JP5666872B2 - 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 ejected from the movable mold by a projecting pin projecting from the rear of the movable mold (this operation is called "protruding" operation), and the take-out machine Is taken out by

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

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

JP-A-60-39581

  In this type of injection molding machine monitoring device, when the main body of the injection molding machine 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 necessary to monitor abnormalities that occur during the mold opening mode (such as “primary monitoring”), such as when a part of the mold is missing (so-called short mold).

  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.

  When the injection molding machine monitoring device detects such an abnormality, the injection molding cycle in the injection molding machine main body is interrupted, and the user opens the safety door provided in the injection molding machine main body and performs maintenance and inspection work. The cause is manually removed, and when the operation is completed, the safety door is closed, the injection molding cycle is restarted, and the injection molded product in which an abnormality has occurred is discarded.

  By the way, the injection molding machine performs stable injection molding immediately after restarting the initial injection molding cycle using a new mold, the injection molding cycle immediately after the mold replacement, or the once stopped injection molding cycle. In some cases, short molds may occur frequently.

  For such short molds that occur frequently, if the injection molding machine monitoring device interrupts the injection molding cycle each time and manually performs maintenance and inspection work, there is a risk that efficient monitoring cannot be performed. .

  The present invention has been made in consideration of the above points, and intends to propose an injection molding machine monitoring apparatus capable of performing monitoring more efficiently.

In order to solve such a problem, in the present invention, when the injection molding machine main body 1 performs the mold opening operation at the start of the monitoring operation, the video signal VD1 obtained by imaging the injection molding machine main body 1 by the imaging means is used. The reference product image data acquisition means for obtaining the reference product image data as the reference image data in the determination of the abnormal operation of the injection molding machine main body 1 and the injection molding cycle of the injection molding machine main body 1 that is sequentially repeated during the mold opening operation Detected product image data acquisition means for obtaining detected product image data as image data for detecting an abnormal operation using the obtained video signal VD1, and comparing the reference product image data and the detected product image data with the product abnormality in the injection molded product Product abnormality which detects the part 46 and calculates the pixel number of the product abnormal part 46 in the detected product image data A minute pixel number finding means, in a plurality of times of the injection molding cycle, only the injection molding cycle preset number, relative to the reference product number of pixels is the number of picture elements corresponding to the injection molding product in the reference product image data, the detection When the ratio of the number of product abnormal part pixels, which is the number of pixels of the product abnormal part 46 in the product image data, is calculated and is smaller than a preset pixel number ratio threshold, the injection molding is not stopped and the injection molding is stopped. Control means is provided for projecting to the machine body 1 to supply an interlock release signal and proceed to an injection molded product take-out operation.

  According to the present invention, even when short molds occur frequently, pseudo primary monitoring is performed as a stage before entering normal monitoring processing including primary monitoring and secondary monitoring, and a product abnormal portion with respect to the number of reference product pixels When the ratio of the number of pixels is smaller than a preset pixel number ratio threshold, it is determined that the injection molded product is insufficiently filled or that a normal injection molded product has been injection molded, and the injection molded product is taken out to the main body of the injection molding machine. By proceeding to the operation, monitoring can be executed without interrupting the injection molding cycle, and an injection molding machine monitoring apparatus that can execute monitoring more efficiently can be realized.

It is a block diagram which shows the whole structure of the injection molding machine monitoring apparatus by this invention. It is a flowchart which shows the monitoring process procedure. It is a flowchart which shows the monitoring cycle process sequence (1). It is a flowchart which shows the monitoring cycle process procedure (2). It is a basic diagram which shows a primary monitoring cancellation setting screen. It is a basic diagram which shows a reference | standard product image. It is a basic diagram which shows a detection product image. It is a basic diagram which shows a product abnormal partial image. It is a basic diagram which shows a primary monitoring cancellation screen.

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

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

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

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

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

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

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

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

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

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

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

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

(2) Monitoring Processing When the user designates the monitoring processing mode via the operation input unit 25, the CPU 17 enters the monitoring processing routine RT1 in FIG. 2, and the primary monitoring cancel setting shown in FIG. The screen DIPX is displayed.

