JP4116761B2 - Injection molding machine monitoring device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an injection molding machine monitoring device, and particularly to improve the monitoring function.
[0002]
[Prior art]
Conventionally, for example, as a monitoring device of an injection molding machine for injection molding of a synthetic resin material, as disclosed in JP-A-60-39581, it is obtained by imaging the injection molding machine main body with a television camera as imaging means. Based on the video signal, one that determines whether or not the injection molding operation of the main body of the injection molding machine is normal is used.
[0003]
The injection molding machine body repeats the injection molding cycle every time one injection molded product is molded.
[0004]
That is, in a state where the movable side mold is in pressure contact with the fixed side mold (this state is referred to as a “clamping” state), by injecting a synthetic resin material through the conduit, an injection molded product is placed in the movable side mold and the fixed side mold. Mold.
[0005]
This injection-molded product has a mold opening position in a state where it is attached to the inner surface of the movable mold when the movable mold side is retracted from the fixed mold side to a position spaced along the guide (this state is referred to as a “mold open” state). The injection molded product that has been brought to the position and then adhered to the movable mold side is pushed down from the movable mold by a protruding pin protruding from the rear of the movable mold (this operation is called “protruding” operation).
[0006]
Thus, when one injection molded product is removed from the main body of the injection molding machine by dropping from the movable mold, one cycle of the injection molding process (that is, one injection molding cycle) is completed and the next injection molding cycle is started. enter.
[0007]
At this time, the movable mold side advances toward the fixed mold and returns to the clamped state in which the movable mold is pressed against the fixed mold, and the injection molding cycle is repeated in the same manner.
[0008]
[Problems to be solved by the invention]
In this type of injection molding machine, when the main body of the injection molding machine opens the mold, the injection molded product remains attached to the fixed side mold (so-called mold residue), or the injection molded product is completely molded. In such a case, a part is missing (so-called short mold), or the movable side mold is out of the normal mounting position (so-called slide core misalignment). It is necessary to monitor an abnormality occurring in the mold opening mode (this is called “primary monitoring”).
[0009]
In addition, after the injection molding machine main body protrudes, the injection molded product remains on the movable mold side without being pushed down (so-called drop failure), or when the injection molded product is pushed down, the protruding pin breaks (so-called pin It is necessary to monitor an abnormality that occurs in the mold opening mode (such as “breaking”) (this is called “secondary monitoring”).
[0010]
If such an abnormality occurs, if this state is left as it is, a derivative accident such as damage to the movable side mold and / or the fixed side mold or molding of a defective product in the next injection molding cycle. It is necessary to immediately detect the occurrence of these abnormalities.
[0011]
The present invention has been made in consideration of the above points, and an object of the present invention is to propose an injection molding machine monitoring apparatus capable of reliably detecting the occurrence of an abnormality with the simplest possible process.
[0012]
[Means for Solving the Problems]
In order to solve this problem, in the present invention, the operation state of the injection molding machine main body 1 when the injection molding machine main body 1 performs the mold opening operation and the protruding operation is imaged by the imaging means 11, and the video signal VD1 of the imaging means 11 is captured. Based on the change in brightness of the image data portion from the primary and secondary monitoring reference image data D1 and D2 of the first image data D6 during the mold opening operation and the second image data D7 during the protruding operation In the injection molding machine monitoring apparatus 10 for primary and secondary monitoring of the abnormal operation of the injection molding machine main body 1, the first and second image data D6 and D7 obtained at the start of the monitoring operation are used as primary monitoring reference image data. First and second memory means 18A and 18B stored as D1 and D2, and primary and secondary monitoring stored in the first and second memory means 18A and 18B at the start of the monitoring operation Between pixels of the quasi image data D1 and D2 side Pixels whose difference is greater than a predetermined threshold Corresponding to position data Third monitoring means 18C for storing AR1 as monitoring area data D3, and primary monitoring detection image data D6 obtained based on video signal VD1 of imaging means 11 during monitoring cycle processing after the start of the monitoring operation, Pixel corresponding to data D3 of By comparing the position with the primary monitoring reference image data D1, the abnormality determining means SP25 for determining the presence or absence of abnormality during the primary monitoring is provided.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described in detail below with reference to the drawings.
[0017]
(1) Overall configuration of injection molding machine monitoring device
In FIG. 1, reference numeral 1 denotes an injection molding machine main body, and by injecting a synthetic resin material through a conduit 4 in a clamped state in which the movable side mold 2 is pressed against the fixed side mold 3, the movable mold side 2 and the fixed side mold 3. Mold the injection molded product inside.
[0018]
This injection-molded product is brought to the mold opening position while being attached to the inner surface of the movable side mold 2 when the movable side mold 2 is in the mold open state separated from the fixed side mold 3 along the guide 5. Thereafter, the pin (not shown) protrudes from the rear side of the movable side mold 2 and protrudes from the movable side mold 2 by performing an operation.
[0019]
The injection molding cycle of the injection molding machine main body 1 is automatically controlled by a sequencer provided in the injection molding machine main body drive control device 6.
[0020]
The injection molding operation of the injection molding machine main body 1 is provided in the injection molding machine monitoring device 10. Is Imaged by a television camera 11 as an imaging means, input The video signal VD1 is converted into video data DATA1 in the image input circuit 12, and is input to the image processing circuit 13 and held therein.
[0021]
The video data held in the image processing circuit 13 is sent to a central processing unit (CPU) 17 that performs processing operations according to a program in the program memory 16 via the bus 15 and an operation input unit according to a user operation via the bus 15. In response to an operation command input from 25, the data is taken in at a predetermined timing and stored in the frame memory 18 via the bus 15 for each pixel.
[0022]
In the case of this embodiment, the timing at which the CPU 17 stores the image data DATA1 in the frame memory 18 is first in the test mode before the injection molding machine monitoring device 10 enters the monitoring operation, and secondly, the injection This is the primary monitoring mode in which the molding machine body 1 has performed the mold opening operation, and thirdly, the secondary monitoring mode in which the injection molding machine body 1 has been projected and operated.
