JP5289777B2 - Injection molding machine monitoring device - Google Patents

Description

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

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

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

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

  When the movable mold is retracted from the fixed mold to a position separated from the fixed mold (this condition is referred to as a “mold open” condition), the injection mold product is opened while attached to the inner surface of the movable mold. The injection molded product brought to the position and then attached to the movable mold is pushed down from the movable mold by a protruding pin protruding from the rear of the movable mold (this operation is called “protruding” operation).

  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.

At this time, the movable side mold advances toward the fixed side mold and returns to the clamped state in which the movable side mold is in pressure contact with the fixed side mold, and the injection molding cycle is repeated in the same manner.
JP-A-60-39581

  In this type of injection molding machine monitoring device, when the main body of the injection molding machine opens the mold, the injection molded product remains attached to the fixed mold (so-called mold residue), or the injection molded product is completely It is not molded into a part that is partially cut (so-called short mold), or the movable side mold is out of the normal mounting position (so-called slide core misalignment). In addition, it is necessary to monitor an abnormality occurring in the mold opening mode (this is referred to as “primary monitoring”).

  In addition, after the injection molding machine main body protrudes and moves, the injection-molded product remains in the movable mold 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 abnormalities that occur during the protruding operation mode (referred to as “secondary monitoring”), such as a (break) state.

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

  The 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.

In order to solve such a 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 taken. Among the monitoring target portions designated in advance, the abnormal operation of the injection molding machine main body 1 is changed according to the change in brightness of the image data portions in the monitoring areas J1 to J4 set at the predetermined display point positions P1 to P4. In the monitoring device 10 for monitoring the injection molding machine to be monitored, in the means for obtaining the monitoring reference image data D1, D2 as the determination reference image data of the abnormal operation using the video signal VD1 obtained at the start of the monitoring operation, Monitoring detected image data D6 as detected image data of abnormal operation using the video signal VD1 obtained at the time of mold opening operation or protruding operation Means for obtaining D7, of monitoring the reference image data D1, D2, the actual image K1 monitored part of the monitored area J1~J4 to monitor the occurrence of abnormal operation, the display point position of the monitoring area J1~J4 and circumscribing lines LH1, LH2, LV1, get a lutein pLATES TP image data such in the position data of the pixels in the determination area M1 surrounded by LV2 means circumscribing the image data of the actual image K1 in ambient, The search range SH is set to a range larger than the pixels surrounded by circumscribing lines LH1, LH2, LV1, and LV2 circumscribing the image data of the actual image K1 in the monitoring detection image data D6 and D7 by a predetermined number of pixels. and while searching by one pixel search range SH by template TP, the brightness and the monitoring detected image data D6, D7 pixel of the pixels in the template TP The monitoring reference image data D1 and D2 for the image portions of the monitoring areas J1 to J4 are recognized by recognizing that the monitoring areas J1 to J4 exist at the search positions of the template TP having a high degree of coincidence. Means is provided for determining the presence or absence of abnormal operation by obtaining a brightness comparison result with the monitor detection image data D6 and D7.

According to the present invention, the monitoring detection image data is represented by the template that represents the monitoring target standard composed of the pixels surrounded by the circumscribed line that circumscribes the image data of the real image of the monitoring target part included in the monitoring region of the monitoring reference image data. The brightness of the monitor reference image data and the monitor detected image data is assumed that the monitor region of the monitor detection image data exists at the search position where the degree of coincidence exists while searching the search range provided in the monitor region portion. By performing the abnormality determination process to obtain the comparison result of the above, when the monitoring area is shifted during the mold opening operation or the protruding operation, the abnormality can be detected with higher accuracy while following the shifted position. An injection molding machine monitoring device can be realized.

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

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

  This injection-molded product is brought to the mold opening position while being attached to the inner surface of the movable side mold 2 when the movable side mold 2 is in the mold open state separated from the fixed side mold 3 along the guide 5. 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.

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

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

  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.

  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.

  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 performs image processing on the determination result image data DATA2 representing the determination result via the bus 15. This is given to the circuit 13.

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

  Thus, the monitor 20 determines the determination result image data 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, the user is presented with a monitoring screen that displays an abnormality occurrence display on the image portion where the abnormality has occurred.

  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.

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

(2) Normal Monitoring Processing (2-1) Reference Data Acquisition Processing 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. After performing the brightness setting process and the monitoring point setting process in SP01 and SP02, it waits for the mold opening limit signal to be turned on in step SP1.

  In the monitoring point setting process in step SP02, the CPU 17 uses the operation input unit 25 to allow the user to use the operation input unit 25 to display an image display area of the monitoring target image part during the mold opening operation and the monitoring target part during the protrusion operation (this is referred to as a monitoring region When the user sets and inputs the display position using the operation input unit 25, the display position is stored as monitoring area position data D9 in the monitoring area position data memory area 18J of the frame memory 18 (FIG. 3).

  In the case of this embodiment, as shown in FIG. 7A, with respect to the video data DATA1 captured from the image input circuit 12, a plurality of monitoring target image portions J1 to J4 are included in one frame of the image DIP. The display positions P1 to P4 are set.

  Subsequently, in step SP1, 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 of executing the subsequent operation with the injection molding machine main body 1, thereby When the movable side mold 2 of the injection molding machine main body 1 is retracted to the mold open position, the molding machine main body drive control device 6 uses the control signal input / output unit as the control signal input / output unit. This is given to the CPU 17 via 21.

  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.

  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.

  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.

  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. .

  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.

  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 has been protruded and is in a completed state) 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.

  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 (FIG. 3) of the frame memory 18 as the secondary monitoring reference image data D2.

  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.

  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.

  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 cavity monitoring region data memory area 18C (FIG. 3) of the frame memory 18 as cavity monitoring region data D3 representing the cavity, and after the brightness correction processing in the next step SP12, in the monitoring cycle processing routine RT2, An injection molding cycle for injection-molding the next injection-molded product is executed by the fixed side mold 3 and the movable side mold 2 of the injection molding machine main body 1.

  Therefore, the primary monitoring image data is image data representing an image in a state where the injection molded product is attached to the movable side mold 2 when the mold is opened, whereas the secondary monitoring image data is the movable side mold 2 when protruding. Since the image data represents an image in which the injection-molded product has dropped and is not attached from the first position, the position of the pixel having the brightness change of | primary monitoring image data−secondary monitoring image data | As shown in FIG. 6A, the space where the injection molded product sometimes existed, that is, the range AR1 where the cavity exists in the image DIP for one frame.

  Therefore, the position data represented by the monitoring area data D3 in the cavity monitoring area data memory area 18C of the frame memory 18 represents the position where the cavity exists in one frame image.

