KR102727816B1 - Motion controller and molding machine - Google Patents

Abstract

The motion controller (201) controls the operation of the main body (10) of the injection molding machine (1), and is equipped with a data collection system (243) that collects data measured by a sensor (140) installed in the main body (10), and an abnormality detection system (244) that detects an abnormality in the main body (10) based on the measurement data collected by the data collection system (243) and control information used for controlling the operation of the main body (10).

Description

Motion controller and molding machine

The present invention relates to a motion controller and a molding machine.

Conventionally, a technology has been known for sensing the behavior of mechanical devices such as molding machines to detect abnormalities in the devices or predict failures (see, for example, Patent Documents 1 and 2).

For example, as shown in Fig. 10, in a machine device having a motor-driven driving unit, an acceleration sensor is installed and vibration detected by the acceleration sensor is monitored. The motor driving the driving unit is controlled by a motion controller through a motor driver.

Vibration data measured by an acceleration sensor is analyzed for frequency using an FFT (Fast Fourier transform) analyzer using the rotation number detected by a tachometer. Then, based on the analysis results, a computing device such as a PC or a human determines whether or not there is an abnormality in the machine device.

Patent Document 1: Japanese Patent Publication No. Hei 5-157662 Patent Document 2: Japanese Patent Publication No. 2018-91033

However, in the above conventional technology, since a dedicated measurement device such as an FFT analyzer or a rotation meter is required, there was a problem in that it was very cumbersome, including the setting of the device and the wiring work between the devices.

The purpose of the present invention is to provide a motion controller and a molding machine capable of easily detecting abnormalities in a mechanical device whose operation is controlled by a motion controller.

The present invention is a motion controller that controls the operation of a mechanical device,

A data collection unit that collects data measured by an external sensor installed in the above-mentioned machine device,

The present invention comprises an abnormality detection unit that detects an abnormality in the mechanical device based on measurement data collected by the data collection unit and control information used to control the operation of the mechanical device.

In addition, the present invention,

A device body having an injection device that injects a molding material and a molding device that moves a mold device into which the molding material is filled,

A molding device having a motion controller that controls the operation of each motor driving the injection device and the molding device,

The above motion controller,

A data collection unit that collects data measured by an external sensor installed in the above device body,

The device is configured to have an abnormality detection unit that detects an abnormality in the device body based on measurement data collected by the data collection unit and control information used to control the operation of the device body.

According to the present invention, a motion controller and a molding machine capable of easily detecting abnormalities in a mechanical device whose operation is controlled by a motion controller can be provided.

Fig. 1 is a diagram showing an injection molding machine according to an embodiment.
Figure 2 is a diagram showing the overall configuration of a control unit equipped with the injection molding machine of Figure 1.
Figure 3 is a block diagram showing the control configuration of a motion controller in an embodiment.
Figure 4 is a block diagram for explaining the flow of abnormality detection processing in a motion controller in an embodiment.
Figure 5 is a diagram showing an example of a setting screen of a simple mode that allows for easy setting of abnormality detection contents.
Figure 6 is a diagram showing an example of a setting screen of a detailed mode in which the abnormality detection contents can be set in detail.
Figure 7a is a diagram showing an example of processing vibration data in anomaly detection processing.
Figure 7b is a diagram showing an example of processing vibration data in anomaly detection processing.
Figure 7c is a diagram showing an example of processing vibration data in anomaly detection processing.
Figure 7d is a diagram showing an example of processing vibration data in anomaly detection processing.
Figure 8 is a time chart showing the occurrence of operating noise in the operating cycle of an injection molding machine.
Fig. 9 is a block diagram showing the control configuration of a modified example of a motion controller in the embodiment.
Figure 10 is a block diagram showing a conventional configuration for detecting an abnormality in a mechanical device.

Hereinafter, an embodiment in which the motion controller according to the present invention is applied to the control of an injection molding machine will be described in detail with reference to the drawings.