  The primary monitoring cancel setting screen DIPX is monitored even if the CPU 17 detects a short mold in the monitoring cycle processing routine RT2 (FIGS. 3 and 4) before performing normal monitoring processing including primary monitoring and secondary monitoring. This is used for setting the primary monitoring cancel, which is a function of proceeding to the secondary monitoring without interrupting the cycle.

  The primary monitoring cancel setting screen DIPX displays an execution operation unit 40 that selects whether or not to execute primary monitoring cancellation, a primary monitoring cancel execution number operation unit 41, and a pixel number ratio threshold operation unit 42. .

  The user selects the ON button 40A in the execution operation unit 40 when executing the primary monitoring cancel, and conversely selects the OFF button 40B in the execution operation unit 40 when not executing the primary monitoring cancel.

  In addition, the user operates the primary monitoring cancel execution count operation unit 41 to input a numerical value, and in the injection molding cycle that is repeatedly executed, the primary indicating how many times the primary monitoring cancel is executed. Set the number of monitoring cancel executions (for example, 10 times). When the primary monitoring cancel execution count is set, the CPU 17 assigns the numerical value of the primary monitoring cancel execution count to the primary monitoring cancel count CNT used when executing the primary monitoring cancellation, and stores it in the frame memory 18.

  Further, the user operates the pixel number ratio threshold value operation unit 42 to input a numerical value, thereby determining whether a short mold has occurred or a remaining mold has occurred when executing the primary monitoring cancel. A pixel number ratio threshold value (for example, 30%), which is a value of

  Subsequently, the CPU 17 waits for the mold opening limit signal to be turned on in step SP2, confirms that the injection molding machine main body 1 is in the mold open state, and sets the timing for executing the subsequent operation to the injection molding machine main body 1. Thus, when the movable mold 2 of the injection molding machine main body 1 is retracted to the mold open position, the injection molding machine main body drive control device 6 makes the mold that has been turned on as the monitoring control signal S1. An opening limit signal is given to the CPU 17 via the control signal input / output unit 21.

  At this time, the CPU 17 supplies the mold clamping interlock setting signal as the sequence control signal S2 to the injection molding machine main body drive control device 6 through the control signal input / output unit 21 in the next step SP3, whereby the injection molding machine main body 1 is given. The injection molding machine main body drive control device 6 is controlled so as not to perform the mold clamping operation, whereby the injection molding machine main body 1 is held in the mold open state.

  Thus, in a state where the injection molding machine main body 1 holds the mold open state, the CPU 17 in the next step SP4, the video signal VD1 currently obtained from the television camera 11 (injection molding in the mold open state). The image of the cavity of the machine body 1 is input to the image processing circuit 13 through the image input circuit 12 as video data DATA1 for one frame.

  Subsequently, the CPU 17 registers the image data for one frame representing the mold open state input to the image processing circuit 13 in step SP5 in the frame memory 18 as the primary monitoring reference image data D1.

  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. When the CPU 17 determines whether the short mold has occurred or the remaining mold has occurred when the primary monitoring cancel is performed on the image data for one frame in the mold open state. That is, it is acquired in the frame memory 18 as reference data used when determining whether or not an abnormality has occurred during the next monitoring.

  Subsequently, in step SP6, the CPU 17 protrudes as the sequence control signal S2 and gives an interlock release signal to the injection molding machine main body drive control device 6 via the control signal input / output unit 21, whereby the protrusion operation of the injection molding machine main body 1 is performed. In the next step SP7 and waits for the protrusion completion signal that has been turned on as the monitoring control signal S1 from the injection molding machine main body drive control device 6 via the control signal input / output unit 21. Become.

  Eventually, when the protrusion completion signal that has turned on is received, the CPU 17 proceeds to the next step SP8 to indicate the video signal VD1 currently obtained from the television camera 11 (indicating that the injection molding machine body 1 is protruding and is in the completed state). Are input to the image processing circuit 13 through the image input circuit 12 as video data DATA1 for one frame.

  Subsequently, in step SP9, the CPU 17 registers the image data for one frame representing the protruding completion state input to the image processing circuit 13 in the frame memory 18 as the secondary monitoring reference image data D2.