  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.

(2-2) Processing at the time of primary monitoring abnormality and confirmation processing of secondary monitoring conditions The CPU 17 executes the monitoring cycle processing routine RT2 shown in FIGS. Each time one is injection-molded one by one, a monitoring process is executed to determine whether or not an abnormality has occurred in the injection molding operation.

  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.

  In this state, the CPU 17 performs reconfirmation processing in the next SP22X, and then in step SP23, the input video data DATA1 for one frame is used as primary monitoring detection image data D6 to perform primary monitoring of the frame memory 18 via the image processing circuit 13. The detected image data is input to the memory area 18F.

  At this time, the CPU 17 temporarily displays the cavity area AR1 (FIG. 6A) on the display screen DIP of the monitor 20 using the cavity monitoring area data D3 of the cavity monitoring area data memory area 18C of the frame memory 18. Thus, the user is notified that a sufficient luminance difference is obtained and that the detection data D6 can be input to the primary monitoring detection image data memory area 18F.

  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 the above, in step SP25, it is determined whether or not the comparison result is abnormal.

  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 reaches a predetermined number or more, it is determined that an abnormality has occurred, and the process moves to step SP26 via step SP25X.

  In the case of this embodiment, in step SP25, as shown in FIG. 7B, only the one monitoring target image portion J1, the CPU 17 displays each monitoring target image portion J1 (J2 to J4) of the image DIP for one frame. The reference image data and the detected image data composed of pixels included in the determination area M1 (M2 to M4) circumscribing the actual image portion K1 (K2 to K4) made of the image data actually obtained with respect to the primary monitoring image Obtained from the primary monitoring image reference data D1 in the reference data memory area 18A and the primary monitoring detection image data D6 in the primary monitoring detection image data memory area 18F, and a deviation between the reference image data and the detection image data is obtained for each pixel. The number of pixels for which the deviation exceeds a predetermined threshold is totaled for each actual image portion K1 (K2 to K4).

  When the total value exceeds a predetermined allowable value, it is determined that an abnormality has occurred in the actual image portions K1 to K4 in the primary monitoring.

  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.

  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 processing returns to the above-described step SP22X and the processing of steps SP22X, SP23, SP24, and SP25 is repeated.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  Here, when the safety door of the injection molding machine main body 1 is closed, the injection molding machine main body drive control device 6 sends 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. .

  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.

  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.

  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.

  Thus, after the injection molding machine main body 1 protrudes and cannot move, the CPU 17 performs a reconfirmation process in step SP34X and moves to step SP35 to input video data DATA1 based on the input video signal VD1 of the television camera 11. As a result, the secondary monitoring detection image data D7 for one frame is input to the secondary monitoring detection image data memory area 18G (FIG. 3).

  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, secondary monitoring is performed in the secondary monitoring abnormal image data memory area 18I (FIG. 3) of data indicating abnormality or normality (“1” or “0”) for each pixel. Store as abnormal image data D9.

  Subsequently, in step SP37, the CPU 17 determines whether there is an abnormality based on the secondary monitoring detection image data D7.

  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.

  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.

  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.

  The secondary monitoring area update process is performed by storing the secondary monitoring area data D5 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. Then, the process for removing the disturbance video is executed, and thereby the user can set a condition for performing the highly stable process in the secondary monitoring following the primary monitoring.

  When a negative result is obtained in step SP39, the CPU 17 jumps to the secondary monitoring area update process in step SP40.

  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. Give a signal.

  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.

  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.

  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 SP21 (FIG. 4).

(2-3) Primary monitoring normal process and secondary monitoring process When the CPU 17 determines that the result of the primary monitoring process is normal in step SP25 of FIG. 4, the process proceeds to step SP50 and the injection molding machine main body. A projecting interlock release signal is given as a sequence control signal S2 to the drive control device 6, and a projecting completion signal that has been turned on is received as a monitoring control signal S1 from the injection molding machine main body drive control device 6 in the next step SP51. I wait for you.

  In this state, the injection molding machine body 1 protrudes from the mold open state and operates.

  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.

  Subsequently, the CPU 17 transfers the secondary monitoring detection image data D7 in the protruding state to 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 in step SP53 via step SP52X. After the capture, secondary monitoring image processing is executed in step SP54.

  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.

  Subsequently, in step SP55, the CPU 17 determines whether or not the secondary monitoring image processing result is abnormal.

  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. The CPU 17 determines whether or not an abnormality has occurred when it is large, and the CPU 17 proceeds to step SP56 via step SP55X.

  In this embodiment, the CPU 17 in step SP55, as described above with reference to FIG. 7B, the actual image portion K1 made up of image data corresponding to each of the monitoring target image portions J1 to J4 of the image DIP for one frame. The reference image data and the detected image data including pixels included in the areas corresponding to the determination areas M1 to M4 having a circumscribed rectangle of ~ K4 are converted into the secondary monitoring image reference data D2 and the secondary monitoring image reference data memory area 18B. The number of pixels obtained from the secondary monitoring detection image data D7 in the secondary monitoring detection image data memory area 18G, the deviation between the reference data and the detection image data is obtained for each pixel, and the deviation exceeds a predetermined threshold value. For each monitoring target image portion J1 to J4.

  When the total value exceeds a predetermined value, it is determined that an abnormality has occurred in the real image portions K1 to K4 in the secondary monitoring.

  Subsequently, in step SP56, it is determined whether or not the number of times of secondary monitoring has reached the third time. When a negative result is obtained, the process returns to the above-described step SP53 to input the secondary monitoring detection image data D7 again and the secondary. Monitor image processing is executed.

  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.

  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.

  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.

  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.

In this state, the CPU 17 proceeds to step SP58 to determine whether or not the operator needs to update the abnormality monitoring area. If a positive result is obtained, the secondary monitoring area data memory of the frame memory 18 is obtained in step SP59. The secondary monitoring area data D5 of the area 18E is changed according to the update process of the operator, and the process returns to the above step SP52X.

  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. Run.

  In this embodiment, after executing the secondary monitoring area update process in step SP59, the CPU 17 executes the secondary monitoring condition confirmation process in steps SP30 to SP45 described above.

  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 proceeds to steps SP60 and SP61 (FIG. 5) and executes the update process of the registered image.

  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.

  Thus, by holding the detected image data during normal operation as reference data, 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.

  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 SP21 (FIG. 4) and the monitoring operation for the next injection molding cycle is started.

  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.

