JP2003080527A - Method for diagnosing abnormality of ejector assembly - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily narrow the abnormal place of an ejector assembly down and to diagnose both of abnormality making a cycle time long and abnormality making the cycle time short to perceive trouble beforehand. SOLUTION: Trial operation is performed to set the restriction value of the cycle time of a moving body and the upper and lower limit values below the restriction value thereof. At the time of automatic operation, the cycle time of the moving body is detected and the detected value is set as history and renewed by the set number of cycles to be recorded. When the detected value of the cycle time is not more than the lower limit value, the moving body is diagnosed to arrive abnormally early to output an early arrival alarm and a part becoming the candidate of an early arrival factor is displayed along with history data. When the detected value of the cycle time is not less than the upper limit value, the moving body is diagnosed to arrive abnormally late to output a late arrival alarm and a part becoming the candidate of a late arrival factor is displayed along with the history data. When an elapse time exceeds the restriction value by midway stop or the like, a servo motor is immediately stopped to output the late arrival alarm.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for diagnosing an abnormality in each part of a machine in a take-out machine for taking out various processed products from various processing machines.

[0002]

2. Description of the Related Art For example, a take-out machine for an injection molding machine is constructed so that a chuck is moved in and out of the molding machine, a resin molded product is taken out of a mold and taken out of the machine. Since this take-out machine operates by linking with the molding machine, an abnormality or failure of the take-out machine has a great influence on the operating rate of the molding machine. Therefore, conventionally, the operating time of one cycle of the moving body supporting the chuck is monitored, and when the cycle time exceeds a preset limit value, the operation of the machine is stopped,
A method of displaying an alarm that the process is abnormal and prompting an early recovery was adopted.

[0003]

However, the conventional abnormality diagnosis method has the following problems. (1) Although it is possible to specify which process has an abnormality, it is not possible to specify in detail which part of the process has an abnormality. (2) Abnormalities that lengthen the cycle time, such as seizure of guides and damage to the bearings, can be diagnosed, but abnormalities that shorten the cycle time, such as cutting the belt and breaking the shaft, could not be diagnosed. (3) In many cases, the parts were already damaged at the time of diagnosing the abnormality, and the failure could not be detected in advance.

An object of the present invention is to solve the above-mentioned problems, to identify the abnormal portion of the unloader in detail, to diagnose both the abnormality that prolongs the cycle time and the abnormality that shortens the cycle time, and to detect the failure in advance. It is to provide an abnormality diagnosis method.

[0005]

In order to solve the above-mentioned problems, a method for diagnosing a take-out machine according to the present invention includes a chuck processing machine (including various processing machines such as a molding machine, a machine tool, and a surface processing machine). In the unloader that moves in and out of the machine and takes out processed products (including various processed products such as molded products, machined products, surface processed products), it detects and detects the operating time of the moving body provided in the chuck moving mechanism. The value is compared with the preset upper and lower limits, and when the detected value is above the upper limit, the parts that are candidates for the delay factor are displayed, and when the detected value is below the lower limit, it is the candidate for the early arrival factor. It is characterized by displaying parts.

Here, the "chuck moving mechanism" is a mechanism for moving the chuck in and out of the processing machine. In the case of the unloader in which the chuck moves in a plurality of directions, a plurality of moving mechanisms are provided for each direction, and abnormality diagnosis is performed in a required part or all of the moving mechanisms. The “moving body” provided in the chuck moving mechanism is, among the elements constituting the mechanism, a member that directly or indirectly supports the chuck and moves in a predetermined stroke (for example, linear movement or rotational movement). .

The "operating time" of a moving body is the time required for the moving body to move a predetermined distance. For example, the time required from the start to the end of the stroke, that is, the cycle time, the time required from the start to the intermediate position, the time required from the intermediate position to the end, or the time required from the intermediate position to another intermediate position is detected. .

The "upper limit value and the lower limit value" define a time range in which it is possible to determine that the operation of the moving body is normal. When setting each value, the operator can manually input based on the operating program and experience value of the processing machine, but the upper limit value and the lower limit value can be set in the point that the data suitable for the actual operating condition can be acquired. It is preferable to set based on the execution value of the trial operation. The upper limit value may be set to the same value as the cycle time limit value, but it is preferable to set the upper limit value to less than the cycle time limit value so that even a relatively slight abnormality can be detected early.

