TW201941904A

TW201941904A - Injection molding machine capable of preventing thickness precision and surface precision of a molded article from being decreased

Info

Publication number: TW201941904A
Application number: TW108109913A
Authority: TW
Inventors: 雷磊; 上遠野智祐
Original assignee: 日商住友重機械工業股份有限公司
Priority date: 2018-03-30
Filing date: 2019-03-22
Publication date: 2019-11-01
Also published as: JP7046675B2; CN110315708A; KR20190114818A; JP2019177535A; CN110315708B; TWI711523B

Abstract

An object of the present invention is to prevent thickness precision and surface precision of a molded article from being decreased due to thermal deformation of an ejection rod or the like during compression molding. One type of the injection molding machine according to one embodiment has an ejection rod and a control part for controlling the advancement and retreat of the ejection rod, wherein the ejection rod is used to move a movable member from a compression standby position to a compression molding position, thereby compressing the molding material filled in the space of a mold cavity, which is characterized in that the control part determines the compression molding position according to the location at which the movable member contacts with a fixed mold when the ejection rod causes the movable member to advance.

Description

Injection molding machine

本申請主張基於2018年3月30日申請之日本專利申請第2018-067179號的優先權。該日本申請的全部內容藉由參閱援用於本說明書中。
本發明係有關一種射出成形機。This application claims priority based on Japanese Patent Application No. 2018-067179 filed on March 30, 2018. The entire contents of this Japanese application are incorporated herein by reference.
The present invention relates to an injection molding machine.

已知有一種壓縮成形技術，是於透鏡等的射出成形中使用具有頂出桿和活動構件的頂出裝置，利用頂出桿將活動構件從壓縮待機位置推進至壓縮成形位置，藉此壓縮填充於模穴空間之成形材料(例如參閱專利文獻1)。
[先前技術文獻]
[專利文獻]
專利文獻1：日本特開2016-83776號公報A compression molding technique is known in which an ejection device having an ejector rod and a movable member is used for injection molding of a lens or the like, and the ejector rod is used to advance the movable member from the compression standby position to the compression molding position, thereby compressing and filling. A molding material in a cavity space (see, for example, Patent Document 1).
[Prior technical literature]
[Patent Literature]
Patent Document 1: Japanese Patent Application Laid-Open No. 2016-83776

[發明所欲解決之問題]
然而，專利文獻1的技術中，若因成形時產生熱而使頂出桿等變形，會有因無法將活動構件之位置以所期望的精度控制而使得成形品的厚度精度及表面精度下降的情況。
本發明係鑑於上述問題而開發完成的，其目的為提供一種防止壓縮成形中因頂出桿等的熱變形致使成形品的厚度精度及表面精度下降。

[解決問題之技術手段]
實施形態的一態樣的射出成形機，係具有頂出桿、及控制前述頂出桿之進退的控制部，藉由前述頂出桿使活動構件從壓縮待機位置前進至壓縮成形位置，藉此壓縮填充於模穴空間之成形材料，其特徵在於，前述控制部，於利用前述頂出桿使前述活動構件前進時，是根據前述活動構件與前述固定模接觸之位置來決定前述壓縮成形位置。

[發明之效果]
依據實施形態的一態樣，能夠防止壓縮成形中因頂出桿等的熱變形致使成形品的厚度精度及表面精度下降。[Problems to be solved by the invention]
However, in the technology of Patent Document 1, if the ejector rod or the like is deformed due to heat generated during molding, the thickness accuracy and surface accuracy of the molded product may be lowered because the position of the movable member cannot be controlled with desired accuracy. Happening.
The present invention has been developed in view of the above-mentioned problems, and an object thereof is to provide a method for preventing a reduction in thickness accuracy and surface accuracy of a molded product due to thermal deformation of an ejector pin or the like during compression molding.

[Technical means to solve the problem]
An injection molding machine according to one aspect of the embodiment includes an ejector lever and a control unit that controls the advancement and retreat of the ejector lever. The ejector lever advances the movable member from the compression standby position to the compression molding position. The molding material compressed and filled in the cavity space is characterized in that the control unit determines the compression molding position based on a position where the movable member contacts the fixed mold when the movable member is advanced by the ejector.

[Effect of the invention]
According to one aspect of the embodiment, it is possible to prevent a reduction in thickness accuracy and surface accuracy of a molded product due to thermal deformation of an ejector pin or the like during compression molding.

以下，參閱圖式對用於實施本發明的形態進行說明，但各圖式中對相同或相應的構成標註相同或相應的符號以省略說明。

[射出成形機]
圖1係表示一實施形態的射出成形機之開模結束時的狀態之圖。圖2係表示一實施形態的射出成形機之合模時的狀態之圖。如圖1~圖2所示，射出成形機具有合模裝置100、頂出裝置200、射出裝置300、移動裝置400及控制裝置700。以下，對射出成形機的各構成要件進行說明。

[合模裝置]
合模裝置100之說明中，以閉模時活動壓板120之移動方向(圖1及圖2中右方向)為前方，以開模時活動壓板120之移動方向(圖1及圖2中左方向)為後方來進行說明。
合模裝置100進行模具裝置10之閉模、合模及開模。合模裝置100例如係臥式，模開閉方向係水平方向。合模裝置100具有固定壓板110、活動壓板120、肘節座130、繫桿140、肘節機構150、合模馬達160、運動轉換機構170及模厚調整機構180。
固定壓板110固定於框架Fr。於固定壓板110之與活動壓板120相對向的面安裝有固定模11。
活動壓板120相對於框架Fr沿模開閉方向移動自如。框架Fr上鋪設有引導活動壓板120之引導件101。於活動壓板120之與固定壓板110相對向的面安裝有活動模12。
使活動壓板120相對於固定壓板110進退，從而進行閉模、合模及開模。由固定模11和活動模12構成模具裝置10。
肘節座130是與固定壓板110隔著間隔連結，且沿模開閉方向移動自如地載置於框架Fr上。又，肘節座130亦可以構成為沿鋪設於框架Fr上之引導件移動自如。肘節座130之引導件可以與活動壓板120之引導件101通用。
又，本實施形態中，固定壓板110固定於框架Fr，肘節座130相對於框架Fr沿模開閉方向移動自如，但亦可以構成為肘節座130固定於框架Fr，固定壓板110相對於框架Fr沿模開閉方向移動自如。
繫桿140於模開閉方向上隔著間隔L連結固定壓板110與肘節座130。繫桿140可以使用複數根(例如4根)。各繫桿140與模開閉方向平行，且因應合模力而伸展。可以於至少1根繫桿140設置有檢測繫桿140之應變的繫桿應變檢測器141。繫桿應變檢測器141將表示其檢測結果之訊號發送至控制裝置700。繫桿應變檢測器141之檢測結果於合模力之檢測等中使用。
又，本實施形態中，作為檢測合模力之合模力檢測器，使用繫桿應變檢測器141，但本發明並不限定於此。合模力檢測器不限於應變計式，亦可以係壓電式、電容式、油壓式、電磁式等，其安裝位置亦不限定於繫桿140。
肘節機構150配設於活動壓板120與肘節座130之間，且使活動壓板120相對於肘節座130沿模開閉方向移動。肘節機構150由十字頭151、一對連桿群等構成。各連桿群具有藉由銷等連結成屈伸自如的第1連桿152及第2連桿153。第1連桿152用銷等安裝成相對於活動壓板120擺動自如，第2連桿153用銷等安裝成相對於肘節座130擺動自如。第2連桿153透過第3連桿154安裝於十字頭151。若使十字頭151相對於肘節座130進退，則第1連桿152及第2連桿153屈伸，活動壓板120相對於肘節座130進退。
又，肘節機構150的構成並不限定於圖1及圖2所示之構成。例如圖1及圖2中，各連桿群之節點的數量係5個，但亦可以係4個，且可以係第3連桿154之一端部結合於第1連桿152與第2連桿153之節點。
合模馬達160安裝於肘節座130，使肘節機構150作動。合模馬達160使十字頭151相對於肘節座130進退，藉此使第1連桿152及第2連桿153屈伸，並使活動壓板120相對於肘節座130進退。合模馬達160直接連結於運動轉換機構170，但亦可以透過帶體或滑輪等連結於運動轉換機構170。
運動轉換機構170將合模馬達160之旋轉運動轉換成十字頭151之線性運動。運動轉換機構170包括螺桿軸171及螺合於螺桿軸171之螺桿螺母172。可以於螺桿軸171與螺桿螺母172之間介入滾珠或滾子。
合模裝置100於控制裝置700之控制下進行閉模製程、合模製程、開模製程等。
閉模製程中，驅動合模馬達160使十字頭151以設定速度前進至閉模結束位置，藉此使活動壓板120前進以使活動模12與固定模11接觸。十字頭151之位置和速度例如使用合模馬達編碼器161等檢測。合模馬達編碼器161檢測合模馬達160之旋轉，並將表示其檢測結果之訊號發送至控制裝置700。
合模製程中，進一步驅動合模馬達160使十字頭151從閉模結束位置進一步前進至合模位置，藉此產生合模力。合模時在活動模12與固定模11之間形成模穴空間14，射出裝置300於模穴空間14填充液態之成形材料。藉由使填充的成形材料固化而獲得成形品。模穴空間14之數量可以係複數個，該情況下，可同時獲得複數個成形品。
開模製程中，驅動合模馬達160使十字頭151以設定速度後退至開模結束位置，藉此使活動壓板120後退，而使活動模12從固定模11分離。之後，頂出裝置200從活動模12頂出成形品。
將閉模製程及合模製程中之設定條件以一系列設定條件的形式統一設定。例如，將閉模製程及合模製程中之十字頭151的速度和位置(包括速度切換位置、閉模結束位置及合模位置)以一系列設定條件的形式統一設定。又，亦可以代替十字頭151之速度和位置等而設定活動壓板120之速度和位置等。又，亦可以代替十字頭之位置(例如合模位置)和活動壓板之位置而設定合模力。
肘節機構150放大合模馬達160之驅動力而傳遞至活動壓板120。其放大倍率亦被稱為肘節倍率。肘節倍率因應第1連桿152與第2連桿153所成之角θ(以下，亦稱為“連桿角度θ”)而變化。連桿角度θ根據十字頭151之位置求出。連桿角度θ為180°時，肘節倍率成為最大。
因模具裝置10之更換和模具裝置10之溫度變化等致使模具裝置10之厚度發生變化時，進行模厚調整以使合模時獲得既定之合模力。模厚調整中，例如將固定壓板110與肘節座130之間隔L調整為，在活動模12與固定模11接觸之模接觸的時點使肘節機構150之連桿角度θ成為既定之角度。
合模裝置100具有藉由調整固定壓板110與肘節座130之間隔L來進行模厚調整之模厚調整機構180。模厚調整機構180具有：螺桿軸181，形成於繫桿140之後端部；螺桿螺母182，旋轉自如地保持於肘節座130上；及模厚調整馬達183，使螺合於螺桿軸181之螺桿螺母182旋轉。
螺桿軸181及螺桿螺母182設置於每個繫桿140。模厚調整馬達183之旋轉可以透過旋轉傳遞部185傳遞至複數個螺桿螺母182。能夠使複數個螺桿螺母182同步旋轉。又，亦能夠藉由變更旋轉傳遞部185之傳遞路徑來使複數個螺桿螺母182個別地旋轉。
旋轉傳遞部185例如由齒輪等構成。該情況下，於各螺桿螺母182之外周形成有從動齒輪，於模厚調整馬達183的輸出軸安裝有驅動齒輪，且與複數個從動齒輪及驅動齒輪嚙合之中間齒輪旋轉自如地保持於肘節座130之中央部。又，旋轉傳遞部185亦可以代替齒輪而由帶體或滑輪等構成。
模厚調整機構180之作動受到控制裝置700之控制。控制裝置700驅動模厚調整馬達183以使螺桿螺母182旋轉，藉此調整將螺桿螺母182保持為旋轉自如的肘節座130相對於固定壓板110之位置，進而調整固定壓板110與肘節座130之間隔L。
間隔L使用模厚調整馬達編碼器184來檢測。模厚調整馬達編碼器184檢測模厚調整馬達183之旋轉量和旋轉方向，並將表示其檢測結果之訊號發送至控制裝置700。模厚調整馬達編碼器184之檢測結果於監視或控制肘節座130之位置、間隔L時使用。
模厚調整機構180藉由使相互螺合之螺桿軸181與螺桿螺母182中之一方旋轉來調整間隔L。可以使用複數個模厚調整機構180，亦可以使用複數個模厚調整馬達183。
又，本實施形態的合模裝置100係模開閉方向為水平方向之臥式，但亦可以係模開閉方向為上下方向之立式。
又，本實施形態的合模裝置100作為驅動源具有合模馬達160，但亦可以代替合模馬達160而具有油壓缸。又，合模裝置100亦可以作為開閉模用具有線性馬達，且作為合模用具有電磁體。

