JP5497624B2 - Injection molding machine - Google Patents

Description

  The present invention relates to an injection molding machine including a power storage device that stores power that can be used when a power failure occurs in an AC power supply.

  Conventionally, an injection molding machine including a storage battery that stores electric power generated by a solar panel is known (see, for example, Patent Document 1).

  This injection molding machine includes a main control device driven by a commercial AC power source and a sub-control device driven by the storage battery, and records control data of the main control device in a memory in the sub-control device in real time. In addition, while maintaining the control data even when a power failure occurs, the contents of the control data recorded in the memory (ie, the situation at the time of the power failure) can be displayed on the CRT when the power failure is resolved. It is possible to assist the operator to restart the injection molding machine stopped due to the occurrence.

  In addition, an injection molding machine is known in which a converter circuit for obtaining a control DC voltage and a converter circuit for obtaining a motor driving voltage are each provided with an energy storage capacitor (for example, Patent Document 2). reference.).

  This injection molding machine uses the energy stored in these capacitors after a power outage to drive each drive shaft to stop the components safely, and also represents the state of the injection molding machine Is stored in a non-volatile storage device.

JP 2000-202886 A JP 2004-216829 A

  However, both of the injection molding machines described in Patent Documents 1 and 2 are based on the premise that the molding operation is stopped after a power failure occurs, and the molding operation is performed using the power stored in the storage battery or the capacitor after the power failure occurs. Therefore, even if the power supply recovery by the emergency AC backup power source or the like is scheduled immediately after the occurrence of a power failure, the molding operation is surely stopped.

  In view of the above-described points, an object of the present invention is to provide an injection molding machine that enables a molding operation to be continued with electric power in a power storage device even when a power failure occurs.

  In order to achieve the above object, an injection molding machine according to an embodiment of the present invention is an injection molding machine including a power storage device that stores power that can be used during a power failure. And a molding operation continuation determination unit that determines whether or not the molding operation can be continued with the electric power stored in the battery.

  With the above-described means, the present invention can provide an injection molding machine that allows a molding operation to be continued with electric power in the power storage device even when a power failure occurs.

It is the schematic which shows the structural example of the molding control system mounted in the injection molding machine which concerns on the Example of this invention. It is a functional block diagram which shows the structural example of the controller in a control part. It is a flowchart which shows the flow of a control process at the time of a power failure.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a schematic diagram illustrating a configuration example of a molding control system SYS mounted on an injection molding machine according to an embodiment of the present invention, and FIG. 2 is a functional block diagram illustrating a configuration example of a controller 21 in a control unit 20. It is.

  The molding control system SYS is a system for controlling the molding operation of the injection molding machine, and mainly includes an AC power source 10, a control unit 20, a power conversion unit 30, an electric motor 40, a molding machine sensor 50, and a peripheral device sensor 51. , A display device 60, and an audio output device 61.

  The AC power source 10 is a device for supplying AC power to the control unit 20 and the power conversion unit 30, and is, for example, a commercial three-phase AC power source.

  The control unit 20 is a device for controlling the molding operation of the injection molding machine, and mainly includes a controller 21, a switching power supply 22, a first power storage device 23, and an AC voltage detection circuit 24.

  The controller 21 is a computer including a CPU (Central Processing Unit), a RAM (Random Access Memory), an SRAM (Static RAM), a flash memory, a ROM, and the like. For example, the molding control unit 210, the power failure determination unit 211, the molding A program corresponding to each functional element of the operation continuation possible time calculation unit 212, the molding operation continuation determination unit 213, the molding operation stop determination unit 214, and the stop mode selection unit 215 (see FIG. 2) is read from the ROM and stored on the RAM. To cause the CPU to execute processing corresponding to each functional element.

  Each functional element may be configured by hardware using an analog circuit, a digital circuit, a PLD (Programmable Logic Device), an FPGA (Field Programmable Gate Array), an FPAA (Field Programmable Analog Array), or the like.

