JP2017193146A - Mold monitoring apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mold monitoring apparatus which can detect the existence of an abnormal operation and abnormal molding in a resin molding machine with high precision.SOLUTION: A mold monitoring apparatus includes: a monitoring camera with which a mold face of a mold in a resin molding machine is captured as a color image; and a monitoring apparatus body which monitors a status of the mold face of the mold based on an image data acquired by the monitoring camera. The reference image data concerning the reference state of the mold face of the above-mentioned mold is recorded beforehand on the monitoring apparatus body. The monitoring apparatus body has functions of: comparing an obtained image data for determination about the mold face of the mold in a status where mold open has been carried out in a molding cycle of the resin molding machine, with the reference image data; and then determining whether a status of a colored image that has specific color information in the image data for determination is within an acceptable range set up on the basis of the reference image data.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a mold monitoring apparatus that monitors a mold surface of a mold attached to a resin molding machine, for example.

In general, in a resin molding machine for manufacturing a resin product, for example, an injection molding machine, a molding cycle including a mold clamping operation, an injection operation, a cooling / solidification of a resin material, a mold opening operation, and a molded product protruding operation is repeatedly performed. .
Thus, in the injection molding machine, when the mold opening operation is performed, the molded product is not held in the molding area of the movable mold surface, for example, is held by a fixed mold, or the molding of the movable mold surface is performed. Operational abnormalities that fall off the area and adhere to other areas may occur. Alternatively, when the molded product protruding operation is performed, an abnormal operation may occur in which the molded product is not released from the mold surface of the movable mold but is held on the mold surface of the movable mold.
When a mold clamping operation of the injection molding machine is performed in a state where such an operation abnormality has occurred, specifically, in a state where the molded product remains on the fixed or movable mold surface, the fixed mold is fixed by the remaining molded product. The mold surface or the movable mold surface may be damaged. When such a situation occurs, the production line must be stopped for a long period of time, so that when the operation abnormality occurs, it is necessary to stop the operation of the injection molding machine.

  For this reason, in the process of manufacturing a resin product using an injection molding machine, for example, a monitoring camera is fixed at a position where a movable mold surface can be imaged at a mold opening completion position, and acquired by this monitoring camera. The state of the movable mold surface is monitored based on the image data to be processed.

  As such a mold monitoring apparatus, during automatic operation of an injection molding machine, primary monitoring image data obtained by imaging a movable mold surface with a monitoring camera after completion of the mold opening operation of the injection molding machine is used as a primary reference. Primary monitoring operation to compare with image data, and secondary monitoring image data obtained by imaging the mold surface of the movable mold with the monitoring camera after completion of the molded product ejection operation of the injection molding machine is compared with the secondary reference image data. A device that performs a secondary monitoring operation is known (see Patent Document 1). Here, the primary reference image data is obtained in advance by imaging a movable mold surface in a state where the molded product is held in the molding area with a monitoring camera, and the secondary reference image data is obtained by molding. This is obtained in advance by imaging the movable mold surface in a state where the molded product is released from the area with the monitoring camera.

In such a mold monitoring apparatus, each of the plurality of pixels constituting the image acquired by the monitoring camera is included in each of the primary reference image data, the secondary reference image data, the primary monitoring image data, and the secondary monitoring image data. Luminance data for is included.
Then, in the primary monitoring operation, at least the luminance data for the plurality of pixels related to the molding area of the movable mold surface among the primary monitoring image data is set for each of the plurality of pixels in the primary reference image data corresponding thereto. Each of the luminance data is compared, and based on the difference between the two, it is determined whether it is a normal state or an abnormal state. When in the normal state, the operation of the injection molding machine is continued and the molded product protruding operation is performed. When in the abnormal state, the operation of the injection molding machine is stopped.
On the other hand, in the secondary monitoring operation, each of the luminance data for the plurality of pixels related to the molding area of at least the movable mold surface among the secondary monitoring image data is set to a plurality of secondary reference image data corresponding thereto. The luminance data for each pixel is compared with each other, and based on the difference between the two, it is determined whether the pixel is in a normal state or an abnormal state. When in the normal state, the operation of the injection molding machine is continued and the mold clamping operation is performed, and when in the abnormal state, the operation of the injection molding machine is stopped.

