U.S. patent application number 12/166878 was filed with the patent office on 2009-05-07 for method of constructing and executing process.
This patent application is currently assigned to INCS, Inc.. Invention is credited to Michiyo Kuwabara, Masayuki Nakao, Tomohito Ohmori, Shinjiro Yamada.
Application Number | 20090119670 12/166878 |
Document ID | / |
Family ID | 30772270 |
Filed Date | 2009-05-07 |
United States Patent
Application |
20090119670 |
Kind Code |
A1 |
Yamada; Shinjiro ; et
al. |
May 7, 2009 |
METHOD OF CONSTRUCTING AND EXECUTING PROCESS
Abstract
Disclosed is a method of constructing and executing a process. A
conventional process is minutely divided into minimum unit
subprocesses, and the minutely divided subprocesses are classified
into a decision subprocesses and a routine subprocess by whether
they require decision-making. Any subprocess which is executable
using the setup condition in a specific decision subprocess is
classified into the routine subprocess in such a manner that the
classified routine subprocess follows on the specific decision
subprocess. One or a series of decision subprocesses are combined
with one or a series of routine subprocesses which are executable
on the condition of the completion of the decision subprocesses to
form one unit process, and a job-support computer program is
created to allow the plurality of subprocesses included in the one
unit process to be successively executed. A plurality of
subprocesses which are executable in accordance with common input
data are detected from the minutely divided minimum unit
subprocesses, and a job flow is constructed to allow the respective
jobs in the plurality of subprocesses to be simultaneously
initiated and executed in parallel. The present invention can
drastically reduce the lead-time of a process while facilitating
execution of the entire process with high efficiency.
Inventors: |
Yamada; Shinjiro;
(Shinjuku-Ku, JP) ; Nakao; Masayuki; (Matsudo-Shi,
JP) ; Ohmori; Tomohito; (Shinjuku-Ku, JP) ;
Kuwabara; Michiyo; (Shinjuku-Ku, JP) |
Correspondence
Address: |
FULBRIGHT & JAWORSKI / WYETH
1301 MCKINNEY, SUITE 5100
HOUSTON
TX
77010-3095
US
|
Assignee: |
INCS, Inc.
Tokyo
JP
|
Family ID: |
30772270 |
Appl. No.: |
12/166878 |
Filed: |
July 2, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10640145 |
Aug 13, 2003 |
7409686 |
|
|
12166878 |
|
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Current U.S.
Class: |
718/102 ; 706/46;
715/781 |
Current CPC
Class: |
G06N 5/04 20130101; B33Y
80/00 20141201; G06Q 10/06 20130101 |
Class at
Publication: |
718/102 ; 706/46;
715/781 |
International
Class: |
G06F 9/46 20060101
G06F009/46; G06N 5/02 20060101 G06N005/02; G06F 3/048 20060101
G06F003/048 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 15, 2002 |
JP |
2002-236802 |
Feb 7, 2003 |
JP |
2003-31187 |
Claims
1-13. (canceled)
14. A method of constructing and executing a process comprising the
steps of: dividing a given process into a plurality of minimum unit
subprocesses; classifying the minimum unit subprocesses into a
decision subprocess requiring a decision-making for executing a job
therein and a routine subprocess executable according to a
predetermined procedure without any decision-making; verifying
whether each of the routine subprocesses including the given
process is essential for executing the entire given process, to
select only the routine subprocesses verified as essential, and
storing the information on the selected routine subprocesses into a
storage section of a computer in the form of computer-readable
digital data; defining a plurality of standardized jobs
corresponding, respectively, to a plurality of parametric
conditional values for an initial condition for a decision job in
each of the decision subprocesses, and storing the information on
the plurality of parametric conditional values and corresponding
standardized jobs into the storage section of the computer in the
form of computer-readable digital data; constructing a job flow to
allow the decision job in each of the decision subprocesses to be
executed under the support of the computer by setting up the
initial condition for the decision job as an input of the computer
in accordance with the digital data of the standardized jobs, and
storing the job flow into the storage section of the computer in
the form of computer-readable data; analyzing the plurality of
divided minimum unit subprocesses to detect and classify the
minimum unit subprocesses which are executable in accordance with
common input data, and storing the information on the classified
subprocesses into the storage section of the computer in the form
of computer-readable digital data; constructing a job flow to allow
the respective jobs in the plurality of subprocesses classified in
the analyzing step, which is executable in accordance with common
input data, to be simultaneously initiated and executed in parallel
under the support of the computer, and storing the job flow into
the storage section of the computer in the form of
computer-readable digital data; reading the data of the job flows
from the storage section of the computer and constructing a job
sequence for the unit subprocesses to create a job-support computer
program for allowing all of the subprocesses to be successively
executed under the support of the job-support computer program; and
entering the initial condition for the decision Job and processing
according to the job-support computer program to execute all of the
unit subprocesses to complete the process.
15. A method of constructing and executing a process comprising the
steps of: dividing the process into a plurality of unit
subprocesses consisting of one or more decision subprocesses
requiring to a decision-making for executing each ofjobs thereof
and one or more routine subprocesses executable according to a
predetermined procedure without any decision-making, and storing
the information on the divided subprocesses into a storage section
of a computer in the form of computer-readable data; combining one
or a series of the decision subprocesses with one or a series of
the routine subprocesses executable on the condition of the
completion of corresponding the decision subprocesses to form one
unit process, creating a job-support computer program to allow the
decision and routine subprocesses included in the one unit process
to be successively executed, so that the plurality of unit
processes can be executed in a predetermined sequential order under
the support of the computer, and storing the computer program into
the storage section of the computer; and operating the job-support
computer program whereby one of the unit process is executed under
the support of the job-support computer program and the unit
processes following on the executed unit process are executed under
the support of the job-support computer program to complete the
process.
16. A computer program product stored in a computer storage media
comprising a job-support computer program having a first
computer-readable data representing a process which is divided into
a plurality of unit subprocesses consisting of one or more decision
subprocesses requiring to set up an unknown condition in the
execution of each of jobs thereof and one or more routine
subprocesses executable according to a predetermined procedure
without any decision-making; and second computer-readable data
representing any subprocess which is executable using the setup
condition in specific one of the decision subprocesses, and
classified into the routine subprocess in such a manner that the
classified routine subprocess follows on the specific decision
subprocess, wherein one or a series of the decision subprocesses
are combined with one or a series of the routine subprocesses
executable on the condition of the completion of corresponding the
decision subprocesses to form one unit process, in accordance with
the first and second data, so as to allow the plurality of
subprocesses included in the one unit process to be successively
executed.
17. A computer program product stored in a computer storage media
comprising a job-support computer program having a first
computer-readable digital data representing a known process which
is divided into a plurality of minimum unit subprocesses, wherein
the plurality of divided minimum unit subprocesses are classified
into a decision subprocess requiring a decision-making for
executing a job therein and a routine subprocess which is
executable according to a predetermined procedure without any
decision-making; second computer-readable digital data representing
a plurality of parametric conditional values for an initial
condition for a decision job in each of the decision subprocesses,
and a plurality of standardized jobs corresponding, respectively,
to the plurality of conditional values; third computer-readable
digital data representing a job flow constructed to allow the
decision job in each of the decision subprocesses to be executed by
setting up the initial condition for the decision job in accordance
with the digital data of the standardized jobs; fourth
computer-readable digital data representing the minimum unit
subprocesses executable in accordance with common input data,
wherein the minimum unit subprocesses are extracted from the
plurality of divided minimum unit subprocesses and classified
through the analysis of the plurality of divided minimum unit
subprocesses; and fifth computer-readable digital data representing
a job flow constructed to allow the respective jobs in the
plurality of subprocesses which are executable in accordance with
common input data to be simultaneously initiated and executed in
parallel, wherein a job sequence for the unit subprocesses is
constructed in accordance with the fifth computer-readable digital
data representing the job flow to allow all of the subprocesses to
be successively executed.
18. A computer program product stored in a computer storage media
comprising a first computer-readable data representing a process
which is divided into a plurality of unit subprocesses consisting
of one or more decision subprocesses requiring a decision-making
for executing each of jobs thereof and one or more routine
subprocesses which are executable according to a predetermined
procedure without any decision-making, wherein one or a series of
the decision subprocesses are combined with one or a series of the
routine subprocesses which are executable on the condition of the
completion of corresponding the decision subprocesses to form one
unit process, to allow the decision and routine subprocesses
included in the one unit process to be successively executed, so
that the plurality of unit processes can be executed in a
predetermined sequential order.
19. The computer program product stored in a computer storage media
of claim 16 wherein the job-support computer program is configured
to provide a window for prompting a user to enter a condition
required for executing the decision subprocess on a screen of a
computer.
20. The computer program product stored in a computer storage media
of claim 17 wherein the job-support computer program is configured
to provide a window for prompting a user to enter a condition
required for executing the decision subprocess on a screen of a
computer.
21. The computer program product stored in a computer storage media
of claim 18 wherein the job-support computer program is configured
to provide a window for prompting a user to enter a condition
required for executing the decision subprocess on a screen of a
computer.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a method of constructing
and executing a process. The term "process" herein is not limited
to a production process as ordinary meaning, but has a broad
meaning including a design or engineering process, a management
process and any other general operation processes. The present
invention is directed to a process construction/execution method
capable of executing a process under the support of a computer with
significantly high efficiency to reduce the lead-time of the
process in its entirety.
