Injection Molding Machine Sound-Based Self-Adjustment
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Solution Overview
Problem
Injection molding machines often require manual intervention by skilled personnel to identify and address abnormal sounds, leading to operational disruptions and inefficiencies.
Innovation Solution
An automated adjustment device that acquires and analyzes operating sounds, specifies the source of abnormal sounds, and adjusts commands to suppress their generation, allowing for continuous operation without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention by skilled personnel is used to identify and address abnormal sounds, then the injection molding machine can be operated, but operational disruptions and inefficiencies occur
Solution Approach 1:
The injection molding machine performs self-diagnosis and self-adjustment by automatically detecting abnormal sounds through sound sensors, analyzing the sound characteristics, and adjusting operation commands to suppress the abnormal sounds without requiring external skilled personnel intervention
Solution Approach 2:
The system continuously monitors operating sounds, compares them against stored abnormal sound characteristics, and provides feedback by automatically adjusting operation commands when abnormalities are detected, creating a closed-loop control system that eliminates the need for manual intervention
2Reliability
If the operation of the injection molding machine is interrupted until a skilled person arrives, then the abnormal sound can be addressed, but productivity is reduced
Solution Approach 1:
The machine automatically handles abnormality detection and correction by adjusting its own operation commands based on detected abnormal sounds, eliminating the need to interrupt operations for skilled personnel intervention
Solution Approach 2:
The system stores characteristics of abnormal sounds in advance and prepares adjustment strategies, enabling immediate automatic response when abnormal sounds are detected without requiring skilled personnel analysis or intervention
3Extent of automation
If automated sound analysis is implemented, then manual intervention is reduced, but device complexity increases
Solution Approach 1:
The controller performs multiple functions including sound acquisition, sound characteristic analysis, abnormal sound specification by comparing with stored characteristics, and operation command adjustment, consolidating these functions into a single control unit rather than requiring separate dedicated devices for each function
Solution Approach 2:
The sound sensor, analysis unit, storage unit, and adjusting unit are integrated into a unified automated adjustment device that combines detection, analysis, storage, and adjustment functions into a cohesive system
Data Source
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AI summary
An adjustment device (710) of an injection molding machine (10) includes an acquisition unit (711) which acquires an operating sound generated by an operation of a machine part constituting the injection molding machine (10), an analysis unit (712) which acquires characteristics of the operating sound acquired by the acquisition unit (711), a storage unit (713) which stores characteristics of an abnormal sound generated by the operation of the machine part, a specifying unit (714) which specifies the machine part in which the abnormal sound is generated from the characteristics acquired by the analysis unit (712) and the characteristics stored in the storage unit (713), and an adjusting unit (715) which adjusts a command for the operation of the machine part specified by the specifying unit (714).