CN115972522B - Defective product control system and method of injection molding machine - Google Patents
Defective product control system and method of injection molding machine Download PDFInfo
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- 238000001746 injection moulding Methods 0.000 title claims abstract description 99
- 230000002950 deficient Effects 0.000 title claims abstract description 64
- 238000000034 method Methods 0.000 title claims abstract description 14
- 230000009471 action Effects 0.000 claims abstract description 52
- 238000004519 manufacturing process Methods 0.000 claims abstract description 49
- 230000001960 triggered effect Effects 0.000 claims description 8
- 238000002347 injection Methods 0.000 claims description 6
- 239000007924 injection Substances 0.000 claims description 6
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- 230000002159 abnormal effect Effects 0.000 abstract description 5
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- 239000002699 waste material Substances 0.000 description 5
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- 239000007787 solid Substances 0.000 description 2
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- 239000003086 colorant Substances 0.000 description 1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention relates to the technical field of injection molding, in particular to a defective product control system, method and control circuit of an injection molding machine, which comprises the following steps: the injection molding machine is used for continuously carrying out an injection molding process to produce injection molding products, wherein the injection molding process comprises an injection molding middle state and an opening mold finished state, and the injection molding middle state and the opening mold finished state are defined as a production period; the first timer continuously receives a mold opening completion signal of the injection molding machine, and outputs a first action signal and a second holding signal. The invention designs a circuit through ingenious utilization of a common timer, can fully automatically and accurately monitor the change of the injection molding period in real time, identify abnormal periods, accurately screen and identify poor starting and poor stopping, control a mechanical arm to keep good products by output signals, reject the bad products, greatly improve the yield and avoid quality accidents.
Description
Technical Field
The invention relates to the technical field of injection molding, in particular to a defective product control system and method of an injection molding machine.
Background
Injection molding is the most commonly used plastic processing technology and is widely applied in production and life. Injection molding is defined as the injection molding process in which after the plastic is heated to a temperature, the injection molding machine injects the dissolved plastic into a closed mold cavity at extremely high pressure, then the mold is cooled to form, and after opening the mold, the plastic product is ejected from the top plate. The injection molding process has the characteristics of good product consistency, stable quality and extremely low probability of generating bad products during continuous and stable production.
The inventor finds that when the production is carried out in a discontinuous stable state, such as the production elements of just starting up the production, unstable period, abnormal shutdown, equipment failure alarm and the like are changed, the probability of defects of the product is increased sharply, and the yield of the product is reduced greatly. Because the existing common mechanical arm is used for automatic production, operators are difficult to monitor and find abnormality in real time, and defective products are difficult to prevent from being mixed into good products.
And when defective products are mixed into good products, the defective products must be manually inspected and screened, which is time-consuming and labor-consuming. And only the poor appearance can be identified, and the non-poor appearance can escape and flow into the next working procedure or be delivered to the customer, so that the quality is reduced and the customer complaints are caused. At present, besides education for operators, increased responsibility and improved operation skills, effective technical means for preventing the quality problems are lacking.
Therefore, how to control the rejection of defective products becomes a technical problem to be solved.
Disclosure of Invention
The first aspect of the present invention proposes a technical solution, a defective product control system of an injection molding machine, including:
the injection molding machine is used for continuously carrying out an injection molding process to produce injection molding products, wherein the injection molding process comprises an injection molding middle state and an opening mold finished state, and the injection molding middle state and the opening mold finished state are defined as a production period;
the first timer continuously receives a mold opening completion signal of the injection molding machine and outputs a first action signal and a first holding signal;
the second timer is connected to the output end of the first timer, receives the first action signal or the first holding signal output by the first timer, and outputs the second action signal or the second holding signal;
a manual button connected to an input end of the second timer, the manual button including an operation signal and a hold signal, the manual hold signal input to the second timer being switched to a manual operation signal when the manual button is triggered;
an action component;
when the time interval between two adjacent production periods of the injection molding machine is greater than T1, the first action signal output by the first timer to the second timer is switched to a first holding signal, and when the manual holding signal and the first holding signal are simultaneously input to the second timer and kept greater than T2 time interval, the second action signal output by the second timer is switched to a second holding signal;
when the production period of the second timer outputting the second action signal is defined as a bad period, and when the production period of the second timer outputting the second holding signal is defined as a good period;
the action part receives the output of the second timer, when the second timer outputs a second action signal, the action part is set to output a visual bad signal and/or reject injection products in a bad period, and when the second timer outputs a second holding signal, the action part is set to output a visual good signal and/or collect injection products in a good period.
