JP5581741B2 - Resin molding method using multiple molds - Google Patents

Resin molding method using multiple molds Download PDF

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JP5581741B2
JP5581741B2 JP2010049656A JP2010049656A JP5581741B2 JP 5581741 B2 JP5581741 B2 JP 5581741B2 JP 2010049656 A JP2010049656 A JP 2010049656A JP 2010049656 A JP2010049656 A JP 2010049656A JP 5581741 B2 JP5581741 B2 JP 5581741B2
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学 石畝
将義 師岡
博 久野
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Denso Corp
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Description

本発明は、射出成形機を金型搬送ライン内に設置して、複数の金型を各ステーション（例えば、射出成形工程、冷却工程、成形品取出し工程）に順次移送して樹脂成形品を成形する樹脂成形方法に関する。   In the present invention, an injection molding machine is installed in a mold conveyance line, and a plurality of molds are sequentially transferred to each station (for example, an injection molding process, a cooling process, and a molded product removal process) to mold a resin molded product. The present invention relates to a resin molding method.

樹脂の射出成形においては、射出成形機より射出された樹脂の冷却硬化をその場で行って硬化した樹脂を取り出し、次の樹脂を射出するという工程をとると、射出成形機は樹脂が硬化するまで次の樹脂の射出に用いることができないため、製造効率が悪いという問題点が生じる。そのため、複数の金型を用意し、射出成形機により樹脂が射出された金型を別の場所へ移動してそこで冷却し、一方射出成形機では直ちに次の金型に樹脂を射出するという成形システムが提案されている（例えば特許文献１、２、３）。   In resin injection molding, when the resin that has been injected from the injection molding machine is cooled and cured on the spot, the cured resin is taken out and the next resin is injected. Then, the injection molding machine cures the resin. Since it cannot be used for the next resin injection, there arises a problem that the production efficiency is poor. Therefore, a plurality of molds are prepared, and the mold in which the resin is injected by the injection molding machine is moved to another place and cooled there, while the injection molding machine immediately injects the resin into the next mold. Systems have been proposed (for example, Patent Documents 1, 2, and 3).

特開平５−１４７０７６号公報Japanese Patent Laid-Open No. 5-147076 特開平５−２６９７８２号公報Japanese Patent Application Laid-Open No. 5-269788 特開２００７−２１６４１３号公報JP 2007-216413 A

しかし、この成形システムにおいては、以下のような問題点があった。すなわち、射出成形の起動時には、射出成形機の射出シリンダやホットランナ内の樹脂を排出するパージ作業が必要であり、このパージ作業直後は、射出成形機の射出シリンダやホットランナ内の樹脂の密度と温度が均一になりにくいいため、パージ作業直後に射出成形した成形品は不良品となり易い。このため、パージ作業直後に射出成形した成形品は通常、廃却しなければならなかった（いわゆる「捨て射ち」）。   However, this molding system has the following problems. That is, at the start of injection molding, it is necessary to purge the resin in the injection cylinder and hot runner of the injection molding machine. Immediately after this purge operation, the density of the resin in the injection cylinder and hot runner of the injection molding machine is required. Therefore, the molded product that is injection-molded immediately after the purge operation tends to be defective. For this reason, a molded product that has been injection-molded immediately after the purge operation usually had to be discarded (so-called “discarding shooting”).

また、射出成形機が金型搬送ライン内に設置されてインサートを使用した成形をする場合、インサートの準備（供給）工程や、インサートを金型に組付ける工程などの工程が通常の成形工程にさらに追加され、これらの工程で不具合が発生すると工程の一時停止の必要が起き、一つの金型における樹脂成形のサイクルタイム（以下、単に「サイクルタイム」と言う）が一定になりにくい現象がある。サイクルタイムが一定でない場合、樹脂滞留熱劣化や、ホットランナ内樹脂の温度変化、金型温度変化が発生し、成形品品質のバラツキが発生しやすくなる。   In addition, when an injection molding machine is installed in the mold conveyance line and performs molding using inserts, processes such as the insert preparation (supply) process and the process of assembling the insert into the mold are normal molding processes. In addition, if a problem occurs in these processes, it is necessary to temporarily stop the process, and there is a phenomenon that the resin molding cycle time in one mold (hereinafter simply referred to as “cycle time”) is difficult to be constant. . If the cycle time is not constant, the resin residence heat deterioration, the temperature change of the resin in the hot runner, and the mold temperature change are likely to occur, resulting in variations in the quality of the molded product.