JP 2002-67115 A

  However, in the above-described mold monitoring apparatus, it is difficult to discriminate between a resin molded product and a mold because the presence or absence of an operation abnormality and a molding abnormality is detected based on luminance data regarding image data obtained by a monitoring camera. Yes, it is not possible to monitor the presence of abnormal operation and abnormal molding with high accuracy. For this reason, if the operation of the injection molding machine is continued or stopped due to an erroneous determination, there is a risk of causing a failure of the injection molding machine or a decrease in manufacturing efficiency. In addition, the labor of inspection work for searching for defective products in the subsequent process becomes great.

  The present invention has been made based on the circumstances as described above, and an object of the present invention is to provide a mold monitoring apparatus capable of detecting an operation abnormality and a molding abnormality in a resin molding machine with high accuracy. To do.

The mold monitoring apparatus of the present invention monitors a mold surface of a mold based on image data acquired by the monitoring camera that captures a mold surface of a mold in a resin molding machine as a color image. A monitoring device main body,
In the monitoring device main body, reference image data relating to the reference state of the mold surface of the mold is recorded in advance,
The monitoring apparatus main body compares the determination image data acquired for the mold surface of the mold in the mold opened state in the molding cycle of the resin molding machine with the reference image data, and determines the determination image data. It has a function of determining whether the state of a colored image having specific color information is within an allowable range set with reference to the reference image data.

In the mold monitoring apparatus of the present invention, the monitoring apparatus main body has a function of executing a primary monitoring operation for monitoring a state of a mold surface of the mold after completion of a mold opening operation in a molding cycle of the resin injection molding machine. Have
Image data relating to a colored image having specific color information indicating the molded product in a color image obtained by imaging the mold surface of the mold in a state where the molded product is held in the molding area is primary. It is recorded as reference image data,
In the primary monitoring operation, in a color image obtained by imaging the mold surface of the movable mold after completion of the mold opening operation of the resin molding machine, a colored image having specific color information indicating the molded product is obtained. Such image data is acquired as primary determination image data, and the primary determination is performed by comparing the shape of the colored image related to the primary determination image data with the shape of the colored image related to the primary reference image data. It is preferable that the identity of the image data for use and the primary reference image data is determined.

Further, in the mold monitoring apparatus of the present invention, the monitoring apparatus body performs a secondary monitoring operation for monitoring the mold surface of the mold after completion of the molded product protruding operation in the molding cycle of the resin molding machine. Have
Image data relating to a color image having the specific color information in a color image obtained by imaging the mold surface of the mold in a state where the molded product is released from the molding area is secondary reference image data. Is recorded as
In the secondary monitoring operation, an image relating to a colored image having the specific color information in a color image obtained by imaging the mold surface of the mold after the molded product protruding operation of the resin molding machine is completed Preferably, the data is acquired as secondary reference image data, and the identity of the determination image data and the secondary reference image data is determined based on the presence or absence of a colored image in the secondary determination image data.

  Furthermore, in the mold monitoring apparatus of the present invention, the color image includes color information included in an allowable color range set based on color information of the reference color when the color of the molded product is used as the reference color. It is preferable that the pixel is composed of pixels having

  Furthermore, in the mold monitoring apparatus of the present invention, the allowable color range includes the reference color coordinates (R, G, B) and black coordinates (0, 0, 0) defined in the RGB color space. When an angle formed by a virtual straight line X connecting the two and an arbitrary virtual straight line Y passing through the black coordinates (0, 0, 0) is θ (°), a relationship of 0.9900 <cos θ <1.000 is established. It is preferable to set so as to satisfy.

  According to the mold monitoring apparatus of the present invention, the identity of the reference image data and the determination image data is determined by the state of the color image having specific color information in the image data acquired by the monitoring camera. High accuracy can be obtained in the determination result. Accordingly, it is possible to reliably detect the operation abnormality and the molding abnormality in the resin molding machine.