BACKGROUND OF THE INVENTION
[0002] In various fields, a number of proposes and actual attempts
have been made to reduce the lead-time of a process. Conventional
techniques of lead-time reduction are intended to shorten or reduce
individual operations, tasks, jobs or subprocess constituting a
process, but not to reduce the lead-time through a technique of
reviewing the entire construction of a process to reorganize
subprocesses or cut useless subprocesses according to need. Thus,
the conventional process includes a number of hidden,
unrecognizable useless jobs. In fact, considerable jobs which could
otherwise be executed in parallel are executed in series, and
useless waiting or holding period involves between subprocesses. In
addition, the conventional process includes a number of decision
subprocesses requiring millions of parameters, and the
decision-making in each of such subprocesses generally relies on a
skilled specialist. The conventional process also has a problem of
including many similar subprocesses to be repeatedly executed.
Heretofore, it has not been achieved to effectively reduce the
entire process time due to no effective means for detecting such
problems.
SUMMARY OF THE INVENTION
[0003] It is a primary object of the present invention to organize
and reconstruct subprocesses constituting a process in their
entireties based on intensive analysis of a conventional process
execution method, to allow the lead-time of a process to be
drastically reduced as compared to the conventional methods.
[0004] It is another object of the present invention to provide a
method of constructing and executing a process, capable of
simplifying a decision job which has relied on a skilled person,
and drastically reducing the number of subprocesses requiring
decision-making as compared to the conventional methods.
[0005] It is still another object of the present invention to
thoroughly eliminate the unnecessary subprocesses in the
conventional process execution methods to provide a drastically
reduced process execution time.
[0006] In order to achieve the above objects, according to the
present invention, a process is classified into a decision
subprocess and a routine subprocess, depending on whether each of
subprocesses constituting the process requires decision-making. The
need for decision-making herein means the need for setting up
unknown condition in the execution of a job in the subprocess.
[0007] The process is segmentized into a number of minimum unit
subprocesses. In present invention, any subprocess executable using
a condition set up in specific one of the decision subprocesses is
classified into the routine subprocess in such a manner that the
classified routine subprocess follows on the specific decision
subprocess. By this method of process construction, the number of
the decision subprocesses can be reduced and the lead-time of the
entire process can be drastically short. The information of the
process is then stored into a storing section of a computer in the
form of computer-readable data. In accordance with these data, one
or a series of the decision subprocesses are combined with one or a
series of the routine subprocesses executable on the condition of
the completion of corresponding the decision subprocesses to form
one unit process, and a job-support computer program is created to
allow the plurality of subprocesses included in the one unit
process to be successively executed under the support of the
computer. An operator sets up a known condition as an input of the
computer under the support of the computer in the decision
subprocess, and operates to run the computer program, so as to
execute all of the routine subprocesses under the support of the
computer in accordance with the created computer program to
complete the process. The program may be configured to allow the
series of subprocesses to be successively executed, or to allow
each of the subprocesses to be individually executed according to
operator's operations.
[0008] The above minutely divided minimum unit subprocesses may
include office work such as making copies or transporting documents
from one department to another department. If any holding period
having no job exists between one minimum unit subprocess and
another minimum unit subprocess, such a holding period is also
checked. That is, it is also encompassed within the scope of the
present invention to extract useless jobs and construct the
computer program so as to cut or reduce the useless jobs. In
present invention, the minimum unit subprocesses are classified
into either routine subprocess executable without any
decision-making or decision subprocess requiring some
decision-making. Then each of the routine subprocesses is checked
whether it is essential to execute the process, and the subprocess
determined unnecessary is eliminated from the process. For the
decision subprocesses, a condition required for each of the
decision subprocesses is represented by an unknown variable value
or parameter, and the respective results of the different variable
values are expressed by a map or a table in the form of digital
data. Then, a job flow is constructed to allow the digital data to
be automatically read from the map or the like in response to an
input of a prerequisite, so as to execute a decision job in the
decision subprocess. Thus, the decision process, which would
otherwise require the decision-making of a skilled person in the
conventional process, can be more readily executed.
[0009] Further, a plurality of subprocesses executable in
accordance with common input data are detected from the minutely
divided minimum unit subprocesses, and a parallel-type job flow is
constructed to allow the respective jobs of the detected
subprocesses to be simultaneously initiated and executed in
parallel. Then, the decision subprocess and the routine subprocess
associated therewith are combined to form one unit process, and the
aforementioned job flow is incorporated therein to organize the
sequence of jobs in each of the unit processes. In this case, a
job-support program is created to allow all of the subprocesses to
be successively executed under the support of the computer.
According to this job-support program, all of the unit processes
can be successively executed without useless holding period, by
entering an initial condition of the decision job.
[0010] The above technical concept of the present invention can be
summarized as follows.
[0011] The first aspect of the present invention is a method of
executing a process using the following steps. (a) A process is
divided minutely into a plurality of unit subprocesses. These unit
subprocesses consist of one or more decision subprocesses and one
or more routine subprocesses. A decision subprocess requires
setting up an unknown condition in the execution of each of jobs
thereof. A routine subprocess is executable according to a
predetermined procedure and does not require any decision-making.
The information on those unit subprocesses is stored into a storage
section of a computer in the form of computer-readable data. (b)
Any subprocess which is executable using the setup condition on
specific one of the decision subprocesses is classified as the
routine subprocess of that specific decision subprocess. The
classified routine subprocess follows after the specific decision
subprocess. The information on the classified subprocesses is
stored into the storing section of the computer in the form of
computer-readable data. (c) One or a series of the decision
subprocesses is combined with one or a series of the routine
subprocesses which is executable upon the completion of those
decision subprocesses to form one unit process, using the data
produced in the steps (a) and (b). A job-support computer program
is created to allow the plurality of subprocesses included in one
unit process to be successively executed under the support of the
computer. The computer program is stored into the storing section
of the computer. (d) For the decision subprocesses, the unknown
condition is set up as an input data of the computer. Computer
program is executed, whereby all of the routine subprocesses
included in the one unit process are successively executed under
the support of the computer to complete the process. In this case,
when the job-support computer program is created in the above step
(c), the unit subprocesses executable in parallel may be specified
among the plurality of subprocesses consisting of the decision and
routine subprocesses. In addition, the job-support computer program
may be configured to organize the job sequence between the unit
subprocesses to allow the jobs in the specified unit subprocesses
to be executed in parallel, so that all of the unit subprocesses
can be successively executed.
[0012] The present invention is also intended to allow the
subprocess, which are otherwise classified into the decision
subprocess, to be handled as the routine subprocess requiring no
decision-making. As a result the number of the decision
subprocesses is reduced. In one specific embodiment of the present
invention, a single standardized condition is preset as a condition
for decision-making and the job-support computer program is
configured to display on the computer whether the standardized
condition is satisfied. In this way the subprocess otherwise being
classified into the decision subprocess can be handled as the
routine subprocess and the number of the decision subprocesses is
reduced. In another specific embodiment of the present invention,
one of the plurality of options which could otherwise be prepared
as a standardized condition is preset as the condition for
decision-making in at least one of the decision subprocesses, which
enables the subprocess otherwise being classified into the decision
subprocess to be handled as the routine subprocess and reduce the
number of the decision processes. Further, in the present
invention, input information required for initiating each
subprocess and output information to be created after the
completion of each subprocess may be specified. A job flow is
constructed such that one subprocess using the output information
of the specific subprocess as the input information successively
follows after that specific subprocess.
[0013] The second aspect of the present invention is a method of
executing a process using the following steps. (a) A process is
divided minutely into a plurality of unit subprocesses. These unit
subprocesses consist of one or more decision subprocesses and one
or more routine subprocesses. A decision subprocess requires
setting up an unknown condition in the execution of each of jobs
thereof. A routine subprocess is executable according to a
predetermined procedure and does not require any decision-making.
The information on those unit subprocesses is stored into a storage
section of a computer in the form of computer-readable data. (a) A
known process is divided minutely into a plurality of minimum unit
subprocesses. The plurality of those minimum unit subprocesses is
classified into a decision subprocess and a routine subprocess. A
decision subprocess requires a decision-making for executing a job
therein. A routine subprocess is executable according to a
predetermined procedure and does not require any decision-making.
Each of the plurality of routine subprocesses included in the known
process is verified whether it is essential for executing the
entire process. Only the routine subprocesses verified as essential
is selected and stored into a storage section of a computer in the
form of computer-readable digital data. (b) A plurality of standard
jobs is defined for a decision job in each of the decision
subprocesses. Each standard job has a plurality of parametric
conditional values for its initial condition. The information on
the plurality of parametric conditional values and corresponding
standardized jobs is stored into the storing section of the
computer in the form of digital data. (c) A job flow is constructed
to allow the decision job in each of the decision subprocesses to
be executed under the support of the computer by setting up the
initial condition for the decision job as an input of the computer
in accordance with the digital data of the standardized jobs. The
job flow is stored into the storing section of the computer in the
form of computer-readable data. (d) The minutely divided minimum
unit subprocesses is analyzed and the minimum unit subprocesses,
which are executable using common input data, are detected. The
information on the detected subprocesses is stored into the storing
section of the computer in the form of computer-readable digital
data. (e) A job flow is constructed to allow the respective jobs in
the plurality of subprocesses detected in the step (d), which is
executable using common input data, to be simultaneously initiated
and executed in parallel under the support of the computer. The job
flow is stored into the storing section of the computer in the form
of computer-readable digital data. (f) The system reads the data of
the job flows constructed in the steps (c) and (e), which include
the selected routine subprocesses in the step (a) and the decision
subprocesses, from the storage section of the computer. A job
sequence is constructed for the unit subprocesses to create a
job-support computer program for allowing all of the subprocesses
to be successively executed under the support of the computer. The
computer program is stored into the storing section of the
computer. (g) A user enters the initial condition for the decision
job and the system runs the computer according to the program so as
to execute all of the unit subprocesses under the support of the
compute to complete the process.
[0014] The third aspect of the present invention is a method of
executing a process using the following steps. (a) A process is
divided minutely into a plurality of unit subprocesses. These unit
subprocesses consist of one or more decision subprocesses and one
or more routine subprocesses. A decision subprocess requires
setting up an unknown condition in the execution of each of jobs
thereof. A routine subprocess is executable according to a
predetermined procedure and does not require any decision-making.