Preferably, the action part includes an indicator lamp including a red indicator lamp and a green indicator lamp, the red indicator lamp being lighted when the second timer outputs the second action signal, and the green indicator lamp being lighted when the second timer outputs the second hold signal.
Preferably, the action component comprises a manipulator, and the manipulator is used for transferring the injection molding product produced by the injection molding machine to a defective product collecting area or a good product collecting area according to the signal output by the second timer.
The second aspect of the present invention provides a technical solution, a defective product control method of an injection molding machine, using the defective product control system of the injection molding machine, comprising the following steps:
continuously detecting the production cycle of the injection molding machine, calculating the time interval of two production cycles, defining that the interval between two adjacent production cycles is smaller than T1 as a condition 1, continuously detecting the state of a manual button, taking the condition that the manual button is not triggered as a condition 2, and continuously operating T2 as a condition 3 when the condition 1 and the condition 2 are simultaneously met;
when the injection molding machine meets the condition 3, defining the production period after the moment as a good product period, and when one of the condition 1, the condition 2 or the condition 3 is not met, switching the good product period into a bad product period and eliminating products in the bad product period.
Preferably, the manual button is manually activated by an operator.
Preferably, the condition 1 controls triggering by means of automatic timer.
Preferably, the product in the defective cycle is removed by transferring the product to a waste bin using a robot.
The third aspect of the invention provides a technical scheme, namely a defective product control circuit of an injection molding machine, which comprises the injection molding machine, a first relay, a second relay, a manual normally open button, a first indicator lamp and a second indicator lamp;
the first relay comprises a first relay coil, a first input interface, a first normally-closed contact and a first normally-open contact, and the first relay coil is connected with a power supply and a public end;
the second relay comprises a second relay coil, two second input interfaces, two second normally-closed contacts and a second normally-open contact, and the second relay coil is connected with a power supply and a public end;
the injection molding machine is connected to the input end of the first relay through a signal wire;
the manual normally-open switch is connected with the first normally-closed contact in parallel, a first end of the second normally-open contact is connected with a common end, and a second end of the second normally-open contact is connected with an action component;
the first indicator lamp is connected with the power supply and the public end through one of the second normally closed contacts in series, and the second indicator lamp is connected with the power supply and the public end through one of the second normally open contacts in series.
Compared with the prior art, the invention has the advantages that:
the invention designs a circuit through ingenious utilization of a common timer, can fully automatically and accurately monitor the change of the injection molding period in real time, identify abnormal periods, accurately screen and identify poor starting and poor stopping, control a mechanical arm to keep good products by output signals, reject the bad products, greatly improve the yield and avoid quality accidents.
The invention can realize the same function without using a Programmable Logic Controller (PLC) with complex circuit and high cost, and has the functions of low cost, simple circuit, full automation and the like. And has the advantages of simple operation, high reliability, convenient maintenance and the like.
Drawings
The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a defective product control system of an injection molding machine according to the present invention;
FIG. 2 is a control block diagram of a defective product control system of an injection molding machine in a defective product state;
FIG. 3 is a control block diagram of a defective control system of an injection molding machine in a defective state;
FIG. 4 is a control circuit diagram illustrating the present invention;
FIG. 5 is a timing diagram of a defective control circuit of an injection molding machine according to the present invention;
Detailed Description
For a better understanding of the technical content of the present invention, specific examples are set forth below, along with the accompanying drawings.
