), the process proceeds to step S230, the device setting values ​​and measurement results at that time are registered in the database 310, and the temperature adjustment of the preform 10 is terminated normally. On the other hand, if the target value is not met (step S222: No), the process terminates with an error. Note that if an error occurs, the flowchart shown in FIG. 11 may be terminated midway, or whether or not to terminate midway may be confirmed with the manufacturing manager via the display screen of the user terminal device 4.

[0089] Next, in step S30 (adjustment step) shown in FIG. 11, the second adjustment processing unit 300B adjusts the "mass distribution of the bottle 11" as the second adjustment item.

[0090] 13 is a flowchart showing details of the adjusting step (step S30) for adjusting the mass distribution of the bottle 11. In the adjusting step for adjusting the mass distribution of the bottle 11, a plurality of setting processes are performed to set the apparatus settings for at least one of the preform heating apparatus 20d and the blow molding apparatus 20f using a plurality of setting methods. The setting methods used are one or more of (a) overall preform heating conditions, (b) individual preform heating conditions, (c) local preform heating conditions, (d) pre-blow conditions, (e) main blow conditions, and (f) bottle cooling conditions. For example, (a) overall preform heating conditions, (b) individual preform heating conditions, and (d) pre-blow conditions are used.

[0091] In Fig. 13, a case where any two of the above setting methods are used as the first setting method and the second setting method will be described. Also, since the basic operation of the flowchart shown in Fig. 13 is common to the flowchart shown in Fig. 12, the explanation will focus on the differences.

[0092] In step S300, the second adjustment processing unit 300B sets initial values ​​of the apparatus setting values ​​related to the mass distribution of the bottle 11. The initial values ​​are set for, for example, the preform heating unit 21, the stretching unit 252, the blow unit 253, and the mold heating unit 254.

[0093] In step S301, the second adjustment processing unit 300B measures the mass distribution of the bottle 11 when the preform 10 is heated using the device setting values ​​set in step S300 for the preform heating unit 21, the stretching unit 252, the blow unit 253, and the mold heating unit 254, and acquires the measurement results. The mass distribution of the bottle 11 can also be acquired, for example, by dividing the bottle 11 into multiple parts (e.g., neck, shoulder, body, bottom, etc.) and measuring the mass of each part using an external measuring device, and then having the second adjustment processing unit 300B accept the measurement results of the measuring device input by the manufacturing manager via the display screen of the user terminal device 4.

[0094] In step S302, the second adjustment processing unit 300B determines whether the measurement result of the mass distribution of the bottle 11 measured in step S301 satisfies the target value of the mass distribution of the bottle 11.

[0095] If the result of determination in step S302 is that the measurement result of the mass distribution of bottle 11 satisfies the target value (step S302: Yes), the process proceeds to step S330, where the device settings and measurement results at that time are registered in database 310, and adjustment of the mass distribution of bottle 11 is normally completed. On the other hand, if the target value is not satisfied (step S302: No), the process proceeds to step S310.

[0096] In step S310, the second adjustment processor 300B performs a setting process to set apparatus settings related to the mass distribution of the bottle 11 using the first setting method. In step S311, the second adjustment processor 300B measures the mass distribution of the bottle 11 when blow-molded using the apparatus settings set using the first setting method in step S310, and acquires the measurement results, similar to step S301. In step S312, the second adjustment processor 300B determines whether the measurement results of the mass distribution of the bottle 11 measured in step S311 satisfy the target value for the mass distribution of the bottle 11, similar to step S302.

[0097] If the result of determination in step S312 is that the measurement result of the mass distribution of bottle 11 satisfies the target value (step S312: Yes), the process proceeds to step S330, where the device settings and measurement results at that time are registered in database 310, and adjustment of the mass distribution of bottle 11 is normally completed. On the other hand, if the target value is not satisfied (step S312: No), the process proceeds to step S320.

[0098] In step S320, the second adjustment processor 300B performs a setting process to set apparatus settings related to the mass distribution of the bottle 11 using the second setting method. In step S321, the second adjustment processor 300B measures the mass distribution of the bottle 11 when blow-molded using the apparatus settings set using the second setting method in step S320, and acquires the measurement results, similar to steps S301 and S311. In step S322, the second adjustment processor 300B determines whether the measurement results of the mass distribution of the bottle 11 measured in step S321 satisfy the target value for the mass distribution of the bottle 11, similar to steps S302 and S312.