[0023]
The CPU 17 determines whether or not an abnormality has occurred based on the video data DATA1 stored in the frame memory 18 in the three monitoring modes, and determines the determination result image data DATA2 representing the determination result via the bus 15 as an image processing circuit. 13
[0024]
The image processing circuit 13 supplies the determination result image data DATA2 to the image display circuit 19, so that the image display circuit 19 superimposes the video signal VD1 supplied from the television camera 11 in the image display circuit 19 to the monitor 20 as the display image signal VD2. give.
[0025]
Thus, the monitor 20 determines the determination result image data representing the abnormal state (or normal state) determined by the CPU 17 with respect to the image of the injection molding machine main body 1 currently captured by the television camera 11 based on the input video signal VD1. Based on DATA2, it is possible to present to the user a monitoring screen in which an abnormality occurrence display is displayed on the image portion where the abnormality has occurred.
[0026]
The CPU 17 determines the timing of the monitoring mode based on the monitoring control signal S1 given from the injection molding machine main body drive control device 6 via the control signal input / output unit 21 to determine the timing for performing the monitoring processing operation. The sequence control signal S2 is given to the injection molding machine main body drive control device 6 via the control signal input / output unit 21 based on the determination operation and the determination result, whereby the injection molding machine main body 1 is controlled by the injection molding machine monitoring device 10. Control that is synchronized with the monitoring operation is executed.
[0027]
Thus, the CPU 17 executes the monitoring processing operation described below while synchronizing with the operation of the injection molding cycle of the injection molding machine body 1.
[0028]
(2) Normal monitoring process
(2-1) Reference data acquisition process
When the user designates the normal monitoring processing mode via the operation input unit 25, the CPU 17 enters the normal monitoring processing routine RT1 in FIG. 2 and waits for the mold opening limit signal to be turned on in step SP1.
[0029]
The processing of this step SP1 means that the CPU 17 confirms that the injection molding machine main body 1 is in the mold open state, and performs processing to match the timing at which the CPU 17 executes the subsequent operation with the injection molding machine main body 1. When the movable mold 2 of the injection molding machine main body 1 is retracted to the mold opening position, the injection molding machine main body drive control device 6 outputs the mold opening limit signal that has been turned on as the monitoring control signal S1. This is given to the CPU 17 via the unit 21.
[0030]
At this time, the CPU 17 proceeds to the next step SP2 to give a mold clamping interlock setting signal as a sequence control signal S2 to the injection molding machine main body drive control device 6 via the control signal input / output unit 21, thereby making the injection molding machine main body. The injection molding machine main body drive control device 6 is controlled so as not to perform the mold clamping operation 1, thereby holding the injection molding machine main body 1 in the mold open state.
[0031]
Thus, in a state where the injection molding machine main body 1 holds the mold open state, the CPU 17 in the next step SP3, the input video signal VD1 (injection in the mold open state) currently obtained from the television camera 11 is performed. The image in the cavity of the molding machine main body 1 is input to the image processing circuit 13 through the image input circuit 12 as input video data DATA1 for one frame.
[0032]
Subsequently, the CPU 17 uses the image data for one frame representing the mold open state input to the image processing circuit 13 in step SP4 as the primary monitoring reference image data D1 as the primary monitoring reference image data memory in the frame memory 18 (FIG. 3). Register in area 18A.
[0033]
Thus, the image data registered in the frame memory 18 indicates that when the injection molding machine main body 1 is operating normally, the movable mold 2 moves to the mold open position with the injection molded product attached to the movable mold 2. The CPU 17 has acquired the image data for one frame in the mold open state in the frame memory 18 as reference data used for determining whether or not an abnormality has occurred during the primary monitoring. .
[0034]
Subsequently, the CPU 17 moves to step SP5 and projects as a sequence control signal S2 and gives an interlock release signal to the injection molding machine main body drive control device 6 via the control signal input / output unit 21, thereby causing the injection molding machine main body 1 to change. In addition to allowing the start of the protruding operation, the next step SP6 waits for the protruding completion signal that has been turned on as the monitoring control signal S1 from the injection molding machine main body drive control device 6 to arrive via the control signal input / output unit 21. It becomes a state.
[0035]
Eventually, when the protrusion completion signal that has turned on is received, the CPU 17 proceeds to the next step SP7, where the input video signal VD1 (the injection molding machine main body 1 is protruded and is in the completed state) that is currently obtained from the television camera 11. 1 frame of input video data DATA1 is input to the image processing circuit 13 as secondary monitoring image data.
[0036]
Subsequently, the CPU 17 proceeds to step SP8 and registers the image data for one frame in the secondary monitoring reference image data memory area 18B of the frame memory 18 as the secondary monitoring reference image data D2.
[0037]
In the processing of this step SP8, the secondary monitoring image data when the injection molded product adhering to the movable side mold 2 is in a dropped state due to the injection molding machine body 1 projecting is used for the subsequent processing operation. It is meant to be used as reference data.
[0038]
Subsequently, the CPU 17 proceeds to the next step SP9 and protrudes as a sequence control signal S2, and gives an interlock setting signal from the control signal input / output unit 21 to the injection molding machine main body drive control device 6 to the injection molding machine main body 1. After controlling to the state where the protruding operation is not performed, in step SP10, a mold clamping interlock release signal is given to the injection molding machine main body drive control device 6 as a sequence control signal S2, thereby permitting the mold clamping operation of the injection molding machine main body 1 To control.
[0039]
Thereafter, the CPU 17 proceeds to the next step SP11 to execute a calculation for subtracting the secondary monitoring image data from the primary monitoring image data to obtain an absolute value thereof, and a pixel position where the difference data is larger than a predetermined threshold value. Is registered in the monitoring area data memory area 18C (FIG. 3) of the frame memory 18 as cavity monitoring area data D3 representing the cavity, and in the next monitoring cycle processing routine RT2, the fixed side mold 3 and An injection molding cycle for injection molding of the next injection molded product is executed by the movable side mold 2.
[0040]
Here, the primary monitoring image data is image data representing an image in a state where the injection-molded product is adhered to the movable side mold 2 when the mold is opened, whereas the secondary monitoring image data is the movable side mold when protruding. 2 is an image data representing an image in which the injection-molded product has dropped and is not attached, the position of a pixel having a brightness change of | primary monitoring image data−secondary monitoring image data | This means that, as shown in FIG. 6 (A), the space where the injection-molded product was present at the time of opening, that is, the area AR1 where the cavity exists in the image DIP for one frame.
