JP3205479B2 - Foam molded body manufacturing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for producing pre-expanded particles.
The present invention relates to an apparatus for manufacturing a foamed molded article for aging and automatically producing a foamed molded article under predetermined conditions using the pre-expanded particles.

[0002]

2. Description of the Related Art Hitherto, various attempts have been made to automate molding in order to save labor in molding a foamed synthetic resin which is a foamed molded article. An automatic resin molding apparatus is disclosed.

In the above-mentioned automatic molding equipment, there are provided a raw material storage device for automatically supplying a designated raw material to a measuring device, and a measuring device for automatically supplying a specified amount of raw material from the raw material storage device to a relay hopper. A raw material recovery device for automatically recovering the remaining raw material of the measuring device and the relay hopper to the raw material storage device,
A batch type prefoaming machine configured to heat and foam the raw material from the relay hopper and automatically supply the foamed prefoamed particles to an aging device is provided.

[0004] The batch type prefoaming machine is provided with an automatic magnification measuring device for automatically measuring the expansion ratio of the pre-expanded particles and an automatic foaming condition automatic selecting device for automatically selecting the optimum heating condition as required. ing.

[0005] The aging device includes a level meter for measuring the upper limit level of the pre-expanded particles in the aging device in order to control the amount and destination of the pre-expanded particles conveyed from the pre-expansion machine. A level meter for detecting that the inside is empty is provided.

[0006] The aging device is to automatically supply the pre-expanded particles from the aging device to the molding device after curing a predetermined amount of the pre-expanded particles from the pre-expansion machine. belongs to.

Further, pipes for feeding the pre-expanded particles are respectively provided between the plurality of pre-expanding machines, the plurality of aging devices, and the plurality of molding devices,
The pre-expanded particles are conveyed from each pre-expansion machine to the corresponding ripening devices N to N by the above-mentioned pipes for aging, and the pre-expanded particles are conveyed from each ripening device to the corresponding molding devices N to N. Each is used for molding.

[0008] In such an automatic molding equipment, a control device having a computer for controlling each of the above-mentioned devices is provided.
A daily production schedule that specifies the type of raw material, foaming ratio, standard date, number of shots, number of shots, and number of productions is input, and the control device controls each device according to such a production schedule and performs a predetermined process. Products.

[0009] In the automatic molding equipment, the operator visually judges the status display indicating the storage amount of the pre-expanded particles in the aging device, and the operator reserves the primary granulation and makes the secondary granulation. Perform the reservation setting operation, foam based on this,
Aging and molding are linked.

[0010]

However, in the above-mentioned conventional configuration, since each device of the automatic equipment is controlled by the control device, the number of the prefoaming machines becomes large, for example, three or more. In such a case, it takes time to process the other devices and delays the control of each pre-foaming machine, so that it may not be possible to respond promptly, and the production efficiency of the pre-expanded particles may be delayed, and the production efficiency of the foam molded product as a product may be reduced. There is a problem of deterioration.

[0011]

Foamed molded article manufacturing system according to claim 1 of the present invention, in order to solve the problems] In order to solve the above problems, foamed for making the foaming conditions a pre-expanded particles
Of raw materials in the foaming machine and the foaming multiple set by the above foaming machine
A plurality of silos for foamed so obtained was pre-expanded particles were respectively housed aging, and the molding machine is provided with a molding by molding conditions foam moldings by conveyed the pre-expanded particles from the silo, a plurality of foaming conditions the main control section stored in advance is provided a plurality of types of pre-expanded particles so as Gyoshi control over Symbol onset foam machine for making, respectively, by the foaming conditions, a plurality of foaming conditions inputted from the main control unit <br/> sub-control unit for storing is set eclipse to the onset foam machine, the main control unit or the sub
From the control unit, which is configured to sequentially update each foaming conditions of the pre-expanded particles of those lots and the next lot, further
In response to the granulation request signal sent from the molding machine,
Silo with pre-expanded particles required for molding conditions?
From the molding machine to the molding machine hopper via the granulation pipe
Control unit is provided to control the
In the grain control unit, when the grain sending request signal is input,
Check whether the request signal is correct,
If it is correct, clean the inside of the granulation pipe and
After that, the pre-expanded particles are sent through a pipe to form the molding machine
It is characterized in that it is sent to a machine hopper .

According to a second aspect of the present invention, there is provided a foam molded article manufacturing apparatus according to the first aspect, wherein the sub-control unit includes a touch panel type display for displaying foaming conditions.
Play, and input means for updating foaming conditions on the screen of the touch panel display .
It is set so that each foaming condition of the pre-expanded particles of the present lot and the next lot is respectively displayed on the touch panel type display .

[0013]

[0014]

According to the structure of the first aspect, the pre-expanded particles conveyed from the silo to the molding machine are molded by the molding machine according to the molding conditions stored in the main control section, and a foam molded article is obtained. . Further, since the sub-control unit is eclipsed set in foamed machine, the foaming conditions of the upper Symbol onset foam machine, the production of pre-expanded particles of this lot is completed, by which can be sequentially updated to foaming conditions of the next lot, quickly the pre-expanded particles
It is possible to Seisuru work.

[0015] Thus, in the above arrangement, since the preparation of pre-expanded particles can Gyoshi by Ri system to the sub-control section in the foamed machine, as in the prior art, pre-foaming machine, soaker, the molding apparatus and their compared to the case that was processing the control by Ri onset foam machine into a single control device for controlling each of the conveyance of the pre-expanded particles during, it can reduce the waiting time for preparation of pre-expanded particles foamed machine.

According to the second aspect of the present invention, the foaming conditions of the pre-expanded particles of the present lot and the next lot are respectively displayed on the touch panel type display. Touch pad
Since the change can be made quickly on the flannel type display , it is possible to quickly respond to a sudden change in the foaming machine.

[0017]

[0018]

[0019]

1 to 14 show an embodiment of the present invention.
This will be described below. As shown in FIG. 1, in an automatic manufacturing system as an apparatus for manufacturing a foamed molded article, a foaming machine 1 for preparing pre-expanded particles in a batch system, and a plurality of apparatuses for storing the pre-expanded particles and aging them for a predetermined period of time. And a plurality of molding machines 3 for foam-molding the aged pre-expanded particles conveyed from the silo 2 are provided. The above-mentioned pre-expanded particles include thermoplastic resin particles such as polystyrene impregnated with a blowing agent such as pentane.

In the foaming machine 1, a foaming machine body 1a for producing pre-expanded particles from the thermoplastic resin, and a foaming machine body 1a
And a foaming machine hopper 1c for temporarily storing pre-foamed particles carried out of the foaming machine main body 1a, the raw material feeder 1b being provided at an upper part of the foaming machine and supplying the raw material particles made of the thermoplastic resin to the foaming machine main body 1a. A multiple measuring device 1d for measuring the expansion multiple of the pre-expanded particles is provided.

The raw material feeder 1b weighs a batch of prefoamed thermoplastic resin particles impregnated with a predetermined brand of a foaming agent as raw material particles, for example, 15 kg each, to form a foaming machine main body 1.
a.

The multiple measuring device 1d is provided above the foaming machine hopper 1c, and extends from the foaming machine main body 1a to the foaming machine hopper 1c.
The pre-expanded particles carried out are sampled in a predetermined volume by, for example, a cylinder, and the weight of the sampled pre-expanded particles in the predetermined volume is measured.
The expansion multiple of the pre-expanded particles can be measured.

In the foaming machine 1, the preliminary foaming operation of the foaming machine main body 1a, the raw material supply operation of the raw material feeder 1b, and the foaming multiple measuring operation of the multiple measuring device 1d are controlled based on the set values such as the foaming conditions. A sequencer 1e for a foaming machine for performing the operation is mounted. The foaming machine sequencer 1e has a communication function of exchanging data such as foaming conditions and the number of times of foaming with an external sequencer or the like.

