JP2022119481A - Management device, management method, and program - Google Patents

Abstract

To provide a management device, a management method, and a program that can manufacture a container without reducing productivity.SOLUTION: A management device manages a manufacturing process for manufacturing a container by reciprocating a metal mold to press a surface of a packaging material, and comprises: an acquisition unit that acquires position information indicating an installation position of the metal mold measured by a position detection sensor; an estimation unit that, when re-installation is performed which is to remove the metal mold and subsequently attach the metal mold to the original installation position again, estimates whether trouble occurs in a container to be manufactured after the re-installation by using first position information being the position information measured before the re-installation and second position information being the position information measured after the re-installation; and an output unit that outputs an estimation result obtained through the estimation made by the estimation unit.SELECTED DRAWING: Figure 9

Description

The present invention relates to a management device, management method and program.

A paper container described in Patent Document 1 is known as a food packaging container. This paper container is manufactured by bending and adhering a part of a paper blank (packaging material). Patent Literature 1 describes a process of placing a blank, a process of supplying hot air to the four corners of the placed blank, a process of pressing the blank using a mold, and the like. By performing such a process, after melting the layer made of hot-melt resin formed on the surface of the blank, the four corners are folded and overlapped, and the overlapped portions are pressed and heat-sealed to join. to manufacture paper containers.

WO2020/31870

However, when a paper container is manufactured by pressing a blank with a mold, problems such as misalignment and deterioration over time tend to occur in the mold, which is a movable part. In order to prevent the mold from becoming hot due to hot air, cooling water may be circulated inside the mold. In this case, the mold is provided with a mechanism for supplying or draining cooling water, and it is necessary to periodically maintain these mechanisms. In maintenance, the mold is disassembled to check if the components have deteriorated over time. After cleaning, the mold is reassembled and installed in the original position.

In the reproduction work, even if the mold was intended to be installed in the original position, there were many cases where the paper container could not be manufactured correctly. In such a case, it was necessary to repeat the test of pressing the blank while changing the position of the mold and make adjustments until the paper container was manufactured correctly. Therefore, there is a problem that the reproduction work after maintenance takes time.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a management apparatus, a management method, and a program capable of suppressing prolongation of reproduction work after maintenance.

A management device of the present invention is a management device for managing a manufacturing process of manufacturing a container by pressing a surface of a packaging material by reciprocating a mold, wherein the mold is measured by a position detection sensor. an acquisition unit that acquires position information indicating an installation position; Using the first position information that is the position information obtained and the second position information that is the position information measured after the reinstallation, whether or not a defect occurs in the container to be manufactured after the reinstallation and an output unit for outputting an estimation result estimated by the estimation unit.

The management method of the present invention is a management method performed by a computer device, which is a management device for managing the manufacturing process of manufacturing a container by pressing the surface of a packaging material by reciprocating a mold, wherein the obtaining unit , the position information indicating the installation position of the mold measured by the position detection sensor is acquired, and the estimation unit removes the mold and then re-installs the mold to the original installation position. the position information measured before the re-installation and the second position information that is the position information measured after the re-installation. It is estimated whether or not a defect will occur in the container to be manufactured after the above, and the output unit outputs the estimation result estimated by the estimation unit.

The program of the present invention is stored in a computer device, which is a management device for managing the manufacturing process of manufacturing a container by pressing the surface of a packaging material by reciprocating the mold, the position of the mold measured by the position detection sensor. In the case where the position information indicating the installation position is acquired and the mold is removed and then reinstalled by attaching the mold to the original installation position again, the position measured before the reinstallation Using the first positional information, which is information, and the second positional information, which is the positional information measured after the re-installation, it is made to estimate whether a defect will occur in the container to be manufactured after the re-installation. , is a program for outputting the estimated estimation result.

ADVANTAGE OF THE INVENTION According to this invention, a container can be manufactured without reducing productivity.

It is a figure which shows the flow of a manufacturing process by embodiment. It is a figure explaining the manufacturing process by embodiment. It is a figure explaining the manufacturing process by embodiment. It is a figure explaining the manufacturing process by embodiment. It is a figure explaining the manufacturing process by embodiment. It is a figure explaining the manufacturing process by embodiment. It is a figure explaining the manufacturing process by embodiment. It is a figure explaining the manufacturing process by embodiment. 1 is a block diagram showing a configuration example of a management system 1 to which a quality control device 90 according to an embodiment is applied; FIG. It is a figure which shows the structural example of the quality control information 921 by embodiment. It is a figure which shows the structural example of maintenance information 922A by embodiment. It is a figure which shows the structural example of the maintenance information 922B by embodiment. 4 is a flow chart showing the flow of processing performed by the quality control device 90 of the embodiment; 4 is a flow chart showing the flow of processing performed by the quality control device 90 of the embodiment;

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings.

The management system 1 is a system that manages manufacturing processes for manufacturing containers. Below, the case where a paper container is manufactured in a manufacturing process is illustrated and demonstrated. However, it is not limited to this. The management system 1 can be applied to at least a process in which a mold is moved to manufacture a product, and a process in which the mold is removed for maintenance or the like and then re-installed in its original position.

First, the manufacturing process will be described with reference to FIGS. 1 to 5. FIG. FIG. 1 is a diagram showing the flow of the manufacturing process according to the embodiment. 2 to 5 are diagrams for explaining the manufacturing process of FIG.

As shown in FIG. 1, in the manufacturing process, a container is manufactured by performing each process of process A, process B, and process C. As shown in FIG. The next process is a process that follows the manufacturing process, and is, for example, a process of filling the contents into the container manufactured in the manufacturing process or joining a lid member to the container.