[Overall configuration of injection molding machine]

Fig. 1 is a diagram showing an injection molding machine (1) according to the present embodiment.

As shown in this drawing, the injection molding machine (1) in the present embodiment is equipped with a main body (10) of the injection molding machine (1) and a control unit (200) for controlling the main body (10). However, Fig. 1 shows a schematic configuration of the control unit (200).

The device body (10) is equipped with an injection device (11) that melts and injects a molding material, a plasticizing moving device (20) that returns the injection device (11), a molding device (12) that moves a molding device (43) into which the molding material is filled, and an ejector device (71) that pushes a solidified molded product out of the molding device (43).

The mold device (43) includes a fixed mold (44) supported on a fixed platen (51) and a movable mold (45) supported on a movable platen (54). The mold device (12) has a mold motor (57) which is a three-phase motor, and when the mold motor (57) is driven, the movable platen (54) supporting the movable mold (45) moves, thereby performing opening and closing and molding of the mold device (43). The injection device (11) has an injection motor (86) which is a three-phase motor, and when the injection motor (86) is driven, the screw (26) moves in translation, and the molding material is injected from the heating cylinder (15). In addition, the injection device (11) has a three-phase motor, a metering motor (83), and the screw (26) rotates by driving the metering motor (83), thereby supplying the molding material from the hopper (17) to the heating cylinder (15). The plasticizing moving device (20) has a three-phase motor, a plasticizing moving motor (22), and the movable part moves by driving the plasticizing moving motor (22). The ejector device (71) has a three-phase motor, an ejection motor (72), and the movable part moves by driving the ejection motor (72).

However, below, the motor for forming (57), the motor for injection (86), the motor for metering (83), the motor for plasticizing movement (22), and the motor for ejection (72) are referred to as the first motor (110A) to the nth motor (110X).

[Control unit configuration]

The control unit (200) is equipped with a motion controller (201) and multiple motor drivers (100A to 100X).

The motion controller (201) controls the operation of the injection molding machine (1) (device body (10)). Specifically, the motion controller (201) outputs motion commands (specifically, speed commands) to a plurality of motor drivers (100A to 100X) of the injection molding machine (1) according to a predetermined control program. The motion commands are control commands for controlling the operation of the injection molding machine (1) (device body (10)), and include information on a series of operations of the injection molding machine (1), such as the order or working time of each process, such as injection or molding. The detailed control configuration of the motion controller (201) will be described later.

A plurality of motor drivers (100A to 100X) output power to each of the first motor (110A) to the n-th motor (110X) based on motion commands from the motion controller (201) and drive each of these motors. In addition, the motor drivers (100A to 100X) acquire information on the position and speed response of each motor from an encoder (120A to 120X) (see Fig. 2) that detects the positions of the first motor (110A) to the n-th motor (110X) and outputs the information to the motion controller (201).

By these, each part of the injection molding machine (1) operates in conjunction with each other, and a predetermined molding process is performed.

However, in Fig. 1, the state in which the motion controller (201) performs serial control of the motor driver (100A to 100X) is shown, but the motion controller (201) may perform parallel control in which it individually communicates with the motor driver (100A to 100X).

In addition, the control unit (200) is equipped with a configuration for detecting an abnormality in the device body (10).

Figure 2 is a diagram showing the overall configuration of the control unit (200).

As shown in this drawing, the control unit (200) is provided with a motion controller (201) and a plurality of motor drivers (100A to 100X), as well as a plurality of external sensors (140) and an HMI (Human Machine Interface) (160).

The plurality of external sensors (140) are sensors that measure and detect information (physical quantities) of each part of the device body (10), and are different from sensors (encoders (120A to 120X), etc.) built into the injection molding machine (1) for motion control. In the present embodiment, as the external sensors (140), a pressure sensor (140a) that measures pressure (force), an acceleration sensor (140b) that measures acceleration, and a microphone (140c) that measures sound are provided. These plurality of external sensors (140) are arranged in each part of the device body (10) and are connected to an analog input unit (210) of a motion controller (201), which is a sensor input terminal.