The "parts that are candidates for the delay factor" are as follows:
Although not particularly limited, guides, bearings, air cylinders, etc.
It is possible to exemplify a component that causes an excessive load due to seizure or deformation to prolong the cycle time. The "part that is a candidate for the cause of early arrival" is not particularly limited, but examples thereof include a part such as a belt, a shaft, a coupling, etc. that causes an underload due to cutting or breakage to shorten the cycle time. However, all of these candidate parts are typical ones, and in practice, they are appropriately selected in consideration of the possibility and frequency of abnormality based on the specific configuration of the chuck moving mechanism.

Further, the abnormality diagnosing method of the present invention is characterized by recording a history of operating time and displaying the history data at any time in order to specify the abnormal portion in more detail. For example, the cycle time for the past several cycles or several hours is updated and stored in the storage device, and when an abnormality occurs, it is displayed on the display device together with the candidate parts. Alternatively, only the peak value of the cycle time may be extracted and the long-term history data over the past several days or months may be recorded.

In this case, it is preferable that the history data be transmitted to the host computer at the remote place via the communication line so that the abnormality of the unloader can be diagnosed at the remote place. The transmission data may include not only history data but also control data such as various set values and communication data with the processing machine. Examples of the communication line include a local communication line using a LAN and a wide area communication line using the Internet. A mobile phone with a mail can also be used as the transmission / reception device.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment in which the present invention is embodied in a take-out machine for an injection molding machine will be described below with reference to the drawings. As shown in FIG. 1, the main frame 2 of the take-out machine 1 is fixed on the injection molding machine 3 so as to extend in the left-right direction. The left-right moving body 4 is supported on the main frame 2, and the left-right moving body 4 has a sub-frame 5 long in the front-rear direction.
Is fixed. A front-rear moving body 6 is supported by the sub-frame 5, and a vertical moving body 8 is supported below the front-rear moving body 6. A revolving unit 9 is supported by the vertical moving unit 8 and a plurality of chucks 10 are mounted on the revolving unit 9. And
The chuck 10 moves back and forth, up and down, and left and right to extract a resin molded product from the mold 11 of the molding machine 3 and take it out of the machine.

The mechanism for moving the chuck 10 in the front-rear direction includes a front-rear moving body 6, a guide 19 for guiding the front-rear moving body 6, and
A servomotor 20 with a speed reducer for driving the front-rear moving body 6,
It is composed of a belt 21 that transmits the power of the servomotor 20 to the front-rear moving body 6. As shown in FIG. 2, the left-right moving mechanism of the chuck 10 includes a left-right moving body 4, a guide 13 for guiding the left-right moving body 4, a servomotor 14 with a speed reducer for driving the left-right moving body 4, and a servo. Motor 14
It is composed of a belt 15 and pulleys 16, 17 and 18 for transmitting the power of the above to the left and right moving body 4.

As shown in FIG. 3, the vertical moving mechanism of the chuck 10 employs a double speed mechanism for driving the vertical moving body 8 at high speed. The vertical moving body 8 is formed in a columnar shape, and is supported by the elevating body 23 via a guide 22. The lifting body 23 is supported by the front-rear moving body 6 via a guide 24,
It is driven by a servomotor 25 with a speed reducer via an end belt 26. The vertically movable endless belt 2 is provided on the lifting body 23.
7, a part on one side is connected to the front-rear moving body 6 by a joint 28, and a part on the other side is connected to the vertical moving body 8 by a joint 29. Then, the endless belt 27 is rotated by the movement of the lifting body 23, and the endless belt 27 is rotated.
The vertical moving body 8 is driven at a speed twice as fast as that of the elevating body 23 by the rotation.

A double speed mechanism using two actuators, a servo motor and an air cylinder, may be adopted as a mechanism for moving the chuck 10 in the vertical direction. Chuck 10
In the turning mechanism, the turning body 9 is driven by the servomotor 30 (see FIG. 1). Guide 1 for each mechanism
LM guides (linear motion guides) using rolling guides are used for 3, 19, 22, 24, and belts 15, 21,
Toothed belts are used for 26 and 27. It is also possible to use chains or ball screws instead of belts.