一つの金型を射出成形機に取り付けた状態で複数ショットの成形を実行する従来の成形方法ではサイクルタイムが２０〜３０秒であった。これに対し、本発明の成形方法は複数の金型を搬送する方法にすることで、サイクルタイムが５〜６秒になった。サイクルタイムが短縮したため、サイクルタイム変動幅が僅かでも、その影響は大きくなる。例えば、サイクルタイム変動幅が１秒のとき、サイクルタイム２０秒では変動幅５％、サイクルタイム５秒では変動幅２０％となる。本発明の成形方法では、サイクルタイム変動の影響がより顕著にあらわれる。   In a conventional molding method in which a plurality of shots are molded with one mold attached to an injection molding machine, the cycle time is 20 to 30 seconds. On the other hand, the cycle time became 5 to 6 seconds by using the molding method of the present invention to transport a plurality of molds. Since the cycle time is shortened, the influence becomes large even if the cycle time fluctuation width is small. For example, when the cycle time fluctuation width is 1 second, the fluctuation width is 5% when the cycle time is 20 seconds, and the fluctuation width is 20% when the cycle time is 5 seconds. In the molding method of the present invention, the influence of cycle time fluctuation is more prominent.

本発明は、上記問題に鑑みてなされたものであり、その目的は、射出成形機を金型搬送ライン内に設置して複数の金型を各ステーションに順次移送して樹脂成形品を成形する樹脂成形方法において、各金型において成形品の品質が安定した射出成形を可能にし、パージ作業直後の捨て射ちの無い成形を可能にする樹脂成形方法を提供することである。   The present invention has been made in view of the above problems, and an object of the present invention is to install an injection molding machine in a mold conveyance line and sequentially transfer a plurality of molds to each station to mold a resin molded product. In the resin molding method, it is an object of the present invention to provide a resin molding method that enables injection molding in which the quality of a molded product is stable in each mold and enables molding without throwing away immediately after a purge operation.

本発明は、前記課題を解決するための手段として、特許請求の範囲の各請求項に記載の樹脂成形方法を提供する。
請求項１に記載の樹脂成形方法は、
射出成形機を金型搬送ライン内に設置して、複数の金型を各ステーションに順次移送して樹脂成形品を成形する樹脂成形方法であり、
前記射出成形機のパージを実行後に最初の金型を前記射出成形機に取付けて第１の射出成形を実行し、第１の射出成形後に最初の金型を取外し、次に、第２の金型を前記射出成形機に取付けて第２の射出成形を実行し、第２の射出成形後に第２の金型を取外し、以下引き続いて別な金型を前記射出成形機に取付けて射出成形を実行した後に取外す同様な工程を複数回繰り返す樹脂成形方法において、
第Ｎ番目の射出成形を開始するときの射出成形条件を第Ｎの射出成形条件とし、第Ｎ番目の射出成形開始時刻から第（Ｎ＋１）番目の射出成形開始時刻までの経過時間を第Ｎの経過時間とするとき、
射出成形条件がマップとして、前記射出成形機を制御する制御装置に記憶されており、前記マップは、第１の射出成形条件を予め設定された射出成形条件とし、第１を含まない第Ｎの射出成形条件を、第（Ｎ−１）の経過時間に基づいた射出成形条件とするデータマップであり、
射出成形は、前記マップに基づいて実行されることにより、第１の射出成形を実行する場合は、第１の射出成形条件で実行し、第１を含まない第Ｎ番目の射出成形の場合は、第（Ｎ−１）の経過時間に基づいた射出成形条件で実行することを特徴とする。 This invention provides the resin molding method as described in each claim of a claim as a means for solving the said subject.
The resin molding method according to claim 1 comprises:
It is a resin molding method in which an injection molding machine is installed in a mold conveyance line, and a plurality of molds are sequentially transferred to each station to mold a resin molded product,
After performing the purge of the injection molding machine, the first mold is attached to the injection molding machine to perform the first injection molding, the first mold is removed after the first injection molding, and then the second mold The mold is attached to the injection molding machine to execute the second injection molding, the second mold is removed after the second injection molding, and another mold is subsequently attached to the injection molding machine to perform the injection molding. In a resin molding method that repeats a similar process multiple times after being executed,
The injection molding condition when starting the Nth injection molding is the Nth injection molding condition, and the elapsed time from the Nth injection molding start time to the (N + 1) th injection molding start time is the Nth injection molding condition. When the elapsed time is
An injection molding condition is stored as a map in a control device that controls the injection molding machine, and the map sets the first injection molding condition as a preset injection molding condition and does not include the first Nth. It is a data map in which the injection molding condition is an injection molding condition based on the (N-1) th elapsed time,
The injection molding is executed based on the map, so that when the first injection molding is executed, the injection molding is executed under the first injection molding condition. In the case of the Nth injection molding not including the first, The process is executed under injection molding conditions based on the (N-1) th elapsed time .