The motion controller (201) has a plurality of signal terminals (ports), including an analog input unit (210). The ports include three types: serial communication, analog signal, and I/O. The serial communication port is used, for example, for encoder input. The analog signal port is used, for example, for input of a tie bar sensor (strain measurement) or load cell injection pressure. The I/O port is used, for example, for a door open/close judgment switch or various limit switches. Each of these three types of ports is provided in multiples, and is provided in greater numbers than the number normally required for operation control of the device main body (10) (for example, the total number of motors or measuring materials of a general injection molding machine).

However, the type of external sensor (140) is not limited to this embodiment, and may include, for example, a gyro sensor or a strain gauge.

HMI (160) is an interface for a user to operate a motion controller (201) or obtain various types of information, and is connected to the motion controller (201). HMI (160) is equipped with a display (161) on which various types of information are displayed, and an input device (mouse, keyboard, touch panel, etc.; not shown) that receives user operations.

However, the interface for the user to operate the motion controller (201), etc., may be provided in the motion controller (201) or the device body (10), or may be a portable terminal such as a tablet connected to communication.

[Motion controller control configuration]

Fig. 3 is a block diagram showing the control configuration of a motion controller (201). However, Fig. 3 mainly shows the control configuration of a motion controller (201) for detecting an abnormality of an injection molding machine (1) (device main body (10)).

As shown in this drawing, the motion controller (201) is configured with an encoder receiving circuit (220), an external sensor receiving circuit (230), an FPGA (Field Programmable Gate Array) (240), and a microcomputer (250).

The encoder receiving circuit (220) receives each position signal of the motor (110A to 110X) output from the encoder (120A to 120X) through the motor driver (100A to 100X).

The external sensor receiving circuit (230) receives each measurement signal output from the external sensors (140a to 140c). The external sensor receiving circuit (230) may be provided for each external sensor (140).

The FPGA (240) has five functional blocks: a position/speed measurement system (241), an external sensor measurement system (242), a data collection system (243), an abnormality detection system (244), and an output unit (245). However, the FPGA (240) of the present embodiment has a built-in CPU (Central Processing Unit).

The position/speed measurement system (241) acquires information on the speed and position of each motor based on the position signal of each motor received by the encoder receiving circuit (220), and outputs this speed/position information to the data collection system (243) and the motion control system (251).

The external sensor measurement system (242) acquires information on measured physical quantities (acceleration, sound, pressure in this embodiment) based on measurement signals from external sensors (140a to 140c) received by the external sensor receiving circuit (230), and outputs information on these measurement values to the data collection system (243). The external sensor measurement system (242) may perform filter processing to remove noise.

The data collection system (243) collects and accumulates information on measured values output from the position/speed measurement system (241) and the external sensor measurement system (242). The data collection system (243) may continuously collect data until a user operates it, or may set the data collection timing (timing of start and end of collection) according to the operation of the device body (10) by acquiring an operation signal of the device body (10) based on motion command information from the motion control system (251) as a trigger signal. In addition, it may be possible to select data to be accumulated from among the collected data. For example, it may be possible to accumulate only data during normal operation and the latest data.

The abnormality detection system (244) detects an abnormality in the device main body (10) based on information of collected measurement values (i.e., measurement data of an external sensor (140) and position and speed information of each motor) and information of motion commands held by the motion control system (251). That is, the abnormality detection system (244) detects an abnormality in the device main body (10) based on measurement data of an external sensor (140) and control information used for operation control of the device main body (10). In this abnormality detection system (244), for example, it is determined that an abnormality has occurred when a measurement value exceeds a predetermined threshold value (or normal value range). The specific contents of the abnormality detection processing will be described later.