  In addition, the controller 21 acquires detection values output from the first power storage device 23, the second power storage device 33, the molding machine sensor 50, the peripheral device sensor 51, and the like, and performs processing corresponding to each functional element described above. The control signal is output to the display device 60 and the audio output device 61 according to the processing result.

  Further, the controller 21 monitors the rotation speed value of the electric motor 40 output from an encoder (not shown) attached to the rotation shaft of the electric motor 40 and includes a command value of a desired motor rotation speed. A control signal is generated, and the generated timing control signal is output to the inverter circuit 34 that drives the electric motor 40.

  The switching power supply 22 is a device that converts AC power of the AC power supply 10 into DC power, and converts AC power of a predetermined voltage into DC power of a predetermined voltage.

  The first power storage device 23 is a device for supplying the DC power to the controller 21 while storing the DC power output from the switching power supply 22. For example, the supply of AC power from the AC power supply 10 is interrupted, Even when the supply of the DC power from the switching power supply 22 is interrupted, the DC power of a predetermined voltage can be continuously supplied to the controller 21 over a certain period.

  In addition, the first power storage device 23 may output information related to a power storage state such as a power storage voltage to the controller 21 so that the controller 21 can monitor and grasp the power storage state of the first power storage device 23.

  The AC voltage detection circuit 24 is a device for detecting the AC voltage supplied to the switching power supply 22. For example, by outputting the detection result to the controller 21, whether or not a power failure has occurred in the AC power supply 10 is detected. The controller 21 can be detected. The AC voltage detection circuit 24 may be replaced with a device for detecting a DC voltage supplied to the first power storage device 23.

  The power conversion unit 30 is an apparatus for converting AC power into DC power and further converting the DC power into AC power suitable for various loads, for example, an inverter mounted on an injection molding machine, A diode module 31, a capacitor 32, a second power storage device 33, and an inverter circuit 34 are provided.

  The diode module 31 is a device that converts AC power of the AC power supply 10 into DC power, and converts AC power of a predetermined voltage into DC power of a predetermined voltage.

  The capacitor 32 is a device for smoothing the output of the diode module 31, and is, for example, an electrolytic capacitor.

  The second power storage device 33 is a device for supplying the DC power to the inverter circuit 34 while storing the DC power output from the diode module 31 and smoothed by the capacitor 32. Even when the supply of AC power is interrupted and the supply of DC power from the diode module 31 is interrupted, DC power of a predetermined voltage can be continuously supplied to the inverter circuit 34 for a certain period.

  Further, the second power storage device 33 may output information related to a power storage state such as a power storage voltage to the controller 21 so that the controller 21 can monitor and grasp the power storage state of the second power storage device 33.

  The inverter circuit 34 is a device for converting the DC power output from the second power storage device 33 into AC power, for example, an IGBT (Insulated Gate Bipolar Transistor), an IPM (Intelligent Power Module), or a power MOSFET (Metal Oxide Semiconductor). The power switching element is configured by a power switching element such as a field effect transistor, and the power switching element is switched on / off in accordance with a timing control signal from the controller 21 in the control unit 20 to convert DC power into AC power.

  The electric motor 40 is an electric load that operates by receiving AC power. For example, the electric motor 40 is a closed-loop control servomotor, and an injection motor and mold clamping when the power conversion unit 30 is mounted on an injection molding machine. Motors, resin metering motors, ejector motors, and the like.

  In FIG. 1, the molding control system SYS is illustrated as including only one combination of the power conversion unit 30 and the electric load (electric motor 40), but another combination (for example, the power conversion unit 30). And a combination of an injection cylinder heater and the like.

  In that case, the second power storage device 33 may be individually included in the power conversion unit 30 in each of the plurality of combinations, or may be shared by the plurality of power conversion units 30. .