射出成形条件は、直前の射出成形開始時刻からの経過時間に対して、射出成形品の品質（例えばボイドの無いこと）を確保するための最適な条件が存在する。この射出成形条件は、例えば射出成形機における保圧圧力又は保圧切換位置等である。そして、本発明の樹脂成形方法は、射出成形機に取付けられた各金型において、測定された前記経過時間に基づいた射出成形条件により射出成形をする。これにより、射出成形機を金型搬送ライン内に設置して、複数の金型を各工程に順次移送して樹脂成形品を成形する樹脂成形方法において、射出成形品の品質を確保することが可能となる。   The injection molding conditions have optimum conditions for ensuring the quality of an injection molded product (for example, no voids) with respect to the elapsed time from the immediately preceding injection molding start time. This injection molding condition is, for example, a holding pressure or a holding pressure switching position in an injection molding machine. In the resin molding method of the present invention, each mold attached to the injection molding machine performs injection molding under the injection molding conditions based on the measured elapsed time. As a result, the quality of the injection molded product can be ensured in the resin molding method in which the injection molding machine is installed in the mold conveyance line and a plurality of molds are sequentially transferred to each process to mold the resin molded product. It becomes possible.

請求項２に記載の樹脂成形方法は、射出成形工程時に金型キャビティ内の樹脂圧力を計測し成形品の品質を判定することを特徴とする。
これにより、不良品を廃棄して良品のみを次の製造工程へ送ることが可能となる。 The resin molding method according to claim 2 is characterized in that the quality of the molded product is determined by measuring the resin pressure in the mold cavity during the injection molding process.
This makes it possible to discard defective products and send only good products to the next manufacturing process.

請求項３に記載の樹脂成形方法は、前記射出成形条件は、射出成形機における保圧圧力又は保圧切換位置であることを特徴とする。射出成形条件を具体的に列挙したものである。   The resin molding method according to claim 3 is characterized in that the injection molding condition is a holding pressure or a holding pressure switching position in an injection molding machine. The injection molding conditions are specifically listed.

請求項４に記載の樹脂成形方法は、前記射出成形はインサートを使用する射出成形であることを特徴とする。樹脂成形方法の種類を例示したものである。
以下、本発明の実施の形態を図面に基づいて説明する。 The resin molding method according to claim 4 is characterized in that the injection molding is injection molding using an insert. The kind of resin molding method is illustrated.
Hereinafter, embodiments of the present invention will be described with reference to the drawings.

本発明に係る方法の第１実施形態に用いる成形システムの全体構成を説明する概念図である。It is a conceptual diagram explaining the whole structure of the shaping | molding system used for 1st Embodiment of the method concerning this invention. 本発明方法の第１実施形態に用いる射出成形システムの制御ブロック図である。It is a control block diagram of the injection molding system used for 1st Embodiment of this invention method. 本発明方法の第１実施形態に用いる射出成形条件のマップである。It is a map of the injection molding conditions used for 1st Embodiment of this invention method. 本発明方法の第１実施形態の射出成形機を中心とした工程の流れを説明する図である。It is a figure explaining the flow of a process centering on the injection molding machine of 1st Embodiment of this invention method. 本発明の実施形態に用いる射出成形工程時に金型キャビティ内の樹脂圧力を計測するセンサーを説明する図である。It is a figure explaining the sensor which measures the resin pressure in a metal mold cavity at the time of the injection molding process used for embodiment of this invention. 本発明の実施形態に用いる射出成形工程時に金型キャビティ内の樹脂圧力を計測する別の形式のセンサーを説明する図である。It is a figure explaining another type of sensor which measures the resin pressure in a metallic mold cavity at the time of an injection molding process used for an embodiment of the present invention.

（第１実施形態）
図１は、本発明の樹脂成形方法を用いる金型搬送式成形システムの全体構成を説明する概念図である。例えば、図１に示すように２列に配置された１０個のステーションＳ１〜Ｓ１０が設けられていて、各ステーションＳ１〜Ｓ１０間を金型Ｍが移動することで、樹脂成形が行われる。即ち、ステーションＳ１で金型Ｍ内のキャビティにインサート部品が投入され、金型Ｍが閉じられる。次に、この閉じられた金型Ｍは、ステーションＳ２に移送され、ここで型締め機構によって、金型Ｍの型締め（クランプ）が行われた後に、金型Ｍは射出成形機に接続され、キャビティ内への溶融樹脂の充填が行われる。このようにして、ステーションＳ２では、金型Ｍの型締め及び射出成形機による溶融樹脂の射出が行われる。 (First embodiment)
FIG. 1 is a conceptual diagram illustrating the overall configuration of a mold conveying molding system using the resin molding method of the present invention. For example, as shown in FIG. 1, ten stations S1 to S10 arranged in two rows are provided, and resin molding is performed by moving the mold M between the stations S1 to S10. That is, the insert part is put into the cavity in the mold M at the station S1, and the mold M is closed. Next, the closed mold M is transferred to the station S2, where after the mold M is clamped (clamped) by the mold clamping mechanism, the mold M is connected to the injection molding machine. The molten resin is filled into the cavity. In this way, at the station S2, the mold M is clamped and the molten resin is injected by the injection molding machine.