The output section (245) appropriately outputs the abnormality detection result received from the abnormality detection system (244) to an external device, etc. In addition, the abnormality detection result may also be output to the motion control system (251), and when an abnormality occurs, the motion control system (251) may limit the torque or speed of each motor.

However, it is preferable that at least two types of function blocks, an external sensor measurement system (242), which can be called a data input unit that receives the measurement value of the external sensor (140) from the FPGA (240), and an output unit (245), are pre-mounted in the FPGA (240). The data collection system (243) and the abnormality detection system (244) may be configured so that they can be mounted on the FPGA (240) by post-mounting. These data collection systems (243) and the abnormality detection systems (244) can be mounted relatively simply by post-mounting, for example, by rewriting the logic circuit in a hardware description language. As a result, even if an abnormality detection function that was initially unnecessary becomes necessary later, it is possible to flexibly respond to such requests from users without requiring major device modifications. However, it is of course desirable that the position/speed measurement system (241) that receives the measurement values of the encoder (120A to 120X) required for motion control be pre-installed on the FPGA (240). Also, in this case, it is desirable that a terminal (analog input unit (210)) for connecting an external sensor (140) is also provided in advance, but this may be added later as needed. However, the external sensor measurement system (242) and the output unit (245) may be pre-installed on the microcomputer (250).

The microcomputer (250) is configured with hardware such as a CPU, memory, and peripheral circuits built in, and integrates and controls a motion controller (201) and has a motion control system (251).

The motion control system (251) generates a speed command for controlling each motor based on the speed and position information of each motor output from the position and speed measurement system (241). When controlling the operation of the device main body (10), this speed command is output to the motor driver (100A to 100X).

[Setting of abnormality detection contents]

Next, we will explain how to set the abnormality detection content by the user.

Figure 4 is a block diagram for explaining the flow of abnormality detection processing in the motion controller (201).

As shown in Fig. 4, the motion controller (201) has, in addition to four functional blocks of a data collection block (261), a data preprocessing block (262), a data processing block (263), and a data output block (264), a memory device (270) capable of reading and writing various types of information.

Abnormality detection processing in the motion controller (201) is executed through a series of processes divided into four function blocks. The processing contents in each function block can be easily set by the user through a user interface provided through HMI (160), as described below.

However, among the four function blocks, the data collection block (261) corresponds to the position/speed measurement system (241), the external sensor measurement system (242), and the data collection system (243) described above, the data preprocessing block (262) and the data processing block (263) correspond to the abnormality detection system (244) described above, and the data output block (264) corresponds to the output section (245) described above.

Among these, the data collection block (261) collects necessary data at set intervals.

The data collected include control data from the motion control system (251), position and speed data of each motor from the built-in sensor, the encoder (120A to 120X), and acceleration, sound, pressure/force, etc. from the external sensor (140). In addition, as data from the built-in sensor, motor current, motor voltage, and internal temperature may be acquired from the motor driver (100A to 100X).

The timing for performing processing is determined by a trigger from the motion control system (251).

The processing cycle can be set to, for example, 1ms, 10ms pitch, etc.

The data preprocessing block (262) performs preprocessing of data to detect abnormalities.

The processing here includes digital filters (low-pass filters, high-pass filters, band-pass filters, smoothing, etc.), integration, frequency conversion, and custom processing by users.

The timing for performing processing is determined by a trigger from the motion control system (251).

The processing cycle can be set to, for example, 1ms, 10ms pitch, etc.

The data processing block (263) detects abnormalities by setting threshold values, etc.

The processing here is the setting of threshold values or customized settings by the user. In the customized settings, for example, it may be possible to predict failures by comparing with already known failure modes. In addition, it may be possible to detect abnormalities using machine learning.

The timing for performing processing is determined by a trigger from the motion control system (251).

The processing cycle can be set to, for example, 1ms, 10ms pitch, etc.

The data output block (264) outputs the results of data processing.