  The processing of this step SP9 is a secondary monitoring standard when the injection molded product attached to the movable mold 2 is removed by the protruding operation of the injection molding machine main body 1 and is taken out by the take-out machine. This means that the image data D2 is used as reference data in the subsequent secondary monitoring process.

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

  Thereafter, in the next step SP12, the CPU 17 performs an operation for subtracting the secondary monitoring reference image data D2 from the primary monitoring reference image data D1 to obtain an absolute value thereof, and the difference data is predetermined as shown in FIG. An image in which a pixel position larger than the threshold value appears as a product portion 45 indicating an injection-molded product is registered in the frame memory 18 as reference product image data D3.

  Subsequently, in the next step SP13, the CPU 17 calculates the number of pixels (for example, 500 pixels) of the product portion 45 in the reference product image data D3 and registers it as the reference product pixel number in the frame memory 18, and then the monitoring cycle processing routine RT2. The injection molding cycle for injection-molding the next injection-molded product by the fixed mold 3 and the movable mold 2 of the injection molding machine main body 1 is executed.

  Therefore, the primary monitoring reference image data D1 is image data representing an image in which the injection molded product is attached to the movable side mold 2 when the mold is opened, whereas the secondary monitoring reference image data D2 is when projected. Since the image data represents an image in a state where the injection molded product is taken out from the movable mold 2 and is not attached, the brightness of the | primary monitoring reference image data D1-2 and the secondary monitoring reference image data D2 | The pixel position means a range where the injection molded product was present when the mold was opened.

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

(3-1) Primary Monitoring Cancel Processing When the ON button 40A is selected on the execution operation unit 40 of the primary monitoring cancel setting screen DIPX in the above-described step SP1 (FIG. 2), the CPU 17 First, the following primary monitoring cancellation process is executed as a process before entering the normal monitoring process, which is the primary monitoring and secondary monitoring.

  The CPU 17 waits for the mold opening limit signal, which has been turned on for the injection molded product currently injection molded by the injection molding machine body 1 in step SP21, to arrive from the injection molding machine body drive control device 6 as the monitoring control signal S1. When the ON state mold opening limit signal has arrived, a mold clamping interlock setting signal is given as a sequence control signal S2 to the injection molding machine main body drive control device 6 in the next step SP22, whereby the injection molding machine main body 1 Is confirmed to be in the mold open state, and the injection molding machine main body 1 is controlled so that the mold clamping operation is not performed.

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

  Subsequently, the CPU 17 determines whether or not the primary monitoring cancel count CNT is 0 in the next step SP24.

  If a negative result is obtained in step SP24, this means that primary monitoring cancellation should be executed. At this time, the CPU 17 moves to step SP25 and sets the primary monitoring cancellation count CNT to only 1 (for example, 10 to 9). Subtract).

  In the next step SP26, the CPU 17 performs a calculation for subtracting the secondary monitoring reference image data D2 from the primary monitoring detection image data D4 to obtain the value, and the difference data is obtained as shown in FIG. An image in which a pixel position larger than a predetermined threshold appears as a product portion 45 indicating an injection molded product is stored in the frame memory 18 as detected product image data D5.

  Subsequently, in the next step SP27, the CPU 17 performs a calculation for subtracting the detected product image data D5 from the reference product image data D3 to obtain the value, and as shown in FIG. 8A, the pixel position of the difference data Is stored in the frame memory 18 as product abnormal part image data D6.

  Subsequently, in the next step SP28, the CPU 17 calculates the number of pixels of the product abnormal part 46 in the product abnormal part image data D6 and stores it in the frame memory 18 as the number of product abnormal part pixels.

  Here, in the above-described step SP26, when the detected product image data D5 shown in FIG. 7A is obtained, the right portion of the product portion 45 in the detected product image data D5 is missing. This means that a short mold has occurred in the injection molded product in the molding cycle.

  When a short mold occurs, the product abnormal portion image data D6 obtained in step SP27 described above shows a portion where insufficient filling occurs as a product abnormal portion 46 as shown in FIG. 8A, and step SP28. The CPU 17 obtains, for example, 140 pixels as the product abnormal portion pixel number that is the number of pixels of the product abnormal portion 46.