[頂出裝置]
頂出裝置200之說明中，與合模裝置100之說明相同地，以閉模時活動壓板120之移動方向(圖1及圖2中右方向)為前方，以開模時活動壓板120之移動方向(圖1及圖2中左方向)為後方來進行說明。
頂出裝置200從模具裝置10頂出成形品。頂出裝置200具有頂出馬達210、運動轉換機構220及頂出桿230等。
頂出馬達210安裝於活動壓板120。頂出馬達210直接連結於運動轉換機構220，但亦可以透過帶體或滑輪等連結於運動轉換機構220。
運動轉換機構220將頂出馬達210之旋轉運動轉換成頂出桿230之線性運動。運動轉換機構220包括螺桿軸及螺合於螺桿軸之螺桿螺母。可以於螺桿軸與螺桿螺母之間介入滾珠或滾子。
頂出桿230於活動壓板120之貫通孔中進退自如。頂出桿230之前端部與進退自如地配設於活動模12之內部的活動構件15接觸。頂出桿230之前端部可以與活動構件15連結，亦可以不與其連結。
頂出裝置200於控制裝置700之控制下進行頂出製程。
頂出製程中，驅動頂出馬達210使頂出桿230以設定速度從待機位置前進至頂出位置，藉此使活動構件15前進而頂出成形品。之後，驅動頂出馬達210使頂出桿230以設定速度後退，並使活動構件15後退至原來的待機位置。
又，頂出裝置200於控制裝置700之控制下進行壓縮成形製程。
壓縮成形製程中，驅動頂出馬達210使頂出桿230以設定速度從壓縮待機位置前進至壓縮成形位置，藉此使活動構件15前進而壓縮填充於模穴空間14之成形材料。
頂出桿230之位置和速度例如使用頂出馬達編碼器211檢測。頂出馬達編碼器211檢測頂出馬達210之旋轉並將表示其檢測結果之訊號發送至控制裝置700。又，於頂出桿230設置有荷重元231。荷重元231檢測施加於頂出桿230之壓力，並將表示檢測結果之訊號發送至控制裝置700。
有關使用頂出桿230、荷重元231及活動構件15等之壓縮製程，另外進行詳述。

[射出裝置]
射出裝置300之說明中，與合模裝置100之說明和頂出裝置200之說明不同，以填充時螺桿330之移動方向(圖1及圖2中左方向)為前方，以計量時螺桿330之移動方向(圖1及圖2中右方向)為後方來進行說明。
射出裝置300設置於相對於框架Fr進退自如的滑動底座301，且相對於模具裝置10進退自如。射出裝置300與模具裝置10接觸，並向模具裝置10內之模穴空間14填充成形材料。射出裝置300例如具有缸體310、噴嘴320、螺桿330、計量馬達340、射出馬達350、壓力檢測器360等。
缸體310加熱從供給口311供給至內部之成形材料。供給口311形成於缸體310之後部。於缸體310之後部的外周設置有水冷缸等的冷卻器312。於比冷卻器312更靠前方，缸體310之外周設置有帶狀加熱器等的加熱器313和溫度檢測器314。
缸體310沿缸體310之軸向(圖1及圖2中左右方向)劃分為複數個區域。於各區域設置有加熱器313和溫度檢測器314。控制裝置700控制加熱器313以使於每個區域之溫度檢測器314的檢測溫度成為設定溫度。
噴嘴320設置於缸體310之前端部，且被緊壓於模具裝置10。於噴嘴320之外周設置有加熱器313和溫度檢測器314。控制裝置700控制加熱器313以使噴嘴320之檢測溫度成為設定溫度。
螺桿330於缸體310內配設成旋轉自如且進退自如。若使螺桿330旋轉，則成形材料沿螺桿330之螺旋狀的溝槽被送往前方。成形材料一邊被送往前方，一邊藉由來自缸體310之熱而逐漸熔融。隨著液態之成形材料被送往螺桿330之前方並蓄積於缸體310之前部，螺桿330後退。之後，若使螺桿330前進，則蓄積於螺桿330前方之液態的成形材料從噴嘴320射出而填充於模具裝置10內。
逆止環331進退自如地安裝於螺桿330之前部以作為逆止閥，該逆止閥於將螺桿330推向前方時防止成形材料從螺桿330之前方向後方逆流。
使螺桿330前進時，逆止環331因螺桿330前方之成形材料之壓力而被推向後方，相對於螺桿330後退至堵住成形材料之流路之封閉位置(參閱圖2)。藉此，防止蓄積於螺桿330前方之成形材料向後方逆流。
另一方面，使螺桿330旋轉時，逆止環331因沿螺桿330之螺旋狀的溝槽被送往前方之成形材料之壓力而被推向前方，相對於螺桿330前進至開放成形材料之流路之開放位置(參閱圖1)。藉此，成形材料被送往螺桿330之前方。
逆止環331可以係與螺桿330一同旋轉之共旋類型和不與螺桿330一同旋轉之非共旋類型中之任一類型。
又，射出裝置300可以具有使逆止環331相對於螺桿330於開放位置與封閉位置之間進退之驅動源。
計量馬達340使螺桿330旋轉。使螺桿330旋轉之驅動源並不限定於計量馬達340，例如可以係油壓泵等。
射出馬達350使螺桿330進退。射出馬達350與螺桿330之間設置有將射出馬達350之旋轉運動轉換成螺桿330之線性運動之運動轉換機構等。運動轉換機構例如具有螺桿軸及螺合於螺桿軸之螺桿螺母。可以於螺桿軸與螺桿螺母之間設置滾珠或滾子等。使螺桿330進退之驅動源並不限定於射出馬達350，例如亦可以係油壓缸等。
壓力檢測器360檢測於射出馬達350與螺桿330之間傳遞之力。檢測出的力通過控制裝置700被換算成壓力。壓力檢測器360設置於射出馬達350與螺桿330之間之力的傳遞路徑，並檢測作用於壓力檢測器360之力。
壓力檢測器360將表示其檢測結果之訊號發送至控制裝置700。壓力檢測器360之檢測結果於控制或監視螺桿330之從成形材料受到之壓力、對於螺桿330之背壓、螺桿330作用於成形材料之壓力等時使用。
射出裝置300於控制裝置700之控制下進行填充製程、保壓製程及計量製程等。
填充製程中，驅動射出馬達350使螺桿330以設定速度前進，並將蓄積於螺桿330之前方的液態之成形材料填充於模具裝置10內之模穴空間14。螺桿330之位置和速度例如使用射出馬達編碼器351檢測。射出馬達編碼器351檢測射出馬達350之旋轉，並將表示其檢測結果之訊號發送至控制裝置700。若螺桿330之位置到達設定位置，則進行從填充製程向保壓製程之切換(所謂，V/P切換)。將進行V/P切換之位置亦稱為V/P切換位置。螺桿330之設定速度可以按照螺桿330之位置或時間等而變更。
又，填充製程中，亦可以於螺桿330之位置到達設定位置之後，使螺桿330於該設定位置暫時停止，之後進行V/P切換。亦可以於即將進行V/P切換之前，代替螺桿330之停止而使螺桿330進行微速前進或微速後退。
保壓製程中，驅動射出馬達350將螺桿330推向前方，並將螺桿330之前端部的成形材料之壓力(以下，亦稱為“保持壓力”)保持為設定壓，將殘留於缸體310內之成形材料推向模具裝置10。能夠補充因模具裝置10內之冷卻收縮引起之不足量之成形材料。保持壓力例如使用壓力檢測器360檢測。壓力檢測器360將表示其檢測結果之訊號發送至控制裝置700。保持壓力之設定值可以按照從保壓製程開始經過之時間等而變更。
保壓製程中，模具裝置10內之模穴空間14的成形材料逐漸冷卻，保壓製程結束時模穴空間14之入口被固化之成形材料封閉。該狀態被稱為進模口密封(gate seal)，可防止成形材料從模穴空間14逆流。保壓製程之後，開始冷卻製程。冷卻製程中，進行模穴空間14內之成形材料之固化。為了縮短成形週期時間，可以於冷卻製程期間進行計量製程。
計量製程中，驅動計量馬達340使螺桿330以設定轉速旋轉，以沿螺桿330之螺旋狀的溝槽將成形材料送至前方。隨之，成形材料逐漸熔融。隨著液態之成形材料被送往螺桿330之前方並蓄積於缸體310之前部，螺桿330後退。螺桿330之轉速例如使用計量馬達編碼器341檢測。計量馬達編碼器341檢測計量馬達340之旋轉，並將表示其檢測結果之訊號發送至控制裝置700。
計量製程中，為了限制螺桿330急劇後退，可以驅動射出馬達350而對螺桿330施加設定背壓。針對螺桿330之背壓例如使用壓力檢測器360檢測。壓力檢測器360將表示其檢測結果之訊號發送至控制裝置700。若螺桿330後退至計量結束位置而於螺桿330之前方蓄積有既定量之成形材料，則計量製程結束。
又，本實施形態的射出裝置300為直列螺桿方式，但亦可以係預塑化方式等。預塑化方式之射出裝置將塑化缸內所熔融之成形材料供給至射出缸，並從射出缸向模具裝置內射出成形材料。螺桿旋轉自如地或旋轉自如且進退自如地配設於塑化缸內，柱塞進退自如地配設於射出缸內。
又，本實施形態的射出裝置300之缸體310的軸向為水平方向之臥式，但亦可以係缸體310之軸向為上下方向之立式。與立式射出裝置300進行組合之合模裝置既可以係立式亦可以係臥式。同樣地，與臥式射出裝置300進行組合之合模裝置既可以係臥式亦可以係立式。

[移動裝置]
移動裝置400之說明中，與射出裝置300之說明相同地，以填充時螺桿330之移動方向(圖1及圖2中左方向)為前方，以計量時螺桿330之移動方向(圖1及圖2中右方向)為後方來進行說明。
移動裝置400使射出裝置300相對於模具裝置10進退。又，移動裝置400將噴嘴320緊壓於模具裝置10，並產生噴嘴接觸壓力。移動裝置400包括液壓泵410、作為驅動源之馬達420、作為油壓致動器之液壓缸430等。
液壓泵410具有第1埠411及第2埠412。液壓泵410係能夠雙向旋轉之泵，藉由切換馬達420之旋轉方向，從第1埠411及第2埠412中之任一方吸入作動液(例如油)並從另一方吐出而產生液壓。又，液壓泵410亦能夠從儲槽抽吸作動液並從第1埠411與第2埠412中之任一方吐出作動液。
馬達420使液壓泵410作動。馬達420以與來自控制裝置700之控制訊號相應之旋轉方向及旋轉轉矩來驅動液壓泵410。馬達420可以係電動馬達，亦可以係電動伺服馬達。
液壓缸430具有缸體主體431、活塞432及活塞桿433。缸體主體431固定於射出裝置300。活塞432將缸體主體431之內部劃分為作為第1室之前室435與作為第2室之後室436。活塞桿433固定於固定壓板110。
液壓缸430之前室435透過第1流路401與液壓泵410之第1埠411連接。從第1埠411吐出之作動液透過第1流路401供給至前室435，射出裝置300被推向前方。射出裝置300前進，使噴嘴320緊壓於固定模11。前室435發揮藉由從液壓泵410供給之作動液之壓力而產生噴嘴320之噴嘴接觸壓力的作為壓力室之功能。
另一方面，液壓缸430之後室436透過第2流路402與液壓泵410之第2埠412連接。從第2埠412吐出之作動液透過第2流路402供給至液壓缸430之後室436，射出裝置300被推向後方。射出裝置300後退，而使噴嘴320從固定模11分離。
又，本實施形態中移動裝置400包含液壓缸430，但本發明並不限定於此。例如亦可以代替液壓缸430而使用電動馬達及將該電動馬達之旋轉運動轉變成射出裝置300之線性運動之運動轉換機構。

[控制裝置]
控制裝置700如圖1~圖2所示具有CPU(Central Processing Unit，中央處理器)701、記憶體等的記憶媒體702、輸入介面703及輸出介面704。控制裝置700使CPU701執行儲存於記憶媒體702之程式，藉此進行各種控制。又，控制裝置700藉由輸入介面703接收來自外部之訊號，藉由輸出介面704向外部發送訊號。
控制裝置700反覆進行閉模製程、合模製程、開模製程等，藉此反覆製造出成形品。又，控制裝置700於合模製程期間進行計量製程或填充製程、保壓製程等。將用於獲得成形品之一系列作動例如從計量製程開始至下一個計量製程開始為止之作動亦稱為“射出成形”或“成形週期”。又，將1次射出成形所需的時間亦稱為“成形週期時間”。
控制裝置700與操作裝置750和顯示裝置760連接。操作裝置750接受使用者的輸入操作，並將與輸入操作相應之訊號輸出至控制裝置700。顯示裝置760於控制裝置700之控制下顯示與操作裝置750中之輸入操作相應的操作畫面。
操作畫面用於進行射出成形機的設定等。操作畫面準備有複數個，用於切換顯示或重疊顯示。使用者一邊看著顯示裝置760顯示之操作畫面，一邊操作操作裝置750，藉此進行射出成形機之設定(包括設定值的輸入)等。
操作裝置750及顯示裝置760例如由觸控面板構成，可以成為一體化。又，本實施形態的操作裝置750及顯示裝置760雖然成為了一體化，但亦可以獨立設置。又，操作裝置750可以設置有複數個。