(3) Monitoring Area Position Correction Processing The CPU 17 performs the temporary monitoring determination cycle of steps SP22X-SP23-SP24-SP25-SP25X-SP26-SP22X in the above-described monitoring cycle processing routine RT2 (FIGS. 4 and 5) and step SP52X- When performing the secondary monitoring determination processing cycle of SP53-SP54-SP55-SP55X-SP56-SP52X, particularly in steps SP25X and SP55X, the position of the monitoring area is corrected by the procedure shown in FIGS.

  This position correction of the monitoring area is performed for the injection molded product to be monitored among the image data obtained in the video data VATA1 obtained based on the input video signal VB1 of the television camera 11 during the mold opening operation and the protruding operation. Even when the position is slightly deviated, the abnormality determination performance is improved by obtaining the original normal determination result without being affected by it.

  In the primary monitoring and the secondary monitoring, as described above with reference to FIG. 7A, when the operator sets the television camera 11 in step SP02 of the normal monitoring processing routine RT1 (FIG. 2), the primary monitoring and the secondary monitoring are performed. The display positions P1 to P4 are set so that an image DIP for one frame in which the four monitoring target image portions J1 to J4 are projected is obtained during the mold opening operation and the protruding operation in the next monitoring.

  After the setting of the monitoring points, primary monitoring reference image data D1 and 2 having the image contents set in FIG. 7A are obtained by obtaining image data at the time of mold opening operation and protruding operation at steps SP3 and SP7. The next monitoring reference image data D2 can be taken into the frame memory 18 (steps SP4 and SP8).

  Based on the primary monitoring reference image data D1 and the secondary monitoring image reference data D2, the CPU 17 enters step SP25X or SP55X (FIG. 4), as shown in FIG. Only one K1 is shown), the determination area M1 (M2 to M4) is set for the actually projected image to be monitored, that is, the actual image portion K1 (K2 to K4).

  In setting the determination area M1 (M2 to M4), as shown in FIG. 8A, the CPU 17 has two horizontal circumscribing lines circumscribing the actual image portion K1 (K2 to K4) from the vertical direction. Two vertical circumscribing lines LV1 and LV2 circumscribing LH1 and LH2 from the left-right direction are obtained, and an image portion surrounded by these four circumscribing lines LH1 and LH2, LV1 and LV2 as shown in FIG. 8B. Is obtained as the template image data TP serving as a monitoring target standard.

  The CPU 17 holds the image data as the monitoring target reference in the template data memory area 18K of the frame memory 18 (FIG. 3) as the template data D10.

  Next, as shown in FIG. 9, the CPU 17 surrounds the display positions P1 to P4 with respect to the primary or secondary monitoring detection data D6 or D7 (held in the frame memory 18 in step SP23 or SP53 in FIG. 4). The search range SH is set in the search range, and the search within the search range SH is searched with the template image data TP, thereby obtaining the correlation between the template image data TP and the primary or secondary monitoring detection image data D6 or D7.

  Here, the template image data TP serving as the monitoring target standard is the horizontal and vertical tangent lines with respect to the actual image portion K1 (K2 to K4) obtained based on the video data DATA1 actually captured by the television camera 11. Since the image data has a size surrounded by LH1 and LH2 and LV1 and LV2, the acquisition is performed as the monitoring target in the primary or secondary monitoring detection image data D6 and D7 obtained during the primary or secondary monitoring operation. Since the image data OB has substantially the same size, if the search range SH having an appropriate width is set around the acquired image data OB, the monitoring target image portions J1 to J4 of the acquired image data OB are displayed. Even if the monitoring object is slightly displaced from the positions P1 to P4, it can be confirmed as a displacement within the search range SH.

  In the case of this embodiment, when the template image data TP as the monitoring target reference is placed at the display positions P1 to P4, the size of the search range SH is higher or lower than the outer tangent lines LH1 and LH2 and LV1 and LV2. An area for eight pixels is set as a search range SH, and the template image data TP is searched in the horizontal search direction d1 and / or the vertical search direction d2 while sequentially shifting the search range SH by one pixel at a time. In the following formula

To obtain a correlation value R representing the degree of approximation between the acquired image data OB and the template image data TP.

  Expression (1) is an expression for obtaining a normalized correlation. The correlation value R is a density value T (also referred to as a brightness value) of each pixel of the template image data TP, and a search at each pixel position of the template image. The correlation with the density value (that is, the brightness value) S of the primary or secondary monitoring detection image data D6 or D7 within the range SH is obtained for the number N of pixels constituting the template image data TP.

  Thus, the CPU 17 determines that the acquired image data OB is at the search position where the largest correlation value is obtained from the correlation values R obtained by the expression (1) at each search position, and the search position is primary or Assuming that a monitoring target exists during the secondary monitoring operation, as shown in FIG. 7C, the monitoring data acquisition position is changed from the display positions P1 to P4 where the monitoring target image portions J1 to J4 are set to the alignment positions P1X to P4X. Align with.

  In the above configuration, when the CPU 17 determines that there is an abnormality in step SP25 or SP55 after fetching image data in step SP23 or SP53 at the time of primary monitoring or secondary monitoring operation mode, a template image is obtained in step SP25X or SP55X. If the acquired image data OB detected by performing the search process using the data has a positional deviation, the monitoring plate image data TP is moved so as to follow the subject of the positional deviation, and the presence / absence of the abnormality is determined again. .

  According to the above configuration, when performing the primary or secondary monitoring during the mold opening operation or the protruding operation, the position of the template image data is corrected so as to follow even if the monitoring target is slightly deviated. By doing so, it is possible to effectively avoid the possibility of determining that the monitoring target itself is normal even though the monitoring target itself is normal, and thus an injection molding machine monitoring device that can further improve the abnormality determination performance. realizable.

(4) Brightness correction processing of image data The CPU 17 inputs the primary monitoring detection image data at step SP23 of the monitoring cycle processing of FIGS. 4 and 5, or the secondary monitoring detection image data at step SP35 or SP53. When input, the primary or secondary monitoring detection image data (hereinafter also referred to as acquired image data) is compared with the primary or secondary monitoring reference image data (hereinafter also referred to as reference image data). ) Before (at step SP24 or SP35 or SP53), a brightness correction process is performed so that the brightness of the image data is substantially matched.

  In this brightness correction processing, when there is a change in the brightness of the external light when the reference image data and the acquired image data are taken into the frame memory 18, if this is left untouched, the change in the brightness is included in the comparison result. To avoid this, if the brightness of the reference image and the brightness of the acquired image are different, the brightness of the darker image is set to be approximately the same as the brightness of the brighter image. After the brightness is adjusted by correcting the brightness, the comparison process is performed.

