JP2012091374A - Apparatus for monitoring injection molding machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve failure detection performance of an apparatus for monitoring an injection molding machine.SOLUTION: In primary or secondary monitoring during mold-open or ejecting operation, a search range specified by a user is searched with primary or secondary template image data to correct the search range so as to follow a misaligned target image part, thereby preventing a false determination due to misalignment when the target image is normal. The search range can be set according to the amount of misalignment of the target image, thereby achieving an apparatus for monitoring an injection molding machine which has further improved failure determination performance.

Description

  The present invention relates to an injection molding machine monitoring device, and particularly to improve the monitoring function.

  Conventionally, for example, as a monitoring device for an injection molding machine for injection molding of a synthetic resin material, an injection molding operation of an injection molding machine main body is performed based on a video signal obtained by imaging the injection molding machine main body with a television camera as an imaging means. What determines whether it is normal is used (refer patent document 1).

  The injection molding machine body repeats the injection molding cycle every time one injection molded product is molded.

  That is, in a state where the movable side mold is in pressure contact with the fixed side mold (this state is referred to as a “clamping” state), by injecting a synthetic resin material through the conduit, an injection molded product is placed in the movable side mold and the fixed side mold. Mold.

  When the movable mold is retracted from the fixed mold to a position separated from the fixed mold (this condition is referred to as a “mold open” condition), the injection mold product is opened while attached to the inner surface of the movable mold. The injection-molded product brought to the position and then attached to the movable mold is ejected from the movable mold by a projecting pin projecting from the rear of the movable mold (this operation is called "protruding" operation), and the take-out machine Is taken out by

  Thus, when one injection molded product is taken out from the main body of the injection molding machine, one cycle of the injection molding process (that is, one injection molding cycle) is completed and the next injection molding cycle is started.

  At this time, the movable side mold advances toward the fixed side mold and returns to the clamped state in which the movable side mold is in pressure contact with the fixed side mold, and the injection molding cycle is repeated in the same manner.

JP-A-60-39581

  In this type of injection molding machine monitoring device, when the main body of the injection molding machine performs the mold opening operation, the injection molded product remains attached to the fixed side mold (so-called fixed side mold remaining), or the injection molded product It is necessary to monitor abnormalities that occur during the mold opening mode (such as “primary monitoring”), such as when the mold is not completely molded and a part thereof is missing (so-called short mold). .

  Also, after the injection molding machine main body protrudes, the injection molded product does not come off the movable side mold and remains on the movable side mold (so-called movable side mold remaining), or protrudes when the injection molded product is protruded. It is necessary to monitor an abnormality that occurs in the protruding operation mode, such as when the pin breaks (so-called pin breakage) (this is called “secondary monitoring”).

  If such an abnormality occurs, if this state is left as it is, a derivative accident such as damage to the movable side mold and / or the fixed side mold or molding of a defective product in the next injection molding cycle. It is necessary to immediately detect the occurrence of these abnormalities.

  The injection molding machine monitoring device acquires monitoring reference image data serving as a reference for determining an abnormality by imaging the movable mold at the start of the monitoring operation, and thereafter, in the injection molding cycle that is sequentially repeated, the monitoring reference image The occurrence of such an abnormality is detected by comparing the data with monitor detection image data that detects an abnormality acquired by imaging the movable side mold.

  However, the mold opening position of the movable-side mold varies due to the quality of the injection molding machine body, variations due to individual differences, vibrations in the injection molding cycle repeated in the injection molding machine body, etc., and the injection molding to be monitored in the monitoring detection image data When the position of the product or the cavity is deviated from the monitoring reference image data, the injection molding machine monitoring apparatus may determine that an abnormality has occurred, and there is a possibility that the accuracy of the abnormality detection is reduced.

  The present invention has been made in consideration of the above points, and intends to propose an injection molding machine monitoring apparatus capable of detecting an abnormality with high accuracy.

  In order to solve such a problem, in the present invention, when the injection molding machine main body 1 performs the mold opening operation and the protruding operation at the start of the monitoring operation, the video signal VD1 obtained by imaging the injection molding machine main body 1 by the imaging means. In the injection molding cycle of the injection molding machine main body 1, the monitoring reference image data acquisition means for obtaining the monitoring reference image data as the reference image data in the determination of the abnormal operation of the injection molding machine main body 1, Monitoring detection image data acquisition means for obtaining monitoring detection image data as image data for detecting abnormal operation using the video signal VD1 obtained at the time of opening operation or protruding operation, and monitoring of occurrence of abnormal operation among monitoring reference image data It is not a pixel surrounded by a circumscribing line that circumscribes the monitoring region K set as a region for monitoring the monitoring target to be monitored. A monitoring target standard obtaining means for obtaining a monitoring target standard, and a search range that is a range including a region surrounded by a tangent line around the display range corresponding to the display range of the monitoring target standard in the monitoring detection image data is specified. While searching the search range specifying means and the search range SH according to the monitoring target criterion, the correlation calculation between the brightness of the pixel of the monitoring target criterion and the brightness of the pixel of the monitoring detection image data is performed, and the search position having a high degree of coincidence is monitored. A moving means for moving the monitoring region K to the search position as the target exists, and obtaining a brightness comparison result between the monitoring reference image data and the monitoring detection image data for the image portion inside the moved monitoring region K. Thus, monitoring means for monitoring abnormal operation of the injection molding machine main body 1 is provided.

