CA3185893A1 - Molding system and method for inspecting molded articles - Google Patents

Abstract

A molding system and a method for molding articles. The molding system includes a molding machine for producing molded articles and at least one inspection device configured to inspect one or more molded articles and a computing apparatus operatively coupled to the at least one inspection device. The inspection device includes at least one multispectral light source configured to illuminate the at least one molded article; and at least one imaging system configured to collect at least some light reflected and scattered from the at least one molded article, the imaging system including at least one detector configured to detect a plurality of wavelengths in light imaged by the imaging system, the detector being communicatively coupled to the computing apparatus. The inspection device is configured to inspect molded articles between an end of a first molding cycle and prior to a start of a second molding cycle.

Description

MOLDING SYSTEM AND
METHOD FOR INSPECTING MOLDED ARTICLES
FIELD OF THE TECHNOLOGY
The present technology relates to molding systems and methods for using the molding systems.
More specifically the present technology relates to a molding system for producing and inspecting molded articles, and a method for inspecting molded articles during operation of the molding system.
BACKGROUND
Molding is a process by virtue of which a molded article can be formed from molding material by using a molding system. Various molded articles can be formed by using the molding process, such as an injection molding process. One example of a molded article that can be formed, for example, from polyethylene terephthalate (PET) material is a preform that is capable of being subsequently blown into a beverage container, such as, a bottle and the like.
Broadly speaking, the cost of producing a molded article is made up of the capital cost of the molding system itself, the cost of resin, and other overheads (electricity, water supply, labour costs, etc.). In order to garner the most profitability from the system, the molding system should be running as much as possible, at full capacity, producing molded articles that meet specification.
In order to minimize downtime of the molding system inspection of the molded articles may be undertaken, downstream of the molding system, and then any required maintenance and process tuning is performed as required. The inspection should not impede operation of the molding system, and inspection of the molded articles should take place with a minimum of delay from when they are molded, to intercept issues as quickly as possible.
For multilayer preforms, where there are multiple layers of molded material together, additional inspection challenges are presented. Inspection by hand of the different layers, as is commonly done in the art, is both time-consuming and difficult.
SUMMARY
It is an object of the present invention to ameliorate at least some of the inconveniences present in the prior art.

Date Regue/Date Received 2023-01-05 According to a first broad aspect of the present technology, there is provided a molding system comprising a molding machine for producing a plurality of molded articles; and at least one inspection device configured to inspect at least one molded article of the plurality of molded articles; and a computing apparatus operatively coupled to the at least one inspection device, the at least one inspection device comprising at least one multispectral light source configured to illuminate the at least one molded article; and at least one imaging system configured to collect at least some light reflected and scattered from the at least one molded article, the at least one imaging system including at least one detector configured to detect a plurality of wavelengths in light imaged by the at least one imaging system, the at least one detector being communicatively coupled to the computing apparatus, the at least one inspection device configured to inspect the at least one molded article between an end of a first molding cycle and prior to a start of a second molding cycle.
In some embodiments of the molding system, the at least one inspection device is configured to image the at least one molded article in a mold of the molding machine prior to ejection of the at least one molded article from the molding machine.
In some embodiments of the molding system, the computing apparatus and the at least one inspection device are configured to detect that one of the plurality of molded articles is missing in the molding machine.
In some embodiments of the molding system, the computing apparatus is communicatively .. coupled to the molding machine and the molding machine is configured to adjust at least one molding process variable in response to detection, by the at least one inspection device, of at least one defect in the at least one molded article.
In some embodiments of the molding system, the at least one molding process variable includes at least one of a mold opening speed profile; a mold closing speed profile; an ejector speed profile;
a mold open dwell time; a part removal function; a transfer air assist function; molding process parameters such as temperature, pressure, time and a part handling device dwell time.
In some embodiments of the molding system, the molding machine comprises a stationary platen, and a moveable platen; the at least one inspection device is mounted to one of the stationary or moveable platens; and the at least one inspection device is configured to image mold cavities in a first mold half associated with the stationary platen and/or mold cores in a second mold half associated with the moveable platen.

2 Date Regue/Date Received 2023-01-05 In some embodiments of the molding system, the at least one inspection device is configured to image the plurality of molded articles during ejection from one of the first mold half or the second mold half.
In some embodiments of the molding system, the at least one inspection system and the computing apparatus are configured to produce hyperspectral images of at least one of a portion of the molding machine and the at least one molded article.
According to another broad aspect of the present technology, there is provided a method for inspecting molded articles from a molding system, the molding system including at least one inspection device and a molding machine. The method comprises illuminating, by at least one light source of the at least one inspection device, at least one molded article produced by the molding machine, the at least one light source providing light having a plurality of wavelengths; imaging, by an imaging system of the at least one inspection device, at least some light reflected and refracted from the at least one molded article onto a detector of the at least one inspection device, the detector being configured to detect at least some of the plurality of wavelengths of illuminating light; and determining, by a computing apparatus communicatively coupled to the detector, at least one attribute of the at least one molded article, the at least one attribute being detectable using a plurality of images of the at least one molded article, the plurality of images being formed by at least some of the plurality of wavelengths.
In some embodiments of the method, the determining the at least one attribute includes executing an image recognition algorithm to analyse the plurality of images formed by the at least some of the plurality of wavelengths.
In some embodiments of the method, determining the at least one attribute includes detecting at least one defect in the at least one molded article; and further comprising, in response to detecting the at least one defect, causing a change in at least one molding process variable of the molding machine.
In some embodiments of the method, causing the change in the at least one molding process variable includes causing change in at least one of a mold opening speed profile; a mold closing speed profile; an ejector speed profile; a mold open dwell time; a part removal function; a transfer air assist function; and a part handling device dwell time.
In some embodiments, the method further comprises determining that the at least one molded article of a previous molding cycle is to be rejected.