(4-1) Effective Image Data Extraction Processing The CPU 17 is in an appropriate range based on histograms representing pixel brightness distributions for the reference image and the acquired image according to the procedure shown in FIGS. Average brightness data is acquired for an image having brightness.

  That is, the CPU 17 first obtains a histogram curve HO based on brightness from the reference image data or acquired image data, as shown in FIG.

  Since this histogram curve HO is obtained by obtaining a realistic brightness frequency distribution of each pixel constituting the reference image or acquired image, it represents the image content of the reference image or acquired image.

  For this histogram curve HO, as shown in FIG. 10B, the CPU 17 obtains a histogram curve HO1 from which a curve portion corresponding to a pixel equal to or lower than the brightness lower limit value B1 is deleted, and thereby makes an abnormality determination. Remove unintended image part data.

  Further, as shown in FIG. 10C, the CPU 17 deletes the image data of the curve portion having the brightness upper limit B2 or more from the histogram curve HO to obtain the histogram curve HO2 shown in FIG.

  In the image portion brighter than the brightness upper limit B2, the video data DATA1 is often saturated in the extremely bright portion of the imaging target captured by the television camera 11, and therefore the brightness information of the imaging target is obtained. Since this is a portion that is not likely to have brightness corresponding to, the data amount to be processed is optimized by deleting this portion.

  Thus, as shown in FIG. 10D, the CPU 17 obtains a histogram curve HO3 from which unnecessary portions are deleted, obtains the sum of brightness values for all the pixels based on the histogram curve HO3, and uses this as a reference image or The brightness average value is obtained by multiplying by the number of pixels of the acquired image, and this is defined as the brightness of the reference image or the acquired image.

(4-2) Cavity Removal Processing In the case of this embodiment, the average brightness data acquisition processing is performed for the reference image data IM1 shown in FIG. This is performed on the cavity removal reference image data IM1X from which CV1 has been removed.

  Also for the acquired image data IM2 shown in FIG. 11B, the average brightness data is acquired for the cavity removal reference image data IM2X from which the cavity portion CV2 has been removed.

  Here, the reference image data IM1 is the primary monitoring image data (image data at the time of mold opening) or secondary monitoring image data (at the time of the protruding operation) registered in step SP4 or SP8 of the normal monitoring processing routine RT1 (FIG. 2). Image data).

  Further, the acquired image data IM2 in FIG. 11B is the primary monitoring detection image data (image data at the time of mold opening operation) in step SP23 of the above-described monitoring cycle processing routine RT2 (FIGS. 4 and 5) or step SP35 or The secondary monitoring detection image data (image data at the time of protruding operation) in SP53 is represented.

  In this reference image data IM1 or acquired image data IM2, abnormality is determined by changing the image in the cavity portions CV1 and CV2, that is, the image of the cavity portion CV2 in the acquired image data IM2 is the image of the cavity portion CV1 of the reference image data IM1. Therefore, the difference between the reference image data IM1 and the acquired image data IM2 is obtained.

  Therefore, if there is a difference in the brightness of the image between the reference image data IM1 and the acquired image data IM2, the difference in the brightness of the image affects the comparison of the cavity portions CV1 and CV2.

  Here, the brightness difference between the reference image data IM1 and the acquired image data IM2 is determined by the brightness of the mold surface portions SA1 and SA2 other than the cavity portions CV1 and CV2 in the image of the movable side mold 2, so that the brightness correction is performed. For the processing, image data obtained by removing the cavity portions CV1 and CV2 from the reference image data IM1 and the acquired image data IM2, such as the cavity removal reference image data IM1X and the cavity removal acquired image data IM2X, is used.

  Thus, based on the average brightness value of the cavity removal reference image data IM1X and the cavity removal acquired image data IM2X,

To obtain the conversion ratio M.

(2) D _A is out of the cavity removing reference data IM1X and cavities removed retrieve data IM2X in expression indicates the lighter average brightness value of, D _B represents the average brightness value of the dimmer.

Thus by using the conversion ratio M is the ratio of the lighter mean brightness value D _A of relative darker average brightness value D _B of the average brightness value D of the darker of the reference image data IM1 and the acquired image data IM2 For each pixel of image data having _B , the following equation

The brightness conversion value V _i is obtained by

In the equation (3), for a pixel having a brightness value i = 0 to 255, this is multiplied by a conversion ratio M to convert the brightness of the pixel to V _i , whereby the reference image data IM1 and the acquired image data IM2 The brightness of the image is corrected so as to match the brighter image data.

  As a result, if the monitoring target displayed in the cavity CV1 of the reference image data IM1 is also present in the cavity portion CV2 of the acquired image data IM2, the brightness of the monitoring targets of the cavity portions CV1 and CV2 coincides, thereby causing an abnormality. It can be determined that it has not occurred.

  On the other hand, if there is a difference in brightness between the monitoring targets of the cavity portion CV1 of the reference image data IM1 and the cavity portion CV2 of the acquired image data IM2, it can be determined that an abnormality has occurred in the acquired image data IM2.

  In determining the abnormality, the brightness difference between the mold surface portions SA1 and SA2 of the cavity removal reference image data IM1X and the cavity removal acquisition image data IM2X is corrected by the equations (2) and (3). Since the brightness difference is not included in the comparison processing of the cavity portions CV1 and CV2, the abnormality determination processing accuracy can be further improved.

(4-3) Mold Surface Abnormal Reflection Image Suppression Processing As shown in FIG. 12A, this image processing has a cavity portion CV1 at the center portion of the mold surface portion SA1 as in the reference image data IM1. When the acquired image data IM2 obtained by injection-molding the injection molded product with the cavity portion CV2 in the mold surface portion SA2 with respect to the reference image data IM1, the surface of the mold surface portion SA2 of the acquired image data IM2 is obtained. When the uneven portion K1 is generated based on the uneven reflected light, the CPU 17 first obtains absolute value difference image data IM11 between the reference image data IM1 and the acquired image data IM2.

  The absolute value difference image data IM11 has a cavity portion CV3 made up of absolute value difference image data between the cavity portion CV1 of the reference image data IM1 and the cavity portion CV2 of the acquired image data IM2, and the mold surface of the acquired image data IM2 An image portion of the uneven portion K1X corresponding to the uneven portion K1 existing in SA2 also appears in the portion.

  Apart from this processing, as shown in FIG. 12 (B), the CPU 17 sets the maximum value image data IM12 having the larger brightness value for each corresponding pixel in the reference image data IM1 and the acquired image data IM2. Get.

  Based on the maximum value image data IM12, the CPU 17 obtains binarized level image data IM13 as shown in FIG.