Further, the sequencer 1e for the foaming machine sets the expansion multiple of the pre-expanded particles of the next batch within the set value range based on the signal indicating the expansion multiple of the pre-expanded particles measured by the multiple measuring device 1d. Raw material feeder 1b
Is controlled.

In addition, the foamer sequencer 1e is provided with a touch panel type display 1g as an input means and a display means at a position where the operator can easily operate. You can set and monitor conditions.

The display 1g is equivalent to a display 3f or 3g to be described later, and has a function as storage means for storing a plurality of, for example, four types of foaming conditions, and a foamer sequencer 1e. And a function as a sub-control unit that controls the foaming machine 1 via the

The silo 2 is formed in a substantially cylindrical shape, so that pre-expanded particles can be aged by storing up to about 20 batches. The above-mentioned 20 batches are the total of the 20 batches, when the batch-type foaming machine 1 produces pre-expanded particles having a multiplication factor of 50 times, with the maximum production amount per batch being one batch.

The silo 2 has an upper limit level meter (not shown) for detecting the upper limit value of the pre-expanded particles stored in the silo 2 and a sensor for detecting that the silo 2 is empty. A lower limit level meter (not shown) for the silo 2 is provided.

In the molding machine 3, a pre-expanded particle as a raw material from the secondary granulation pipe main body 5a is temporarily stored in an upper portion of the molding machine main body 3a via an automatic damper 5e for the molding machine described later. A molding machine hopper 3b is provided as a means.

The molding machine hopper 3b is capable of accommodating a maximum of 2 to 3 batches of pre-expanded particles. A level meter 11 is attached as a detecting means for detecting the lower limit value of the pre-expanded particles in the molding machine hopper 3b. The lower limit amount is set to, for example, about several shots in the molding machine 3.

In the molding machine 3, a mold 3c composed of a movable mold and a fixed mold for producing a foamed molded article from the pre-expanded particles is removably mounted. A plunger for reciprocating a mold between a position where a foam molded body separated from a stationary mold is taken out and a position for clamping the foam molded body pressed against the stationary mold. 3d is provided. In the molding machine 3, the foam molded article molded by the mold 3c is carried out from the lower portion of the molding machine main body 3a to the outside.

Further, the molding machine 3 includes a hopper 3 for the molding machine.
b, a molding machine sequencer 3e for controlling the operation of the plunger 3d and the like and the heating time and heating steam pressure of the mold 3c during molding in the molding machine main body 3a based on set values.

The mold 3c is provided with a pressure sensor for measuring the foaming pressure and the vapor pressure of the foamed molded product, and the molding machine sequencer 3e is used by the molding machine sequencer 3e based on the measurement results from the pressure sensors. The molding condition of the foam molded article may be controlled by pressure auto-tuning in which the difference between the foaming pressure and the steam pressure is integrated and the difference between the integrated value and the set value is within a predetermined range.

Further, a primary granulating line 4 is provided as a pipe for conveying the pre-expanded particles from the foaming machine 1 to each silo 2 by an air flow. The primary granulation line 4 is connected to each silo 2 from the foaming machine hopper 1c.
And a primary granulation blower 4b for generating the air flow in the primary granulation pipe main body 4a.

Further, the primary granulation line 4 includes a receiving line damper 4c as an automatic damper, which is a three-way valve for branching the air flow to each silo 2, and a corresponding receiving line damper 4c. And each intake pipe 4d for taking in the pre-expanded particles that connects the silos 2 to be used.

On the other hand, there is provided a secondary granulating line 5 as a granulating means which is a pipe for conveying the pre-expanded particles from each silo 2 to each molding machine 3 by an air flow. The secondary granulation line 5 has a secondary granulation pipe main body 5 extending from below each silo 2 to above each molding machine 3.
a, a secondary granulation blower 5b for generating the air flow in the secondary granulation pipe main body 5a, and a pre-expanded particle from each silo 2 to be sent to the secondary granulation pipe main body 5a. And each delivery pipe 5c.

Further, the secondary granulation line 5 sends the pre-expanded particles from each of the delivery pipes 5c to the air flow of the secondary granulation pipe main body 5a, and connects the secondary granulation pipe main body 5a to the secondary granulation pipe main body 5a. A silo discharge damper 5d as an automatic damper, which is a three-way valve that shuts off the air, and a three-way valve for individually supplying the pre-expanded particles from the secondary granulation pipe main body 5a to each molding machine 3. And an automatic damper 5e for a molding machine.

A discharge damper (not shown) for removing residual pre-expanded particles in the secondary granulation pipe main body 5a at the time of pre-blow or after-blow described later is provided in the secondary granulation line 5. May be provided.

In place of the discharge damper, the automatic damper 5e for the molding machine which was opened before the pre-blow and after-blow processes is opened, and the remaining pre-expanded particles are connected to the automatic damper 5e for the molding machine. The pre-expanded particles may be discharged to the molding machine hopper 3b because the amount of the remaining pre-expanded particles is usually very small. There is no particular problem in the production of the foamed molded article.

The molding machine 3 is provided with a display 3f as control means and display input means.
A display 3g similar to the display 3f is provided in the lower part of the molding machine main body 3a, which is provided near the mounting position of the mold 3c in FIG.

Each of the displays 3f and 3g is
The selected foaming conditions, molding conditions, raw materials and raw material numbers corresponding to the above molding conditions and their multiples, and the current connection status and operation status between the foaming machine 1 and the silo 2 and between the silo 2 and the molding machine 3 are shown. Each has a screen 3h for display.

Further, each of the displays 3f and 3g has a coordinate input means 3i such as a graphic tablet for inputting coordinates on the screen 3h on the screen 3h.
And a touch-panel display in which information and instructions can be input in a touch manner from the screen 3h by the coordinate input means 3i.

In addition, each of the displays 3f and 3g has a communication function for exchanging information such as foaming conditions, molding conditions, and data such as the number of defective products with the outside.
In this case, a granulation request signal, which will be described later, can be sent to the outside so that mature pre-expanded particles required for producing a foamed molded article are conveyed by granulation.

Each of the displays 3f and 3g is connected to the molding machine sequencer 3e so that information of the molding machine sequencer 3e can be converted into a predetermined format and transmitted to the outside. The information such as the molding conditions from the outside of the machine, the raw material of the molding conditions, the raw material No. and the number of times of expansion are converted into a format for the molding machine sequencer 3e and transmitted to the molding machine sequencer 3e. It can be controlled via the machine sequencer 3e, and can store the above information and data.

In the automated manufacturing system, the primary particle feed control section 6 for controlling the sequencer 1e for the foaming machine, the primary particle feed blower 4b, and each receiving line damper 4c under predetermined conditions.
Is provided so as to sequentially feed particles from the foaming machine 1 to the silos 2 from the silos 2 having a long idle time. Therefore, the primary granulation control unit 6 indicates the idle time of each silo 2, the raw material of the stored pre-expanded particles, the raw material No., the expansion multiple, and the aging time of the pre-expanded particles stored in the silo 2. There is provided storage means for storing silo management information.

On the other hand, each silo discharge damper 5d, the automatic damper 5e for the molding machine, and the secondary granulation blower 5b of the secondary granulation line 5 of each molding machine 3 are used to remove pre-expanded particles necessary for predetermined molding conditions. Is provided with a secondary granulation control unit 7 for controlling granulation from the silo 2 having the above to a predetermined molding machine 3.

Further, the secondary particle feed control unit 7 selects the silo 2 and the molding machine 3 based on the above-mentioned particle supply request signal, and sends the pre-expanded particles from the silo 2 to the molding machine 3. It is supposed to. The control units 6 and 7 are provided with display / input units 6a and 7a similar to the touch panel display 3g described above.

The above-described primary particle feed controller 6, secondary particle feed controller 7, foamer sequencer 1e, and each display 3
A bus line 8 is provided to connect f.3g with a common line.
7, foamer sequencer 1e and each display 3f / 3
Information such as data indicating molding conditions and the like, changes in each condition, the number of defective products, and the like can be exchanged between g.