The servomotors 14, 20, 25 of each mechanism,
30 is servo-controlled by the controller of the unloader 1.
For example, in the mechanism for moving the chuck 10 in the vertical direction, as shown in FIG.
The servo motor 25 is controlled via 2 and the moving amount and speed of the vertical moving body 8 are detected based on a signal from an encoder 33 attached thereto. Further, the control device 31 has a timer function and outputs a stop signal to the servo control unit 32 when the amount of movement of the vertical moving body 8 reaches a set distance, and detects the cycle time from the start signal to the stop signal. . The control device 31 is connected with an input device 35 for inputting various set values, a storage device 36 for storing the set values, detected values and the like, and a display device 37 for displaying the stored data, alarms and the like.

The take-out machine 1 having the above-mentioned construction takes out the molded product in the order of steps shown in FIGS. During the molding operation of the molding machine 3, the chuck 10 stands by at the origin position O above the mold 11. When the molding machine 3 finishes one shot and a take-out start command is issued after the mold is opened, first, the vertical moving body 8 descends, the front-back moving body 6 advances, and the chuck 10 holds the molded product. Next, the front-rear moving body 6 retreats, the vertical moving body 8 rises to the origin position O, and the unloader 1 outputs a mold clamping start command to the molding machine 3. Subsequently, the left and right moving body 4 moves out of the machine, the swinging body 9 swings to change the direction of the chuck 10, and the up and down moving body 8 descends to move the chuck 10
Releases the molded article. Thereafter, (10) the vertical moving body 8 rises, (11) the swinging body 9 swings to restore the orientation of the chuck 10, (12) the horizontal moving body 4 moves into the machine, and the chuck 10 moves to the origin position O. Return to.

Next, a method of diagnosing the abnormality of the unloader 1 will be described. As shown in FIG. 7, when starting operation of the unloader 1, a trial operation (manual operation) for one cycle is executed (step S1). Here, the cycle times of the left and right moving body 4, the front and rear moving body 6, the up and down moving body 8, and the revolving body 9 are detected for each process, and as shown in FIG. In addition, the limit value of the cycle time during automatic operation and the upper limit value and the lower limit value less than the limit value are set in the storage device 36 (step S2). By doing so, it is possible to automatically set the optimum value for the actual operating condition without checking each part at the start of operation.

In the automatic operation, substantially the same diagnostic program is executed in each process (except the process of gripping and releasing the molded product). First, when the start signal of the process is confirmed based on the end signal of the previous process (step S11), the timer is started (step S12), the servo motor 14,
20, 25 and 30 are driven (step S13). Next, after the elapsed time is compared with the limit value (step S1
4) The stop signal is confirmed (step S15), and the moving bodies 4, 6, 8, and 9 are continuously driven until the stop signal is confirmed within the time period equal to or less than the limit value. The stop signals for the front-rear moving body 6, the left-right moving body 4, and the revolving body 9 are output from a detector (not shown) such as a limit switch provided at the stroke end.

Then, when the moving bodies 4, 6, 8 and 9 move through the entire process and the stop signal is confirmed, the servo motor 1
4, 20, 25, 30 are stopped (step S16),
The timer is stopped (step S17). Then, the cycle time of the moving bodies 4, 6, 8, 9 is detected (step S18), and the detected value is updated as the history of the operation time by the set number of cycles and recorded in the storage device 36 (step S19). . Then, the detected value of the cycle time is compared with the lower limit value set in the trial operation (step S20),
If it is greater than or equal to the lower limit, it is compared with the upper limit (step S
21). If the detected value is less than or equal to the upper limit value, it is diagnosed that the cycle time of the moving bodies 4, 6, 8, 9 is normal, and the process end signal is output (step S22).

On the other hand, when the detected value of the cycle time is less than or equal to the lower limit value, it is diagnosed that the moving bodies 4, 6, 8 and 9 have arrived abnormally early, and an alarm signal for notifying this early arrival is output. After that (step S23), a signal for stopping the operation of the unloader 1 is output (step S2).
5). At this time, the display device 37 responds to the alarm signal.
, The parts that are candidates for the early arrival factor in the process are displayed on the display device 37. For example, as shown in FIG. 9, in the case of the chuck lowering step, the belts 26 and 27 (cutting),
A plurality of candidate parts that shorten the cycle time, such as the reducer shaft (broken) of the servo motor 25 and its coupling (damage), are listed together with the part number and the abnormality content.