[頂出裝置的詳細情況]
圖3係表示一實施形態的頂出裝置之待機時的狀態之圖。
頂出裝置200安裝於活動壓板120。活動壓板120具有：安裝活動模12之活動壓板主體部121及安裝第1連桿152之擺動軸之活動壓板連桿安裝部125。活動壓板主體部121和活動壓板連桿安裝部125可以藉由鑄造等形成為一體。
活動壓板主體部121形成為板狀部。可以於活動壓板主體部121之4個角落沿繫桿140形成有缺口。亦可以代替缺口而形成供繫桿140插穿之貫通孔。活動壓板主體部121於中央部具有供頂出桿230插穿之貫通孔122。
活動壓板連桿安裝部125，於活動壓板主體部121之與肘節座130相對向之表面(後表面)是例如上下設有一對。於各活動壓板連桿安裝部125之頂端部形成貫通孔，擺動軸插穿於該貫通孔，藉此第1連桿152透過擺動軸擺動自如地安裝於活動壓板連桿安裝部125。
又，活動壓板連桿安裝部125還可以具有從活動壓板主體部121之背面向後方突出之筒狀部。筒狀部從模開閉方向觀察時形成為方框狀，於內部形成容納頂出裝置200之至少一部分之空間。
如圖3所示，頂出裝置200例如具有頂出馬達210、運動轉換機構220、頂出桿230、十字頭240及接頭250等。
頂出馬達210固定於活動壓板120。頂出馬達210之旋轉運動透過帶和帶輪傳遞至運動轉換機構220，但亦可以直接傳遞至運動轉換機構220。
運動轉換機構220將頂出馬達210之旋轉運動轉換成十字頭240之線性運動。十字頭240之直線運動透過接頭250傳遞至頂出桿230。
運動轉換機構220具有螺桿軸221及螺合於螺桿軸221之螺桿螺母222。可以於螺桿軸221和螺桿螺母222之間介入滾珠或滾子。螺桿軸221貫穿於活動壓板主體部121之後方與活動壓板主體部121隔著既定之間隔而設置的安裝板223，且於前端部固定於十字頭240。另一方面，螺桿螺母222藉由安裝板223保持為旋轉自如且無法進退。
若驅動頂出馬達210使螺桿螺母222旋轉，則螺桿軸221及十字頭240進退。又，螺桿軸221和螺桿螺母222的配置並無特別限定。例如，可以係螺桿軸221被安裝板223保持為旋轉自如且無法進退，螺桿螺母222固定於十字頭240。該情況下，若驅動頂出馬達210使螺桿軸221旋轉，則螺桿螺母222和十字頭240進退。
十字頭240沿架設於安裝板223與活動壓板主體部121之間之導桿241進退自如。導桿241為了防止十字頭240之旋轉而可以設置有複數根。又，導桿241可以懸臂支承於安裝板223與活動壓板主體部121中之任一方。
頂出桿230於沿前後方向貫穿活動壓板120(更詳細而言為活動壓板主體部121)之貫通孔122中進退自如，可隨著十字頭240之進退而進退。頂出桿230之根數於圖3~圖6中係1根，但亦可以係複數根。
頂出桿230之前端部與於活動模12之內部配設成進退自如的活動構件15接觸。頂出桿230之前端部沒有與活動構件15連結，但亦可以與活動構件15連結。又，頂出桿230之前端部與活動構件15連結時，可以沒有彈簧16。
若驅動頂出馬達210使頂出桿230前進，則活動構件15前進而進行成形材料2之壓縮。之後，若驅動頂出馬達210使頂出桿230後退，則藉由彈簧16之彈性復原力使得活動構件15一邊被頂出桿230按壓一邊後退而進行成形品之脫壓。經脫壓之成形品藉由頂出桿230之前進而從活動模12被頂出。
模具裝置10包括：安裝於固定壓板110之固定模11及安裝於活動壓板120之活動模12。如圖3所示，合模時於固定模11與活動模12之間形成模穴空間14。圖3係模具裝置10閉模之狀態。固定模11與活動模12之邊界為所謂分模線。
成形材料2透過形成於固定模11之澆口17、於澆口17之終端部分支的澆道18及設置於澆道18之終端部的進模口19到達模穴空間14。
圖4係表示一實施形態的活動構件和頂出桿之剖面圖。
如上前述，活動構件15進退自如地配設於活動模12之內部。於活動模12之內部設置有導軸25，導軸25透過活動構件15所具備之滾珠保持器26而與活動構件15連接。藉由導軸25與滾珠保持器26之組合，活動構件15沿導軸25之軸向進退自如。導軸25與滾珠保持器26之組合數為4組，但亦可以係其他組合數。
於活動模12與活動構件15之間配設有彈簧16。如上前述，藉由彈簧16之彈性復原力，活動構件15一邊被頂出桿230按壓一邊後退。
頂出桿230之前端部通過設置於活動模12之孔而與活動構件15所具有之頂出板21之按壓面21a接觸。於頂出桿230設置有荷重元231。荷重元231檢測施加於頂出桿230之壓力，並將表示檢測結果之訊號發送至控制裝置700。
活動構件15具有：與前後方向垂直之板狀的頂出板21、從頂出板21朝前方延伸之棒狀的壓縮芯銷22、從頂出板21朝前方延伸之棒狀的頂出銷23及從頂出板21朝前方延伸之棒狀的抵接銷24。
頂出板21藉由配置在比頂出板21更後方之頂出桿230推向前方。又，頂出板21藉由配置在比頂出板21更前方之彈簧16推到後方。
壓縮芯銷22從頂出板21朝前方延伸並貫穿活動模12。壓縮芯銷22之前端面成為模穴空間14之壁面的一部分。壓縮芯銷22與頂出板21一起進退，而進行成形材料2之壓縮、壓縮成形的成形品之脫壓、脫壓的成形品之頂出。
頂出銷23從頂出板21朝前方延伸並貫穿活動模12。如圖4所示，於澆道18流動之成形材料2抱住頂出銷23之前端部而固化。頂出銷23用於頂出於澆道18固化之成形材料2。
抵接銷24從頂出板21朝前方延伸並貫穿活動模12。一實施形態的頂出裝置200中，於進行壓縮成形時，利用頂出桿230使頂出板21前進時，根據抵接銷24之前端部與固定模11接觸之位置來決定壓縮成形位置。
頂出裝置200用於進行填充於模具裝置10之模穴空間14之成形材料之壓縮及從模具裝置10之藉由該壓縮所成形之成形品之(以下，亦稱為“壓縮成形後的成形品”)頂出這兩個作動。成形材料之壓縮於成形材料完全固化之前進行。以下，對使用一實施形態的控制裝置700和頂出裝置200之壓縮成形之作動進行說明。
圖5係用功能塊表示一實施形態的控制裝置700之構成要件之圖。又，圖5中圖示的各功能塊係概念性的，並不一定需要物理上如圖示那樣構成。能夠將各功能塊全部或一部分以任意之單位功能性或物理性地分散/結合來構成。各功能塊中進行之各處理功能其全部或任意一部分可藉由由CPU執行之程式而實現，或可作為基於佈線邏輯之硬體來實現。
如圖5所示，控制裝置700具有頂出桿位置控制部710、頂出桿位置檢測部711、頂出桿壓力控制部712、荷重元初始化部713及頂出桿壓力檢測部714。又，控制裝置700具有轉矩控制部715、轉矩檢測值初始化部716、轉矩檢測部717、螺桿位置控制部718及螺桿位置檢測部719。
頂出桿位置控制部710與頂出馬達210電連接。藉由驅動頂出馬達210來使頂出桿230進退，以控制頂出桿230之位置。
頂出桿位置檢測部711與設置於頂出馬達210之頂出馬達編碼器211電連接。頂出桿位置檢測部711接收頂出馬達編碼器211所產生之檢測訊號並檢測頂出桿230之位置。檢測結果輸出至頂出桿位置控制部710。
又，亦可以不使用頂出馬達編碼器211，而由頂出桿位置控制部710依據供給至頂出馬達210之驅動脈衝數來檢測頂出桿230之位置。
頂出桿壓力控制部712與頂出馬達210電連接。藉由驅動頂出馬達210來使頂出桿230進退，以控制活動構件15施加於模穴空間14內之成形材料之壓力。
荷重元初始化部713向荷重元231發送初始化訊號，並將荷重元231之檢測值進行初始化。
頂出桿壓力檢測部714與設置於頂出桿230之荷重元231電連接。頂出桿壓力檢測部714接收荷重元231所產生之檢測訊號來檢測施加於頂出桿230之壓力。檢測結果輸出至頂出桿壓力控制部712。
轉矩控制部715與頂出馬達210電連接。藉由驅動頂出馬達210來控制頂出桿230之轉矩。
轉矩檢測值初始化部716將轉矩檢測部717之檢測值進行初始化。
轉矩檢測部717與頂出馬達210電連接。接收表示驅動頂出馬達210之馬達電流值之訊號來檢測頂出桿230之轉矩。檢測結果輸出至轉矩控制部715。又，以下將“表示驅動頂出馬達210之馬達電流值之訊號”簡稱為“馬達電流值”。
螺桿位置控制部718與射出馬達350電連接，藉由驅動射出馬達350來控制螺桿330之位置。
螺桿位置檢測部719與設置於射出馬達350之射出馬達編碼器351電連接。螺桿位置檢測部719接收射出馬達編碼器351所產生之檢測訊號來檢測螺桿330之位置。檢測結果輸出至螺桿位置控制部718。
又，荷重元231及轉矩檢測部717分別係“檢測機構”之一例。又，荷重元初始化部713及轉矩檢測值初始化部716分別係“初始化機構”之一例。
控制裝置700於進行壓縮成形之前，先求出壓縮成形位置。控制裝置700藉由頂出桿位置控制部710使頂出桿230和活動構件15前進，並檢測抵接銷24接觸固定模11之位置。控制裝置700以該位置為基準求出壓縮成形位置。
圖6係表示一實施形態的抵接銷24接觸固定模11時的頂出桿230和活動構件15之剖面圖。又，圖6係進行成形材料2之填充製程之前之狀態，模穴空間14內未填充成形材料。
頂出桿位置控制部710驅動頂出馬達210使頂出桿230前進，而使活動構件15前進。活動構件15所具備之抵接銷24之前端部若貫穿設置於活動模12之貫通孔，則與固定模11接觸。
抵接銷24之前端部是否與固定模11接觸，藉由由頂出桿壓力檢測部714接收荷重元231之檢測值而檢測施加於頂出桿230之壓力來偵知。或者，藉由由轉矩檢測部717接收馬達電流值而檢測施加於頂出桿230之轉矩來偵知。又，亦藉由輸出於既定時間使頂出桿230前進之命令，來判斷是否接觸。
頂出桿位置控制部710將該位置設定為壓縮成形位置。或者，亦可以將抵接銷24接觸固定模11之位置或從接觸之位置後退預先規定之距離後之位置設定為壓縮成形位置。於壓縮成形位置由頂出馬達編碼器211檢測之頂出桿230之位置之檢測值儲存於記憶媒體702，進行壓縮成形時可參閱。如此，求出壓縮成形位置。
又，抵接銷24之長度，是按照接觸固定模11之後使頂出桿230移動之距離來決定。
設定壓縮成形位置之後，頂出桿位置控制部710使頂出桿230從壓縮成形位置後退與預先規定之壓縮量相應之距離。此時之位置成為壓縮待機位置。
圖7係表示從圖6之狀態後退至一實施形態的壓縮待機位置時的頂出桿和活動構件之剖面圖。頂出桿230和活動構件15向圖中左方向後退。其結果，模穴空間14之體積變大。又，於頂出銷23之前端部與固定模11之間及抵接銷24之前端部與固定模11之間產生間隙。
使頂出桿230後退至壓縮待機位置之後，荷重元初始化部713發送初始化訊號，而將荷重元231之檢測值進行初始化。如後述，將荷重元231之檢測值進行初始化之理由為，依據荷重元231之檢測值來觸發壓縮成形開始。藉由將荷重元231之檢測值進行初始化，荷重元231之溫度變化和彈簧16之阻力變化等影響被消除，而能夠於適當時點觸發壓縮成形開始。
又，亦可以由轉矩檢測值初始化部716將轉矩檢測值進行初始化，以代替對荷重元231之檢測值進行初始化，並將轉矩檢測值作為壓縮成形開始的觸發。
頂出桿230後退至壓縮待機位置，荷重元231或轉矩檢測值被初始化之後，進行填充製程。螺桿位置控制部718驅動射出馬達350使螺桿330前進，而向模穴空間14填充成形材料2。
圖8係表示向一實施形態的模穴空間填充成形材料時的頂出桿和活動構件之剖面圖。圖8中塗黑表示之成形材料2通過澆口17、澆道18及進模口19而到達模穴空間14。但是，圖8係成形材料2沒有遍及整個模穴空間14之狀態。
隨著進行成形材料2之填充，模穴空間14之內部的成形材料2推壓壓縮芯銷22，因此施加使頂出桿230後退之方向的力。藉此，利用荷重元231檢測之壓力及轉矩檢測部717之檢測值上升。
頂出桿位置控制部710於填充成形材料2之期間，透過頂出桿壓力檢測部714來監視荷重元231之檢測值。以檢測值到達預先規定之壓力值之情況作為觸發，頂出桿位置控制部710使頂出桿230前進而開始進行壓縮成形。
或者，壓縮成形開始之觸發可以監視轉矩檢測值來偵知。亦即，頂出桿位置控制部710於填充成形材料2之期間監視轉矩檢測部717之檢測值。以檢測值到達預先規定之轉矩值之情況作為觸發，頂出桿位置控制部710使頂出桿230前進而開始進行壓縮成形。
又，亦可以從填充成形材料2經過既定時間之後開始進行壓縮成形。
壓縮成形中，頂出桿位置控制部710使頂出桿230前進至上述壓縮成形位置而使活動構件15前進，而壓縮模穴空間14之內部的成形材料2。
圖9係表示壓縮一實施形態的模穴空間之成形材料時的頂出桿和活動構件之剖面圖。與圖8相比，頂出桿230和活動構件15向圖中右方向前進。又，壓縮芯銷22前進，成形材料2被壓縮而遍及整個模穴空間14。
接著，按照螺桿330之位置以及頂出桿230之位置、轉矩及壓力之時間變化來說明以上說明的作動。
圖10係表示螺桿330之位置、以及頂出桿230之位置、轉矩及壓力的時間變化之圖。圖10之橫軸表示時間，縱軸表示頂出馬達編碼器211、荷重元231、轉矩檢測部717及射出馬達編碼器351之檢測值。實際檢測值的單位各不相同，方便起見於圖10之縱軸一併示出。
圖10中，用一點鏈線表示之螺桿位置檢測值71，是表示射出馬達編碼器351之檢測值。用虛線表示之頂出桿位置檢測值72，是表示頂出馬達編碼器211之檢測值。用黑色實線表示之頂出桿轉矩檢測值73，是表示轉矩檢測部717之檢測值。用點線表示之頂出桿壓力檢測值74，是表示荷重元231之檢測值。
橫軸之時間，是以模具裝置10合模(參閱圖2)之後頂出桿230開始前進時作為起點。圖10中用二點鏈線表示之時刻t₀ ~t₄ ，是表示從起點經過既定時間時之時刻。
於至時刻t₀ 為止之期間，為了求出壓縮成形位置，頂出桿位置控制部710驅動頂出馬達210而使頂出桿230和活動構件15逐漸前進。此時，頂出桿位置控制部710為了保護模具裝置10而使頂出桿230以低速前進。
於時刻t₀ ，抵接銷24之前端部接觸固定模11。於時刻t₀ ~t₁ 之期間，頂出桿230因接觸而停止。頂出桿轉矩檢測值73和頂出桿壓力檢測值74於成為時刻t₀ 之後一度急劇上升，上升之後，至時刻t₁ 為止成為大致恆定。這表示抵接銷24之前端部與固定模11進行了接觸，藉由從固定模11受到之反作用力使施加於頂出桿230之轉矩和壓力急劇上升。藉由頂出桿230的停止，轉矩和壓力的上升平息下來。
抵接銷24之前端部對固定模11之接觸，於荷重元231或轉矩檢測部717之檢測值到達預先規定之既定值時被偵知。於時刻t₁ ，頂出桿位置控制部710將於時刻t₁ 之頂出馬達編碼器211之檢測值設定為壓縮成形位置。
又，圖10中將抵接銷24之前端部接觸固定模11之位置設定為壓縮成形位置，但如上前述，亦可以將使頂出桿230後退預先規定之距離後之位置設定為壓縮成形位置。
抵接銷24接觸固定模11之位置(接觸的位置)與壓縮成形位置之間的關係(相對距離)，已被預先儲存。接觸之位置與壓縮成形位置可以相同，亦可以不同。以抵接銷24接觸固定模11之位置為基準來決定壓縮成形位置。例如，可以預先調整抵接銷24之長度，俾於抵接銷24接觸固定模11時使壓縮芯銷22之位置成為壓縮成形位置。
又，接觸固定模11之構件只要係活動構件15即可，並不限定於抵接銷24。亦可以使壓縮芯銷22接觸固定模11。但是，壓縮芯銷22為形成模穴空間14之構件，其前端面被精密地加工。為了決定壓縮成形位置而使壓縮芯銷22接觸固定模11，有可能導致破損，因此不理想。
於時刻t₁ ~t₂ 之期間，頂出桿230向壓縮待機位置後退。圖10中，頂出桿位置檢測值72急劇下降，下降之後成為大致恆定。
同樣地，頂出桿轉矩檢測值73和頂出桿壓力檢測值74亦從時刻t₁ 急劇下降，下降之後成為大致恆定。這表示頂出桿位置控制部710使頂出桿230後退，藉由彈簧16的彈性復原力使活動構件15後退至壓縮待機位置。
於時刻t₂ ，荷重元初始化部713向荷重元231發送初始化訊號。圖10中，於時刻t₃ 荷重元231進行初始化，檢測值成為零。
又，亦可以係轉矩檢測值初始化部716發送初始化訊號，將轉矩檢測部717之檢測值進行初始化，而使用轉矩檢測部717之檢測值作為壓縮成形開始之觸發。
於時刻t₃ ~t₄ 之期間，向模穴空間14填充成形材料2。螺桿位置控制部718驅動射出馬達350使螺桿330前進，而向模穴空間14填充成形材料2。圖10中，從時刻t₃ 起螺桿位置檢測值71下降。表示螺桿330向圖3中之左方向前進。
這期間，頂出桿230不移動，因此頂出桿位置檢測值72恆定。
另一方面，頂出桿轉矩檢測值73和頂出桿壓力檢測值74逐漸上升。表示隨著成形材料2之填充，模穴空間14內部之成形材料2推壓壓縮芯銷22之力增大，而施加使頂出桿230後退的方向之力。
隨著成形材料2之填充，利用荷重元231檢測的壓力上升，於荷重元231之檢測值到達預先規定之既定的壓力值之時刻t₄ ，開始進行壓縮成形。
又，如圖10所示，隨著成形材料2之填充，利用轉矩檢測部717檢測之轉矩亦上升，因此也可以使用轉矩檢測部717之檢測值來觸發壓縮成形開始。
於時刻t₄ 以後之期間，頂出桿位置控制部710至壓縮成形位置為止對頂出桿230進行前進控制，使活動構件15前進以壓縮模穴空間14之內部的成形材料2。圖10中，頂出桿位置檢測值72至壓縮成形位置為止上升，隨之，頂出桿轉矩檢測值73和頂出桿壓力檢測值74上升。
於時刻t₄ 以後之期間，亦可以藉由頂出桿壓力控制部712或轉矩控制部715，控制壓力或轉矩，藉此控制模穴空間14內之成形材料2之狀態。
藉由如上操作，按照一實施形態的壓縮成形之作動，螺桿330之位置以及頂出桿230之位置、轉矩及壓力發生變化。
圖11係表示一實施形態的壓縮成形處理之流程圖。
首先，合模裝置100於控制裝置700之控制下進行模具裝置10之合模(步驟S111)。
接著，頂出桿位置控制部710對頂出桿230進行前進控制，使活動構件15前進(步驟S112)。頂出桿位置控制部710一邊使頂出桿230前進，一邊監視荷重元231之檢測值。
藉由活動構件15之前進，抵接銷24之前端部接觸固定模11。頂出桿位置控制部710因荷重元231之檢測值到達預先規定之既定值而偵知抵接銷24之前端部已接觸固定模11，停止對頂出桿230進行前進控制(步驟S113)。
頂出桿位置控制部710將從抵接銷24之前端部接觸固定模11之位置後退預先規定之距離後之位置設定為壓縮成形位置(步驟S114)。
接著，若使頂出桿230後退而從壓縮成形位置後退至與預先規定之壓縮量相應之壓縮待機位置，則頂出桿位置控制部710停止頂出桿230之後退(步驟S115)。
接著，荷重元初始化部713向荷重元231發送初始化訊號，將荷重元231之檢測值進行初始化(步驟S116)。初始化之後，射出裝置300於控制裝置700之控制下使螺桿330移動而向模穴空間14填充成形材料2。頂出桿位置控制部710於填充途中透過頂出桿壓力檢測部714來監視荷重元231之檢測值。
以荷重元231之檢測值到達預先規定之壓力值之情況作為觸發而開始進行壓縮成形(步驟S117)。
頂出桿位置控制部710對頂出桿230進行前進控制，若到達壓縮成形位置，則停止頂出桿230之前進(步驟S118)。藉由頂出桿230之前進，模穴空間14內之成形材料2被壓縮。
頂出桿壓力控制部712於保壓中及冷卻中使頂出桿230進退，而控制活動構件15施加於模穴空間14內之成形材料之壓力(步驟S119)。
如此，進行壓縮成形。又，上述說明中藉由檢測頂出桿230之壓力來開始壓縮成形，但亦可以檢測頂出桿230之轉矩。
如以上說明，本實施形態中，於進行壓縮成形之前，利用頂出桿230使活動構件15前進時，根據抵接銷24接觸固定模11之位置來決定壓縮成形位置。
例如，頂出桿230因熱變形而伸長時，壓縮成形時之活動構件15之前進的開始位置向前方(圖4的右方向)偏移頂出桿230的伸長量。與此相應地，壓縮成形時壓縮芯銷22之前端面之位置向前方偏移，模穴空間14在前後方向變窄。藉此，成形品之厚度會有產生誤差的情況。
又，相反地，頂出桿230收縮時，壓縮成形時之活動構件15之前進的開始位置向後方(圖4的左方向)偏移。與此相應地，壓縮成形時壓縮芯銷22之前端面之位置向後方偏移，模穴空間14在前後方向擴展。藉此，會有因成形品之厚度產生誤差、壓縮不足所致之成形材料2不均勻而使成形品表面之形狀精度降低的情況。
依據本實施形態，於進行壓縮成形之前，求出相對於基準之壓縮成形位置，因此即使於如上述般頂出桿230因熱變形而伸縮之情況下，亦能夠防止壓縮成形時壓縮芯銷22之前端面發生位置偏移。藉此能夠防止壓縮成形中因頂出桿等的熱變形致使成形品之厚度精度及表面精度降低。
本實施形態中，將使活動構件15從壓縮成形位置後退與壓縮量相應之距離後之位置作為壓縮待機位置。即使於頂出桿230因熱變形而伸縮之情況，亦能夠以壓縮芯銷22之前端面之未發生位置偏移之壓縮成形位置為起點而以所期望之壓縮量進行壓縮成形。藉此能夠防止壓縮成形中因頂出桿等的熱變形致使成形品之厚度精度及表面精度降低。
本實施形態中，依據施加於頂出桿230之壓力或轉矩，來偵知抵接銷24對固定模11之接觸。能夠以簡便之構成偵知抵接銷24對固定模11之接觸。
依據本實施形態，具有將荷重元231之檢測值進行初始化之荷重元初始化部713，荷重元231是用於檢測施加於頂出桿230之壓力。於壓縮待機位置，荷重元初始化部713將荷重元231之檢測值進行初始化，開始對模穴空間14填充成形材料2之後，於荷重元231之檢測值成為既定的壓力值時開始進行壓縮成形。藉此，能夠根據模穴空間14內部之成形材料2之流動狀況於適當時點開始進行壓縮成形。能夠進一步提高成形品之厚度及形狀的再現性。
又，於壓縮待機位置將荷重元231之檢測值進行初始化，藉此能夠消除荷重元231之溫度變化和頂出板21所具備之彈簧16之阻力變化等的影響，而於適當時點開始進行壓縮成形。
又，依據本實施形態，具有將轉矩檢測部717之檢測值進行初始化之轉矩檢測值初始化部716，轉矩檢測部717是用於檢測施加於頂出桿230之轉矩。於壓縮待機位置，轉矩檢測值初始化部716將轉矩檢測部717之檢測值進行初始化，開始對模穴空間14填充成形材料2之後，於轉矩檢測部717之檢測值成為既定的壓力值時開始進行壓縮成形。藉此，能夠根據模穴空間14內部之成形材料2之流動狀況於適當時點開始進行壓縮成形。能夠進一步提高成形品的厚度及形狀的再現性。
又，於壓縮待機位置將轉矩感測器717之檢測值進行初始化，藉此能夠消除頂出板21所具備之彈簧16之阻力變化等的影響，而於適當時點開始進行壓縮成形。
又，頂出桿230之熱變形量，會有於每次進行壓縮成形時發生變化的情況。因此，為了確實地防止頂出桿230之熱變形影響，每次進行壓縮成形時實施設定壓縮成形位置之處理為較佳。
以上，對射出成形機等的實施形態等進行了說明，但本發明並不限定於上述實施形態等，於記載於申請專利範圍內的本發明的宗旨的範圍內，能夠進行各種變形、改進。Hereinafter, the embodiments for implementing the present invention will be described with reference to the drawings. However, the same or corresponding components are denoted by the same or corresponding symbols in the drawings to omit the description.