It is explanatory drawing which shows the structure of the metal mold | die monitoring apparatus of this invention with the structure of a resin molding machine. It is a block diagram which shows one structural example of the monitoring apparatus main body in the metal mold | die monitoring apparatus of this invention. It is explanatory drawing which shows the allowable color range set based on the reference color prescribed | regulated in RGB color space. It is explanatory drawing which shows roughly an example of (a) primary reference | standard image data and (b) secondary reference | standard image data. It is an operation | movement flowchart of the monitoring operation | movement performed in the metal mold | die monitoring apparatus of this invention. It is explanatory drawing which shows an example of the image data about the movable type | mold surface after completion | finish of mold | die opening operation | movement, Comprising: (a) is image data for primary monitoring, (b) is image data for primary determination. It is explanatory drawing which shows the other example of the image data for primary determination about the movable mold surface after completion | finish of a mold opening operation | movement. It is explanatory drawing which shows an example of the image data about the mold surface of a movable mold | type after completion | finish of molded article protrusion operation | movement, (a) is image data for secondary monitoring, (b) is image data for secondary determination. It is explanatory drawing which shows the other example of the image data for secondary determination about the movable mold surface after completion | finish of a mold opening operation | movement.

Hereinafter, embodiments of the present invention will be described in detail.
FIG. 1 is an explanatory view showing the configuration of the mold monitoring apparatus of the present invention together with the configuration of a resin molding machine. FIG. 2 is a block diagram showing a configuration example of a monitoring device main body in the mold monitoring device of the present invention.
First, the configuration of the resin molding machine will be described. This resin molding machine melts a mold 11 composed of a fixed mold 12 and a movable mold 13 that are in a male-female relationship with a resin material that is a molded product forming material. The injection molding machine includes an injection unit 15 for injection, a mold drive unit 20 for opening and clamping the mold 11, and a control unit 25 for controlling operations of the injection unit 15 and the mold drive unit 20. 10.

The injection unit 15 of the injection molding machine 10 includes a cylindrical cylinder 16 having an injection nozzle 16a at the tip (left end in FIG. 1), and a screw drive mechanism 17 that drives a screw (not shown) disposed in the cylinder 16. And a hopper 18 connected to a supply port (not shown) formed on the outer peripheral surface of the rear end portion of the cylinder 16.
A heater (not shown) is provided on the outer peripheral surface of the cylinder 16, and the resin material put into the hopper 18 is supplied into the cylinder 16 while being melted. The screw is arranged so as to be able to advance and retreat along the axial direction of the cylinder 16, and the molten resin material is supplied while being kneaded from the rear end to the front end of the cylinder 16 by rotating the screw. .

  The mold drive unit 20 of the injection molding machine 10 includes a fixed platen 21 to which the fixed mold 12 is fixed, a movable platen 22 to which the movable mold 13 is fixed, which is arranged to be movable relative to the fixed platen 21, and movable. A plurality of tie bars 23 for guiding the platen 22 in the horizontal direction, a mold clamping operation for moving the movable platen 22 along the tie bar 23 toward the fixed platen 21, and a mold opening operation for moving the movable platen 22 backward relative to the fixed platen 21. A mold clamping / mold opening mechanism 24 is provided.

  The mold monitoring device 30 is a monitoring camera 31 that images the mold surface of the movable mold 13 in the mold 11, and a monitoring device that monitors the state of the mold surface of the movable mold 13 based on image data acquired by the monitoring camera 31. And a main body 40. The monitoring apparatus main body 40 in this example is connected to the control unit 25 in the injection molding machine 10 via, for example, a signal input / output device 35, and is configured to be able to control the operation of the injection molding machine 10.

  The monitoring camera 31 may be any camera that captures a color image. For example, a color CCD camera or the like can be used.