[0099] If the result of determination in step S322 is that the measurement result of the mass distribution of the bottle 11 satisfies the target value (step S322: Yes), the process proceeds to step S330, where the device settings and measurement results at that time are registered in database 310, and the adjustment of the mass distribution of the bottle 11 is terminated normally. On the other hand, if the target value is not satisfied (step S322: No), the process terminates with an error.

[0100] Next, in step S40 (adjustment step) shown in FIG. 11, the third adjustment processing unit 300C adjusts the "height of the bottle 11" as the third adjustment item.

[0101] 14 is a flowchart showing details of the adjustment step (step S40) for adjusting the height of the bottle 11. In the adjustment step for adjusting the height of the bottle 11, multiple setting processes are performed to set device settings for at least one of the preform heating device 20d and the blow molding device 20f using multiple setting methods. The setting methods used are one or more of (a) overall preform heating conditions, (b) individual preform heating conditions, (c) local preform heating conditions, (d) pre-blow conditions, (e) main blow conditions, and (f) bottle cooling conditions. For example, (c) local preform heating conditions, (d) pre-blow conditions, and (f) bottle cooling conditions are used.

[0102] In Fig. 14, a case where any two of the above setting methods are used as the first setting method and the second setting method will be described. Also, since the basic operation of the flowchart shown in Fig. 14 is common to the flowchart shown in Fig. 12, the explanation will focus on the differences.

[0103] In step S400, the third adjustment processing unit 300C sets initial values ​​of apparatus setting values ​​related to the height of the bottle 11. The initial values ​​are set for, for example, the preform heating unit 21, the stretching unit 252, the blow unit 253, and the mold heating unit 254.

[0104] In step S401, the third adjustment processing unit 300C measures the height of the bottle 11 when the preform 10 is heated using the device setting values ​​set in step S400 for the preform heating unit 21, the stretching unit 252, the blow unit 253, and the mold heating unit 254, and acquires the measurement results. The height of the bottle 11 can also be measured, for example, by an external measuring device, and the third adjustment processing unit 300C can acquire the measurement results by accepting the measurement results of the measuring device input by the manufacturing manager via the display screen of the user terminal device 4.

[0105] In step S402, the third adjustment processing unit 300C determines whether the measurement result of the height of the bottle 11 measured in step S401 satisfies the target value of the height of the bottle 11.

[0106] If the result of determination in step S402 is that the measurement result of the height of the bottle 11 satisfies the target value (step S402: Yes), the process proceeds to step S430, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the height of the bottle 11 is normally completed. On the other hand, if the target value is not satisfied (step S402: No), the process proceeds to step S410.

[0107] In step S410, the third adjustment processing unit 300C performs a setting process to set apparatus settings related to the height of the bottle 11 using the first setting method. In step S411, the third adjustment processing unit 300C measures the height of the bottle 11 when blow-molded using the apparatus settings set using the first setting method in step S410, and acquires the measurement results, similar to step S401. In step S412, the third adjustment processing unit 300C determines whether the measurement result of the height of the bottle 11 measured in step S411 satisfies the target value for the height of the bottle 11, similar to step S402.

[0108] If the result of determination in step S412 is that the measurement result of the height of the bottle 11 satisfies the target value (step S412: Yes), the process proceeds to step S430, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the height of the bottle 11 is normally completed. On the other hand, if the target value is not satisfied (step S412: No), the process proceeds to step S420.

[0109] In step S420, the third adjustment processing unit 300C performs a setting process to set apparatus settings related to the height of the bottle 11 using the second setting method. In step S421, the third adjustment processing unit 300C measures the height of the bottle 11 when blow-molded using the apparatus settings set using the second setting method in step S420, and acquires the measurement results, similar to steps S401 and S411. In step S422, the third adjustment processing unit 300C determines whether the measurement result for the height of the bottle 11 in step S421 satisfies the target value for the height of the bottle 11, similar to steps S402 and S412.

[0110] If the result of determination in step S422 is that the measurement result of the height of the bottle 11 meets the target value (step S422: Yes), the process proceeds to step S430, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the height of the bottle 11 is terminated normally. On the other hand, if the target value is not met (step S422: No), the process terminates with an error.