3 Date Regue/Date Received 2023-01-05 In some embodiments, the method further comprises determining that the at least one molded article of a subsequent molding cycle is to be rejected.
In some embodiments of the method, imaging the at least one molded article includes imaging the plurality of molded articles.
In some embodiments of the method, imaging the plurality of molded articles includes imaging the plurality of molded articles in the molding machine prior to ejection.
In some embodiments, the method further comprises producing a hyperspectral image block, by the computing apparatus, based on the imaging the plurality of molded articles in the plurality of wavelengths.
In some embodiments of the method, at least some of the plurality of wavelengths are wavelengths outside of a visible light spectrum.
According to yet another broad aspect of the present technology, there is provided a molding system comprising a molding machine for producing a plurality of molded articles; and at least one inspection device configured to inspect at least one molded article of the plurality of molded articles; and a computing apparatus operatively coupled to the at least one inspection device, the at least one inspection device comprising at least one multispectral light source configured to illuminate the at least one molded article; and at least one imaging system configured to collect at least some light reflected and scattered from the at least one molded article, the at least one imaging system including at least one detector configured to detect a plurality of wavelengths in light imaged by the at least one imaging system, the at least one detector being communicatively coupled to the computing apparatus.
In some embodiments, the system further comprises a display arrangement for receiving the at least one molded article from the molding machine; and the at least one inspection device is configured to image the at least one molded article in the display arrangement.
In some embodiments of the system, the computing apparatus and the at least one inspection device are configured to detect at least one attribute in the at least one molded article, the at least one attribute being detectable using light with at least a first wavelength of the plurality of wavelengths.
In some embodiments of the system, the first wavelength is outside a visible spectrum.

4 Date Regue/Date Received 2023-01-05 In some embodiments of the system, the computing apparatus is communicatively coupled to the molding machine; and the molding machine is configured to adjust at least one molding process variable in response to detection of the at least one attribute in the at least one molded article.
In some embodiments of the system, the plurality of molded articles produced by the molding machine is a plurality of multilayer preforms; and each of the plurality of multilayer preforms includes a core layer and a skin layer enveloping the core layer.
In some embodiments of the system, the at least one inspection device is configured to image the skin layer and the core layer of at least one of the plurality of multilayer preforms; and the computing apparatus is configured to identify defects in at least one of the skin layer and the core layer.
In some embodiments of the system, the computing apparatus is communicatively coupled to the molding machine; and the molding machine is configured to adjust at least one molding process variable in response to identified defects in the at least one of the skin layer and the core layer.
In some embodiments of the system, the computing apparatus is communicatively coupled to the molding machine; the at least one inspection device is configured to inspect the at least one molded article prior to ejection of the at least one molded article from the molding machine; and the molding machine is configured to adjust at least one molding process variable in response to detection, by the at least one inspection device, of at least one defect in the at least one molded article.
In the context of the present specification, the words "first", "second", "third", etc. have been used as adjectives only for the purpose of allowing for distinction between the nouns that they modify from one another, and not for the purpose of describing any particular relationship between those nouns. Further, as is discussed herein in other contexts, reference to a "first" element and a "second" element does not preclude the two elements from being the same actual real-world element.
These and other aspects and features of non-limiting embodiments of the present technology will now become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the technology in conjunction with the accompanying drawings.
Embodiments of the present technology each have at least one of the above-mentioned object and/or aspects, but do not necessarily have all of them. It should be understood that some aspects

5 Date Regue/Date Received 2023-01-05 of the present technology that have resulted from attempting to attain the above-mentioned object may not satisfy this object and/or may satisfy other objects not specifically recited herein.
Additional and/or alternative features, aspects and advantages of embodiments of the present technology will become apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the embodiments of the present technology (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the non-limiting embodiments along with the following drawings, in which:
Figure 1 is a cross-sectional view of a multilayer preform, which can be inspected by non-limiting embodiments of the present technology;
Figure 2 is a plan view schematic diagram of an injection molding machine, which can be adapted for implementation of the non-limiting embodiments of the present technology;
Figure 3 is a schematic diagram of a molding system, which can be adapted for implementation of the non-limiting embodiments of the present technology;
Figure 4 is a schematic diagram of another embodiment of a molding system being implemented in accordance with another non-limiting embodiment of the present technology;
Figure 5 is a schematic diagram of yet another embodiment of a molding system being implemented in accordance with another non-limiting embodiment of the present technology; and Figure 6 depicts a block diagram of a method executable in accordance with non-limiting embodiments of the present technology and executable within the system of Figures 3 to 5.
DETAILED DESCRIPTION
With reference to Fig. 1, there is depicted, in cross-section, a non-limiting embodiment of a molded article produced by a molding machine of the present technology, specifically a multi layer preform 50. The illustrated preform 50 is produced by an injection molding machine 100, described below with reference to Fig. 2, but it is contemplated that preforms 50 could be produced by another type of molding machine in other non-limiting embodiments in accordance with the present technology.
It is also contemplated that different types of molded articles could be produced by molding