The information on those unit subprocesses is stored into a storage
section of a computer in the form of computer-readable data. (b)
One or a series of the decision subprocesses is combined with one
or a series of the routine subprocesses, which are executable on
the condition of the completion of corresponding the decision
subprocesses, to form one unit process. A job-support computer
program is created to allow the decision and routine subprocesses
included in the one unit process to be successively executed, so
that the plurality of unit processes can be executed in a
predetermined sequential order under the support of the compute.
The computer program is stored into the storing section of the
computer. (d) The system runs the computer according to the
program, whereby one of the unit subprocesses is executed under the
support of the computer. The unit subprocesses following on the
executed unit process are executed under the support of the
computer according to the program in the same way to complete the
process.
[0015] The present invention also provides a computer program for
executing the above method. The fourth aspect of the present
invention is a job-support computer program using the following
data. (a) Computer-readable data representing a process which is
minutely divided into a plurality of unit subprocesses consisting
of one or more decision subprocesses and one or more routine
subprocesses. A decision subprocess requires an unknown condition
in the execution of each of jobs thereof. A routine subprocesses is
executable according to a predetermined procedure and does not
require any decision-making. (b) Computer-readable data
representing any subprocess, which is executable using the setup
condition in specific one of the decision subprocesses, classified
into the routine subprocess. The classified routine subprocess
follows on the specific decision subprocess. Using the data in a)
and b), one or a series of the decision subprocesses are combined
with one or a series of the routine subprocesses, which are
executable on the condition of the completion of corresponding
decision subprocesses, to form one unit process. The plurality of
subprocesses included in the one unit process is successively
executed.
[0016] The fifth aspect of the present invention is a job-support
computer program using the following data. (a) Computer-readable
digital data representing a known process which is minutely divided
into a plurality of minimum unit subprocesses consisting of one or
more decision subprocesses and one or more routine subprocesses. A
decision subprocess requires an unknown condition in the execution
of each of jobs thereof. A routine subprocesses is executable
according to a predetermined procedure and does not require any
decision-making. (b) Computer-readable digital data representing a
plurality of parametric conditional values for an initial condition
for a decision job in each of the decision subprocesses. A
plurality of standard jobs corresponds to the plurality of
conditional values. (c) Computer-readable digital data representing
a job flow constructed to allow the decision job in each of the
decision subprocesses to be executed by setting up the initial
condition for the decision job in accordance with the digital data
of the standard jobs. (d) Computer-readable digital data
representing the minimum unit subprocesses which are executable in
accordance with common input data. Such minimum unit subprocesses
are detected through the analysis of the plurality of minutely
divided minimum unit subprocesses. (e) Computer-readable digital
data representing a job flow constructed to allow the respective
jobs in the plurality of subprocesses executable in accordance with
common input data to be simultaneously initiated and executed in
parallel. Using the data of (a), (b), (c), (d) and (e), a job
sequence for the unit subprocesses is constructed to allow all of
the subprocesses to be successively executed.
[0017] The sixth aspect of the present invention is a job-support
computer program using the following data. (a) Computer-readable
data representing a process which is minutely divided into a
plurality of minimum unit subprocesses consisting of one or more
decision subprocesses and one or more routine subprocesses. A
decision subprocess requires an unknown condition in the execution
of each of jobs thereof. A routine subprocesses is executable
according to a predetermined procedure and does not require any
decision-making. One or a series of the decision subprocesses are
combined with one or a series of the routine subprocesses which are
executable on the condition of the completion of corresponding the
decision subprocesses to form one unit process. The decision and
routine subprocesses included in the one unit process are
successively executed. The plurality of unit processes can be
executed in a predetermined sequential order.
[0018] The above job-support computer program may be configured to
provide a window for prompting a user to enter a condition required
for executing the decision subprocess, on the screen of the
computer.
[0019] Further, the present invention provides a method of
executing the aforementioned job-support computer program on a
computer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1A is an exemplary flowchart showing a process
execution method according to one embodiment of the present
invention.
[0021] FIG. 1B is a flowchart showing steps following on the steps
of FIG. 1A.
[0022] FIG. 2 is exemplary diagrams showing maps A, B and C for use
in computing in the embodiment of FIG. 1.
[0023] FIG. 3 is diagrams showing the method of minutely dividing a
conventional process in another embodiment of the present
invention, wherein FIG. 3A shows the conventional process, and FIG.
3B shows the minutely divided subprecesses.
[0024] FIG. 4 is diagram showing one example of an improved process
according to the present invention, wherein FIG. 4A shows a reduced
number of subprocesses achieved through standardization and
automatization, and FIG. 4B shows a reduced process lead-time
achieved by executing some subprocesses in parallel.
[0025] FIG. 5 is a process chart showing a die design process,
wherein the process is divided into a plurality subprocesses, and
each progress of the subprocesses is illustrated along the time
axis.
[0026] FIG. 6 is a diagram showing the link between
subprocesses.
[0027] FIG. 7 is a perspective view of a front case of a cell phone
as one example of a product to be molded with a die assembly
produced by applying the present invention.
[0028] FIG. 8 is a perspective view showing a designing depression
and protrusion of upper and lower dies after a die separation
subprocess in the die design process.
[0029] FIG. 9 is a perspective view showing an upper die block in
its fixing subprocess.
[0030] FIG. 10 is a perspective view showing a lower die block in
its fixing subprocess.
[0031] FIG. 11 is a schematic sectional view showing a slider.
[0032] FIG. 12 is a perspective view showing one example of a
slider unit.
[0033] FIG. 13 is a side view of the slider unit.
[0034] FIG. 14 is a perspective view showing the slider unit
arranged to the lower die block.
[0035] FIG. 15 is a sectional view of the die assembly having the
slider unit attached thereto.
[0036] FIG. 16 is a schematic sectional view showing a lifter or
spring core.
[0037] FIG. 17 is an explanatory perspective view of a subprocess
for creating numerical control data.
[0038] FIG. 18 is a top plan view of a die block shown in FIG.
17.
[0039] FIG. 19 is a sectional view of the die assembly.
[0040] FIG. 20 is an explanatory perspective view of a subprocess
for correcting product data in the die design process.
[0041] FIG. 21 is a perspective view showing a subprocess for
placing product data and adding the shrinkage.
[0042] FIG. 22 is top plan views showing the type and the location
of gates, wherein FIG. 22 A shows a side gate, and FIG. 22 B shows
a direct gate.
[0043] FIG. 23 is a schematic top plan view showing the product
data placed in the die block.
[0044] FIG. 24 is a sectional view showing the allowable range for
placing the lifter or spring core.
[0045] FIG. 25 is schematic sectional views showing the formation
of a parting surface at an aperture or other openings, wherein FIG.
25A show the formation of a parting surface at an opening such as
button apertures, and FIG. 25B shows the formation of a parting
surface at a stepped portion.
[0046] FIG. 26 is a sectional view showing upper and lower dies
matched together.
[0047] FIG. 27 is diagrams showing one example of standard
gate.
[0048] FIG. 28A is diagrams showing one example of a standard
slider material.
[0049] FIG. 28B is diagrams showing one example of a standard
lifter.
[0050] FIG. 28C is diagrams showing one example of a table for
fixing the dimensions of a lifter.
[0051] FIG. 29 is a schematic diagram showing a job distribution
system in one embodiment of the present invention.
[0052] FIG. 30A is a flowchart showing a login process in the
system of FIG. 29.
[0053] FIG. 30B is a flowchart showing a data correction
sprocess.
[0054] FIG. 30C is a flowchart showing a layout process.
[0055] FIG. 30D is a flowchart following on FIG. 30C.
[0056] FIG. 30E is an enlarged view of a system interface shown in
the flowchart of FIG. 30A.
[0057] FIG. 30F is an enlarged view of a system interface shown in
the upper position of the flowchart of FIG. 30B.
[0058] FIG. 30G is an enlarged view of a system interface shown in
the middle position of the flowchart of FIG. 30B.
[0059] FIG. 30H is an enlarged view of a system interface shown in
the lower position of the flowchart of FIG. 30B.
[0060] FIG. 30I is an enlarged view of a system interface shown in
the upper position of the flowchart of FIG. 30C.
[0061] FIG. 30J is an enlarged view of a system interface shown in
the middle position of the flowchart of FIG. 30C.
[0062] FIG. 30K is an enlarged view of a system interface shown in
the lower position of the flowchart of FIG. 30C.
[0063] FIG. 30L is an enlarged view of a system interface shown in
the flowchart of FIG. 30D.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0064] with reference to the drawings, various embodiments of the
present invention will now be described. FIGS. 1A and 1B are
flowcharts showing a process for production cost estimation of a
stereolithography model. Stereolithography is a technique of
molding a 3-dimensional object analogous to an intended product by
exposing resin to a light according to the product data. The light
is sequentially irradiated on each of layers defined by slicing the
3-dimensional shape of the product along its height direction at
given intervals. A vertically movable support plate is provided in
a vessel containing resin. A first resin layer located at the level
in the vessel is first exposed to the light. After the support
plate moves downward by a distance equal to the thickness of one
layer, the second resin layer is exposed to the light.
Subsequently, the support plate moves downward to expose each of
the layers corresponding to the 3-dimensional shape of the product.
When the support plate moves downward by the distance equal to the
thickness of one layer after the completion of the first exposure,
a recoat operation is performed to supply a liquid resin on the
support plate at an amount required for forming one resin
layer.
[0065] A production method for such stereolithography products is
disclosed in detail, for example, in Japanese Patent Laid-Open
Publication Nos. S56-144478 and H03-246025 and U.S. Pat. No.