[0111] Next, in step S50 (adjustment step) shown in FIG. 11, the fourth adjustment processing unit 300D adjusts the "internal volume of the bottle 11" as the fourth adjustment item.

[0112] 15 is a flowchart showing details of the adjustment step (step S50) for adjusting the internal volume of the bottle 11. In the adjustment step for adjusting the internal volume of the bottle 11, a plurality of setting processes are performed to set device settings for at least one of the preform heating device 20d and the blow molding device 20f using a plurality of setting methods. The setting methods used are one or more of (a) overall preform heating conditions, (b) individual preform heating conditions, (c) local preform heating conditions, (d) pre-blow conditions, (e) main blow conditions, and (f) bottle cooling conditions. For example, (a) overall preform heating conditions, (e) main blow conditions, and (f) bottle cooling conditions are used.

[0113] In Fig. 15, a case where any two of the above setting methods are used as the first setting method and the second setting method will be described. Also, since the basic operation of the flowchart shown in Fig. 15 is common to the flowchart shown in Fig. 12, the explanation will focus on the differences.

[0114] In step S500, the fourth adjustment processing unit 300D sets initial values ​​of device setting values ​​related to the internal volume of the bottle 11. The initial values ​​are set for, for example, the preform heating unit 21, the stretching unit 252, the blow unit 253, and the mold heating unit 254.

[0115] In step S501, the fourth adjustment processing unit 300D measures the internal volume of the bottle 11 when the preform 10 is heated using the device setting values ​​set in step S500 for the preform heating unit 21, the stretching unit 252, the blow unit 253, and the mold heating unit 254, and acquires the measurement result. The internal volume of the bottle 11 can also be measured, for example, by an external measuring device, and the fourth adjustment processing unit 300D can acquire the measurement result by accepting the measurement result of the measuring device input by the manufacturing manager via the display screen of the user terminal device 4.

[0116] In step S502, the fourth adjustment processing unit 300D determines whether the measurement result of the internal volume of the bottle 11 measured in step S501 satisfies the target value of the internal volume of the bottle 11.

[0117] If the result of determination in step S502 is that the measurement result of the internal volume of bottle 11 satisfies the target value (step S502: Yes), the process proceeds to step S530, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the internal volume of bottle 11 is normally completed. On the other hand, if the target value is not satisfied (step S502: No), the process proceeds to step S510.

[0118] In step S510, the fourth adjustment processing unit 300D performs a setting process to set apparatus settings related to the internal volume of the bottle 11 using the first setting method. In step S511, the fourth adjustment processing unit 300D measures the internal volume of the bottle 11 when blow-molded using the apparatus settings set using the first setting method in step S510, and acquires the measurement results, similar to step S501. In step S512, the fourth adjustment processing unit 300D determines, similar to step S502, whether the measurement result of the internal volume of the bottle 11 measured in step S511 satisfies the target value for the internal volume of the bottle 11.

[0119] If the result of determination in step S512 is that the measurement result of the internal volume of bottle 11 satisfies the target value (step S512: Yes), the process proceeds to step S530, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the internal volume of bottle 11 is normally completed. On the other hand, if the target value is not satisfied (step S512: No), the process proceeds to step S520.

[0120] In step S520, the fourth adjustment processing unit 300D performs a setting process to set apparatus settings related to the internal volume of the bottle 11 using the second setting method. In step S521, the fourth adjustment processing unit 300D measures the internal volume of the bottle 11 when blow-molded using the apparatus settings set using the second setting method in step S520, and acquires the measurement results, similar to steps S501 and S511. In step S522, the fourth adjustment processing unit 300D determines whether the measurement result of the internal volume of the bottle 11 measured in step S521 satisfies the target value for the internal volume of the bottle 11, similar to steps S502 and S512.

[0121] If the result of determination in step S522 is that the measurement result of the internal volume of bottle 11 satisfies the target value (step S522: Yes), the process proceeds to step S530, where the device setting values ​​and measurement results at that time are registered in database 310, and the adjustment of the internal volume of bottle 11 is normally terminated. On the other hand, if the target value is not satisfied (step S522: No), the process ends with an error.