[0041]
Therefore, the position data represented by the monitoring area data D3 in the monitoring area data memory area 18C of the frame memory 18 represents the position where the cavity exists in one frame image.
[0042]
Thus, the CPU 17 registers the primary monitoring reference image data D1 at the time of mold opening and the secondary monitoring reference image data D2 at the time of projecting completion by executing the processing of steps SP1 to SP11, and to these reference image data. Based on this, it is possible to automatically acquire the monitoring area data D3 representing the position of the cavity, and the monitoring cycle processing routine RT2 is executed using this monitoring area data D3.
[0043]
(2-2) Primary monitoring abnormality processing and secondary monitoring condition confirmation processing
The CPU 17 executes the monitoring cycle processing routine RT2 shown in FIGS. 4 and 5 to determine whether or not an abnormality has occurred in the injection molding operation each time the injection molding machine main body 1 performs injection molding of the injection molded products one by one. The monitoring process is executed.
[0044]
When the monitoring cycle processing routine RT2 is entered, the CPU 17 monitors and controls from the injection molding machine main body drive control device 6 the mold opening limit signal that has been turned on for the injection molded product currently injection molded by the injection molding machine main body 1 in step SP21. While waiting for arrival as signal S1, and when an ON-state mold opening limit signal has arrived, a mold clamping interlock setting signal is sent as a sequence control signal S2 to the injection molding machine main body drive control device 6 in the next step SP22. Thus, it is confirmed that the injection molding machine main body 1 is in the mold open state, and the injection molding machine main body 1 is controlled so as not to perform the mold clamping operation.
[0045]
In this state, in the next step SP23, the CPU 17 inputs the input video data DATA1 for one frame as the primary monitoring detection image data D6 to the primary monitoring detection image data memory area 18F of the frame memory 18 through the image processing circuit 13. To do.
[0046]
At this time, the CPU 17 uses the cavity monitoring area data D3 in the cavity monitoring area data memory area 18C of the frame memory 18 to temporarily display the cavity area AR1 (FIG. 6A) on the monitor 20, so that sufficient The user is notified that the luminance difference has been obtained and that the detection data D6 has been input to the primary monitoring detection image data memory area 18F.
[0047]
Subsequently, in the next step SP24, the CPU 17 performs primary monitoring detection image data D6 in the primary monitoring detection image data memory area 18F and primary monitoring reference image data D1 registered in the primary monitoring reference image data memory area 18A. After executing the primary monitoring process for comparing with, it is determined whether or not there is an abnormality in step SP25.
[0048]
At this time, the CPU 17 determines that the pixel data of the pixel represented by the cavity monitoring region data D3 is the pixel data corresponding to the primary monitoring reference image data D1 among the pixel data of the primary monitoring detection image data D6 in step SP25. If the number of non-matching pixels exceeds a predetermined number, it is determined that an abnormality has occurred, and the process moves to step SP26.
[0049]
In practice, the determination at step SP25 is that the deviation between the primary monitoring detection image data D6 in the primary monitoring detection image data memory area 18F and the primary monitoring image reference data D1 in the primary monitoring image reference data memory area 18A is one frame. When the deviation exceeds a predetermined threshold, the pixel is determined to be abnormal, and the number of pixels in which the abnormality has occurred is totaled. When the total value exceeds a predetermined allowable value When the area of the abnormal portion is larger than the threshold area, it is determined that an abnormality has occurred in the mold opening operation of the injection molding machine body 1.
[0050]
When making such a determination, the CPU 17 determines that an abnormality occurs when pixels that do not match are adjacent to each other by a predetermined number or more (this number can be designated and input by the user through the operation input unit 25). Even if there is noise such as smaller dust, this is ignored.
[0051]
In this embodiment, the CPU 17 counts the number of abnormality determinations in step SP26, determines whether the count result is a predetermined number of times, for example, three times or more (including the third time), and the negative result is When it is obtained (that is, when it is the first time or the second time), the process returns to the above-described step SP23 and the processes of steps SP23, SP24, and SP25 are repeated.
[0052]
Thus, when the CPU 17 determines that the abnormality detection result during the mold opening operation of the injection molding machine main body 1 is only the first or second time and is normal for the third time, the mold opening operation for the injection molded product is performed. Therefore, when the injection molding machine monitoring apparatus 10 performs a temporarily unstable abnormality detection operation due to some disturbance (for example, when the brightness of the cavity temporarily changes). ), So as not to respond to this.
[0053]
Thus, if a positive result is obtained in step SP26, this means that it has been determined that there are three abnormalities as a result of the three abnormality determination processes, and at this time, the CPU 17 sends an abnormality warning output in step SP27.
[0054]
Here, as a method for sending out the abnormality warning output, the CPU 17 stores the position data of the pixels determined to be abnormal in step SP25 as the primary monitoring abnormal image data D8 in the primary monitoring abnormal image data memory area 18H of the frame memory 18, The frame data including the primary monitoring abnormal image data D8 can be superimposed on the video signal VD1 via the image processing circuit 13 and the image display circuit 19 and displayed on the monitor 20, and thus the injection molding machine main body 1 can be displayed. Is displayed on the display screen of the monitor 20 (for example, the abnormal part is displayed in high brightness white), so that the user can easily and reliably recognize the abnormal part.
[0055]
As described above, after sending the abnormality warning output in step SP27, the CPU 17 moves to step SP28 to determine whether or not the monitoring area needs to be updated, and the user updates the monitoring area using the operation input unit 25. When inputting that it is necessary, the CPU 17 moves to step SP29 and executes the update process of the primary monitoring area.
[0056]
As shown in FIG. 6A, the update of the primary monitoring area is performed when the data of the monitoring area AR1 representing the cavity is registered in the monitoring area memory area 18C in the image data DIP for one frame. As shown in FIG. 6B, when the disturbance image DT is generated in the monitoring area AR1 (when a part of the components in the cavity is abnormally brightly reflected), the disturbance image is displayed. Focusing on the fact that if it can be easily removed, the correct monitoring operation can be performed, and the process of setting the determination exclusion area ARX surrounding the disturbance video DT is performed by the user as the primary monitoring area update process in step SP29. 25 is stored in the primary monitoring area data memory area 18D of the frame memory 18 as the primary monitoring area data D4.