For the output destination, an external device or alarm notification, etc. can be selected. In addition, the result can be output to the motion control system (251), and if an abnormality is detected, a predetermined operation (such as stopping the device main body (10) or decelerating each motor) can be executed.

The timing for performing processing is determined by a trigger from the motion control system (251).

The processing cycle can be set to, for example, 1ms, 10ms pitch, etc.

In addition, when processing in each function block, data to be processed may be written to or read from the memory device (270). Specifically, data collected by the data collection block (261) may be written to the memory device (270), or the data preprocessing block (262) may process the data and write the processed data to the memory device (270). In addition, the data processing block (263) may process the data and write the processed result to the memory device (270), or the data output block (264) may read it out and output it.

[Example of setting abnormality detection contents]

Next, the settings of the above-described abnormality detection contents will be explained using specific examples.

In the motion controller (201) of the present embodiment, a user can select a simple mode in which the abnormality detection contents can be easily set and a detailed mode in which the contents can be set in detail by executing a predetermined setting program from the HMI (160).

First, when a new sensor is connected to the port of the analog input unit (210), an address or ID is assigned to the sensor signal, for example, based on a predetermined operation. On the display (161) of the HMI (160), a plurality of tabs corresponding to a plurality of sensor signals connected to the port are displayed, and by operating/selecting a tab, the waveform (e.g., a raw waveform) of the sensor signal corresponding to the tab is displayed. The address or ID of the corresponding sensor signal is displayed on the tab. The tab to be displayed on the display (161) can be appropriately selected (added or deleted). In addition, a plurality of tabs may be divided into a plurality of pages, so that a page to be displayed on the display (161) can be selected.

<Easy mode>

Figure 5 is a diagram showing an example of a setting screen in simple mode.

In simple mode, no data preprocessing is performed, and data processing is judged by threshold values.

When the user selects the simple mode, as shown in Fig. 5, the microcomputer (250) (or CPU on the FPGA (240)) displays the simple setting list (Ls) on the display (161) of the HMI (160).

In the simple setting list (Ls), multiple abnormality detection points are listed. The contents of each item in the simple setting list (Ls) except for the status display column (B5) can be selected by the user using a button, and the selected contents are displayed on the button.

Specifically, the simple setting list (Ls) displays a section selection button (B1), a measurement target selection button (B2), a threshold setting button (B3), an output destination selection button (B4), a status display column (B5), and a start/stop button (B6).

In the section selection button (B1), the user selects a section of the device main body (10) that performs abnormality detection processing. When the user operates the section selection button (B1), selectable sections corresponding to each process of the injection molding machine, such as “mold closing” or “mold opening,” are displayed as a drop-down list, and one of them can be selected.

In the measurement target selection button (B2), the user selects the physical quantity of the measurement target (e.g., acceleration, sound, pressure, current, etc.). If there are multiple identical measurement targets in the same section, the channel number is also selected. However, here, it is also possible to simply select the terminal ch number of the analog input unit (210).

In the threshold setting button (B3), the user sets the threshold value that is judged to be abnormal. The unit is determined by the physical quantity of the measurement target selected by the measurement target selection button (B2). The threshold value can be set arbitrarily by the user. The threshold value can be set to not only a simple level, but also various physical quantities such as the change per unit time, the time average value for the reference level, the change amount, and the change rate.

In the output destination selection button (B4), the output destination of data when the value of the measurement target exceeds the threshold value or the operation in that case is selected. Here, “notification” for outputting a predetermined alarm display or voice, “stop” for stopping the device main body (10), “external” for notifying an external device of an abnormality detection, etc. can be selected. In addition, the output of data or “notification” may be transmitted to a predetermined terminal, server, or cloud by wired or wireless communication.

The status display column (B5) displays the execution status of the abnormality detection process. In this embodiment, one of the following is displayed: “Monitoring” in which abnormality detection is being performed, “Stopping” in which abnormality detection has been stopped, or “Adjusting” in which abnormality detection cannot be performed due to some factor.