[0122] 11, the output processing unit 301 performs an output process to output the adjustment results obtained in steps S20 to S50. For example, the output processing unit 301 outputs the adjustment results to the user terminal device 4, whereby the adjustment results are provided to the production manager via the display screen of the user terminal device 4. The output processing unit 301 also outputs the adjustment results to the bottle manufacturing apparatus 2, whereby the adjustment results are stored in the device setting information 2241 for the preform heating apparatus 20d and the device setting information 2641 for the blow molding apparatus 20f. The bottle manufacturing apparatus 2 then operates in accordance with the adjustment results, i.e., the adjusted molding conditions, to manufacture the bottle 11.

[0123] 11 to 15 is completed. The molding condition adjustment method is executed at any timing before the start of the production of the bottle 11, for example, based on instructions from a production manager, but may also be executed when a specific execution condition is met, such as a change in the ambient environment (e.g., temperature, humidity, etc.), a change in raw materials, etc.

[0124] As described above, according to the molding condition adjustment device 3 and the molding condition adjustment method using the molding condition adjustment device 3 of this embodiment, when each of the multiple adjustment steps (steps S20 to S50) performed by the adjustment processing units 300A to 300D adjusts multiple adjustment items according to a predetermined adjustment order, the adjustment items are adjusted by setting the device setting values ​​for the adjustment items using at least one of the multiple setting methods. Therefore, the molding conditions for blow molding can be appropriately adjusted.

[0125] In this case, the multiple adjustment steps (steps S20 to S50) include at least adjustment steps, in this order, for adjusting the temperature of the preform 10, the mass distribution of the bottle 11, the height of the bottle 11, and the internal volume of the bottle 11. As a result, by first adjusting the temperature of the preform 10, which affects all of the adjustment items, and then adjusting the mass distribution of the bottle 11, the height of the bottle 11, and the internal volume of the bottle 11 in this order, it is possible to appropriately adjust the molding conditions in blow molding.

[0126] Furthermore, each of the multiple adjustment steps (steps S20 to S50) performs multiple setting processes to set device setting values ​​related to adjustment items using multiple setting methods in a predetermined setting order for the multiple setting methods. As a result, since setting processes using multiple setting methods are performed for each adjustment item, even if it is difficult to adjust an adjustment item using only a specific setting method, it is possible to appropriately adjust molding conditions in blow molding.

[0127] (Other Embodiments) The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit and scope of the present invention, all of which are included in the technical concept of the present invention.

[0128] In the above embodiment, the database 310 has been described as being stored in the storage unit 31 of the molding condition adjustment device 3. However, the database 310 may be stored in an external storage device, in which case each of the devices 2 to 4 may access the database 310 via the network 5.

[0129] In the above embodiment, the molding condition adjusting device 3 operates in accordance with the steps shown in the flowcharts of FIGS. 11 to 15. In the above embodiment, the molding condition adjusting device 3 operates in accordance with the steps shown in the flowcharts of FIGS.

[0130] On the other hand, some of the steps may be omitted, or other steps may be added. For example, although each of the adjustment steps (steps S20 to S50) shown in FIGS. 12 to 15 performs two setting methods, three or more setting methods may be performed. In that case, in each of the adjustment steps (steps S20 to S50) shown in FIGS. 12 to 15, after the setting process using the second setting method, for example, a setting process using a third setting method may be added, and after that a setting process using a fourth setting method may be added, thereby performing setting processes using three or more setting methods.

[0131] Furthermore, the setting process for each adjustment step (steps S20 to S50) may be performed using the setting method defined below.

[0132] For example, each of the adjustment steps (steps S30 to S50) that are set second or later in the adjustment order may perform a setting process to set the device setting values ​​using a setting method that is different from the setting methods already used in the other adjustment steps as the setting method set first in the setting order. In the example shown in Figures 11 to 15, if (a) the preform overall heating conditions and (b) the preform individual heating conditions have already been set as the setting methods in step S20, the first setting method in step S30 performs a setting process using (d) the pre-blow conditions, which are different from these setting methods. As a result, when adjusting a new adjustment item, a setting method that has not been used in the other adjustment steps is used as the first setting method in the setting order, thereby preventing the need to readjust adjusted adjustment items that have already been adjusted.

