1. Field of the Invention
The present invention relates to a step time display device for an injection molding machine for measuring and displaying operation time of operation steps executed by the injection molding machine so as to contribute to management of molding steps.
2. Description of the Related Art
Operation steps executed by an injection molding machine are roughly divided into a mold clamping step, an injection step, a holding-pressure step, a metering step, a mold opening step, and a molded article ejection step. A user analyzes time of each of these steps so as to evaluate stability of the molding steps and to intend to shorten a molding cycle.
As shown in
As disclosed in, for example, Japanese Patent Application Laid-Open No. 11-179520, a method of measuring and displaying time from start to end of operation performed by an actuator included in an injection molding machine which executes operation steps such as a mold clamping step and an injection step is conventionally used.
Furthermore, there are known conventional techniques for visually displaying molding steps on a screen. For example, a technique for measuring time of a series of molding steps such as a mold clamping step, an injection step, a charging step, a suck-back step, a mold opening step, and an ejection step in one cycle, and displaying the measured time of each of the steps on a timing chart (graph) with a horizontal axis indicating time is disclosed in Japanese Patent Application Laid-Open No. 2-55117. Further, a technique for displaying measurement data on a charging step, a mold opening step, an injection step, and an ejection step to correspond to time or screws is disclosed in Japanese Patent Application Laid-Open No. 5-42575. A technique for measuring execution time of steps executed in parallel with each other and displaying these parallel steps on a graph with a horizontal axis indicating time is disclosed in Japanese Patent Application Laid-Open No. 2006-15527.
As stated, according to the conventional techniques, the execution time of each of the operation steps such as injection step and mold clamping step is displayed, display contents are analyzed, stabilities of the molding steps are evaluated, and such considerations as shortening of the molding cycle are given.
However, the conventional techniques have the following problems. In a recent molding process, simultaneous operations such as injection during mold clamping, mold opening during metering, ejection during mold opening, and ejection during mold clamping are increasingly performed so as to shorten cycle time. With the conventional method of measurement for each of these steps, it is disadvantageously impossible to measure necessary and appropriate time such as multiple operation execution time of these simultaneous operations, time of starting the simultaneous operations, and total execution time of operations including the simultaneous operations.
For example, if injection is started during a mold clamping step, time from start of mold clamping to start of injection is important, but time covering an entire mold clamping step is not so important from viewpoints of cycle time. Moreover, from viewpoints of molded article quality, time from start of injection to completion of mold clamping is important because of the problem of outgassing from between the molds (from within the mold) during mold clamping, but time covering entire mold clamping step is not so important in a similar way. As can be seen, it is desirable to measure time at arbitrary timing irrespective of start or end of an operation of each actuator if simultaneous operations are performed.
It is, therefore, an object of the present invention to provide a step time display device for an injection molding machine capable of selecting arbitrary events such as a start and an end of each step of a molding operation and measuring and displaying a time interval between the selected events.
According to a first aspect of the present invention, there is provided a step time display device for an injection molding machine which comprises: a selection unit selecting, in measuring a time interval between two events, a first event being a time measurement start event and a second event being a time measurement end event from among a plurality of events in one molding cycle; a detection and storage unit which detects and stores occurrence time of each of the first and second events selected by the selection unit; and a display unit which calculates a time interval from occurrence of the first event to occurrence of the second event based on the occurrence time of each of the first and second events stored in the detection and storage unit, and displays the calculated time interval on a screen.
The display unit may display the occurrence of each of the first and second events selected by the selection unit on a logic chart with a horizontal axis indicating time.
According to a second aspect of the present invention, there is provided a step time display device for an injection molding machine which comprises: a selection unit selecting, in measuring a time interval between two events, a first event being a time measurement start event and a second event being a time measurement end event from among a plurality of events in one molding cycle; a time measurement unit which measures the time interval between the first and second events selected by the selection unit; a measured time storage unit which stores time intervals between the selected first and second events for a plurality of molding cycles, respectively; and a display unit which displays the time intervals between the first and second events for the plurality of molding cycles, stored in the measured time storage unit, on a trend chart with a horizontal axis indicating number of shots.
The time measurement unit may include a detection and storage unit detecting and storing occurrence time of each of the first and second events selected by the selection unit, and may measure the time interval between the first and second events based on the occurrence time of each of the first and second events stored in the detection and storage unit.