  On the other hand, in the above-described step SP26, when the detected product image data D5 shown in FIG. 7B is obtained, the product portion 45 in the detected product image data D5 has no missing portion. This means that the injection molded product in the cycle was a normal product.

  When a normal injection-molded product is injection-molded, the product abnormal part 46 does not appear in the product abnormal part image data D6 obtained in step SP27 described above, as shown in FIG. Then, 0 pixel is obtained as the product abnormal partial pixel number.

  On the other hand, in the above-described step SP26, when the detected product image data D5 shown in FIG. 7C is obtained, the detected product image data D5 does not include the product portion 45, which is the result of this injection molding cycle. This means that the injection-molded product remains attached to the fixed-side mold 3 and a mold residue is generated.

  When mold residue occurs, the product abnormal portion image data D6 obtained in step SP27 described above has the same shape as the product portion 45 (FIG. 6) in the reference product image, as shown in FIG. 8C. The product abnormal portion 46 appears, and in step SP28, the CPU 17 obtains 500 pixels that are the same as the reference product pixel number as the product abnormal portion pixel number.

  Thereafter, in the next step SP29, the CPU 17 determines that the ratio of the product abnormal partial pixel number to the reference product pixel number is the number of pixels set via the primary monitoring cancel setting screen (FIG. 5) in the above-described step SP1 (FIG. 2). It is determined whether or not the percentage threshold (30%) or more.

  Here, when a mold residue occurs in this injection molding cycle, the number of product abnormal partial pixels is 500 pixels as described above, so the number of product abnormal partial pixels (500 pixels) with respect to the standard product pixel number (500 pixels). The ratio is 100%, which is equal to or greater than the pixel number ratio threshold (30%).

  In this way, when the remaining mold occurs, the CPU 17 obtains an affirmative result in step SP29, moves to step SP30, sends an abnormality warning output, and performs abnormality processing in steps SP30 to SP33.

  Thus, when the remaining mold occurs when the primary monitoring cancellation is executed, the user actually operates the injection molding machine main body 1 by opening the safety door of the injection molding machine main body 1 and operating the manual operation panel 31. Thus, 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 a reset signal, which has transitioned to the OFF state, as the monitoring control signal S1 to the CPU 17 via the control signal input / output unit 21. .

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

  Subsequently, in the next step SP33, the CPU 17 gives a mold clamping interlock release signal to the injection molding machine main body drive control device 6 as a sequence control signal S2, thereby controlling the mold clamping operation of the injection molding machine main body 1 to be permitted. Thereafter, the process returns to the above-described step SP21 (FIG. 3) to enter a monitoring operation for the next injection molding cycle.

  Thus, when a mold residue occurs during execution of the primary monitoring cancel, the injection molding machine monitoring device 10 interrupts the injection molding cycle in the injection molding machine main body 1 and removes the injection molded product attached to the fixed side mold 3. It is designed to perform maintenance and inspection work.

  On the other hand, when a short mold occurs in this injection molding cycle, the number of product abnormal partial pixels is 140 pixels as described above, so the ratio of the product abnormal partial pixel number (140 pixels) to the standard product pixel number (500 pixels) Is 28%, which is below the pixel number ratio threshold (30%).

  When the short mold occurs in this way, the CPU 17 obtains a negative result at step SP29, and proceeds to step SP34.

  On the other hand, when a normal product is injection-molded in this injection molding cycle, the number of abnormal product partial pixels is 0 as described above, so the number of product abnormal partial pixels (0 pixels) with respect to the standard product pixel number (500 pixels). ) Is 0%, which is lower than the pixel number ratio threshold (30%).

  When the normal product is injection molded in this way, the CPU 17 obtains a negative result at step SP29 as in the case where the short mold occurs, and proceeds to step SP34.

  Thus, the pixel number ratio threshold indicates the threshold of the ratio of the product abnormal partial pixel number to the reference product pixel number. When the ratio of the product abnormal partial pixel number to the reference product pixel number is smaller than the pixel number ratio threshold, the short mold is performed. Means that a generated or normal injection molded product has been injection molded, while if the ratio of the number of abnormal product pixels to the reference product pixel number is equal to or greater than the pixel number ratio threshold, it means that a mold residue has occurred. doing.