  This binarized level image data IM13 is obtained by multiplying the brightness data of each pixel of the maximum value image data IM12 by a value of [sensitivity / 128].

  The CPU 17 performs an expansion filter process on the binarized level image data IM13 as shown in FIG. 12D, whereby image elements included in the binarized level image data IM13, that is, molds. Expansion filter image data IM14 obtained by performing expansion processing on the image portions of the uneven portion K4 and the cavity portion CV5 is obtained.

  In this expansion process, two types of filters having a filter size of 5 × 5 and 3 × 3 are used once as an expansion filter, and processing for replacing the target pixel with the brightest pixel in the filter size range is executed. .

  Thereafter, as shown in FIG. 12E, the CPU 17 subtracts the expansion filter image data IM14 described above with reference to FIG. 12D from the absolute value difference image data IM11 described with reference to FIG. Then, the brightness data subtraction process is performed to obtain the reflection portion removed image data IM15.

  The reflection part removal image data IM15 obtained as a result of the subtraction process includes a cavity part CV representing a subtraction result between the cavity part CV3 in the absolute value difference image data IM11 and the cavity part CV6 in the expansion filter image data IM14. However, by subtracting the uneven portion K5 of the maximum filter image data IM14 from the uneven portion K2 of the absolute value difference image data IM11, the reflected portion removal image data IM15 has an uneven portion K6 compared to the cavity portion CV7. The lateral width of can be greatly reduced.

  Thereafter, the CPU 17 performs binarization processing on the reflection portion removal image data IM15 with a predetermined threshold value as shown in FIG. 13A, so that the binarized image data in which the cavity portion CV8 appears clearly is obtained. By performing abnormality determination processing using the binarized image data IM16 to obtain IM16 instead of the acquired image data IM2, abnormality determination processing that is not affected by the uneven portion K7 can be performed.

  However, when the image data of the uneven portion K7 of the binarized image data IM16 cannot be sufficiently reduced, the CPU 17 contracts the binarized image data IM16 as shown in FIG. 13B. By performing the expansion process, the uneven portion K7 that has remained unreduced in the binarized image data IM16 is removed, and as a result image data IM17 can be obtained in which the cavity CV9 is clearly displayed.

  According to the above configuration, based on the first and second image average brightness values of the image portion from which the cavity portion is removed from the reference image data and the acquired image data, the average brightness values of the image portions are adjusted to each other. By comparing the reference image data and the acquired image data, the accuracy of the abnormality determination result can be further improved.

  In this way, even if there is an uneven portion on the surface of the mold, even if the acquired image data IM2 is mixed with the uneven portion K1 based on the reflected light from the uneven portion that does not exist in the reference image data IM1, this is ensured. By reducing or eliminating the problem, it is possible to prevent the abnormality determination process from becoming an obstacle.

  The contraction and expansion processes in FIG. 13B are performed near the processing level 8, and the number of processes is arbitrarily set (standard is one) according to the set value.

  As a result, when the image portion of the cavity portion CV9 becomes equal to or less than a preset NG removal value, the product manufactured in the injection molding cycle is removed as a defective product.

(5) Brightness setting processing When entering the brightness setting processing step SP01 of the normal monitoring processing routine RT1 of FIG. 2, the CPU 17 executes the processing shown in FIG.

  When entering the brightness setting processing step SP01, the CPU 17 first displays the lens adjustment screen DIPX shown in FIG. 15 on the monitor 20 in step SP70.

  This lens adjustment screen DIPX displays an image of the movable side mold 2 currently captured by the television camera 11. In the case of FIG. 15, the surface of the mold 41 set at the center of the movable side mold 2. Is projected.

  There is no injection molded product in the cavity 42 formed in the mold 41, and therefore the surface of the movable mold 2 and the surface of the mold 41 are projected as the lens adjustment screen DIPX.

  In this state, the CPU 17 determines in step SP71 that

Based on the "sum of the brightness values of all the pixels" determine the "average brightness value" by dividing calculated by "total number of pixels".

  In the case of this embodiment, the image data DATA1 obtained in the image input circuit 12 based on the video signal VD1 imaged by the television camera 11 is image data of 640 pixels wide and 480 pixels long, and the brightness is The brightness value of 0 to 255 is converted, and the numerical value of the conversion result 0 to 255 is displayed in the brightness display field 43 provided on the lens adjustment screen DIPX.

Thus the user, by looking at the lens adjustment screen DIPX monitor 20, now, the brightness of the entire movable mold 2, by viewing the numerical values displayed in the brightness display column 43 of the lens adjustment screen DIPX, The brightness of the lens adjustment screen DIPX can be read accurately.

  Subsequently, the CPU 17 proceeds to SP72 and determines whether or not to determine the average brightness value.

  The determination in step SP72 is to confirm whether or not the operator who has seen the brightness display column 43 has operated the determination button provided in the operation input unit 25. When a negative result is obtained, It is determined that no operation has been performed, and the lens adjustment process of step SP73 is entered.

  In the lens adjustment process in step SP73, the operator operates the lens diaphragm of the television camera 11 to adjust the overall brightness of the television image signal VD1, and thus the lens adjustment screen DIPX.

  When the adjustment operation in step SP73 is completed, the CPU 17 proceeds to step SP70 described above to display the adjusted lens adjustment screen DIPX on the monitor 20 and obtains the average brightness value in step SP71 to obtain the brightness display column 43. Update the numeric display.

  Thus, the operator can confirm the aperture adjustment result as a change in the number in the brightness display field 43 of the lens adjustment screen DIPX.

  If the operator operates the enter button of the operation input unit 25 as a result of this confirmation, the CPU 17 obtains a positive result in step SP72, thereby ending the brightness setting processing step SP01 and returning from step SP74 to the main routine.

  According to the above configuration, the operator can adjust the brightness of the lens adjustment screen DIPX while confirming the brightness displayed numerically in the brightness display field 43 provided on the lens adjustment screen DIPX. The brightness of the image data DATA1 obtained as a result of imaging by the John camera 11 can be adjusted appropriately.

  Incidentally, in the conventional injection molding machine monitoring apparatus 10 of this type, since the adjustment of the aperture of the television camera 11 is left to the operator's intuition, if the operator changes, the subsequent monitoring process cannot always be performed with an appropriate brightness. Although there is a possibility, the brightness of the lens adjustment screen DIPX is converted into a numerical value so that the operator can confirm it, and the adjustment accuracy can be further improved.