  The monitoring apparatus main body 40 includes a central control unit 41, an operation display unit 42, an image signal input unit 43 to which an image signal from the monitoring camera 31 is input, and image data for processing image data from the image signal input unit 43. A processing unit 44, an image data recording unit 45 that records image data processed by the image data processing unit 44, a RAM 46 in which information necessary for the operation of the central control unit 41 is temporarily recorded, and a central control unit 41 And a ROM 47 in which a program for operating the computer is recorded.

  The operation display unit 42 is configured by, for example, a touch panel type operation display panel, and various operation screens and setting screens for accepting input operations for operating the mold monitoring apparatus 30, reference image data and a determination image described later. Various image data such as image data is displayed.

  The image data processing unit 44 sets a color of a molded product or a resin material for forming a molded product as a reference color in a color image related to image data acquired by the monitoring camera 31, and is set based on color information of the reference color. It has a function of extracting (specifying) pixels having color information included in the allowable color range and performing image processing for calculating image data of a colored image in an image area configured by the pixels having the specific color information. .

Specifically, for example, as shown in FIG. 3, an allowable color range (a hatched area in FIG. 3) is set based on color information of the reference color α defined in the RGB color space, that is, RGB values (coordinates). Then, a pixel having color information included in the allowable color range acquired by the monitoring camera 31 is specified. The allowable color range can be arbitrarily set according to the conditions required for the actual molded product, the state of the mold surface of the movable mold 13 to be monitored, and other conditions, but should be set as follows. Is preferred.
That is, in the plane perpendicular to the virtual straight line X connecting the coordinates (R, G, B) of the reference color α and the coordinates (0, 0, 0) of black, the coordinates (R1) of the color β positioned on the plane. , G1, B1) and the virtual line X connecting the black coordinates (0, 0, 0) and the virtual line X is θ, the allowable color range for the reference color α is 0.9900. It is preferable to set so as to satisfy the relationship of <cos θ <1.000 (0.000 ° <θ <8.100 °). Thereby, the image data of the colored image having specific color information can be compared regardless of the brightness, and high accuracy can be obtained. However, the black part is excluded.

Here, the color information (RGB value) of the reference color α is, for example, an image indicating a molded product in a color image acquired by the monitoring camera 31 for the mold surface of the movable mold 13 after the mold opening operation in a molding cycle described later. It can be obtained by analyzing the color information of at least one pixel arbitrarily selected in the region. Further, the color information of each of a plurality of pixels arbitrarily selected in the image region indicating the molded product may be analyzed, and the average value of the color information of each pixel may be used as the color information of the reference color.
Data relating to color information including the reference color and its allowable color range is recorded in the image data recording unit 45.

In addition, primary reference image data and secondary reference image data are recorded in the image data recording unit 45 in advance.
As shown in FIG. 4 (a), the primary reference image data is obtained by confirming that the mold surface of the movable mold 13 in a normal state after completion of the mold opening operation of the injection molding machine 10, specifically, a defect or deformation in the molding area. This is data calculated by performing the above-described image processing on the color image obtained for the mold surface of the movable mold 13 in a state where a molded product having no irregularity is held. Therefore, the primary reference image data relates to a colored image having specific color information from which a background image such as a mold is erased, and indicates the shape of a molded product. In FIG. 4A, for convenience, the mold surface 13a of the movable mold 13 is indicated by a broken line.
As shown in FIG. 4 (b), the secondary reference image data indicates that the mold surface of the movable mold 13 in a normal state after completion of the molded product protruding operation of the injection molding machine 10, specifically, the molded product is released from the mold. This is data calculated by performing the above-described image processing on the color image obtained with respect to the mold surface of the movable mold 13 in the state in which it is formed. Therefore, the secondary reference image data does not have a colored image having specific color information. In FIG. 4B, for convenience, the mold surface 13a of the movable mold 13 and the molding area MA are indicated by broken lines.

  In addition, as primary reference image data and secondary reference image data, position data for each of a plurality of pixels constituting a color image acquired for the mold surface of the movable mold 13 and luminance data for each of the plurality of pixels. May be recorded. Note that the luminance data represents the luminance of each pixel in the pattern image as a relative value of an integer from 0 to 255, where 0 is the minimum and 255 is the maximum.