4,575,330. Heretofore, in a process of preparing a cost-estimation
in response to a production request for a stereolithography model,
all of cost-estimation data, such as the amount of resin to be used
in the production of the optical modeling product and a man-hour
required for the modeling, have been calculated based on predictive
values made by an experienced personnel according to related
drawings. Such a cost-estimation, however, relies almost
exclusively on the experiences and intuitions of the personnel, and
the preparation of a written estimate can be seriously delayed due
to the absence of a personnel responsible for the
cost-estimation.
[0066] In one embodiment of the present invention as shown in FIG.
1, a cost-estimation process for production of stereo lithography
models can be accurately executed through a simple operation of a
computer without relying upon experienced persons as in the
conventional process. Data in each of steps of a process as shown
in FIGS. 1A and 1B are stored in a storage section of a computer in
the form of computer-readable digital data. Process or job flow for
executing the process is also stored in the storage section of the
computer as a job-support computer program.
[0067] In this embodiment, as shown by Step S1 in FIG. 1A,
product-design data is first entered into the computer in the form
of digital data. The product-design data can be created using
appropriate software of a 3-dimensional CAD system.
At Step S2, the volume V, surface area S, projected area P in top
plan view and height h of the rapid prototyping model (RP model)
are computed by the computer. At Step S3, the number of RP models
to be produced is read out. For example, if the modeling product is
a container composed of a case body and a cover, the number of
models will be calculated as two. The number of models can be read
from the product-design digital data.
[0068] At Step S4, a data-processing time of the product-design
data is calculated in accordance with the number of models which
has been read out at Step S3. This calculation is executed using a
map A in FIG. 2 which is created according to a standardization
concept of the present invention. As seen in the map A of FIG. 2,
the data-processing man-hour is standardized. Specifically, it is 2
hours for one or two components, and 1 hour/component for three or
more components. The number of components has been entered as input
data at Step S1, and the computer executes the calculation in
accordance with the input data and the map A. After reading out the
data-processing man-hour, the data-processing cost is computed
according to the following computing expression in Step 5.
Data-processing cost=basic charge+(data-processing
man-hour.times.labor charge) Formula (I)
[0069] In this expression, the basic charge is a predetermined
value independent of the number of components of a modeling
product, and the labor charge is a labor charge/hour which is also
a predetermined value. In this way, the calculation is standardized
in order to determine the data-processing time of product-design
data in accordance with the number of components of a modeling
product. Thus, any person capable of operating a computer can
calculate the data-processing time.
[0070] At Step S6, the volume V of the modeling product is read
out. Based on the volume V of the modeling product, a material cost
of the modeling product is determined through computing at Step S7.
This computing is executed according to the following computing
expressions II-(1) and II-(2) in a two-step manner.
Material weight(W)=volume(V).times.specific
gravity.times.coefficient a Formula (II-1)
Material cost=material weight(W).times.price/unit weight Formula
(II-2)
[0071] This calculation is also standardized in order to determine
the material cost using the predetermined expressions in accordance
with the volume V of the modeling product calculated from the
product-design digital data. Thus, any person capable of operating
a computer can execute this calculation.
[0072] The process then skips to FIG, 1B, where the projected area
P from the top view of the modeling product is read out at Step S8.
The projected area P is obtained from the product-design data which
has been entered at Step S1. Then, a designated specification of
the modeling product is read out at Step S9. The designated
specification relates to customer's designations concerning the
finishing level of the optical modeling product, and is entered
into the computer in advance as a designated condition at Step S1.
Then, a recoat time t.sub.1/layer associated with exposure is
determined through computing at Step S10. The recoat operation in
the production of stereo lithography models can be understood in
reference to the aforementioned patent publications.
[0073] A map B as shown in FIG. 2 is prepared to compute the recoat
time. The recoat time/layer is determined in accordance with the
projected area which has been obtained at Step S8. In the map B,
the column represented as "trap" and "quick cast" relates to the
designated specification which has been read at Step S9, and is one
of the initial conditions based on customer's designations. The
recoat time t.sub.1/layer consists of a basic part and an
area-associated part. The area-associated part is read from the map
B, and added to the basic time depending on the designated
specification. Then, an exposure time/layer or laser irradiation
time t.sub.2/layer is computed at Step S11. This laser irradiation
time t.sub.2 is also computed using the map B. The computing at
these Steps S10 and S11 can be executed in accordance with the same
data, or the projected area V and the designated specification.
Thus, these Steps S10 and S11 may be concurrently executed. While
the advantage of concurrently executing the Steps S10 and S11 is
small in this embodiment because both Steps can be executed without
taking a particularly long time, a process time can be reduced
drastically in some cases.
[0074] Then, at Step S12, the height h of the modeling product is
read out. Based on the height h of the modeling product at Step S
12, the number n of layers is computed at Step S 13. The following
computing expression III is used in this computing.
n=(h+H)/b Formula (III)
[0075] In this expression, H is the thickness of a support portion
to be formed in the bottom of the modeling product. Generally, in
the production of stereo lithography models, the support portion is
designed to have a thickness of about 10 mm. In the above
expression, b is the thickness of one layer. Then, at Step S 14, a
modeling time T is computed. This computing is executed using the
following computing expression IV.
T=(t.sub.1+t.sub.2)n Formula (IV)
[0076] The process proceeds to Step S15 to compute an optical
modeling cost. This computing is executed using the following
computing expression V.
Optical modeling cost=modeling time T.times.unit cost/hour Formula
(V)
[0077] Then, the process proceeds to Step S16 to calculate a
man-hour t.sub.3 of a finishing subprocess. This computing is
executed according to the following computing expression VI.
t.sub.3=finishing man-hour+2 hours Formula (VI)
[0078] The breakdown of the finishing man-hour calculation is shown
as follows.
[0079] Finishing Man-Hour
TABLE-US-00001 1. Cleaning 30 minutes 2. Removal of n .times. 10
minutes .times. 0.5 (in case of 10 to 200 square) Support n .times.
10 minutes .times. 1.5 (in case of 200 or more square) 3. Post-Cure
60 minutes (in case of 10 to 200 square) 90 minutes (in case of 200
or more square) 4. Surface surface area .times. finishing level
Finishing (Polishing)
[0080] The finishing is divided into 5-levels A, B, C, D and E.
According to a finishing level table as shown by a map C in FIG. 2,
the finishing man-hour is determined depending on the surface area
to be finished.
[0081] The results obtained from the above calculation steps can be
put together to provide the production cost estimation of the
optical modeling product. According to this embodiment of the
present invention, an estimation job, which heretofore has relied
on the experiences and intuitions of a skilled person, can be
standardized, and more quickly executed than ever before. In
particular, the subprocess requiring decision-making is
standardized to allow the estimate to be prepared without relying
on any skilled person.
[0082] FIG. 3 shows another embodiment of the present invention.
FIG. 3A is a diagram simply showing a conventional method of
executing a process consisting of a series of jobs: a job A
executed by a worker, a job B executed by a machine, a job C
executed by a worker and a job D executed by a machine. FIG. 3B is
a diagram, corresponding to FIG. 3A, showing the result of minutely
subdividing each of the jobs in the process of FIG. 3A into a
plurality of minimum unit subprocess according to the concept of
the present invention. The minutely divided units are classified
into a routine subprocess executable without any decision-making,
and a decision subprocess requiring decision-making for executing a
job therein. For example, a job such that a clerical assistant
sends a received document to a predetermined user belongs to the
routine process.
[0083] An example of the process shown in FIG. 3 includes an
injection molding process for producing a plastic product using a
die assembly. In such a production process, a die design is first
executed. The job A corresponds to the die design process in this
case. The job A starts with receiving a job instruction, and
product data such as product drawings or product instructions. The
job instruction and these product data are given to a die-design
planner (subprocess a) through a clerical person. The die-design
planner prepares a die design plan (subprocess b). Then, the die
design plan is delivered to a die design engineer (subprocess c),
and the die design is executed by the die design engineer
(subprocess d). For approval, a prepared die design is delivered to
an immediate supervisor of the die design engineer through a
clerical person (subprocess e). If the immediate supervisor is out
of his/her office or is pressed by another job, a certain holding
period (g) is generated before the approval (subprocess f). After
the approval of the immediate supervisor of the die design
engineer, the die design is delivers to an upper supervisor to
obtain his/her approval (subprocess h). In this subprocess, it is
highly possible that another holding period (j) is also generated
before the approval (subprocess i).
[0084] The job B corresponds to a die production process. This job
includes a subprocess of obtaining a material or preparing a
machining center, a subprocess of setting the material to the
machining center, a subprocess of processing/polishing a die and
others. Since the arrangement of the material is generally
initiated after receiving the die design data, a temporal blank is
generated between the completion of the job A and the initiation of
the job B. In addition, the timing of finalizing the die assembly
will be delayed due to the above procedure of initiating the
arrangement of the material after receiving the die design
data.
[0085] In the jobs C and D, a plastic product is injection-molded
using the die assembly created in process B. The job C includes
various preliminary jobs to be manually executed. The job D is a
molding job to be executed using an injection molding apparatus.
These jobs also include a certain holding period (k), and actually
include some useless jobs.
[0086] FIG. 4 shows an improved process according to the present
invention. In this process, all data for design and production are
stored in a storage section of a central processing unit 10 in the
form of computer-readable digital data, and effectively utilized in
each of subprocesses. The data stored in the storage section of the
central processing unit 10 can be accessed from any one of terminal
devices 11 connected with the central processing unit 10.