  In step SP34, the CPU 17 displays the primary monitoring cancel screen DIPY shown in FIG. The primary monitoring cancel screen DIPY displays an image of the movable side mold 2 currently captured by the television camera 11. In the case of FIG. 9, the cavity 51 is projected at the center of the mold 50.

  In addition to this, the primary monitoring cancel screen DIPY displays “1ST CANCEL” indicating that the primary monitoring cancellation is currently being executed in the upper left part of the screen and also displays the primary monitoring cancel count CNT. This indicates to the user how many cycles of primary monitoring cancellation are to be executed.

  Subsequently, the CPU 17 sends out an abnormality warning output in step SP35, and in step SP36, the CPU 17 protrudes as a sequence control signal S2 to the injection molding machine main body drive control device 6 to give an interlock release signal, and in the next step SP37, the injection molding machine main body. As the monitoring control signal S1 from the drive control device 6, it waits for the protruding completion signal that has been turned on.

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

  As a result, when the protrusion completion signal transitions to the ON state, the CPU 17 proceeds to step SP38 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. The state is maintained and the process proceeds to the secondary monitoring described below.

  In this way, the injection molding machine monitoring device 10 treats this in the same way as when a normal product is injection-molded, because short molding frequently occurs in the first several injection molding cycles after changing the mold. However, by proceeding to secondary monitoring, the injection molding cycle is not interrupted each time a short mold occurs.

Here, since the injection-molded product that has been injection-molded during the execution of the primary monitoring cancellation is one that has been injection-molded with the injection molding machine main body 1 in an unstable state, the CPU 17 performs step SP29 (FIG. 3) described above. The same processing is performed regardless of whether the injection molding is normally performed or a short mold is generated, and the injection molded product taken out thereafter is discarded without being adopted as a normal product.

  Subsequently, in step SP39, the CPU 17 captures and stores the secondary monitoring detection image data D7 in the protruding state in the frame memory 18 based on the video signal VD1 of the television camera 11.

  Thereafter, in step SP40, the CPU 17 executes secondary monitoring processing for comparing the secondary monitoring detection image data D7 stored in the frame memory 18 with the secondary monitoring reference image data D2, and then the comparison result is obtained in step SP41. Determine whether there is an abnormality.

  At this time, the CPU 17 determines whether or not each pixel data of the secondary monitoring detection image data D7 matches the data of the corresponding pixel of the secondary monitoring reference image data D2 in step SP40, and the number of pixels that do not match is determined. Assuming that an abnormality has occurred when the number exceeds the predetermined number, the process returns to step SP30, and the same processing as the above-described abnormality processing is executed.

  On the other hand, when a result of normality is obtained in step SP41, this means that a determination result that the injection molding machine main body 1 is normal in the secondary monitoring is obtained. At this time, the CPU 17 Moves to step SP42.

  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 SP43, whereby the injection molding machine main body 1 is clamped. Operate to get ready for the injection molding process.

  In step SP44, the CPU 17 waits for the arrival of a mold opening limit signal that has shifted to the OFF state as the monitoring control signal S1 from the injection molding machine main body drive control device 6, and executes primary monitoring cancellation in the next step SP45. If YES, the abnormal warning output is deleted, and the process returns to the above-described step SP21 (FIG. 3) to start the monitoring operation for the next injection molding cycle.

  When the user ends the injection molding cycle by operating the operation input unit 25, the CPU 17 obtains a positive result in step SP42 (FIG. 4), thereby ending all the processing of the monitoring cycle processing routine RT2. Then, the process returns from step SP46 to the main routine, that is, the monitoring process routine RT1 (FIG. 2), and then all the processes of the monitoring process routine RT1 are ended in step SP47.

  In this way, the injection molding machine monitoring apparatus 10 does not interrupt the injection molding cycle of the injection molding machine body 1 even if a short mold occurs until the injection molding cycle is repeated by the number of times of primary monitoring cancellation execution. The process proceeds to secondary monitoring.

  In addition, the injection molding machine monitoring device 10 treats the injection molded product in the unstable state immediately after the mold change, even if the injection molded product is normally injection molded during the primary monitoring cancel execution, by treating it as in the short mold. Injection molded products are not used as normal products but are discarded.