[0057]
If the monitoring area is updated in steps SP28 and SP29 in this way, the area of the primary monitoring area data D4 is changed, for example, when the mold is changed or when the ambient light changes over time. By removing so as not to perform the determination operation, the subsequent monitoring operation can be stabilized.
[0058]
Thus, when an abnormality occurs in the primary monitoring mode, the user actually operates the injection molding machine body 1 manually by opening the safety door of the injection molding machine body 1 and operating the manual operation panel 31. Then, the cause of the abnormality is manually removed, and when the work is completed, the safety door is closed and the automatic monitoring cycle is resumed.
[0059]
Thus, when the safety door of the injection molding machine main body 1 is closed, the injection molding machine main body drive control device 6 sends the reset signal that has been turned on as the monitoring control signal S1 to the CPU 17 via the control signal input / output unit 21. send.
[0060]
At this time, the CPU 17 receives the reset signal transitioned to the ON state in step SP30, moves to step SP31, deletes the abnormality warning output, and executes the confirmation process of the secondary monitoring operation as described below.
[0061]
In the confirmation process of the secondary monitoring operation, first, the CPU 17 protrudes and operates the injection molding machine main body 1 by giving an interlock release signal as a sequence control signal S2 to the injection molding machine main body drive control device 6 in step SP32.
[0062]
When the operator then closes the safety door of the injection molding machine main body 1 in step SP33, the CPU 17 receives a reset signal that has been shifted to the off state as the monitoring control signal S1 from the injection molding machine main body drive control device 6, and then step SP34. Then, as a sequence control signal S2 for the injection molding machine main body drive control device 6, it protrudes and gives an interlock setting signal.
[0063]
Thus, after the injection molding machine main body 1 protrudes and cannot move, the CPU 17 moves to step SP35 and performs secondary monitoring detection for one frame as the input video data DATA1 based on the input video signal VD1 of the television camera 11. The image data D7 is input to the secondary monitoring detection image data memory area 18G.
[0064]
Subsequently, the CPU 17 executes secondary monitoring image processing in step SP36. In this secondary monitoring image processing, the secondary monitoring reference image data D7 captured by the CPU 17 in the secondary monitoring detection image data memory area 18G is stored in the secondary monitoring reference image data memory area 18B. Compared with the image data D2, data ("1" or "0") indicating abnormality or normality for each pixel is stored in the secondary monitoring abnormal image data memory area 18I of the frame memory 18 in the secondary monitoring abnormal image data D9. Remember as.
[0065]
Subsequently, in step SP37, the CPU 17 determines whether there is an abnormality based on the secondary monitoring detection image data D7.
[0066]
At this time, the CPU 17 determines whether or not the number of pixels indicating abnormality (representing the size of the abnormal image) is larger than a predetermined value. Send warning output.
[0067]
Here, the CPU 17 superimposes the determination result image data DATA2 in which the abnormal pixel in the secondary monitoring abnormal image data D9 has a high luminance among the secondary monitoring abnormal image data D9 on the input video signal VD1 and displays it on the monitor 20. Thus, the operator can easily grasp the abnormal part as in the case of the primary monitoring process.
[0068]
Thereafter, the CPU 17 determines whether or not the user designates and inputs the monitoring area updating process in step SP39, and executes the secondary monitoring area updating process in step SP40 when a positive result is obtained.
[0069]
In the update process of the secondary monitoring area, the secondary monitoring area data D5 is formed and stored in the secondary monitoring area data memory area 18E in the same manner as described above for the updating process at the time of primary monitoring in step SP29. As a result, a process for removing the disturbance video is executed, whereby the user can set a condition for performing a highly stable process in the secondary monitoring following the primary monitoring.
[0070]
When a negative result is obtained in step SP39, the CPU 17 jumps to the secondary monitoring area update process in step SP40.
[0071]
Thus, the confirmation of the secondary monitoring process result and the update process of the secondary monitoring area are completed, and the CPU 17 receives the reset signal that has been switched to the ON state as the monitoring control signal S1 from the injection molding machine main body drive control device 6 in step SP41. When it arrives, the process proceeds to step SP42 to project as the sequence control signal S2 to the injection molding machine main body drive control device 6 to give the interlock release signal, thereby causing the injection molding machine body 1 to project and to perform the injection molding in step SP43. As a monitoring control signal S1 of the machine main body drive control device 6, it waits for a reset signal that has transitioned to the OFF state, and when it arrives, in step SP44, it projects as a sequence control signal S2 for the injection molding machine main body drive control device 6 and is set to interlock. Give a signal.
[0072]
Thus, the CPU 17 returns to the above-described step SP35 after the injection molding machine main body 1 is protruded and set to the state at the completion.
[0073]
In this way, the CPU 17 reconfirms the result of the secondary monitoring process and executes a process of reconfirming the abnormality warning output and the monitoring area update process.
[0074]
Eventually, when the CPU 17 determines that the secondary monitoring process result is normal in step SP37, the process proceeds to step SP45, and after giving the mold clamping interlock release signal as the sequence control signal S2 to the injection molding machine body drive control device 6, The process returns to the primary monitoring detection image data input process in step SP23 (FIG. 4).
[0075]
(2-3) Primary monitoring normal processing and secondary monitoring processing
When the CPU 17 determines in step SP25 in FIG. 4 that the result of the primary monitoring process is normal, the CPU 17 proceeds to step SP50 and projects a sequence control signal S2 to the injection molding machine body drive control device 6 to give an interlock release signal. At the same time, in the next step SP51, it waits for the protrusion completion signal that has been turned on as the monitoring control signal S1 from the injection molding machine main body drive control device 6.
[0076]
In this state, the injection molding machine body 1 protrudes from the mold open state and operates.
[0077]
As a result, when the protrusion completion signal transitions to the ON state, the CPU 17 proceeds to step SP52 and protrudes as the sequence control signal S2 to the injection molding machine main body drive control device 6 to give the interlock setting signal, thereby protruding the injection molding machine main body 1. Keep it in a state.
[0078]
Subsequently, in step SP53, the CPU 17 fetches the secondary monitoring detection image data D7 in the protruding state into the secondary monitoring detection image data memory area 18G of the frame memory 18 based on the input video signal VD1 of the television camera 11, and then the step. In SP54, secondary monitoring image processing is executed.