溶融樹脂の射出・充填が行われた金型Ｍは、次のステーションＳ３及びＳ４に送られ、ここで充填樹脂の冷却が行われる。次いで、ステーションＳ５では、型締め機構による金型Ｍの型締めの解除（アンクランプ）が行われ、ステーションＳ６では、金型Ｍの型開きが行われる。更に、エジェクタ機構によりエジェクタピンで成形品を型から突き出す。ステーションＳ７では、型からの成形品の取り出しが行われる。成形品が取り出された金型Ｍは、ステーションＳ８〜Ｓ１０を搬送され、当初のステーションＳ１に戻される。このような閉サイクルが繰り返されて成形が行われる。なお、金型Ｍは、例えばレールによって各ステーション間を移動する。   The mold M in which the molten resin has been injected and filled is sent to the next stations S3 and S4, where the filled resin is cooled. Next, in the station S5, the mold clamping of the mold M is released (unclamped) by the mold clamping mechanism, and the mold M is opened in the station S6. Further, the molded product is ejected from the mold by the ejector pin by the ejector mechanism. In the station S7, the molded product is taken out from the mold. The mold M from which the molded product has been taken out is conveyed through the stations S8 to S10 and returned to the original station S1. Such closed cycle is repeated to perform molding. The mold M moves between the stations by, for example, rails.

図２は、本発明方法の第１実施形態に用いる射出成形システムの制御ブロック図である。制御装置１１は、金型搬送路Ｈの搬送手段、型締めステーションＳ１の型締め装置、射出ステーションＳ２の射出成形機Ｙ、型開きステーション６の型開き装置及びエジェクタ機構等を制御する。この制御装置１１には操作盤１９が接続されている。制御装置１１はカウンタを備えている。後に詳述するが、パージ直後の最初の射出成形を第１番目の射出成形としたときの第Ｎ番目の射出成形開始時刻から第（Ｎ＋１）番目の射出成形開始時刻までの経過時間（以下、「直前サイクルタイム」と言う）を第Ｎの経過時間（例えば第１の射出成形開始時刻から第２の射出成形開始時刻までの経過時間である第１の経過時間）とするとき、全ての第Ｎの経過時間を、カウンタがサイクル毎にリセットをしながら計測している。   FIG. 2 is a control block diagram of the injection molding system used in the first embodiment of the method of the present invention. The control device 11 controls the conveyance means of the mold conveyance path H, the mold clamping device of the mold clamping station S1, the injection molding machine Y of the injection station S2, the mold opening device of the mold opening station 6, the ejector mechanism, and the like. An operation panel 19 is connected to the control device 11. The control device 11 includes a counter. As will be described in detail later, an elapsed time from the Nth injection molding start time to the (N + 1) th injection molding start time when the first injection molding immediately after the purge is the first injection molding (hereinafter, When the Nth elapsed time (for example, the first elapsed time that is the elapsed time from the first injection molding start time to the second injection molding start time) is referred to as “immediately preceding cycle time”) The elapsed time of N is measured while the counter is reset every cycle.

又、制御装置１１は、射出成形条件を記憶する記憶装置２３を備えており、本発明方法を実施する前の初期化の段階において、作業者が操作盤１９を操作して、射出成形条件を記憶装置２３に予め記憶させるようになっている。そして、第Ｎ番目の射出成形を開始するときの射出成形条件を第Ｎの射出成形条件とするとき、射出成形条件はマップ（図３参照）になっている。このマップは、図３に示すように、第１の射出成形条件を予め設定された射出成形条件とし、第１を含まない第Ｎの射出成形条件を、直前サイクルタイムに基づいた射出成形条件（以下、「直前サイクルタイム等に基づいた射出成形条件」と言う）とするデータマップである。そして、制御装置１１は、このマップに基づいて射出成形条件を選択し、その射出成形条件に基づき射出ステーションＳ２の射出成形機Ｙを制御して各金型に応じた射出成形を行うようになっている。   Further, the control device 11 is provided with a storage device 23 for storing the injection molding conditions, and the operator operates the operation panel 19 at the initialization stage before carrying out the method of the present invention to set the injection molding conditions. The information is stored in the storage device 23 in advance. When the injection molding condition when starting the Nth injection molding is the Nth injection molding condition, the injection molding condition is a map (see FIG. 3). As shown in FIG. 3, this map uses the first injection molding condition as a preset injection molding condition, and the Nth injection molding condition not including the first as the injection molding condition based on the immediately preceding cycle time ( The data map is hereinafter referred to as “injection molding conditions based on the immediately preceding cycle time”). And the control apparatus 11 selects injection molding conditions based on this map, controls injection molding machine Y of injection station S2 based on the injection molding conditions, and performs injection molding according to each metal mold | die. ing.