  In the subsequent injection molding cycle, the CPU 17 executes the primary monitoring cancel until the primary monitoring cancel count CNT becomes 0, and when the primary monitoring cancel count CNT becomes 0, an affirmative result is obtained in step SP24, Control goes to step SP48.

(3-2) Normal Monitoring Processing The CPU 17 repeats the primary monitoring cancellation for the cycle of the number of times of primary monitoring cancellation set on the primary monitoring cancel setting screen DIPX (FIG. 5), and then proceeds to step SP48 and described below. Normal monitoring processing, which is normal primary monitoring and secondary monitoring, is executed.

  In step SP48, the CPU 17 designates and inputs the primary monitoring detection image data D4 input in step SP23 before entering the determination in step SP24 as the primary monitoring reference image data D1 in the subsequent injection molding cycle. In step SP49, update processing of the primary monitoring reference image data D1 is executed when an affirmative result is obtained.

  The primary monitoring reference image data D1 is updated by re-registering the primary monitoring reference image data D1 currently stored in the frame memory 18 with the primary monitoring detection image data D4.

  When a negative result is obtained in step SP48, the CPU 17 jumps to the update process of the primary monitoring reference image data D1 in step SP49, and performs the primary monitoring process in step SP50.

  In the primary monitoring process in step SP50, the primary monitoring detection image data D4 and the primary monitoring reference image data D1 stored in the frame memory 18 are obtained in the same manner as the secondary monitoring process described in step SP40. When the number of pixels that do not match each pixel is equal to or greater than a predetermined number, an abnormality is executed, and when the number is less than the predetermined number, normal processing is executed.

  Thus, the injection molding machine monitoring apparatus 10 performs primary monitoring detection image data D4 in a state where the primary monitoring cancellation is completed and the injection molding machine main body 1 is stabilized (that is, in a normal state where no short mold is generated) as primary. By registering as monitoring reference image data D1, the abnormality determination performance of monitoring in the subsequent injection molding cycle is maintained.

  Subsequently, the CPU 17 determines whether or not the result of the primary monitoring process is abnormal in step SP51. If it is determined that it is abnormal, the CPU 17 returns to step SP30 to execute the same process as the above-described abnormal process, and is normal. If it is determined, the process proceeds to step SP36 and proceeds to the secondary monitoring described above.

  By the way, since a short mold is likely to occur immediately after changing the mold, some short molds are also generated in the product portion 45 in the reference product image data D3 used as the determination reference image when executing the primary monitoring cancel. In such a case, the primary monitoring cancellation is performed on the basis of the image data in which the short mold has occurred.

  As described above, even if a slight short mold occurs in the product part 45 in the reference product image data D3, if a residual mold occurs, the product part 45 in the detected product image data D5 does not exist (FIG. 7 ( C)), since the ratio of the product abnormal partial pixel number to the reference product pixel number is 100%, the injection molding machine monitoring device 10 can ensure the remaining mold by practically setting the pixel number ratio threshold appropriately. It is possible to detect, and damage to the injection molding machine main body 1 can be prevented.

  At the same time, immediately after changing the mold, which is likely to cause a short mold, the injection molding is performed only for a predetermined number of injection molding cycles, even if a short mold is generated, without proceeding to the secondary monitoring without interrupting the injection molding cycle. The machine monitoring device 10 can perform monitoring without interfering with the flow of the injection molding cycle.

  In the case of this embodiment, since the number of primary monitoring cancellation executions and the pixel number ratio threshold can be set by the user, the manufacturing difficulty of the injection molded product, the stability of the injection molding machine main body 1 and the like are taken into consideration. The primary monitoring cancel execution count and the pixel number ratio threshold value, which are conditions for executing the primary monitoring cancellation, can be adjusted as appropriate.