  According to the present invention, the monitoring target image data is provided in the monitoring target portion of the monitoring detection image data by the monitoring target reference composed of pixels surrounded by the circumscribed line of the monitoring area set to surround the monitoring target among the monitoring reference image data. By performing correlation calculation while searching the search range specified by the user and performing abnormality determination processing assuming that the monitoring target exists at the search position with a high degree of coincidence, monitoring during mold opening operation or protruding operation It is possible to detect anomalies with higher accuracy while following the displaced position when the object is displaced, and the possibility that the monitored object itself is normal, but it is determined that it is abnormal due to the displacement Therefore, it is possible to realize an injection molding machine monitoring device that can be avoided and that can further improve the abnormality determination performance.

It is a block diagram which shows the whole structure of the injection molding machine monitoring apparatus by this invention. It is a flowchart which shows the monitoring process procedure. It is a flowchart which shows the monitoring cycle process sequence (1). It is a flowchart which shows the monitoring cycle process procedure (2). It is a basic diagram which shows a position correction setting screen. It is a basic diagram which shows primary monitoring reference | standard image data and secondary monitoring reference | standard image data. It is a basic diagram with which it uses for description of the setting of a monitoring area | region. It is an approximate line figure used for explanation of creation of template image data. It is an approximate line figure used for explanation of setting of a search range. It is a basic diagram with which it uses for description of the position shift of the monitoring object image part. It is an approximate line figure used for explanation of search operation by template image data. It is an approximate line figure used for explanation of position alignment of a monitoring field.

  Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

(1) Overall Configuration of Injection Molding Machine Monitoring Device In FIG. 1, reference numeral 1 denotes an injection molding machine main body, and injects a synthetic resin material through a conduit 4 in a clamped state in which the movable mold 2 is pressed against the fixed mold 3. Thus, an injection molded product is molded in the movable side mold 2 and the fixed side mold 3.

  This injection-molded product is brought to the mold opening position while being attached to the inner surface of the movable side mold 2 when the movable side mold 2 is in the mold open state separated from the fixed side mold 3 along the guide 5. Then, the pin (not shown) protrudes from the rear side of the movable mold 2 and is removed from the movable mold 2 by the protruding operation, and is taken out by the take-out machine (not shown).

  The injection molding cycle of the injection molding machine main body 1 is automatically controlled by a sequencer provided in the injection molding machine main body drive control device 6.

  The injection molding operation of the injection molding machine main body 1 is imaged by a television camera 11 as imaging means provided in the injection molding machine monitoring device 10, and the video signal VD1 is converted into video data DATA1 by the image input circuit 12. It is input to the image processing circuit 13 and held.

  The video data DATA1 held in the image processing circuit 13 is taken in at a predetermined timing to a central processing unit (CPU: Central Processing Unit) 17 that performs processing operation according to a program in the program memory 16 via the bus 15 and each pixel. And stored in the data memory 18 via the bus 15.

  The CPU 17 determines whether or not an abnormality has occurred based on the video data DATA1 stored in the data memory 18, and provides determination result image data DATA2 representing the determination result to the image processing circuit 13 via the bus 15.

  The image processing circuit 13 supplies the determination result image data DATA2 to the image display circuit 19, so that the image display circuit 19 superimposes the video signal VD1 supplied from the television camera 11 in the image display circuit 19 to the monitor 20 as the display image signal VD2. give.

  Thus, the monitor 20 determines the determination result image data DATA2 representing the abnormal state (or normal state) determined by the CPU 17 with respect to the image of the injection molding machine main body 1 currently captured by the television camera 11 based on the video signal VD1. Based on the above, a monitoring screen in which an abnormality occurrence display is displayed on the image portion where the abnormality has occurred is presented to the user.

  The monitor 20 incorporates an operation input unit 25 formed of a touch panel, and the user inputs various operation commands to the CPU 17 via the bus 15 by operating the operation input unit 25. .

  The CPU 17 recognizes the timing at which the monitoring processing operation should be performed based on the monitoring control signal S1 given from the injection molding machine main body drive control device 6 via the control signal input / output unit 21 and performs the determining operation. Based on the determination result, the sequence control signal S2 is given to the injection molding machine main body drive control device 6 via the control signal input / output unit 21, thereby the injection molding machine main body 1 is synchronized with the monitoring operation of the injection molding machine monitoring device 10. Execute the control that

  Thus, the CPU 17 executes the monitoring processing operation described below while synchronizing with the operation of the injection molding cycle of the injection molding machine body 1.

(2) Monitoring processing When the user designates the monitoring processing mode via the operation input unit 25, the CPU 17 enters the monitoring processing routine RT1 in FIG. 2 and waits for the mold opening limit signal to be turned on in step SP1, After confirming that the injection molding machine main body 1 is in the mold open state, the timing for executing the subsequent operation is matched with the injection molding machine main body 1, whereby the injection molding machine main body drive control device 6 performs the injection molding. When the movable mold 2 of the machine main body 1 is retracted to the mold opening position, a mold opening limit signal that has been turned on is supplied to the CPU 17 via the control signal input / output unit 21 as the monitoring control signal S1.

  At this time, the CPU 17 gives the injection molding machine main body 1 to the injection molding machine main body drive control device 6 through the control signal input / output unit 21 as a sequence control signal S2 in the next step SP2. The injection molding machine main body drive control device 6 is controlled so as not to perform the mold clamping operation, whereby the injection molding machine main body 1 is held in the mold open state.

  Thus, in a state where the injection molding machine main body 1 holds the mold open state, the CPU 17 in the next step SP3, the video signal VD1 currently obtained from the television camera 11 (injection molding in the mold open state). The image inside the mold of the machine body 1 is input to the image processing circuit 13 through the image input circuit 12 as video data DATA1 for one frame. The image display circuit 19 is supplied with the video signal VD1 from the television camera 11, and supplies the video signal VD1 to the monitor 20 as the display image signal VD2.