Process A is a process of arranging the blank BR at a predetermined position. Step B is a step of supplying hot air to the four corners of the blank BR. Process C is a process of pressing blank BR to manufacture a container. The blank BR is a substantially rectangular packaging material made of paper, and has a plurality of folding lines formed in advance by embossing or the like. At the center of the blank BR, a square forming the bottom surface of the container is formed by part of the folding lines.

FIG. 2 shows the relative positional relationship between the blank BR and the mold (male OG and female MG) in process A. As shown in FIG. In step A, blank BR is placed between male OG and female MG.

The male OG is configured to be operable in a direction D up and down. For example, the male OG is attached to a shaft T that connects with a drive mechanism (not shown). When the shaft T is driven by the drive mechanism, the male OG moves up and down together with the shaft T. The female MG is installed below the male OG, and its installation position is fixed.

FIG. 3 shows the relative positional relationship between the blank BR and the hot air supply units HA1 to HA4 in the process B. As shown in FIG. In step B, the hot air supply units HA1 to HA4 blow hot air from the blow holes toward the four corners of the blank. The hot air melts the hot melt resin layer formed on the surface of the blank BR.

Fig. 4 shows the relative positional relationship between the blank BR and the mold before pressing and Fig. 5 after pressing.

As shown in FIG. 4, in step A, a blank BR is placed between the male OG and the female MG.

As shown in FIG. 5, in step C, the male OG reaches the position where the blank BR is arranged from above the blank BR in close proximity to the blank BR, and moves toward the female MG while being in contact with the blank BR. to descend. As a result, the blank BR is bent along the bending line and formed into a container shape having a bottom portion and side portions rising from the bottom portion by bending.

As shown in FIG. 5, a roller R (an example of a mold) is installed below the female mold. The rollers R have a cylindrical shape having a diameter and length corresponding to the shape of the side surface of the container, and are installed one by one on the left and right sides of the mold. After the male OG descends to the position where the female MG is installed and forms the blank BR in the shape of the container, it further descends to the position where the roller R is installed in contact with the bottom surface of the container. When the container descends to the position of the roller R, the side surface of the container is pressed by the roller R. As a result, the bent and overlapped portions of the side surfaces of the container are closely joined together to complete the container.

The following controls are performed in the manufacturing process.
(Management 1) Management of hot air supply units HA1 to HA4 (Management 2) Cooling water and mold temperature management (Management 3) Mold position and operation timing management (Management 4) Blank BR melting management (Management 5) ) Container identification management

In (Management 1), the temperature and volume of hot air supplied from the hot air supply units HA1 to HA4 are measured, and the measured values are recorded. In order to perform (Management 1), in the manufacturing process, for example, a temperature sensor for measuring the temperature near the ejection holes of the hot air supply units HA1 to HA4 and an air volume sensor for measuring the air volume are provided. In step B, the temperature measured by the temperature sensor is recorded, and the airflow measured by the airflow sensor is recorded.

In (Management 2), the temperatures of the cooling water and the mold are measured, and the measured values are recorded. In order to perform (Management 2), temperature sensors for measuring the respective temperatures of the male OG, the female MG, and the roller R are provided in the manufacturing process, for example. The temperature measured by the temperature sensor is recorded in each step of steps A to C. Further, a temperature sensor for measuring the temperature of cooling water circulating through each of the male OG, female MG, and roller R is provided. The temperature measured by the temperature sensor is recorded in each step of steps A to C.

In (Management 3), the mold position is measured and the measured value is recorded. In order to perform (Management 3), for example, position sensors for measuring the positions of the dies (male OG, female MG, and roller R) are provided in the manufacturing process. The position sensor is installed, for example, on a pillar that supports the mold, and measures the distance from the position where the position sensor is installed to the mold. A position sensor is, for example, an optical sensor. In this case, the position sensor irradiates the mold to be measured with laser light (for example, infrared rays) separated by short intervals (pulses), and the light receiving section detects the reflection. The position sensor measures the distance based on the difference (phase difference, etc.) between the irradiated laser light and the received laser light.

FIG. 6 is a diagram illustrating a method for measuring the mold position. As shown in FIG. 6, for example, the position sensors for measuring the position of the male OG include a sensor PS1 for measuring the distance to the upper surface S1 of the male OG, a sensor PS2 for measuring the distance to the side surface S2, and a sensor PS2 for measuring the distance to the side surface S3. each of the sensors PS3 measuring the distance to. As for the positions of the female mold MG and the roller R, similarly, the three-dimensional positions including the positions in the height direction are measured. For example, in step A, position sensors measure the position of each mold and record the measurements.

As mentioned above, the male OG moves up and down. Therefore, when the male mold moves, its installation position changes. The position sensor measures the position of the male OG that moves up and down at a fixed timing each time. For example, the position sensor measures the position of the male OG at the timing when the vertical movement of the male OG changes from upward to downward. Movement stops when going from up to down. At the timing when this movement stops, the position sensor measures the position of the male OG. Thereby, the position can be measured with high accuracy.

Also, in (Management 3), the operation timing of the mold is measured and the measured value is recorded. In order to detect the operation timing of (Management 3), a detection sensor is provided in the manufacturing process to detect the operation of the drive section of the mold (the drive section that moves the male mold OG up and down). The detection sensor detects the operation timing by, for example, detecting a change in the measurement value of a position sensor that measures the position of the male OG in the height direction. Alternatively, the detection sensor may detect the operation timing by detecting a signal (for example, a signal instructing start of driving) output from a drive control section that controls the drive section of the mold.