  Therefore, if the four types of calculations are executed and displayed at intervals as small as about 100 [milliseconds], the brightness can be adjusted with higher responsiveness, so that the movable side type 2 to be imaged can be obtained. Adjustments that are finely adapted to the configuration of

(6) Sensitivity correction display processing The CPU 14 displays a sensitivity setting screen DIPY as shown in FIG. 6 on the monitor 20 in the sensitivity correction processing step SP12 of the normal monitoring processing routine RT1 (FIG. 2).

  The sensitivity setting screen DIPY displays the sensitivity setting screen DIPY shown in FIG. 16 using the image data registered as the primary monitoring image data by the processing in steps SP1 to SP11 described above.

  The sensitivity setting screen DIPY has an image in which the video portion of the cavity 50 is displayed on the video portion of the mold 51 for the monitoring video portion in the monitoring area AR1.

  In addition, the sensitivity setting screen DIPY displays a sensitivity setting operation item 52 outside the monitoring area AR1.

  The sensitivity setting operation item 52 has a high-sensitivity operation element 53 that is an upward triangular indicator and a sensitivity-decrease operation element 54 that is a downward-triangular display element. In contrast to this, when the sensitivity is lowered, the sensitivity lowering operator 54 may be operated.

  The sensitivity setting screen DIPY sets the sensitivity in step SP37 (FIG. 5) or SP55 (FIG. 4) in which the CPU 17 determines whether the secondary monitoring image is abnormal in the monitoring cycle processing routine RT2 (FIGS. 4 and 5). Therefore, when the injection molding machine main body 1 protrudes, whether the injection molded product remains in the cavity 50 (determines that there is an abnormality at this time) or has not been pushed out and remains (normally operated at this time) This is used to set the sensitivity required when determining whether or not to determine.

  In this secondary monitoring image processing, the image data acquired during the protruding operation is compared with the reference data, and an abnormality is determined based on whether or not a change in brightness has occurred in the monitoring area AR1. In the display portion of the mold 51, it is desirable that there is no portion that causes a luminance difference. When an image having a partial luminance is obtained, binarization when performing binarized screen processing is performed. Decrease sensitivity by raising the processing threshold level.

  As a result, a screen having a brightness of logic “1” can be obtained in which the mold 51 is always uniform.

  On the other hand, in the image portion of the cavity 50, if there is a luminance difference in part, it is necessary to have a sensitivity that can be displayed without overlooking this, so that there is no luminance difference in the cavity 50 portion. Since the sensitivity is inappropriate, the sensitivity is raised by lowering the binarization threshold level.

  In the case of this embodiment, when the sensitivity is increased by the user operating the sensitivity setting operation item 52, the area of the display portion of the cavity 50 is displayed so that the area increases according to the sensitivity level. On the other hand, when the sensitivity is lowered, the area of the cavity 50 is reduced according to the lowered sensitivity.

  Thus, the user can easily confirm that the sensitivity is set according to his / her operation by looking at the change in the size of the cavity 50.

  In the above configuration, when entering the sensitivity correction processing SP12, the CPU 17 displays the sensitivity setting screen DIPY on the monitor 20 so that the user can operate the sensitivity setting operation item 52.

  At this time, the default sensitivity when the display of the sensitivity setting screen DIPY is started is set to an intermediate value. If the default sensitivity is acceptable, the sensitivity correction process can be terminated without performing the sensitivity correction operation. good.

  On the other hand, when correction of sensitivity is necessary, the user operates the high sensitivity operation element 53 or the low sensitivity operation element 54 of the sensitivity setting operation item 52 while watching the change in the size of the cavity 50. Adjust sensitivity with.

  According to the above configuration, the user can easily set the sensitivity level at the time of secondary monitoring intuitively while looking at the sensitivity setting screen DIPY displayed on the monitor 20.

(7) Reconfirmation processing When the CPU 17 performs the process of the monitoring cycle processing routine RT2 of FIGS. 4 and 5, when the injection molding machine main body 1 performs the mold opening operation, the primary monitoring reconfiguration shown in FIG. When the confirmation process is executed, and when the injection molding machine main body 1 protrudes, the secondary monitoring reconfirmation process shown in FIG. 18 is executed at step SP34X or SP52X.

  This reconfirmation process makes the injection molding machine main body 1 stand by without performing the monitoring operation of the injection molding machine monitoring device 10 until it is confirmed that the safety door provided for repair work is closed. This is intended to further enhance the safety of the injection molding monitoring operation.

CPU17 is monitoring cycle routine RT2, in step SP21, when in the mold open limit signal on waiting, mold open limit signal IN-1 in the time point t1 as shown in FIG. 17 (A) is turned on Time (indicating that the injection molding machine main body 1 is in the mold opening operation ), the process proceeds to step SP22 to send the mold clamping interlock setting signal to the injection molding machine main body drive control device 6 via the control signal input / output unit 21. After giving, the reconfirmation processing operation is entered in step SP22X.

That is, the CPU 17 confirms the operation state of the safety door signal IN-3 as shown in FIG. 17B after the mold opening limit signal IN-1 is turned on at the time t1 as shown in FIG. and, as the shown in safety until the door signal iN-3 is turned on at time t3 after the off operation at time t2 (during safety door to open from the I closed) FIG 17 (C), 1 The injection molding machine monitoring apparatus 10 is maintained in a state in which the next monitoring operation is not performed.

  Actually, when the safety door signal IN-3 is turned off, the safety door of the injection molding machine main body 1 is opened and the maintenance inspection work is being performed. Therefore, the injection molding machine monitoring apparatus 10 automatically operates. If the injection molding monitoring operation is performed, there is a risk of inconvenience, and the CPU 17 confirms this state based on the safety door signal IN-3 sent from the safety door switch 7 being turned off.

  Thereafter, when the safety door signal IN-3 is turned on at the time t3, the CPU 17 can confirm that the maintenance / inspection work has been completed because the safety door 7 is closed. At this time, the CPU 17 performs the reconfirmation process. After completing step SP22X and proceeding to SP23, the primary monitoring operation is executed thereafter.

  Further, when the injection molding machine main body 1 performs the projecting operation, the CPU 17 performs the reconfirmation process in step SP34X after projecting in step SP34 and giving an interlock setting signal.

In this case, as shown in FIG. 18A, the CPU 17 protrudes at the time t11 and the completion signal IN-2 is turned on (indicating that the injection molding machine main body 1 is in the protruding operation) . As shown in FIG. 18C, the secondary monitoring operation is performed until the safety door signal IN-3 is switched to the OFF state at the time t12 until the safety gate signal IN-3 is switched to the ON state at the time t13 . Is kept from starting.