[Injection molding machine]
FIG. 1 is a diagram showing a state at the end of mold opening of an injection molding machine according to an embodiment. FIG. 2 is a diagram showing a state of the injection molding machine according to the embodiment when the mold is closed. As shown in FIGS. 1 to 2, the injection molding machine includes a mold clamping device 100, an ejection device 200, an injection device 300, a moving device 400, and a control device 700. Hereinafter, each component of the injection molding machine will be described.

[Clamping device]
In the description of the mold clamping device 100, the moving direction of the movable platen 120 (right direction in FIG. 1 and FIG. 2) when the mold is closed is forward, and the moving direction of the movable platen 120 (left direction in FIG. 1 and FIG. 2) when the mold is opened ) Will be described later.
The mold clamping device 100 performs mold closing, mold clamping, and mold opening of the mold device 10. The mold clamping device 100 is, for example, a horizontal type, and the mold opening and closing direction is a horizontal direction. The mold clamping device 100 includes a fixed platen 110, a movable platen 120, a toggle seat 130, a tie bar 140, a toggle mechanism 150, a mold clamping motor 160, a motion conversion mechanism 170, and a mold thickness adjustment mechanism 180.
The fixed platen 110 is fixed to the frame Fr. A fixed die 11 is mounted on a surface of the fixed platen 110 that faces the movable platen 120.
The movable platen 120 can move freely in the mold opening and closing direction with respect to the frame Fr. A guide 101 for guiding the movable platen 120 is laid on the frame Fr. A movable die 12 is mounted on a surface of the movable platen 120 that faces the fixed platen 110.
The movable platen 120 is advanced and retracted relative to the fixed platen 110 to perform mold closing, closing, and opening. The fixed mold 11 and the movable mold 12 constitute a mold device 10.
The toggle seat 130 is connected to the fixed platen 110 at intervals, and is placed on the frame Fr so as to be movable in the mold opening and closing direction. In addition, the toggle joint 130 may be configured to move freely along a guide member laid on the frame Fr. The guide of the toggle seat 130 can be used in common with the guide 101 of the movable platen 120.
In this embodiment, the fixed platen 110 is fixed to the frame Fr, and the toggle bracket 130 can move freely in the mold opening and closing direction with respect to the frame Fr. However, the toggle plate 130 may be fixed to the frame Fr, and the fixed platen 110 may be fixed to the frame Fr moves freely along the mold opening and closing direction.
The tie bar 140 connects the fixed platen 110 and the toggle seat 130 with a space L in the mold opening and closing direction. The tie rod 140 may use a plurality (for example, 4). Each tie bar 140 is parallel to the mold opening and closing direction, and extends in response to the mold clamping force. A tie rod strain detector 141 may be provided on at least one tie rod 140 to detect the strain of the tie rod 140. The tie rod strain detector 141 sends a signal indicating the detection result to the control device 700. The detection result of the tie bar strain detector 141 is used for detecting the clamping force and the like.
In this embodiment, the tie rod strain detector 141 is used as the clamping force detector for detecting the clamping force, but the present invention is not limited to this. The clamping force detector is not limited to the strain gauge type, and may be a piezoelectric type, a capacitive type, a hydraulic type, an electromagnetic type, and the like, and its installation position is not limited to the tie rod 140.
The toggle mechanism 150 is disposed between the movable platen 120 and the toggle seat 130, and moves the movable platen 120 in the mold opening and closing direction relative to the toggle seat 130. The toggle mechanism 150 includes a cross head 151, a pair of link groups, and the like. Each link group includes a first link 152 and a second link 153 that are connected to each other so as to be flexibly extendable by pins or the like. The first link 152 is mounted with a pin or the like to swing freely with respect to the movable platen 120, and the second link 153 is mounted with a pin or the like to swing freely with respect to the toggle seat 130. The second link 153 is attached to the cross head 151 through the third link 154. When the crosshead 151 is advanced and retracted with respect to the toggle joint 130, the first link 152 and the second link 153 are flexed and extended, and the movable platen 120 is advanced and retracted with respect to the toggle joint 130.
The configuration of the toggle mechanism 150 is not limited to the configuration shown in FIGS. 1 and 2. For example, in FIG. 1 and FIG. 2, the number of nodes of each link group is five, but it may also be four, and one end of the third link 154 may be combined with the first link 152 and the second link. 153 nodes.
The mold clamping motor 160 is mounted on the toggle base 130 and operates the toggle mechanism 150. The mold clamping motor 160 advances and retracts the crosshead 151 relative to the toggle base 130, thereby flexing and extending the first link 152 and the second link 153, and advances and retracts the movable platen 120 relative to the toggle base 130. The mold clamping motor 160 is directly connected to the motion conversion mechanism 170, but may also be connected to the motion conversion mechanism 170 through a belt or a pulley.
The motion conversion mechanism 170 converts the rotational motion of the mold clamping motor 160 into a linear motion of the cross head 151. The motion conversion mechanism 170 includes a screw shaft 171 and a screw nut 172 screwed to the screw shaft 171. Balls or rollers may be interposed between the screw shaft 171 and the screw nut 172.
The mold clamping device 100 performs a closed mold process, a mold clamping process, an open mold process, and the like under the control of the control device 700.
During the mold closing process, the mold clamping motor 160 is driven to advance the crosshead 151 to the mold closing end position at a set speed, thereby moving the movable platen 120 to contact the movable mold 12 and the fixed mold 11. The position and speed of the crosshead 151 are detected using, for example, a mold clamping motor encoder 161 and the like. The mold clamping motor encoder 161 detects the rotation of the mold clamping motor 160 and sends a signal indicating the detection result to the control device 700.
During the mold clamping process, the mold clamping motor 160 is further driven to further advance the crosshead 151 from the mold closing end position to the mold clamping position, thereby generating a mold clamping force. When the mold is closed, a cavity space 14 is formed between the movable mold 12 and the fixed mold 11. The injection device 300 fills the cavity space 14 with a liquid molding material. A molded article is obtained by curing the filled molding material. The number of the cavity spaces 14 may be plural, and in this case, plural shaped articles may be obtained at the same time.
During the mold opening process, the mold clamping motor 160 is driven to move the crosshead 151 back to the mold opening end position at a set speed, thereby moving the movable platen 120 back and separating the movable mold 12 from the fixed mold 11. Thereafter, the ejection device 200 ejects the molded product from the movable mold 12.
The set conditions in the closed molding process and the mold clamping process are uniformly set in the form of a series of setting conditions. For example, the speed and position of the crosshead 151 (including the speed switching position, the mold closing position, and the mold clamping position) in the mold closing process and the mold clamping process are uniformly set in the form of a series of setting conditions. The speed and position of the movable platen 120 may be set instead of the speed and position of the cross head 151. In addition, the clamping force may be set instead of the position of the crosshead (for example, the clamping position) and the position of the movable platen.
The toggle mechanism 150 amplifies the driving force of the mold clamping motor 160 and transmits it to the movable platen 120. Its magnification is also known as the toggle magnification. The toggle ratio changes according to an angle θ (hereinafter, also referred to as a “link angle θ”) formed by the first link 152 and the second link 153. The link angle θ is obtained from the position of the cross head 151. When the link angle θ is 180 °, the toggle ratio becomes the maximum.
When the thickness of the mold device 10 is changed due to the replacement of the mold device 10 and the temperature change of the mold device 10, the mold thickness is adjusted to obtain a predetermined clamping force when the mold is closed. In the mold thickness adjustment, for example, the interval L between the fixed platen 110 and the toggle holder 130 is adjusted so that the link angle θ of the toggle mechanism 150 becomes a predetermined angle when the movable mold 12 and the mold in contact with the fixed mold 11 contact.
The mold clamping device 100 includes a mold thickness adjustment mechanism 180 that adjusts the mold thickness by adjusting the interval L between the fixed platen 110 and the toggle base 130. The mold thickness adjustment mechanism 180 includes: a screw shaft 181 formed at the rear end of the tie rod 140; a screw nut 182 that is rotatably held on the toggle base 130; and a mold thickness adjustment motor 183 that is screwed onto the screw shaft 181 The screw nut 182 rotates.
A screw shaft 181 and a screw nut 182 are provided on each tie bar 140. The rotation of the mold thickness adjusting motor 183 can be transmitted to the plurality of screw nuts 182 through the rotation transmitting portion 185. The plurality of screw nuts 182 can be rotated simultaneously. In addition, the plurality of screw nuts 182 can be individually rotated by changing the transmission path of the rotation transmission section 185.
The rotation transmission portion 185 is configured by, for example, a gear. In this case, a driven gear is formed on the outer periphery of each screw nut 182, a driving gear is mounted on the output shaft of the mold thickness adjustment motor 183, and an intermediate gear that meshes with the plurality of driven gears and the driving gear is rotatably held at The central part of the toggle seat 130. In addition, the rotation transmission part 185 may be comprised of a belt body, a pulley, etc. instead of a gear.
The operation of the mold thickness adjusting mechanism 180 is controlled by the control device 700. The control device 700 drives the die thickness adjustment motor 183 to rotate the screw nut 182, thereby adjusting the position of the toggle bracket 130 holding the screw nut 182 to rotate freely with respect to the fixed platen 110, thereby adjusting the fixed platen 110 and the toggle plate 130 The interval L.
The interval L is detected using a mold thickness adjustment motor encoder 184. The mold thickness adjustment motor encoder 184 detects the rotation amount and rotation direction of the mold thickness adjustment motor 183 and sends a signal indicating the detection result to the control device 700. The detection result of the mold thickness adjustment motor encoder 184 is used when monitoring or controlling the position and interval L of the toggle seat 130.
The die thickness adjusting mechanism 180 adjusts the interval L by rotating one of the screw shaft 181 and the screw nut 182 which are screwed together. A plurality of mold thickness adjustment mechanisms 180 may be used, or a plurality of mold thickness adjustment motors 183 may be used.
The mold clamping device 100 of the present embodiment is a horizontal type in which the mold opening and closing direction is a horizontal direction, but may be a vertical type in which the mold opening and closing direction is a vertical direction.
In addition, the mold clamping device 100 according to the present embodiment includes a mold clamping motor 160 as a drive source, but may include a hydraulic cylinder instead of the mold clamping motor 160. The mold clamping device 100 may include a linear motor for mold opening and closing, and an electromagnet for mold clamping.

[Ejector device]
In the description of the ejection device 200, as with the description of the mold clamping device 100, the moving direction of the movable platen 120 (right direction in FIG. 1 and FIG. 2) when the mold is closed is forward, and the movable platen 120 is moved when the mold is opened. The direction (left direction in FIGS. 1 and 2) will be described below.
The ejection device 200 ejects a molded product from the mold device 10. The ejection device 200 includes an ejection motor 210, a motion conversion mechanism 220, an ejection lever 230, and the like.
The ejection motor 210 is mounted on the movable platen 120. The ejection motor 210 is directly connected to the motion conversion mechanism 220, but may be connected to the motion conversion mechanism 220 through a belt or a pulley.
The motion conversion mechanism 220 converts a rotary motion of the ejection motor 210 into a linear motion of the ejection lever 230. The motion conversion mechanism 220 includes a screw shaft and a screw nut screwed onto the screw shaft. Balls or rollers can be interposed between the screw shaft and the screw nut.
The ejection lever 230 moves forward and backward freely in the through hole of the movable platen 120. The front end of the ejector lever 230 is in contact with the movable member 15 which is freely arranged inside the movable mold 12. The front end of the ejector rod 230 may or may not be connected to the movable member 15.
The ejection device 200 performs an ejection process under the control of the control device 700.
In the ejection process, the ejection motor 210 is driven to advance the ejection lever 230 from the standby position to the ejection position at a set speed, thereby advancing the movable member 15 to eject the molded product. Thereafter, the ejection motor 210 is driven to retreat the ejection lever 230 at a set speed, and retract the movable member 15 to the original standby position.
In addition, the ejection device 200 performs a compression molding process under the control of the control device 700.
In the compression molding process, the ejection motor 210 is driven to advance the ejection lever 230 from the compression standby position to the compression molding position at a set speed, so that the movable member 15 is advanced and the molding material filled in the cavity space 14 is compressed.
The position and speed of the ejection lever 230 are detected using, for example, an ejection motor encoder 211. The ejection motor encoder 211 detects the rotation of the ejection motor 210 and sends a signal indicating the detection result to the control device 700. A load element 231 is provided on the ejector rod 230. The load cell 231 detects the pressure applied to the ejector 230 and sends a signal indicating the detection result to the control device 700.
The compression process using the ejector 230, the load cell 231, and the movable member 15 will be described in detail.

[Injection device]
The description of the injection device 300 is different from the description of the mold clamping device 100 and the ejection device 200. The movement direction of the screw 330 (left direction in FIG. 1 and FIG. 2) during filling is forward, and the measurement of the screw 330 during measurement The moving direction (right direction in FIG. 1 and FIG. 2) will be described below.
The injection device 300 is provided on the sliding base 301 that can move forward and backward with respect to the frame Fr, and can move forward and backward with respect to the mold device 10. The injection device 300 is in contact with the mold device 10 and fills the cavity space 14 in the mold device 10 with a molding material. The injection device 300 includes, for example, a cylinder 310, a nozzle 320, a screw 330, a metering motor 340, an injection motor 350, a pressure detector 360, and the like.
The cylinder 310 heats the molding material supplied from the supply port 311 to the inside. The supply port 311 is formed at the rear of the cylinder block 310. A cooler 312 such as a water-cooled cylinder is provided on the outer periphery of the rear portion of the cylinder block 310. Further ahead of the cooler 312, a heater 313 such as a band heater and a temperature detector 314 are provided on the outer periphery of the cylinder block 310.
The cylinder block 310 is divided into a plurality of regions along the axial direction of the cylinder block 310 (left-right direction in FIGS. 1 and 2). A heater 313 and a temperature detector 314 are provided in each area. The control device 700 controls the heater 313 so that the temperature detected by the temperature detector 314 in each area becomes a set temperature.
The nozzle 320 is disposed at the front end of the cylinder block 310 and is tightly pressed against the mold device 10. A heater 313 and a temperature detector 314 are provided on the outer periphery of the nozzle 320. The control device 700 controls the heater 313 so that the detected temperature of the nozzle 320 becomes a set temperature.
The screw 330 is arranged in the cylinder body 310 to rotate freely and move forward and backward freely. When the screw 330 is rotated, the molding material is sent forward along the spiral groove of the screw 330. The molding material is gradually melted by the heat from the cylinder 310 while being sent forward. As the liquid forming material is sent to the front of the screw 330 and accumulated in the front of the cylinder 310, the screw 330 moves backward. Thereafter, when the screw 330 is advanced, the liquid molding material accumulated in front of the screw 330 is ejected from the nozzle 320 and filled in the mold device 10.
The check ring 331 is movably mounted on the front of the screw 330 as a check valve. The check valve prevents the molding material from flowing backward from the front of the screw 330 when the screw 330 is pushed forward.
When the screw 330 is advanced, the check ring 331 is pushed backward by the pressure of the molding material in front of the screw 330, and is retracted relative to the screw 330 to a closed position blocking the flow path of the molding material (see FIG. 2). This prevents the molding material accumulated in front of the screw 330 from flowing backward.
On the other hand, when the screw 330 is rotated, the check ring 331 is pushed forward by the pressure of the molding material sent forward along the spiral groove of the screw 330, and advances to the flow of the open molding material relative to the screw 330. Open position of the road (see Figure 1). Thereby, the molding material is sent in front of the screw 330.
The check ring 331 may be any one of a co-rotation type that rotates with the screw 330 and a non-co-rotation type that does not rotate with the screw 330.
In addition, the injection device 300 may include a driving source that advances and retracts the check ring 331 between the open position and the closed position with respect to the screw 330.
The metering motor 340 rotates the screw 330. The driving source for rotating the screw 330 is not limited to the metering motor 340, and may be, for example, a hydraulic pump.
The injection motor 350 advances and retreats the screw 330. A motion conversion mechanism or the like is provided between the injection motor 350 and the screw 330 to convert a rotational motion of the injection motor 350 into a linear motion of the screw 330. The motion conversion mechanism includes, for example, a screw shaft and a screw nut screwed to the screw shaft. Balls or rollers can be placed between the screw shaft and the screw nut. The driving source for advancing and retreating the screw 330 is not limited to the injection motor 350, and may be, for example, a hydraulic cylinder.
The pressure detector 360 detects a force transmitted between the injection motor 350 and the screw 330. The detected force is converted into a pressure by the control device 700. The pressure detector 360 is provided in a force transmission path between the injection motor 350 and the screw 330, and detects the force acting on the pressure detector 360.
The pressure detector 360 sends a signal indicating the detection result to the control device 700. The detection result of the pressure detector 360 is used when controlling or monitoring the pressure received by the screw 330 from the molding material, the back pressure on the screw 330, and the pressure acting on the molding material by the screw 330.
The injection device 300 performs a filling process, a pressing process, a metering process, and the like under the control of the control device 700.
In the filling process, the injection motor 350 is driven to advance the screw 330 at a set speed, and the liquid molding material stored in front of the screw 330 is filled in the cavity space 14 in the mold device 10. The position and speed of the screw 330 are detected using, for example, an injection motor encoder 351. The injection motor encoder 351 detects the rotation of the injection motor 350, and sends a signal indicating the detection result to the control device 700. When the position of the screw 330 reaches the set position, switching from the filling process to the holding process (so-called V / P switching) is performed. The position where the V / P switching is performed is also referred to as the V / P switching position. The set speed of the screw 330 can be changed according to the position, time, etc. of the screw 330.
In the filling process, after the position of the screw 330 reaches the set position, the screw 330 may be temporarily stopped at the set position, and then V / P switching may be performed. Before the V / P switching is performed, the screw 330 may be moved forward or back slightly instead of stopping the screw 330.
During the holding process, the injection motor 350 is driven to push the screw 330 forward, and the pressure (hereinafter, also referred to as “holding pressure”) of the molding material at the front end of the screw 330 is maintained at a set pressure to remain in the cylinder 310 The inner molding material is pushed toward the mold device 10. It is possible to supplement the insufficient amount of the molding material due to the cooling shrinkage in the mold device 10. The holding pressure is detected using a pressure detector 360, for example. The pressure detector 360 sends a signal indicating the detection result to the control device 700. The setting value of the holding pressure can be changed according to the elapsed time from the start of the holding process.
During the holding process, the forming material in the cavity space 14 in the mold device 10 is gradually cooled, and the entrance of the cavity space 14 is closed by the solidified forming material at the end of the holding process. This state is called a gate seal, and prevents the molding material from flowing backward from the cavity space 14. After the holding process, the cooling process is started. During the cooling process, the molding material in the cavity space 14 is solidified. In order to shorten the forming cycle time, a metering process can be performed during the cooling process.
In the measurement process, the measurement motor 340 is driven to rotate the screw 330 at a set rotation speed, and the forming material is sent forward along the spiral groove of the screw 330. As a result, the molding material gradually melts. As the liquid forming material is sent to the front of the screw 330 and accumulated in the front of the cylinder 310, the screw 330 moves backward. The rotation speed of the screw 330 is detected using, for example, a metering motor encoder 341. The measuring motor encoder 341 detects the rotation of the measuring motor 340 and sends a signal indicating the detection result to the control device 700.
In order to limit the rapid retreat of the screw 330 during the measurement process, the injection motor 350 may be driven to apply a set back pressure to the screw 330. The back pressure on the screw 330 is detected using, for example, a pressure detector 360. The pressure detector 360 sends a signal indicating the detection result to the control device 700. If the screw 330 is retracted to the measurement end position and a predetermined amount of molding material is accumulated in front of the screw 330, the measurement process ends.
In addition, although the injection device 300 of this embodiment is an in-line screw type, it may be a pre-plasticizing type or the like. The injection device of the pre-plasticizing method supplies the molding material melted in the plasticizing cylinder to the injection cylinder, and injects the molding material from the injection cylinder into the mold device. The screw is freely rotatable or rotatable and freely advancing and retreating is provided in the plasticizing cylinder, and the plunger is freely advancing and retreating in the injection cylinder.
In addition, the axial direction of the cylinder 310 of the injection device 300 of the present embodiment is a horizontal type in which the axial direction is horizontal, but it may be a vertical type in which the axial direction of the cylinder 310 is vertical. The mold clamping device combined with the vertical injection device 300 can be either vertical or horizontal. Similarly, the mold clamping device combined with the horizontal injection device 300 may be a horizontal type or a vertical type.

