CN108136657B - 型坯异物检测系统 - Google Patents

型坯异物检测系统 Download PDF

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CN108136657B
CN108136657B CN201680052854.1A CN201680052854A CN108136657B CN 108136657 B CN108136657 B CN 108136657B CN 201680052854 A CN201680052854 A CN 201680052854A CN 108136657 B CN108136657 B CN 108136657B
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parison
foreign matter
determinating area
detection system
thermal camera
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高柳公照
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Yachiyo Industry Co Ltd
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Abstract

一种检测从排出器(21)连续排出的型坯(11)中的异物的系统，其具备：红外摄像机(2)，其检测从型坯(11)释放的红外线；以及判定部，其根据由红外摄像机(2)检测到的红外线来判定型坯(11)中是否存在异物。相对于型坯(11)，在型坯(11)的排出方向上设定判定区域，具备存储部，其存储相对于判定区域设定的红外线的阈值，判定部对红外摄像机的检测值与阈值进行比较。

Description

型坯异物检测系统
技术领域
本发明涉及一种型坯异物检测系统。
背景技术
作为检测型坯的异物的现有技术，能够列举专利文献1所述的技术。专利文献1中记载了通过由CCD摄像机对型坯进行摄像并电处理该型坯的摄像数据来检测异物的有无。
现有技术文献
专利文献
专利文献1：日本特开昭59-31437号公报
发明内容
发明所要解决的技术问题
然而，在专利文献1的技术中，对型坯要求透明性，因此会有无法对不透明的型坯检测异物的问题。
本发明是为了解决这种问题而创作的，其目的在于提供一种即使对于不透明的型坯也能够检测内部的异物的型坯异物检测系统。
用于解决技术问题的手段
为了解决上述问题，本发明的系统，其检测从排出器连续排出的型坯中的异物，其特征在于，具备：红外摄像机，其检测从所述型坯释放的红外线；以及判定部，其根据由所述红外摄像机检测到的红外线，来判定型坯中是否存在异物，
相对于所述型坯部分地设定判定区域，
具备存储部，其存储相对于所述判定区域设定的红外线的阈值，
所述判定部对所述红外摄像机的检测值与所述阈值进行比较，
所述判定区域是与用于安装零件的所述型坯的安装部相对应的区域。
根据本发明，通过检测从型坯释放的红外线，即使型坯是不透明的，也可以检测出型坯内部的异物。
根据本发明，可以将异物的检测范围限定为期望的范围，因此可以抑制成型品的不必要的不合格的发生。
根据本发明，可以在防止异物影响零件的安装部的同时、抑制成型品的不必要的不合格的发生。此外，本发明的特征在于：设定有所述阈值不同的多个判定区域。
根据本发明，可以按每个判定区域改变异物的容许度，因此可以进一步抑制成型品的不必要的不合格的发生。
此外，本发明的特征在于：具备控制部，其在所述判定部判定为存在异物时，发出该型坯的废弃指令。
如果具备在所述判定部判定为存在异物时发出该型坯的废弃指令的控制部，则可以通过简单的结构废弃不合格的型坯。
此外，本发明的特征在于：所述控制部向输送切开的型坯的输送机发出所述废弃指令。
根据本发明，通过利用输送机，可以进一步通过简单的结构废弃不合格的型坯。
此外，本发明的特征在于：从所述排出器排出的型坯在水平截面中呈圆弧形，所述红外摄像机在所述型坯周围布置多个。
根据本发明，可以将在水平截面中呈圆弧形的型坯在整个圆周上作为红外线的检测范围。
发明效果
根据本发明，通过检测从型坯释放的红外线，即使型坯是不透明的，也能够检测出型坯内部的异物。
附图说明
图1是本发明的型坯异物检测系统的外观图。
图2是本发明的型坯异物检测系统的结构框图。