6 Date Regue/Date Received 2023-01-05 machines according to non-limiting embodiments of the present technology, including but not limited to: closures, thin-wall containers, medical appliances, and the like.
The multilayer preform 50 consists of a neck portion 32, a gate portion 36 and a body portion 34 extending between the neck portion 32 and the gate portion 36. The gate portion 36 is associated with a substantially spherical shape that terminates in a vestige portion 38.
The multilayer preform 50 is formed by at least two layers. On exterior sides, the multilayer preform 50 has a skin layer 20. The skin layer 20 can be made of various materials. For example, in multilayer preforms 50 for making beverage containers, the skin layer 20 is made of virgin polyethylene terephthalate (PET), which is approved by the FDA for use in contact with foodstuffs.
It is contemplated that the skin layer 20 could be made of various other materials, including any appropriate polymer resins and thermoplastics, as will be appreciated by those skilled in the art.
The multilayer preform 50 has a cavity identification number 25 imprinted in the skin layer 20.
Even though the cavity identification number 25 is depicted to be located in the neck portion 32, this does not need to be so in alternative embodiments of the present technology. In alternative embodiments, the cavity identification number 25 can be located anywhere within the gate portion 36 or the body portion 34.
As will be described below, each cavity 118 of one or more mold cavities 118 of the injection molding machine 100 has a cavity origin insert which imprints the cavity identification number 25 of each cavity 118, each cavity identification number 25 being unique to each cavity 118. In some alternative embodiments, it is contemplated that that the cavity origin insert could be omitted.
The skin layer 20 surrounds a core layer 40, the core layer 40 being generally made of a different material, or a different variety of the same material, e.g. recycled PET, than the skin layer 20. At a top end of the preform 50, the core layer 40 begins at a leading edge 42. At a bottom end of the preform 50, the core layer 40 terminates at a trailing edge 44. In some embodiments, the core layer 40 is used to impart different properties to the preforms 50. The core layer 40, in some embodiments, can act as a barrier layer in the eventual blow-molded container blown from the preform 50. In such cases, the barrier layer can help to prevent transmission of, for example, oxygen or light into an interior of the blow-molded container. The core layer 40 can also be made from any one of various appropriate thermoplastics and polymer resins as will be appreciated by those skilled in the art. It is contemplated that the core layer 40 could be also contain various additives, coloring, or property adjusting agents to affect different properties of the multilayer preform 50.

7 Date Regue/Date Received 2023-01-05 With reference to Fig. 2, there is depicted a non-limiting embodiment of the injection molding machine 100 which can be adapted to implement embodiments of the present technology. For illustration purposes only, it shall be assumed that the injection molding machine 100 makes the multilayer preforms 50 described above that are subsequently processed by a molding system 200 of the present technology. However, it should be understood that in alternative non-limiting embodiments, the injection molding machine 100 may comprise other types of molding systems, such as, but not limited to, compression molding systems, compression injection molding systems, transfer molding systems, metal molding systems and the like.
In the non-limiting embodiment of Fig. 2, the molding machine 100 comprises a stationary platen 102 and a movable platen 104. The stationary platen 102 is also referred to as a fixed platen 102.
In some embodiments of the present technology, the molding machine 100 may include a third non-movable platen (not depicted). Alternatively or additionally, the molding machine 100 may include turret blocks, rotating cubes, turning tables and the like (all not depicted but known to those of skill in the art).
The injection molding machine 100 further comprises an injection unit 106 for plasticizing and injection of the molding material. The injection unit 106 can be implemented as a single stage or a two-stage injection unit.
In operation, the movable platen 104 is moved towards and away from the stationary platen 102 by means of stroke cylinders (not shown) or any other suitable means. Clamp force (also referred to as closure or mold closure tonnage) can be developed within the molding machine 100, for example, by using tie bars 108, 110 (typically, four tie bars 108, 110 are present in the molding machine 100) and a clamping mechanism 112. It will be appreciated that clamp tonnage can be generated using alternative means, such as, for example, using a column-based clamping mechanism, a toggle-clamp arrangement (not depicted) or the like.
A first mold half 114 can be associated with the stationary platen 102 and a second mold half 116 can be associated with the movable platen 104. In the non-limiting embodiment of Fig. 2, the first mold half 114 comprises the one or more mold cavities 118. As will be appreciated by those of skill in the art, the one or more mold cavities 118 may be formed by using suitable mold inserts (such as a cavity insert, a gate insert and the like) or any other suitable means. As such, the first mold half 114 can be generally thought of as a "mold cavity half".
The second mold half 116 comprises one or more mold cores 120 complementary to the one or more mold cavities 118. As will be appreciated by those of skill in the art, the one or more mold

8 Date Regue/Date Received 2023-01-05 cores 120 may be formed by using suitable mold inserts or any other suitable means. As such, the second mold half 116 can be generally thought of as a "mold core half'. Even though not depicted in Fig. 2, the first mold half 114 may be further associated with a melt distribution network, commonly known as a hot runner, for distributing molding material from the injection unit 106 to each of the one or more mold cavities 118. Also, the second mold half 116 may include neck rings (not depicted) with which to mold neck portions 32 of preforms 50. The neck rings may be used to for imprinting the cavity identification number 25 on the multilayer preforms 50.
The first mold half 114 can be coupled to the stationary platen 102 by any suitable means, such as a suitable fastener (not depicted) or the like. The second mold half 116 can be coupled to the movable platen 104 by any suitable means, such as a suitable fastener (not depicted) or the like.
Fig. 2 depicts the first mold half 114 and the second mold half 116 in a so-called "mold open position" where the movable platen 104 is positioned generally away from the stationary platen 102 and, accordingly, the first mold half 114 is positioned generally away from the second mold half 116. For example, in the mold open position, a molded article (not depicted) can be removed from the first mold half 114 and/or the second mold half 116. In a so-called "mold closed position"
(not depicted), the first mold half 114 and the second mold half 116 are urged together (by means of movement of the movable platen 104 towards the stationary platen 102) and cooperate to define (at least in part) a molding cavity (not depicted) into which the molten plastic (or other suitable molding material) can be injected, as is known to those of skill in the art.
It should be appreciated that one of the first mold half 114 and the second mold half 116 can be associated with a number of additional mold elements, such as for example, one or more leader pins (not depicted) and one or more leader bushings (not depicted), the one or more leader pins cooperating with one more leader bushings to assist in alignment of the first mold half 114 with the second mold half 116 in the mold closed position, as is known to those of skill in the art.
The injection molding machine 100 can further comprise a robot 122 operatively coupled to the stationary platen 102. Those skilled in the art will readily appreciate how the robot 122 can be operatively coupled to the stationary platen 102 and, as such, it will not be described here in any detail. The robot 122 comprises a mounting structure 124, an actuating arm 126 coupled to the mounting structure 124 and a take-off plate 128 coupled to the actuating arm 126. The take-off plate 128 comprises a plurality of molded article receptacles 130.
Generally speaking, the purpose of the plurality of molded article receptacles 130 is to remove molded articles 50 from the one or more mold cores 120 (or the one or more mold cavities 118)