In the start/stop button (B6), "START", "STOP", and "AUTO" (automatic adjustment start) are displayed as a drop-down list by user operation, and the start, stop, and automatic adjustment start of the abnormality detection processing can be selected. However, the selection result is not displayed on the start/stop button (B6). In addition, in the case where the processing cannot be started, for example, due to adjustment in progress, the color of the start/stop button (B6) is changed to gray or the like, and the operation is not accepted.

<Detailed Mode>

Figure 6 is a diagram showing an example of a settings screen in detailed mode.

When the user selects the detailed mode, as shown in Fig. 6, the microcomputer (250) (or CPU on the FPGA (240)) displays the detailed setting list (Ld) on the display (161) of the HMI (160).

In the detailed settings list (Ld), multiple abnormality detection points are displayed in a list.

Specifically, in the detailed settings list (Ld), in addition to the section selection button (B1), measurement target selection button (B2), output destination selection button (B4), status display column (B5), and start/stop button (B6) that are the same as those in the simple settings list (Ls), a data preprocessing selection button (B7) and a data processing selection button (B8) are also displayed.

In the data preprocessing selection button (B7), the user selects the contents of data preprocessing (digital filter, integration, frequency conversion, etc.). The selected contents are displayed on the button.

In the data processing selection button (B8), the user selects the content of data processing. The content of data processing, for example, abnormality judgment by a threshold value of a predetermined value, can be separately set by the user. The selected data processing name is displayed on the button.

In this way, in the motion controller (201) of the present embodiment, a user can easily set abnormality detection contents by displaying a GUI (Graphical User Interface) such as a simple setting list (Ls) or a detailed setting list (Ld) that accepts user operations on the display (161).

However, the threshold value may be set so that the threshold value line can be set for the waveform while the waveform of the sensor signal is displayed on the display (161) of the HMI (160) (i.e., during normal operation of the device main body (10)). In this case, the threshold value may be set arbitrarily by the user, or may be set automatically according to the numerical value (e.g., maximum value) of the sensor signal.

[Example of abnormality detection processing]

Next, the operation of the motion controller (201) when executing abnormality detection processing will be explained with a specific example.

<Operation example 1>

First, a description will be given of a case in which vibration caused by rattling of a rotating device such as a motor is detected by an acceleration sensor (140b) to detect an abnormality.

Figures 7a to 7d are diagrams showing examples of processing vibration data in anomaly detection processing.

As shown in Fig. 7a, in a rotating machine with rattling, vibration data that increases periodically is obtained.

In the motion controller (201), the vibration data is acquired, position and speed information is acquired, and the cycle for collecting the vibration data is determined based on this information.

And, if the collected vibration data exceeds a preset threshold value, it is determined that an abnormality has occurred. At this time, as shown in Fig. 7b, the abnormality may be detected by setting a threshold value for a simple time response waveform of the vibration data, or, as shown in Fig. 7c, the abnormality may be detected by performing frequency analysis of the vibration data and setting a threshold value for the result. Alternatively, as shown in Figs. 7a and d, the abnormality may be detected by performing frequency analysis on an envelope-processed (envelope-analyzed) raw waveform of the vibration and setting a threshold value for the result.

In addition, when analyzing the vibration of a rotating machine that moves an axis, such as a plasticizing motor (22) (see Fig. 1) that moves a moving part in a linear manner, information on the position (e.g., tip position) in the direction of movement may be acquired and the vibration response to this position may be viewed. In other words, instead of the time response of the vibration, an analysis may be performed with the position as the horizontal axis.

In this way, the correlation between movement position and vibration, and further, the correlation between movement position and abnormal occurrence timing, can be clarified.

<Operation example 2>

Next, a description will be given of a case in which an abnormality is detected by detecting the operating sound of a specific axis (e.g., mold axis) of an injection molding machine (1) using a microphone (140c).