Hereinafter, with respect to the operation of the monitoring device of the present invention, an example of controlling the operation of the injection molding machine 10 by monitoring the mold surface of the movable mold 13 of the mold 11 in the injection molding machine 10 during automatic operation will be given as an example. explain.
During automatic operation of the injection molding machine 10, a mold clamping permission command and a molded product protrusion prohibition command are output from the monitoring device main body 40 of the mold monitoring device 30 via the signal input / output device 35, and the injection molding machine 10 is controlled. When input to the unit 25, the molding cycle of the injection molding machine 10 is started.

  Specifically, in the mold drive unit 20 of the injection molding machine 10, a mold clamping operation for moving the movable platen 22 along the tie bar 23 toward the fixed platen 21 is performed. Thus, the mold surface of the movable mold 13 fixed to the movable platen 22 is pressed against the mold surface of the fixed mold 12 fixed to the fixed platen 21, and as a result, a molding space is formed in the mold 11. Next, in the injection section 15 of the injection molding machine 10, an injection operation for injecting the molten resin material in the cylinder 16 into the molding space of the mold 11 from the injection nozzle 16a is performed, so that the molding space of the mold 11 is obtained. The inside is filled with molten resin material. Thereafter, the resin material is cooled and solidified in the mold 11 to obtain a molded product. Next, in the mold driving unit 20 of the injection molding machine 10, the mold surface of the movable mold 13 is separated from the mold surface of the fixed mold 12 by performing a mold opening operation for retracting the movable platen 22 along the tie bar 23. The

  When the mold opening operation of the injection molding machine 10 is completed, a mold opening limit signal is output from the control unit 25 of the injection molding machine 10 and the monitoring device main body 40 of the mold monitoring device 30 via the signal input / output device 35. Is input. As a result, a mold clamping prohibition command is output from the monitoring device main body 40 of the mold monitoring device 30 and is input to the control unit 25 of the injection molding machine 10, whereby the mold open state of the injection molding machine 10 is maintained. The timer operates in the monitoring device main body 40, and the primary monitoring operation is executed in the mold monitoring device 30 after the standby time set in the timer has elapsed after the mold open limit signal is input. Here, the standby time set in the timer is, for example, 0.1 to 0.4 sec.

  In this primary monitoring operation, as shown in FIG. 5, first, the monitoring camera 31 images the mold surface of the movable mold 13 to obtain primary monitoring image data for the mold surface of the movable mold 13. (Step 1). An example of primary monitoring image data is shown in FIG. In this example, a state in which a molded product is held in each of, for example, four molding areas MA on the mold surface 13a of the movable mold 13 is shown.

  Next, image processing of this primary monitoring image data is performed by the image data processing unit 44 in the monitoring apparatus main body 40. In other words, pixels having color information included in the allowable color range set based on the color information of the reference color (color of the molded product) in the color image related to the primary monitoring image data are extracted (specified). (Step 2). Then, as shown in FIG. 6B, the colored image C in the image area constituted only by the pixels having the specific color information is calculated as the primary determination image data (step 3). The primary determination image data is displayed on the operation display unit 42 in the monitoring apparatus main body 40 together with the primary reference image data.

The primary determination image data acquired in this way is compared with the primary reference image data, and a determination process is performed to determine whether the primary reference image data matches the primary determination image data ( step 4).
Specifically, in this determination process, the identity of both image data is determined by comparing the shape of the colored image C in the primary determination image data with the shape of the colored image in the primary reference image data. The As described above, the primary reference image data relates to a colored image indicating the shape of the molded product. Therefore, the image area of the colored image is used as a monitoring area for monitoring the shape of the molded product, and is obtained by analyzing the state of the colored image C in the image area of the primary determination image data corresponding to the monitoring area. The quality of the primary shape of the obtained molded product can be determined. In addition, in the primary determination image data, the state of the mold surface 13a of the movable mold 13 can be determined by analyzing the presence or absence of pixels having specific color information in an area other than the image area corresponding to the monitoring area. .