  The molding machine sensor 50 is a sensor for detecting the operating state of the injection molding machine main body. For example, the molding machine sensor 50 detects the rotational states of the injection motor, mold clamping motor, resin metering motor, and ejector motor. To detect the pressure in the injection cylinder, the encoder attached to the drive shaft of each motor, the strain sensor for detecting the back pressure of the injection screw, the temperature sensor for detecting the temperature in the injection cylinder The detected value is output to the controller 21.

  The peripheral device sensor 51 is a sensor for detecting the operating state of the peripheral device attached to the injection molding machine. For example, a feeder for supplying resin pellets to the injection cylinder or an injection cylinder for heating the injection cylinder It is a sensor that detects the operating state of a heater or the like, and outputs the detected value to the controller 21.

  The display device 60 is a device for displaying various types of information. For example, the display device 60 is a liquid crystal display or an LED (Light Emitting Diode) and the like. Information related to the molding operation of the injection molding machine, such as the start of power supply by an emergency AC backup power source, etc.) is displayed.

  The sound output device 61 is a device for outputting various kinds of information as sound. For example, the sound output device 61 is a speaker or a buzzer, which generates a power outage, starts a molding operation with power from the power storage device, eliminates the power outage (emergency AC backup power supply) Information regarding the molding operation of the injection molding machine, such as the start of power feeding by

  Next, each functional element included in the controller 21 will be described.

  The molding control unit 210 is a functional element for controlling the molding operation of the injection molding machine. For example, one or a plurality of electric motors 40 (for example, an injection motor) are controlled in accordance with outputs from the molding machine sensor 50 and the peripheral device sensor 51. A timing control signal for each of the inverter circuits 34 corresponding to each of the motor, mold clamping motor, resin metering motor, ejector motor, etc.), and each of the one or a plurality of inverter circuits 34 is generated. The generated timing control signals are output.

  In addition, the molding control unit 210 is configured to output one or a plurality of peripheral devices (for example, an ejector, a resin supply feeder, a mold heater, an injection cylinder heater, etc.) according to the outputs of the molding machine sensor 50 and the peripheral device sensor 51. And may be a device driven by a power source different from that of the injection molding machine, or may be a device driven by the same power source as the injection molding machine). Alternatively, the generated control signals are output to a plurality of peripheral devices.

  The molding control unit 210 records the output of the molding machine sensor 50 and the peripheral device sensor 51 received at a predetermined sampling interval in the RAM in a time series as a part of log information, and changes the molding operation of the injection molding machine. Enable post-mortem analysis.

  The power failure determination unit 211 is a functional element for determining whether or not the supply of AC power to the control unit 20 or the power conversion unit 30 is interrupted. For example, based on the output of the AC voltage detection circuit 24, the AC power supply 10 The presence or absence of the occurrence of a power failure (including instantaneous power failure) and the presence or absence of a power failure in the AC power source 10 (for example, the start of power supply by the emergency AC backup power source) are determined.

  The molding operation continuation possible time calculation unit 212 is a time during which the molding operation of the injection molding machine can be continued without receiving supply of AC power from an external power source (hereinafter referred to as “molding operation continuation possible time”). A functional element for calculating, for example, a power storage state output by the second power storage device 33 to the controller 21 when the power failure determination unit 211 determines that the supply of AC power from the AC power supply 10 has been interrupted. On the basis of the information related to this, the molding operation continuation possible time by the electric power of the second power storage device 33 is calculated.

  Further, the molding operation continuation time calculation unit 212 derives the power consumption per molding cycle based on the output of the molding machine sensor 50, and the power consumption per molding cycle and the power storage of the second power storage device 33. Based on the information on the state, the molding operation continuation possible time by the power of the second power storage device 33 may be calculated.

  The molding operation continuation possible time calculation unit 212 estimates the power storage state of the second power storage device 33 without receiving information from the second power storage device 33 (for example, estimates that the power storage device is fully charged), and the estimated You may make it calculate shaping | molding operation continuation time by the electric power of the 2nd electrical storage apparatus 33 based on an electrical storage state.