Fig. 8 is a time chart showing the occurrence of operating noise in the operating cycle of an injection molding machine (1). However, the molding shaft is a shaft driven by a molding motor (57), and the injection shaft is a shaft driven by an injection motor (86).

As shown in this drawing, when the injection molding machine (1) is operated, a loud operating noise is generated during the “mold closing” and “mold opening” sections in which the mold shaft, etc., moves, or during the “injection” section in which the injection shaft, etc., moves.

In the motion controller (201), based on the motion command information of the device main body (10) that is held in advance, the operating sound data is collected only for the “form closing” and “form opening” sections in which the form axis operates.

And, if the collected driving sound data exceeds the threshold value set in advance for this section "형폐" and "형개", it is determined that an abnormality has occurred. In the example of Fig. 8, an abnormality has occurred in the Nth driving sound data. However, the threshold value may be set to a value that is a predetermined value greater than the normal driving sound that has been saved in advance.

[Technical Effects]

As described above, according to the present embodiment, the motion controller (201) that controls the operation of the injection molding machine (1) (device body (10)) collects data measured by an external sensor (140), and detects an abnormality in the device body (10) based on the measured data and control information for controlling the operation of the device body (10).

That is, in order to control the device main body (10), abnormality detection of the device main body (10) can be performed using the control information (position/speed information or motion command information of each motor) possessed by the motion controller (201). Accordingly, unlike the conventional case where a measurement-only device such as an FFT analyzer or a rotation meter was required, abnormality detection of the device main body (10) can be performed simply by connecting an external sensor (140) to the motion controller (201).

Accordingly, it is possible to easily perform abnormality detection of the injection molding machine (1) (device body (10)) whose operation is controlled by the motion controller (201). In addition, by utilizing motion command information, for example, data collection can be performed using this information as a trigger, thereby making abnormality detection processing easier.

In addition, the FPGA (240) is pre-mounted with an external sensor measurement system (242), which is an input unit that receives a measurement signal from an external sensor (140), and an output unit (245) that outputs an abnormality detection result from an abnormality detection system (244). The data collection system (243) and the abnormality detection system (244) may be configured to be mounted on the FPGA (240) (or microcomputer (250)) as a post-mount unit.

By configuring in this way, abnormality detection processing by the data collection system (243) and the abnormality detection system (244) can be constructed relatively easily even later. Furthermore, for example, it is possible to flexibly respond to user requests, such as an abnormality detection function that was initially unnecessary but later becomes necessary, without requiring major device modification.

In addition, the data collection system (243) and the abnormality detection system (244) are mounted on an FPGA (240), not on a microcomputer (250) in which a motion control system (251) is mounted.

In this way, abnormality detection processing by the data collection system (243) and abnormality detection system (244) can be realized without affecting the motion control of the injection molding machine (1).

In addition, since the data collection timing can be set by a trigger signal based on motion command information, the user can easily set the data collection timing.

In addition, the motion controller (201) is configured to be able to connect to an HMI (160), and a setting screen (simple setting list (Ls) or detailed setting list (Ld)) for setting abnormality detection contents based on user operation is displayed on the display (161) of the HMI (160).

With this, users can easily set the abnormality detection contents using the GUI setting screen.

[Other]

Above, each embodiment of the present invention has been described, but the present invention is not limited to the above embodiments.

For example, in the above embodiment, in the motion controller (201), the data collection system (243) and the abnormality detection system (244) are mounted on the FPGA (240). However, as shown in Fig. 9, the data collection system (243) and the abnormality detection system (244) may be mounted on a microcomputer (250) instead of the FPGA (240). In this case, the data collection system (243) may receive position and speed information from the motion control system (251).