[0079]
In this secondary monitoring image processing, the secondary monitoring detection image data D7 in the secondary monitoring detection image data memory area 18G is transferred to the secondary monitoring reference image data memory area 18B in the same manner as described above in steps SP35 and SP36. Secondary monitoring reference image data D2 that is stored and secondary monitoring abnormal image data D9 that is abnormal when the deviation exceeds a predetermined threshold and normal when the deviation exceeds a predetermined threshold Processing such as storing in the abnormal image data memory area 18I is executed.
[0080]
Subsequently, in step SP55, the CPU 17 determines whether or not the secondary monitoring image processing result is abnormal.
[0081]
This determination is based on whether the number of pixels indicating an abnormality (representing the size of the abnormal portion) in the secondary monitoring abnormal image data D9 stored in the secondary monitoring abnormal image data memory area 18I is greater than a predetermined value. If it is large, it is determined that an abnormality has occurred, and the CPU 17 proceeds to the next step SP56 to determine whether or not the secondary monitoring frequency is the third time, and a negative result is obtained. Then, the process returns to the above-described step SP53, and the input of the secondary monitoring detection image data D7 and the secondary monitoring image processing are executed again.
[0082]
Thus, the CPU 17 executes a process of taking the input video data DATA1 based on the input video signal VD1 of the television camera 11 into the frame memory 18 up to the third time as the secondary monitoring detection image data D7.
[0083]
As a result, after the injection molding machine main body 1 has protruded, when the injection molded product is caught in the injection molding machine main body 1 and does not fall in the first protruding operation, the second and third monitoring is performed. By performing the operation, it is possible to perform processing such as dropping the caught injection molded product. As a result, instead of immediately performing abnormality processing according to one determination result, repeating the abnormality confirmation processing three times If a normal determination result is obtained, it is processed as normal, whereby the determination process for secondary monitoring can be performed efficiently.
[0084]
If a positive result is obtained in step SP56, this means that it is still determined to be abnormal when the third secondary monitoring operation is performed. At this time, the CPU 17 proceeds to step SP57 and outputs an abnormality warning output. Send it out.
[0085]
The abnormality warning output at this time is the determination result image data DATA2 in which the pixel representing the abnormality is increased in brightness among the secondary monitoring abnormal image data D9 stored in the secondary monitoring abnormal image data memory area 18I. By sending from the image processing circuit 13, the operator can continue to display an image in which a portion where an abnormality has occurred in the image of the injection molding machine main body 2 protruding on the monitor 20 with high brightness. Makes it easy to grasp the location of the abnormality.
[0086]
In this state, the CPU 17 proceeds to step SP58 to determine whether or not the operator is updating the abnormality monitoring area. If a positive result is obtained, the secondary monitoring area data memory area 18E of the frame memory 18 is obtained in step SP59. The secondary monitoring area data D5 is changed according to the update process of the operator, and the process returns to step SP53.
[0087]
Thus, when the secondary monitoring image representing the abnormality is obtained when the injection molding machine body 1 is in the protruding state, the CPU 17 performs the updating process of the secondary monitoring area only after the monitoring operation is repeated three times and still abnormal. Execute.
[0088]
In the case of this embodiment, after executing the secondary monitoring area update process, the CPU 17 executes the secondary monitoring condition confirmation process in steps SP30 to SP45 described above.
[0089]
On the other hand, when a result of normality is obtained in step SP55 (FIG. 4), this means that when the injection molding machine main body 1 is in the primary monitoring image processing in the mold opening operation mode and in the protruding mode 2 The result of determination that it is normal in both of the next monitoring image processes is obtained. At this time, the CPU 17 moves to steps SP60 and SP61 (FIG. 5) and executes the update process of the registered image.
[0090]
The registration image is updated by replacing the primary monitoring reference image data D1 currently stored in the primary monitoring reference image data memory area 18A with the primary monitoring detection image data stored in the primary monitoring detection image data memory area 18F. The secondary monitoring reference image data D2 stored in the secondary monitoring reference image data memory area 18B is re-registered with the data 18F, and the secondary monitoring detection image stored in the secondary monitoring detection image data memory area 18G. Update with data D7.
[0091]
By storing the detected image data during normal operation as reference data in this way, for example, the ambient light changes with time, or the mold position gradually shifts when the injection molding cycle is repeated. Even if this occurs, the reference data can be changed so as to follow the phenomenon, so that the injection molding machine can be monitored with sufficient accuracy.
[0092]
Thus, since one injection molding cycle is completed, the CPU 17 gives a mold clamping interlock release signal as a sequence control signal S2 to the injection molding machine main body drive control device 6 in step SP62, whereby the injection molding machine main body 1 is clamped. After the operation is performed so that the injection molding process can be started, the process proceeds to the above-described step SP23 (FIG. 4) and the monitoring operation for the next injection molding cycle is started.
[0093]
When the user terminates the injection molding cycle by operating the operation input unit 25, the CPU 17 obtains a positive result in step SP60 (FIG. 5), thereby ending all the processes of the monitoring cycle processing routine RT2. Then, the process returns from step SP63 to the main routine, that is, the normal monitoring process routine RT1 (FIG. 2), and then all the processes of the normal monitoring process routine RT1 are ended in step SP64.
[0094]
(3) Re-protrusion monitoring process
7 to 9 show a second embodiment. In this case, during the secondary monitoring in which the injection molding machine main body 1 is in the protruding mode state, the protruding operation is performed a plurality of times N (for example, N = By repeating the process up to 5 times, the injection molded product attached to the movable mold 2 will not protrude and remain untouched during operation, thereby further improving the monitoring function of the injection molding machine main body 1. It is what.
[0095]
(3-1) Reference data acquisition processing
In the case of this embodiment, when the operator selects and designates the re-projection processing mode by the operation input unit 25, the CPU 17 executes the re-projection processing routine RT11 of FIG.
[0096]
This re-protrusion processing routine RT11 includes processing steps corresponding to the normal monitoring processing routine RT1 of FIG. 2 as a part of processing steps (in FIG. 7, the same processing step number with a subscript X is added to the corresponding processing step. The CPU 17 outputs three protrusion request signals as a sequence control signal S2 to the injection molding machine main body drive control device 6 in the processing steps that are not in the normal monitoring processing routine RT1 but only in the re-extrusion processing routine. There is in point to do.