[Mobile device]
In the description of the moving device 400, the movement direction of the screw 330 (left direction in FIG. 1 and FIG. 2) during filling is the same as the description of the injection device 300, and the movement direction of the screw 330 (Figure 1 and FIG. 2 center right direction) will be described as the rear.
The moving device 400 advances and retreats the injection device 300 with respect to the mold device 10. The moving device 400 presses the nozzle 320 against the mold device 10 and generates a nozzle contact pressure. The moving device 400 includes a hydraulic pump 410, a motor 420 as a driving source, a hydraulic cylinder 430 as a hydraulic actuator, and the like.
The hydraulic pump 410 includes a first port 411 and a second port 412. The hydraulic pump 410 is a pump capable of bidirectional rotation. By switching the rotation direction of the motor 420, an operating fluid (for example, oil) is sucked in from either one of the first port 411 and the second port 412 and is discharged from the other to generate hydraulic pressure. In addition, the hydraulic pump 410 can also suck the working fluid from the storage tank and spit out the working fluid from any of the first port 411 and the second port 412.
The motor 420 operates the hydraulic pump 410. The motor 420 drives the hydraulic pump 410 with a rotation direction and a rotation torque corresponding to a control signal from the control device 700. The motor 420 may be an electric motor or an electric servo motor.
The hydraulic cylinder 430 includes a cylinder body 431, a piston 432, and a piston rod 433. The cylinder body 431 is fixed to the injection device 300. The piston 432 divides the inside of the cylinder body 431 into a front chamber 435 as a first chamber and a rear chamber 436 as a second chamber. The piston rod 433 is fixed to the fixed platen 110.
The front chamber 435 of the hydraulic cylinder 430 is connected to the first port 411 of the hydraulic pump 410 through the first flow path 401. The working fluid discharged from the first port 411 is supplied to the front chamber 435 through the first flow path 401, and the injection device 300 is pushed forward. The injection device 300 advances and presses the nozzle 320 against the fixed mold 11. The front chamber 435 functions as a pressure chamber that generates the nozzle contact pressure of the nozzle 320 by the pressure of the working fluid supplied from the hydraulic pump 410.
On the other hand, the rear chamber 436 of the hydraulic cylinder 430 is connected to the second port 412 of the hydraulic pump 410 through the second flow path 402. The working fluid discharged from the second port 412 is supplied to the rear chamber 436 of the hydraulic cylinder 430 through the second flow path 402, and the injection device 300 is pushed backward. The injection device 300 is retracted, and the nozzle 320 is separated from the fixed mold 11.
Although the moving device 400 includes the hydraulic cylinder 430 in the present embodiment, the present invention is not limited to this. For example, instead of the hydraulic cylinder 430, an electric motor and a motion conversion mechanism that converts the rotary motion of the electric motor into the linear motion of the injection device 300 may be used.

[Control device]
As shown in FIGS. 1 to 2, the control device 700 includes a CPU (Central Processing Unit, central processing unit) 701, a storage medium 702 such as a memory, an input interface 703, and an output interface 704. The control device 700 causes the CPU 701 to execute a program stored in the storage medium 702, thereby performing various controls. In addition, the control device 700 receives a signal from the outside through the input interface 703, and sends a signal to the outside through the output interface 704.
The control device 700 repeatedly performs a closed mold process, a mold clamping process, an open mold process, and the like, thereby repeatedly manufacturing a molded product. In addition, the control device 700 performs a measurement process, a filling process, a pressing process, and the like during the mold clamping process. A series of operations for obtaining a molded product, for example, operations from the start of a measurement process to the start of the next measurement process are also referred to as "injection molding" or "molding cycle". The time required for one injection molding is also referred to as the "molding cycle time".
The control device 700 is connected to the operation device 750 and the display device 760. The operation device 750 receives an input operation by the user and outputs a signal corresponding to the input operation to the control device 700. The display device 760 displays an operation screen corresponding to an input operation in the operation device 750 under the control of the control device 700.
The operation screen is used for setting the injection molding machine. There are multiple operation screens prepared for switching display or overlapping display. The user operates the operation device 750 while looking at the operation screen displayed on the display device 760, thereby performing settings (including input of setting values) of the injection molding machine and the like.
The operation device 750 and the display device 760 are configured by, for example, a touch panel, and can be integrated. In addition, although the operation device 750 and the display device 760 of this embodiment are integrated, they may be provided independently. The operation device 750 may be provided in plural.