In addition, even in this configuration, the data collection system (243) and the abnormality detection system (244) may be configured to be mounted on the microcomputer (250) as a post-mount. These data collection systems (243) and the abnormality detection systems (244) can be installed relatively easily later by preparing functions for data collection, data preprocessing, and data processing described in, for example, the C language, and installing these on the microcomputer (250). However, the external sensor measurement system (242) and the output section (245) may be mounted on the microcomputer (250).

In addition, in the above embodiment, the injection molding machine (1) (device main body (10)) is described as a mechanical device whose operation is controlled by the motion controller (201), but this mechanical device may be a molding machine other than an injection molding machine. In addition, the present invention can be widely applied to mechanical devices other than a molding machine, such as a press machine or a rolling mill, as long as the operation is controlled by the motion controller.

In addition, the details shown in the embodiment may be appropriately changed without departing from the scope of the invention.

Industrial applicability

As described above, the motion controller and molding machine according to the present invention are useful for detecting abnormalities in a mechanical device whose operation is controlled by the motion controller.

1 Injection molding machine
10 Device body
11 Injection device
12 Shape Device
43 Mold device
100A~100X motor driver
110A~110X motor
120A~120X Encoder
140 External Sensor
160 HMI
161 display
200 control unit
201 Motion Controller
210 analog input unit
220 Encoder receiving circuit
230 External sensor receiving circuit
240 FPGA
241 Position and velocity measurement system
242 External sensor measurement system
243 Data Collection System
244 Anomaly Detection System
245 Output section
250 Microcomputer
251 Motion Control System
261 Data Collection Block
262 Data preprocessing block
263 Data Processing Block
264 data output block
270 memory device
B1 Section Selection Button
B2 Measurement target selection button
B3 Threshold Setting Button
B4 Output Selection Button
B5 Status Indicator
B6 Start/Stop Button
B7 Data Preprocessing Selection Button
B8 Data Processing Selection Button
Ld detailed settings list
Ls simple settings list

Claims (11)

As a motion controller that controls the operation of a mechanical device,
A data collection unit that collects data measured by an external sensor installed in the above-mentioned machine device,
An abnormality detection unit that detects an abnormality in the mechanical device based on the control information used for the operation control of the mechanical device and the measurement data collected by the data collection unit,
The signal terminal to which the above external sensor is connected,
Equipped with microcomputers and FPGAs,
The data measured by the above external sensor includes data regarding the vibration of the machine device.
The above control information includes position information and speed information of the motor driving the mechanical device and motion command information for the mechanical device.
The above data collection unit collects the measurement data based on the position information and speed information of the motor, or the motion command information.
The above microcomputer is equipped with a motion control system that generates motion commands.
The above FPGA has the data collection unit and the abnormality detection unit mounted on it.
Motion controller. In the first paragraph,
A motion controller in which the position information and speed information of the above motor are acquired based on a signal from an encoder provided in the motor. In the second paragraph,
The above data collection unit is a motion controller that sets data collection timing by a trigger signal based on the above motion command information. In any one of claims 1 to 3,
It is configured to be connected to a device having a display,
A motion controller having a microcomputer that displays a setting screen for setting abnormality detection contents based on user operation on the display. In any one of claims 1 to 3,
A motion controller wherein the external sensor includes at least one of an acceleration sensor, a microphone, a pressure sensor, a gyro sensor, and a strain gauge. In any one of claims 1 to 3,
A motion controller having multiple signal terminals, including those for serial communication, analog signals, and I/O. In Article 6,
The above plurality of signal terminals are a motion controller having a number greater than that normally required for controlling the operation of the mechanical device. In any one of claims 1 to 3,
A display that displays the waveform of the sensor signal of the external sensor input to the signal terminal,
A motion controller having a threshold setting button for setting a threshold value for abnormality judgment of a signal from the external sensor on the display based on user operation. In any one of claims 1 to 3,
The above-mentioned abnormality detection unit is a motion controller that detects an abnormality in the mechanical device based on data measured by the external sensor, position information and speed information of a motor driving the mechanical device, and motion command information for the mechanical device. delete delete