  In the above configuration, the CPU 17 compares the reference product image data with the detected product image data, detects a product abnormal portion in the injection molded product, calculates the number of product abnormal portion pixels in the detected product image data, and calculates the reference product image. If the ratio of the product abnormal part pixel number to the reference product pixel number that is the product part 45 in the data is greater than or equal to a preset pixel number ratio threshold, and if the ratio is greater than or equal to the pixel number ratio threshold, On the other hand, if it is smaller than the pixel number ratio threshold, it is determined that a short mold has occurred or that a normal injection molded product has been injection molded, and the injection molding machine body 1 continues from the mold opening operation without interrupting the injection molding cycle. The injection molded product was taken out and the injection molded product was discarded.

  According to the above configuration, even if a short mold frequently occurs in the first several injection molding cycles such as after a mold change, pseudo-primary monitoring is performed as a stage before entering the normal monitoring process. By proceeding to the injection molded product take-out operation without interrupting the cycle, it is possible to realize an injection molding machine monitoring device that can perform monitoring more efficiently.

  In addition, if the ratio of the product abnormal partial pixel number to the reference product pixel number is equal to or greater than the pixel number ratio threshold, it is determined that the remaining mold has occurred, and the injection molding cycle is stopped to remove the cause of the abnormality, Damage to the injection molding machine main body 1 can be prevented.

(4) Other Embodiments In the case of the above-described embodiment, primary monitoring cancellation is executed based on the threshold value of the number of pixels, which is one value, for the number of injection molding cycles specified by the number of times of primary monitoring cancellation execution. However, instead of this, for example, a pixel count ratio threshold is set to 30% for 10 cycles, and a pixel count ratio threshold is set to 10% for the subsequent 5 cycles. A number ratio threshold may be set.

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

  DESCRIPTION OF SYMBOLS 1 ... Injection molding machine main body, 2 ... Movable side type | mold, 3 ... Fixed side type | mold, 4 ... Conduit, 5 ... Guide, 6 ... Injection molding machine main body drive control apparatus, 10 ... Injection molding machine monitoring 11: Television camera, 12: Image input circuit, 13: Image processing circuit, 15: Bus, 16: Program memory, 17: Central processing unit (CPU), 18: Frame memory, DESCRIPTION OF SYMBOLS 19 ... Image display circuit, 20 ... Monitor, 21 ... Control signal input / output part, 31 ... Manual operation panel, 40 ... Execution operation part, 41 ... Primary monitoring cancel execution frequency operation part, 42 ... Pixel number ratio threshold value operation unit, 45... Product portion, 46... Product abnormal portion, D1... Primary monitoring reference image data, D2... Secondary monitoring reference image data, D3. ... primary monitoring detection image data, D5 ... Out product image data, D6 ...... product anomalous partial image data, D7 ...... 2 primary surveillance detection image data, DIPX ...... 1 primary monitoring Cancel screen, DIPY ...... 1 primary monitoring cancel screen.

Claims (2)

When the injection molding machine main body performs a mold opening operation at the start of the monitoring operation, the video signal obtained by imaging the injection molding machine main body with the imaging means is used as a reference in determining the abnormal operation of the injection molding machine main body. Reference product image data acquisition means for obtaining reference product image data as image data,
In the injection molding cycle of the injection molding machine body that is sequentially repeated, detected product image data acquisition means for obtaining detected product image data as image data for detecting abnormal operation using the video signal obtained during the mold opening operation;
Product abnormal part pixel number calculating means for comparing the reference product image data with the detected product image data to detect a product abnormal part in an injection molded product and calculating the number of pixels of the product abnormal part in the detected product image data When,
In the plurality of injection molding cycles, the detected product image with respect to the reference product pixel number which is the number of pixels corresponding to the injection molded product in the reference product image data for the preset number of times of the injection molding cycle. When the ratio of the product abnormal part pixel number which is the number of pixels of the product abnormal part in the data is calculated and the ratio is smaller than a preset pixel number ratio threshold, the injection molding is not stopped without stopping the injection molding cycle. An injection molding machine monitoring device comprising: a control unit that protrudes from the machine body and supplies an interlock release signal to proceed to an injection molded product take-out operation. The control means includes
If the ratio of the number of abnormal product partial pixels to the number of reference product pixels is equal to or greater than the pixel number ratio threshold, it is determined that the injection molded product remains in the fixed mold, and the injection molding cycle is stopped. The injection molding machine monitoring apparatus according to claim 1.