  The molding operation continuation determination unit 213 is a functional element for determining whether or not the molding operation of the injection molding machine can be continued without receiving supply of AC power from an external power source. When the unit 211 determines that the supply of AC power from the AC power supply 10 has been interrupted, each of the one or more peripheral devices performs a molding operation based on the detection value output from the peripheral device sensor 51 to the controller 21. It is determined whether or not it is in a state suitable for continuing the molding, and it is determined whether or not the molding operation can be continued based on the determination results.

  In this case, the molding operation continuation determination unit 213 continues the molding operation when one or more peripheral devices are in an inoperable state or when the output from the one or more peripheral device sensors 51 cannot be received. Is determined to be impossible.

  Further, the molding operation continuation determination unit 213 determines the molding operation continuation possible time calculated by the molding operation continuation possible time calculation unit 212 and the time from the occurrence of a power failure in the AC power supply 10 to the start of power supply by the emergency AC standby power It is possible to determine whether or not the molding operation can be continued on the basis of “the standby power supply switching time”).

  In this case, the molding operation continuation determination unit 213 determines that the molding operation can be continued when the molding operation continuation possible time is equal to or longer than the standby power supply switching time. If it is shorter than the switching time, it is determined that the molding operation cannot be continued.

  The molding operation continuation determination unit 213 determines that the molding operation cannot be continued regardless of the length of the molding operation continuation time when the standby power supply switching time is not set. Also good.

  The molding operation stop determination unit 214 is a functional element for determining whether or not to stop the molding operation that has been continued without receiving supply of AC power from an external power source. For example, the standby power switching time has elapsed. Nevertheless, when the power supply from the external power source does not return, it is determined that the molding operation should be stopped.

  In addition, the molding operation stop determination unit 214, when the power supply by the external power source does not return even though the standby power source switching time has elapsed, and when the storage voltage of the second power storage device 33 falls below a predetermined voltage, It may be determined that the molding operation should be stopped.

  The stop mode selection unit 215 should stop the molding operation that has been continued by the molding operation stop determination unit 214 when the molding operation continuation determination unit 213 determines that the molding operation cannot be continued. Is a functional element for selecting a stop mode of the injection molding machine.

  The “stop mode” is a method for stopping an operating injection molding machine. For example, a “one-cycle stop mode” for stopping an injection molding machine after completing a currently executed molding cycle is being executed. "Stop mode after completion of pressure holding" after stopping the pressure-holding process in the molding cycle in progress, and the injection-molding machine after completing the mold opening process in the molding cycle currently being executed There are “stop mode after mold opening” etc.

  The stop mode selection unit 215 grasps the current state of the injection molding machine based on the output of the molding machine sensor 50, selects a stop mode most suitable for the current state, and executes the selected stop mode.

  Specifically, the stop mode selection unit 215 outputs the selection result to the molding control unit 210, and the molding control unit 210 that has received the selection result receives a timing control signal corresponding to the selected stop mode. And the timing control signal thus generated is output to each of one or a plurality of inverter circuits 34 to stop the molding operation by the injection molding machine.

  Next, the flow of power failure control processing by the molding control system SYS will be described with reference to FIG. FIG. 3 is a flowchart showing the flow of the power failure control process, and the molding control system SYS repeatedly executes the power failure control process at a predetermined cycle.

  First, the controller 21 of the control unit 20 determines whether or not a power failure has occurred by the power failure determination unit 211 based on the output of the AC voltage detection circuit 24 (step S1).

  If it is determined that a power failure has not occurred (NO in step S1), the controller 21 ends the current power failure control process.

  When it is determined that a power failure has occurred (YES in step S1), the controller 21 outputs a control signal to the display device 60 and the sound output device 61 to display or sound output that the power failure has occurred. This is notified to the person (step S2).