  Thus, the monitor 20 presents to the user an image inside the mold that is currently captured by the television camera 11 based on the video signal VD1.

  Subsequently, the CPU 17 registers the image data for one frame representing the mold open state input to the image processing circuit 13 in step SP4 in the data memory 18 as the primary monitoring reference image data D1.

  In the case of this embodiment, the CPU 17 registers primary monitoring reference image data D1 on which four injection molded products IM1 to IM4 are displayed on the monitor 20 as shown in FIG.

  Thus, the image data registered in the data memory 18 indicates that when the injection molding machine body 1 is operating normally, the movable mold 2 is in the mold open position with the injection molded products IM1 to IM4 attached to the movable mold 2. The CPU 17 has acquired the image data for one frame in the mold open state in the data memory 18 as reference data used to determine whether or not an abnormality has occurred during primary monitoring. It will be.

  Subsequently, in step SP5, the CPU 17 protrudes as a sequence control signal S2 and gives an interlock release signal to the injection molding machine main body drive control device 6 via the control signal input / output unit 21, whereby the protruding operation of the injection molding machine main body 1 is performed. In the next step SP6 and waits for the protrusion completion signal that has been turned on as the monitoring control signal S1 from the injection molding machine main body drive control device 6 to arrive via the control signal input / output unit 21. Become.

  When an overhang completion signal that has turned to the ON state is received, the CPU 17 presents the video signal VD1 (injection machine main body 1 is in an unfolded and complete state) currently obtained from the television camera 11 in the next step SP7. ) Is input to the image processing circuit 13 through the image input circuit 12 as video data DATA1 for one frame.

  Subsequently, in step SP8, the CPU 17 registers the image data for one frame representing the protruding completion state input to the image processing circuit 13 in the data memory 18 as the secondary monitoring reference image data D2.

  In the case of this embodiment, the CPU 17 registers secondary monitoring reference image data D2 in which four cavities CV1 to CV4 are displayed on the monitor 20 as shown in FIG.

  Thus, the image data registered in the data memory 18 is the injection-molded product attached to the movable mold 2 when the injection molding machine main body 1 is operating normally when the injection molding machine main body 1 is operating normally. Represents the state taken out by the take-out machine, and the CPU 17 uses the image data for one frame in the protruding state as a data memory as reference data used to determine whether or not an abnormality has occurred during secondary monitoring. It will be acquired to 18.

  Subsequently, in step SP9, the CPU 17 sets the position of an area to be monitored (hereinafter also referred to as a monitoring area) during the mold opening operation and the protrusion operation, and stores the monitoring area in the data memory 18. To do.

  Here, the monitoring area indicates a range of pixel data to be compared in the reference image data and the detected image data when comparing the reference image data and the detected image data in primary monitoring and secondary monitoring described later. The CPU 17 does not compare the pixel data outside the range of the monitoring area, thereby causing light reflection, dust adhesion, or the like generated outside the monitoring area in the primary monitoring and the secondary monitoring. The disturbance video is removed, and monitoring processing can be performed without being affected by the disturbance video.

  In this monitoring area setting, as shown in FIG. 7, the CPU 17 uses the operation input unit 25 while watching the monitor 20 so that the user surrounds the cavities CV1 to CV4 in the secondary monitoring reference image data D2. When K1 to K4 are set and input, the cavities CV1 to CV4 are set as the monitoring target image portions J1 to J4, respectively, and the display positions P1 to P4 of the monitoring target image portions J1 to J4 (that is, the cavities CV1 to CV4) are set. This is set and stored in the data memory 18 as monitoring area data D3.

  Further, the CPU 17 sets the injection molded products IM1 to IM4 as the monitoring target image portions J1 to J4 in the primary monitoring reference image data D1 described above.

  Thus, the position data represented by the monitoring area data D3 represents the positions of the injection molded products IM1 to IM4 in the primary monitoring reference image data D1, while the positions of the cavities CV1 to CV4 in the secondary monitoring reference image data D3. Will be.

  Subsequently, the CPU 17 projects as a sequence control signal S2 in the next step SP10, and provides an interlock setting signal from the control signal input / output unit 21 to the injection molding machine body drive control device 6, thereby projecting from the injection molding machine body 1. In step SP11, the mold clamping interlock release signal is given to the injection molding machine main body drive control device 6 as a sequence control signal S2, and thereby the mold clamping operation of the injection molding machine main body 1 is controlled. To do.

  Thereafter, the CPU 17 registers the template image data TP in the data memory 18 in the next step SP12. In registering the template image data TP, as shown in FIG. 8, the CPU 17 sets the monitoring area K1 in the primary monitoring reference image data D1 in the same area as the monitoring areas K1 to K4 set in the secondary monitoring reference image data D2. ~ K4 are set, and the image portions of the determination areas M1 to M4 surrounded by circumscribing lines circumscribing from the vertical direction and the horizontal direction with respect to each of the monitoring areas K1 to K4 become the monitoring target reference in the position correction process described later. Obtained as primary template image data TP1_1 to TP1_4 (hereinafter also referred to as primary template image data TP1).

  Here, the template image data is a template that is set by a user in a position correction process to be described later, and searches for the inside of the search range that is an area that is larger than the template image data including the area occupied by the template image data. This is image data used when detecting whether or not pixel data having a correlation with the image data exists.