  Then, when the state of the colored image C related to the primary determination image data is within the allowable range set with reference to the primary reference image data, it is determined that the primary determination image data matches the primary reference image data. In this case, since the obtained molded product is a non-defective product and the molded product is held in the molding area on the mold surface 13a of the movable mold 13, the operation of the injection molding machine 10 is normal. As a result, the operation of the injection molding machine 10 is continued.

On the other hand, when the state of the color image in the image data for primary determination is outside the allowable range set with reference to the primary reference image data, it is determined that the image data for primary determination is different from the primary reference image data. One of the abnormalities is considered to have occurred. In this case, the operation of the injection molding machine 10 is stopped (step 5).
For example, as shown in FIG. 7A, when some of the pixels in the image area corresponding to the monitoring area in the primary determination image data do not have specific color information, the mold surface 13a of the movable mold 13 is used. It is considered that at least a part of the molded product is released from the molding area MA in FIG. Similarly, for example, as shown in FIG. 7B, when there is a pixel having specific color information in an area other than the image area corresponding to the monitoring area in the primary determination image data, It is considered that any abnormality of molding has occurred. Examples of such cases include, for example, a state in which the molded product is dropped from the molding area of the movable mold 13 and adhered to the non-molding area after the mold opening operation of the injection molding machine 10 or the molded product protruding operation is completed. And the case where the molded product forming material and the non-molded area are adhered to each other, or the molded product forming material is adhered to the non-molded area.
Since the primary reference image data and the primary determination image data are displayed on the operation display unit 42 in the monitoring apparatus main body 40, the user confirms the image data displayed on the operation display unit 42, thereby injection molding. It is also possible to identify whether the reason why the operation of the machine 10 is stopped is a molding abnormality or an operation abnormality of the injection molding machine 10.

  When it is assumed that the operation of the injection molding machine 10 is normal by such primary monitoring operation and the operation of the injection molding machine 10 is continued, a request for projecting a molded product is received from the central control unit 41 in the monitoring device main body 40. A command signal is output (step 5). The molded product protrusion request command signal is input to the control unit 25 of the injection molding machine 10 via the signal input / output device 35, whereby, for example, the protruding pin protrudes from the mold surface of the movable mold 13 in the injection molding machine 10. The molded product protruding operation is performed.

  When the molded product projecting operation of the injection molding machine 10 is completed, a molded product projecting completion signal from the control unit 25 of the injection molding machine 10 is input to the monitoring device main body 40 central control unit 41 and the monitoring device main body 40 In step 6, the timer is started. Then, after the standby time set in the timer has elapsed after the molded product protrusion completion signal is input, the secondary monitoring operation is executed.

  In this secondary monitoring operation, first, the monitoring camera 31 images the mold surface of the movable mold 13 to acquire secondary monitoring image data for the mold surface of the movable mold 13 (step 7). An example of secondary monitoring image data is shown in FIG. In this example, the state where the molded product is normally released in each of, for example, four molding areas MA on the mold surface 13a of the movable mold 13 is shown.

  Next, image processing of the secondary monitoring image data is performed by the image data processing unit 44 in the monitoring apparatus main body 40. That is, a pixel having color information included in the allowable color range set based on the color information of the reference color (color of the molded product) in the color image related to the secondary monitoring image data is specified (extracted). (Step 8), image data for secondary determination is calculated (step 9). FIG. 8B shows secondary determination image data corresponding to the secondary monitoring image data shown in FIG. Since the secondary determination image data is in a state in which the molded product is normally released, it does not have a colored image. The secondary determination image data is displayed on the operation display unit 42 in the monitoring apparatus main body 40 together with the secondary reference image data.

  Determination processing for determining whether the secondary determination image data and the secondary reference image data match by comparing the secondary determination image data acquired in this way with the secondary reference image data. Is performed (step 10). Specifically, the identity of the secondary determination image data and the secondary reference image data is determined based on the presence or absence of a colored image in the secondary determination image data.