[0087] FIG. 4A shows a process in which the number of subprocesses
thereof is reduced as the result of standardization and
automatization. In die design, product-design data is prepared by a
3-dimensional CAD in the form of digital data, and the die design
is executed using this product design data. Components used in a
die assembly, such as sliders or inserts, are standardized to allow
predetermined components to be selected in accordance with the
dimensions and shape of an intended product. This technique is
described in detail in Japanese Patent Application No. 2000-396690,
and the technical content described in this patent application may
be applied directly to the present invention. If the technique of
the die design using the 3-dimensional digital data is applied to
the present invention, the supervisor's approval as in the job B of
FIG. 3A is seldom or never required. In a die production process,
without relying on an electric discharge machining process, a
highly accurate processing has been realized according to a
technique developed by the applicant, as described in the above
patent application, and thus the number of subprocesses in the job
B can be reduced.
[0088] FIG. 4A shows that the entire process time is further
shortened according to the present invention. For example, between
the jobs A and B, the arrangement of the material required in the
job B can be executed before the completion of the job B. Further,
as shown by m, n and o in FIG. 4B, the design of sliders or inserts
can be executed in parallel with the job A even before the
completion of the job A. Between the jobs B and C, a part of
subprocesses in the job C can be initiated before the completion of
the job B, as shown by p and q in FIG. 4B. In the same manner,
between the jobs C and D, a part of subprocesses in the job D can
be initiated before the completion of the job C, as shown by r, s
and t in FIG. 4B.
[0089] In order to allow the subprocesses r, s and t in the job D
to be initiated before the completion of all subprocesses included
in the job C, in this embodiment of the present invention, input
information required for initiating the job and output information
to be created after the completion of the job are specified to
construct a job flow such that one subprocess included in the job
D, e.g, the subprocess r, s, t, requiring the output information
from another subprocesses included in the job C, e.g. the
subprocess q, as the input information for initiating the job in
the subprocess r, s, t can be initiated any time after the
completion of the subprocess q. The job flow is stored in the
storage section of the computer in the form of computer-readable
digital data.
[0090] This point will be described in more detail later in
connection with another embodiment.
[0091] As mentioned above in detail, according to the present
invention, based on intensive analysis of a conventional process
execution method, the subprocesses constituting a process can be
reconstructed to allow the subprocesses to be fully automatically
executed in their entireties. Further, based on intensive
standardization, the present invention can provide a process
execution method capable of thoroughly eliminating the need for
decision-making of skilled persons. Furthermore, according to the
present invention, any useless subprocess in the conventional
process execution method can be intensively eliminated to provide a
drastically reduced process time.
[0092] FIG. 5 is a process chart showing a design stage of a die
assembly for use in injection-molding a plastic product. This
process chart can be regarded as the process in FIG. 4B applied to
an actual die design process. The horizontal axis of the process
chart represents a lapsed time (5 minutes/scale mark) expended by
jobs
[0093] The process chart in FIG. 5 includes unique marks attached
to respective subprocesses divided into P1 to P15. More
specifically, when a prerequisite is satisfied, the job in a
routine subprocess requiring no decision-making can be executed
regardless of the level of skill by following a predetermined
procedure. For this type of subprocess, a triangle "GO" symbol is
attached at a time point of initiating the subprocess, and a
crossbar having a length corresponding to a standard subprocess
time is described after the triangle. A flag mark indicating the
completion of the subprocess is also attached at a position where
the standard subprocess time lapses or the job in the subprocess is
completed. In this subprocess, a computer program is constructed
such that the job in the subprocess can be initiated by clicking an
execution button on a computer screen after a condition of
initiating the subprocess is satisfied, and subsequently the job
can be executed by performing given operations according to
instructions appearing on the computer screen.
[0094] In FIG. 5, for a decision subprocess requiring
decision-making, a diamond mark indicating the decision subprocess
is attached at a position where the subprocess is initiated. This
decision subprocess includes a job of making a decision on all
factors from beginning in accordance with experiences or knowledge,
or a job of selecting optimal one from several options in
accordance with experiences or knowledge. This job is executed
through a user's operation on the computer screen of one of the
terminal devices. A final decision subprocesses is a final check
subprocess for deciding whether the process should be advanced to
the next process, and required to make a most important decision.
Thus, a thickly outlined diamond mark is attached to this
subprocess. This job is also executed through a user's operation on
the computer screen of one of the terminal devices.
[0095] In this process chart, the subprocesses represented with the
different marks depending on the classifications of job makes it
easy to distinguish between the routine and decision subprocesses.
In addition, the ratio of the decision subprocesses to the entire
process can be recognized at a glance, and used as a guideline for
further improving the process.
[0096] In the die design process shown in FIG. 5, the subprocesses
P1 to P4 are in a simple preliminary stage, and required to make no
decision. The subsequent "Fix Layout" subprocess P5 and other
subprocesses include authentic design jobs. The "Fix Layout"
subprocess P5 which requires decision includes a job of determining
the position of the product data in a die block, and a parting line
PL or parting surface. A routine process, "Create Parting Surfaces"
subprocess P6 and "Separate Upper and Lower Dies" subprocess P7
follow on the subprocess P5. These subprocesses P6 and P7 can be
executed as a simple job successively after the completion of the
"Fix Layout" subprocess P5 which is a decision subprocess. In the
present invention, the decision subprocess and the routine process
executable in response to or on the condition of the completion of
the decision process are defined as one unit process. That is,
(one or a series of decision processes)+(one or a series of routine
processes)=one unit process
[0097] The data for the unit processes are stored in the storage
section of the computer in the form of computer-readable digital
data.
[0098] In the above description, all of the information data
related to subprocesses are stored in the storage section of the
central processing unit 10 of the computer in the form of
computer-readable digital data, and a job-support program for
executing the subprocesses under the support of the computer is
constructed and stored in the storage section of the central
processing unit 10.
[0099] FIG. 6 shows the linkage between the subprocesses P5 and P6
constituting one unit process. A certain rule is necessary to link
these subprocesses with one another Upon completing the subprocess
P5, data of parting line PL is generated as output information. The
computer will retrieve subprocess requiring this output information
as its input information, which in this case is "Create Parting
Surfaces" subprocess P6. In this way, the "Fix Layout" subprocess
P5 is liked to the "Create Parting Surfaces" subprocess P6 using
the output information parting line generated upon the completion
of the "Fix Layout" subprocess P5.
[0100] The "Separate Upper and Lower Die" subprocess P7 is executed
by using output information from the "Create Parting Surfaces"
subprocess P6 as input information, Upon completing in subprocess
P7, die separation data representing that the upper/lower dies are
separated from one another is generated as output information.
Then, based on this output information, an upper-die design process
A and a lower die design process B are registered in the computer
as individual processes, and the processes A and B will be executed
in parallel separately.
[0101] In FIG. 5, the subprocess P8 and subsequent subprocesses are
provided to execute jobs for designing one of the upper or lower
dies, and the corresponding jobs for the other die are executed in
the same manner.
[0102] The decision subprocesses comprising a "Fix Gate/Spool
Position" subprocess P8, a "Fix Runner Channel/Curvature-radius"
subprocess P9, a "Fix Seeve Pin Position" subprocess P10 and a
"Choose Slider Type (Stroke)" subprocess P11 follows on the
subprocess P7. Given that these decision subprocesses are defined
as the aforementioned one or a series of the decision subprocesses,
a series of routine subprocesses consisting of a "Create Sliders"
subprocess P12, a "Create Lifters" subprocess P13 and a "Create
Inserts" subprocess P14 will follow on the above one or a series of
decision subprocesses in conjunction therewith. The combination of
these subprocesses P8, P9, P10, P11, P12, P13 and P14 can be
regarded as one unit process.
[0103] Before describing the present invention in more detail with
reference to FIG. 5, a conventional die design/production process
will be described in connection with a die assembly for use in
molding an outer case of a cell phone, for developing a better
understanding.
[0104] FIG. 7 is a perspective view showing a shape of a front case
1 of a cell phone. A case of the cell phone comprises the front
case 1 as shown in FIG. 7, and a rear case (not shown) to be fitted
to the front case 1. Design digital data representing the shapes of
the front case 1 and the rear case are created by a 3-dimensional
CAD. A currently widely used 3-dimensional CAD includes CATIA, UG,
Pro/E and I-DEAS, all of which can be used in designing the case of
the cell phone. As shown in FIG. 7, the front case 1 includes a
window hole 2 for attaching a liquid-crystal display screen
therethrough, a hole 3 for fitting number keys, buttons, and a hole
4 for another operational button, on the side of the front surface
thereof. While not clearly shown in FIG. 7, an opening is formed in
the sidewall of the front case 1 in its lateral direction. A number
of protrusions and ribs are formed on the rear surface of the front
case to create several undercut portions which will interfere in
releasing the injection-molded front case 1 from the dies.
[0105] The 3-dimensional shape of the front case 1 as shown in FIG.
7 can be displayed on the computer screen in accordance with the
design digital data.
[0106] In a die design process, the first subprocess comprises
fixing the parting surface between upper and lower dies. The
parting surfaces are typically set along a line connecting points
which protrude most outward in the external profile of a
product.
[0107] The position of the parting surfaces can be defined as
coordinates by arranging the x-axis, y-axis and z-axis in the
longitudinal, lateral and vertical directions of the product,
respectively, and plotting the points which are located on the
external surface of the product crossing the parting surface.
[0108] The parting surfaces can be displayed with a particular
color, such as red, as one alternative of the parting line PL on
the surface of the product in a screen image. Only a part of one
example of the parting lines is indicated by a two-dot chain line
in FIG. 7.
[0109] While the parting line PL in FIG. 7 is depicted apart from
the product to avoid graphical complication, the actual parting
line is located on the surface of the 3-dimensional image
representing the product displayed on the computer screen. A
computer program for fixing the parting surface may be configured
to display not only one but also multiple alternatives of the
parting surface.