[0097]
That is, when the re-protrusion processing routine RT11 is entered, the CPU 17 waits for the arrival of the mold opening limit signal that has transitioned to the ON state in the processing loop from step SP1X to SP4X as in the case of the normal monitoring processing routine RT1 (step ST1). SP1X) A mold clamping interlock setting signal is given when the mold opening limit signal that has transitioned to the ON state is received (step SP2X), and primary monitoring image data is input via the image processing circuit 13 (step SP3X). This is registered as primary monitoring reference image data D1 in the primary monitoring reference image data memory area 18A of the frame memory 18 (step SP4X).
[0098]
Thereafter, the CPU 17 protrudes as a sequence control signal S2 to the injection molding machine main body drive control device 6 and gives an interlock release signal (step SP5X), and transitions to an ON state as a monitoring control signal S1 from the injection molding machine main body drive control device 6 It waits for the arrival of the protruding completion signal (step SP6X).
[0099]
Thus, the CPU 17 controls the injection molding machine main body drive control device 6 so that the injection molding machine main body 1 performs the first protruding operation.
[0100]
In this embodiment, the CPU 17 forces the injection molding machine main body 1 by outputting the first re-projection request signal as the sequence control signal S2 to the injection molding machine main body drive control device 6 in step SP71 following step SP6X. After the projecting operation is performed, in step SP72, it waits for the projecting completion signal that has been turned on as the monitoring control signal S1 from the injection molding machine main body drive control device 6.
[0101]
Eventually, when the protrusion completion signal that has transitioned to the ON state arrives, the CPU 17 outputs a second re-protrusion request signal as a sequence control signal S2 to the injection molding machine main body drive control device 6 in the next step SP73, and then step SP74. In FIG. 2, the control unit waits for the projection completion signal that has been turned on as the monitoring control signal S1 from the injection molding machine main body drive control device 6.
[0102]
Eventually, when the protrusion completion signal that has transitioned to the ON state comes in step SP74, the CPU 17 indicates that the injection molding machine main body 1 has been forced to perform the protrusion operation three times. At this time, the CPU 17 inputs the input video data DATA1 obtained by imaging the injection molding machine main body 1 in the protruding operation mode to the image processing circuit 13 as the secondary monitoring reference image data D2 (step SP7X), and then inputs it to the frame memory. 18 is registered in the secondary monitoring reference image data memory area 18B (step SP8X), and then sequentially protrudes to provide an interlock setting signal (step SP9X) and a mold clamping interlock release signal (step SP10X), and then a cavity monitoring area Data D3 is calculated and registered in the primary monitoring area data memory area 18C (step SP11X).
[0103]
In this way, the CPU 17 forcibly causes the injection molding machine main body 1 to perform three protruding operations, and then stores the primary and secondary monitoring reference image data D1 and D2 and the cavity monitoring area data D3 in the frame memory 18. Is then re-projected and the monitoring cycle processing routine RT12 is entered.
[0104]
(3-2) Processing at the time of primary monitoring abnormality and confirmation of secondary monitoring conditions
Upon entering the re-protrusion monitoring cycle processing routine RT12, the CPU 17 performs processing in exactly the same way as the processing steps SP21 to SP45 of the monitoring cycle processing routine RT2 (FIGS. 4 and 5), as shown in FIGS. When the occurrence of an abnormality is detected as a result of executing the primary monitoring process on the injection molding machine main body 1 in steps SP21X to SP45X, an abnormality warning is displayed on the monitor 20 and the primary monitoring area according to the user's request. The update process is performed, and then the process for confirming the conditions for performing the secondary monitoring process is executed.
[0105]
(3-3) Primary monitoring normal processing and secondary monitoring processing
The re-protrusion monitoring routine RT12 is the same as the monitoring cycle processing routine RT2 (FIG. 4) in that the CPU 17 enters the secondary monitoring process when no abnormality is detected during the primary monitoring process. When the next monitoring process result is normal (step SP25X), the CPU 17 executes the secondary monitoring process for the injection molding machine body 1 in the protruding mode (steps SP50X to SP55X).
[0106]
However, when a determination result that there is an abnormality is obtained in step SP55X, the CPU 17 determines whether or not the maximum number of secondary monitoring operations has reached a plurality of M times (for example, M = 5th time) in the next step SP75. If it is not the fifth time, the process proceeds to step SP76 to re-project as the sequence control signal S2 to the injection molding machine main body drive control device 6 to give a request signal.
[0107]
At this time, the injection molding machine main body 1 forcibly performs the re-projection operation by the re-projection request signal.
[0108]
When the process of step SP76 is completed, the CPU 17 returns to the above-described step SP50X and repeats the secondary monitoring operation again for the injection molding machine main body 1 in the protruding mode state.
[0109]
Eventually, when a positive result is obtained in step SP75, this means that the injection molding machine main body 1 has finished the protrusion operation of M = 5 times by the re-projection request signal of the CPU 17, and at this time, the CPU 17 performs the step. In SP57X, a processing operation similar to the monitoring cycle processing device routine RT2 (FIG. 4) is performed in which an abnormality warning is issued on the monitor 20.
[0110]
Thus, when the injection molding machine main body 1 is in the protruding operation mode, the CPU 17 can reliably push out the injection molded product attached to the movable mold 2 by forcibly performing the protruding operation five times. .
[0111]
While processing this re-projection request processing loop, if the secondary monitoring image processing result is normal in step SP55X, this means that the injection molded product adhered to the movable side mold 2 has been pushed out. At this time, CPU1 7 is The registered image is updated in SP61X via step SP60X, and thus the protruding operation can be terminated before the maximum number of re-projections reaches 5.
[0112]
As described above, if the re-protrusion monitoring cycle processing routine RT2 (FIGS. 8 and 9) is executed, it is possible to completely avoid the occurrence of an abnormality in which the injection molded product does not fall practically. Can be realized.
[0113]
(4) Manual test processing
In the case of this embodiment, the CPU 17 of the injection molding machine monitoring apparatus 10 can execute a manual test processing routine RT31 as shown in FIG.