The step time display device for the injection molding machine according to the present invention is constituted as stated above. Therefore, an operator can easily measure time of a desired interval and display this measurement result as a time function. Furthermore, by displaying time measurement results for a plurality of molding cycles as a trend chart, it is possible to shorten one molding cycle based on the display of these measurement results and improve molded article quality.
The above and other objects and features of the present invention will be readily apparent from the description of the following embodiments with reference to the accompanying drawings, wherein:
In
The servo motor 20 driving the movable axes via a servo amplifier 18 is connected to the axis control unit 15. Although the axis control unit 15, the servo amplifier 18, and the servo motor 20 are provided for every movable axis, only one set of the axis control unit 15, the servo amplifier 18, and the servo motor 20 is shown in
Various sensors and actuators provided in the injection molding machine are connected to the input/output circuit (I/O) 16.
The processor 11 outputs the moving command to the axis control unit 15 corresponding to each movable axis and controls operations of steps including mold clamping, injection, holding pressure, metering, mold opening, molded article ejection steps of the injection molding machine based on a program stored in the memory. This control over the injection molding machine is similar to the conventional control. According to the embodiment, software having a function to designate events in a molding operation and to measure and display a operation time interval between these designated events is further added to the memory 12, and the step time display device according to the present invention is constituted by this added software, the display unit 13, the input unit 14 and the like.
Molding operation steps of the injection molding machine generally include a mold clamping step of closing and clamping a mold, an injection step of moving a screw forward, and injecting and filling up molten resin into the mold, a holding-pressure step of controlling a pressure of the molten resin in the mold after the resin is filed up into the mold, a cooling step of cooling the resin in the mold, a metering step of melting the resin by rotating a screw while applying a backpressure to the screw and metering the molten resin, a mold opening step of opening the mold, an ejection step of ejecting a molded article from within the mold, and the like.
In the embodiment, events of a start and end of each of these steps in the molding operation are designated, a time interval between the designated events is measured, and the measured time interval is displayed.
As shown in
In the example shown in
First, event identifiers Idx(0) to Idx(11) corresponding to 12 selectable events as shown in
If a molding operation starts, the processor 11 stars a processing shown in
Determination as to whether or not the event occurs is made based on a command signal issued from the processor 11 based on a program or on a signal from one of the various sensors. For example, as a command of an event such as mold clamping start, injection start, metering start or ejection start is issued from a program, the processor 11 can determine whether the event occurs by reading the command. Furthermore, the processor 11 can determine whether or not an event such as mold clamping completion, injection/holding-pressure switching, metering completion, mold opening completion or ejection end occurs by determining whether or not a corresponding actuator (e.g., the servo motor 20) moves to a designated position (e.g., whether or not the servo motor 20 reaches the designated position and an in-position signal is issued). The processor 11 can determine whether or not an event such as cooling start (holding-pressure end) or cooling end occurs by checking whether a preset holding-pressure time or cooling time is timed up by a timer (not shown) or not.
If the processor 11 cannot confirm that the event identified by the event identifier Idx(i) occurs (step a2; No), the processing proceeds to step a8. If the processor 11 can confirm that the event identified by the event identifier Idx(i) occurs (step a2; Yes), the processor 11 stores current time indicated by the clock unit 17 as event occurrence time T(i) in the event occurrence time storage table Tb1 in association with the event identifier Idx(i) (step a3). “1” is added to the counter C (step a4). The processor 11 determines whether a value of the counter C is equal to or greater than the number of events (=12) (step a5). In this embodiment, the total number of events is “12”, the counter C starts counting from “0”, and “1” is added to the counter C whenever current time is stored. Therefore, if the counter C indicates “12” after “1” is added to the counter C (step a5; Yes), this means that the event occurrence time of each of all the 12 events is stored. Furthermore, each event occurs only once in one molding cycle (one shot). Due to this, if all the events occur and the occurrence time of the events is stored, no other event of which time is to be stored in the cycle (shot) is present. This means that one molding cycle (one shot) ends in the event occurrence time storage processing. The processing proceeds to step a6, at which the processor 11 performs a time measurement processing to be described later. If the value of the counter C is not equal to or greater than the number of events (=12) (step a5; No), the processing proceeds to step a8.