[Detail of ejector]
FIG. 3 is a diagram showing a state of the ejector device according to an embodiment during standby.
The ejection device 200 is mounted on the movable platen 120. The movable platen 120 includes a movable platen main body portion 121 on which the movable mold 12 is mounted, and a movable platen link mounting portion 125 on which a swing shaft of the first link 152 is mounted. The movable platen main body portion 121 and the movable platen link attachment portion 125 may be integrally formed by casting or the like.
The movable platen main body portion 121 is formed as a plate-like portion. Notches may be formed along the tie bar 140 at four corners of the movable platen main body portion 121. Instead of the notch, a through hole through which the tie rod 140 is inserted may also be formed. The movable platen main body portion 121 has a through hole 122 in the central portion through which the ejector rod 230 is inserted.
The movable platen link mounting portion 125 is, for example, a pair of upper and lower surfaces (rear surface) of the movable platen main body portion 121 facing the toggle base 130. A through hole is formed in the top end portion of each movable platen link mounting portion 125, and a swing shaft is inserted through this through hole, whereby the first link 152 is swingably mounted on the movable platen link installation portion 125 through the swing shaft.
The movable platen link attachment portion 125 may further include a cylindrical portion protruding rearward from the rear surface of the movable platen main body portion 121. The cylindrical portion is formed in a rectangular shape when viewed from the mold opening and closing direction, and a space for accommodating at least a part of the ejection device 200 is formed inside.
As shown in FIG. 3, the ejection device 200 includes, for example, an ejection motor 210, a motion conversion mechanism 220, an ejection lever 230, a cross head 240, a joint 250, and the like.
The ejection motor 210 is fixed to the movable platen 120. The rotary motion of the ejection motor 210 is transmitted to the motion conversion mechanism 220 through the belt and the pulley, but may also be directly transmitted to the motion conversion mechanism 220.
The motion conversion mechanism 220 converts the rotary motion of the ejection motor 210 into a linear motion of the crosshead 240. The linear motion of the crosshead 240 is transmitted to the ejector rod 230 through the joint 250.
The motion conversion mechanism 220 includes a screw shaft 221 and a screw nut 222 screwed to the screw shaft 221. Balls or rollers may be interposed between the screw shaft 221 and the screw nut 222. The screw shaft 221 penetrates the mounting plate 223 provided behind the movable platen main body portion 121 and the movable platen main body portion 121 at a predetermined interval, and is fixed to the crosshead 240 at the front end portion. On the other hand, the screw nut 222 is rotatably held by the mounting plate 223 and cannot be moved forward and backward.
When the ejector motor 210 is driven to rotate the screw nut 222, the screw shaft 221 and the crosshead 240 advance and retreat. The arrangement of the screw shaft 221 and the screw nut 222 is not particularly limited. For example, the screw shaft 221 may be held by the mounting plate 223 to be freely rotatable and unable to advance and retreat, and the screw nut 222 may be fixed to the crosshead 240. In this case, when the ejector motor 210 is driven to rotate the screw shaft 221, the screw nut 222 and the crosshead 240 advance and retreat.
The cross head 240 moves forward and backward along a guide rod 241 erected between the mounting plate 223 and the movable platen main body 121. A plurality of guide rods 241 may be provided to prevent the crosshead 240 from rotating. The guide rod 241 may be cantilevered to be supported by either the mounting plate 223 or the movable platen main body portion 121.
The ejection lever 230 advances and retracts freely in the through hole 122 penetrating the movable platen 120 (more specifically, the movable platen main body 121) in the front-rear direction, and can advance and retreat as the crosshead 240 advances and retreats. The number of the ejector rods 230 is one in FIG. 3 to FIG. 6, but it can also be a plurality.
The front end of the ejector lever 230 is in contact with the movable member 15 which is arranged inside the movable mold 12 so as to be able to move forward and backward freely. The front end of the ejector rod 230 is not connected to the movable member 15, but may be connected to the movable member 15. When the front end of the ejector lever 230 is connected to the movable member 15, the spring 16 may be omitted.
When the ejection motor 210 is driven to advance the ejection lever 230, the movable member 15 advances to compress the molding material 2. After that, if the ejection motor 210 is driven to retract the ejection lever 230, the movable member 15 is retracted while being pressed by the ejection lever 230 by the elastic restoring force of the spring 16 to release the molded product. The decompressed molded product is ejected from the movable mold 12 before passing through the ejector 230.
The mold device 10 includes a fixed mold 11 mounted on a fixed platen 110 and a movable mold 12 mounted on a movable platen 120. As shown in FIG. 3, a cavity space 14 is formed between the fixed mold 11 and the movable mold 12 during mold clamping. FIG. 3 shows a state in which the mold device 10 is closed. The boundary between the fixed mold 11 and the movable mold 12 is a so-called parting line.
The molding material 2 reaches the cavity 14 through the gate 17 formed on the fixed mold 11, the runner 18 branched on the terminal portion of the gate 17, and the mold inlet 19 provided on the terminal portion of the runner 18.
Fig. 4 is a sectional view showing a movable member and an ejector rod according to an embodiment.
As described above, the movable member 15 is freely arranged inside the movable mold 12. A guide shaft 25 is provided inside the movable mold 12, and the guide shaft 25 is connected to the movable member 15 through a ball holder 26 provided in the movable member 15. With the combination of the guide shaft 25 and the ball retainer 26, the movable member 15 moves forward and backward freely along the axial direction of the guide shaft 25. The number of combinations of the guide shaft 25 and the ball retainer 26 is four, but other combinations may be used.
A spring 16 is disposed between the movable mold 12 and the movable member 15. As described above, by the elastic restoring force of the spring 16, the movable member 15 moves backward while being pressed by the ejection lever 230.
The front end of the ejection lever 230 is in contact with the pressing surface 21 a of the ejection plate 21 of the movable member 15 through a hole provided in the movable mold 12. A load element 231 is provided on the ejector rod 230. The load cell 231 detects the pressure applied to the ejector 230 and sends a signal indicating the detection result to the control device 700.
The movable member 15 includes a plate-shaped ejection plate 21 perpendicular to the front-rear direction, a rod-shaped compression core pin 22 extending forward from the ejection plate 21, and a rod-shaped ejection pin extending forward from the ejection plate 21. 23 and a rod-shaped abutment pin 24 extending forward from the ejector plate 21.
The ejection plate 21 is pushed forward by an ejection lever 230 disposed rearward of the ejection plate 21. In addition, the ejection plate 21 is urged to the rear by a spring 16 disposed more forward than the ejection plate 21.
The compression core pin 22 extends forward from the ejection plate 21 and penetrates the movable mold 12. The front end surface of the compression core pin 22 becomes a part of the wall surface of the cavity space 14. The compression core pin 22 advances and retracts together with the ejector plate 21 to perform compression of the molding material 2, decompression of the compression-molded molded product, and ejection of the decompressed molded product.
The ejection pin 23 extends forward from the ejection plate 21 and penetrates the movable mold 12. As shown in FIG. 4, the molding material 2 flowing in the runner 18 is solidified by holding the front end of the ejector pin 23. The ejector pin 23 is used to eject the molding material 2 cured by the runner 18.
The abutment pin 24 extends forward from the ejection plate 21 and penetrates the movable mold 12. In the ejection device 200 according to one embodiment, when the ejection lever 230 is used to advance the ejection plate 21 during compression molding, the compression molding position is determined based on the position where the front end of the contact pin 24 contacts the fixed mold 11.
The ejection device 200 is used for compressing the molding material filled in the cavity space 14 of the mold device 10 and for forming a molded product formed by the compression from the mold device 10 (hereinafter, also referred to as "compression molding Product ") to highlight these two actions. Compression of the molding material is performed before the molding material is completely cured. Hereinafter, the operation of compression molding using the control device 700 and the ejection device 200 according to one embodiment will be described.
FIG. 5 is a diagram showing functional components of a control device 700 according to an embodiment using functional blocks. Each functional block shown in FIG. 5 is conceptual and does not necessarily need to be physically configured as shown in the figure. All or a part of each functional block can be constructed by functionally or physically dispersing / combining in arbitrary units. All or any part of each processing function performed in each functional block can be realized by a program executed by the CPU, or can be realized as hardware based on wiring logic.
As shown in FIG. 5, the control device 700 includes an ejection lever position control unit 710, an ejection lever position detection unit 711, an ejection lever pressure control unit 712, a load element initialization unit 713, and an ejection lever pressure detection unit 714. The control device 700 includes a torque control unit 715, a torque detection value initialization unit 716, a torque detection unit 717, a screw position control unit 718, and a screw position detection unit 719.
The ejection lever position control unit 710 is electrically connected to the ejection motor 210. The ejection motor 230 is driven to advance and retreat by driving the ejection motor 210 to control the position of the ejection rod 230.
The ejection lever position detecting section 711 is electrically connected to an ejection motor encoder 211 provided on the ejection motor 210. The ejection lever position detecting section 711 receives the detection signal generated by the ejection motor encoder 211 and detects the position of the ejection lever 230. The detection result is output to the ejection lever position control section 710.
In addition, instead of using the ejection motor encoder 211, the ejection lever position control unit 710 may detect the position of the ejection lever 230 based on the number of driving pulses supplied to the ejection motor 210.
The ejection lever pressure control unit 712 is electrically connected to the ejection motor 210. The ejection lever 230 is driven forward and backward by driving the ejection motor 210 to control the pressure of the molding material that the movable member 15 applies to the cavity 14.
The load cell initialization unit 713 sends an initialization signal to the load cell 231, and initializes the detection value of the load cell 231.
The ejection rod pressure detecting portion 714 is electrically connected to a load cell 231 provided on the ejection rod 230. The ejector rod pressure detecting section 714 receives the detection signal generated by the load cell 231 to detect the pressure applied to the ejector rod 230. The detection result is output to the ejector pressure control section 712.
The torque control unit 715 is electrically connected to the ejection motor 210. The torque of the ejection lever 230 is controlled by driving the ejection motor 210.
The torque detection value initialization section 716 initializes the detection value of the torque detection section 717.
The torque detection unit 717 is electrically connected to the ejection motor 210. A signal indicating a motor current value for driving the ejection motor 210 is received to detect the torque of the ejection lever 230. The detection result is output to the torque control unit 715. In the following, the "signal indicating the motor current value for driving the ejector motor 210" is simply referred to as "motor current value".
The screw position control unit 718 is electrically connected to the injection motor 350 and controls the position of the screw 330 by driving the injection motor 350.
The screw position detection unit 719 is electrically connected to an injection motor encoder 351 provided in the injection motor 350. The screw position detecting section 719 receives a detection signal generated by the injection motor encoder 351 to detect the position of the screw 330. The detection result is output to the screw position control section 718.
The load cell 231 and the torque detection unit 717 are examples of a “detection mechanism”, respectively. The load element initialization unit 713 and the torque detection value initialization unit 716 are examples of the "initialization mechanism", respectively.
The control device 700 obtains a compression molding position before performing compression molding. The control device 700 advances the ejection lever 230 and the movable member 15 by the ejection lever position control unit 710, and detects the position where the contact pin 24 contacts the fixed mold 11. The control device 700 obtains a compression molding position based on this position.
FIG. 6 is a cross-sectional view showing the ejector lever 230 and the movable member 15 when the contact pin 24 of one embodiment contacts the fixed mold 11. 6 shows a state before the filling process of the molding material 2 is performed, and the molding cavity space 14 is not filled with the molding material.
The ejection lever position control unit 710 drives the ejection motor 210 to advance the ejection lever 230 and advance the movable member 15. If the front end of the contact pin 24 provided in the movable member 15 penetrates the through hole provided in the movable mold 12, it contacts the fixed mold 11.
Whether the front end of the abutting pin 24 is in contact with the fixed mold 11 is detected by receiving the detection value of the load cell 231 by the ejector rod pressure detecting section 714 and detecting the pressure applied to the ejector rod 230. Alternatively, the torque detection unit 717 receives the motor current value and detects the torque applied to the ejector lever 230 to detect it. In addition, it is determined whether or not to make contact by outputting a command to advance the ejector rod 230 at a predetermined time.
The ejection lever position control unit 710 sets this position as a compression molding position. Alternatively, the position where the contact pin 24 contacts the fixed mold 11 or the position retracted from the contact position by a predetermined distance may be set as the compression molding position. The detection value of the ejection lever 230 position detected by the ejection motor encoder 211 at the compression forming position is stored in the memory medium 702, and can be referred to when performing compression forming. In this way, the compression molding position is determined.
The length of the contact pin 24 is determined by the distance that the ejector lever 230 is moved after contacting the fixed mold 11.
After the compression molding position is set, the ejection lever position control unit 710 causes the ejection lever 230 to retract from the compression molding position by a distance corresponding to a predetermined compression amount. The position at this time becomes the compression standby position.
FIG. 7 is a cross-sectional view showing the ejector lever and the movable member when retracting from the state of FIG. 6 to the compression standby position of the embodiment. The ejection lever 230 and the movable member 15 move backward in the left direction in the figure. As a result, the volume of the cavity space 14 becomes large. In addition, a gap is generated between the end portion before the ejection pin 23 and the fixed mold 11 and between the end portion before the contact pin 24 and the fixed mold 11.
After the ejector lever 230 is retracted to the compression standby position, the load cell initialization unit 713 sends an initialization signal to initialize the detection value of the load cell 231. As described later, the reason for initializing the detection value of the load element 231 is to trigger the start of compression molding based on the detection value of the load element 231. By initializing the detection value of the load element 231, the influence of the temperature change of the load element 231 and the change of the resistance of the spring 16 is eliminated, and the start of compression molding can be triggered at an appropriate point.
In addition, instead of initializing the detection value of the load cell 231, the torque detection value may be initialized by the torque detection value initialization unit 716, and the torque detection value may be used as a trigger for starting compression molding.
The ejector lever 230 is retracted to the compression standby position, and after the load cell 231 or the torque detection value is initialized, the filling process is performed. The screw position control unit 718 drives the injection motor 350 to advance the screw 330 and fills the cavity space 14 with the molding material 2.
8 is a cross-sectional view showing an ejector rod and a movable member when a cavity is filled with a molding material according to an embodiment. The molding material 2 shown in black in FIG. 8 passes through the gate 17, the runner 18, and the mold inlet 19 to reach the cavity space 14. However, FIG. 8 shows a state in which the molding material 2 does not cover the entire cavity space 14.