[0133] In this case, at least one of the adjustment steps (steps S30 to S50) that are set second or later in the adjustment order may perform a setting process to set the device setting values ​​using a setting method that is different from the setting method used at the end of the previous adjustment step. In the example shown in Figures 11 to 15, if (b) preform individual heating conditions are set at the end of step S20, the first setting method in step S30 performs a setting process using (d) pre-blow conditions, which is a different setting method. As a result, when adjusting a new adjustment item, the setting method that is first set in the setting order is the setting method that was not used at the end of the previous adjustment step, which prevents the need for readjustment of adjusted adjustment items.

[0134] In addition, at least one of the adjustment steps (steps S30 to S50) set second or later in the adjustment order may perform a setting process to set the device setting values ​​using a setting method common to the setting methods already performed in other adjustment steps as at least one of the setting methods set second or later in the setting order. In the example shown in Figures 11 to 15, if (a) the preform overall heating conditions or (b) the preform individual heating conditions have already been set as the setting method in step S20, the setting process for the second or later setting methods in step S30 is performed using the common setting methods (a) the preform overall heating conditions or (b) the preform individual heating conditions. As a result, when adjusting a new adjustment item, the setting method already used in other adjustment steps is used as the setting method set second or later in the setting order, so that the adjustment for the new adjustment item can be converged while minimizing the impact on the adjusted adjustment items.

[0135] Furthermore, each of the plurality of adjustment steps (steps S20 to S50) may perform a setting process to set device settings for the preform heating module 210 as at least one of the plurality of setting methods. That is, when (a) overall preform heating conditions, (b) individual preform heating conditions, and (c) local preform heating conditions are classified as preform heating conditions, each of the plurality of adjustment steps (steps S20 to S50) may perform a setting process to set device settings for the preform heating module 210 and the local preform heating module 211 using any of the setting methods included in the preform heating conditions. In this way, the heating conditions for the preform 10, which have a large impact on the shape and quality of the bottle 11, are set in each of the plurality of adjustment steps, allowing the molding conditions for blow molding to be appropriately adjusted.

[0136] Various aspects of the present disclosure are summarized below as appendices.

[0137] (Supplementary Note 1) A molding condition adjustment method using a computer to adjust molding conditions when a molded body is blow molded to produce a hollow molded body using a molded body manufacturing apparatus that operates according to a plurality of apparatus setting values, the molding condition adjustment method including a plurality of adjustment steps that adjust a plurality of adjustment items related to the molded body and the molded body according to a predetermined adjustment order for the plurality of adjustment items, and each of the plurality of adjustment steps adjusts the adjustment item by setting the apparatus setting value related to the adjustment item using at least one of a plurality of setting methods.

[0138] (Supplementary Note 2) The molding condition adjusting method according to Supplementary Note 1, wherein each of the plurality of adjustment steps performs a plurality of setting processes to set the device setting values ​​related to the adjustment items by a plurality of setting methods in accordance with a predetermined setting order for the plurality of setting methods.

[0139] (Supplementary Note 3) The molding condition adjusting method according to Supplementary Note 1 or Supplementary Note 2, wherein each of the plurality of adjusting steps determines whether a target value for the adjustment item is met by the device setting value set by the setting process performed in order of earliest in the setting order, and if the target value is met, ends the adjustment of the adjustment item, and if the target value is not met, continues the adjustment of the adjustment item by proceeding to the setting process by the setting method of the next in the setting order.

[0140] (Supplementary Note 4) The molding condition adjusting method according to any one of Supplementary Note 1 to Supplementary Note 3, wherein each of the plurality of adjusting steps performs the plurality of setting processes in accordance with the setting order in which the setting order of the setting method for making a rough adjustment for the adjustment item is determined earlier for the plurality of setting methods and the setting order of the setting method for making a fine adjustment for the adjustment item is determined later.

[0141] (Supplementary Note 5) The molding condition adjusting method according to any one of Supplementary Note 1 to Supplementary Note 4, wherein each of the adjustment steps whose adjustment order is determined second or later performs the setting process of setting the device setting values ​​by a setting method whose setting order is determined first and which is different from the setting method used at the end of the adjustment step whose adjustment order is immediately preceding.

[0142] (Supplementary Note 6) The molding condition adjusting method according to any one of Supplementary Note 1 to Supplementary Note 5, wherein at least one of the adjustment steps whose adjustment order is determined to be second or later performs the setting process of setting the device setting values ​​by a setting method whose setting order is determined to be first and which is different from the setting method already performed in the other adjustment steps.