The bus line 8 is connected to a host computer 9 serving as a main control unit for sending foaming conditions of the foaming machine 1, operating conditions of the silo 2, molding conditions of the molding machine 3 and the like as initial values. The host computer 9 includes:
While a display unit 9a for displaying molding conditions, foaming conditions, operation conditions, operation status, and the like is provided, master data of all products to be produced is registered and stored in advance. The foaming conditions include the set value of the aging time of the pre-expanded particles.

The contents of the above master data are the product name, product registration number, raw material used, its grade, its foaming multiple,
The host computer 9 is capable of registering master data of each foam molded product as a product of about 500 types, including a standard foaming condition, a product standard weight, a number of products, a standard molding condition, and the like.

Further, a printer 10 for printing a daily report and a monthly report indicating the molding conditions and the production status of the foam molded article as described later is connected to the host computer 9. It should be noted that, between the host computer 9 and the bus line 8, data and information are exchanged with each of the sequencers 1e and 3e and each of the displays 3f and 3g in order to reduce the processing in the host computer 9 and are necessary. A host sequencer (not shown) for performing information processing is provided.

Each of the touch panel displays 3f
3g is connected to each of the sequencers 1e and 3e and the host computer 9, so that various molding conditions and operating conditions in the molding machine 3 and various operations of the secondary granulating line 5 connected to the molding machine 3 are performed. Conditions and operation statuses are input and stored as needed, and the above-mentioned conditions, statuses, and the like are changed by the operator's instruction by the coordinate input means 3i, that is, the display screen on the screen 3h is changed by a menu operation. By doing so, each can be displayed.

Further, each of the displays 3f and 3g can call up and display various foaming conditions and operating conditions of the foaming machine 1 as well as operating conditions and operating conditions of the primary granulation line 4 as necessary. I can do it.

In addition, the coordinate input means 3i of each of the displays 3f and 3g presses a predetermined position on the screen 3h such as a condition field such as a molding condition on the screen 3h, an icon for changing the display screen, and a ten-key display. The screen 3h
Can be replaced with another display screen, the condition in the above condition column can be changed, and the number of defective products in the foam molded article can be input. The above-mentioned raw material indicates the name of the raw material, and when the raw material is changed, the raw material can be changed by updating the raw material No. of the raw material.

Thus, in the configuration of the above embodiment, the operator can change each condition read from the host computer 9 via the coordinate input means 3i or send the number of defective products to the host computer 9. it can.

Each of the displays 3f and 3g receives, from the host computer 9, an instruction for producing a desired foamed molded article, molding conditions for the foamed molded article, its raw material, raw material No., and its foaming multiple. In this case, based on the above-mentioned raw material, raw material No.,
The silo management information of the primary granulation control unit 6 is searched through the storage unit, and the raw material, the raw material No., the matured pre-expanded particles corresponding to the expansion multiple thereof are stored, and the maturation time of the silo is the longest. 2 can be detected.

In addition, each of the displays 3f and 3g
From the detected silo 2 to each of the displays 3f and 3
In order to transfer the pre-expanded particles to the molding machine 3 provided with g, a particle feed instruction signal is sent to the secondary particle feed controller 7.

Further, when a detection signal indicating that the lower limit value of the pre-expanded particles in the molding machine hopper 3b is detected from the level meter 11 of the molding machine 3 is input to each of the displays 3f and 3g, In the same manner as described above, the optimum silo 2 is detected, and the pre-expanded particles are
b.

In the display 1g, a plurality of types, for example, four types of foaming conditions are inputted from the host computer 9 in advance, and can be stored in association with the respective raw materials and the foaming multiple thereof. Moreover,
As shown in FIG. 2, the four types of foaming conditions are set so that they can be displayed on the screen 1f as foaming conditions 1 to 4, for example.

In the display 1g, the foaming condition of the current lot and the foaming condition of the next lot selected on the screen 1f can be displayed on the same screen 1f, and can be changed on the screen 1f. It is set to be able to. When the completion of the preparation of the pre-expanded particles of the foaming machine 1 of the lot is detected from the count of the number of times of foaming in the foaming machine 1, the foaming condition of the next lot is changed to the foaming condition of the lot. It has been updated.

In this case, the foaming conditions for the next lot are as follows:
It may be set by the operator according to the raw material and the foaming multiple, or may be set according to an instruction from the host computer 9.

Next, the operation of producing the pre-expanded particles in the configuration of the above embodiment will be described. First, when the operator inputs the model number and quantity of the desired foamed molded article into the host computer 9, Calls the target master data based on the model number and quantity, and the raw material and raw material N described in the master data.
o, the number of times of foaming, and foaming conditions are displayed on the display unit 9a, and data indicating each condition is output to the foamer sequencer 1e and the display 1g.

Subsequently, in the foaming machine sequencer 1e, the control of the foaming machine 1 is started based on the inputted conditions, and
A raw material in which a foaming agent is impregnated into a thermoplastic resin, for example, a polystyrene resin or the like, to be fed into the raw material feeder 1b is designated, and the raw material in the raw material feeder 1b is increased by a predetermined amount by a predetermined number of times, for example, 50 times. After pre-expanded to obtain pre-expanded particles, the pre-expanded particles are carried out of the foaming machine main body 1a into the foaming machine hopper 1c. The foaming time of the preliminary foaming is about 3 minutes at a foaming ratio of about 50 times.

At this time, the multiple measuring device 1d samples a part of the transported pre-expanded particles, measures the expanded multiple, and outputs the measurement result to the expander sequencer 1e. The foaming machine sequencer 1e stores in advance the measured value of the foaming multiple, an adjustment factor based on the difference in the filling rate due to the difference in the foaming multiple, and stores the adjusted factor of the pre-expanded particles obtained from the measured value in accordance with the adjusted factor. Calculate the actual value of the foaming multiple.

Further, the foaming machine sequencer 1e operates based on the actual value of the above-mentioned foaming multiple so that the foaming multiple of the pre-expanded particles of the next batch falls within the set value range. 1b can be controlled.

Further, the sequencer 1e for the foaming machine sends a signal indicating the actual value of the above-mentioned foaming multiple via the bus line 8 to another control unit, for example, the primary granulation control unit 6 or the secondary granulation control unit 7.
It can be transmitted to. Thus, in the configuration of the embodiment, for example, the secondary granulation control unit 7 can change the molding conditions based on the signal, and can stably produce a foam molded body with less variation.

Further, the foamer sequencer 1e can display the difference from the set value on the display 1g of the foamer sequencer 1e based on the actual value. Thus, the above configuration enables the foaming conditions of the pre-expanded particles to be changed according to an operator's instruction from the display 1g, which is the same as the coordinate input means 3i.

In addition, since the foaming condition of the current lot and the foaming condition of the next lot are displayed on the display 1g, even if the foaming condition needs to be changed suddenly, for example, the foaming condition of the next lot is required. Is changed according to the raw material and the foaming multiple, when the production of the pre-expanded particles under the foaming conditions of this lot is completed, the foaming conditions of the changed next lot are automatically changed to the foaming conditions of this lot. Will be updated to

From this, it is possible to update the above-mentioned foaming conditions by avoiding monitoring the state of the foaming operation in the foaming machine 1 one by one, so that the preparation of the pre-expanded particles under the changed foaming conditions can be promptly performed. It is possible to execute.

Thereafter, the primary particle feed control unit 6 sends a signal for operating the foaming machine 1 from the foaming machine sequencer 1 e to the bus line 8.
, The primary granulation blower 4b in the primary granulation line 4 is operated to generate an air flow for transferring the pre-expanded particles into the pipe main body 4a.

Next, the primary granulation control unit 6 is in the state where the pre-expanded particles are not stored for the longest time, that is, the monitor in the silo 2 having the longest free time, for example, the display / input unit 6a shown in FIG. As shown on the screen, the silo 2 of No. 1 at the left end is detected by a monitor function described later in detail, and the receiving line damper 4c of the silo 2 is moved into the silo 2 by the air flow. Switching control to introduce.