In (Management 4), the temperature of the blank BR is measured and the measured value is recorded. In order to perform (Management 4), for example, an infrared camera for measuring the surface temperature of the blank BR is provided in the manufacturing process.

7 and 8 are diagrams explaining a method of measuring the temperature of the blank BR. As shown in FIG. 7, for example, in step B, an image (a so-called heat map) showing the temperature distribution of the blank BR in colors is captured using an infrared camera TC installed above the blank BR. Then, as shown in FIG. 8, the results of analysis of the captured image are recorded. In the example of this figure, an overall view, an enlarged view, and an analysis result of the captured image are shown. The overall view is an image showing the temperature distribution of the entire blank BR captured by the infrared camera TC. The enlarged view is an image showing the temperature distribution at the four corners of the blank BR where it is desired to confirm whether the melting temperature has been reached. The analysis result is the result of analyzing the temperature distribution in the enlarged view, and in the example of this figure, the maximum temperature and the area reaching the predetermined temperature range (T2 to T3 [° C.] in the example of this figure). Area (number of pixels) is indicated.

In (Management 5), information (individual identification information) that uniquely identifies the container is added to the container manufactured in the manufacturing process, and the added information is recorded. In order to perform (Management 5), for example, a two-dimensional code in which individual identification information of the container is embedded is printed on the blank BR. In the manufacturing process, the two-dimensional code printed on the blank BR is read by a code reader or the like, and the read information is recorded.

By performing the above-described (Management 1) to (Management 5), the quality of the container manufactured in the manufacturing process is managed. For example, if the temperature of the hot air supplied from the hot air supply units HA1 to HA4 measured in (Management 1) is less than the threshold temperature, the heat sealing may be insufficient and the container may be defective. high. For this reason, management is performed such that a container for which the temperature of the hot air supplied from the hot air supply units HA1 to HA4 is recorded as being less than the threshold temperature is regarded as a defective product.

In addition, by performing (Management 1) to (Management 5), the manufacturing equipment used in the manufacturing process is managed so that no defects or failures occur. For example, if the temperature of the mold and cooling water measured in (Management 2) is equal to or higher than the threshold temperature, the temperature of the mold rises, which may cause the manufacturing apparatus to malfunction. Therefore, it is checked whether the cooling water is circulating properly in the mold, whether the cooling water supply port and the cooling water outlet are clogged, and whether there is any problem with the pump that circulates the cooling water. , measures are taken to keep the temperature of the mold and cooling water below the threshold temperature.

Furthermore, in this embodiment, the information recorded in (Management 1) to (Management 5) is used to efficiently perform post-maintenance reproduction work. The configuration for performing reproduction work after maintenance will be described in detail below.

FIG. 9 is a block diagram showing a configuration example of a quality control device 90 to which the control system 1 of the embodiment is applied. The management system 1 includes, for example, various sensor groups and a quality control device 90 . Various sensor groups are composed of, for example, a mold management device 10, a hot air ejection hole management device 20, a thermal imaging device 30, and a code reader 40. FIG.

The mold management device 10 includes a sensor group for managing molds. The mold management apparatus 10 includes, for example, a first position detection sensor 11, a second position detection sensor 12, a third position detection sensor 13, a mold temperature sensor 14, a cooling water temperature sensor 15, and a mold operation sensor. and a sensor 16 . The first position detection sensor 11 is a sensor that detects the position of the male OG, and is, for example, sensors PS1 to PS3 that measure distances from three directions to the male OG as shown in FIG. The second position detection sensor 12 is a sensor that detects the position of the female MG. A third position detection sensor 13 is a sensor that detects the position of the roller R. As shown in FIG. The second position detection sensor 12 and the third position detection sensor 13 have the same configuration as the first position detection sensor 11, for example.

The mold temperature sensor 14 is a sensor that measures the temperature of the mold. For example, a sensor that measures the temperature of the male OG, a sensor that measures the temperature of the female MG, and a sensor that measures the temperature of the roller R. be. The cooling water temperature sensor 15 is a sensor that measures the temperature of cooling water circulating inside the mold. The mold movement sensor 16 is a sensor that detects the movement of the mold. Information indicating measured values measured by a group of sensors included in the mold control device 10 is output to the quality control device 90 .

The hot air outlet management device 20 includes a group of sensors for managing the hot air supply units HA (hot air supply units HA1 to HA4). The hot air outlet management device 20 includes, for example, a hot air temperature sensor 21 and an air volume sensor 22 . The hot air temperature sensor 21 measures the temperature of the hot air jetted from the hot air jetting holes of the hot air supply unit HA. The air volume sensor 22 measures the air volume of hot air ejected from the hot air ejection holes of the hot air supply unit HA. Information indicating the measured values measured by the sensor group included in the hot air ejection hole management device 20 is output to the quality control device 90 .

The thermal imaging device 30 is an infrared camera that measures the temperature of the blank BR. The thermal imaging device 30 receives infrared rays emitted from the blank BR and detects the wavelength and intensity of the received infrared rays to pick up an image showing the temperature distribution of the blank BR. The thermal imaging device 30 outputs the captured image showing the temperature distribution to the quality control device 90 .

The code reader 40 reads a two-dimensional code (a code embedded with individual identification information) printed on the blank BR. The code reader 40 outputs information read from the two-dimensional code to the quality control device 90 .

The quality control device 90 is a computer device that controls the quality of the container manufactured in the manufacturing process, and is, for example, a PC (Personal Computer), a server device, or the like. The quality control device 90 includes, for example, a communication section 91 , a storage section 92 , a control section 93 , a display section 94 and an input section 95 .