9 Date Regue/Date Received 2023-01-05 and/or to implement post mold cooling of the molded articles. In the non-limiting example illustrated herein, the plurality of molded article receptacles 130 comprises a plurality of cooling tubes for receiving a plurality of molded preforms. However, it should be expressly understood that the plurality of molded article receptacles 130 may have other configurations. The exact number of the plurality of molded article receptacles 130 is not particularly limited.
Schematically depicted in Fig. 2 is the robot 122 of a side-entry type.
However, it should be understood that in alternative non-limiting embodiments of the present technology, the robot 122 can be of a top-entry type. It should also be expressly understood that the term "robot" is meant to encompass structures that perform a single operation, as well as structures that perform multiple operations. In at least some embodiments, it is also contemplated that the robot 122 could be omitted and/or replaced with a differently implemented device for moving the molded articles 50.
The molding machine 100 further comprises a post-mold treatment device 132 operatively coupled to the movable platen 104. Those skilled in the art will readily appreciate how the post-mold treatment device 132 can be operatively coupled to the movable platen 104 and, as such, it will not be described here in any detail. The post-mold treatment device 132 comprises a mounting structure 134 used for coupling the post-mold treatment device 132 to the movable platen 104. The post-mold treatment device 132 further comprises a plenum 129 coupled to the mounting structure 134. Coupled to the plenum 129 is a plurality of treatment pins and pickers 133. In at least some embodiments, it is also contemplated that the post-mold treatment device 132 could be omitted and/or replaced with a differently implemented device for treating the molded articles 50.
The molding machine 100 further comprises a computing apparatus 140, also referred to herein as a controller 140, configured to control one or more operations of the molding machine 100. The controller 140 is further configured to control one ore more operations of molding systems 200, 300, 400 described below with respect to Figs. 3 to 5. As will be appreciated by those skilled in the art, the computing apparatus 140 may comprise a plurality of controllers or computer-implemented devices operatively connected together.
The controller 140 includes a human-machine interface (not separately numbered) or an HMI, for short. The HMI of the controller 140 can be implemented in any suitable interface. As an example, the HMI of the controller 140 can be implemented in a multi-functional touch screen. An example of the HMI that can be used for implementing non-limiting embodiments of the present technology is disclosed in co-owned United States patent 6,684,264, content of which is incorporated herein by reference, in its entirety.
Date Regue/Date Received 2023-01-05 Those skilled in the art will appreciate that the controller 140 may be implemented using pre-programmed hardware or firmware elements (e.g., application specific integrated circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.), or other related components. In other embodiments, the functionality of the controller 140 may be achieved using a processor that has access to a code memory (not shown) which stores computer-readable program code for operation of the computing apparatus, in which case the computer-readable program code could be stored on a medium which is fixed, tangible and readable directly by the various network entities, (e.g., removable diskette, CD-ROM, ROM, fixed disk, USB drive), or the computer-readable program code could be stored remotely but transmittable to the controller 140 via a modem or other interface device (e.g., a communications adapter) connected to a network (including, without limitation, the Internet) over a transmission medium, which may be either a non-wireless medium (e.g., optical or analog communications lines) or a wireless medium (e.g., microwave, infrared or other transmission schemes) or a combination thereof.
In alternative non-limiting embodiments of the present technology, the HMI
does not have to be physically attached to the controller 140. As a matter of fact, the HMI for the controller 140 can be implemented as a separate device. In some embodiments, the HMI can be implemented as a wireless communication device (such as a smai _______________________________ (phone, for example) that is "paired" or otherwise communicatively coupled to the controller 140.
The controller 140 can perform several functions including, but not limited to, receiving from an operator control instructions, controlling the molding machine 100 based on the operator control instructions or a pre-set control sequence stored within the controller 140 or elsewhere within the molding machine 100, acquire one or more operational parameters associated with the molding system and the like. According to non-limiting embodiments of the present technology, the controller 140 is further configured to process one or more of the acquired operational parameters associated with the molding system 200, 300, 400 and output information to the operator using the HMI and the like.
The molding machine 100 further includes a number of monitoring devices (not depicted), the monitoring devices being configured to acquire various operational parameters associated with the performance of the molding machine 100. Generally speaking, these monitoring devices are known in the art and, as such, will not be described here at any length.
Just as an example, the injection molding machine 100 may include a counter to count mold opening and closing to determine the number of cycles over a period of time and/or the cycle time Date Regue/Date Received 2023-01-05 of each cycle. The injection molding machine 100 may also include a number of pressure gauges to measure pressure within various components of the injection molding machine 100 (such as hydraulic fluid pressure or molding material pressure).
According to non-limiting embodiments of the present technology, the controller 140 is configured to acquire a plurality of operational parameters associated with the molding machine 100. The nature of the so-acquired plurality of operational parameters can vary. How the controller 140 acquires the plurality of operational parameters will depend, of course, on the nature of the so-acquired plurality of operational parameters.
The controller 140 can acquire machine variables by monitoring the operation of the molding machine 100. Just as an example, the controller 140 can acquire the cycle time by monitoring the performance of the molding machine 100. Naturally, the controller 140 can acquire some of the machine variables by either the operator entering them using the HMI or by reading a memory tag (not depicted) associated with the mold (i.e. the above described first mold half 114 and the second mold half 116) that is used in the molding machine 100. Various implementations of the memory tag (not depicted) are known in the art. Generally speaking, the memory tag (not depicted) may store information about the mold, the molded article to be produced, pre-defined control sequences, set-up sequences and the like.