以上の工程を、更に詳述する。図２に示すように、制御装置１１は、記憶装置２３から射出成形機に取付けられた金型Ｍ１の射出成形条件を選択し、選択した射出成形条件に基づき図２に示すようにポンプ２５の油圧制御弁２５ａに流量・圧力制御信号を送って射出成形機Ｙのスクリュー用モータ２７の回転速度等を調整しながらスクリュー２９を後退させて、ノズル３１内に、金型Ｍ１の充填に必要なの樹脂材料３３を計量しながら充填する。   The above process will be further described in detail. As shown in FIG. 2, the control device 11 selects the injection molding conditions of the mold M1 attached to the injection molding machine from the storage device 23, and based on the selected injection molding conditions, the control device 11 of the pump 25 as shown in FIG. The flow rate / pressure control signal is sent to the hydraulic control valve 25a to adjust the rotational speed of the screw motor 27 of the injection molding machine Y, and the screw 29 is moved backward to fill the nozzle 31 with the mold M1. The resin material 33 is filled while being measured.

そして、スクリュー２９の回転を停止して計量が終了したら、ノズルタッチ圧抜きの後、ノズル３１を若干下降させてノズル３１先端の注入口を金型Ｍ１の注入孔に圧接し、ノズルタッチ圧力を上昇させる。   Then, when the measurement is completed by stopping the rotation of the screw 29, after releasing the nozzle touch pressure, the nozzle 31 is slightly lowered to press the injection port at the tip of the nozzle 31 against the injection hole of the mold M1, and the nozzle touch pressure is reduced. Raise.

そして、制御装置１１は、射出成形条件に基づきポンプ２５の油圧制御弁２５ａを制御しながら、シリンダ３５を下降させて、マップより選択した速度制御から圧力制御への切換位置（保圧切換位置）に基づきながらスクリュー２９を前進させながら速度制御から圧力制御（保圧）へ切換えて、金型Ｍ１内に樹脂材料３３を射出注入する。保圧時はマップより選択した保圧圧力により保圧される。その後、金型Ｍ１は射出成形機Ｙから取外されて、次の充填樹脂の冷却ステーションＳ３に移動することとなる。   Then, the control device 11 lowers the cylinder 35 while controlling the hydraulic control valve 25a of the pump 25 based on the injection molding conditions, and switches from the speed control selected from the map to the pressure control (holding pressure switching position). Based on the above, the speed control is switched to the pressure control (holding pressure) while the screw 29 is advanced, and the resin material 33 is injected and injected into the mold M1. At the time of holding pressure, it is held by the holding pressure selected from the map. Thereafter, the mold M1 is removed from the injection molding machine Y and moved to the next filling resin cooling station S3.

以下同様に、各金型Ｍは、射出ステーションＳ２において射出成形機Ｙにより、直前サイクルタイム等に基づいた射出成形条件により、そのキャビティ内に樹脂を射出充填される。そして、ステーションＳ１で金型Ｍ内のキャビティにインサート部品が投入され、金型Ｍが閉じられる工程から、金型Ｍからの成形品の取り出しが行われ、成形品が取り出された金型Ｍが、ステーションＳ８〜Ｓ１０を搬送され、当初のステーションＳ１に戻されるまでの工程を、成形品供給の１サイクルとして順次繰り返されていくこととなる。   Similarly, each mold M is injected and filled with a resin in its cavity by an injection molding machine Y at an injection station S2 under injection molding conditions based on the immediately preceding cycle time or the like. Then, the insert part is put into the cavity in the mold M at the station S1, and the molded product is taken out from the mold M from the process of closing the mold M, and the mold M from which the molded product is taken out is obtained. The steps from being transported through the stations S8 to S10 and being returned to the original station S1 are sequentially repeated as one cycle of supplying the molded product.

図３は本発明方法の第１実施形態に用いる射出成形条件のマップである。図３に示すように、直前サイクルタイム等に対する射出成形条件（保圧圧力、保圧切換位置、他）がデータマップになっている。保圧圧力とは、樹脂材料の金型キャビティ内への注入が終了したとき、スクリューが金型キャビティ内の樹脂材料に掛ける圧力を言う。金型キャビティ内の樹脂材料を保圧することにより、溶融樹脂材料内部の小さい空洞がつぶされて樹脂成形品の品質が確保される。保圧切換位置とは、スクリューを前進させ金型内に樹脂材料を射出注入している操作中に、スクリュー前進移動を速度制御から圧力制御へ切換える位置を言う。加工スピードの点からスクリューを最初は速度制御し、途中からは溶融樹脂の材料内部品質の確保の点から圧力制御することが望ましいため、このような制御を実行する。特に注目したい点は、条件番号１のパージ直後の保圧圧力を５８ＭＰａにすることである。このような高い圧力に設定することにより、パージ直後の不安定な溶融樹脂の状態を安定化することができる。   FIG. 3 is a map of injection molding conditions used in the first embodiment of the method of the present invention. As shown in FIG. 3, the injection molding conditions (holding pressure, holding pressure switching position, etc.) with respect to the immediately preceding cycle time or the like are a data map. The holding pressure refers to a pressure applied by the screw to the resin material in the mold cavity when the injection of the resin material into the mold cavity is completed. By holding the resin material in the mold cavity, the small cavity inside the molten resin material is crushed, and the quality of the resin molded product is ensured. The holding pressure switching position refers to a position where the forward movement of the screw is switched from speed control to pressure control during the operation in which the screw is advanced and the resin material is injected and injected into the mold. Since it is desirable to control the speed of the screw first from the point of processing speed and to control the pressure from the point of ensuring the internal quality of the molten resin material in the middle, such control is executed. Of particular note is that the holding pressure immediately after purging under condition number 1 is 58 MPa. By setting such a high pressure, it is possible to stabilize the state of the unstable molten resin immediately after the purge.