图3是示出型坯的层结构的截面图。
图4是红外摄像机的温度分布图像。
图5是示出燃料箱的判定区域和非判定区域的平面图。
图6是型坯异物检测系统的作用说明图。
具体实施方式
在图1中，本发明的型坯异物检测系统1是检测从排出器21连续排出的型坯11中的异物12(图3)的系统，其具备：红外摄像机2，其检测从型坯11释放的红外线；以及控制装置3。如图2所示，控制装置3构成为具备判定部4、存储部5及控制部6。作为控制装置3，可以利用个人计算机。
排出器21构成为具备模具及型芯，型坯11从排出器21的底面上形成的环形排出口成为圆筒形而向下方排出。在图1中，示出了在通过布置在排出器21的排出口处的未示出的刀具将型坯11竖切成在水平截面中分别呈半圆弧形的一对型坯片之后向下方延伸的形式。红外摄像机2在型坯11周围大约180度正对的位置处设置成一对，从而能够对各型坯片进行摄影。然而，在本发明中，型坯的形状并非限定于此，也可以是不竖切成两半而直接以圆筒形的状态向下方排出的形式。此外，也可以是将型坯11以大致平面形状向下方排出的形态。
图3示出了成型品是汽车用燃料箱时的型坯11的层结构的一个例子。该层结构是从燃料箱内侧依次形成有热塑性树脂层11A、粘合层11B、阻隔层11C、粘合层11D、再生层11E、热塑性树脂层11F的四种六层结构。热塑性树脂层11A、11F例如由HDPE(高密度聚乙烯)形成。阻隔层11C由燃料不渗透性优异的材料、例如EVOH(乙烯-乙烯醇共聚物)形成。再生层11E由将通过对燃料箱的去毛刺处理而获得的毛刺、在成型过程、检验过程中不合格的产品熔融混合的再生材料形成。
异物12主要存在于再生层11E。型坯11是不透明的，因此再生层11E内的异物12难以通过目视检查来识别。红外摄像机2检测从异物12释放的红外线，因此即使型坯11是不透明的，也可以有效地检测出异物12。从物体释放的红外线能量由式(1)示出。
Q＝ε·σ·T4…式(1)
Q：红外线能量[W/m2]
ε：放射率
σ：斯特藩-玻尔兹曼系数5.67×10-8[W/m2K4]
T：绝对温度[K]
作为再生层11E内包含的异物12，除了来自外部的附着物，还有阻隔层11C的EVOH、热塑性树脂层11A、11F的聚乙烯等氧化劣化而材质发生变化的物质等。式(1)的放射率ε是根据物体的材质、表面状态而不同的值。因此，由于再生层11E和异物12的各放射率ε不同，仅异物12的存在部分的红外线能量变化，可以通过利用红外摄像机2对其进行检测来确定异物12。具体地，红外摄像机2内置有在电磁波中吸收红外线(7.5μm-13μm)的检测元件、以及对吸收红外线且温度上升的检测元件的温度变化进行检测的温度传感器，根据温度传感器的温度分布，向外部输出摄影区域的温度分布图像的信号。图4示出了由红外摄像机2围绕圆筒形的型坯的下部进行摄影并显示在监视器9(图1)上的温度分布图像，(a)为滤波处理前的图像，(b)为滤波处理后的图像。通过进行滤波处理，可以利用监视器9容易地视觉辨认异物12的有无。
在图2中，判定部4根据红外摄像机2的检测值D1、具体是根据前述的关于温度分布图像的信号，判定型坯11中是否存在异物12。其中，在图5中，在作为型坯成型品的燃料箱T中，形成有用于安装燃料泵(未示出)的泵安装座13、以及用于安装抑制燃料箱内的燃料的起伏的吸收器(未图示)的两端的吸收器安装座14A、14B。当异物12存在于这些泵安装座13、吸收器安装座14A、14B的形成部分中时，泵安装座13、吸收器安装座14A、14B有可能会形状不合格而而阻碍燃料泵、吸收器的安装。另一方面，对于零件的未安装部，即使存在异物12也可能不会成为那么严重的问题。
在这种情况下，优选部分地设定判定区域。在本实施方式中，相对于预定长度(燃料箱等成型品的单品成型所需的长度)的型坯11，在型坯11的排出方向上设定有判定区域和非判定区域。判定区域是进行判定部4的判定的区域，非判定区域是不进行判定部4的判定的区域。在图5中示出了从型坯11的排出方向下游侧依次设定为非判定区域16A、判定区域15A、非判定区域16B、判定区域15B、非判定区域16C的例子。判定区域15A是包括泵安装座13和吸收器安装座14A的区域，判定区域15B是包括吸收器安装座14B的区域。即，判定区域15A、15B是包括零件的安装部的区域。非判定区域16A～16C是不包括零件的安装部的区域。
在图2中，存储部5存储有相对于判定区域15A、15B设定的红外线的阈值D2。判定区域15A的阈值D2和判定区域15B的阈值D2可以是彼此相同的值，也可以是不同的值。判定部4比较从红外摄像机2输入的检测值D1和存储部5中存储的阈值D2，在检测值D1大于阈值D2时，判定为在判定区域15A、15B中存在异物12。