As a result, the pre-expanded particles in the foaming machine hopper 1c are conveyed to the silo 2 and the cycle is repeated by a predetermined amount, whereby the desired raw material is expanded at a predetermined expansion multiple and a predetermined amount by the pre-expansion. The particles are stored and aged in the silo 2.

Next, a method of detecting the silo 2 having the longest idle time as described above will be described with reference to the flowchart of FIG. 4. First, the upper limit level of the pre-expanded particles in the silo 2 is set to the lower limit by the silo lower limit level meter. It is detected whether the level is equal to or less than a value (step 1, hereinafter, step is referred to as S). When it is detected that the level is equal to or less than the lower limit, a timer is operated (S2), and the timer elapses a predetermined time. Until the above, the detection (S1) cycle of detecting that the level is equal to or less than the lower limit value a predetermined number of times is repeated.

As a result, since the pre-expanded particles are granular and the upper surface is not always horizontal, even if the level detection by the silo lower limit level meter becomes slightly unstable, it may cause vibrations during the elapsed time. Since the upper surface level of the pre-expanded particles remaining in the silo 2 is made uniform, it is possible to reliably detect the level. If the level detection by the silo lower limit level meter exceeds the lower limit value in the middle of the cycle, the timer is reset.

When the level of the pre-expanded particles in the silo 2 is reliably detected to be equal to or lower than the lower limit value, the silo 2 is recognized as empty and the No. of the silo 2 is stored. Then, the aging time of the silo 2 is reset (S4). Then, the elapsed time of the idle time of the silo 2 is counted from the initial value of zero (S5).

On the other hand, if it is detected in S1 that the level of the pre-expanded particles in the silo 2 has exceeded the lower limit, a timer is activated (S6) and a plurality of timers are operated until a predetermined time elapses. A predetermined number of times, the cycle (S1) of detecting that the level has exceeded the lower limit, is repeated. This makes it possible to reliably detect the level as described above. If the level detection by the silo lower limit level meter becomes equal to or less than the lower limit value in the middle of the cycle, the timer in S6 is reset.

Thereafter, when it is detected that the level of the silo 2 has exceeded the lower limit value, the storage that the silo 2 is empty is reset (S7). Recognizing that the expanded particles are stored, the aging time of the pre-expanded particles is counted (S
Along with 8), the count of the elapsed time of the idle time of the silo 2 is reset (S9).

In the configuration of the embodiment, the detection cycle of the lower limit of the level as described above is sequentially executed in each silo 2 so that the idle time and the aging time of each silo 2 can be counted.

The set time required for the maturation of the pre-expanded particles in the silo 2 is preset according to the type of resin used, for example, the type of polystyrene resin, and the number of times of expansion. The time is stored in the host computer 9 in advance as an aging time table.

On the other hand, the primary grain feed control section 6 stores the ripening time of the silo 2 during each ripening while sequentially updating the ripening time based on the ripening time table by a monitor function described later. In the granulation control unit 6, the storage of the elapsed time from when the silo 2 becomes empty and the storage of the elapsed time from the completion of ripening are sequentially updated and stored as silo management information. Silo management information indicating the raw material, raw material No. of the pre-expanded particles sent to the silo 2 and the expansion multiple thereof is also updated and stored.

In the above-mentioned silo 2, the actual value of the expansion multiple measured by the multiple measuring device 1d for the pre-expanded particles is:
From the raw material feed amount per batch from the raw material feeder 1b to the foaming machine main body 1a and the number of batches, the total transport amount to the silo 2 is detected by the primary granulation control unit 6, and the detected amount is also a silo. It is stored as management information.

Thus, when the total amount of the pre-expanded particles in the foaming machine 1 cannot be accommodated in one silo 2, the primary granulation control section 6 sets the silo 2 having a predetermined capacity.
Is detected from the upper limit level meter or the conveyance amount, the silo 2 is filled with the pre-expanded particles.
Is closed, the other silo 2 having the next longest empty period is selected, and the receiving line damper 4c of the silo 2 is opened.
In this way, the pre-expanded particles produced in the above can be continuously transported.

Further, the primary particle feed controller 6 controls the remaining of the pre-expanded particles in each of the silos 2 based on a signal indicating the number of shots of each molding machine 3 from a molding machine sequencer 3e as described later. The amount can be detected.

That is, while the transport amount to each silo 2 is accurately calculated from the actual value of the foaming multiple by the multiple measuring device 1d, the number of molds 3c for each molding machine 3 and the preliminary foaming used The weight of the particles is set in advance. From these facts, the remaining amount of the pre-expanded particles in each silo 2 can be accurately calculated from each transport amount to each silo 2 and the number of shots of each molding machine 3.

From this, in each silo 2, in order to detect the lower limit and the upper limit of the level of the pre-expanded particles,
An upper level meter and a lower level meter such as an ultrasonic level meter for measuring the volume of the pre-expanded particles in the silo 2 can be omitted.

The silo 2 in the state where the pre-expanded particles are carried in and stored as described above is referred to as being granulated, and for example, as shown in FIG. 3, the operation state of the primary granulation line is displayed. On the display / input unit 6a or the like, for example, as indicated by a silo (No. 1) 2 in the figure, the color is different from other silos 2, for example, red.

The pre-expanded particles charged in the silo 2 need to be aged for a predetermined time, for example, 24 hours.
Silo 2 with such pre-expanded particles during aging,
On the display / input unit 6a or the like, for example, a silo (No.
As shown in 2), the color is different from the other silos 2, for example, yellow.

On the other hand, the silos 2 having the pre-expanded particles having been aged are, for example, Nos. 4 to 8, Nos. 10 to 11, N
o. As shown in each of the silos 13 to 14, the display / input unit 6a
Etc. are shown in green. The silo 2 with the pre-expanded particles empty is, for example, No. 2 to No. 3 and No. 9 in the figure.
It is shown as a blank silo.

Although not shown, the silo 2 containing the pre-expanded particles that do not meet the molding conditions even after aging is displayed intermittently, for example, in a flashing purple color. Thus, when the selection of the silo 2 is manually selected from the display / input unit 6a or the like, the inconvenience of erroneously selecting the silo 2 which is prohibited from feeding under certain foaming conditions is reliably prevented.

Next, a description will be given of an operation for producing a foamed molded article using the pre-expanded particles put into the molding machine hopper 3b as described above. First, as an initial operation, when the set molding conditions are input from the host computer 9 to the display 3g and / or the display 3f, the display 3g and / or the display 3f displays the raw material and raw material No. The silo management information stored in the primary granulation control unit 6 is searched based on the .times.

As a result, the display 3g and / or the display 3f store the raw material, the raw material No. and the aged pre-expanded particles having the expansion multiple, and find the silo 2 having the longest aging time by the above search. Then, the above-mentioned particle sending request signal indicating that the pre-expanded particles are sent from the silo 2 to the molding machine hopper 3b of the molding machine 3 is output to the secondary particle sending control section 7.

When the secondary feed control unit 7 receives the feed request signal, the secondary feed control unit 7 checks whether the feed request signal is correct during a preset timer period, and then transmits the feed request signal. When it is confirmed that the granulation request signal is correct, the secondary granulation blower 5b is operated to perform a pre-blow for a predetermined time to clean the inside of the secondary granulation pipe main body 5a.

Thereafter, the silo dispensing damper 5d of the predetermined silo 2 and the automatic damper 5e for the molding machine are actuated to detect the aged pre-expanded particles in the silo 2 through the secondary granulation pipe main body 5a. Hopper 3 for the molding machine
b by air flow. After the completion of such conveyance, the inside of the secondary granulation pipe main body 5a is cleaned by after blowing for a predetermined time.

Subsequently, the display 3g and / or the display 3f inputs the input and stored molding conditions to the molding machine sequencer 3e, and the molding machine sequencer 3e uses the molding machine sequencer 3e. A trial production is performed. From this result, if the foamed molded article under the above molding conditions is within the range of the standard value, the molding of the foamed molded article in the molding machine 3 is continued without changing the above molding conditions.