  The CPU 17 sets the image portions of the determination areas M1 to M4 that are circumscribed rectangles circumscribing the monitoring regions K1 to K4 as the primary template image data TP1, thereby making the image portions of the polygonal monitoring regions K1 to K4 the primary. The processing can be simplified as compared with the template image data TP1, and the shape of the search range can be easily set when setting the search range described later.

  Similarly, as shown in FIG. 8, the CPU 17 determines the determination areas M1 to M4 surrounded by circumscribing lines that circumscribe each of the monitoring areas K1 to K4 set in the secondary monitoring reference image data D2 from the vertical direction and the horizontal direction. Are obtained as secondary template image data TP2_1 to TP2_4 (hereinafter also referred to as secondary template image data TP2) that are to be monitored in a position correction process described later.

  Thereafter, the CPU 17 displays the position correction setting screen DIPX shown in FIG.

  The position correction setting screen DIPX is based on the position of an injection molded product or cavity to be monitored when the CPU 17 performs primary monitoring and secondary monitoring in a monitoring cycle processing routine RT2 (FIGS. 3 and 4) described later. Is used for setting the position correction process, which is a function for correcting the positions of the monitoring areas K1 to K4, which are areas where the injection molded product or cavity should be monitored.

  The position correction setting screen DIPX displays a position correction execution operation unit 40 and a search range designation value execution operation unit 41.

  When the user executes position correction processing for correcting the position by moving the positions of the monitoring areas K1 to K4 set in the monitoring target image portions J1 to J4, the ON button on the position correction execution operation unit 40 is executed. On the contrary, when the position correction process is not executed, the OFF button 40B in the position correction execution operation unit 40 is selected.

  Further, the user operates the search range designation value operation unit 41 to input a numerical value, thereby setting a search range designation value CS indicating a range to which position correction is applied to the monitoring target. When the search range designation value CS is set, the CPU 17 stores the search range designation value CS in the data memory 18.

  Thus, the search range designation value CS is set manually by the user who has confirmed the position of the injection molded products IM1 to IM4 or the cavities CV1 to CV4 in the mold displayed on the monitor 20, Compared to the case where the search range designation value CS is set to a fixed value in advance, the search range SH described later can be designated by the user's intention, and the monitoring target is predicted to be largely displaced. Can widen the range in which the monitoring area can follow the monitoring target by setting the search range SH wide.

  Subsequently, the CPU 17 proceeds to the next monitoring cycle processing routine RT2, and executes an injection molding cycle for injection molding the next injection molded product by the fixed side mold 3 and the movable side mold 2 of the injection molding machine body 1.

(3) Monitoring cycle processing The CPU 17 executes the monitoring cycle processing routine RT2 shown in FIGS. 3 and 4 to perform the injection molding operation every time the injection molding machine main body 1 performs injection molding of the injection molded products one by one. A monitoring process is performed to determine whether an abnormality has occurred.

(3-1) Primary monitoring process When the monitoring cycle processing routine RT2 is entered, the CPU 17 injects the mold opening limit signal that has been turned on for the injection molded product currently injection molded by the injection molding machine body 1 in step SP21. In the next step SP22, the sequence control signal for the injection molding machine main body drive control device 6 is awaited to arrive as a monitoring control signal S1 from the machine main body drive control device 6 and when an on-state mold opening limit signal arrives. A mold clamping interlock setting signal is given as S2, thereby confirming that the injection molding machine main body 1 is in the mold open state and controlling the injection molding machine main body 1 so as not to perform the mold clamping operation.

  In this state, the CPU 17 stores the video data DATA1 for one frame in the data memory 18 through the image processing circuit 13 as the primary monitoring detection image data D4 in the next step SP23.

  In step SP24, the CPU 17 executes a primary monitoring process for comparing the primary monitoring detection image data D4 shown in FIG. 10 stored in the data memory 18 and the primary monitoring reference image data D1, and then in step SP25. It is determined whether or not the comparison result is abnormal.

  In step SP25, the CPU 17 obtains reference image data and detection image data composed of pixels included in the monitoring areas K1 to K4 (FIG. 7) from the primary monitoring reference image data D1 and the primary monitoring detection image data D4. A deviation between the reference image data and the detected image data is obtained for each pixel, and the number of pixels in which the deviation exceeds a predetermined threshold is totaled for each of the monitoring areas K1 to K4.

  When the total value exceeds a predetermined allowable value, the CPU 17 determines that an abnormality has occurred in the monitoring areas K1 to K4 in the primary monitoring, and proceeds to step SP26.

  As described above, the CPU 17 compares the primary monitoring reference image data D1 with the primary monitoring detection image data D4 only in the monitoring areas K1 to K4 set in step SP9 (FIG. 2) described above, thereby performing the primary monitoring. The processing is reduced as compared with the case where the entire reference image data D1 and the entire primary monitoring detection image data D4 are compared, and disturbance video generated outside the monitoring area is removed.

  Here, if it is determined that there is an abnormality in the primary monitoring, this means that the injection-molded products IM1 to IM4 in the primary monitoring detection image data D4 (FIG. 10) due to variations in the mold opening limit position of the movable side mold 2. The case where the position is the first problem due to the positional deviation with respect to the injection molded products IM1 to IM4 (that is, the monitoring target image portions J1 to J4) in the primary monitoring reference image data D1 (FIG. 6) is fixed. There may be a second problem due to the occurrence of a side mold residue or a short mold.