For example, the operator may enter an indication of cavitation of the injection molding machine 100 using the HMI of the controller 140 (in which case, the cavitation can be considered to be an operational and supervisory variable). Alternatively, the mold (i.e. the above described first mold half 114 and the second mold half 116) may be equipped with the memory tag, which memory tag may for example store an indication of the cavitation of the mold. In those implementations, the controller 140 can acquire the cavitation by accessing the memory tag and reading the information therefrom (in which case, the cavitation can be considered to be a machine variable). In yet further embodiments, the memory tag may contain an indication of the mold cavitation of the mold (i.e.
the above described first mold half 114 and the second mold half 116), but some of the mold cavities may not be operational at the time. Within those examples, the operator or the supervisor could enter the actual cavitation using the HMI (in which case, the cavitation could again be considered to be an operational and supervisory variable).
In some non-limiting embodiments of the present technology, the controller 140 can acquire the operational and supervisory variables by receiving an indication of those parameters from the operator. However, within some implementations of the molding machine 100, it is possible for Date Regue/Date Received 2023-01-05 the controller 140 to acquire some (or even all) of the operational and supervisory variables by monitoring performance of the molding machine 100. For example, some implementations of the molding machine 100 may include a device for weighing molded articles and/or a device to keep track of scrapped molded articles (for example, those molded articles that do not quality or weight specifications). Within those embodiments, the controller 140 can acquire the part weight and/or scrap rates by monitoring the performance of the molding machine 100.
Naturally, other ways for the controller 140 to acquire some or all of these or other operational parameters are possible, some of which will be described below.
With reference to Fig. 3, there is depicted a non-limiting embodiment of the molding system 200 which can be adapted to implement embodiments of the present technology. The molding system 200 comprises the injection molding machine 100 for making the multilayer preforms 50. The molding system 200 is illustrated and will be described herein with respect to the embodiment of the injection molding machine 100 described above. The robot 122 and the post-mold treatment device 132 are excluded from the illustrations for simplicity but are contemplated to the included in at least some embodiments.
It is contemplated that different embodiments of the injection molding machine 100 could be included in the molding system 200. It is also contemplated that the molding system 200 could further include different molding equipment, such as but not limited to: a compression molding machine, injection compression molding machine, extrusion blow molding machine, transfer molding machine and the like.
Along with the injection molding machine 100, the molding system 200 according to the present technology also comprises a multispectral inspection device 250. As is illustrated schematically in Figure 3, the inspection device 250 and the controller 140 are operably coupled together. As will be described in more detail below, the inspection device 250 and the controller 140 are communicatively coupled to permit control of the inspection device 250 by the controller 140, as well transfer of information and/or indications from the inspection device 250 to the controller 140 for controlling the molding machine 100. While not illustrated herein, it is contemplated that the molding system 200 could include a plurality of inspection devices according to at least some of the embodiments set out below.
Broadly, the inspection device 250 is arranged and configured to investigate one or more of the molded articles 50 and/or the molding machine 100 using multispectral light.
Different materials in the molded articles 50 and components of the molding machine 100 may have different Date Regue/Date Received 2023-01-05 reflection, absorption, and scattering properties in one wavelength or wavelength band in the multispectral light than in other bands of the multispectral light. In this way, different images formed from different wavelengths of light can be inspected separately and compared to determine aspects of the molded articles 50 and/or the molding machine 100. For example, multispectral images from the inspection device 250 could indicate presence or absence of one of the molded articles 50 in the molding machine 100 after a given molding cycle. Further example inspection variations are described in more detail below.
In order to illuminate the molded articles, not shown, such as preforms 50 (FIG. 1), located in or on one of the mold halves, and/or portions of the molding machine 100 in the illustrated embodiment of Figure 3, the inspection device 250 includes one or more multispectral light sources 260. One light source 260 is shown schematically for ease of illustration. The light source 260 is configured to illuminate one or more of the molded articles in or produced by the molding machine 100. In the embodiment of Figure 3 specifically, the light source 260 is arranged to illuminate the mold cavities 118 of the first mold half 114 that is associated with the stationary platen 102, as well as any molded articles that may be disposed therein at the time of inspection. Similarly, in an alternative embodiment, not shown, the location of the light source 260 may be arranged to illuminate the mold cores 120 of the stationary platen 102, as well as any molded articles that may be disposed thereon at the time of inspection The multispectral light source 260 produces light in a plurality of wavelengths, in order to inspect and image the molded articles and/or portions of the molding machine 100 with different light wavelengths. In at least some embodiments, the light source 260 produces light in multiple wavelength bands. The different wavelength bands produced could include, but are not limited to, visible light, near infrared, infrared, ultraviolet, and portions of the x-ray band. The light source 260, depending on the embodiment, could include a plurality of light producing elements, especially in embodiments producing light in large range of wavelengths or in several wavelength bands. The light producing elements could include, but are not limited to, electroluminescent sources such as light emitting diodes (LEDs), electric discharge sources (lamps), incandescent sources, and laser sources.
The light source 260 further includes one or more optical elements (not shown) for projecting the multispectral light in a generally even manner over the molding machine portions. The particular optical components required will depend on the exact embodiment of the light source 260. For example, different optical component arrangements could depend on the particular physical structure of the molding machine 100 and the wavelengths produced by the light source 260.