On the other hand, when the foamed molded article under the above molding conditions is out of the range of the standard value, the operator inputs the finely adjusted conditions of the above molding conditions through the display 3g or the display 3f, and the molding machine 3 The molding conditions are updated so that the foam molded article produced in the above step is within the range of the standard value.

The molding conditions updated in this way are stored, for example, on the display 3g, and transmitted to the other display 3f, the molding machine sequencer 3e, and the host computer 9 via the bus line 8 and stored. .

Thus, in the configuration of the above-described embodiment, the foam molded body produced by each molding machine 3 can be quickly set within the range of the set value for each molding machine 3. Can be stably manufactured, and for example, the foaming conditions updated by the foaming machine sequencer 1e and the molding conditions updated by, for example, the display 3g can be transmitted to the host computer 9, the primary granulation control unit 6, the secondary Since the data can be input to and displayed on the grain control unit 7 and each of the displays 3g and 3f via the bus line, it is possible to quickly respond to a change in the process caused by the update.

[0098] In this way, the foamed molded product within the standard value is continuously formed by the predetermined number of shots by the secondary granule feeding control unit 7, the molding machine sequencer 3e, and the displays 3g and 3f. When a defective article is generated in the foamed molded article, the number of the defective article is notified to the host computer 9 via the display 3g provided at a lower portion of the molding machine main body 3a near the outlet of the foamed molded article. Can be entered. This makes it easy to manage the number of defective products in real time.

In the case where the foamed molded article is continuously molded by the molding machine 3 described above, if the pre-expanded particles in the hopper 3b for the molding machine are sequentially reduced by molding and fall below a predetermined amount,
Based on a signal from the level meter 11 of the molding machine hopper 3b for detecting the storage amount of the pre-expanded particles, the display 3g and / or the display 3f are used to input the raw material, raw material No. and the foaming multiple inputted together with the molding conditions. , And retrieves the silo management information stored in the primary granulation control unit 6.

Accordingly, the display 3g and / or the display 3f store the raw material, the raw material No. and the matured pre-expanded particles having the expansion multiple thereof, and the silo 2 having the longest aging time is stored in the silo 2 described above. The detection is detected by the search, and the above-described granulation request signal indicating that the prefoamed particles are to be granulated from the silo 2 to the molding machine hopper 3b of the molding machine 3 is output to the secondary granulation control unit 7.

When the secondary feed control unit 7 receives the feed request signal, in the same manner as described above, the silo discharge damper 5d of the silo 2 and the automatic molding machine based on the feed request signal are used. The damper 5e is operated to remove the aged pre-expanded particles in the silo 2 from the molding machine hopper 3b.
Conveyed by an air stream.

By repeating the production cycle of the foamed molded article in the molding machine 3 and the cycle of transporting the pre-expanded particles to the hopper 3b for a molding machine, a predetermined number of foamed molded articles satisfying a prescribed standard value can be obtained. Can be

In this case, since the granulation request signal can be sent from each molding machine 3 by the display 3g and / or the display 3f, even if the number of molding machines 3 installed increases, each granulation request signal can be transmitted. As compared with the case where the transmission is processed by a single control device as in the related art, it is possible to avoid the occurrence of a waiting time when each of the granulation request signals is transmitted.

Thus, in the configuration of the present embodiment, the occurrence of the waiting time can be prevented, so that the continuous production of the foamed molded article can be more reliably performed, and the deterioration of the production efficiency of the foamed molded article can be avoided. .

If more pre-expanded particles than the maximum amount of pre-expanded particles that can be aged in one silo 2 are required, pre-expanded particles of the same type and the same multiplication factor are sequentially produced to prepare a plurality of silo 2 The pre-expanded particles from the silo 2 having a longer aging period are used first.

Subsequently, the level meter 1 of the hopper 3b for the molding machine is used.
When the hopper 3b for the molding machine does not reach the predetermined amount due to the pre-expanded particles from the silo 2 according to the granulation request based on the above, the secondary granulation control unit 7 judges that the silo 2 is empty. I do.

Thereafter, another silo 2 having the next longer aging period is used.
, Each silo discharge damper 5d is switched so that the pre-expanded particles can be supplied to the molding machine hopper 3b.
This makes it possible to supply the pre-expanded particles to the molding machine hopper 3b without delay. Thus 2
By setting the next granulation control unit 7, the upper limit level meter and the lower limit level meter of the silo 2 in the above embodiment can be omitted.

Further, since the pre-expanded particles of the silo 2 having a long aging period are sequentially used, the length of the aging period of the pre-expanded particles in each silo 2 can be reduced, and the aging period of each obtained foam molded article can be reduced. Can be prevented from being varied due to the difference between the two.

Next, the foaming machine 1 in the configuration of the above embodiment is described.
Of the pre-expanded particles from the powder to a predetermined silo 2, usually 1
The step called next feeding will be described in more detail with reference to FIG. 3, FIG. 5 and FIG.

First, when the operator inputs the model number and quantity of the desired foam molded article into the host computer 9, the above-mentioned master data is called up based on the model number and quantity, and the master data is used to retrieve the foam molded article. The data indicating the set values of the foaming conditions and the molding conditions, which are the production conditions, are stored in the primary granulation control unit 6, the display 1g, and the foaming machine sequencer 1.
e, the secondary particle feed control unit 7, the molding machine sequencer 3e, and the respective displays 3f and 3g. The data includes information indicating the production name, production number, and the number of foaming times of the molding conditions.

The foaming machine sequencer 1e controls the foaming machine 1 on the basis of the above data to produce desired pre-expanded particles, and the primary granulation control section 6 matures the pre-expanded particles. Silo 2 is selected.

Next, a method of selecting the silo 2 will be described. First, as shown in FIG. 5, a silo No. stored as empty is searched (S11), and an empty silo N is searched.
It is determined whether o. is stored (S12).

If it is determined in S12 that the No. of the empty silo 2 is not stored, the process ends and the empty silo 2
Is determined to be stored, the empty silo 2
Are searched (S13), and the respective free times are compared (S14).

Thereafter, No. 2 of the silo 2 having the longest available time is used.
Is stored (S15), and the receiving line damper 4c of the silo 2 of that No. is opened (S16). Subsequently, the open state of the receiving line damper 4c is confirmed by, for example, a microswitch that detects the open / closed state of the valve of the damper by contact with the free end of the valve or the like (S17).

Next, in the foaming machine 1, the step of discharging the pre-expanded particles to the foaming machine hopper 1c is performed by the foaming machine hopper 1c.
It is detected whether or not the payout process is completed due to the opening time of the opening (S18). If the payout process is not completed, S18 is repeated to enter a standby state, and the payout process is completed. Is detected, the primary feed blower 4
b is turned on (S19).

Thus, before all the pre-expanded particles produced in the foaming machine 1 are dispensed to the foaming machine hopper 1c, it is determined that the dispensing is completed, and the granulation to the set silo 2 is started. Therefore, it is possible to speed up the feeding of the pre-expanded particles.

Next, the primary grain blowing blower 4b is turned on.
At the same time, the raw material, raw material No., and the multiple of the pre-expanded particles sent to the silo 2 are stored in the memories of the primary granulation control unit 6 and the secondary granulation control unit 7 storing the No. of the silo 2. And setting values such as aging time.

Thereafter, the operation time of the primary granulating blower 4b is detected by a timer (S21), and the amount of the pre-expanded particles in the silo 2 is detected, and the upper limit level of the silo 2, that is, It is detected whether the silo 2 has been filled with the pre-expanded particles (S22).

When it is detected that the silo 2 is full, as shown in FIG. 6, a timer for repeating the above detection cycle a predetermined number of times is operated (S23), and the above detection is ensured as described above. After the primary granulation blower 4b
Is turned off (S24), the receiving line damper 4c is closed (S25), and the process returns to S13.

