Patent Number: 
Section: description

Based on FIG. 1, one embodiment of the method of this invention for supporting maintenance for a molding system and for determining or anticipating which apparatus must be maintained before a molding system is caused to be interrupted by the problem is explained. First, at short periods, data on cycle times that correspond to the time for the cycle of each operation of the molding system and the operation times of the steps performed by the apparatuses is stored. The operation times affect the cycle time. Then, a step is done to determine any cycle times that is longer than a normal cycle time from a database in which the cycle times and the operation times are stored. Then, a step is carried out to select which step may cause a problem among the steps of the apparatuses, based on the sum of the operation times for the cycle times specified that exceed a predetermined time or the sum of the number of operation times that exceed the predetermined time. Based on FIG. 2, one embodiment of the method of this invention for supporting maintenance for a molding system and for determining which apparatus must be maintained before a molding system is caused to be interrupted by a problem is explained. First, a short periods, data on cycle times that each correspond to the time for the cycle of each operation of the molding system and the operation times of the steps performed by the apparatuses is stored. The operation times affect the cycle time. Then, any cycle time that is longer than a normal cycle time from a database in which the cycle times and the operation times are stored is determined. Then, a step is carried out to select which step may cause a problem among the steps of the apparatuses, based on the sum of the operation times for the cycle times specified that exceed a predetermined time or the sum of the number of operation times that exceed the predetermined time. Then, the changes are monitored between the operation times of the step determined. When the operation times become long, the parts of the apparatuses are exchanged. Based on FIG. 3, one embodiment of the method of this invention for supporting maintenance for a molding system and for anticipating which apparatus must be maintained before a molding system is caused to be interrupted by the problem is explained. First, at short periods, data on cycle times, each corresponding to the time for a cycle of each operation of the molding system, and operation times of the steps performed by the apparatuses is stored. The operation times affect the cycle time. Then, data on any cycle time that is longer than a normal cycle time from a database in which the cycle times and the operation times are stored is determined. Then, any step that may cause a problem among the steps of the apparatuses is selected, based on the sum of the operation times for the cycle times specified that exceed a predetermined time or the sum of the number of operation times that exceed the predetermined time. Then, the transitions of the operation times of the step determined are monitored. When the operation times become long, the parts of the apparatuses are exchanged. Based on FIG. 4, one embodiment of the maintenance system of this invention for a molding system and for determining or anticipating which apparatus must be maintained before the molding system is interrupted by the problem is explained. The system comprises a memory part or storage apparatus 1 for measuring and storing at short periods data on cycle times that each correspond to the time of the cycle of each operation of the molding system and the operation times of the steps performed by the apparatuses. The operation times affect the cycle time. A retrieving apparatus 2 retrieves data on any cycle time that is longer than a normal cycle time from a database in which the cycle times and the operation times are stored by the memory part. A determination apparatus 3 determines any step that may cause a problem among the steps of the apparatuses, which affect the cycle time, based on the sum of the operation times for each cycle time specified that exceed a predetermined time or the sum of the number of operation times that exceed the predetermined time. Based on FIG. 5, one embodiment of the maintenance system of this invention for a molding system and for determining which apparatus must be maintained before the molding system is interrupted by any problem in the apparatus is explained. The system comprises a memory part or a storage apparatus 1 for measuring and storing at short periods data on cycle times that each correspond to the time of the cycle of each operation of the molding system and the operation times of the steps performed by the apparatuses. The operation times affect the cycle time. A retrieving apparatus 2 retrieves a cycle time that is longer than a normal cycle time from a database in which the cycle times and the operation times are stored by the memory part. A determination apparatus 3 determines any step that that may cause a problem. Then, a monitoring apparatus 4 monitors changes between the operation times of the step that is determined may cause a problem among the steps of the apparatuses, which steps affect the cycle time, based on the sum of the operation times for each cycle time specified by the retrieving part that exceed a predetermined time or the sum of the number of operation times that exceed the predetermined time. Based on FIG. 6, one embodiment of the maintenance system of the invention for a molding system and for anticipating which apparatus must be maintained before the molding system is caused to be interrupted by the apparatus is explained. The maintenance system comprises a storage apparatus 1 for measuring and storing at short periods data on cycle times that each correspond to the time of a cycle of each operation of the molding system and the operation times of the steps performed by the apparatuses. The operation times affecting the cycle time. A retrieving apparatus 2 retrieves data on any cycle times that is longer than a normal