  As in the primary monitoring detection image data D4 shown in FIG. 10, for example, when the monitoring target image portion J1 is displaced to the left with respect to the reference, the position of the monitoring region K1 itself that monitors the monitoring target image portion J1 moves. Therefore, when primary monitoring is performed on the monitoring region K1 that monitors the monitoring target image portion J1 in a state where the monitoring target image portion J1 is displaced in this way, primary monitoring reference image data in the monitoring region K1 is displayed. D1 and the primary monitoring detection image data D4 have a large deviation between the pixels, and are judged to be abnormal in the primary monitoring.

  If it is determined that the fixed side mold residue or short mold has occurred as in the second problem, the injection molded product is abnormal and cannot be used as a product. However, if it is determined that there is an abnormality only due to the occurrence of misalignment in the injection molded product as in the first problem, the injection molded product itself is normally injection molded. If such an injection-molded product is discarded, the synthetic resin material and the process of the injection-molding cycle are wasted, and moreover, only one of the injection-molded products attached to the mold is positioned. Since the deviation has occurred, the injection molded product other than the injection molded product is also discarded.

  For this reason, the injection molding machine monitoring apparatus 10 executes the following position correction process, and even if it is determined that there is an abnormality due to the displacement of the injection molded product in the primary monitoring process described above, By executing the primary monitoring process again without the influence of the deviation, it is possible to prevent the abnormality from being judged due to only the positional deviation of the injection molded product and not to discard the injection molded product that has been normally injection molded. In addition, the next step is performed without interrupting the injection molding cycle.

(3-2) Position Correction Process and Partial Primary Monitoring Process In step SP26, the CPU 17 determines whether or not the ON button 40A in the position correction execution operation unit 40 (FIG. 5) described above is selected. If a positive result is obtained here, this means that the position correction process should be executed. At this time, the CPU 17 proceeds to step SP27 and executes the position correction process.

  This position correction processing is performed by injection molding in which a positional deviation has occurred among the injection molded products IM1 to IM4 to be monitored in the image data obtained in the video data DATA1 based on the video signal VD1 of the television camera 11 during the mold opening operation. By moving the monitoring area corresponding to the product, the original normal determination result can be obtained without being affected by the positional deviation, and the abnormality determination performance is improved.

  Here, if the CPU 17 sets search ranges SH1 to SH4 having appropriate sizes around the determination areas M1 to M4 as shown in FIG. 9, for example, the monitoring target image in the primary monitoring detection image data D4 shown in FIG. Even if the portion J1 is slightly displaced from the monitoring target image portion J1 in the primary monitoring reference image data D1, it can be confirmed as a positional displacement within the search range SH1. In FIG. 10, the search ranges SH2 to SH4 are not shown and are omitted.

  In the case of this embodiment, as shown in FIG. 9, the CPU 17 searches the area expanded from the determination areas M1 to M4 by the number of pixels of the search range designated value CS designated in step SP13 (FIG. 2). The range is set as SH1 to SH4.

Here, the search ranges SH1 to SH4 indicate ranges in which the template image TP1 that is image data of the determination areas M1 to M4 circumscribing the monitoring areas K1 to K4 is searched in a search process in position correction described later. When image data having a strong correlation with the template image data TP1 is detected within the search range SH1 to SH4, the monitoring regions K1 to K4 are corrected at the detected positions. SH4 indicates how much the positional deviation of the injection molded products IM1 to IM4 (that is, the monitoring target image portions J1 to J4) is allowed by the user with respect to the primary monitoring reference image data D1.

  Further, as shown in FIG. 11, the CPU 17 places the primary template image data TP1 as the monitoring target reference at the display positions P1 to P4 set in the primary monitoring reference image data D1 in the primary monitoring detection image data D4. Sometimes, the primary template image data TP1 is searched in the horizontal search direction d1 and / or the vertical search direction d2 while sequentially shifting the search range SH1 to SH4 by one pixel at a time.

To obtain a correlation value R representing the degree of approximation between the primary monitoring detection image data D4 and the primary template image data TP1.

  Expression (1) is an expression for obtaining a normalized correlation. The correlation value R is the density value T of each pixel of the primary template image data TP1 (also referred to as a brightness value), and the primary template image data TP1. A correlation with the density value (that is, brightness value) S of the primary monitoring detection image data D4 in the search range SH1 to SH4 at each pixel position is obtained for the number N of pixels constituting the primary template image data TP1. It is.

  Thus, the CPU 17 assumes that the monitoring target image portions J1 to J4 exist at the search position where the largest correlation value is obtained among the correlation values R obtained by the equation (1), and the primary monitoring reference shown in FIG. The positions of the monitoring areas K1 to K4 in the image data D1 are changed from the display positions P1 to P4 to the alignment positions P1X to P4X like the primary monitoring detection image data D4 shown in FIG.

  In this way, the CPU 17 sets, as the search ranges SH1 to SH4, areas that are expanded from the determination areas M1 to M4 by the number of pixels of the search range specified value CS specified by the user, and the inside of the search ranges SH1 to SH4 is set as a template. Even if the monitoring target image portions J1 to J4 (that is, the injection molded products IM1 to IM4) are misaligned by performing a search using the image TP1, the misalignment is within the search range SH1 to SH4. If there is, it is possible to move the monitoring area corresponding to the monitoring target image portion that has caused the positional shift, and therefore the influence of the positional shift is removed by partial primary monitoring described later. In this state, the monitoring process can be performed again.

  As described above, in the present embodiment, even if the injection molded products IM1 to IM4 in the primary monitoring detection image data D4 are largely misaligned with respect to the primary monitoring reference image data D1, it is desired to remove the influence of the misalignment. When the user desires, the CPU 17 searches the template image data TP1 for the inside of the search ranges SH1 to SH4 that are greatly expanded with respect to the determination areas M1 to M4 by designating the search range designation value CS to a large value. The position of the monitoring area can be corrected.