At step a8, the processor 11 increments the index i by “1”. Further, the processor 11 determines whether the index i is equal to or greater than the number of selectable events (=12) (step a9). If the index i is not equal to or greater than the number of selectable events (=12) (step a9; No), the processor 11 determines whether the molding operation ends or not (step a11). If the molding operation does not end (step a11; No), the processing returns to step a2. Thereafter, processing in steps a2, a8, a9, a11, and a2 or processing in steps a2, a3, a4, a5, a8, a9, a11, and a2 are repeatedly executed while incrementing the index i by “1” until the index i reaches the number of all selectable events (=12). If the index i is equal to or greater than the number of selectable events (=12) (step a9; Yes), the processor 11 resets the index i to “0” (step a10) and determines whether the molding operation ends or not (step a11). If the molding operation does not end (step a11; No), the processing returns to step a2 and executes the above-stated procedures.
If the value of the counter C is equal to or greater than the number of selectable events (=12) and each of occurrence time T(0) to T(11) is stored in the event occurrence time storage table Tb1 for all the events (step a5; Yes), the processing proceeds to step a6, at which the processor 11 performs the time measurement processing. Further, the processor 11 resets the counter C to “0” (step a7) and processing proceeds to step a8.
If the “time measurement processing” starts at step a6, the processor 11 sets indexes j and k to “0” (step b1) and calculates a time interval (measured time) between the events indicated by the indexes j and k, respectively as Int(j, k) (step b2). Namely, the processor 11 subtracts occurrence time T(j) stored in the event occurrence time storage table Tb1 in association with an event j (event identifier Idx(j)) from occurrence time T(k) stored in the event occurrence time storage table Tb1 in association with an event k (event identifier Idx(k)), thereby calculating the time interval Int(j, k) from the occurrence time of the event j to that of the event k, and stores the calculated time interval Int(j, k) in the corresponding inter-event measured time storage table Tb2.
The processor 11 increments the index k by “1” (step b3) and determines whether the index k is equal to or greater than the number of all selectable events (=12) (step b4). If the index k is not equal to or greater than the number of all selectable events (=12) (step b4; No), the processing proceeds to step b7. At step b7, the processor 11 determines whether the index j is equal to or greater than the number of all selectable events (=12). If the index j is not equal to or greater than the number of all selectable events (=12) (step b7, No), the processing returns to step b2. Thereafter, the processor 11 repeatedly executes the processing in steps b2 to b4 and b7 while incrementing the index k by “1” until the index k reaches the number of all selectable events (=12). If the processor 11 determines that the index k is equal to or greater than the number of all selectable events (=12) (step b4; Yes), the processor 11 resets the index k to “0” (step b5) and increments the index j by “1” (step b6), and determines whether the index j is equal to or greater than the number of all selectable events (=12) (step b7). If the index j is not equal to or greater than the number of all selectable events (=12) (step b7; No), the processing returns to step b2. In this way, the processor 11 stores measured time intervals Int(j, k) between the events in the inter-event measured time storage table Tb2 shown in
In the inter-event measured time storage table Tb2 shown in
In this manner, the time intervals between the events are stored in the inter-event measured time storage table Tb2. If the difference (time interval) between the same event such as Int(0, 0), Int(1, 1) . . . or Int(11, 11) is calculated, the value is “0” and a corresponding box in the inter-event measured time storage table Tb2 shown in
If a command to display the logic chart displaying the time intervals between the selected and designated events as shown in
Likewise, in the example shown in
When one molding cycle ends and the event occurrence time storage table Tb1 shown in
Moreover, if a trend chart display command for illustrating a trend of the time interval between the two events (measurement interval) selected in one molding cycle (shot) is input from the input unit 14, the processor 11 draws a trend chart shown in
The processor 11 reads the measured time intervals Int (j, k) each between the events corresponding to the event (Idx(j)) set as the measurement start event and the event (Idx(k)) set as the measurement end event are read from the inter-event measured time storage table Tb2 shown in
In the example shown in
Likewise, in the second measurement interval, the “injection start” is set as the measurement start event and the “mold clamping completion” is set as the measurement end event. Due to this, the time intervals Int(2, 1) are read from the inter-event measured time storage tables Tb2 corresponding to the respective molding cycles (shot) and displayed as shown in
Since measured time (time interval) is from the “injection start” to the “injection/holding-pressure switching” in the third measurement interval, the time intervals Int(2, 3) are read from the inter-event measured time storage tables Tb2 corresponding to the respective molding cycles (shot) and displayed as shown in
Since the measured time of each molding cycle (shot) is displayed for every measurement interval in the trend chart shown in
In the embodiment stated above, in the processing shown in
Number | Date | Country | Kind |
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2007-177208 | Jul 2007 | JP | national |