[0110] FIG. 8 is a perspective view showing the respective shapes
of molding surfaces to be formed in upper and lower dies after the
parting line is fixed. In FIG. 8, the front case 1 as a product is
shown at the center thereof a depression 5 defining the molding
surface of the upper die being shown above the front case 1, and a
protrusion 6 defining the molding surface of the lower die being
shown below the front case 1. When the upper and lower dies are
closed, the depression 5 of the upper die and the protrusion 6 of
the lower die will define a molding cavity therebetween.
[0111] FIG. 9 shows the depression 5 with an upper die block 7
superimposed thereon. FIG. 10 shows the protrusion 6 with a lower
die block 8 superimposed thereon. If a portion of the front case,
such as a hole formed in the sidewall thereof, has a shape
interfering in releasing the molded front case from the dies, it is
required to arrange a slider at a position of such a portion. FIG.
11 shows a concept of the slider. In FIG. 11, a molding cavity 9 is
defined between the depression 5 of the upper die block 7 and the
protrusion 6 of the lower die block 8, and a molten plastic
injected into the molding cavity 9 is cooled and solidified to form
a product. If it is necessary to form a hole 10 in the sidewall of
the product, a slider 11 will be arranged in such a manner that it
slides in a direction of an arrow in FIG. 11. The front end of the
slider 11 is a core 11a forming the hole, which protrudes into the
molding cavity 9. After the product is cooled and solidified, the
upper die block 7 slides upward, and the slider 11 moves in a
direction getting away from the molding cavity, so as to allow the
product to be taken out of the die assembly.
[0112] For example, the slider may be designed as a slider unit 12
as shown in FIGS. 12 and 13. In FIG. 12, the slider unit 12
includes a slider guide 13 to be fixed to the lower die block B.
The slider unit 12 is provided with a movable member 14 which is
guided along a guide groove 13a formed in the slider guide 13 and
slides in a direction of an arrow in FIG. 12, and the slider 11 is
detachably attached at the front end of the movable member 14. The
front end of the slider 11 is formed with a forming core 11 having
a desired shape. In addition, the slider unit 12 includes a locking
block 15 to be fixed to the upper die block 7. As clearly shown in
FIG. 13, the locking block 15 has an inclined cam groove 15a having
an opening facing downward. The cam groove 15a extends downward to
get away from the front end of the slider 11. The upper surface of
the movable member 14 is formed with an inclined cam-follower
member 14a to be engaged with the cam groove 15a of the locking
block 15.
[0113] Thus, in a position where the upper die block 7 is matched
with the lower die block 8, the movable member 14 and the slider 11
are pushed toward the molding cavity 9 to allow the forming core
11a at the front end of the slider 11 to be inserted into a desired
position in the molding cavity 9. When the upper die block 7 is
moved upward, the movable member 14 and the slider 11 move in the
direction getting away from the molding cavity to allow the forming
core 11a to get out of the molding cavity.
[0114] FIG. 14 shows the slider unit 12 which is arranged at a
desired position of the lower die block 8 in the die assembly for
molding the cell phone front case 1 as shown in FIG. 7.
[0115] FIG. 15 is a sectional view showing the die assembly having
the slider unit 12 placed therein.
[0116] A lifter or a forming core similar thereto is arranged at a
position of the die assembly corresponding to an undercut portion
of the product. FIG. 16 is a schematic sectional view showing one
example of a lifter. A molding cavity 9 is defined between a
molding depression 5 of an upper die block 7 and a molding
protrusion 6 of a lower die block 8. In some cases, it is necessary
to form an undercut portion 18 in a product to be obtained by
cooling and solidifying molten plastic filled in the molding cavity
9. If it is left without any treatment, the undercut portion 18
will interfere in releasing the molded product from the die blocks.
A lifter 20 as shown in FIG. 16 is one of measures against this
problem. The lifter 20 includes an elongate rod-shaped core member
19 which has a protrusion 19a with a shape corresponding to that of
an undercut portion 18, and a molding surface 19b around the
protrusion.
[0117] The lower die block 8 has a guide surface 21 located at a
position corresponding the lifter 20 to extend upward with an
inclination in the inward direction of the lower die block. The
rear surface of the lifter 20 is disposed along the guide surface
21 of the lower die block 8.
[0118] A movable plate 22 is disposed below the lower die block 8.
The movable plate 22 is adapted to move vertically while leaving a
certain vertical distance relative to the lower die block 8. The
lower end of the core member 19 is coupled with the movable plate
22 through a pivot pin.
[0119] In FIG. 16 the die assembly is closed. After a molten
plastic material injected into the molding cavity 9 is cooled and
solidified, a resulting molded product is released from the die
blocks. For this releasing operation, an ejector pin 23 is attached
to the movable plate 22. In the releasing operation, the lower die
block 8 moves downward. This movement allows the movable plate 22
to move upward relative to the lower die block 8. Thus, the molded
product is pushed upward relative to the lower die block 8 by the
ejector pin 23, and released from the molding cavity 6 of the lower
die block 8. During this operation, the core member 19 of the
lifter 20 also moves upward relative to the lower die block 8,
together with the molded product. Since the core member 19 moves
along the guide surface 21 of the lower die block 8, the protrusion
19a and the molding surface 19a of the core member 19 move away
from the molded product in the inward direction, so that the molded
product can be completely released from the die assembly.
[0120] In FIG. 14, the reference numeral 24 indicates a position
where the lifter 20 is placed.
[0121] It is necessary to arrange the ejector pin indicated by the
reference numeral 23 in FIG. 16 at multiple positions in the molded
product. In consideration of the shape of the molded product, the
ejector pin is preferably arranged to push a region of the molded
product having high rigidity. While a number of ejector pins are
actually arranged for the molding product as shown in FIG. 7 in
consideration of its shape, only four ejector pins 23 among them
are shown in FIG. 7.
[0122] After the completion of the designs of the upper and lower
die blocks 7, 8, and the insert cores including the sliders and
lifters, it is necessary to create NC data or numerical control
data for defining a tool path to perform a cutting operation in
accordance with design data created in the above design processes.
FIGS. 17 and 18 are schematic diagrams showing one example of a
subprocess for creating numerical control data for cutting an upper
die block for molding a product which is different from but
substantially equivalent to the cell phone front case as shown in
FIG. 7. In FIG. 17, each of thin lines is a contour line
representing a region having the same height. The surface of the
die block is first cut up to two contour lines 26 corresponding to
the highest region indicated by a one-dot chain line. This cutting
operation can be achieved by appropriately setting the two-way path
of a cutting tool. As a first step, the numerical control data is
created to define this two-way path of the cutting tool. Then, the
path of the cutting tool is controlled to provide the die block
surface smoothly continuing from the contour lines 26 to a contour
line 27 adjacent thereto, and then to shift toward an adjacent
contour line sequentially so as to cut the die block surface. The
numerical control data is create to define the path of the cutting
tool in this way, and stored in the form of digital data.
[0123] The created numerical control data for a cutting operation
is sent to a numerical control cutting machine to perform the
cutting operation of the die blocks and materials in accordance
with the data.
[0124] FIG. 19 is a sectional view showing a typical die assembly.
While this die assembly has approximately the same structure as
that in FIG. 16, the components of the die assembly are illustrated
in more detail in FIG. 19. In the die assembly of FIG. 19, a
movable plate 22 supporting an ejector pin 23 comprises an upper
plate 22a, and a lower plate 22b. A lifter comprises a core member
19, and a spring member 19a for attaching the core member 19 to a
movable plate 22. The lower end of the spring member 19a is cramped
and held between the upper plate 22a and the lower plate 22b. The
lifter 20 is referred to as "spring core" in some cases, because it
is supported by the spring member 19a.
[0125] In the die assembly of FIG. 19, a sleeve pin 50 is provided
in addition to a regular ejector pin 23. The sleeve pin 50 includes
a sleeve 50a, and a center pin 50b inserted into the sleeve 50a.
The upper end of the sleeve 50a is located at a position lower than
that of the surface of a molding protrusion 6 of a lower die block
8. The center pin 50b penetrates through the sleeve 50a, and the
upper end of the center pin 50b protrudes upward from the upper end
of the sleeve 50a. This sleeve pin 50 plays a role of forming a
protrusion as illustrated in a product to be molded. More
specifically, the protrusion is formed to have a hollow cylindrical
shape called bosses that extend in the inward direction of the
product. The lower end of the sleeve pin 50a is held between the
upper plate 22a and the lower plate 22b of the movable plate 22.
The lower end of the center pin 50b extends downward beyond the
lower end of the sleeve 50a and is held between a center-pin
stopper plate 51 and an ejector support plate 52 which are disposed
below the movable plate 22.
[0126] In addition, the die assembly of FIG. 19 includes a core pin
53. The lower end of the core pin 53 is supported by a receiving
plate 54 which holds the lower surface of the lower die block 8.
The upper end of the core pin 53 is in contact with the surface of
a molding depression 5 of an upper die block 7 after extending
upward to penetrates the lower die block 8 and enter into the
molding cavity 9. Such a core pin is intended to create a hole on
the molded product.
[0127] While a slider 11 in the die assembly of FIG. 19 comprises a
pair of cores 11c, 11d disposed vertically, its structure may be
regarded as the same as that of the sliders described with
reference to FIGS. 11 to 15.
[0128] Returning to the process chart of FIG. 5, the die design
process reconstructed according to the concept of the present
invention will be descried in more detail.
[0129] In response to the receipt of an order for production of a
die assembly, an order sheet is issued. Together with the
production order, product design data are supplied from a customer
in the form of 3-dimensional digital data. The product design data
is converted into CAD data compatible with software for use in the
die design. These subprocesses are indicated by P1 and P2 in FIG.
5, which are simple or routine jobs requiring no decision. At the
time this data conversion is completed, the die design is
initiated.