Defective product control system of injection molding machine
The first aspect of the present invention proposes a technical solution, a defective product control system of an injection molding machine, mainly including an injection molding machine 2, a controller and an action component, it can be understood that the injection molding machine 2 continuously performs an injection molding process to produce an injection molding product, where the injection molding process includes an injection molding state and an mold opening state, and a production cycle is defined by passing through the injection molding state and the mold opening state.
In the production process, the inventor finds that the probability of defective products is increased when the injection molding machine is in a discontinuous stable production state such as just started production, unstable period, abnormal shutdown, equipment failure and the like, so the invention aims to define the production period as a good product period and a defective period according to the production state of the injection molding machine, reject products produced in the defective period by the injection molding machine through an action part and recycle the products so as to ensure the yield of the produced products.
The invention aims to monitor the production cycle of an injection molding machine by using simple electronic components, and the production cycle comprises a first timer and a second timer. The method comprises the steps that a first timer continuously receives a mold opening completion signal of an injection molding machine, and the first timer outputs a first action signal and a first holding signal; the second timer is connected to the output end of the first timer, receives the first action signal or the first holding signal output by the first timer, and outputs the second action signal or the second holding signal.
Further, in order to increase the flexibility of operators and improve the production guarantee, a manual button is arranged and connected to the input end of the second timer, the manual button comprises an action signal and a holding signal, and when the manual button is triggered, the manual holding signal input to the second timer is switched into the manual action signal; it can be understood that the manual button has the function of completely and manually eliminating defective products.
Under the hardware control of the two timers and the manual button, the control logic is realized as follows:
referring to fig. 2 and 3, when the time interval between two adjacent production cycles of the injection molding machine 2 is greater than T1, the first action signal output by the first timer to the second timer is switched to the first holding signal, and when the manual holding signal and the first holding signal are simultaneously input to the second timer and maintained for a time interval greater than T2, the second action signal output by the second timer is switched to the second holding signal;
when the second timer outputs the production period of the second action signal, the production period is defined as a bad period, and when the second timer outputs the production period of the second holding signal, the production period is defined as a good period;
the action part receives the output of the second timer, when the second timer outputs a second action signal, the action part is set to output a visual bad signal and/or reject injection products in a bad period, and when the second timer outputs a second holding signal, the action part is set to output a visual good signal and/or collect injection products in a good period.
Good product period: when the injection molding machine is started and then is in a bad production state, the first timer continuously detects the mold opening completion signals of the injection molding machine, two adjacent mold opening completion signals are defined as a production period, when the adjacent production period is smaller than T1, the manual button is not pressed at the same time, and after the state T2 is delayed and maintained by the second timer, the production period of the injection molding machine is switched from the bad period to a good period, and at the moment, products in the good period are collected.
Failure period: when the first timer detects that the adjacent production period of the injection molding machine is greater than T1, the production period is changed from a good period to a bad period; when the manual button is pressed, the production period is changed from a good period to a bad period; when the two conditions occur simultaneously or any one occurs, the injection molding machine is triggered to change from a good product period to a bad period.
Optionally, the action component includes an indicator light, the indicator light includes a red indicator light and a green indicator light, the red indicator light is turned on when the second timer outputs the second action signal, and the green indicator light is turned on when the second timer outputs the second hold signal.
In an alternative embodiment, the manual button, the first timer, the second timer, and the indicator lamp are integrated onto the controller 1 as operation means for rejecting defective products.
Preferably, the action part comprises a mechanical arm, and the mechanical arm is used for transferring the injection molding product produced by the injection molding machine to the defective product collecting area or the good product collecting area according to the signal output by the second timer.
It can be appreciated that the action part aims at visually distinguishing the good product period and the bad product period of the injection molding machine, for example, the action part adopts the indicator lamps with different colors, and further, the action part classifies the good product and the bad product according to different periods.