[0114]
This manual test processing routine RT31 is an operation required for testing the injection molding machine main body 1 when the user operates the manual operation panel 31 provided on the injection molding machine main body 1 side of the injection molding machine main body driving device 6. The state, for example, a push-down operation mode (an operation mode in which the protrusion operation can be performed in the mold open state) can be set.
[0115]
At the same time, a monitoring control signal manual input unit 32 is provided on the injection molding machine monitoring device 10 side, whereby the injection molding machine monitoring device 10 automatically performs the normal monitoring processing routine RT1 and the monitoring cycle processing routine RT2, and the re-extrusion processing. When executing the routine RT11 and the re-projection monitoring cycle processing routine RT12, the monitoring control signal manual input unit 32 monitors the bus 15 instead of the signal that arrives as the monitoring control signal S1 from the injection molding machine body drive control device 6. A control signal can be input.
[0116]
That is, when entering the manual test processing routine RT31, the CPU 17 sets parameters input by the operator through the operation input unit 25 and various inspection items in step SP81.
[0117]
The parameter is specified by a threshold value for determining whether or not the CPU 17 is abnormal in steps SP25, SP37 and SP55 of the monitoring cycle processing routine RT2 (FIGS. 4 and 5), and a re-protrusion monitoring cycle processing routine RT12 (FIG. 8 and FIG. 9), threshold values for determining whether or not there is an abnormality in the processing steps SP25X, SP37X and SP55X are input.
[0118]
As inspection items, the number of times of monitoring in steps SP26 and SP56 of the monitoring cycle processing routine RT2 (FIGS. 4 and 5) and the processing steps SP26X and SP75 of the re-protrusion monitoring cycle processing routine RT12 (FIGS. 8 and 9) are used. The number of monitoring is set.
[0119]
Furthermore, in order to simulate normal or abnormal conditions when the injection molding machine main body 1 is in the mold opening mode or the protruding mode, the fixed side mold 3 and By attaching or removing the injection molded product between the movable side molds 2, the abnormal operation state or normal operation state of the injection molding machine main body 1 can be set in a simulated manner.
[0120]
In the test processing step SP82, the CPU 17 causes the CPU 17 to execute each processing step by starting the normal monitoring processing routine RT1 or the re-projection processing routine RT11 for the injection molding machine body 1 set in a simulated manner.
[0121]
At this time, the supervisory control signal S1 to be taken into the CPU 17 from the injection molding machine main body drive control device 6 is a simulated manual supervisory control by the operator operating a manual switch provided in the supervisory control signal manual input unit 32. The signal S1 is input.
[0122]
That is, when the normal monitoring process routine RT1 (FIG. 2) is executed in the test process step SP82, the condition that the mold opening limit signal that has been turned on in step SP1 arrives from the injection molding machine main body drive control device 6 is satisfied. Is given to the CPU 17 in a simulated manner by operating the mold opening limit signal switch of the supervisory control signal manual input unit 32.
[0123]
Thus, the CPU 17 executes the processes of steps SP2, SP3, SP4, and SP5 on the assumption that the mold opening limit signal that has been turned on is reached in step SP1.
[0124]
Subsequently, when the CPU 17 needs to receive a protrusion completion signal that has been turned on in step SP6, the operator operates the protrusion completion signal switch of the supervisory control signal manual input unit 32 to turn it on in a simulated manner. The transition completion signal that has been transferred is given to the CPU 17.
[0125]
Thus, the CPU 17 executes the processing of steps SP7, SP8, SP9, SP10 and SP11, and then enters the monitoring cycle processing routine RT2.
[0126]
When entering the monitoring cycle processing routine RT2 (FIGS. 4 and 5), the CPU 17 waits for the mold opening limit signal that has been turned on in step SP21. By operating the mold opening signal switch, the CPU 17 is given a mold opening signal that has been simulated and turned on.
[0127]
Similarly, when the user enters a standby state for the reset signal that has transitioned to the on state in step SP30, the user has simulated the transition to the on state by operating the reset signal switch of the supervisory control signal manual input unit 30. A reset signal is input to the CPU 17.
[0128]
Similarly, the reset signal in step SP33, the protrusion completion signal in step SP51, the reset signal in step SP41, and the reset signal in step SP43 are input from the monitoring control signal manual input unit 32.
[0129]
Similarly, for the re-extrusion processing routine RT11 (FIGS. 7 to 9), the mold opening limit signal at step SP1X, the protrusion completion signal at step SP6X, the protrusion completion signal at step SP72, the protrusion completion signal at step SP74, and the mold at step SP21X An opening limit signal, a reset signal at step SP30X, a reset signal at step SP33X, a protrusion completion signal at step SP51X, a reset signal at step SP41X, and a reset signal at step SP43X are respectively operated by the user on the monitoring control signal manual input unit 32. Is input.
[0130]
Thus, the CPU 17 receives a signal coming from the supervisory control signal manual input unit 32 as if it came from the injection molding machine body 6 and continues a series of processing operations.
[0131]
Thus, the CPU 17 executes input of primary monitoring image data and registration of reference data in steps SP3 and SP4 of the normal monitoring processing routine RT1, and executes input and registration of secondary monitoring image data in steps SP7 and SP8. In step SP11, the primary monitoring area data is registered. In steps SP23 and SP24, the primary monitoring detection image data is input and the primary monitoring process is executed. Then, the abnormality determination process in step SP25 is executed. In step SP27, an abnormality warning display is displayed on the monitor 20, and after the abnormality warning is deleted in step SP31, secondary monitoring detection image data is input from the television camera 11 in steps SP35 and SP36 to perform secondary monitoring processing. After execution, step SP37 With a definitive anomaly determination operation is performed on the monitor 20 an abnormality warning display at the step SP38.
[0132]
In this way, the CPU 17 is set to normal or abnormal manually set in the injection molding machine main body 1 based on the input signal from the monitoring control signal manual input unit 32 and the input video data DATA1 that can be captured from the television camera 11. Processing according to the operation state can be executed in the same manner as in the case of automatic processing.
[0133]
Such manual image processing by the CPU 17 can be similarly executed in the re-projection processing routine RT11 (FIGS. 7 to 9).