On the other hand, in S22, if the silo 2 is not full even after the primary granulating blower 4b feeds for a predetermined time, it is calculated whether or not the actual amount of foaming has exceeded the expected foaming amount. (S26), when S26 is NO Subsequently, it is calculated whether or not the actual number of times of foaming is equal to or more than the expected number of foaming (S27), and when S27 is NO, S18 is performed.
In the same manner as described above, it is determined whether or not the dispensing process of the foaming machine 1 has been completed in S18, and if not, the process enters a standby state, and if it is determined that the dispensing process has been completed, the process proceeds to S19 and thereafter. Then, the pre-expanded particles are stored in the silo 2. However, in this case, S20 is skipped.

When the actual foaming amount exceeds the expected foaming amount in S26 and S27, and when the actual number of times of foaming exceeds the expected foaming number, 1
The preparation process of the pre-expanded particles under two expansion conditions is completed.

The information of each silo 2 produced under various foaming conditions in this way is sequentially updated in the primary granulation control unit 6 as silo management information indicating the raw material, the raw material No., and the expansion multiple thereof. In accordance with an instruction from the operator, for example, as shown in FIG. 7, the display 1g, the displays 3g and 3f, and the display / input units 6 are displayed as a list.
a.7a, the display section 9a of the host computer 9, and the menu selection by the operator on the screens 1f and 3h.

Next, the search for a silo No. with a long idle time in the above foaming process will be described. First, as shown in the flowchart of FIG. 8, 1 is substituted for n (S3).
1) The idle times of the n-th silo 2 and the (n + 1) -th silo 2 are compared based on the information stored in the memory (S32).

Subsequently, the silo No. with the longer idle time and the idle time X are stored (S33). Thereafter, it is determined whether or not n is equal to a number obtained by subtracting 1 from the total number of silos (MAX number) registered in advance (S34). If not equal, n + 1 is substituted for n (S35). Then, n + 1
After comparing the silo idle time with the idle time X stored as the longest idle time so far (S36),
It returns to S33. On the other hand, when n is equal to the number obtained by subtracting 1 from the total number of silos (MAX number) registered in advance in S34, the search process is completed.

Next, the operation of producing a foam molded article from pre-expanded particles in the structure of the above embodiment will be described.
First, when the operator inputs the model number and quantity of the desired foam molded article to the host computer 9, the above-mentioned master data is called up based on the model number and quantity, and the molding conditions of the foam molded article are determined from the master data. The indicated data is output to the molding machine sequencer 3e via each of the displays 3f and 3g, and is also output to the secondary particle feed controller 7.

In the secondary granulation control unit 7, when a signal indicating that the required amount of pre-expanded particles has been matured in the silo 2 is completed from the primary granulation control unit 6 via the bus line 8. The mold used by the molding machine 3 to be used is displayed on a display 3f attached to the molding machine 3, and the mold 3c mounted by the operator from the display 3f or the like is a predetermined one, and the molding conditions , Raw materials used (raw materials N
o.) and instructions for confirming the multiple of the foam.

At least one of the displays 3f and 3g displays the used raw material (used raw material N) set by the molding machine 3 based on the detection signal from the level meter 11 of the molding machine 3.
o.) and a silo 2 to be used based on the foaming multiple, and a silo 2 to be used is set by searching for the silo 2 having the longest aging period from the selected silo 2; A transmission request signal for transmitting the pre-expanded particles to 3 is transmitted via the bus line 8. Note that such displays 3f and 3g
The function of (2) also has the secondary particle feed control unit 7.

Then, after confirming the above-mentioned particle-feeding request signal, the secondary particle-feeding control section 7 activates the secondary particle-feeding blower 5b based on the particle-feeding request signal, and outputs the silo discharge damper of the silo 2 to be used. While opening 5d, the automatic damper 5e for the molding machine is controlled so as to convey the pre-expanded particles to the hopper 3b for the molding machine of the selected molding machine 3. Thereby, the pre-expanded particles corresponding to 3 to 4 batches in the foaming machine 1 are carried into the hopper 3b for the molding machine in a few seconds.

The granulating step of the secondary granulating line 5 will be described in more detail. First, as shown in the flowchart of FIG. It is determined whether or not a molding request has been input (S41).
When a molding request is input in step 1, when a molding request is input, the level, which is the amount of pre-expanded particles stored in the molding machine hopper 3 b, is detected by the level meter 11 (S 42).

When the level is equal to or less than the set value, that is, less than the amount of the pre-expanded particles required for one shot, a timed timer is set to ensure the above detection, and the detected time is set within the set time of the timed timer. The above detection is performed even if the timed timer reaches the set time, that is, when the time is up, a granulation request signal is output to the bus line 8 together with the number of the molding machine 3 to output the granulation request signal. Is completed.

On the other hand, if the level detection in S42 exceeds the set value, the time limit timer is reset (S42).
45), and return to S42. By using such a timed timer, the malfunction of the level meter 11 caused by the fluctuation of the level of the pre-expanded particles in the molding machine hopper 3b due to blowback from the mold 3c or the like, The above level meter 1 due to the pre-expanded particles being granular
1 can be avoided.

Next, when the granulation request signal is output to the bus line 8 as described above, the case where each granulation process in the secondary granulation line 5 is operated by automatic selection will be described with reference to FIG.
This will be described with reference to FIGS.

First, as shown in FIG.
It is detected whether or not a granulation request signal has been output from the molding machine 3 (S51). If not, the process returns to S51 to be in a standby state, while it is detected that a granulation request signal has been output. Then, each molding machine No. of each detected particle feed request signal and their detection order are stored (S52).

Thereafter, a search is made for a silo 2 having the same set value as that of the raw material in the first molding machine 3 in the detection order (S53). At this time, in the comparison of the set values for the search, first, the material or the material No. is compared (S
54). As a result of the comparison, the corresponding silo No. is stored (S55).

Subsequently, the stored silos 2 are compared for their foaming multiples (S56).
Is stored (S57). Among the stored silos 2, one having the aging time of the pre-expanded particles longer than the set aging time is selected (S58), and the No. 2 of the corresponding silo 2 is selected.
Is stored (S59).

Next, in the stored silo 2,
The ripening times are compared (S60), and the No. of the silo 2 having the longest ripening time is stored (S61). Thereafter, as shown in FIG. 11, it is determined whether or not the first granulation request signal is still in the ON state, that is, whether or not the flag is set (S6).
2) If the flag is on, open each damper of the secondary granulation line 5 from the silo 2 to the molding machine 3.
However, the silo payout damper 5d of the corresponding silo 2 is excluded (S63).

After that, the secondary granulating blower 5b is turned on,
The pre-blow timer is operated so that the secondary granulation blower 5b is in the period from the start to the steady state, and during that time, the discharge damper is in the ON state, that is, opened, and the secondary granulation pipe main body 5a is opened. The remaining pre-expanded particles are discharged to the outside.

As described above, when the pre-expanded particles in the silo 2 are conveyed to the predetermined hopper 3b for a molding machine, before the conveyance of the pre-expanded particles is started, the residue in the secondary granulation pipe main body 5a is removed. Is removed, and a pre-blow is performed for a predetermined time to bring the secondary feed blower 5b into a steady state (S66).

Subsequently, after the unloading damper is turned off (S67), the silo dispensing damper 5d is opened (S6).
8) Activate the particle feed timer to move the hopper 3 for the molding machine from the silo 2 for a predetermined time set by the mounting position of the silo 2 and the mounting position of the molding machine 3.
The pre-expanded particles are sent to b (S69).

When a predetermined time has elapsed by the particle sending timer,
The silo payout damper 5d is closed (S70), and thereafter,
The discharge damper is opened (S71), the after-blow timer is operated, and the residue in the secondary granulation pipe main body 5a after the conveyance of the pre-expanded particles is completed is removed by the air from the secondary granulation blower 5b. After-blowing for removing by the flow and cleaning the inside of the secondary granulation pipe main body 5a is performed for a predetermined time (S72).