The communication unit 91 is a functional unit that communicates with an external device, which is realized by, for example, a general-purpose communication IC (Integrated Circuit). The communication unit 91 receives, for example, information (sensor information) output from each of the mold management device 10, the hot air ejection hole management device 20, the thermal imaging device 30, and the code reader 40. FIG. The display unit 94 includes a display device such as a liquid crystal display, for example, and displays an image according to the control unit 93 on the display device. The input unit 95 includes an input device such as a mouse and a keyboard, acquires information input to the input device, and outputs the acquired information to the control unit 93 .

The storage unit 92 is implemented by, for example, a storage device (a storage device having a non-transitory storage medium) such as a HDD (Hard Disk Drive) or flash memory, or a combination thereof. The storage unit 92 stores a program for realizing each component of the quality control device 90, variables used when executing the program, and various kinds of information.

The storage unit 92 includes sensor information 920, quality control information 921, and maintenance information 922, for example. The sensor information 920 is information output by each of the mold management device 10 , the hot air ejection hole management device 20 , the thermal imaging device 30 and the code reader 40 .

The quality control information 921 is information for managing the quality of the container manufactured in the manufacturing process, and is information in which the sensor information 920 is associated with each container manufactured in the manufacturing process. FIG. 10 is a diagram showing a configuration example of the quality control information 921 of the embodiment. As shown in FIG. 10, the quality control information 921 includes items such as container code, process, mold position, mold temperature, cooling water temperature, operation timing, hot air supply, blank temperature, and presence/absence of defects. . The container code is the individual identification information of the container read by the code reader 40 in (Management 5). The process indicates the process from which the sensor information was acquired, and is information indicating any one of the processes A to C. FIG. The mold position is information indicating the position of the mold measured by the first position detection sensor 11 or the like in (Management 3). The mold temperature is information indicating the temperature of the mold measured by the mold temperature sensor 14 in (Management 2). The cooling water temperature is information indicating the cooling water temperature measured by the cooling water temperature sensor 15 in (Management 2). The motion timing is information indicating the motion timing measured by the mold motion sensor 16 in (Management 3). The hot air supply is information indicating the temperature and air volume of the hot air measured by the hot air ejection hole management device 20 in (Management 1). The blank temperature is information indicating the temperature distribution of the blank BR imaged by the thermal imaging device 30 in (Management 4). The presence or absence of defects is information indicating whether or not the container has been determined to be defective. Defectiveness of the container is determined, for example, based on whether various sensor information satisfies predetermined manufacturing conditions, inspection results, and the like.

The maintenance information 922 is information used for reproduction work during maintenance. 11 and 12 are diagrams showing configuration examples of the maintenance information 922 of the embodiment. Maintenance information 922A shown in FIG. 11 shows an example of information used in the position adjustment stage during maintenance. Maintenance information 922B shown in FIG. 12 shows an example of information used in the prototype stage during maintenance.

The position adjustment step is the step of adjusting the installation positions of the molds that have been reassembled and installed in the original positions during maintenance. The trial production stage is a stage in which a container is prototyped in order to test whether the container can be manufactured correctly during maintenance. In this way, in the post-maintenance reproduction work, adjustments are made in a plurality of stages, for example, a position adjustment stage and a prototype stage.

As shown in FIG. 11, the maintenance information 922A includes items such as maintenance ID, mold position, reference position, and difference. A maintenance ID is information that uniquely identifies maintenance. The mold position is information indicating the installation position of the mold measured in the adjustment stage. The reference position is information indicating the installation position of the metal mold serving as a reference, for example, information indicating the respective reference positions of the male mold, the female mold, and the rollers. The difference is information indicating the difference between the mold position and the reference position.

As shown in FIG. 12, the maintenance information 922B includes items equivalent to those of the quality control information 921, for example. That is, the maintenance information 922B indicates measured values such as mold position, mold temperature, cooling water temperature, operation timing, hot air supply, blank temperature, etc., which were measured during the manufacturing process of the prototype container during maintenance.

Returning to the description of FIG. 10 , the control unit 93 stores processing units such as a CPU (Central Processing Unit) and a GPU (Graphics Processing Unit) as hardware included in the quality control device 90 in the storage unit 92 . Functions are realized by executing the program.

The control unit 93 includes an acquisition unit 930, an estimation unit 931, a quality control unit 932, and a device control unit 933, for example. In the position adjustment stage, the acquisition unit 930 acquires information (position information) indicating the installation position of the mold via the communication unit 91 and outputs the acquired information to the estimation unit 931 . Also, in the prototype stage, the acquisition unit 930 acquires information (sensor information) measured by various sensor groups in the manufacturing process via the communication unit 91 and outputs the acquired information to the estimation unit 931 .

Based on the information indicating the installation position of the mold acquired from the acquiring unit 930 in the position adjusting stage, the estimating unit 931 estimates whether or not a defect such as a molding defect will occur in the prototype container in the prototyping stage.

In the position adjustment stage, for example, the estimating unit 931 acquires, from the acquiring unit 930, information indicating the installation position of the mold measured before removing the mold during maintenance, and uses the acquired information as a reference position to obtain the maintenance information 922A. be memorized. The estimating unit 931 also acquires information indicating the installation position of the mold measured in the position adjustment stage from the acquiring unit 930, and stores the acquired information as the mold position in the maintenance information 922A. When the difference between the mold position and the reference position is equal to or greater than a predetermined threshold, the estimation unit 931 estimates that a defect will occur in the prototype container in the prototype stage.