In a specific embodiment, as shown in fig. 1, the products produced by the injection molding machine 2 are transferred to the collection box 5 or the waste box 6 on the conveyor belt 4 by the manipulator 3 according to different periods, the collection box 5 on the conveyor belt 4 is transferred to the good product bin after being fully collected, and the products in the waste box 6 are recycled.
Defective product control method of injection molding machine
The second aspect of the present invention provides a technical solution, a defective product control method of an injection molding machine, using the defective product control system of the injection molding machine, comprising the following steps:
continuously detecting the production cycle of the injection molding machine, calculating the time interval of two production cycles, defining that the interval between two adjacent production cycles is smaller than T1 as a condition 1, continuously detecting the state of a manual button, taking the condition that the manual button is not triggered as a condition 2, and continuously operating T2 as a condition 3 when the condition 1 and the condition 2 are simultaneously met;
when the injection molding machine meets the condition 3, defining the production period after the moment as a good product period, and when one of the condition 1, the condition 2 or the condition 3 is not met, switching the good product period into a bad product period and eliminating products in the bad product period.
Preferably, the manual button is manually activated by an operator.
Preferably, the triggering of the condition 1 and the condition 3 is controlled by means of automatic timer.
Preferably, the product in the defective cycle is removed by transferring the product to a waste bin using a robot.
Defective product control circuit of injection molding machine
The third aspect of the invention provides a technical scheme, namely a defective product control circuit of an injection molding machine, which comprises the injection molding machine, a first relay, a second relay, a manual normally open button, a first indicator lamp and a second indicator lamp;
the first relay comprises a first relay coil, a first input interface, a first normally-closed contact and a first normally-open contact, and the first relay coil is connected with a power supply and a public end;
the second relay comprises a second relay coil, two second input interfaces, two second normally closed contacts and a second normally open contact, and the second relay coil is connected with a power supply and a public end;
the injection molding machine is connected to the input end of the first relay through a signal wire;
the manual normally-open switch is connected with the first normally-closed contact in parallel, the first end of the second normally-open contact is connected with the common end, and the second end of the second normally-open contact is connected with the action component;
the first indicator lamp is connected with the power supply and the public end through a second normally closed contact in series, and the second indicator lamp is connected with the power supply and the public end through a second normally open contact in series.
Examples
As shown in fig. 4 and 5, the input pulse signal presence state is defined as ON, the signal absence state is defined as OFF in the timing chart, and the signal presence state is defined as ON in the timing chart. The default output contact ON state is ON, indicated by a high level in the timing chart, the output contact OFF state is OFF, and indicated by a low level in the timing chart.
KT1 represents a first timer, and KT2 represents a second timer.
As shown in fig. 5, the first timer works as follows: the No. 6 port of the first timer is input, the No. 3 port is a normally open output end, the No. 4 port is a normally closed output end, and T1 is the set time period of the E mode solid state timer 12. When the input pulse signal generates a rising edge between the No. 6 port and the common end 2, the No. 1 port and the No. 3 port are connected, the output is ON, and when the set time period T1 is reached, the No. 1 port and the No. 3 port are disconnected, and the output is OFF. Normally closed output signals are output from ports 1 and 4, and the states are opposite. When the interval between input pulse signals is < T1, the output state remains continued.
The second timer works as follows: the port No. 6 of the second timer is input, the port No. 3 (or No. 9) is a normally open output end, the port No. 4 (or No. 8) is a normally closed output end, and T2 is the set time period of the D-mode solid state timer 13. When an input pulse signal is input from the rising edge between the No. 6 port and the common end 2, the No. 1 port and the No. 3 port are connected, the output is ON, until the falling edge of the input pulse signal comes, the timer counts, and when the set time period T2 is reached, the No. 1 port and the No. 3 port are disconnected, and the output is OFF. Normally closed output signals are output from ports 1 and 4, and the states are opposite. When the interval between input pulse signals is < T2, the output state remains continued.