控制部6在判定部4判定为存在异物12时，发出该预定长度的型坯11的废弃指令。在排出器21的下方布置有用于切开排出到预定长度的型坯11的上端的刀具7(图6)、以及用于抓持切开的型坯11的上端一周并将其输送到未示出的成型模具的输送机8(图6)，控制部6向输送机8发出所述废弃指令。由此，输送机8不将因异物12而不合格的型坯11输送到成型模具中，而是输送到预定的废弃地点并废弃。
[作用]
对型坯异物检测系统1的作用进行说明。图6(a)是型坯11被排出前的状态，刀具7和输送机8处于待机位置。如图6(b)所示，当型坯11被排出时，通过一对红外摄像机2对型坯11的上游侧的外表面侧进行摄影。判定部4比较红外摄像机2的检测值D1和存储部5中存储的阈值D2，对判定区域15A、15B中是否存在异物12进行判定。另外，判定区域15A、15B的范围可以根据型坯11的排出速度(排出经过时间)容易地确定。
在判定为在任何判定区域15A、15B中都不存在异物12时，以预定长度切开的型坯11被输送机8输送到成型模具。在判定为判定区域15A、15B中的任何一方中都存在异物12时，通过控制部6将废弃指令发送到输送机8中，如图6(c)所示，以预定长度切开的型坯11被输送机8输送到废弃地点。
综上所述，如果具备检测从型坯11释放的红外线的红外摄像机2、以及根据由红外摄像机2检测到的红外线来判定型坯11中是否存在异物12的判定部4，则即使型坯11是不透明的，也可以检测出型坯11内部的异物12。
此外，相对于型坯11部分地设定判定区域15A、15B，具备存储相对于判定区域15A、15B设定的红外线的阈值D2的存储部5，如果判定部4为对红外摄像机2的检测值D1与阈值D2进行比较的结构，则可以将异物12的检测范围限定为期望的范围，因此可以抑制成型品的不必要的不合格的发生。尤其是，如果设定阈值D2彼此不同的多个判定区域15A、15B，则能够对每个判定区域改变异物的容许度，因此能够进一步抑制成型品的不必要的不合格的发生。
相对于型坯1，还部分地设定未进行判定的非判定区域16A-16B，如果判定区域15A、15B被配置为包括零件安装部的区域，则在防止异物12影响零件安装部的同时，可以抑制成型品发生不必要的不合格。
如果具备在判定部4判定为存在异物12时发出该型坯11的废弃指令的控制部6，则可以通过简单的结构废弃不合格的型坯11。尤其是，如果控制部6为向输送切开的型坯11的输送机8发出废弃指令的结构，则可以进一步通过简单的结构废弃不合格的型坯11。
此外，在从排出器21排出的型坯11在水平截面中呈圆弧形(也包括圆筒形)时，如果在型坯11周围布置多个红外摄像机2，则可以将在水平截面中呈圆弧形的型坯11在整个圆周上作为红外线的检测范围。
以上说明了本发明的优选的实施方式。在已说明的实施方式中，将预定长度的型坯11分成判定区域和非判定区域，但是，也可以不设置非判定区域，而是仅设置多个判定区域，使得各阈值D2不同。
符号说明
1 型坯异物检测系统
2 红外摄像机
3 控制装置
4 判定部
5 存储部
6 控制部
7 刀具
8 输送机
15A、15B 判定区域
16A、16B、16C 非判定区域

Claims (5)

1.一种型坯异物检测系统，其检测从排出器连续排出的型坯中的异物，其特征在于，具备：
红外摄像机，其检测从所述型坯释放的红外线；以及
判定部，其根据由所述红外摄像机检测到的红外线，来判定型坯中是否存在异物，
相对于所述型坯部分地设定判定区域，
具备存储部，其存储相对于所述判定区域设定的红外线的阈值，
所述判定部对所述红外摄像机的检测值与所述阈值进行比较，
所述判定区域是与用于安装零件的所述型坯的安装部相对应的区域。
2.如权利要求1所述的型坯异物检测系统，其特征在于，
设定有所述阈值不同的多个判定区域。
3.如权利要求1所述的型坯异物检测系统，其特征在于，
具备控制部，其在所述判定部判定为存在异物时，发出该型坯的废弃指令。
4.如权利要求3所述的型坯异物检测系统，其特征在于，
所述控制部向输送切开的型坯的输送机发出所述废弃指令。
5.如权利要求1所述的型坯异物检测系统，其特征在于，
从所述排出器排出的型坯在水平截面中呈圆弧形，
所述红外摄像机在所述型坯周围布置多个。
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