図４は射出成形機Ｙを中心とした本発明方法の第１実施形態の工程の流れを説明する図である。ステップ１（ＳＴ１）では、射出ステーションＳ２の射出成形機Ｙにおいて、ノズル３１とスクリュー２９の間に存在する樹脂材料をパージする。いわば前回の成形作業の残りかすである樹脂材料を掃除するのが、このパージ工程である。ステップ２（ＳＴ２）では、最初の金型が射出成形機Ｙに取付けられる。ステップ３（ＳＴ３）では、最初の金型内のキャビティへ溶融樹脂を射出充填する第１射出成形が実行される。第１射出成形はパージ直後の射出成形であるので、マップ（図３参照）の条件番号１の射出成形条件（保圧圧力５８ＭＰａ、保圧切換位置１０ｍｍ）が選択されて、この条件により第１射出成形が実行される。第１射出成形が終了すると、ステップ４（ＳＴ４）では、第１金型が射出成形機Ｙから取り外されステーションＳ３へ搬送される。ステップ５（ＳＴ５）では、第２金型が射出成形機Ｙに取り付けられる。   FIG. 4 is a view for explaining the flow of steps of the first embodiment of the method of the present invention centering on the injection molding machine Y. In step 1 (ST1), the resin material existing between the nozzle 31 and the screw 29 is purged in the injection molding machine Y at the injection station S2. In other words, the purging process is to clean the resin material that remains from the previous molding operation. In step 2 (ST2), the first mold is attached to the injection molding machine Y. In step 3 (ST3), first injection molding is performed in which molten resin is injected and filled into the cavity in the first mold. Since the first injection molding is injection molding immediately after purging, the injection molding condition (holding pressure 58 MPa, holding pressure switching position 10 mm) of condition number 1 on the map (see FIG. 3) is selected, and the first injection molding is performed according to this condition. Injection molding is performed. When the first injection molding is completed, in step 4 (ST4), the first mold is removed from the injection molding machine Y and conveyed to the station S3. In step 5 (ST5), the second mold is attached to the injection molding machine Y.

ステップ６（ＳＴ６）では、第２射出成形が実行される。このとき、制御装置１１のタイマーが第１射出成形の開始時刻から第２射出成形の開始時刻までの直前サイクルタイムｔ１をカウントしている。タイマーは、ｔ１を５秒とカウントしており、ｔ１をカウント後にタイマーはリセットされる。そこで、制御装置１１は、記憶装置２３からマップの条件番号２の射出成形条件（保圧圧力５３ＭＰａ、保圧切換位置１０．０５ｍｍ）を選択し、射出成形機Ｙに第２射出成形を実行させる。第２射出成形が終了すると、ステップ７（ＳＴ７）では、第２金型が射出成形機Ｙから取り外されステーションＳ３へ搬送される。ステップ８（ＳＴ８）では、ステーションＳ１でインサートの第３金型への装着に問題が起きたため一時的に工程を停止している。このような一時的な工程停止は通常の工程ではなく、言わば異常事態時の工程である。ステップ９（ＳＴ９）では、インサートの装着が無事完了した第３金型が射出成形機Ｙへ取り付けられる。   In step 6 (ST6), the second injection molding is executed. At this time, the timer of the control device 11 counts the immediately preceding cycle time t1 from the start time of the first injection molding to the start time of the second injection molding. The timer counts t1 as 5 seconds, and the timer is reset after counting t1. Therefore, the control device 11 selects the injection molding condition (holding pressure 53 MPa, holding pressure switching position 10.05 mm) of map condition number 2 from the storage device 23 and causes the injection molding machine Y to execute the second injection molding. . When the second injection molding is completed, in step 7 (ST7), the second mold is removed from the injection molding machine Y and conveyed to the station S3. In Step 8 (ST8), the process is temporarily stopped because a problem has occurred in the insertion of the insert into the third mold at the station S1. Such a temporary process stop is not a normal process, but is a process in an abnormal situation. In step 9 (ST9), the third mold for which the insertion of the insert has been successfully completed is attached to the injection molding machine Y.