cycle time from a database in which the cycle times and the operation times are stored by the memory part. A determination apparatus 3 determines any step that may cause a problem among the steps of the apparatuses, which steps affect the cycle time, based on the sum of the operation times for each cycle time specified by the retrieving part that exceed a predetermined time or the sum of the number of operation times the exceed the predetermined time. Then, a monitoring apparatus 4 monitors the transitions of the operation times of the step that are determined by the determination part. Based on FIGS. 7-16, one of the embodiments of this invention is now explained. As in FIG. 7, a control system of a molding system of this invention comprises a control panel 11, a CPU 12 for a counter sequencer, and a computer 13. The control panel 11 has a CPU 14 for a control sequencer. The CPU 14 is electrically connected to the CPU 12 through a line 15, which is of the type suitable for carrying signals from the CPU 14 to CPU 12, which can include outputs from sensors, and signals which represent operations of the apparatuses or components of the molding system 30. As shown in FIG. 7, the molding system can include air cylinders 34, oil cylinders 36, and other molding system components 38 and apparatuses 40, and sensors 42 which monitor such components and apparatuses. The CPU 12 is also electrically connected to the computer 13 through a communication line 16. The control panel 11 generates control signals and sends them to the apparatuses of the molding system 30 via communication line 32 to control the entire system. The CPU 12 of the counter sequencer receives signals from the CPU 14 of the control panel 11. Those signals include those that represent operations of the apparatuses or that are output from sensors, etc. Based on those signals the CPU 12 calculates the actual cycle time and the operation time during each step for each apparatus, and then stores them. The computer 13 reads out from the CPU 12 the actual cycle times and operation times for each apparatus at intervals of 0.01 second, and then makes a database as actual data on the operation times for the steps. The computer 13 previously stored data on a predetermined operation time during each step for each apparatus, and made the database on the predetermined operation time. Thus, the computer 13 functions as a problem-resolving component that includes a memory component 1, a searching or retrieving component 2, a determination part 3, and a checking or monitoring component 4 for monitoring changes of operation times (FIG. 7). Below, a procedure is explained in which the control system determines which component or elements will be soon repaired, as described above. First, both the cycle time that corresponds to the time of one cycle of the operation of the entire system and the operation time of each step of the specific component that will affect the cycle time are measured at short intervals, and then stored by the computer 13, which functions as a storage part 1. The data is stored for a long time, as in FIG. 8. Then, from the database on the cycle time and the operation time for each step the computer 13, which functions as a retrieving part 2, retrieves and determines periods that cause the cycle time to be long. As in FIG. 9, the computer 13 can generate a frequency table and histogram that represent relationships between those cycle times that have different values and the numbers of the cycle times for respective values. As in FIG. 10, the computer 13 also generates a graph of a transition of the cycle times. The graph represents the relationship between the cycle times that have different values and the dates and times. From the frequency table and histogram and the graph that represents the transitions of the cycle times, the periods that cause the cycle times to be long can be retrieved. Then, based on the sum of the operation times that exceed a predetermined time during a specific period or based on the sum of the numbers of the excessive times of the operation times from a predetermined time, the computer 13, which acts as a determination part 3, determines which steps may have problems, among the steps of the components that can affect the cycle times. The computer 13 can generate the sum of the times of those operations that exceed a predetermined time and a Pareto diagram that represents the relationships between various components, as in FIG. 11. The computer 13 can generate the sum of the number of times that the operations exceed a predetermined time and a Pareto diagram that represents relationships between various components, as in FIG. 12. Also, the computer 13 generates a frequency table and a histogram of the operation time of each step, as in FIG. 13. The frequency table and histogram allow a step that may have a problem to be determined. Then the computer 13 works as a monitor part 4 to monitor changes in an operation time, and monitors changes of cycle times of a plurality of operation times of a step that may cause a problem. That is, the computer 13 generates a distribution table that represents relationships between possible problem steps and the cycle times when those steps are performed. Then the computer 13 checks the table. As a result, if a plurality of the operation times of the steps become long, it can be determined that the components of those steps must be soon repaired. The computer 13 can have a monitor part 4 which monitors the transitions, instead of the monitor part 4, which checks changes of the operation times. That is, as in FIG. 15, the computer 23 functions as the problem-solving, part that has the memory part 1, the retrieving part 2, the determination part 3, which determines steps that have problems, and the monitor part 4, which monitors the transitions. Those parts allow components that need to be inspected and repaired to be anticipated. That is, the computer 23 checks the steps that are determined and that may cause a problem. Then, the computer 23 checks the transitions in the changes of a plurality