As shown in fig. 5, when the injection molding machine 2 is not continuously operated, the mold opening signal OFF, such as a1 pulse front state, is performed, at this time KT1 inputs 6 and 2 ports OFF, normally open outputs 3 and 1 ports OFF, normally closed outputs 4 and 1 ports ON, c1=on, KT2 inputs 6 and 2 ports OFF, d1=on, normally open outputs 3 and 1 ports ON, e1=on, the red indicator lamp 14 (HR 1) is turned ON, normally open outputs 9 and 11 ports ON, f1=on, the defective signal output ON, normally closed outputs 1 and 4 ports OFF, the green indicator lamp (HG 1) is turned OFF, and the whole circuit is in the defective mode.
When the injection molding machine 2 starts to continuously run, the mold opening completion signals are periodically ON and OFF, periodic pulse signals a1-a3 are generated at the KT1 input 6 and the No. 2 ports, the pulse period is < T1, pulse signals b1=on are generated at the normally open output 3 and the No. 1 ports, the normally closed output 4 and the No. 1 ports are inverted, c1=off is carried out when b1=on, the KT2 input 6 and the No. 2 ports are in the same state, d1=off is carried out when c1=off, the normally open output 3 and the No. 1 ports are e 1=off after d1 falling edge +delay T2, the red indicator lamp (HR 1) is out in a power-OFF state, the normally open output 9 and the No. 11 ports are OFF, the defective signal output OFF is carried out, the normally closed output 4 and the No. 1 ports are ON, the green indicator lamp (HG 1) is powered ON, and the whole circuit is switched from the defective mode to the good mode. As the period a1-a3 is in the defective product mode, the mechanical arm 3 receives the defective product signal and discards the defective products generated in the period. From the period a4, the circuit is switched to a good product mode, the mechanical arm 3 does not receive a defective product signal, and the good product generated at the moment is packaged.
After period a5, the injection molding machine 2 encounters a fault, resulting in a6 signal > T1 period, at this time KT1 inputs 6 and No. 2 ports OFF, normally open outputs 3 and 1 ports a5 rising edge +t1 back b1=off, normally closed outputs 4 and 1 ports ON, c2=on, KT2 inputs 6 and No. 2 ports ON, d2=on, normally open outputs 3 and 1 ports ON, e2=on, red indicator lamp (HR 1) is powered ON, normally open outputs 9 and 11 ports ON, f2=on, defective signal output ON, normally closed outputs 1 and 4 ports OFF, green indicator lamp (HG 1) is powered OFF, and the whole circuit is switched from a defective mode to a defective mode. Any two mold opening signal periods are more than T1 period, namely, the switching is triggered, the abnormal period of the injection molding machine 2 is automatically and effectively monitored, and the mode is timely switched.
In the period of a6-a7, the circuit is the same as the working mode of the period of a1-a2, and the product exceeding the period of T1 is regarded as defective products. In the period of a8-a10, the circuit is the same as the working mode of the period of a1-a2, and the product exceeding the period of T1 is regarded as defective products. And in the period a11, the circuit is the same as the working mode of the period a4, the circuit is switched to the good product mode, and in the stable period a12 and later, the product is processed according to the good product mode.
If at this point the operator considers the product to have some kind of defect, some of the product needs to be discarded. The operator presses a manual key, a pulse signal d4=on is generated at the KT2 input 6 and the No. 2 port, the circuit generates a switching action similar to d1 or d2 pulse, normally open output 3 and 1 port ON, e1=on, a red indicator lamp (HR 1) is powered ON, normally open output 9 and 11 port ON, f1=on, a defective signal output ON, normally closed output 1 and 4 port OFF, a green indicator lamp (HG 1) is powered OFF, and the whole circuit is switched to a defective mode. In the following pulse period a12-a14, the product taken out of the injection molding machine 2 by the manipulator 3 is regarded as defective and discarded. In a continuous stable period of a15 and later, the circuit generates a state similar to a4 or a11 pulse input, automatically switches to a good product mode, and the mechanical arm 3 does not receive a defective product signal, and packs the good products generated at the moment.
