Injection Molding Robot Return Control for Collision Recovery
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Solution Overview
Problem
In injection molding systems, errors during the removal of molded objects can occur due to unclear distinctions between machine and robot operations, making it difficult to determine and rectify the source of the error, leading to potential collisions and inefficiencies.
Innovation Solution
An injection molding system that includes an injection molding machine, a robot, and a control device capable of transmitting commands in different languages to control both the machine and the robot. The control device determines errors and initiates return operations for both the machine and the robot, ensuring they execute return operations independently to prevent collisions and rectify issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot is used to take out molded objects from the injection molding machine, then productivity is improved through automated handling, but the complexity of error identification and system coordination worsens when errors occur
Solution Approach 1:
The system segments error handling by creating separate return operation routines for the injection molding machine and the robot. When an error occurs, the control device independently manages return operations for each device based on their respective command languages, simplifying error identification and handling while maintaining automated productivity
Solution Approach 2:
The control device acts as an intermediary that translates high-level error recovery commands into device-specific commands. It receives error information, determines the appropriate return operation, and transmits commands in the respective languages (first language for the injection molding machine, second language for the robot), thereby coordinating complex multi-device error recovery without increasing operational complexity
2Adaptability or versatility
If the control device transmits commands in different languages to the injection molding machine and robot, then adaptability is improved for controlling different devices, but the difficulty of detecting and measuring errors worsens
Solution Approach 1:
The error detection system is segmented into device-specific monitoring channels. The control device maintains separate error detection mechanisms for the injection molding machine and the robot, allowing errors to be identified and attributed to specific devices despite using different command languages for control
Solution Approach 2:
The system implements feedback mechanisms where the control device receives status information and error signals from both the injection molding machine and the robot. This feedback loop enables the control device to identify error sources by analyzing responses from each device in their respective command languages, maintaining adaptability while improving error detectability
3Reliability
If return operations are executed independently for both the injection molding machine and robot, then reliability is improved by preventing collisions, but the loss of time increases due to sequential error recovery
Solution Approach 1:
The system performs preliminary error detection and determines the need for return operations before actual collisions or malfunctions occur. By proactively initiating coordinated return operations for both the injection molding machine and the robot when errors are detected, the system prevents collisions while minimizing downtime through early intervention
Data Source
AI summary
An injection molding system includes: an injection molding machine configured to operate in accordance with a command generated using a first language, and inject a molten material into a mold to mold a molded object; a robot configured to operate in accordance with a command generated using a second language, and convey the molded object; and a control device configured to control the injection molding machine and the robot. When determining that an error occurs in at least one of the injection molding machine and the robot, the control device transmits, to the injection molding machine, a command generated using the first language and for causing the injection molding machine to execute a return operation, and transmits, to the robot, a command interpretable by the second language and for causing the robot to execute a return operation, so as to cause the injection molding machine and the robot to execute the return operations.