[0143] (Supplementary Note 7) The molding condition adjusting method according to any one of Supplementary Note 1 to Supplementary Note 6, wherein at least one of the adjustment steps whose adjustment order is determined to be second or later performs the setting process of setting the device setting value by a setting method that is common to the setting methods already performed in other adjustment steps, as at least one of the setting methods whose setting order is determined to be second or later.

[0144] (Appendix 8) A molding condition adjusting method according to any one of Appendices 1 to 7, wherein the plurality of adjustment items include the temperature of the molded body, the mass distribution of the molded body, and at least one of the height and internal volume of the molded body, and the plurality of adjustment steps include at least one of the following adjustment steps: adjusting the temperature of the molded body, adjusting the mass distribution of the molded body, adjusting the height of the molded body, and adjusting the internal volume of the molded body.

[0145] (Appendix 9) A molding condition adjusting method according to any one of Appendices 1 to 8, wherein the plurality of adjustment items include the temperature of the molded body, the mass distribution of the molded body, and at least one of the height and internal volume of the molded body, and the plurality of adjustment steps include at least one of the adjustment steps of adjusting the temperature of the molded body, adjusting the mass distribution of the molded body, adjusting the height of the molded body, and adjusting the internal volume of the molded body.

[0146] (Supplementary Note 10) The molding condition adjusting method according to any one of Supplementary Note 1 to Supplementary Note 9, wherein the adjustment order for the temperature of the molded body is determined earlier than the adjustment orders for the other adjustment items.

[0147] (Appendix 11) The molding condition adjusting method according to any one of Appendices 1 to 10, wherein the adjustment order for the temperature of the molded body is determined earlier than the adjustment order for the mass distribution of the molded body, and the adjustment order for the mass distribution of the molded body is determined earlier than the adjustment order for the mass distribution of the molded body.

[0148] (Supplementary Note 12) The molded body manufacturing apparatus includes at least a molded body heating device that heats the molded body, and a blow molding device that blow molds the molded body heated by the molded body heating device to manufacture the molded body, and the adjustment step of adjusting the temperature of the molded body includes performing a plurality of setting processes to set the device setting values ​​for the molded body heating device using one or more setting methods selected from the molded body overall heating conditions that set device setting values ​​for the molded body overall heating, the molded body individual heating conditions that set device setting values ​​for the molded body individual heating conditions, and the molded body local heating conditions that set device setting values ​​for the molded body local heating conditions, and the adjustment step of adjusting the mass distribution of the molded body, the adjustment step of adjusting the height of the molded body, and the adjustment step of adjusting the internal volume of the molded body include performing a plurality of setting processes to set the device setting values ​​for the molded body heating device using one or more setting methods selected from the molded body overall heating conditions, the molded body individual heating conditions, the molded body local heating conditions, pre-blow conditions that set device setting values ​​for pre-blow, and device setting values ​​for main blow. A molding condition adjustment method according to any one of Appendix 1 to Appendix 11, wherein a plurality of setting processes are performed to set the device setting values ​​for at least one of the molded body heating device and the blow molding device using one or more of the setting methods of main blow conditions that set setting values ​​and molded body cooling conditions that set device setting values ​​related to cooling of the molded body.

[0149] (Supplementary Note 13) The molding condition adjusting method according to any one of Supplementary Note 1 to Supplementary Note 12, wherein each of the plurality of adjustment steps performs a plurality of setting processes to set the device setting values ​​related to the adjustment items by a plurality of setting methods in accordance with a setting order predetermined for the plurality of setting methods, and each of the adjustment steps whose adjustment order is set second or later performs the setting process to set the device setting values ​​by a setting method whose setting order is set first and which is different from the setting method used at the end of the adjustment step immediately preceding the adjustment step whose adjustment order is set first.

[0150] (Supplementary Note 14) The molding condition adjusting method according to Supplementary Note 12 or Supplementary Note 13, wherein at least one of the adjustment steps whose adjustment order is determined to be second or later performs the setting process of setting the device setting values ​​by a setting method whose setting order is determined to be first and which is different from the setting methods already performed in the other adjustment steps.

[0151] (Supplementary Note 15) The molding condition adjusting method according to any one of Supplementary Note 12 to Supplementary Note 14, wherein at least one of the adjustment steps whose adjustment order is determined to be second or later performs the setting process of setting the device setting value by a setting method that is common to the setting methods already performed in other adjustment steps, as the setting method of at least one of the setting methods whose setting order is determined to be second or later.