一方、タイマーは、第２射出成形開始時刻にリセットされており、第２射出成形開始時刻から第３射出成形開始時刻までの直前サイクルタイムｔ２をカウントしている。タイマーは、ｔ２を４１秒とカウントしており、ｔ２をカウント後にタイマーはリセットされる。そこで、ステップ１０（ＳＴ１０）では、制御装置１１は、記憶装置２３からマップの条件番号４の射出成形条件（保圧圧力５５ＭＰａ、保圧切換位置１０．００ｍｍ）を選択し、射出成形機Ｙに第３射出成形を実行させる。第３射出成形が終了すると、ステップ１１（ＳＴ１１）では、第３金型が射出成形機Ｙから取り外されステーションＳ３へ搬送される。   On the other hand, the timer is reset to the second injection molding start time, and counts the previous cycle time t2 from the second injection molding start time to the third injection molding start time. The timer counts t2 as 41 seconds, and the timer is reset after counting t2. Therefore, in step 10 (ST10), the control device 11 selects the injection molding condition (holding pressure 55 MPa, holding pressure switching position 10.00 mm) of the condition number 4 on the map from the storage device 23, and sends it to the injection molding machine Y. The third injection molding is executed. When the third injection molding is completed, in step 11 (ST11), the third mold is removed from the injection molding machine Y and conveyed to the station S3.

以下、同様な射出成形サイクルが繰り返される。   Thereafter, the same injection molding cycle is repeated.

（他の実施形態）
本発明の樹脂成形方法は、射出成形工程時に金型キャビティ内の樹脂圧力を計測し成形品の品質を判定する工程をさらに備えることもできる。金型キャビティ内の樹脂圧力を計測する方法を図５及び図６を用いて説明する。図５は、本発明の実施形態に用いる射出成形工程時に金型キャビティ内の樹脂圧力を計測するセンサーを説明する図である。 (Other embodiments)
The resin molding method of the present invention can further include a step of measuring the resin pressure in the mold cavity during the injection molding process to determine the quality of the molded product. A method for measuring the resin pressure in the mold cavity will be described with reference to FIGS. FIG. 5 is a diagram illustrating a sensor for measuring the resin pressure in the mold cavity during the injection molding process used in the embodiment of the present invention.

金型Ｍは上型１と、下型２と、キャビティ５と、受圧ピン６を備え、支持台４の上に配置される。上板３は、圧力センサー７（例えばロードセル）を備え、所定の間隙を設けて金型Ｍの真上に配置される。この状態で上板３を図５の矢印方向に移動させ、溶融樹脂をキャビティ５に充填する。キャビティ５に溶融樹脂が充填されると、樹脂圧力によって受圧ピンが上昇し，圧力センサー７の下端と受圧ピン６の上端とが当接し、キャビティ５内の溶融した樹脂の圧力を計測することができる。   The mold M includes an upper mold 1, a lower mold 2, a cavity 5, and a pressure receiving pin 6, and is disposed on the support base 4. The upper plate 3 includes a pressure sensor 7 (for example, a load cell), and is disposed right above the mold M with a predetermined gap. In this state, the upper plate 3 is moved in the direction of the arrow in FIG. 5 to fill the cavity 5 with molten resin. When the cavity 5 is filled with molten resin, the pressure receiving pin rises due to the resin pressure, the lower end of the pressure sensor 7 and the upper end of the pressure receiving pin 6 come into contact, and the pressure of the molten resin in the cavity 5 can be measured. it can.

図６は、本発明の実施形態に用いる射出成形工程時に金型キャビティ内の樹脂圧力を計測する別の形式のセンサーを説明する図である。同一の機能を持つ部材は同一の番号を付してその説明を省略する。図６の実施形態では、金型Ｍの下に開口部４ａを持つ支持台４が配置され、金型Ｍの真下には、圧力センサー７を内蔵した下板が配置されている。この状態で下板８を図６の矢印方向に移動させると、圧力センサー７の上端７ａと受圧ピン６の下端６ａとが当接して、さらに上型１の上面１ａと上板３の下面３ａが当接する。この状態で、キャビティ５内に溶融樹脂を充填すると、溶融樹脂圧力によって受圧ピンがおしさげられ、圧力センサーをおすことでキャビティ５内の溶融した樹脂材料の圧力を計測することができる。   FIG. 6 is a diagram for explaining another type of sensor for measuring the resin pressure in the mold cavity during the injection molding process used in the embodiment of the present invention. Members having the same function will be given the same reference numerals and description thereof will be omitted. In the embodiment of FIG. 6, a support base 4 having an opening 4 a is disposed under the mold M, and a lower plate incorporating the pressure sensor 7 is disposed directly under the mold M. When the lower plate 8 is moved in the arrow direction in FIG. 6 in this state, the upper end 7a of the pressure sensor 7 and the lower end 6a of the pressure receiving pin 6 come into contact with each other, and the upper surface 1a of the upper mold 1 and the lower surface 3a of the upper plate 3 are brought into contact. Abut. In this state, when the cavity 5 is filled with the molten resin, the pressure receiving pin is applied by the molten resin pressure, and the pressure of the molten resin material in the cavity 5 can be measured by passing the pressure sensor.