Date Regue/Date Received 2023-01-05 The inspection device 250 further includes an imaging system 270 configured to collect at least some light reflected and scattered from the molded articles, when the inspection device 250 is in operation. The imaging system 270 includes at least one detector 275 configured to detect at least some of the wavelengths of light produced by the light source 260. In some embodiments, the range of wavelength bands accepted by the detector 275 could be matched exactly to the wavelengths produced by the light source 260. It is also contemplated that the detector 275 could accept and measure only a portion of the wavelengths produced by the light source 260. It is further contemplated that the detector 275 could comprise a plurality of detectors configured to measure different wavelength bands.
The imaging system 270 also includes optical elements (not shown) for optically transferring light collected from light reflected and scattered from the molded articles to the one or more detectors 275. Similarly to the optical elements of the light source 260, the particular form and details of the optical elements for imaging by the imaging system 270 vary depending on the particular wavelengths of light from the light source 260, the particular arrangement of the molding machine 100, and implementational details of the one or more detectors 275.
The one or more detectors 275 is communicatively coupled to the computing apparatus 140. In some embodiments, the imaging system 270 could include an internal computing apparatus for receiving data from the detector 275 and forming images, and in turn transmitting information and/or images to the controller 140. In some embodiments, the controller 140 could receive unprocessed or only partially processed data from the detector 275. Depending on the particular embodiment, the inspection device 250 and/or the controller 140 could produce different types of images. For example, compound images produced by a combination of images formed in different wavelengths could be computed. In at least some embodiments, it is also contemplated that the inspection system 250 and the controller 140 could be configured to produce hyperspectral images of at least one of a portion of the molding machine 100 and/or one or more of the molded articles 50.
In the present embodiment, the inspection device 250 is mounted to the movable platen 104. In such an arrangement, the inspection device 250 is configured to image the mold cores 120 associated with the stationary platen 102 and/or the molded articles 50 prior to ejection from the molding machine 100, as is illustrated by the example rays of Figure 3.
Specifically, the inspection device 250 is configured to image one or more of the molded articles 50 in the molds (i.e. the first mold half 114 and the mold cavities 118) of the molding machine 100 prior to ejection of the molded articles 120 from the molding machine 100 or between an end of a first molding cycle and Date Regue/Date Received 2023-01-05 prior to a start of a second molding cycle. It is contemplated that the controller 140 and the inspection device 250 could also be configured to detect that one of the molded articles 50 is missing in the molding machine 100 in such a case.
In the present embodiment, the inspection device 250 is mounted to the movable platen 104. In such a configuration, the inspection device 250 could also be used to verify that all molded articles 50 have been properly removed from the mold cavities 118 of the first mold half 114, that is associated with the stationary platen 102, with opening of the mold following a given molding cycle and prior to the beginning of a subsequent molding cycle. In at least some embodiments, the inspection device 250 could also be configured to image molded articles 50 during ejection from the mold cores 120 of the second mold half 116 that is associated with the moveable platen 102 (further illustrated in Figure 5). In an alternative embodiment, not shown, the inspection device 250 may be mounted to the stationary platen 102. In such a configuration, the inspection device 250 could be used to verify that all molded articles 50 have been properly ejected from the mold cores 120 following a given molding cycle and prior to the beginning of a subsequent molding cycle.
As is noted above, the controller 140 is communicatively coupled to the molding machine 100 for controlling at least some operational aspects thereof. As the inspection device 250 is further communicatively coupled to the controller 140, the controller 240 could be configured to control one or more aspects of the molding machine 100 in response to information from the inspection device 250. It is contemplated, for example, that the molding machine could be configured to adjust one or more molding process variables in response to detection, by the inspection device 250, of at least one defect in one or more of the molded articles 50. In at least some embodiments, as one non-limiting example, the controller 140 could detect the presence of a molded article 50 that has not properly ejected and, in response, control the molding machine 100 to stop the subsequent molding cycle to prevent damage due to the improperly ejected molded article 50.
Depending on the specific embodiment of the inspection device 250 (or others) and the molding machine 100, it is contemplated that adjustments could be made at a variety of molding process variables. The mold process variables to be controlled could include, but is not limited to: a mold opening speed profile, a mold closing speed profile, an ejector speed profile, a mold open dwell time, a part removal function, a transfer air assist function, a part handling device dwell time, and molding process parameters such as temperature, pressure, and time.