As the molding material 2 is filled, the molding material 2 inside the cavity space 14 presses the compression core pin 22, and therefore, a force in a direction to retract the ejector rod 230 is applied. Thereby, the detection value of the pressure and torque detection part 717 detected by the load cell 231 rises.
The ejector position control unit 710 monitors the detection value of the load cell 231 through the ejector pressure detection unit 714 while the molding material 2 is filled. When the detected value reaches a predetermined pressure value as a trigger, the ejector lever position control unit 710 advances the ejector lever 230 to start compression molding.
Alternatively, the trigger of the start of compression forming can be detected by monitoring the torque detection value. That is, the ejection lever position control unit 710 monitors the detection value of the torque detection unit 717 while the molding material 2 is filled. When the detected value reaches a predetermined torque value as a trigger, the ejector lever position control unit 710 advances the ejector lever 230 to start compression molding.
Alternatively, the compression molding may be started after a predetermined time has elapsed from the filling molding material 2.
In compression molding, the ejector lever position control unit 710 advances the ejector lever 230 to the compression-molding position and advances the movable member 15 to compress the molding material 2 inside the cavity space 14.
9 is a cross-sectional view showing an ejector rod and a movable member when a molding material in a cavity space of an embodiment is compressed. Compared with FIG. 8, the ejection lever 230 and the movable member 15 advance in the right direction in the figure. Further, the compression core pin 22 advances, and the molding material 2 is compressed so as to extend throughout the entire cavity space 14.
Next, the operation described above will be described in accordance with the position of the screw 330 and the time change of the position, torque, and pressure of the ejector rod 230.
FIG. 10 is a graph showing the position of the screw 330 and the position, torque, and pressure of the ejector rod 230 over time. The horizontal axis in FIG. 10 represents time, and the vertical axis represents detection values of the ejection motor encoder 211, the load cell 231, the torque detection unit 717, and the ejection motor encoder 351. The units of actual detection values are different, and are shown together on the vertical axis of FIG. 10 for convenience.
In FIG. 10, the screw position detection value 71 indicated by a one-dot chain line indicates the detection value of the injection motor encoder 351. The ejection lever position detection value 72 indicated by the broken line is the detection value of the ejection motor encoder 211. The ejection lever torque detection value 73 indicated by a solid black line is a detection value of the torque detection section 717. The ejection rod pressure detection value 74 indicated by the dotted line is a detection value indicating the load cell 231.
The time on the horizontal axis is the starting point when the ejector lever 230 starts to advance after the mold device 10 closes the mold (see FIG. 2). Time t indicated by the two-dot chain line in FIG. 10 ₀ ~ t ₄ Is the time when a given time has passed from the starting point.
At time t ₀ During this period, in order to obtain the compression molding position, the ejection lever position control unit 710 drives the ejection motor 210 to gradually advance the ejection lever 230 and the movable member 15. At this time, the ejection lever position control unit 710 advances the ejection lever 230 at a low speed in order to protect the mold device 10.
At time t ₀ , The front end of the contact pin 24 contacts the fixed mold 11. At time t ₀ ~ t ₁ During this time, the ejection lever 230 stops due to contact. Ejection torque detection value 73 and ejection rod pressure detection value 74 become time t ₀ After a sharp rise, after the rise, until time t ₁ So far, it becomes almost constant. This means that the front end of the contact pin 24 was in contact with the fixed mold 11 and the torque and pressure applied to the ejector rod 230 sharply increased by the reaction force received from the fixed mold 11. With the stop of the ejector lever 230, the increase in torque and pressure subsides.
The contact between the front end of the abutting pin 24 and the fixed mold 11 is detected when the detection value of the load cell 231 or the torque detection section 717 reaches a predetermined value that is predetermined. At time t ₁ , The ejector position control section 710 will be at time t ₁ The detection value of the ejector motor encoder 211 is set to the compression molding position.
In FIG. 10, the position where the front end of the abutment pin 24 contacts the fixed mold 11 is set as the compression molding position. .
The relationship (relative distance) between the position where the abutment pin 24 contacts the fixed mold 11 (the contact position) and the compression molding position has been stored in advance. The contact position and the compression molding position may be the same or different. The compression molding position is determined based on the position where the contact pin 24 contacts the fixed die 11. For example, the length of the contact pin 24 may be adjusted in advance, and when the contact pin 24 contacts the fixed mold 11, the position of the compression core pin 22 becomes a compression molding position.
The member contacting the fixed mold 11 may be a movable member 15 and is not limited to the contact pin 24. The compression core pin 22 may be brought into contact with the fixed mold 11. However, the compression core pin 22 is a member forming the cavity space 14 and its front end surface is precisely processed. In order to determine the compression-molding position, the compression core pin 22 is in contact with the fixed mold 11 and may cause damage, which is not desirable.
At time t ₁ ~ t ₂ During this time, the ejection lever 230 moves back to the compression standby position. In FIG. 10, the ejection lever position detection value 72 drops sharply, and becomes substantially constant after the fall.
Similarly, the ejection rod torque detection value 73 and the ejection rod pressure detection value 74 are also from the time t ₁ It drops sharply and becomes almost constant after falling. This means that the ejection lever position control unit 710 retracts the ejection lever 230 and retracts the movable member 15 to the compression standby position by the elastic restoring force of the spring 16.
At time t ₂ The load element initialization unit 713 sends an initialization signal to the load element 231. In FIG. 10, at time t ₃ The load cell 231 is initialized and the detection value becomes zero.
In addition, the torque detection value initialization unit 716 may send an initialization signal to initialize the detection value of the torque detection unit 717, and use the detection value of the torque detection unit 717 as a trigger for the start of compression molding.
At time t ₃ ~ t ₄ During this period, the cavity space 14 is filled with the molding material 2. The screw position control unit 718 drives the injection motor 350 to advance the screw 330 and fills the cavity space 14 with the molding material 2. In FIG. 10, from time t ₃ The lift screw position detection value 71 decreases. Shows that the screw 330 advances in the left direction in FIG. 3.
During this period, since the ejection lever 230 does not move, the ejection lever position detection value 72 is constant.
On the other hand, the ejection lever torque detection value 73 and the ejection lever pressure detection value 74 gradually increase. It means that as the molding material 2 is filled, the molding material 2 inside the cavity space 14 presses the compression core pin 22 with increasing force, and exerts a force in the direction in which the ejector rod 230 moves backward.
With the filling of the molding material 2, the pressure detected by the load element 231 rises, and the time t when the detection value of the load element 231 reaches a predetermined pressure value which is predetermined ₄ , Start compression molding.
As shown in FIG. 10, as the filling material 2 is filled, the torque detected by the torque detection unit 717 also increases. Therefore, the detection value of the torque detection unit 717 may be used to trigger the start of compression molding.
At time t ₄ During the subsequent period, the ejector lever position control unit 710 controls the ejector lever 230 to the compression molding position to advance the movable member 15 to compress the molding material 2 inside the cavity space 14. In FIG. 10, the ejection lever position detection value 72 increases to the compression molding position, and accordingly, the ejection lever torque detection value 73 and the ejection lever pressure detection value 74 increase.
At time t ₄ In the following period, the state of the molding material 2 in the cavity space 14 can be controlled by controlling the pressure or torque by the ejector pressure control section 712 or the torque control section 715.
With the above operation, the position of the screw 330 and the position of the ejector rod 230, the torque, and the pressure change according to the compression molding operation of one embodiment.
Fig. 11 is a flowchart showing a compression molding process according to an embodiment.
First, the mold clamping device 100 performs mold clamping of the mold device 10 under the control of the control device 700 (step S111).
Next, the ejection lever position control unit 710 controls the advancement of the ejection lever 230 to advance the movable member 15 (step S112). The ejection lever position control unit 710 monitors the detection value of the load cell 231 while advancing the ejection lever 230.
As the movable member 15 advances, the front end of the contact pin 24 contacts the fixed mold 11. The ejector position control unit 710 detects that the front end of the contact pin 24 has contacted the fixed mold 11 because the detection value of the load element 231 has reached a predetermined predetermined value, and stops the advance control of the ejector 230 (step S113).
The ejection lever position control unit 710 sets the position retracted from the position where the end of the abutting pin 24 contacts the fixed mold 11 by a predetermined distance to the compression molding position (step S114).
Next, when the ejector lever 230 is retracted and retracted from the compression molding position to a compression standby position corresponding to a predetermined compression amount, the ejector lever position control unit 710 stops the ejector lever 230 and retracted (step S115).
Next, the load cell initialization unit 713 sends an initialization signal to the load cell 231 to initialize the detection value of the load cell 231 (step S116). After the initialization, the injection device 300 moves the screw 330 under the control of the control device 700 to fill the cavity space 14 with the molding material 2. The ejection lever position control unit 710 monitors the detection value of the load cell 231 through the ejection lever pressure detection unit 714 during filling.
Compression molding is started with the detection value of the load cell 231 reaching a predetermined pressure value as a trigger (step S117).
The ejection lever position control unit 710 controls the advancement of the ejection lever 230, and when it reaches the compression molding position, it stops the advancement of the ejection lever 230 (step S118). By advancing the ejector rod 230 forward, the molding material 2 in the cavity space 14 is compressed.
The ejector rod pressure control unit 712 advances and retracts the ejector rod 230 during the holding pressure and cooling, and controls the pressure of the molding material that the movable member 15 applies to the cavity space 14 (step S119).
In this way, compression molding is performed. In the above description, the compression molding is started by detecting the pressure of the ejector rod 230, but it is also possible to detect the torque of the ejector rod 230.
As described above, in this embodiment, before the compression molding, when the movable member 15 is advanced by the ejector lever 230, the compression molding position is determined based on the position where the contact pin 24 contacts the fixed mold 11.
For example, when the ejector lever 230 is extended due to thermal deformation, the moving start position of the movable member 15 during compression molding is shifted forward (right direction in FIG. 4) by the amount of extension of the ejector lever 230. Accordingly, the position of the front end face of the compression core pin 22 is shifted forward during compression molding, and the cavity space 14 is narrowed in the front-rear direction. This may cause an error in the thickness of the molded product.
On the contrary, when the ejector lever 230 is retracted, the starting position of the movable member 15 advanced during compression molding is shifted backward (left direction in FIG. 4). Accordingly, the position of the front end face of the compression core pin 22 is shifted rearward during compression molding, and the cavity space 14 is expanded in the front-rear direction. As a result, there is a case where the accuracy of the shape of the surface of the molded product is lowered due to an error in the thickness of the molded product and unevenness of the molding material 2 due to insufficient compression.
According to this embodiment, the compression molding position relative to the reference is obtained before compression molding. Therefore, even when the ejector rod 230 expands and contracts due to thermal deformation as described above, the core pin 22 can be prevented from being compressed during compression molding. The front end face is out of position. This can prevent the thickness accuracy and surface accuracy of the molded product from being lowered due to thermal deformation of the ejector rod or the like during compression molding.
In the present embodiment, the position where the movable member 15 is retracted from the compression molding position by a distance corresponding to the amount of compression is used as the compression standby position. Even in the case where the ejector rod 230 expands and contracts due to thermal deformation, it is possible to perform compression molding with a desired compression amount starting from the compression molding position at which the position of the front end face of the compression core pin 22 is not shifted. This can prevent the thickness accuracy and surface accuracy of the molded product from being lowered due to thermal deformation of the ejector rod or the like during compression molding.
In this embodiment, the contact of the contact pin 24 with the fixed mold 11 is detected based on the pressure or torque applied to the ejector 230. The contact between the contact pin 24 and the fixed mold 11 can be detected with a simple structure.
According to this embodiment, there is a load element initialization section 713 that initializes the detection value of the load element 231, and the load element 231 is used to detect the pressure applied to the ejector 230. At the compression standby position, the load cell initialization unit 713 initializes the detection value of the load cell 231, starts filling the cavity space 14 with the molding material 2, and starts compression molding when the detection value of the load cell 231 becomes a predetermined pressure value. Thereby, compression molding can be started at an appropriate time according to the flow condition of the molding material 2 inside the cavity space 14. It is possible to further improve the reproducibility of the thickness and shape of the molded product.
In addition, the detection value of the load cell 231 is initialized at the compression standby position, so that the influence of the temperature change of the load cell 231 and the resistance change of the spring 16 provided in the ejection plate 21 can be eliminated, and compression can be started at an appropriate time. Forming.
In addition, according to this embodiment, there is a torque detection value initialization section 716 that initializes the detection value of the torque detection section 717, and the torque detection section 717 is configured to detect the torque applied to the ejector lever 230. At the compression standby position, the torque detection value initialization unit 716 initializes the detection value of the torque detection unit 717 and starts filling the cavity space 14 with the molding material 2. The detection value of the torque detection unit 717 becomes a predetermined pressure value. Compression molding is started. Thereby, compression molding can be started at an appropriate time according to the flow condition of the molding material 2 inside the cavity space 14. It is possible to further improve the reproducibility of the thickness and shape of the molded product.
In addition, by initializing the detection value of the torque sensor 717 at the compression standby position, the influence of changes in the resistance of the spring 16 included in the ejector plate 21 can be eliminated, and compression molding can be started at an appropriate point.
In addition, the amount of thermal deformation of the ejector rod 230 may change each time compression molding is performed. Therefore, in order to reliably prevent the influence of thermal deformation of the ejector rod 230, it is preferable to perform a process of setting a compression molding position each time compression molding is performed.
Although the embodiments and the like of the injection molding machine have been described above, the present invention is not limited to the above-mentioned embodiments and the like, and various modifications and improvements can be made within the scope of the gist of the present invention described in the scope of patent application.