[0152] (Appendix 16) A molding condition adjustment method according to any one of Appendices 1 to 12, wherein each of the plurality of adjustment steps performs a plurality of setting processes to set the device setting values ​​for the adjustment items using a plurality of setting methods in accordance with a predetermined setting order for the plurality of setting methods, and performs the setting process to set the device setting values ​​for the molded body heating device using one of the overall molding body heating conditions, individual molding body heating conditions, and local molding body heating conditions as the setting method for at least one of the plurality of setting methods.

[0153] REFERENCE SIGNS LIST 1...bottle manufacturing management system, 2...bottle manufacturing apparatus, 3...molding condition adjustment apparatus, 4...user terminal device, 5...network, 10...preform (molded object), 11...bottle (molded body), 20a...injection molding apparatus, 20b...preform removal apparatus, 20c...preform transport conveyor, 20d...preform heating apparatus, 20e...preform supply apparatus, 20f...blow molding apparatus, 20g...molded body removal apparatus, 20h...molded body transport conveyor, 21...preform heating unit, 22...control unit, 24...rotary unit, 25...molding unit, 26...control unit, 30...control unit, 31...storage unit, 32...communication unit, 33...input unit, 34...output unit, 200...mold, 210...preform heating module, 211...preform local heating module, 212...temperature sensor, 240...rotary support unit, 241...rotation mechanism unit, 250... mold support unit, 251... holding unit, 252... stretching unit, 253... blow unit, 254... mold heating unit, 300A... first adjustment processing unit, 300B... second adjustment processing unit, 300C... third adjustment processing unit, 300D... fourth adjustment processing unit, 301... output processing unit, 310... database, 311... molding condition adjustment program, 900... computer

Claims

1. A molding condition adjustment method using a computer to adjust molding conditions when a molded body is blow molded to produce a hollow molded body by a molded body manufacturing apparatus that operates according to a plurality of apparatus setting values, the molding condition adjustment method including a plurality of adjustment steps for adjusting a plurality of adjustment items related to the molded body and the molded body in accordance with a predetermined adjustment order for the plurality of adjustment items, each of the plurality of adjustment steps adjusting the adjustment item by setting the apparatus setting value related to the adjustment item by at least one of a plurality of setting methods.

2. A molding condition adjustment method as described in claim 1, wherein each of the plurality of adjustment steps performs a plurality of setting processes to set the device setting values ​​related to the adjustment items using a plurality of the setting methods in accordance with a predetermined setting order for the plurality of the setting methods.

3. The molding condition adjustment method described in claim 2, wherein each of the plurality of adjustment steps determines whether a target value for the adjustment item is satisfied by the device setting value set by the setting process performed in the order from earliest to latest in the setting order, and if the target value is satisfied, terminates the adjustment of the adjustment item, and if the target value is not satisfied, continues the adjustment of the adjustment item by proceeding to the setting process by the setting method of the next setting order.

4. A molding condition adjustment method as described in claim 2, wherein each of the multiple adjustment steps performs multiple setting processes according to a setting order in which the setting order of the setting methods for making rough adjustments to the adjustment items is determined early for the multiple setting methods, and the setting order of the setting methods for making fine adjustments to the adjustment items is determined late.

5. The molding condition adjustment method described in claim 2, wherein each of the adjustment steps whose adjustment order is set second or later performs the setting process of setting the device setting value using a setting method different from the setting method used at the end of the previous adjustment step whose adjustment order is set first.

6. A molding condition adjustment method as described in claim 5, wherein at least one of the adjustment steps whose adjustment order is set second or later performs the setting process of setting the device setting value by a setting method whose setting order is set first and which is different from the setting method already performed in the other adjustment steps.

7. A molding condition adjustment method as described in claim 6, wherein at least one of the adjustment steps whose adjustment order is determined to be second or later performs the setting process of setting the device setting value by a setting method that is common to the setting methods already performed in other adjustment steps, as at least one of the setting methods whose setting order is determined to be second or later.

8. The molding condition adjustment method described in claim 1, wherein the multiple adjustment items include at least one of the temperature of the molded body, the mass distribution of the molded body, the height of the molded body, and the internal volume of the molded body, and the multiple adjustment steps include at least one of the adjustment steps of adjusting the temperature of the molded body, adjusting the mass distribution of the molded body, adjusting the height of the molded body, and adjusting the internal volume of the molded body.