以上のように、射出成形機を金型搬送ライン内に設置して複数の金型を各ステーションに順次移送して樹脂成形品を成形する樹脂成形方法において、各金型において成形品の品質が安定した射出成形を可能にし、パージ作業直後の捨て射ちの無い成形を可能にする樹脂成形方法を提供することが可能となる。   As described above, in a resin molding method in which an injection molding machine is installed in a mold conveyance line and a plurality of molds are sequentially transferred to each station to mold a resin molded product, the quality of the molded product in each mold is It is possible to provide a resin molding method that enables stable injection molding and molding without throwing away immediately after the purge operation.

Ｓ ステーション
Ｍ 金型
Ｙ 射出成形機 S station M mold Y injection molding machine

Claims (4)

射出成形機を金型搬送ライン内に設置して、複数の金型を各ステーションに順次移送して樹脂成形品を成形する樹脂成形方法であり、
前記射出成形機のパージを実行後に最初の金型を前記射出成形機に取付けて第１の射出成形を実行し、第１の射出成形後に最初の金型を取外し、次に、第２の金型を前記射出成形機に取付けて第２の射出成形を実行し、第２の射出成形後に第２の金型を取外し、以下引き続いて別な金型を前記射出成形機に取付けて射出成形を実行した後に取外す同様な工程を複数回繰り返す樹脂成形方法において、
第Ｎ番目の射出成形を開始するときの射出成形条件を第Ｎの射出成形条件とし、第Ｎ番目の射出成形開始時刻から第（Ｎ＋１）番目の射出成形開始時刻までの経過時間を第Ｎの経過時間とするとき、
射出成形条件がマップとして、前記射出成形機を制御する制御装置に記憶されており、前記マップは、第１の射出成形条件を予め設定された射出成形条件とし、第１を含まない第Ｎの射出成形条件を、第（Ｎ−１）の経過時間に基づいた射出成形条件とするデータマップであり、
射出成形は、前記マップに基づいて実行されることにより、第１の射出成形を実行する場合は、第１の射出成形条件で実行し、第１を含まない第Ｎ番目の射出成形の場合は、第（Ｎ−１）の経過時間に基づいた射出成形条件で実行することを特徴とする樹脂成形方法。 It is a resin molding method in which an injection molding machine is installed in a mold conveyance line, and a plurality of molds are sequentially transferred to each station to mold a resin molded product,
After performing the purge of the injection molding machine, the first mold is attached to the injection molding machine to perform the first injection molding, the first mold is removed after the first injection molding, and then the second mold The mold is attached to the injection molding machine to execute the second injection molding, the second mold is removed after the second injection molding, and another mold is subsequently attached to the injection molding machine to perform the injection molding. In a resin molding method that repeats a similar process multiple times after being executed,
The injection molding condition when starting the Nth injection molding is the Nth injection molding condition, and the elapsed time from the Nth injection molding start time to the (N + 1) th injection molding start time is the Nth injection molding condition. When the elapsed time is
An injection molding condition is stored as a map in a control device that controls the injection molding machine, and the map sets the first injection molding condition as a preset injection molding condition and does not include the first Nth. It is a data map in which the injection molding condition is an injection molding condition based on the (N-1) th elapsed time,
The injection molding is executed based on the map, so that when the first injection molding is executed, the injection molding is executed under the first injection molding condition. In the case of the Nth injection molding not including the first, The resin molding method is performed under injection molding conditions based on the (N-1) th elapsed time . 射出成形工程時に金型キャビティ内の樹脂圧力を計測し成形品の品質を判定することを特徴とする請求項１に記載の樹脂成形方法。   The resin molding method according to claim 1, wherein the resin pressure in the mold cavity is measured during the injection molding step to determine the quality of the molded product. 前記射出成形条件は、射出成形機における保圧圧力又は保圧切換位置であることを特徴とする請求項１又は２に記載の樹脂成形方法。   The resin molding method according to claim 1 or 2, wherein the injection molding condition is a holding pressure or a holding pressure switching position in an injection molding machine. 前記射出成形はインサートを使用する射出成形であることを特徴とする請求項１から３のいずれか１項に記載の樹脂成形方法。   The resin molding method according to any one of claims 1 to 3, wherein the injection molding is injection molding using an insert.
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