In this case, the estimating unit 931 may use statistics of the mold position measured in the manufacturing process before maintenance as the reference position instead of using the mold position measured before removing the mold as the reference position. . The statistic here is, for example, an average value, a mode value, a maximum value, a minimum value, and the like. The estimating unit 931 may use, as the reference position, a statistic of the mold positions when the manufactured container is a non-defective product among the positions of the molds measured in the manufacturing process before maintenance.

In the position adjustment stage, if the difference between the mold position and the reference position is equal to or greater than a predetermined threshold, the estimation unit 931 estimates that the cause of the defect is the installation position of the mold installed after maintenance. . The estimation unit 931 outputs information indicating the difference (estimation result) between the mold position and the reference position to the display unit 94 for display. As a result, the maintenance worker can be guided to bring the position of the mold after maintenance closer to the reference position.

In the position adjustment stage, if the estimation unit 931 estimates that no problem will occur, the reproduction work after maintenance proceeds to the prototype stage.

Based on the sensor information acquired from the acquisition unit 930 in the trial production stage, the estimation unit 931 estimates whether or not a defect such as a molding defect will occur in the trial production stage of the container.

The estimating unit 931 acquires, for example, the quality control information 921 acquired in the manufacturing process before maintenance from the acquiring unit 930 as the reference information in the prototype stage. The estimation unit 931 also acquires sensor information measured in the prototype stage from the acquisition unit 930, and stores the acquired information as maintenance information 922B.

For example, when the difference between the corresponding sensor information between the reference information and the maintenance information 922B is equal to or greater than a predetermined threshold value, the estimating unit 931 estimates that a defect will occur in the prototype container in the prototype stage. In this case, the estimation unit 931 outputs sensor information (estimation result) in which the difference is equal to or greater than a predetermined threshold to the display unit 94 for display. As a result, the maintenance worker can be guided so that the sensor information after maintenance approaches the value of the sensor information in the reference information.

Alternatively, if the tendency of the sensor information indicated in the reference information and the tendency of the sensor information indicated in the maintenance information 922B are different, the estimating unit 931 estimates that a defect will occur in the prototype container. may The tendency here is an example of "degree of strength of correlation".

For example, consider a case in which the maintenance information 922 shows a tendency of the mold temperature to be high and the blank temperature to be low, even though the temperature of the hot air is almost unchanged compared to the reference information. A possible cause of such a tendency is, for example, a situation in which the direction of the hot air changes after maintenance, and the hot air is blown in the direction of the male die instead of the direction of the blank. Alternatively, the position of the blank placed in the process A is changed, and the hot air is not blown to the blank, but is blown to the female die. If the container is manufactured under such circumstances, there is a high possibility that defects will occur. Based on this way of thinking, the estimating unit 931 determines that if the tendency of the sensor information indicated in the reference information and the tendency of the sensor information indicated in the maintenance information 922B are different, there is a defect in the sample container. presumed to occur.

On the other hand, in the maintenance information 922, the hot air temperature tends to be lower than the reference information, but the mold temperature and the blank temperature also tend to be lower, and neither temperature is below the threshold. think. A possible cause of such a tendency is, for example, a situation in which the hot air blowing unit cools down after maintenance and the temperature is lower than before maintenance. Although the temperature is lower than before maintenance, if the specified temperature is reached, even if the container is manufactured in such a situation, the possibility of causing a problem is low. Based on this way of thinking, the estimating unit 931 determines that if the tendency of the sensor information indicated in the reference information and the tendency of the sensor information indicated in the maintenance information 922B are the same, there is a defect in the prototype container. Assuming it won't happen.

When the estimation unit 931 estimates that a problem will occur based on the difference in tendency between the reference information and the maintenance information 922B, it outputs information (estimation result) indicating that the two information tend to differ to the display unit 94. to display. In this case, the estimation unit 931 may display, for example, the correlation coefficient and additional information that makes it easier for the maintenance worker to grasp the correlation of various sensor information. The additional information is, for example, an image in which various types of sensor information are superimposed in a circle graph (radar chart) for each of the reference information and the maintenance information 922B. This allows the maintenance worker to grasp the difference in the tendency of the two pieces of information.

Also, the estimation unit 931 may manufacture a plurality of containers in the trial production stage, and use the maintenance information 922 corresponding to each of the plurality of manufactured containers to estimate whether or not a problem will occur.

In this case, for example, the estimator 931 calculates a correlation coefficient between the reference information and the maintenance information 922 . The correlation coefficient is an example of "degree of strength of correlation". The correlation coefficient is, for example, an arbitrary real number from +1 to -1, where the closer to +1 the stronger the positive correlation and the closer to -1 the stronger the negative correlation.

A strong positive correlation indicates that one information (for example, reference information) and the other information (for example, maintenance information 922) have the same tendency. For example, if one piece of information indicates that the blank temperature tends to increase as the hot air flow rate increases, and the other information indicates that the blank temperature also tends to increase as the hot air rate increases, Positive correlation becomes stronger. In this case, it is considered that the air volume of the hot air is appropriate even after the maintenance, and the temperature of the blank is appropriately increased. If the container is manufactured under such circumstances, the possibility of defects occurring is low. Based on this way of thinking, the estimating unit 931 estimates that there will be no defects in the prototype container if the correlation coefficient between the reference information and the maintenance information 922 has a strong positive correlation.