9. The molding condition adjustment method described in claim 1, wherein the multiple adjustment items include the temperature of the molded body, the mass distribution of the molded body, and at least one of the height and internal volume of the molded body, and the multiple adjustment steps include at least one of an adjustment step of adjusting the temperature of the molded body, an adjustment step of adjusting the mass distribution of the molded body, an adjustment step of adjusting the height of the molded body, and an adjustment step of adjusting the internal volume of the molded body.

10. The molding condition adjusting method according to claim 9, wherein the adjustment order for the temperature of the molded body is determined earlier than the adjustment orders for the other adjustment items.

11. A molding condition adjusting method as described in claim 9, wherein the adjustment sequence for the temperature of the molded body is determined earlier than the adjustment sequence for the mass distribution of the molded body, and the adjustment sequence for the mass distribution of the molded body is determined earlier than the adjustment sequence for the height of the molded body and the adjustment sequence for the internal volume of the molded body.

12. The molded body manufacturing apparatus includes at least a molded body heating device that heats the molded body, and a blow molding device that blow molds the molded body heated by the molded body heating device to manufacture the molded body, and the adjustment step of adjusting the temperature of the molded body includes performing a plurality of setting processes to set the device setting values ​​for the molded body heating device using one or more of the setting methods of molded body overall heating conditions that set device setting values ​​for overall heating of the molded body, molded body individual heating conditions that set device setting values ​​for individual heating of the molded body, and molded body local heating conditions that set device setting values ​​for local heating of the molded body, and the adjustment step of adjusting the mass distribution of the molded body, the adjustment step of adjusting the height of the molded body, and the adjustment step of adjusting the internal volume of the molded body include 12. The molding condition adjustment method according to claim 8, further comprising the step of performing a plurality of setting processes for setting the device setting values ​​for at least one of the molded body heating device and the blow molding device by one or more of the setting methods selected from the overall heating conditions for the molded body, the individual heating conditions for the molded body, the local heating conditions for the molded body, the pre-blow conditions for setting device setting values ​​related to the pre-blow, the main blow conditions for setting device setting values ​​related to the main blow, and the molded body cooling conditions for setting device setting values ​​related to cooling of the molded body.

13. A molding condition adjustment method as described in claim 12, wherein each of the plurality of adjustment steps performs a plurality of setting processes to set the equipment setting values ​​related to the adjustment items by a plurality of the setting methods in accordance with a predetermined setting order for the plurality of the setting methods, and each of the adjustment steps for which the adjustment order is set second or later performs the setting process to set the equipment setting values ​​by a setting method for which the setting order is set first that is different from the setting method performed at the end of the adjustment step immediately preceding the adjustment step in the adjustment order.

14. A molding condition adjustment method as described in claim 13, wherein at least one of the adjustment steps whose adjustment order is set second or later performs the setting process of setting the device setting value by a setting method whose setting order is set first and which is different from the setting method already performed in the other adjustment steps.

15. A molding condition adjustment method as described in claim 14, wherein at least one of the adjustment steps whose adjustment order is set to second or later performs the setting process of setting the device setting value by a setting method that is common to the setting methods already performed in other adjustment steps, as at least one of the setting methods whose setting order is set to second or later.

16. The molding condition adjustment method described in claim 12, wherein each of the multiple adjustment steps performs multiple setting processes to set the device setting values ​​for the adjustment items using multiple setting methods in accordance with a predetermined setting order for the multiple setting methods, and performs the setting process to set the device setting value for the molded body heating device using at least one of the multiple setting methods, which is a heating condition for the entire molded body, an individual heating condition for the molded body, and a local heating condition for the molded body.

17. A molding condition adjustment device that adjusts molding conditions when a molded body is blow molded to produce a hollow molded body by a molded body manufacturing apparatus that operates according to a plurality of apparatus setting values, the molding condition adjustment device comprising a plurality of adjustment processing units that adjust a plurality of adjustment items related to the molded body and the molded body in accordance with a predetermined adjustment order for the plurality of adjustment items, and each of the plurality of adjustment processing units adjusts the adjustment item by setting the apparatus setting value related to the adjustment item by at least one of a plurality of setting methods.

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