Date Regue/Date Received 2023-01-05 While not illustrated herein, embodiments of the molding system 200 could also further include one or more conveyance devices for transporting multilayer preforms 50 between different portions or the molding system 200 and/or additional devices operationally arranged with the molding system 200. Many variations of conveyance devices can be implemented in non-limiting embodiments of the present technology, as will be appreciated by those skilled in the art. As such, specific implementation details need not be supplied here.
With reference to Figure 4, another implementation of molding system 300 according to the present technology is illustrated. Elements of the molding system 300 that are similar to those of the molding system 200 retain the same reference numeral and will generally not be described again. The robot 122 and the post-mold treatment device 132 are excluded from the illustrations for simplicity but are contemplated to the included in at least some embodiments.
The molding system 300 includes the molding machine 100, as well as another non-limiting embodiment of an inspection device 350. The inspection device 350 includes the light source 260 and the imaging system 270 with the detector 275 according to one of the non-limiting embodiments described above.
The inspection device 350 is arranged and configured to image one or more of the molded articles 50 when disposed on the pickers 133 of the post-mold treatment device 132. It is also contemplated that the inspection device 350 could be arranged to inspect the molded articles 50 after molding at a different point of transferring the molded articles 50 from the molding machine 100 in some embodiments, for example when the molded articles 50 are being held or moved by the molded article receptacles 130 of the take-off plate 128 (see Figure 2). It is further contemplated that the molding system 300 could include a display arrangement for receiving the molded articles 50 from the molding machine 100, for example from the take-off plate 128 and/or the pickers 133. In such an arrangement, the inspection device 350 could be configured to image the molded articles 50 in the display arrangement.
In at least some of the above described arrangements, the controller 140 and the inspection device 250 could be configured to detect one or more attributes of the molded articles 50. For example, the attribute may include the presence or absence of core layer in parts of the preform. In another example the attribute may be the detection of an impurity in the article. A
particular impurity could be detectable using a specific wavelength of light, the light source 250 producing the specific wavelength amongst the multispectral light produced. In at least some embodiments, the specific wavelength for detecting the impurity could be outside the visible spectrum.
It is also contemplated Date Regue/Date Received 2023-01-05 that a plurality of wavelengths produced and detected by the inspection device 250 could be chosen for detecting a plurality of impurities in the molded articles. In at least some embodiments, the molding machine 100 and the controller 40 could further be configured to adjust one or more molding process variables in response to detection of one or more impurities in the molded articles 50. The mold process variables to be controlled could include, but is not limited to: a mold opening speed profile, a mold closing speed profile, an ejector speed profile, a mold open dwell time, a part removal function, a transfer air assist function, a part handling device dwell time, and molding process parameters such as temperature, pressure, and time.
In at least some embodiments, the inspection device 350 could be configured to image the skin layer 20 and the core layer 40 for embodiments where the molded articles 50 are preforms 50. In some such embodiments, the controller 140 could be configured to identify defects in the skin layer 20 and/or the core layer 40. In at least some embodiments, the molding machine 100 could further be configured to adjust one or more molding process variables, described above, in response to identifying defects in the skin layer 20 and/or the core layer 40.
Upon detection of an attribute, such as an impurity or defect, of one of the molded articles 50 by the inspection device 250, the controller 140 could receive and record the information related to the attribute determined. In some embodiments, the controller 140 could be configured to determine if the attribute falls outside a pre-determined range, such as if the attribute falls outside of an acceptable range of values. In some embodiments, the controller 140 is further configured to generate an alert for the operator that the attribute falls outside the pre-determined range. For example, the operator may receive a visual or audio alert on the HMI that the preforms 50 being inspected have core layers 40 having an impurity. The controller 140 may also be configured to adjust at least one of the operational settings of the molding system 200, or specifically the molding machine 100, if the attribute falls outside the pre-determined range.
With reference to Figure 5, yet another implementation of molding system 400 according to the present technology is illustrated. Elements of the molding system 400 that are similar to those of the molding system 200 retain the same reference numeral and will generally not be described again. The robot 122 and the post-mold treatment device 132 are excluded from the illustrations for simplicity but are contemplated to the included in at least some embodiments.
The molding system 400 includes the molding machine 100, as well as another non-limiting embodiment of an inspection device 350. The inspection device 350 includes the light source 260 Date Regue/Date Received 2023-01-05 and the imaging system 270 with the detector 275 according to one of the non-limiting embodiments described above.
In the illustrated embodiment, the inspection device 450 is arranged to image in the space between the movable platen 104 and the stationary platen 102 when the machine 100 is in the open position.
In such a position, the inspection device 450 is configured to image molded articles on one or both of the first mold half 114 and the second mold half 116, or even molded during ejection.
A technical effect associated with embodiments of the present technology may include the ability to minimize down time of the molding machine 100 by performing regular, automated inspection of molded articles 50 or by monitoring clearance of the molded articles 50 from the molding machine 100. Another technical effect associated with embodiments of the present technology may include the ability to image defect or other attributes of the molded articles 50 which may not be detectable at only a single wavelength or within a given wavelength band.
With reference to Figure 6, illustrated by a block diagram, a method 500 is executable in accordance with non-limiting embodiments of the present technology. The method 500 will be described herein with respect to the molding system 200, detailed above, but it is contemplated that the method applies equally to the molding systems 300, 400 as well as other non-limiting embodiments of an injection molding system according to the present technology.
Step 510 ¨ illuminating at least one molded article produced by the molding machine The method 500 begins, at step 510, with illuminating, by the light source 260, one or more of the molded articles and/or portions of the molding machine with light having a plurality of wavelengths.
Step 520 - imaging at least some light reflected and refracted from the at least one molded article onto the detector The method 500 then continues, at step 520, with imaging, by the imaging system 270, at least some of the light reflected and refracted from the molded articles and/or portions of the molding machine 100 onto the detector 275. As is noted above, the detector 275 is configured to detect at least some of wavelengths of illuminating light.
In at least some embodiments, imaging the molded articles 50 includes imaging the molded articles 50 in the molding machine 100 prior to ejection. It is also contemplated that the method 500 could Date Regue/Date Received 2023-01-05 further include producing a hyperspectral image block, by the controller 140, based on the imaging the plurality of molded articles 50 in the plurality of wavelengths.
Step 530 ¨ determining at least one attribute of the at least one molded article The method 500 then terminates, at step 530, with determining, by the controller 140, at least one attribute of the one or more molded articles. The controller 140 determines the attribute(s) through detection using a plurality of images of the molded article(s) formed at different wavelengths.
In at least some embodiments, determining the attribute(s) includes executing an image recognition algorithm to analyse the images formed at least some of the plurality of wavelengths produced by the light source 260.
In some embodiments, determining the attribute(s) includes detecting at least one defect in one of the molded articles 50. In such a case, the method 500 could further include, in response to detecting the defect, causing a change in at least one molding process variable of the molding machine 100. It is contemplated that causing the change in the molding process variable could include causing change in a mold opening speed profile, a mold closing speed profile, an ejector speed profile, a mold open dwell time, a part removal function, a transfer air assist function, and/or a part handling device dwell time.
In some embodiments, the method 500 could further include determining that one or more of the molded articles 50 of a previous molding cycle should be rejected. The method 500 could also include, in some embodiments, determining that one or more of the molded articles of a subsequent molding cycle should be rejected.
Modifications and improvements to the above-described embodiments of the present technology may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present technology is therefore intended to be limited solely by the scope of the appended claims.
The description of the embodiments of the present technology provides only examples of the present technology, and these examples do not limit the scope of the present technology. It is to be expressly understood that the scope of the present technology is limited by the claims only. The concepts described above may be adapted for specific conditions and/or functions and may be further extended to a variety of other applications that are within the scope of the present technology. Having thus described the embodiments of the present technology, it will be apparent Date Regue/Date Received 2023-01-05 that modifications and enhancements are possible without departing from the concepts as described.