After the completion of such after-blowing, the discharge damper is closed (S73), the first particle feed request signal is reset (S74), and the process returns to S51. If the first feed request signal is not in the ON state in S62, the process proceeds to S74.

The after-blow time depends on the length of the secondary granulation pipe main body 5a between each silo 2 and each molding machine hopper 3b. It can be set via the sections 6a and 7a.

That is, as shown in FIG. 12, for example, the length of the secondary granulation pipe main body 5a between the silo (No. 5) 2 and the molding machine (No. 6) 3 is equal to the silo (No. 5). 2) and the length of the secondary granulation pipe main body 5a between the molding machine (No. 8) 3 and the after-blow time are set according to the difference. In addition, such after-blowing is similarly set and executed in the above-described primary granulation line 4.

In the configuration of the above embodiment, when the pre-expanded particles having the same expansion ratio and material are used in a plurality of molding machines 3, the pre-expanded silo 2, for example, silo (No. A plurality of molding machines 3 such as molding machine (No. 6) 3 and molding machine (No.
8) Can be sequentially supplied to 3.

Thus, in the above-described structure, the pre-expanded particles that have been aged can be consumed rapidly and sequentially from the pre-expanded particles.
Variations in the actual value of the foamed molded article due to the lapse of time after completion of aging can be reduced, so that a foamed molded article with less variation can be stably manufactured.

In the above configuration, as shown in FIG. 13, a silo No. in which pre-expanded particles meeting the molding conditions specified for each molding machine 3 are stored below the block indicating each molding machine 3. Are shown in the figure. The setting of the one-to-one particle feed between each silo 2 and each molding machine 3 based on the silo number is performed by each display / input unit 6a, 7a.
It is easily possible by manual operation on the screen.

Next, the storage of the granulation request signal in the granulation step in the secondary granulation line 5 will be described. First, the granulation request signal is output to the bus line 8 as shown in FIG. Is detected (S81),
The number of the molding machine 3 output together with the feed request signal is set to FI
Store sequentially using the FO (First-In First-Out) method (S8)
2). It should be noted that if no particle sending request signal is detected in S81, the apparatus enters a standby state.

After that, the completion of the first grain feeding is
When it is detected that the particle feed timer in S69 is completed, that is, it is up (S83), in the storage order of the No. of each molding machine 3 which has transmitted the particle feed request signal, the number 1 is determined.
Is reset and the storage order is shifted (S84).

Subsequently, in the memory area storing the No. of each molding machine 3 that has transmitted the granulation request signal, the N of the molding machine 3 is stored.
It is determined whether or not the memory of o. remains (S85),
If there is, the process proceeds to S83, and if not, the process proceeds to S81.

In the above embodiment, the data transmitted on the bus line 8 uses a predetermined format. However, when a molding machine sequencer having another data format is used, the data format from the molding machine sequencer is used. May be provided between the molding machine sequencer and the display 3f or the display 3g, or a function of converting the software by the display 3f or the display 3g may be provided.

As described above, in the configuration of the above-described embodiment, the host computer 9 and each sequencer 1e having a communication function are connected.
3e and the respective controllers 6 and 7 and the displays 3f and 3g having a communication function are linked by the bus line 8 to form a network.
Even if e · 3e or the display 3f · 3g increases, it is possible to easily cope with it.

Further, in the above configuration, various instructions to the foaming machine 1 and the molding machine 3 and centralized management such as grasping of the situation at the site are performed by the network, not only by the host computer 9 but also by the control units 6 and 7. Can be easily operated by a menu operation on the display screen of the display / input sections 6a and 7a. Such a menu operation can be performed on the display 3g.
Etc. are performed in the same manner as the coordinate input means 3i.

Further, since similar operations can be performed on each of the molding machines 3 on the touch panel displays 3g and 3f installed on the molding machine 3 at the site, it is possible to immediately respond to a sudden process change or trouble. ing. As a result, the automatic manufacturing system can improve productivity (labor saving), stabilize quality, and reduce costs (uptime and efficiency).
It can be done.

As described above, each of the displays 3f and 3g having the screen 3h for displaying the stored molding conditions and including the coordinate input means 3i capable of updating the molding conditions and the like on the screen 3h is provided for each molding machine 3. For example, when a foam molded article is trial-produced by the molding machine 3 based on molding conditions according to the instruction, when the actual value of the foam molded article is out of the set value range due to a change in environment or the like. The operator operates each display 3f provided on the molding machine 3
The molding condition displayed on the 3g screen 3h can be updated by the coordinate input means 3i.

Thus, in the above configuration, when the actual value of the foam molded article prototyped by the molding machine based on the instruction from the control device falls outside the range of the set value, the molding condition is changed. It is possible to reduce the trouble of the operation of changing the instruction from the control device remote from the molding machine for updating.

Further, in the above configuration, if the operator determines that the foam molded article obtained by the molding machine 3 is defective, the operator inputs the number of defective articles on the display 3g. Can be input by the coordinate input means 3i from the display screen, and the number of defective products can be transmitted to the host computer 9 via the display 3g.

Thus, in the above configuration, the display 3g is provided in the vicinity of the outlet of the foam molded article in the molding machine 3, so that the number of defective foam molded articles can be easily input. The production control of the foam molded article can be easily performed.

In addition, in the above configuration, even if a defective product occurs in the molding machine 3, for example, the molding conditions updated on the display 3g can be input to the host computer 9, so that the change in the process caused by the updating can be prevented. Since it is possible to respond quickly, the foam molded article to be produced can be produced stably.

In the above example, three silos 2 were used,
Although an example using two molding machines 3 and an example using 14 silos 2 and 12 molding machines 3 have been described, the present invention is not limited to the above. Up to 5-6 foaming machines 1 and 4 silos 2
Even if 0 to 50 units and 30 molding machines 3 are added, it is possible to respond.

In the configuration of this embodiment, even if the silo 2 and the molding machine 3 are added as described above, the control of the feeding of the pre-expanded particles from each silo 2 to each molding machine 3 is controlled by each display 3f. Since each control is performed by a single control device as in the related art, the control processes are concentrated and the control device is likely to be in a busy state, since each control is performed by a particle feed request signal from 3g. As compared with the case, it is possible to prevent occurrence of the waiting time for the above-mentioned particle sending.

Thus, in the above configuration, particularly when the number of molding machines 3 installed is large, it is possible to avoid delaying the production of the foam molded article due to the waiting time. It is possible to produce the foamed molded article, and it is possible to prevent the production efficiency of the foam molded article from deteriorating.

In addition, the host computer 9 centrally manages the conditions of the foaming machine 1 and the molding machine 3, automatically operates the foaming machine 1, manages the number of times of foaming, centrally manages the actual data, prepares a daily report and a primary / secondary particle feed. Can be easily automated by menu operations on the display screen of the display unit 9a and the display / input units 6a and 7a.

Further, as long as beads as a raw material are supplied to the raw material tank for each kind at any time, the pre-foaming operation is performed only in the operation work, so that two or three straight foaming can be performed. Thereby, the number of silos 2 and the number of foaming machines 1 can be reduced.

In addition to the centralized management, the input / output unit 6a / 7a of each control unit 6/7, the display 1g installed in the foaming machine 1, and the display 3g / 3f of the molding machine 3 also input data. Touch panel type screen 3h with functions
By using the coordinate input means 3i and its equivalent, the foaming conditions and the molding conditions can be changed (filling, heating, water cooling, cooling time).

In the display 3g provided at the lower part of the molding machine 3, the defect quantity and the breakdown can be easily input from the screen 3h by the coordinate input means 3i and transmitted to the host computer 9, so that the real-time It is possible to grasp the production amount of the foam molded article in real time.

Further, in the above configuration, since each display 3f or 3g for controlling the sequencer 3e is provided with a communication function, the network can be formed via the bus line 8, and the foam molded article can be formed. It can be easily introduced into existing factories as well as new factories for manufacturing.

