Molding Machine Logic Graph Display for Signal Change Detection
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Solution Overview
Problem
Existing logic graph displaying systems for molding machines struggle to reliably detect and display minute changes in on/off signals, especially when these changes occur in extremely short times, leading to difficulties in diagnosing defective moldings and inefficiencies in production due to limited screen resolution and the need for external devices.
Innovation Solution
A logic graph displaying apparatus and method that acquires and logs on/off data, using a ring buffer to store timing information, and displays this data on a logging screen with adjustable cursors and magnification options, allowing for detailed analysis of signal changes without the limitations of conventional display screens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional display screens are used to display logic graphs of I/O signals, then the display system is simple and cost-effective, but minute on/off signal changes occurring in extremely short time cannot be reliably detected or displayed
Solution Approach 1:
The patent segments the signal detection and display functions: the control unit segments signal sampling at high frequency intervals independent of screen refresh rate, while the display unit segments presentation by showing logic graphs with time-axis magnification. This allows precise detection (segment 1) without requiring the entire display system to operate at high speed (segment 2), resolving the contradiction between precision and complexity.
Solution Approach 2:
The patent adds a time-dimension to the display by introducing magnification capability on the time axis. Instead of trying to display rapid signal changes at normal screen resolution, the system magnifies the time dimension to spread out minute signal changes across the display area, enabling detection of changes smaller than the original screen refresh interval without increasing hardware complexity.
2Measurement precision
If external dedicated devices are used to record and display signal changes, then minute signal changes can be detected, but the device complexity and cost increase
Solution Approach 1:
The patent merges the signal recording function and the display function into a single integrated system within the molding machine's control unit. The control unit performs high-frequency signal sampling and stores data in its memory, then displays logic graphs directly on its screen with time-axis magnification. This eliminates the need for separate external recording devices and dedicated display systems, reducing overall device complexity while maintaining detection precision.
Solution Approach 2:
The patent makes the control unit multi-functional by enabling it to both control the molding machine operations and simultaneously perform high-precision signal recording and analysis. The control unit's processor and memory serve dual purposes: executing molding control logic and capturing/displaying I/O signal changes with magnification capability. This universal usage eliminates dedicated external devices, reducing system complexity.
3Measurement precision
If the screen refresh rate is increased to display faster signal changes, then detection precision improves, but the response time for other operations decreases and system performance degrades
Solution Approach 1:
The patent segments the sampling function from the display refresh function. The control unit continuously samples I/O signals at high frequency intervals independent of screen refresh rate, storing data in memory. The display then presents this data with time-axis magnification. This segmentation allows precise signal capture without forcing the entire system to operate at high refresh rates, preserving molding cycle efficiency.
Solution Approach 2:
The patent performs preliminary signal sampling and data storage in memory at high frequency before display is needed. The control unit continuously records signal changes in advance, storing them with timestamp information. When display is required, the pre-captured data with magnified time axis is presented. This preliminary action allows high-precision detection without requiring continuous high-speed display refresh, maintaining productivity.
Data Source
AI summary
A logging data about a signal identifier of the I/O signals which changed in on/off state are stored in a ring buffer. A logging screen includes identifier display parts, logic-graph display parts and first and second cursors. The logic-graph display parts display logic graphs associated with signal identifiers, respectively. When any one of the identifier display parts displayed on the logging screen is clicked, the logging screen is changed to an input window. If a desired input identifier is input in the input window, the logging data associated with the signal identifier is read from the ring buffer and the logic graph is displayed in the logic-graph display parts. The logic graph can be modified.