  Thus, when the operator performs maintenance and inspection work with the safety door switch 7 turned off when the operator opens the safety door, the CPU 17 turns off the safety door signal IN-3. Accordingly, as a confirmation, the injection molding machine monitoring apparatus 10 is held in a standby state so as not to perform the secondary monitoring operation.

  Thereafter, as shown in FIG. 18B, when the safety door signal IN-3 is switched on at time t13, the CPU 17 monitors the secondary monitoring operation as shown in FIG.

Thus when the injection molding machine body 1 has a projecting operation, in a state where CPU17 safety door is opened by that Separate the secondary monitoring operation, it is possible to sufficiently ensure the safety of the injection molding machine body 1.

  Even when the CPU 17 performs the protruding operation in steps SP50 to SP52, the CPU 17 performs the safety reconfirmation operation of the injection molding machine main body 1 in the same manner as described above with reference to FIGS.

  According to the above configuration, when the injection molding machine main body 1 is in the mold clamping operation or the protruding operation state, when the operator opens the safety door and performs maintenance and inspection work, the CPU 17 confirms this and follows the primary. By controlling the injection molding machine monitoring apparatus 10 in a standby state in which the monitoring process or the secondary monitoring process is not performed, safety can be further improved.

(8) Other Embodiments of Secondary Monitoring Process (8-1) FIG. 19 shows another embodiment of the secondary monitoring process, and step SP53- is included in the monitoring cycle processing routine RT2 of FIG. The processing between SP54-SP55-SP55X-SP56-SP57 from the incoming connector T1 to the outgoing connectors T2 and T3 is replaced with the processing shown in FIG.

  In FIG. 19, when the CPU 17 enters the secondary monitoring process from the incoming connector T1, first, the secondary monitoring timer is started in step SP71.

  The secondary monitoring timer is in a state where the injection molding machine main body 1 performs a mold opening operation and protrudes in step SP52 (FIG. 4) and receives an interlock setting signal from the injection molding machine monitoring apparatus 10. Counts the maximum allowable time required for performing the secondary monitoring process, and the CPU 17 stores the secondary monitoring timer data stored in advance in the secondary monitoring timer data memory unit 18L of the frame memory 18 (FIG. 3). Time counting is performed by subtracting D11.

  After starting the secondary monitoring timer, the CPU 17 inputs the secondary monitoring detection image data D7 to the secondary monitoring detection image data memory unit 18G of the frame memory 18 in step SP72, and then secondary monitoring reference image data in step SP73. The secondary monitoring image processing is performed by comparing with the secondary monitoring reference image data D2 stored in the memory unit 18B.

  In step SP74, the CPU 17 determines whether or not the result of the secondary monitoring image processing in step SP73 is abnormal. When a result of determination as abnormal is obtained, whether or not the number of repeated determinations has reached the limit number N in step SP75. If a negative result is obtained, the process returns to step SP72 described above to execute a secondary monitoring processing loop (this is called secondary monitoring cycle means) at the time of abnormality of SP72-SP73-SP74-SP75-SP72. repeat.

  Thus, in FIG. 20A, after the secondary monitoring timer signal S11 switches from the off state to the on state at the start time t21, the CPU 17 continues until the secondary monitoring timer set time elapses at the secondary monitoring end time tNX. In the meantime, as shown in FIG. 20 (B1), (B2)... (BN), the processing loop time signals S121, S122.

  As described above, when only the determination result of abnormality is obtained in step SP74 even though the CPU 17 performs the secondary monitoring image processing N times, the CPU 17 determines the determination signal S3 as shown in FIG. As shown in FIG. 20D, a signal for instructing the stop is continuously sent as a next cycle start signal S4.

  After the last processing loop time signal S12N is sent in this state, when the secondary monitoring timer finishes the timing operation at the secondary monitoring end time tNX, the CPU 17 obtains an affirmative result in step SP76. In step SP77, the abnormality warning output S5 is sent (FIG. 20E), and the process proceeds to the above-described step SP58 (FIG. 4) via the output connector T2.

  Thus, when the determination result of abnormality is obtained in step SP74 from the start of the secondary monitoring timer to the end of the timing operation at the secondary monitoring end time tNX, the CPU 17 performs the timing operation of the secondary monitoring timer. After the completion, the abnormality warning output S5 is output.

  On the other hand, as shown in FIG. 21A, the CPU 17 starts generating the processing loop time signals S121, S1222,... S12N by starting the secondary monitoring timer at time t21. When the determination result is normal in step SP74, the CPU 17 moves to the next processing step via the output connector T3 at the timing when the determination result is normal (this processing loop is changed to 2). This is called the next monitoring operation end means).

  In the case of the embodiment of FIG. 4, when the CPU 17 moves from the output connector T3 to the next step, the processing of the CPU 17 determines whether or not the monitoring cycle processing routine RT2 is completed in step SP60 of FIG. Migrate to

  The condition for shifting to the processing of step SP60 is that the CPU 17 obtains a result of determination as normal in step SP74, and after the secondary monitoring timer S11 starts the time measuring operation at time t21 in FIG. When the determination at step SP74 during the first processing loop time S121 in FIG. 21B is normal, when the first processing loop time S121 ends, normality is obtained as shown in FIG. By obtaining the representing determination signal S3, the CPU 17 raises the next cycle start signal S4 to the start instruction state at that timing as shown in FIG. 21D, thereby immediately starting the next cycle at the next point t22. to go into.

  At this time, the CPU 17 does not perform the processing of step SP77 which is executed when the abnormality determination result is obtained, so that the monitoring cycle processing routine RT2 is executed without raising the abnormality alarm output S5 as shown in FIG. Terminate.

  If the CPU 17 obtains a normal determination result at any one of the processing loop times S122, S123,... S12N, as well as the case where it is determined that the abnormality is normal from the beginning as described above, as shown in FIG. As indicated by a broken line in 21 (C), when the determination signal S3 is switched to the normal output state at the timing when the determination result is obtained, the process can proceed to the next step at that timing.

  Thus, according to the configuration of FIG. 19 to FIG. 21, in the secondary monitoring processing operation from the input connector T1 to the output connector T2 of FIG. 4, a normal determination result is obtained at the processing timing of step SP74. Unless otherwise specified, the processing of the loop of steps SP72-SP73-SP74-SP75-SP72 is repeated. As a result, when a result of determination of normality is obtained in step SP74, immediately after that (secondary monitoring timer S11 performs the timing operation). By being able to move to the next step (before reaching the end time tNX), the secondary monitoring process can be executed more efficiently.