In addition, during the operation of the automatic manufacturing system,
Data such as molding conditions are also stored in the lower sequencers 1e and 3e and the displays 3f and 3g. Even if a trouble occurs in the host computer 9, the displays 1g, 3f,
Since each of the 3 g is provided, the foaming machine 1 and the molding machine 3 can be operated as usual by the operator's instruction from the displays 1 g, 3 f, 3 g. Therefore, in the configuration of the above embodiment, the host computer 9
Even if a failure occurs, the production of the foamed molded article can be continued, and the production efficiency of the foamed molded article can be prevented from deteriorating.

Conventionally, the weighing device is controlled so that the expansion ratio of each batch falls within a predetermined range based on the measurement result of the expansion ratio by the automatic magnification measurement device. When it occurs due to a change in the environment or the like, the actual value of the foamed synthetic resin obtained in accordance with such variations fluctuates, so that the production of the foamed synthetic resin may become unstable.

However, in the configuration of the above embodiment, the signal indicating the actual value of the foaming multiple by the multiple measuring device 1d is:
Not only for changing the raw material supply amount and foaming conditions of the pre-expanded particles of the next batch in the foaming machine main body 1a, but also transmitted to the secondary granulation control unit 7 and the like via the bus line 8, It is also used for changing molding conditions when molding a foam molded article using the pre-expanded particles.

Thus, in the above configuration, even if the expansion factor of the pre-expanded particles varies within the range, the variation of the actual value of the foamed molded article caused by the variation of the expansion factor is determined by the molding conditions. Can be suppressed by changing.
Therefore, the above-described configuration is capable of stably producing a foam molded article with less variation.

Conventionally, a plurality of ripening devices are provided to automate the production of the foamed synthetic resin. To automate the supply of the pre-expanded particles to each such ripening device, The aging devices are provided with level meters, respectively, and the mechanism is complicated, leading to an increase in cost.

However, in the configuration of the above embodiment, since the upper limit level meter and the lower limit level meter of the silo 2 can be omitted, the mechanism can be simplified and the cost can be reduced as compared with the prior art.

Further, in the above configuration, even if expansion of the foaming machine 1 or the molding machine 3 which is a production device, a layout change, or the like occurs, only by changing the device connection setting using the display / input sections 6a and 7a, for example. Can respond immediately. In addition, if the above-mentioned configuration can introduce a production process plan and a warehouse receipt / delivery management system in the future, it will be possible to further drastically rationalize the OA.
Data communication with a computer is possible.

In the configuration of the above-described embodiment, an example is described in which the molding machine 3 is provided with only the molding machine sequencer 3e. However, for example, a molding machine with a display can be used. Even in this case, since the display is usually provided on the side of the molding machine, the display 3g may be provided in the vicinity of the outlet of the foam molded article of the molding machine in the same manner as in the above embodiment.

[0175]

Foamed molded article manufacturing apparatus of the present invention exhibits, as above, for making the foaming conditions a pre-expanded particles
Foamed machine settings vignetting, the sub control unit capable of controlling the foaming conditions the foaming machine is set up Symbol onset foam machine vignetting, the foam molding to co When storing a plurality of foaming conditions from the main control unit It is set to sequentially update each foaming condition of the pre-expanded particles of this lot and the next lot to sequentially produce the body , and further,
In response to the granulation request signal sent from the molding machine,
Send the pre-expanded particles required for the conditions from the silo
Through the grain pipe to the molding machine hopper of the molding machine.
A feeding control unit for controlling the feeding is provided.
The control unit receives the particle transmission request signal and receives the particle transmission request signal.
Check that the signal is correct, and check that the
If it is confirmed that
After that, the pre-expanded particles are sent to the molding machine
Is a configuration you Okutsubu to use the hopper.

[0176] Thus, in the above arrangement, since the sub-control unit is eclipsed set in foamed machine, the foaming conditions of the upper Symbol onset foam machine, the production of pre-expanded particles of this lot is completed, the next lot the ability sequentially updated foaming conditions, it is possible to quickly Seisuru create the pre-expanded particles.

[0177] Thus, in the above arrangement, since the preparation of pre-expanded particles can Gyoshi by Ri system to the sub-control section in the foamed machine, as in the prior art, foamed machine, soaker, the molding apparatus and their compared to the case that was processing the control by Ri onset foam machine into a single control device for controlling each of the conveyance of the pre-expanded particles during, since it is possible to reduce the waiting time for preparation of pre-expanded particles foamed machine This has the effect of suppressing a decrease in the production efficiency of the foam molded article.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram of an apparatus for producing a foamed molded article of the present invention.

FIG. 2 is an explanatory diagram of a setting screen of a foaming step of the foam molded article manufacturing apparatus.

FIG. 3 is an explanatory diagram of a display screen showing a state of a primary granulation line of the foam molded article manufacturing apparatus.

FIG. 4 is a flow chart when measuring the idle time or the aging time of each silo in the foam molded article manufacturing apparatus.

FIG. 5 is a flowchart showing a first half of a process of sending particles to each silo in the above-mentioned apparatus for producing a foamed molded product.

FIG. 6 is a flowchart showing the latter half of the above-mentioned particle sending configuration.

FIG. 7 is an explanatory view of a display screen showing silo information in the foam molded article manufacturing apparatus.

FIG. 8 is a flowchart for searching for a silo No. with a long idle time in the foam molded article manufacturing apparatus.

FIG. 9 is a flowchart when a granulation sending request signal is output from a molding machine in the above-mentioned foamed molded article manufacturing apparatus.

FIG. 10 is a first half of a flow chart when particles are sent from a silo to a molding machine in the foam molded article manufacturing apparatus.

FIG. 11 is a second half of the above flowchart.

FIG. 12 is an explanatory diagram of a display screen when granules are sent from the silo to a molding machine.

FIG. 13 is an explanatory diagram of a display screen showing information of each molding machine in the above-mentioned apparatus for manufacturing a foamed molded product.

FIG. 14 is a flow chart when storing a granulation request signal in the foam molded article manufacturing apparatus.

[Explanation of symbols]

 Reference Signs List 1 foaming machine 1g display (sub-control unit) 2 silo 3 molding machine 9 host computer (main control unit)

──────────────────────────────────────────────────の Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 44/00-44/60 B29C 67/20 B29C 45/76-75/82 G05B 15/00-15 / 02

Claims (2)

(57) [Claims] 1. A pre-expanded and particles foamed machine for making the foaming conditions, the raw material pre-expanded is the expansion ratio set by the foaming machine
A plurality of silos for accommodating and aging the pre-expanded particles obtained respectively, and a molding machine for molding an expanded molded article by the pre-expanded particles conveyed from the silo under molding conditions are provided. a plurality of main control unit that stores are provided a plurality of types of pre-expanded particles so as Gyoshi control the <br/> upper Symbol onset foam machine for making, respectively, by the foaming conditions, are inputted from the main control unit sub-control unit for storing the foaming conditions are set eclipse to the onset foam machine, set from the main control unit or the sub-control unit, so that each foaming conditions of the pre-expanded particles of those lots and the next lot sequentially updates It is, further in response to Okutsubu request signal sent from the molding machine,
The pre-expanded particles required for the molding conditions
B to the molding machine hopper of the molding machine
A granulation control unit for controlling the granulation is provided, and in the granulation control unit, when the granulation request signal is input.
Check whether the granulation request signal is correct, and
If the signal is confirmed to be correct, clean the inside of the above granulation pipe
After that, the pre-expanded particles are sent through a pipe
A foam molded article manufacturing apparatus , wherein the granulated particles are sent to a molding machine hopper . 2. A foaming molded article manufacturing apparatus according to claim 1, wherein the sub-control unit includes a touch panel type display for displaying foaming conditions.
Play, and input means for updating foaming conditions on the screen of the touch panel display .
An apparatus for manufacturing a foamed molded article, characterized in that each foaming condition of pre-expanded particles of the present lot and the next lot is set to be displayed on a touch panel display .