When the detected value of the cycle time is equal to or more than the upper limit value, it is diagnosed that the moving bodies 4, 6, 8 and 9 have arrived abnormally late, and an alarm signal for notifying this extension is output (step S24), and in response thereto, the display device 37 displays the parts that are candidates for the delay factor in the process. For example, as shown in FIG. 10, in the case of the chuck lowering step, the LM guide 25 (baking), the reducer bearing (damage) of the servomotor 25, the belts 26 and 27.
A plurality of candidate parts such as (slip, meandering) that increase the cycle time are displayed in a list together with the part number and the abnormality content.

If the moving bodies 4, 6, 8, 9 stop in the middle of their strokes or the speed drops abnormally due to seizure of the guides or damage to the bearings, the elapsed time exceeds the limit value. At this time (step S14), the servomotors 14, 20, 25, 30 are immediately stopped without waiting for the stop signal (step S16). Then, this limit value is recorded as a history of operation time (step S19), and similarly to the case where the upper limit value is exceeded, a delay alarm and an operation stop signal are output (steps S21, 24, 25), and candidates for delay factors are output. The parts to be displayed are displayed on the display device 37 (see FIG. 1).
0).

Therefore, the following operational effects can be obtained. (A) From the two alarm display screens, it is possible to narrow down to a component level and specify in detail what kind of abnormality has occurred in what part of which process, and it is possible to specify in detail and quickly, and it is possible to shorten the recovery time, that is, the down time. (B) It is possible to accurately diagnose not only an abnormality that prolongs the cycle time, such as seizure of a guide or damage to a bearing, but also an abnormality that shortens the cycle time, such as a broken belt or a broken shaft. (C) By strictly setting the upper and lower limits,
Abnormalities can be detected before parts are damaged, and measures can be taken early to avoid failures. (D) Since the upper limit value is set to be less than the limit value, there is an advantage that a relatively slight abnormality that cannot be detected by the limit value can be detected early.

As shown in FIGS. 9 and 10, the display device 3
7, an up scroll button 39 and a down scroll button 40 for displaying all candidate parts, a previous button 41 and a next button 42 for switching the screen, and a send button 43 for starting the send program. It is provided. Then, when the next button 42 is pressed on the alarm display screen, as shown in FIG. 11, the history data for the set number of cycles executed in the past in the process is displayed. For example, the history data of the chuck lifting process is the vertical moving body 8
Cycle time, date, product number, upper and lower limit values, etc. are listed in order from the latest data.

Therefore, the following effects can be obtained. (D) When an abnormality occurs, the history data and the candidate parts on the previous screen can be compared to narrow down the abnormal part and the abnormal part in more detail. (E) The history data is displayed at any time, the cycle time of the moving body is collated, and the life of parts can be predicted, which is useful for pre-maintenance. (F) History data can be accumulated as technical data for new product development.

When the send button 43 is pressed, the send program is started and the history data, various set values, and the molding machine 3 are pressed.
A diagnostic file containing the data necessary for a technician at a remote location to inspect the abnormality, such as communication data, is automatically created. Then, this file is transmitted by a transmission / reception device (not shown) attached to the unloader 1 through a premises or wide area communication line,
It is transmitted to a host computer at a remote place using a LAN or the Internet.

Therefore, the following operational effects can be obtained. (G) A user or a full-time engineer of a manufacturer can diagnose the abnormality of the unloader in detail while being in a remote place. (H) It is not necessary for a manufacturer's full-time engineer to visit the site, and after-sales service costs can be saved. (I) A replacement part or a preparation part can be quickly arranged according to the diagnosis result. (J) If a mobile phone with an email is used as the transmitting / receiving device, the unloader can be recovered early regardless of where the dedicated engineer is. (K) The manufacturer can promptly deliver the new or modified program to the user by using this system at the time of production start-up of a new molded product or when a program abnormality occurs.

The present invention is not limited to the above-described embodiment, but may be embodied with various modifications as appropriate without departing from the spirit of the invention, for example, as follows. (1) By setting the maximum speed of the moving body, detecting the acceleration time from the start of the process to reaching the maximum speed as the operation time, and comparing the detected value with the upper limit value and the lower limit value, an abnormality is detected at the beginning of the process. Be able to diagnose. (2) Two timing points are set in the middle of the stroke of the moving body, the passing time between them is detected as the operation time, and the detected value is compared with the upper limit value and the lower limit value, so that an abnormality can be diagnosed in the middle of the process. To do so. (3) The abnormality diagnosis method of the above embodiment is applied to a take-out machine that takes out various processed products from various processing machines such as a machine tool, a surface processing machine, a packaging machine, and a food processing machine.