  When a power failure occurs (when the supply of AC power from the AC power supply 10 is interrupted), the injection molding machine automatically changes the control operation of the controller 21 by the AC power to the control operation by the power stored in the first power storage device 23. The control operation by the electric power stored in the first power storage device 23 is started, and the molding operation by the AC power is automatically switched to the molding operation by the power stored in the second power storage device 33, The molding operation using the electric power stored in the second power storage device 33 is started.

  Thereafter, the controller 21 determines whether or not the molding operation can be continued with the power stored in the second power storage device 33 by the molding operation continuation determination unit 213 (step S3).

  Specifically, the controller 21 determines whether each of one or a plurality of peripheral devices is in a state suitable for continuing the molding operation based on the detection value received from the peripheral device sensor 51, or molding It is determined whether or not the molding operation can be continued by comparing the molding operation continuation possible time calculated by the operation continuation possible time calculation unit 212 and the standby power supply switching time.

  When it is determined that the molding operation can be continued (YES in step S3), the controller 21 stores power in the second power storage device 33 as in the case where AC power is supplied from the AC power supply 10. The molding operation with electric power is continued (step S4).

  Thereafter, the controller 21 uses the power failure determination unit 211 to determine whether or not the power failure has been resolved based on the output of the AC voltage detection circuit 24 (step S5).

  If it is determined that the power failure has been resolved (YES in step S5), the controller 21 outputs a control signal to the display device 60 and the audio output device 61 to display or output a sound to the effect that the power failure has been resolved. To that effect (step S6), and terminates the current power failure control process.

  When the power failure is resolved (for example, when the supply of AC power from the AC power supply 10 or the emergency AC backup power supply is resumed), the injection molding machine controls the controller 21 using the power stored in the first power storage device 23. The control operation is automatically switched to the control operation using AC power, the control operation using AC power is started, and the molding operation using the power stored in the second power storage device 33 is automatically switched to the molding operation using AC power. Thus, the molding operation using AC power is started. In addition, the injection molding machine automatically starts the power storage of the first power storage device 23 and the second power storage device 33 by the AC power.

  On the other hand, if it is determined that the power failure has not been resolved (NO in step S5), the controller 21 causes the molding operation stop determination unit 214 to stop the molding operation using the power stored in the second power storage device 33. In order to determine whether or not the standby power switching time has elapsed (step S7).

  Instead of determining whether or not the standby power supply switching time has elapsed, the controller 21 determines whether or not the storage voltage of the second power storage device 33 has fallen below a predetermined voltage, thereby causing the second power storage device 33 to You may make it determine whether the shaping | molding operation | movement with the stored electric power is stopped.

  If it is determined that the standby power switching time has not elapsed (NO in step S7), the controller 21 executes the determination in step S5 again.

  When it is determined that the standby power supply switching time has elapsed (YES in step S7), the controller 21 uses the stop mode selection unit 215 to grasp the current state of the injection molding machine based on the output of the molding machine sensor 50, and The most suitable stop mode is selected (step S8).

  Thereafter, the controller 21 outputs the selection result to the molding control unit 210 by the stop mode selection unit 215, and generates a timing control signal corresponding to the selected stop mode by the molding control unit 210. Alternatively, the molding operation by the injection molding machine is stopped by outputting the generated timing control signals to each of the plurality of inverter circuits 34 (step S9).

  Even when it is determined in step S3 that the molding operation cannot be continued with the power stored in the second power storage device 33 (NO in step S3), the controller 21 causes the stop mode selection unit 215 to Based on the output of the molding machine sensor 50, the current state of the injection molding machine is grasped, and the stop mode most suitable for the current state is selected (step S8).

  Then, the controller 21 outputs the selection result to the molding control unit 210, and the molding control unit 210 generates a timing control signal corresponding to the selected stop mode, and the one or a plurality of inverter circuits 34. By outputting the generated timing control signals to each, the molding operation by the injection molding machine is stopped (step S9).

  With the above configuration, the molding control system SYS in the injection molding machine including the second power storage device 33 that stores power that can be used during a power failure is stored in the second power storage device 33 even when a power failure occurs. The molding operation is continued after determining that it is possible to continue the molding operation with the generated power (execution of the molding operation until the supply of AC power is resumed). Can be continued.