of operation times of a step that is selected. FIG. 16 shows a bar graph that represents the transitions of an operation time for each step that is selected and may cause a problem. The computer 13 can generate it. As a result of that check, if the plurality of those operation times become long, it can be recognized that the components having the operation times must be soon repaired. Therefore, in accordance with the present invention, a method is provided for determining or anticipating which apparatuses of a molding system must be maintained before such apparatuses reach a state where their operation causes actual interruption of the operation of the molding system. In this method, cycle times are measured and stored that correspond to each cycle of operation of the molding system. Also measured and stored are the operation times of the steps performed by the apparatuses during each cycle of operation of the molding system, where the operation times that are measured are for those steps that have an effect on the cycle times. Data on the cycle times are evaluated to identify any cycle time that is longer than a normal cycle time. When such a cycle time is identified, the method examines the operation times of those steps performed by the apparatuses which affect the cycle time for the identified cycle of operation of the molding system. For each of those steps, the examination is based on the sum of the operation times that exceed a predetermined time, or on the sum of the number of operation times that exceed the predetermined time. Once the steps which may cause a problem are identified, the apparatuses associated with those steps can be checked. This method allows an operator to determine a step of the molding system operation that may cause a problem, so that any apparatuses or components that must be repaired can be early, easily, and certainly determined and anticipated, before the molding system operation must be stopped because of a malfunction. In a further embodiment of the method of the present invention, once steps which may cause a problem are identified, the method monitors changes in the operation times of the identified steps. As changes in the operation times increase, the apparatuses associated with the monitored steps can be checked. The monitoring of operation time changes of this method allows an operator to find a step that has operation times that become long over time, so that associated components that must be repaired can be early, easily, and certainly determined and anticipated, before the system is caused to stop. In another embodiment of the method of the present invention, the method further monitors transitions of operation times of the identified steps in order to anticipate apparatuses which must be maintained before the operation of a molding system is caused to be interrupted. That is once a step is identified which may cause a problem, the transitions of operation times for the identified step are monitored. Changes in the transitions of operation times of the identified steps can indicate that the apparatuses associated with such steps should be checked. This embodiment of the method of the present invention therefore allows an operator to determine a step that may cause a problem, so that associated components that must be repaired can be early, easily, and with more certainty determined and anticipated, before the system is caused to stop. In view of the foregoing, it is to be understood that the maintenance system in accordance with the present invention is operable to determine or anticipate which apparatuses in a molding system must be maintained before the molding system is interrupted by a problem in that apparatus. One embodiment of the maintenance system includes a memory part, a retrieving part, and a determining part. The measuring part measures and stores cycle times for each operation of the molding system, and also measures and stores operation times of steps performed by the apparatuses during the molding system operation. The operation times measured are those that affect the cycle times. The memory part stores the measured cycle times and the measured operation times in a database. The retrieving part retrieves cycle time data from the database and specifies any of the retrieved cycle times that is longer than a normal cycle time. The determining part determines from among the steps performed by the apparatuses that affect the specified retrieved cycle time, any step that may cause a problem that might lead to interruption of the operation of the molding system. This determination is made by examining the stored operation times for the determined step, and is based on the sum of the operation times that exceed a predetermined time, or the sum of the number of operation times that exceed the predetermined time. This embodiment of the maintenance system of the present invention allows an operator to determine which step may cause a problem, so that that associated components or apparatuses that must be repaired can be early, easily, and certainly determined and anticipated, before the system is caused to stop. Another embodiment of the maintenance system of the present invention further includes a monitoring part. The monitoring part checks changes in the operation times of the determined step. Using a monitoring part to check changes in the operation times allows an operator to determine which step may cause a problem, so that the associated components that must be repaired can be early, easily, and certainly determined and anticipated, before the system is caused to stop. In a further embodiment of the maintenance system of the present invention, the monitoring part checks the transistors of the operation times of the determined step, instead of merely checking for changes in operation times. This embodiment of the maintenance system also allows an operator to determine which step may cause a problem, so that those associated components that must be repaired can be early, easily, and certainly determined and anticipated, before the system is caused to stop.