  As shown in FIG. 8B, when the secondary determination image data does not have a colored image, it is determined that the secondary determination image data matches the secondary reference image data. In this case, the molded product is released from the molding area MA on the mold surface of the movable mold 13, and the operation of the injection molding machine 10 is considered to be normal. Then, the operation of the injection molding machine 10 is continued, and for example, the next molding cycle is started (step 11). When the molded product is released from the mold surface of the movable mold 13, the released molded product is taken out from the injection molding machine 10 by, for example, a molded product take-out device.

  On the other hand, when the secondary determination image data has a colored image, it is determined that the secondary determination image data is different from the secondary reference image data, and it is considered that an operation abnormality of the injection molding machine 10 has occurred. In this case, a determination process (t> T) is performed as to whether or not the elapsed time t from the execution of the first molded product protruding operation has exceeded a preset time T. Then, if the preset time T has not elapsed since the first molded product protruding operation, the molded product protruding request command signal is output again from the central control unit 41 of the monitoring device body 40 (step 5), and injection molding is performed. In the machine 10, the molded product protruding operation is executed again. When the molded product protrusion operation is completed in the injection molding machine 10, the secondary monitoring operation is re-executed (step 7 to step 10) with the input of the molded product protrusion completion signal as a trigger (step 6). Such re-execution of the molded product projecting operation of the injection molding machine 10 and the secondary monitoring operation of the mold monitoring device 30 is determined by the secondary monitoring operation that the secondary determination image data matches the secondary reference image data. Or until a preset time T elapses from the first part protruding operation.

Even if the re-execution of the molded product protruding operation and the secondary monitoring operation is repeated until a preset time T elapses from the first molded product protruding operation, the secondary determination image data is secondary in the secondary monitoring operation. When it is determined that it is different from the reference image data, it is considered that an operation abnormality of the injection molding machine 10 has occurred. In this case, the operation of the injection molding machine 10 is stopped (step 12).
For example, as shown in FIG. 9A, when a pixel (colored image C) having specific color information exists in a part of the image area corresponding to the monitoring area in the secondary determination image data, it is movable. The molded product is held in at least a part of the molding area MA on the mold surface 13a of the mold 13, and it is considered that an abnormal operation has occurred. For example, as shown in FIG. 9B, there is a case where a pixel (colored image C) having specific color information is present in an area other than the image area corresponding to the monitoring area in the secondary determination image data. Similarly, it is considered that an operation abnormality has occurred. Examples of such cases include, for example, a state in which the molded product has dropped from the molding area MA of the movable mold 13 and adhered to the non-molded area after completion of the molded product protruding operation of the injection molding machine 10, or the molding area of the movable mold 13 The case where it is in the state which has shifted | deviated from MA and adhered over the molding area MA and the non-molding area etc. is mentioned.
Since the secondary reference image data and the secondary determination image data are displayed on the operation display unit 42 in the monitoring apparatus main body 40, the user confirms the image data displayed on the operation display unit 42. It is also possible to identify the reason why the operation of the injection molding machine 10 is stopped.

As described above, in the mold monitoring apparatus of the present invention, the reference image data related to the reference state of the mold surface of the movable mold 13 in the mold 11 and the mold surface state of the movable mold 13 acquired during the molding cycle are displayed. As the image data for determination, for example, image data of a colored image including only pixels having color information within an allowable color range set for the reference color using the color of the obtained molded product as a reference color is used. That is, in the color image related to the image data acquired by the monitoring camera 31, the background image such as the mold 11 is erased, and the reference image data is determined based on the state of the colored image having specific color information indicating the molded product. Comparison with the image data for use is performed. In the primary monitoring operation, the identity between the primary reference image data and the primary determination image data can be determined based on the shape of the colored image. In the secondary monitoring operation, the identity between the secondary reference image data and the secondary determination image data can be determined based on the presence or absence of a colored image.
Therefore, according to the mold monitoring apparatus of the present invention, the coincidence / difference between the reference image data and the determination image data can be identified with high accuracy. It can be detected reliably.