[0030]

As described above in detail, according to the abnormality diagnosing method of the present invention, the parts that are candidates for the delay factor and the parts that are candidates for the early arrival factor are displayed separately, so that the details of the abnormal point can be determined. This has an excellent effect that it is possible to identify and diagnose both the abnormality in which the cycle time is long and the abnormality in which the cycle time is short, and the failure can be detected in advance.

[Brief description of drawings]

FIG. 1 is a perspective view showing an entire unloader in which an abnormality diagnosis method of the present invention is carried out.

FIG. 2 is a front view showing a lateral movement mechanism of a chuck in the take-out machine.

FIG. 3 is a front view showing a vertical movement mechanism of a chuck in the take-out machine.

FIG. 4 is a block diagram showing an abnormality diagnosis system for the unloader.

FIG. 5 is a process explanatory view of the same take-out machine.

FIG. 6 is a time chart showing the operation of the mobile body.

FIG. 7 is a flowchart showing an embodiment of an abnormality diagnosis method according to the present invention.

FIG. 8 is a supplementary explanatory diagram of the diagnostic method.

FIG. 9 is a front view of a display device showing a display screen of a delay alarm.

FIG. 10 is a front view of a display device showing a display screen for an early arrival alarm.

FIG. 11 is a front view of a display device showing a display screen of history data.

[Explanation of symbols]

1 unloader 3 injection molding machine 4 left and right moving objects 6 Front-rear moving body 8 Vertical moving body 9 revolving structure 10 chuck 14 Servo motor 15 belts 19 Guide 20 Servo motor 21 belt 22 Guide 24 guides 25 Servo motor 26 Ended Belt 27 Endless belt 30 Servo motor 31 Control device 32 Servo control unit 33 encoder 35 input device 36 Storage 37 Display 43 Send button

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Koji Nanasawa             3-133 Akita Stock Association, Oguchi Town, Niwa District, Aichi Prefecture             Company Star Seiki (72) Inventor Shinichi Kakimoto             3-133 Akita Stock Association, Oguchi Town, Niwa District, Aichi Prefecture             Company Star Seiki (72) Inventor Tsukasa Nakamoto             3-133 Akita Stock Association, Oguchi Town, Niwa District, Aichi Prefecture             Company Star Seiki (72) Inventor Keiji Matsunaga             3-133 Akita Stock Association, Oguchi Town, Niwa District, Aichi Prefecture             Company Star Seiki (72) Inventor Yasushi Iwanari             3-133 Akita Stock Association, Oguchi Town, Niwa District, Aichi Prefecture             Company Star Seiki (72) Inventor Atsushi Morikawa             3-133 Akita Stock Association, Oguchi Town, Niwa District, Aichi Prefecture             Company Star Seiki F-term (reference) 4F202 AM09 AP10 CA11 CA30 CB01                       CM12 CS07                 4F206 AM09 AP10 JA07 JL02 JN41                       JP15 JP27 JQ90                 5H223 AA05 DD03 DD07 EE30 FF01                       FF08

Claims (5)

[Claims] 1. An upper limit value and a lower limit value of a detection value set in advance by detecting an operation time of a moving body provided in a chuck moving mechanism in an unloader for moving a chuck in and out of a processing machine to take out a processed product. Compared to
Abnormality diagnosis of the unloader characterized by displaying parts that are candidates for delay factors when the detected value is greater than or equal to the upper limit value, and displaying parts that are candidates for early arrival factors when the detected value is less than or equal to the lower limit value. Method. 2. The method for diagnosing an abnormality in a unloader according to claim 1, wherein the upper limit value and the lower limit value are set based on an execution value of trial operation. 3. The abnormality diagnosing method for the unloader according to claim 1, wherein the upper limit value is set to be less than the limit value of the cycle time. 4. The unloader abnormality diagnosis method according to claim 1, 2 or 3, wherein a history of operating time is recorded and the history data is displayed at any time. 5. The method for diagnosing an abnormal condition of a unloader according to claim 4, wherein the history data is transmitted to a host computer at a remote place via a communication line.