  On the other hand, if the user desires to perform position correction only for a small misalignment, the user designates the search range designation value CS to a small value, so that the CPU 17 performs a search that is slightly expanded with respect to the determination areas M1 to M4. Since the inside of the range SH1 to SH4 can be searched with the template image data TP1, the injection molding machine monitoring apparatus 10 sets how much the positional deviation of the monitoring target image portion is allowed according to the user's intention. Can do.

  When the position correction process is executed as described above, the CPU 17 then moves to step SP28, where the primary monitoring detection image data D4 stored in the data memory 18 and the primary monitoring reference image data D1 are compared to the primary part. After executing the monitoring process, it is determined in step SP29 whether or not the comparison result is abnormal.

  At this time, the CPU 17 in the primary monitoring detection image data D4 indicates that each pixel data in the monitoring area where the injection molded product determined to be abnormal by the primary monitoring process described above should be monitored is the primary monitoring reference image data D1. In order to determine whether or not it matches the data of the corresponding pixel, for example, the number of pixels in which the pixel data in the monitoring area K1 does not match the data of the corresponding pixel in the primary monitoring reference image data D1 becomes a predetermined number or more. For this reason, when an abnormality occurs in the primary monitoring, in the partial primary monitoring process, the primary monitoring process is performed only for the monitoring region K1, so that the primary monitoring process in step SP24 is executed again. It is designed to reduce processing.

  In step SP29, when the number of non-matching pixels is equal to or greater than a predetermined number, this means that even if the position correction processing is performed, the positional deviation cannot be corrected, or that the fixed side mold remains or a short mold has occurred. At this time, the CPU 17 determines that an abnormality has occurred, moves to step SP30, sends out an abnormality warning output, and performs an abnormality processing in steps SP30 to SP33.

  If a negative result is obtained in step SP26 described above, this means that the OFF button 40B in the position correction execution operation unit 40 is selected in the position correction setting screen DIPX (FIG. 5) in step SP13 (FIG. 2) described above. Even if it is determined that the abnormality is caused by the primary monitoring due to the displacement of the injection molded product, the user determines that the injection molded product can be discarded without performing the position correction. In this case, the CPU 17 moves to step SP30 and performs an abnormality process.

(3-3) Processing at the time of abnormality When it is determined as abnormal in the partial primary monitoring processing as described above, the user actually opens the safety door of the injection molding machine body 1 (FIG. 1) and operates the manual operation panel 31. Thus, the injection molding machine main body 1 is manually operated, whereby the cause of the abnormality is manually removed, and when the operation is completed, the safety door is closed and the automatic monitoring cycle is returned again.

  Here, when the safety door of the injection molding machine main body 1 is closed, the injection molding machine main body drive control device 6 sends a reset signal, which has transitioned to the OFF state, as the monitoring control signal S1 to the CPU 17 via the control signal input / output unit 21. .

  At this time, the CPU 17 receives the reset signal transitioned to the OFF state in step SP31, moves to step SP32, and deletes the abnormality warning output.

  Subsequently, in the next step SP33, the CPU 17 gives a mold clamping interlock release signal to the injection molding machine main body drive control device 6 as a sequence control signal S2, thereby controlling the mold clamping operation of the injection molding machine main body 1 to be permitted. Thereafter, the process returns to the above-described step SP21 to enter a monitoring operation for the next injection molding cycle.

  On the other hand, when the result that the primary monitoring process in step SP25 or the partial primary monitoring process in step SP29 is normal is obtained, this indicates that the injection molding machine body 1 is normal in the primary monitoring. This means that the determination result is obtained. At this time, the CPU 17 proceeds to step SP41 (FIG. 4).

(3-4) Secondary monitoring processing The CPU 17 projects as a sequence control signal S2 to the injection molding machine main body drive control device 6 in step SP41 and gives an interlock release signal, and in the next step SP42, the injection molding machine main body drive control device. 6 waits for an overhang completion signal that has transitioned to the ON state as the supervisory control signal S1.

  In this state, the injection molding machine main body 1 protrudes from the mold open state to cause the injection molded product to protrude from the movable mold 2 and be taken out by the take-out machine.

  As a result, when the protrusion completion signal transitions to the ON state, the CPU 17 proceeds to step SP43 and protrudes as the sequence control signal S2 to the injection molding machine body drive control device 6 to give the interlock setting signal, thereby protruding the injection molding machine body 1. The state is maintained and the process proceeds to the secondary monitoring described below.

  Subsequently, in step SP44, the CPU 17 captures and stores the secondary monitoring detection image data D5 in the protruding state in the data memory 18 based on the video signal VD1 of the television camera 11.

  In step SP45, the CPU 17 executes secondary monitoring processing for comparing the secondary monitoring detection image data D5 stored in the data memory 18 with the secondary monitoring reference image data D2, and then the comparison result is abnormal in step SP46. Judge whether or not.

  In step SP46, the CPU 17 obtains reference image data and detection image data including pixels included in the monitoring areas K1 to K4 set in FIG. 7 from the secondary monitoring reference image data D2 and the secondary monitoring detection image data D5. A deviation between the reference image data and the detected image data is obtained for each pixel, and the number of pixels in which the deviation exceeds a predetermined threshold is totaled for each of the monitoring areas K1 to K4.

  When the total value exceeds a predetermined allowable value, the CPU 17 determines that an abnormality has occurred in the monitoring areas K1 to K4 in the secondary monitoring, and proceeds to step SP47.