  Of course, when the abnormality detection repetitive operation reaches the limit number N before the secondary monitoring timer finishes the time measuring operation, the CPU 17 sends an abnormality warning output in step SP77 and proceeds to the next step of the monitoring cycle processing routine RT2. (This processing loop is called abnormality warning output means).

  According to the above configuration, in the secondary monitoring process, the CPU 17 repeatedly performs the abnormality determination operation unless a normal determination result is obtained, but when a normal determination result is obtained, Even at an early timing such as the first time or the second time, it is possible to immediately shift to the next processing cycle, so that the secondary monitoring process can be executed safely and efficiently.

(8-2) FIG. 22 shows an embodiment of the secondary monitoring process from the input connector T4 to the output connectors T5 and T6 in FIG. 5 in the monitoring cycle processing routine RT2. As shown in FIG. 19, the CPU 17 enters the incoming connector T4 in FIG. 5 and then moves from the outgoing connector T5 to the next processing cycle. Processing from step SP71 to step SP77 is performed.

  Thus, when it is determined in step SP74 that the result is normal, the CPU 17 proceeds to the next processing cycle in exactly the same manner as described with reference to FIG. 19 via the output connector T6.

  Also with the configuration of FIG. 22, as described above with reference to FIG. 19, the CPU 17 can perform the secondary monitoring process safely and efficiently.

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

It is a block diagram which shows the whole structure of the injection molding machine monitoring apparatus by this invention. It is a flowchart which shows a normal monitoring process procedure. FIG. 2 is a schematic diagram illustrating a configuration of a frame memory 18 in FIG. 1. It is a flowchart which shows the monitoring cycle process sequence. It is a flowchart which shows the monitoring cycle process sequence. (A) And (B) is a basic diagram with which it uses for description of the update process of a monitoring area | region. (A), (B) and (C) are schematic diagrams for explaining the position correction of the monitoring area. (A) And (B) is an approximate line figure used for explanation of creation processing of template image data. It is an approximate line figure used for explanation of search operation by template image data. (A)-(D) is a characteristic curve figure which shows the process sequence of the image data used in the case of the brightness correction process of image data. (A) And (B) is a basic diagram with which it uses for description of a cavity removal process. (A)-(E) is a basic diagram with which it uses for description of a reflection part removal process. (A) And (B) is a basic diagram with which it uses for description of the process when a reflection part has not fully reduced. It is a flowchart which shows the brightness setting process sequence. It is a basic diagram which shows a lens adjustment screen. It is a basic diagram which shows a sensitivity setting screen. It is a signal waveform diagram which comes to description of the primary monitoring reconfirmation processing procedure. It is a signal waveform diagram which comes to description of the secondary monitoring reconfirmation processing procedure. It is a flowchart which shows other embodiment of the secondary monitoring process from the input connector T1 of FIG. 4 to the output connector T2 or T3. FIG. 20 is a signal waveform diagram required for explaining the processing operation at the time of abnormality in the secondary monitoring process of FIG. 19. FIG. 20 is a signal waveform diagram for explaining the normal operation in the secondary monitoring process from the input connector T1 to the output connector T2 or T3 in FIG. It is a flowchart which shows other embodiment of the secondary monitoring process from the input connector T4 of FIG. 5 to the output connector T5 or T6 in the monitoring cycle processing routine RT2.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Injection molding machine body, 2 ... Movable side type, 3 ... Fixed side type, 4 ... Conduit, 5 ... Guide, 6 ... Injection molding machine body drive control device, 7 ... Safety door switch, DESCRIPTION OF SYMBOLS 10 ... Injection molding machine monitoring apparatus, 11 ... Television camera, 12 ... Image input circuit, 13 ... Image processing circuit, 15 ... Bus, 16 ... Program memory, 17 ... Central processing unit (CPU) , 18 ... Frame memory, 19 ... Image display circuit, 20 ... Monitor, 21 ... Control signal input / output section, 31 ... Manual operation panel, 32 ... Monitoring control signal manual input section, 41, 51 ... Die, 42, 50 ... Cavity, 43 ... Brightness display field, 52 ... Sensitivity setting operation item, 53 ... High sensitivity operation, 54 ... Decrease sensitivity operation, P1-P4 ... Display position , J1 to J4... Monitoring target image part, DIP. Image for one frame, K1 to K4... Real image portion, LH1, LH2... Horizontal outer tangent, LV1, LV2... Vertical outer tangent, D1, D2. TP: Template image data, D6, D7: Primary, secondary monitoring and monitoring detected image data, SH: Search range, OB: Acquired image data, HO, HO1, HO2: Histogram curve, IM1: Reference Image data, IM2 ... Acquired image data, CV1 to CV7 ... Cavity part, SA1, SA2 ... Die surface part, IM1X, IM2X ... Cavity removal reference acquisition image data, K1, K2 ... Uneven part.

Claims (2)

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 an imaging means, and a predetermined monitoring target portion is included in a video signal of the imaging means, according to the brightness change of the set image data portion of the monitor area in Table 示位 location, in an injection molding machine monitoring apparatus for monitoring an abnormal operation of the injection molding machine body,
Means for obtaining monitoring reference image data as determination reference image data of abnormal operation using the video signal obtained at the start of the monitoring operation;
Means for obtaining monitoring detection image data as detection image data of an abnormal operation using the video signal obtained at the time of the mold opening operation or the protrusion operation in an injection molding cycle that is sequentially repeated;
Of the monitoring reference image data, the actual image of the monitored portion of the surveillance area to be monitored occurrence of an abnormal operation, circumscribing the image data of the actual image at the periphery of the display position location of the monitoring region Means for obtaining template image data consisting of position data of pixels in a determination area surrounded by circumscribing lines;
A search range is set in a range larger than the pixels surrounded by the circumscribing line circumscribing the image data of the actual image among the monitoring detection image data by a predetermined number of pixels, and the search range is determined by the template. While searching for each pixel, the correlation between the brightness of the pixels in the template and the brightness of the pixels of the monitoring detection image data is calculated, and the monitoring area exists at the search position of the template having a high degree of matching. Means for recognizing and determining the presence or absence of an abnormal operation by obtaining a brightness comparison result between the monitoring reference image data and the monitoring detection image data for the image portion of the monitoring area. Injection molding machine monitoring device. By correcting the position of the detection image data so that the display position of the monitoring area is aligned with the position where the monitoring area is recognized as being present in the monitoring detection image data, the monitoring detection image Means for matching the position of the monitoring area of the monitoring detection image data obtained by the means for obtaining data with the position of the monitoring area of the monitoring reference image data,
The injection molding machine monitoring apparatus according to claim 1, wherein a determination operation by means for determining the presence or absence of the abnormal operation is performed in the matched state.