[0134]
Thus, since the CPU 17 can execute the test process of step SP82, the user can confirm whether or not the test process result is good in step SP83. If the test result is bad, the user returns to step SP81 to execute the setting process again. It is possible to input setting information such that the result is good, and thus, in step SP83, it is possible to set conditions in the injection molding machine monitoring apparatus 10 so that it can be determined that the test processing result in step SP82 is good. it can.
[0135]
At this time, the process of the manual test process routine RT31 ends at step SP84.
[0136]
Since the test process can be manually executed in this manner, the injection molding machine monitoring apparatus 10 can be set to an optimum operating condition. In this way, the injection molding machine main body 1 is automatically and automatically forced. Since there is no need to perform an injection molding operation, it is possible to prevent the mold from being damaged or destroyed.
[0137]
(5) Other embodiments
(5-1) In the case of the above-described embodiment, in the primary monitoring, it is determined whether or not it is normal using the monitoring area determined by step SP11 or SP11X. However, instead of this, all the pixels are used for both the primary monitoring and the secondary monitoring, or abnormality determination is performed in the monitoring region determined by steps SP11 and SP11X for both the primary monitoring and the secondary monitoring. Alternatively, an arbitrary rectangular area may be set for each of the primary monitoring and the secondary monitoring, and the presence / absence of occurrence of abnormality may be determined using image data in the rectangular area.
[0138]
(5-2) Implementation of the above Form In this case, as an abnormal display when an abnormality occurs, the luminance of the pixel in which the abnormality has occurred is increased and superimposed on the video signal obtained from the television camera. Various display methods such as changing the brightness or darkening the brightness can be adopted.
[0139]
(5-3) In the above-described embodiment, in the primary monitoring, the monitoring operation is repeated three times, but the same effect as in the above case can be obtained even if it is configured to end in one time. Can do.
[0140]
Further, the number of times of secondary monitoring may be set to a number other than 3, and the number of re-projections may be changed to a number other than 5.
[0141]
(5-4) In the above-described embodiment, the case where the threshold value is used as the setting parameter in step SP81 of the manual test process has been described. However, the area of the abnormal portion is used as the abnormality determination criterion. Anyway.
[0142]
(5-5) In the case of the above-described embodiment, the size of the abnormal portion is obtained by adding the number of abnormal pixels when determining the abnormality. Anomalies in the area (ie noise of about 1 pixel to 1000 pixels) may be excluded so as not to be subject to abnormality determination, and thus the influence of noise may not affect the determination result. good.
[0143]
【The invention's effect】
As described above, according to the present invention, the image data obtained from the imaging unit at the start of the monitoring operation is used as the primary and secondary monitoring reference image data to perform primary and secondary monitoring in the subsequent monitoring cycle processing. Between primary and secondary monitoring reference image data for primary monitoring side Since the primary monitoring is performed for the monitoring region corresponding to a pixel whose difference is larger than a predetermined size, the primary and secondary monitoring can be reliably performed by a simpler processing procedure.
[Brief description of the drawings]
FIG. 1 is a block diagram showing an overall configuration of an injection molding machine monitoring apparatus according to the present invention.
FIG. 2 is a flowchart showing a normal monitoring processing procedure.
3 is a schematic diagram showing a configuration of a frame memory 18 of FIG.
FIG. 4 is a flowchart showing a monitoring cycle processing procedure.
FIG. 5 is a flowchart showing a monitoring cycle processing procedure.
FIGS. 6A and 6B are schematic diagrams for explaining monitoring area update processing;
FIG. 7 is a flowchart showing a re-projection processing procedure.
FIG. 8 is a flowchart showing a re-protrusion monitoring cycle processing procedure.
FIG. 9 is a flowchart showing a re-protrusion monitoring cycle processing procedure.
FIG. 10 is a flowchart showing a manual test processing procedure.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Injection molding machine main body, 2 ... Movable side type | mold, 3 ... Fixed side type | mold, 4 ... Conduit, 5 ... Guide, 6 ... Injection molding machine main body drive control apparatus, 10 ... Injection molding machine monitoring 11: Television camera, 12: Image input circuit, 13: Image processing circuit, 15: Bus, 16: Program memory, 17: Central processing unit (CPU), 18: Frame memory, DESCRIPTION OF SYMBOLS 19 ... Image display circuit, 20 ... Monitor, 21 ... Control signal input / output part, 31 ... Manual operation panel, 32 ... Monitoring control signal manual input part.

Claims (3)

The operation state of the injection molding machine main body when the injection molding machine main body performs the mold opening operation and the protruding operation is imaged by the imaging means, and the first image data at the time of the mold opening operation based on the video signal of the imaging means, The abnormal operation of the main body of the injection molding machine is subjected to primary and secondary monitoring according to the change in brightness of the image data portion from the primary and secondary monitoring reference image data of the second image data during the protruding operation. In the injection molding machine monitoring device,
First and second memory means for storing the first and second image data obtained at the start of the monitoring operation as the primary and secondary monitoring reference image data;
Position data corresponding to a pixel whose deviation between the pixels of the primary and secondary monitoring reference image data stored in the first and second memory means at the start of the monitoring operation is larger than a predetermined threshold value is monitored region data. Third memory means for storing as:
The primary monitoring detection image data obtained based on the video signal of the imaging means at the time of the monitoring cycle processing after the start of the monitoring operation is compared with the primary monitoring reference image data for the position of the pixel corresponding to the monitoring area data. An injection molding machine monitoring device comprising: an abnormality determining means for determining whether there is an abnormality during primary monitoring by comparing. Fourth memory means for storing primary or secondary monitoring abnormal image data representing an abnormally operating image data portion when an abnormal operation occurs during the primary monitoring or the secondary monitoring;
A display means for displaying a location where an abnormality has occurred by superimposing the primary or secondary monitoring abnormal image data on the video signal obtained from the imaging means. The injection molding machine monitoring apparatus according to 1. The monitoring control signal manual input means for inputting the injection molding machine operation information given from the injection molding machine main body at the time of the monitoring cycle processing and the parameters required when responding to the injection molding operation information is provided. A condition for using the first and second image data obtained at the start of the monitoring operation as the primary and secondary monitoring reference image data is set by executing a manual test process by the control signal manual input means. The injection molding machine monitoring apparatus according to claim 1.

Images