On the other hand, a strong negative correlation indicates that one information (for example, reference information) and the other information (for example, maintenance information 922) have opposite tendencies. For example, if one piece of information indicates that the higher the flow of hot air, the higher the blank temperature, and the other indicates that the higher the flow of hot air, the lower the blank temperature, the negative correlation becomes stronger. In this case, for example, a situation can be considered in which the air volume is too large, the position of the blank is shifted, and the temperature of the blank does not rise. If the container is manufactured under such circumstances, there is a high possibility that defects will occur. Based on this way of thinking, the estimator 931 estimates that a defect will occur in the prototype container when the correlation coefficient between the reference information and the maintenance information 922 has a strong negative correlation.

Also, when both the positive correlation and the negative correlation are not strong, the correlation is weak. For example, if the reference information indicates that the higher the temperature of the mold, the higher the temperature of the cooling water, the maintenance information 922 indicates that the temperature of the cooling water is low regardless of whether the temperature of the mold is high or low. If a trend is shown, the correlation will be weak. When the correlation is weak, it means that the tendency shown in the reference information is not shown in the maintenance information 922 . In such a case, for example, a situation can be considered in which cooling water is not supplied to the inside of the mold and the mold is not cooled by the cooling water. If the container is manufactured under such circumstances, there is a high possibility that defects will occur. Based on this way of thinking, the estimation unit 931 estimates that a defect will occur in the prototype container when the correlation coefficient between the reference information and the maintenance information 922 is weak.

Based on the correlation coefficient between the reference information and the maintenance information 922B, the estimation unit 931 outputs the correlation coefficient (estimation result) to the display unit 94 and causes the display unit 94 to display it. In this case, the estimation unit 931 may display additional information that can be easily understood by the maintenance worker. The additional information is an image showing the correlation of various sensor information. It is an image superimposed on a pie chart (radar chart) so that the information and the maintenance information 922 can be compared.

Note that the estimating unit 931 may use, as the reference information, a statistic of sensor information measured in the manufacturing process before maintenance. A statistic of sensor information may be used when the product is a non-defective product.

In calculating the correlation coefficient, the estimating unit 931 may perform weighting by multiplying the respective sensor information of the reference information and the maintenance information 922B by a predetermined coefficient. Among the sensor information, for example, information in which a slight difference can cause a problem (for example, information indicating the installation position of the mold) is multiplied by a relatively large value (for example, 2.0). On the other hand, information that does not affect the occurrence of defects (for example, container identification information) is multiplied by a relatively small value (for example, 0.1) even if there is a difference in the measured values. The estimating unit 931 estimates whether or not a defect will occur in the container based on the weighted reference information and the correlation coefficient of the maintenance information 922B. As a result, it is possible to estimate whether or not a defect will occur in the container based on the strength of the correlation in the information that greatly contributes to the occurrence of the defect, and it is possible to improve the accuracy of the estimation.

The quality control section 932 manages the quality of containers manufactured in the manufacturing process. The quality control unit 932 acquires various sensor information in the process of manufacturing the container, and stores the acquired information in the storage unit 92 as the quality control information 921 .

The device control unit 933 comprehensively controls the quality control device 90 . For example, the device control unit 933 causes the storage unit 92 to store sensor information received by the communication unit 91 and information input to the input unit 95, and outputs the information to the estimation unit 931 and the like. For example, various threshold values are set and input to the input unit 95 by a maintenance worker or the like.

Here, the flow of processing performed by the quality control device 90 will be described with reference to FIGS. 13 and 14. FIG. 13 and 14 are flowcharts showing the flow of processing performed by the quality control device 90. FIG.

FIG. 13 shows the flow of processing for storing various sensor information in the manufacturing process. First, the quality control device 90 executes process A (step S10), acquires sensor information corresponding to process A, and stores the acquired information (step S11). The sensor information corresponding to the process A is, for example, information indicating the container code, the temperature of the mold, the temperature of the cooling water, the position of the mold, and the like. Next, the quality control device 90 executes process B (step S12), acquires sensor information corresponding to process B, and stores the acquired information (step S13). The sensor information corresponding to the process B is, for example, information indicating the temperature and air volume of hot air, the temperature distribution of the blank, the temperature of the mold, the temperature of cooling water, the position of the mold, and the like. Next, the quality control device 90 executes process C (step S14), acquires sensor information corresponding to process C, and stores the acquired information (step S15). The sensor information corresponding to the process C is, for example, information indicating the time when the male die starts to descend, the time when the male die starts to rise, the temperature of the mold, the temperature of the cooling water, and the like. Then, the quality control device 90 acquires information indicating whether or not a defect has occurred in the manufactured container, and stores the acquired information (step S16). Finally, the quality control device 90 generates quality control information 921 by storing the information obtained in steps S11, S13, S15 and S16 in association with the container code.

FIG. 14 shows the flow of processing performed by the quality control device 90 in reproduction work after maintenance. In the position adjustment stage, the quality control device 90 acquires information (position information) indicating the installation position of the mold and stores it as maintenance information 922A (steps S20 to S21). The quality control device 90 determines whether the difference between the maintenance information 922A and the reference position is less than a predetermined threshold. If the difference is less than the predetermined threshold, the quality control device 90 executes step S24 and proceeds to the trial production stage. On the other hand, if the difference is equal to or greater than the predetermined threshold, the quality control device 90 displays the difference and prompts the maintenance worker to make adjustments (steps S22 and S23). Then, the process returns to step S20 to repeat the position adjustment.