(3-5) Position Correction Process and Partial Secondary Monitoring Process Subsequently, in step SP47, the CPU 17 determines whether or not the ON button 40A in the position correction execution operation unit 40 (FIG. 5) described above is selected. If a positive result is obtained here, this means that the position correction process should be executed. At this time, the CPU 17 moves to step SP48 and executes the position correction process.

  This position correction processing is performed on the cavities in which positional deviation occurs among the cavities CV1 to CV4 to be monitored in the image data obtained in the video data DATA1 obtained based on the video signal VD1 of the television camera 11 during the protruding operation. By moving the corresponding monitoring area, the original normal determination result can be obtained without being affected by the positional deviation, and the abnormality determination performance is improved.

  In the case of this embodiment, the CPU 17 searches from the determination areas M1 to M4 in step SP13 (FIG. 2) as shown in FIG. 9 in the position correction processing at the time of primary monitoring in step SP27 described above. Areas expanded by the number of pixels of the range specification value CS are set as search ranges SH1 to SH4.

  Further, the CPU 17 performs display positions P1 to P1 set in the secondary monitoring reference image data D2 in the secondary monitoring detection image data D5 as shown in FIG. 11 in the same manner as the position correction processing during the primary monitoring described above. When the secondary template image data TP2 as the monitoring target reference is placed in P4, the secondary template image data TP2 is shifted in the horizontal search direction d1 and / or the vertical search direction d2 while sequentially shifting the search range SH1 to SH4 pixel by pixel. The correlation value R representing the degree of approximation between the secondary monitoring detection image data D5 and the secondary template image data TP2 is obtained by the above-described equation (1) at each search position.

  Thus, the CPU 17 assumes that the monitoring target image portions J1 to J4 (that is, the cavities CV1 to CV4) exist at the search position where the largest correlation value is obtained among the correlation values R obtained by the equation (1). The positions of the monitoring areas K1 to K4 set in the secondary monitoring detection image data D5 shown in FIG. 6 are changed from the display positions P1 to P4 to the alignment positions P1X to P4X like the secondary monitoring detection image data D5 shown in FIG. To do.

  When the position correction processing is executed in this way, the CPU 17 then moves to step SP49 to compare the secondary monitoring detection image data D5 stored in the data memory 18 with the secondary monitoring reference image data D2, and the partial secondary monitoring. After executing the process, it is determined in step SP50 whether the comparison result is abnormal.

  At this time, in the secondary monitoring detection image data D5, the CPU 17 corresponds to each pixel data in the monitoring area where the cavity determined to be abnormal by the above-described secondary monitoring processing should be monitored in the secondary monitoring reference image data D2. It is determined whether or not it matches the pixel data.

  In step SP50, when the number of non-matching pixels is equal to or greater than a predetermined number, this means that even if the position correction processing is performed, the positional deviation cannot be completely corrected, or the movable side mold remains and pin breakage has occurred. At this time, the CPU 17 determines that an abnormality has occurred and moves to step SP30 (FIG. 3) to perform the above-described abnormality processing.

  Further, when a negative result is obtained in step SP47 described above, even if this is determined to be abnormal by secondary monitoring due to the displacement of the cavity, position correction is not performed and injection molding is performed. This means that the user has determined that the product can be discarded. At that time, the CPU 17 moves to the above-described step SP30 and performs an abnormal process.

  On the other hand, when a result of normality is obtained in the secondary monitoring process in step SP46 or the partial secondary monitoring process in step SP50 described above, this indicates that the injection molding machine body 1 is normal in the secondary monitoring. That is, the determination result is obtained. At this time, the CPU 17 proceeds to steps SP51 and SP52 to execute the update process of the registered image.

(3-6) Update Processing In updating this registered image, the CPU 17 re-registers the primary monitoring reference image data D1 currently stored in the data memory 18 with the primary monitoring detection image data D4, and the secondary monitoring reference. The image data D2 is updated with the secondary monitoring detection image data D5.

  Thus, by holding the detected image data during normal operation as reference image data, for example, the ambient light changes with time, or the mold position gradually shifts when the injection molding cycle is repeated. Even if a phenomenon occurs, the reference image data can be changed so as to follow the phenomenon, so that the injection molding machine can be continuously monitored with sufficient accuracy.

  Subsequently, in step SP53, the CPU 17 executes a template image data update process. In this template image data update process, the CPU 17 performs the same process as in step SP12 (FIG. 2) described above on the primary monitoring reference image data D1 updated in step SP52 to thereby obtain primary template image data. Update TP1.

  Similarly, the CPU 17 updates the secondary template image data TP2 by executing the same processing as in step SP12 described above for the secondary monitoring reference image data D2 updated in step SP52.

  Thus, since one injection molding cycle is completed, the CPU 17 gives a mold clamping interlock release signal as a sequence control signal S2 to the injection molding machine main body drive control device 6 in step SP54, whereby the injection molding machine main body 1 is clamped. After the operation is performed and the injection molding process can be started, the process proceeds to the above-described step SP21 (FIG. 3) and the monitoring operation for the next injection molding cycle is started.

  When the user ends the injection molding cycle by operating the operation input unit 25, the CPU 17 obtains a positive result in step SP51 (FIG. 4), thereby ending all the processes of the monitoring cycle processing routine RT2. Then, the process returns from step SP55 to the main routine, that is, the monitoring process routine RT1 (FIG. 2), and then all the processes of the monitoring process routine RT1 are terminated in step SP60.

  In the above configuration, in step SP13, the CPU 17 designates the search range designation value CS indicating the number of pixels expanded from the determination areas M1 to M4 as the search range SH1 to SH4, and the search range designation value The CS is stored in the data memory 18.