For a user, when the production is started or the stop-and-go time is out, the injection molding defective controller is automatically in a defective product mode, a red indicator lamp is lighted, and a defective product signal is output to control the manipulator 3 to discard defective products; when in continuous production state, injection molding defective product controller automatic switch to the good product mode, green pilot lamp lights, stops outputting defective products signal to manipulator 3, and manipulator 3 is with the good product vanning. The operator presses the manual key once at any moment, and the defective product controller of the injection molding part is immediately switched to a defective product mode;
all the processes are completed fully automatically without manual intervention, so that the degree of automation is effectively improved, the quality risk of mixing is avoided, the loss of recyclable materials is avoided, and the waste is reduced.
While the invention has been described with reference to preferred embodiments, it is not intended to be limiting. Those skilled in the art will appreciate that various modifications and adaptations can be made without departing from the spirit and scope of the present invention. Accordingly, the scope of the invention is defined by the appended claims.
Claims (5)
1. A defective product control system of an injection molding machine is characterized by comprising:
the injection molding machine is used for continuously carrying out an injection molding process to produce injection molding products, wherein the injection molding process comprises an injection molding middle state and an opening mold finished state, and the injection molding middle state and the opening mold finished state are defined as a production period;
the first timer continuously receives a mold opening completion signal of the injection molding machine and outputs a first action signal and a first holding signal;
the second timer is connected to the output end of the first timer, receives the first action signal or the first holding signal output by the first timer, and outputs the second action signal or the second holding signal;
a manual button connected to an input end of the second timer, the manual button including an operation signal and a hold signal, the manual hold signal input to the second timer being switched to a manual operation signal when the manual button is triggered;
an action component;
when the time interval between two adjacent production periods of the injection molding machine is greater than T1, the first action signal output by the first timer to the second timer is switched to a first holding signal, and when the manual holding signal and the first holding signal are simultaneously input to the second timer and kept greater than T2 time interval, the second action signal output by the second timer is switched to a second holding signal;
when the production period of the second timer outputting the second action signal is defined as a bad period, and when the production period of the second timer outputting the second holding signal is defined as a good period;
the action part receives the output of the second timer, when the second timer outputs a second action signal, the action part is set to output a visual bad signal and/or reject injection products in a bad period, and when the second timer outputs a second holding signal, the action part is set to output a visual good signal and/or collect injection products in a good period;
the action part comprises an indicator lamp, the indicator lamp comprises a red indicator lamp and a green indicator lamp, the red indicator lamp is lightened when the second timer outputs a second action signal, and the green indicator lamp is lightened when the second timer outputs a second holding signal;
the action part comprises a manipulator, and the manipulator is used for transferring the injection molding product produced by the injection molding machine to a defective product collecting area or a good product collecting area according to the signal output by the second timer.
2. A defective control method of an injection molding machine, characterized by using the defective control system of an injection molding machine according to claim 1, comprising the steps of:
continuously detecting the production cycle of the injection molding machine, calculating the time interval of two production cycles, defining that the interval between two adjacent production cycles is smaller than T1 as a condition 1, continuously detecting the state of a manual button, taking the condition that the manual button is not triggered as a condition 2, and continuously operating T2 as a condition 3 when the condition 1 and the condition 2 are simultaneously met;
when the injection molding machine meets the condition 3, defining the production period after the moment as a good product period, and when one of the condition 1, the condition 2 or the condition 3 is not met, switching the good product period into a bad product period and eliminating products in the bad product period.
3. The method of claim 2, wherein the manual button is manually activated by an operator.
4. The defective product control method of an injection molding machine according to claim 2, wherein the condition 1 controls triggering by means of timer automatic timing.
5. The method of claim 2, wherein the removing of the product during the reject cycle is performed by transferring the product to a reject bin using a robot.
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