In the trial production stage, the quality control device 90 makes a trial production of a container, acquires various sensor information in the manufacturing process, and stores it as maintenance information 922B (step S25). Based on the maintenance information 922B and the reference information, the quality control device 90 estimates whether or not there will be a problem with the prototype container (step S26). For example, when the difference between the sensor information corresponding to the maintenance information 922B and the reference information is equal to or greater than a predetermined threshold value, the quality control device 90 estimates that a problem has occurred in the container. Alternatively, when the correlation coefficient between the maintenance information 922B and the reference information is within a predetermined range, the quality control device 90 presumes that the correlation between the maintenance information 922B and the reference information is weak and that the container is defective.

When the quality control device 90 estimates that the container is defective, it estimates the cause of the defect (step S26). For example, the quality control device 90 estimates that the difference between the sensor information corresponding to the maintenance information 922B and the reference information is equal to or greater than a predetermined threshold value, which is the cause of the defect in the container. Alternatively, the quality control device 90 estimates that the fact that the correlation coefficient between the maintenance information 922B and the reference information is less than a predetermined threshold is the cause of the defect in the container. The quality control device 90 displays the estimated cause of failure (estimation result) on the display unit 94 (step S27).

As described above, the quality control device 90 of the embodiment is a control device that controls manufacturing processes. A container is manufactured in the manufacturing process. In the manufacturing process, the container is manufactured by pressing the blank BR (packaging material) by reciprocating the mold. The quality control device 90 includes an acquisition section 930 , an estimation section 931 and a display section 94 . Acquisition unit 930 acquires position information. The position information is information indicating the installation position of the mold. The position information includes the position of the male OG measured by the first position detection sensor 11, the position of the female MG measured by the second position detection sensor 12, and the position of the roller R measured by the third position detection sensor 13. This is information indicating each position. The estimation unit 931 uses the first position information and the second position information in the reproduction work (reinstallation) after maintenance to estimate whether or not a defect will occur in the container to be manufactured after the reinstallation. The first position information is information measured before maintenance, such as position information measured before removal during maintenance or position information measured during the manufacturing process before maintenance.

Thereby, the quality control device 90 of the embodiment can adjust the position of the mold after the reinstallation using the position information measured before the reinstallation. Therefore, it can be returned exactly to the position before re-installation. For this reason, the molds can be returned to the positional relationship before maintenance, and in the production after re-installation, the molds do not mesh with each other, and the pressing force is insufficient or excessive. It can be eliminated, and the reproduction work can be advanced efficiently. Therefore, it is possible to suppress an increase in the time required for maintenance, and thus it is possible to manufacture containers without lowering productivity.

Further, in the quality control device 90 of the embodiment, the acquisition unit 930 acquires defect information. The defect information is information indicating whether or not a defect has occurred in the container manufactured in the manufacturing process. The defect information is, for example, information indicated in the item "presence or absence of defect" in the quality control information 921 . The estimating unit 931 uses the statistic of the position information measured in the manufacturing process of the containers that have been determined to be non-defective and non-defective among the containers manufactured in the manufacturing process before maintenance as the reference position. do. The estimation unit 931 determines that a problem occurs when the difference between the position information measured after the re-installation and the reference position is equal to or greater than the threshold. As a result, the quality control device 90 of the embodiment can adjust the position after maintenance based on the conditions under which non-defective products are manufactured. Therefore, it is possible to produce the same effects as those described above, and to manufacture the container without lowering the productivity.

Also, in the quality control device 90 of the embodiment, the acquisition unit 930 acquires the quality control information 921 . The quality control information 921 is information measured to control the quality of manufactured containers. Based on the quality control information 921 and the maintenance information 922 measured before and after the reinstallation, the estimation unit 931 estimates whether or not the container to be manufactured after the reinstallation will have a defect. As a result, the quality control device 90 of the embodiment can perform maintenance efficiently using the quality control information 921 measured during the manufacturing process without acquiring new information.

In addition, in the quality control device 90 of the embodiment, the estimation unit 931 stores quality control information 921 (reference information) acquired before reinstallation and quality control information (maintenance information 922) acquired after reinstallation. Based on the correlation coefficient (the degree of correlation strength), it is estimated whether defects will occur in the container to be manufactured after the reinstallation. As a result, even if the quality control information 921 includes a large number of sensor information and it is not possible to unconditionally determine which sensor information is the cause of the defect, the degree of similarity of the overall information, that is, the correlation is strong. Based on whether or not, it is possible to estimate whether or not a problem will occur. Therefore, even when a large number of sensor information are measured as the quality control information 921, accurate estimation is possible.

In the quality control device 90 of the embodiment, the acquisition unit 930 acquires the installation position of the male OG measured at the timing when the direction of movement of the reciprocating male OG changes as the sensor information 920 (position information). You may make it Thereby, even when the male mold moves up and down, the installation position of the male mold can be measured at the timing when the movement stops, and the position can be measured with high accuracy.

Further, in the quality control device 90 of the embodiment, a blank is placed between the male mold and the female mold, and the male mold is moved to reciprocate in the direction of the female mold to form the container. This allows the blank to be folded correctly along the fold lines to form the container in the correct shape.

Further, in the quality control device 90 of the embodiment, the quality control information may include information indicating the temperature and volume of hot air (hot air supply information). Also, the quality control information may include information (temperature distribution information) indicating the temperature distribution of the blank (packaging material). Also, the quality control information may include information (temperature information) indicating the temperature of the mold and cooling water. This makes it possible to estimate the possibility of a problem occurring based on the tendency of the hot air temperature and air volume, the temperature distribution of the blank, the temperature of the mold and the cooling water, or the correlation coefficient.