  Further, when the CPU 17 determines that there is an abnormality in step SP25 or SP46 after capturing image data in the primary monitoring or secondary monitoring, the primary or secondary detected in the position correction processing in step SP27 or SP48. If there is a positional shift in the monitoring target image portions J1 to J4 in the monitoring detection image data D4 or D5, the search range SH inside designated by the user is searched using the primary or secondary template image data TP1 or TP2. The monitoring areas K1 to K4 are moved so as to follow the monitored image portions J1 to J4 that are displaced, and the presence / absence of an abnormality is determined again.

  According to the above configuration, when performing primary or secondary monitoring during mold opening operation or protruding operation, even if the monitoring target is slightly deviated, the position of the monitoring area is corrected so as to follow this. Thus, since it is possible to effectively avoid the possibility of determining that the monitoring target itself is normal but the position is shifted, it is possible to realize an injection molding machine monitoring apparatus that can further improve the abnormality determination performance.

  Further, in the conventional injection molding machine monitoring apparatus, the search ranges SH1 to SH4 are fixed to a predetermined range, so that even when the user desires to allow a large displacement of the monitoring target, the search ranges SH1 to SH4. If the object to be monitored is displaced greatly, even if the search range is searched with the template image data, pixel data having a large correlation with the template image is found within the search range. In some cases, the monitoring area cannot follow the positional deviation of the monitoring target.

  Further, in the conventional injection molding machine monitoring apparatus, since the search ranges SH1 to SH4 are fixed to a predetermined range, the search range SH1 can be used even if the user does not want to allow a large displacement of the monitoring target. SH4 cannot be narrowed, and even if the positional deviation of the monitoring target is small, the search process is performed with the template image data even in the search range even within the search range, and unnecessary processing is performed. There was a case.

  In contrast, the injection molding machine monitoring apparatus 10 of the present invention allows the user to specify the search range specification value CS so that the search ranges SH1 to SH4 can be freely set. If the user allows such a large misalignment, the search range SH1 to SH4 can be set wide so that the range in which the monitoring area can follow the monitoring target can be expanded. When it is predicted that the positional deviation of the image is small or the user does not allow a large positional deviation, the search processing by the template image data can be reduced by setting the search ranges SH1 to SH4 narrow. Compared to the case where the search ranges SH1 to SH4 are fixed to a predetermined range, the user can Product or in association with the intention what extent allowable misalignment of the cavity, it is possible to set the search range.

(4) Other Embodiments In the case of the above-described embodiment, the monitoring regions K1 to K4 are set to individually surround the monitoring target image portions J1 to J4. For example, a region surrounding the monitoring target image portions J1 and J2 may be set as the monitoring target image portion, or a region surrounding all the monitoring target image portions J1 to J4 may be set as all the monitoring target image portions.

  In this case, the CPU 17 sets a region that is wider than the determination area circumscribing the designated monitoring region by a search range designated value as a search range, and performs the above-described position correction, so that each of the monitoring target image portions J1 to J4 is individually primary. The processing can be simplified as compared with the case where monitoring and secondary monitoring are performed and position correction is performed.

  The present invention can be applied to monitoring the injection molding operation of an injection molding machine.

  DESCRIPTION OF SYMBOLS 1 ... Injection molding machine main body, 2 ... Movable side type | mold, 3 ... Fixed side type | mold, 4 ... Conduit, 5 ... Guide, 6 ... Injection molding machine main body drive control apparatus, 10 ... Injection molding machine monitoring 11: Television camera, 12: Image input circuit, 13: Image processing circuit, 15: Bus, 16: Program memory, 17: Central processing unit (CPU), 18: Data memory, DESCRIPTION OF SYMBOLS 19 ... Image display circuit, 20 ... Monitor, 21 ... Control signal input / output part, 31 ... Manual operation panel, 40 ... Position correction execution operation part, 41 ... Search range specification value execution operation part, D1 ... ... primary monitoring reference image data, D2 ... secondary monitoring reference image data, D3 ... monitoring area data, D4 ... primary monitoring detection image data, D5 ... secondary monitoring detection image data, DIPX ... position correction Settings screen.

Claims (1)

Determination of abnormal operation of the injection molding machine body using a video signal obtained by imaging the injection molding machine body with an imaging means when the injection molding machine body opens and protrudes at the start of the monitoring operation Monitoring reference image data acquisition means for obtaining monitoring reference image data as reference image data in
Monitoring detection image data for obtaining monitoring detection image data as image data for detecting an abnormal operation using the video signal obtained at the time of the mold opening operation or the protruding operation in the injection molding cycle of the injection molding machine main body which is sequentially repeated. Acquisition means;
Monitoring target standard acquisition means for obtaining a monitoring target standard consisting of pixels surrounded by a circumscribed line circumscribing a monitoring region set as a region for monitoring a monitoring target to be monitored for occurrence of abnormal operation in the monitoring reference image data When,
Search range designating means for designating a search range that is a range including a region surrounded by the circumscribing line around a display range corresponding to the display range of the monitoring target reference among the monitoring detection image data;
While searching the search range based on the monitoring target criterion, the correlation between the brightness of the pixel of the monitoring target criterion and the brightness of the pixel of the monitoring detection image data is calculated, and the monitoring target exists at a search position with a high degree of coincidence. Moving means for moving the monitoring area to the search position,
Monitoring means for monitoring an abnormal operation of the injection molding machine main body by obtaining a brightness comparison result between the monitoring reference image data and the monitoring detection image data for the image portion in the moved monitoring area. Injection molding machine monitoring device.