  In addition, the molding control system SYS has a time during which the molding operation of the injection molding machine can be continued without receiving supply of AC power from the external power source. If it is longer than the switching time, it is determined that the molding operation using the power stored in the second power storage device 33 can be continued. Therefore, the continued molding operation is interrupted before resuming the supply of AC power due to power shortage. Therefore, the molding operation during the power failure period can be reliably continued.

  In addition, when the molding control system SYS determines that the predetermined peripheral device is in a state suitable for continuing the molding operation, the molding control system SYS determines that the molding operation using the power stored in the second power storage device 33 can be continued. Even if there is a peripheral device that is driven by a power source different from the main body of the injection molding machine, the peripheral device remains inoperable and the molding operation is not continued. The molding operation during the power failure can be continued reliably and appropriately.

  Note that the molding control system SYS has two power storage devices: a first power storage device 23 that supplies power to the controller 21 when a power failure occurs, and a second power storage device 33 that supplies power to the inverter circuit 34 when a power failure occurs. Although a device is provided, a single power storage device that supplies power to both the controller 21 and the inverter circuit 34 when a power failure occurs may be provided.

  In this case, the one power storage device supplies the DC power to the inverter circuit 34 and the controller 21 of the control unit 20 while storing the DC power output from the diode module 31 and smoothed by the capacitor 32, for example, Even when the supply of AC power from the AC power supply 10 is interrupted and the supply of DC power from the diode module 31 is interrupted, DC power of a predetermined voltage is continuously supplied to the inverter circuit 34 for a certain period. It is comprised so that it can do, and it is comprised so that DC power of a predetermined voltage can be continuously supplied with respect to the controller 21 over a fixed period.

  With this configuration, the configuration of the molding control system SYS in the injection molding machine including the one power storage device that stores power that can be used during a power failure can be further simplified.

  Although the preferred embodiments of the present invention have been described in detail above, the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the present invention. Can be added.

  For example, in the above-described embodiment, the injection molding machine equipped with the molding control system SYS includes the second power storage device 33 that stores electric power for operating the electric motor 40 during a power outage. You may make it provide the electrical storage apparatus which accumulate | stores the electric power for operating the heater for cylinders.

  DESCRIPTION OF SYMBOLS 10 ... AC power supply 20 ... Control part 21 ... Controller 22 ... Switching power supply 23 ... 1st electrical storage apparatus 24 ... AC voltage detection circuit 30 ... Power conversion part 31 ... Diode module 32 ... Capacitor 33 ... Second power storage device 34 ... Inverter circuit 40 ... Electric motor 50 ... Molding machine sensor 51 ... Peripheral device sensor 60 ... Display device 61 ... Voice output device 210 ... molding control unit 211 ... power failure determination unit 212 ... molding operation continuation possible time calculation unit 213 ... molding operation continuation possibility determination unit 214 ... molding operation stop determination unit 215 ..Stop mode selection unit SYS ... Molding control system

Claims (3)

An injection molding machine equipped with a power storage device that stores power that can be used during a power failure,
When a power failure occurs, a molding operation continuation determination unit is provided that determines whether or not the molding operation can be continued with the power stored in the power storage device.
An injection molding machine characterized by that. The molding operation continuation enable / disable determining unit determines that the molding operation with the power stored in the power storage device can be continued when it is determined that the predetermined peripheral device is in a state suitable for continuing the molding operation.
The injection molding machine according to claim 1. The molding operation continuation determination unit determines that the time during which the molding operation of the injection molding machine can be continued without receiving supply of AC power from an external power source is longer than the scheduled time from the occurrence of a power failure to the start of power feeding by the external power source. In some cases, it is determined that the molding operation with the power stored in the power storage device can be continued.
The injection molding machine according to claim 1 or 2, characterized in that.

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