As mentioned above, although embodiment of this invention was described, this invention is not limited to said embodiment, A various change can be added.
For example, the color space defined when setting the allowable color range for the reference color is not limited to the RGB color space, and other color spaces may be used.
Further, the color information of the reference color does not have to be acquired by analyzing an image area indicating a molded product in the image data actually acquired by the monitoring camera.
Furthermore, in the primary monitoring operation and the secondary monitoring operation, determination based on luminance data may be performed in addition to determination based on the state of a colored image (color determination).

DESCRIPTION OF SYMBOLS 10 Injection molding machine 11 Mold 12 Fixed mold 13 Movable mold 13a Movable mold surface 15 Injection part 16a Injection nozzle 16 Cylinder 17 Screw drive mechanism 18 Hopper 20 Mold drive part 21 Fixed platen 22 Movable platen 23 Tie bar 24 Clamping Mold opening mechanism 25 Control unit 30 Mold monitoring device 31 Monitoring camera 35 Signal input / output device 40 Monitoring device body 41 Central control unit 42 Operation display unit 43 Image signal input unit 44 Image data processing unit 45 Image data recording unit 46 RAM
47 ROM
C Colored image MA Molding area

Claims (5)

A monitoring camera that captures a mold surface of a mold in a resin molding machine as a color image, and a monitoring device main body that monitors the state of the mold surface of the mold based on image data acquired by the monitoring camera. ,
In the monitoring device main body, reference image data relating to the reference state of the mold surface of the mold is recorded in advance,
The monitoring apparatus main body compares the determination image data acquired for the mold surface of the mold in the mold opened state in the molding cycle of the resin molding machine with the reference image data, and determines the determination image data. A mold monitoring apparatus having a function of determining whether or not a state of a colored image having specific color information is within an allowable range set with reference to the reference image data. The monitoring device main body has a function of executing a primary monitoring operation for monitoring a state of a mold surface of the mold after completion of a mold opening operation in a molding cycle of the resin injection molding machine,
Image data relating to a colored image having specific color information indicating the molded product in a color image obtained by imaging the mold surface of the mold in a state where the molded product is held in the molding area is primary. It is recorded as reference image data,
In the primary monitoring operation, in a color image obtained by imaging the mold surface of the movable mold after completion of the mold opening operation of the resin molding machine, a colored image having specific color information indicating the molded product is obtained. Such image data is acquired as primary determination image data, and the primary determination is performed by comparing the shape of the colored image related to the primary determination image data with the shape of the colored image related to the primary reference image data. The mold monitoring apparatus according to claim 1, wherein the identity of the image data for use and the primary reference image data is determined. The monitoring device main body has a function of executing a secondary monitoring operation for monitoring a mold surface of the mold after completion of a molded product protruding operation in a molding cycle of the resin molding machine,
Image data relating to a color image having the specific color information in a color image obtained by imaging the mold surface of the mold in a state where the molded product is released from the molding area is secondary reference image data. Is recorded as
In the secondary monitoring operation, an image relating to a colored image having the specific color information in a color image obtained by imaging the mold surface of the mold after the molded product protruding operation of the resin molding machine is completed Data is acquired as secondary reference image data, and the identity of the determination image data and the secondary reference image data is determined based on the presence or absence of a colored image in the secondary determination image data. The mold monitoring apparatus according to claim 2.   The colored image is composed of pixels having color information included in an allowable color range set based on color information of the reference color when the color of the molded product is a reference color. The mold monitoring apparatus according to claim 2 or 3. The allowable color range includes a virtual straight line X connecting the coordinates (R, G, B) of the reference color defined in the RGB color space and the black coordinates (0, 0, 0) and the black coordinates (0 , 0, 0) is set so as to satisfy a relationship of 0.9900 <cos θ <1.000, where θ (°) is an angle formed by an arbitrary virtual straight line Y passing through. 4. The mold monitoring apparatus according to 4.

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