Date Regue/Date Received 2023-01-05

Claims (27)

1. A molding system comprising:
a molding machine for producing a plurality of molded articles; and at least one inspection device configured to inspect at least one molded article of the plurality of molded articles; and a computing apparatus operatively coupled to the at least one inspection device, the at least one inspection device comprising:
at least one multispectral light source configured to illuminate the at least one molded article; and at least one imaging system configured to collect at least some light reflected and scattered from the at least one molded article, the at least one imaging system including at least one detector configured to detect a plurality of wavelengths in light imaged by the at least one imaging system, the at least one detector being communicatively coupled to the computing apparatus, the at least one inspection device configured to inspect the at least one molded article between an end of a first molding cycle and prior to a start of a second molding cycle.

2. The molding system of claim 1, wherein the at least one inspection device is configured to image the at least one molded article in a mold of the molding machine prior to ejection of the at least one molded article from the molding machine.

3. The molding system of claim 1, wherein the computing apparatus and the at least one inspection device are configured to detect that one of the plurality of molded articles is missing in the molding machine.

4. The molding system of claim 3, wherein:
the computing apparatus is communicatively coupled to the molding machine; and wherein the molding machine is configured to adjust at least one molding process variable in response to detection, by the at least one inspection device, of at least one defect in the at least one molded article.

5. The molding system of claim 4, wherein the at least one molding process variable includes at least one of:
a mold opening speed profile;
a mold closing speed profile;
an ejector speed profile;
a mold open dwell time;
a part removal function;
a transfer air assist function;
molding process parameters such as temperature, pressure, time and a part handling device dwell time.

6. The molding system of claim 1, wherein:
the molding machine comprises:
a stationary platen, and a moveable platen;
the at least one inspection device is mounted to one of the stationary or moveable platens; and the at least one inspection device is configured to image mold cavities in a first mold half associated with the stationary platen and/or mold cores in a second mold half associated with the moveable platen.

7. The molding system of claim 6, wherein the at least one inspection device is configured to image the plurality of molded articles during ejection from one of the first mold half or the second mold half.

8. The molding system of claim 1, wherein the at least one inspection system and the computing apparatus are configured to produce hyperspectral images of at least one of a portion of the molding machine and the at least one molded article.

9. A method for inspecting molded articles from a molding system, the molding system including at least one inspection device and a molding machine, the method comprising:

illuminating, by at least one light source of the at least one inspection device, at least one molded article produced by the molding machine, the at least one light source providing light having a plurality of wavelengths;
imaging, by an imaging system of the at least one inspection device, at least some light reflected and refracted from the at least one molded article onto a detector of the at least one inspection device, the detector being configured to detect at least some of the plurality of wavelengths of illuminating light; and determining, by a computing apparatus communicatively coupled to the detector, at least one attribute of the at least one molded article, the at least one attribute being detectable using a plurality of images of the at least one molded article, the plurality of images being formed by at least some of the plurality of wavelengths.

10. The method of claim 9, wherein the determining the at least one attribute includes executing an image recognition algorithm to analyse the plurality of images formed by the at least some of the plurality of wavelengths.

11. The method of claim 9, wherein:
determining the at least one attribute includes detecting at least one defect in the at least one molded article; and further comprising, in response to detecting the at least one defect, causing a change in at least one molding process variable of the molding machine.

12. The method of claim 11, wherein causing the change in the at least one molding process variable includes causing change in at least one of:
a mold opening speed profile;
a mold closing speed profile;
an ejector speed profile;
a mold open dwell time;
a part removal function;
a transfer air assist function;
molding process parameters such as temperature, pressure, time and a part handling device dwell time.

13. The method of claim 11, further comprising determining that the at least one molded article of a previous molding cycle is to be rejected.

14. The method of claim 11, further comprising determining that the at least one molded article of a subsequent molding cycle is to be rejected.

15. The method of claim 9, wherein imaging the at least one molded article includes imaging the plurality of molded articles.

16. The method of claim 15, wherein imaging the plurality of molded articles includes imaging the plurality of molded articles in the molding machine prior to ejection.

17. The method of claim 15, further comprising producing a hyperspectral image block, by the computing apparatus, based on the imaging the plurality of molded articles in the plurality of wavelengths.

18. The method of claim 9, wherein at least some of the plurality of wavelengths are wavelengths outside of a visible light spectrum.

19. A molding system comprising:
a molding machine for producing a plurality of molded articles; and at least one inspection device configured to inspect at least one molded article of the plurality of molded articles; and a computing apparatus operatively coupled to the at least one inspection device, the at least one inspection device comprising:
at least one multispectral light source configured to illuminate the at least one molded article; and at least one imaging system configured to collect at least some light reflected and scattered from the at least one molded article, the at least one imaging system including at least one detector configured to detect a plurality of wavelengths in light imaged by the at least one imaging system, the at least one detector being communicatively coupled to the computing apparatus.

20. The molding system of claim 19, further comprising:
a display arrangement for receiving the at least one molded article from the molding machine; and wherein the at least one inspection device is configured to image the at least one molded article in the display arrangement.

21. The molding system of claim 19, wherein the computing apparatus and the at least one inspection device are configured to detect at least one attribute in the at least one molded article, the at least one attribute being detectable using light with at least a first wavelength of the plurality of wavelengths.

22. The molding system of claim 21, wherein the first wavelength is outside a visible spectrum.

23. The molding system of claim 21, wherein:
the computing apparatus is communicatively coupled to the molding machine; and wherein the molding machine is configured to adjust at least one molding process variable in response to detection of the at least one impurity in the at least one molded article.

24. The molding system of claim 19, wherein:
the plurality of molded articles produced by the molding machine is a plurality of multilayer preforms; and wherein each of the plurality of multilayer preforms includes a core layer and a skin layer enveloping the core layer.

25. The molding system of claim 24, wherein:
the at least one inspection device is configured to image the skin layer and the core layer of at least one of the plurality of multilayer preforms; and wherein the computing apparatus is configured to identify defects in at least one of the skin layer and the core layer.

26. The molding system of claim 25, wherein:
the computing apparatus is communicatively coupled to the molding machine; and wherein the molding machine is configured to adjust at least one molding process variable in response to identified defects in the at least one of the skin layer and the core layer.

27. The molding system of claim 19, wherein:
the computing apparatus is communicatively coupled to the molding machine;
the at least one inspection device is configured to inspect the at least one molded article prior to ejection of the at least one molded article from the molding machine;
and the molding machine is configured to adjust at least one molding process variable in response to detection, by the at least one inspection device, of at least one defect in the at least one molded article.