[0130] The first subprocess of the die design is a data correction
subprocess P3. The data correction subprocess P3 includes a job of
checking any possible defect in the converted 3-dimensional CAD
data, and correcting the defect. Specifically, it is checked
whether a 3-dimensional image displayed in accordance with the data
includes the missing surfaces and unintended clearance, and a
responsible person operates the computer to correct a detected
defect manually. The corrected data is stored in the computer. FIG.
20 shows one example of a 3-dimensional image to be checked. In the
3-dimensional image, a surface 1 has a clearance due to a defect
such as data discontinuity, and an unclosed corner appears therein.
For example, data-checking software may be configured to indicate
the presence of a data defect by displaying the entire product with
light blue color if data discontinuity is found, and to display the
defective region or unclosed corner with purple color, so as to
allow the responsible person to readily find the defect. Check
items such as a surface defect may be standardized in such a manner
that discontinuity in data is determined as surface defect, and the
software may be configured to display the check result to the
responsible person under the support of the computer. In this case,
a subprocess which should be regarded as a decision subprocess if
it is executed through visual checking can be handled as a routine
subprocess requiring no decision. That is, a die-design engineer
can execute this job as a simple routine subprocess by checking the
defect of the data and immediately correcting a detected defect.
Thus, according to this embodiment of the present invention, the
data correction subprocess otherwise been regarded as a decision
process can be handled as a routine subprocess requiring no
decision to reduce the number of decision subprocesses in its
entirety.
[0131] The next subprocess P4 is a "Mold Layout/Add Shrinkage
Ratio" subprocess. In an injection molding process for plastic
products, a final product has a smaller dimension than that
immediately after molding due to shrinkage caused in resin
material. In the die design process, information about a resin
material to be used has been provided from a customer, and stored
as history information on the order. In the subprocess P4, this
history information is first checked to read out the shrinkage
ratio of the resin material. Then, the respective dimensions of the
resin material before and after adding shrinkage are calculated for
each of three directions X, Y, Z. FIG. 21 shows one example of a
computer display image for use in the subprocess P4. In this
example, the shrinkage ratio of the resin material is 0.5%. The
product data is enlarged by this shrinkage ratio, and stored as
corrected data. FIG. 21B shows an image of correction data. This
subprocess is classified as a simple or routine job requiring no
decision.
[0132] Subsequent to the "Add Shrinkage Ratio" subprocess, a "Fix
Layout" subprocess P5 is executed. In this subprocess, a
responsible person or a terminal computer user applies the product
data to a pre-standardized die block, and checks whether the
product data fall within the block. The respective shapes of the
product data and the die block are displayed as an image. In this
subprocess, the layout is fixed in consideration of not only
whether the product data fall within the block but also whether
necessary components such as a sliders and lifters can be placed
without interference. Thus, this subprocess is an important
decision subprocess having an impact on subsequent subprocesses.
Further, in terms of the type of runner serving as a passage of
molding resin, either one of hot and cold runners is selected in
this process. This selection is determined according to the shape
of the product.
[0133] It a hot runner is selected, a hot runner aperture is
layouted in the die block. As one example, the layout of a spool
55a, a runner 55b and a gate 55c is shown in FIG. 22. A parting
line PL or parting surface between the upper and lower dies is also
fixed in this subprocess.
[0134] FIG. 22 shows the type of gate, wherein FIG. 22 A shows a
side gate 55d, and FIG. 22 B shows a direct gate 55e. FIG. 23 shows
the product data placed in the die block. As shown in FIG. 23, a
rectangular line 7a is displayed on the computer screen to indicate
an allowable layout range of the product data. In consideration of
the type of gate, the product data is positioned in the allowable
range.
[0135] If an alternative of the parting line PL displayed on the
screen is acceptable, the user can click a "decision" button
displayed on the computer screen to fix a surface along the
displayed parting line PL as a parting surface. If the parting line
PL displayed on the screen is not acceptable, the user can click an
"Alternative" button to display a parting line as the second
alternative. In this way, an optimal parting line can be selected
while displaying several alternatives.
[0136] In response to the fixing of the parting line PL, the system
will automatically choose a die block 7 and 8 optimal to the
dimensions and shapes of the depression 5 and the protrusion 6 and
display on the computer screen, for example, as shown in FIG. 9 or
10.
[0137] After the die block position is fixed, it is studied whether
sliders can be placed. What considered mainly is whether a slider
can be reasonably placed, particularly, with respect to the
dimension in the height direction. If there is not any margin for
reasonably placing the slider in the height direction, the user may
adjust the position of the product data in the height direction to
allow the slider to be adequately placed.
[0138] Then, the user will study whether a lifter or spring core
20, for example, as shown in FIG. 24 can be adequately placed. The
user will consider whether an escape hole 54a, for the spring core
20, in a receiving plate interferes with a coolant hole 54b formed
in the same receiving plate 54, and whether a horizontal distance
from the center of the die is in an allowable range. FIG. 24 shows
this relationship. The distance L between the center of lower end
of an aperture 19a formed in a lower die 8 to receive a core member
19 therein and the center of the lower die 8 is required to set in
a given value positively in both the width and longitudinal
directions of the dies. In an example of an outer case for cell
phones as shown in FIG. 26, the distance L should be minimum of 23.
4 mm and 73.9 mm, respectively, in the width and longitudinal
directions of the dies. In addition, the lateral displacement
between the center of the lower end of the aperture 19a of the
lower die 8 and the escape hole 54 formed in the receiving plate 54
is set at 2.0 mm. The distance between the respective edges of the
escape hole 54a and the coolant hole 54b is required to be minimum
of 1.0 mm.
[0139] The position of the product data is fixed in consideration
of the aforementioned various requirements. Problems which would
otherwise occur in subsequent subprocesses can be avoided in
advance by fixing the layout in consideration of all of conditions
having an impact on the positions of various components in the
subsequent subprocesses.
[0140] Subsequent to the subprocess P5, a "Create Parting Surface"
subprocess P6 is executed. This subprocess includes a job of
operationally adding parting surfaces on to the holes of the
product data in preparation of separating upper and lower dies.
FIGS. 25A and 25B show one example of a subprocess for forming
parting surfaces ta, tb.
[0141] Then, a "Separated Upper/Lower Die" subprocess P7 is
executed. As descried in conjunction with FIGS. 7 and 8, this
subprocess includes a job of choosing parting lines of upper and
lower dies, and registering the data of upper and lower dies
separately to allow the respective data to be processed in separate
process flows. Both the subprocesses P6 and P7 are classified as a
routine subprocess requiring no decisions.
[0142] According to one embodiment of the present invention, in a
specific die assembly, for example, an injection molding die
assembly for a cell phone outer case, as shown in FIG. 26, each of
the respective widths A, B of lower and upper die 8, 7 of the
matching surface between the upper and lower does 7, 8, and the
clearance C in a general parting surface is set at a constant
value. In this way there is no decision necessary in the
upper/lower separation subprocess. Thus, a subprocess otherwise
being regarded as a decision subprocess can be handled as a routine
by setting a single condition as a condition otherwise requiring
decision, reducing the number of decision subprocess.
[0143] A subsequent subprocess is a "Fix Gate/Spool Position"
subprocess P8. This subprocess includes a job for fixing the
respective positions of the spool 55a, the runner 55b and the gate
55c for injecting molten resin into the molding cavity 9. FIG. 27
shows one example of a side gate.
[0144] When design data of a gate in the "Fix Gate/Spool Position"
subprocess P8 is created, conditions, such as the width d1 of a
runner portion, the width w or thickness t of a gate portion or the
presence of the inclination in the gate potion, may be preset for
each type of resin to be used, reducing the number of decision
subprocess drastically.
[0145] Subsequent to the "Fix Gate/Spool Position" subprocess PB, a
"Fix Runner Path/Curvature-radius" subprocess P9 is executed. This
subprocess P9 includes a job for fixing the position and shape of
the runner 55b. These subprocesses P8 and P9 are classified as a
decision subprocess. Depending on the shape and size of a product,
each of the spool, runner and gate may be limited to a single type
and the path and curvature radius of the runner may be limited to a
single type accordingly, so as to necessarily use the predetermined
type of spool, runner, gate, and the path and curvature radius of
the runner. In this case, the subprocesses P8, P9 otherwise being
classified as a decision process can be handled as a routine
subprocess.
[0146] A subsequent subprocess is a "Fix Sleeve Pin Position"
subprocess P10. In addition to a job for fixing the position of the
ejector pin 23, this subprocess includes a job for determining if
the sleeve pin described in conjunction with FIG. 19 is necessary,
and, if necessary, fixing the size and position of the sleeve pin.
Subsequently, a "Choose Slider Type (Stroke)" subprocess 11 is
executed to determine if a slider or a lifter is necessary, and, if
necessary, fixing the type and the amount of stroke thereof. The
subprocesses P10, P11 are classified as a decision subprocess.
[0147] After the completion of the subprocess P11, a "Create
Sliders" subprocess P12 and a "Create Lifters" subprocess P13 are
sequentially executed.
[0148] These subprocesses can be executed through a manual
operation of fixing the size and type of the slider unit 12 in FIG.
14, position a cursor to a given position while viewing the
computer screen, and clicking the position. A program incorporated
in the computer is configured such that when the size and type of
the slider unit 12 are fixed, and the position of the slider unit
is designated, each of a concave portion 16 for fittingly receiving
a slide guide 13, and a groove 17 for allowing a movable member 14
and a slider 11 to slide therealong is automatically depicted at
the designated position of the lower die block 8.