In the above-described embodiment, since the female mold is installed below the male mold, the case where the male mold moves up and down has been described as an example. However, it is not limited to this. The male type should be able to reciprocate at least in the direction of the female type. For example, the male type may reciprocate in an arbitrary trajectory such as a left-right direction or an arc. In such a case, the position sensor measures the position of the male OG at the timing when the direction of movement in the reciprocating motion changes. This makes it possible to measure the position with high accuracy.

Further, in the above-described embodiment, male type maintenance was described as an example. However, it is not limited to this. It can also be applied to the maintenance of the female die and rollers. It can also be applied when performing maintenance on a plurality of molds at the same time. For example, when the male mold and the roller are removed and then reassembled and installed at the original position, for example, the installation position of the male mold is first adjusted. For example, with the installation position of the female type as a reference, the installation position of the male type is adjusted so that it has the same positional relationship as before maintenance. After that, the installation position of the roller is adjusted based on the installation position of the female type (or the adjusted male type).

Further, in the above-described embodiment, an example using a mold has been described. However, the mold is not limited to metal molds, and of course any mold made of any material such as wood or resin may be used.

All or part of the management system 1 and the quality control device 90 in the above-described embodiment may be realized by a computer. In that case, a program for realizing this function may be recorded in a computer-readable recording medium, and the program recorded in this recording medium may be read into a computer system and executed. It should be noted that the "computer system" referred to here includes hardware such as an OS and peripheral devices. The term "computer-readable recording medium" refers to portable media such as flexible discs, magneto-optical discs, ROMs and CD-ROMs, and storage devices such as hard discs incorporated in computer systems. Furthermore, "computer-readable recording medium" refers to a program that dynamically retains programs for a short period of time, like a communication line when transmitting a program via a network such as the Internet or a communication line such as a telephone line. It may also include something that holds the program for a certain period of time, such as a volatile memory inside a computer system that serves as a server or client in that case. Further, the program may be for realizing a part of the functions described above, or may be capable of realizing the functions described above in combination with a program already recorded in the computer system, It may be implemented using a programmable logic device such as FPGA.

Although the embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and design and the like are included within the scope of the gist of the present invention.

1... Management system 90... Quality control device (control device)
92... Storage unit 920... Sensor information 921... Quality control information 922... Maintenance information 93... Control unit 930... Acquisition unit 931... Estimation unit 932... Quality control unit 933... Apparatus control unit 94... Display unit (output unit)

Claims (9)

A management device for managing a manufacturing process for manufacturing a container by pressing a surface of a packaging material by reciprocating a mold,
an acquisition unit that acquires position information indicating the installation position of the mold measured by a position detection sensor;
After removing the mold, when the mold is reinstalled to the original installation position again, the first position information that is the position information measured before the reinstallation; an estimating unit that estimates whether a defect will occur in the container to be manufactured after the reinstallation, using the second position information that is the position information measured after the reinstallation;
an output unit that outputs an estimation result estimated by the estimation unit;
A management device comprising The acquisition unit acquires defect information indicating whether or not a defect has occurred in the container manufactured in the manufacturing process,
The estimating unit uses the defect information from the first position information measured each time the container is manufactured in the manufacturing process performed before the re-installation to identify the container in which the defect has not occurred. The position information measured in the manufacturing process is extracted, and based on the difference between the statistic of each installation position corresponding to the extracted information and the second position information, if the difference is a threshold value or more Presuming that the malfunction occurs,
The management device according to claim 1. The acquisition unit acquires quality control information measured to control the quality of the manufactured container,
The estimation unit uses first quality control information, which is the quality control information measured before the reinstallation, and second quality control information, which is the quality control information measured after the reinstallation. , estimating whether a defect will occur in the container to be manufactured after the re-installation;
The management device according to claim 1 or 2. The estimating unit estimates whether the defect will occur based on a degree indicating the strength of correlation between the first quality control information and the second quality control information.
The management device according to claim 3. The mold is cooled by cooling water circulating inside the mold,
The acquisition unit acquires temperature information indicating the temperature of the mold and the temperature of the cooling water as the quality control information.
The management device according to claim 3 or 4. The acquisition unit acquires, as the position information, the installation position of the mold measured at the timing when the movement direction of the mold reciprocating changes.
The management device according to any one of claims 1 to 5. The mold comprises a first mold and a second mold,
The first mold is installed at a first position, the second mold is installed at a second position different from the first position, and the packaging material is arranged between the first position and the second position. is,
In the manufacturing process, the packaging material is pressed by reciprocating the first mold from the first position toward the second position.
The management device according to any one of claims 1 to 6. A management method performed by a computer device, which is a management device for managing the manufacturing process of manufacturing a container by pressing the surface of a packaging material by reciprocating a mold, comprising:
An acquisition unit acquires position information indicating the installation position of the mold measured by a position detection sensor,
When the estimating unit removes the mold and then reinstalls the mold to the original installation position again, the first position that is the position information measured before the reinstallation using the information and the second position information, which is the position information measured after the reinstallation, to estimate whether a defect will occur in the container to be manufactured after the reinstallation;
An output unit outputs an estimation result estimated by the estimation unit;
Management method. A computer device, which is a management device for managing the manufacturing process of manufacturing a container by pressing the surface of the packaging material by reciprocating the mold,
Acquiring position information indicating the installation position of the mold measured by a position detection sensor,
After removing the mold, when the mold is reinstalled to the original installation position again, the first position information that is the position information measured before the reinstallation; Using the second position information, which is the position information measured after the re-installation, to estimate whether a defect will occur in the container to be manufactured after the re-installation,
outputting the estimated estimation result;
program.

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