2‧‧‧成形材料2‧‧‧forming materials

10‧‧‧模具裝置 10‧‧‧Mould device

11‧‧‧固定模 11‧‧‧Fixed

12‧‧‧活動模 12‧‧‧Activity mode

14‧‧‧模穴空間 14‧‧‧Mould cavity space

15‧‧‧活動構件 15‧‧‧Activity component

21‧‧‧頂出板 21‧‧‧ ejector board

22‧‧‧壓縮芯銷 22‧‧‧ compression core pin

23‧‧‧頂出銷 23‧‧‧ Top Out

24‧‧‧抵接銷 24‧‧‧Amortization

210‧‧‧頂出馬達 210‧‧‧Ejector motor

211‧‧‧頂出馬達編碼器 211‧‧‧Ejection motor encoder

230‧‧‧頂出桿 230‧‧‧ Ejection

231‧‧‧荷重元 231‧‧‧Loading Yuan

351‧‧‧射出馬達編碼器 351‧‧‧ Injection motor encoder

700‧‧‧控制裝置 700‧‧‧control device

710‧‧‧頂出桿位置控制部 710‧‧‧ ejector position control unit

711‧‧‧頂出桿位置檢測部 711‧‧‧Ejection rod position detection section

712‧‧‧頂出桿壓力控制部 712‧‧‧Ejection rod pressure control unit

713‧‧‧荷重元初始化部 713‧‧‧Load Element Initialization Department

714‧‧‧頂出桿壓力檢測部 714‧‧‧Ejection rod pressure detection section

715‧‧‧轉矩控制部 715‧‧‧Torque Control Department

716‧‧‧轉矩檢測值初始化部 716‧‧‧Torque detection value initialization section

717‧‧‧轉矩檢測部 717‧‧‧Torque detection department

718‧‧‧螺桿位置控制部 718‧‧‧Screw position control section

719‧‧‧螺桿位置檢測部 719‧‧‧Screw position detection section

圖1係表示一實施形態的射出成形機之開模結束時的狀態之圖。FIG. 1 is a diagram showing a state at the end of mold opening of an injection molding machine according to an embodiment.

圖2係表示一實施形態的射出成形機之合模時的狀態之圖。 FIG. 2 is a diagram showing a state of the injection molding machine according to the embodiment when the mold is closed.

圖3係表示一實施形態的頂出裝置之待機時的狀態之圖。 FIG. 3 is a diagram showing a state of the ejector device according to an embodiment during standby.

圖4係表示一實施形態的頂出桿和活動構件之剖面圖。 Fig. 4 is a sectional view showing an ejector lever and a movable member according to an embodiment.

圖5係用功能塊表示一實施形態的控制裝置之構成要件之圖。 Fig. 5 is a diagram showing functional components of a control device according to an embodiment using functional blocks.

圖6係表示在一實施形態的銷接觸固定模時的頂出桿和活動構件之剖面圖。 6 is a cross-sectional view showing an ejector lever and a movable member when a pin contacts a fixed mold according to an embodiment.

圖7係表示在一實施形態的後退至壓縮待機位置時的頂出桿和活動構件之剖面圖。 7 is a cross-sectional view showing an ejector lever and a movable member when retracted to a compression standby position according to an embodiment.

圖8係表示在向一實施形態的模穴空間填充成形材料時的頂出桿和活動構件之剖面圖。 FIG. 8 is a cross-sectional view showing an ejector rod and a movable member when a cavity is filled with a molding material according to an embodiment.

圖9係表示在壓縮一實施形態的模穴空間之成形材料時的頂出桿和活動構件之剖面圖。 9 is a cross-sectional view showing an ejector rod and a movable member when a molding material in a cavity space of an embodiment is compressed.

圖10係表示一實施形態的螺桿之位置、頂出桿之位置、轉矩及壓力之時間變化的圖。 FIG. 10 is a diagram showing changes in the position of the screw, the position of the ejector, the torque, and the pressure over time according to the embodiment.

圖11係表示一實施形態的壓縮成形處理之流程圖。 Fig. 11 is a flowchart showing a compression molding process according to an embodiment.

Claims

An injection molding machine having: Ejector, and A control unit that controls the advancement and retreat of the ejector lever, The movable member is advanced from the compression standby position to the compression molding position by the ejector rod, thereby compressing the molding material filled in the cavity space, which is characterized in that: The control unit determines the compression molding position based on a position where the movable member is in contact with the fixed mold when the movable member is advanced by the ejector lever.

The injection molding machine described in item 1 of the scope of patent application, wherein: The aforementioned molding material is compressed with a predetermined compression amount, The compression standby position is a position where the movable member is retracted from the compression molding position by a distance corresponding to the compression amount.

The injection molding machine according to item 1 or 2 of the scope of patent application, wherein: The control unit detects the contact based on the pressure or torque applied to the ejector rod during the advance.

The injection molding machine described in item 1 or 2 of the scope of patent application, which has: A detection mechanism that detects the pressure or torque applied to the ejector, and An initialization mechanism that initializes the detection value of the aforementioned detection mechanism, The initialization mechanism initializes the detection value of the detection mechanism at the compression standby position, After the control unit starts to fill the cavity space with the molding material, when the detection value of the detection mechanism becomes a predetermined value, the compression is started.