[0149] The design of the slider unit is executed as a job in a
separated process flow. A standardized component is applied to each
of the slider guide 13 in the slider unit 12, the movable member 14
and the locking block 15. More specifically, several different
sizes, shapes and types of slider units are prepared, and an
optimal one is manually selected therefrom depending on the size,
shape and position of a molding core 11b in FIG. 12 required for
molding a product. The result of this selection is also used in
forming the concave portion 16 and the groove 17 in the lower die
block of the aforementioned die assembly. In the design process of
the slider unit 12, the user will select the standardized slider
units depending on the level of an undercut. FIG. 28 shows one
example of a material for sliders standardized and registered in
the form of 3-dimensional data in advance. In the table described
at the top of FIG. 28A, numerals in the column of size indicate the
length, width and thickness, respectively, in turn from left to
right. The above standardized material is a material having a
length of 150 mm and a width of 15 mm as illustrated just below the
table, and three kinds of standardized materials each having a
different thickness are prepared. Typically, a material to be used
is appropriately selected from the standardized materials. Only if
the standardized materials cannot be used, an appropriate material
is selected from other materials having a length of 300 mm and a
width of 300 mm, and the selected material is cut through a wire
cut process to form a slide as shown by a wire cut material in the
bottom of FIG. 28A. The standardized slider unit comprises a
pre-combined set of the slider guide 13, the movable member 14 and
the locking block 15. Further, a material having a size and shape
large enough of cutting out the movable member 14 is selected and
used for the slider 11. Then, a molding core 11a having a desired
shape and size is formed at the front end of the selected material.
The formation of the molding core 11a is executed through a
computer processing in accordance with information from the design
data of the product, front case 1.
[0150] In the same way, the core member 19 of the lifter 20 is
designed by preparing a number of materials for the core member,
designating an optimal one among different sizes and types of
standardized materials registered in the computer in the form of
3-dimensional data, and forming a protrusion 19a and a molding
surface 19b having a desired shape. The design data of the
protrusion 19a and the molding surface 19b can be created in
accordance with the data of the product in FIG. 7. FIG. 28B shows
one example of the shape of the core member 19 of the lifter 20
standardized and registered in the computer in the form of
3-dimensional data, and FIG. 28C shows a table for fixing the
dimension of the lifter. As shown in FIG. 28, the lifter design can
be adequately executed depending on the size of undercut.
[0151] When the size and type of the core member 19 of the lifter
20 is fixed, and their positions are designated, a desired shape of
the guide surface 21 is written in the lower die block 8 on the
computer screen, and stored as the digital design data.
[0152] As the ejector pin 23, several kinds of ejector pins each
having a different diameter are prepared as standardized
components. After the position of the ejector pin 23 is fixed, an
ejector pin having an optimal diameter is selected depending on the
shape and dimension of a product. In response to the fixing of the
diameter of the ejector pin, its length is automatically fixed.
Simultaneously, a hole 25 corresponding to the ejector pin 23 is
formed in the lower die block 8, and the resulting data is stored
as the design data. In this way, the design of the ejector pin 23
is completed only by fixing the position of the ejector pin 23 and
selecting the diameter of the ejector pin 23 from the standardized
components. In addition, the design of associated components, for
example the hole 23 and groove of the ejector pin 23, will also be
automatically designed by the system.
[0153] This subprocess 13 also includes a job for forming an
ejector-pin groove for guiding the ejector pin 23. Since the design
data of the ejector-pin groove has been fixed in the "Fix Sleeve
Pin Position" subprocess, and the position and standardization type
of the sliders and lifters has also been fixed in the precedent
subprocess, each of the subprocesses P12 and P13 will simply
execute the fixed conditions in the precedent decision subprocess
on the computer according to the job-support computer program.
Thus, these the subprocesses P12 and P13 are classified as a
routine subprocess requiring no decision. After the completion of
the "Create Sliders" and "Create lifters" subprocesses P12 and P13,
the slider and lifter data are registered as a separate
component.
[0154] A "Create Inserts" subprocess P 14 is subsequently executed.
This subprocess P14 includes a job for creating data of inserts to
be arranged in the molding cavity 9, such as the core pin 53
descried in connection with FIG. 19, and registering the created
data in the computer as one component.
[0155] Finally, a parting check subprocess P15 is executed. This
subprocess includes a job for checking whether the design data on
each of the upper and lower dies is adequate. The subprocess P15 is
classified as the most important decision subprocess as the final
decision subprocess.
[0156] FIG. 29 schematically shows a management system of managing
the jobs for creating the die design and preparation data. A
central processing unit 60 is connected with a number of terminal
computers 61A, 61B, 61C, 61D, 61E, 61F via a network. The central
computing unit 60 is provided with a job distribution server 60a
which is connected to a job management database 60b,
job-skill-level management database 60c and a file management
server 60d.
[0157] As shown by a fragmentary enlarged view in FIG. 29, process
charts 62 for a plurality of orders are stored in the job
management database 60b. The process chart 62 may be the same type
as that in FIG. 5. In the example of FIG. 29, 01-type, 02-type and
03-type of process charts are prepared by numbering in sequence of
order-receipt timing. This number represents the priority level of
job. Further, in each of the process charts, each of subprocesses
is also numbered. This number represents the sequence of initiation
timing, and it means that either one of two or more subprocess
having the same number may be initiated earlier. When one
subprocess is completed, this information is recorded in an
operation management list associated with a corresponding process
chart 62.
[0158] The job-skill-level management database 60c stores a list
for describing therein data on subprocesses which can be executed
by a user of each of the terminal computers, or a job-skill-level
list. For example, when represented by the indication of the
process chart 62, if the user of the terminal computer 61A has an
ability of executing the jobs in the subprocess 2, 3 and 4, but any
jobs in other subprocess cannot trust to the user, this information
is stored in the job-skill-level management database as the skill
level of the terminal computer 61A. In the same way, the user's
skill level of each of other terminal computers is stored in the
database.
[0159] FIG. 30 is a flow chart showing the function of a die design
system constructed by the central computing unit 60 and the
terminal computer 61, wherein FIG. 30A shows a login stage in the
system. A system interface in FIG. 30A is enlarged and separately
shown in FIG. 30E. After coming to the office and being ready for
job, a user first enters a login ID through a system interface, and
pushes a login button. In response to this operation, software
recognizes the push of the login button, and registers the status
of the user. In the job distribution server 60a, the central
computing unit 60 has a terminal status list for recording the
status of the terminal computer handled by the user. At this
moment, the status of the use is "BREAK", and this information is
recorded in the terminal status list.
[0160] If ready to initiate a job, the user pushes a "READY" button
in the system interface. Thus, the software recognizes the push of
the READY button, and changes the status of the user from "BREAK"
to "READY". Then, the software acquires the job skill level of the
user from the job-skill-level management database to check any
executable job for the user through retrieval of the job management
database 60b. An optimal job for the user is selected by sorting
the data according to the priority level of the order, and then
selecting the sequence of the initiation timing, or the subprocess
having the smallest number. The selected job is distributed to the
terminal computer of the user to allow the user to execute the
assigned job. Then, the software writes a resulting job performance
into a performance management table included in the job management
database. In this writing operation, time required for the user to
execute the assigned job. Further, the software changes the status
of the user from "READY" to "ACTIVE".
[0161] FIG. 30B is a flowchart showing a data correction process. A
system interface in FIG. 30B is enlarged and separately shown in
FIGS. 30F, 30G, 30H. A user pushes a system startup button through
a system interface. In response to this operation, software
activates a data correction system having a solid check command to
acquire a file number to be opened according to an order number.
Further, the software retrieves the job management database 60b
based on the acquired file number to open a 3-dimensional model of
a product in question from the file management server 60d.
[0162] Then, the user pushes a transmit button to notify the
completion of the job. The user also notifies the software of
whether his/her status is "READY" or "BREAK". In response the
transmitted information from the terminal computer, the software
writes the information of the result, or the completion of the
subprocess, into the performance management table. Further,
according to the status notified from the user, the software
rewrites the user status to "READY" or "BREAK".
[0163] FIGS. 30C and 30D are flowcharts showing jobs between the
"Fix Layout" subprocess and the "Separated Upper/Lower Die"
subprocess. A system interface in FIG. 30C is enlarged and
separately shown in FIGS. 30I, 30J, 30K, and a system interface in
FIG. 30D is enlarged and separately shown in FIG. 30L. A user
clicks "JOB HISTORY" tab to display a job-history screen of on the
system interface. Then, the user double-clicks a shrinkage ratio
table on the screen to activate the shrinkage ratio table. The
software recognizes the double-click of the shrinkage ratio table,
and selects the JOB HISTORY table of a subprocess in question to
display it on the system interface. The shrinkage ratio is
predetermined according to resin to be used. In the illustrated
example, the shrinkage ratio is 0.5%. The user executes an
operation of adding the displayed shrinkage ratio to reflect
shrinkage to a product shape.
[0164] The user pushes a layout fixing system button through a
system interface to activate the system. The software recognizes
the push of the layout system fixing system button to acquire a
file according to an order number, and open a model from the file
management 60d. For example, the model to be open is the image as
shown in FIG. 7, and displayed together with a die material block.
Then, the shrinkage of the resin is added to the displayed model to
create corrected data. The corrected data will be the image as
shown in FIG. 21B. Subsequently a parting line PL is fixed. The
fixing of the parting line PL is executed through the same method
as that descried in connection with FIG. 7. Then, the respective
types of a runner for injecting resin therethrough and a gate as a
resin inlet are fixed. These types are fixed in consideration of
the shape of a product and the type of resin to be used. The type
of the runner is fixed by selecting from a hot runner and a cold
runner, and the type of the gate is fixed by selecting from a side
gate and a direct gate. A layout is fixed in consideration of the
above fixed types of runner and gate.
[0165] After the layout is fixed, the user may discontinue the job
concerning this order. In this case, the created data is saved in
the file management server 60d, and then information about his/her
current status is transmitted.
[0166] While the present invention has been described in detail
with reference to specific embodiments, the process and program of
the specific embodiments are made by way of example rather than to
limit the scope of the present invention. Therefore, it is intended
to cover within the spirit and scope of the invention all changes
and modifications.
* * * * *