JP6444952B2 - Molded article monitoring device - Google Patents

Description

  The present invention relates to a monitoring device for a molded product molded by an injection molding machine, and more particularly to a molded product monitoring device that can grasp a tendency of occurrence of molding defects by acquiring images of a plurality of molded products.

  When a defect occurs in a molded product molded by an injection molding machine, specifying the position where the defect occurs is extremely important in taking measures against the defect. For example, when burrs or shorts occur at the end of the molded product, the pressure in the pressure holding process may not be appropriate. If silver is generated around the gate of the molded product, the injection speed may not be appropriate. Moreover, when a carbide | carbonized_material is seen at random on the molded article surface, resin temperature may not be appropriate.

  In recent years, various means for acquiring an image of a molded product and finding defects such as the above-described burrs, shorts, silver, and carbides based on the image have been proposed. For example, Patent Literature 1 discloses a mold monitoring apparatus that acquires an image of a molded product and operates a molding machine or an accessory device at a position where an abnormality has occurred. Patent Document 2 discloses an injection molding machine monitoring apparatus that acquires an image of a molded product with a video camera and determines the presence or absence of an abnormality based on the brightness of a mesh detection unit region. Patent Document 3 discloses a molding machine management system that compares a non-defective product image with a defective product image and stores the difference data. Patent Document 4 discloses a nonconforming product generation preventing molding system that corrects molding conditions by specifying the type and degree of failure based on a photographed molded product image. Patent Document 5 discloses a failure factor that allows the number of failures to be tabulated for each failure occurrence location and displayed as a graph, and the process value of an injection molding machine to be compared between a plurality of shots including shots where failures have occurred. A determination system is disclosed.

JP 2009-061786 A JP-A-3-231824 JP 2007-160642 A JP 2006-297759 A JP 2014-69382 A

  In order to determine whether the defects such as burrs, shorts, silvers, carbides, etc. mentioned above are sudden or due to the molding conditions such as pressure, injection speed, resin temperature, etc. It is effective to grasp the tendency of occurrence of defects based on the state of occurrence of defects in the product.

  However, all of the techniques described in Patent Documents 1 to 4 only determine the quality of each molded product, and do not grasp the tendency of occurrence of defects. Moreover, since the technique described in Patent Document 5 cannot compare the occurrence of defects between a plurality of shots having different molding conditions, it is difficult to specify the molding conditions that cause molding defects. For this reason, with the techniques described in Patent Documents 1 to 5, it is difficult to determine optimum molding conditions and realize long-term stable molding even if it is useful for countermeasures for sudden molding defects.

  The present invention has been made to solve such problems, and by acquiring images of a plurality of molded products in different periods, it is possible to grasp the difference in occurrence tendency of molding defects between different periods. An object of the present invention is to provide a molded product monitoring apparatus.

A molded product monitoring apparatus according to an embodiment of the present invention includes a molded product image acquisition unit that acquires an image of a molded product molded by an injection molding machine, and whether or not there is an abnormality in the molded product based on the image. And an abnormality occurrence position specifying means for specifying an abnormality occurrence position when there is an abnormality, wherein the molded product image acquisition means includes at least two of the molded articles. acquiring an image, the abnormality occurrence position specifying means, said abnormality calculating at least any one of the abnormality occurrence count or abnormal occurrence frequency for each location, the different periods of several, said each of the abnormality occurrence position Comparing means for generating a graph indicating the number of times of occurrence of abnormality or the frequency of occurrence of abnormality is provided.

In the molded product monitoring apparatus according to another embodiment, the abnormality occurrence position specifying unit is provided for each abnormality occurrence position on a plane indicating the abnormality occurrence position for each different period instead of the graph . A numerical value indicating the number of occurrences of the abnormality or the frequency of occurrence of the abnormality is displayed on a display unit.

  In the molded article monitoring apparatus according to another embodiment, the abnormality occurrence position specifying means includes a plane indicating the abnormality occurrence position and the number of occurrences of abnormality or the abnormality for each abnormality occurrence position for each different period. A three-dimensional graph is displayed on the display means in a space including an axis indicating the occurrence frequency.

In the molded article monitoring apparatus according to another embodiment, the comparison unit obtains , for each abnormality occurrence position, the difference between the number of occurrences of abnormality or the frequency of occurrence of abnormality between the different periods instead of the graph, and the abnormality A numerical value indicating the difference is displayed on a display unit on a plane indicating the generation position.

  In the molded product monitoring apparatus according to another embodiment, the comparison unit obtains a difference between the number of occurrences of abnormality or the frequency of occurrence of abnormality between the different periods for each abnormality occurrence position, and a plane indicating the abnormality occurrence position; A three-dimensional graph is displayed on the display means in a space including the axis indicating the difference.

  In the molded product monitoring apparatus according to another embodiment, the different period is a period in which a predetermined number of molding cycles is molded, or a predetermined time.

  In the molded product monitoring apparatus according to another embodiment, the apparatus includes a physical quantity acquisition unit that acquires the physical quantity of the injection molding machine for each molding cycle, and the abnormality occurrence position specifying unit is configured to determine the physical quantity and the abnormality occurrence position. The information is stored in the storage means in association with each other.

  In the molded product monitoring apparatus according to another embodiment, the molded product monitoring apparatus includes a physical quantity acquisition unit that acquires a physical quantity of the molded product for each molding cycle, and the abnormality occurrence position specifying unit associates the physical quantity with the abnormality occurrence position. In addition, it is stored in the storage means.

In the molded article monitoring apparatus according to another embodiment, the abnormality occurrence position specifying unit is configured to calculate the abnormality occurrence number for each abnormality occurrence position calculated when the physical quantity is within a predetermined range and outside the predetermined range. Alternatively, at least one of the abnormality occurrence frequencies is displayed on the display unit when the frequency is within the predetermined range and when the frequency is out of the predetermined range.

  In the molded product monitoring apparatus according to another embodiment, the abnormality occurrence position specifying unit stores in advance a reference molded product image serving as a reference for determining abnormality of the molded product, and the reference molded product image and the image are stored in advance. To determine whether or not there is an abnormality in the molded product.

  The molded product monitoring apparatus according to another embodiment is characterized in that the reference molded product image is acquired in advance by the molded product image acquisition means.

  According to the present invention, it is possible to provide a molded product monitoring apparatus capable of grasping a difference in occurrence tendency of molding defects between different periods by acquiring images of a plurality of molded products in different periods.

2 is a block diagram illustrating a configuration of a molded product monitoring apparatus 100. FIG. It is a figure which shows the example of the identification method of the abnormality occurrence position of a molded article. It is a figure which shows the example of a display of abnormality occurrence frequency or abnormality occurrence frequency. It is a figure which shows the example of a display of abnormality occurrence frequency or abnormality occurrence frequency. It is a figure which shows the example of a display of abnormality occurrence frequency or abnormality occurrence frequency. It is a figure which shows the comparative display example of the frequency | count of abnormality occurrence or the frequency of abnormality occurrence under different molding conditions. It is a figure which shows the example of matching with a physical quantity and abnormality occurrence position.

<Embodiment 1>
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a block diagram showing a configuration of a molded product monitoring apparatus 100 according to an embodiment of the present invention. The molded product monitoring apparatus 100 may be built in the injection molding machine as shown in FIG. 1 or may be a separate device from the injection molding machine. A typical molded article monitoring apparatus 100 performs various processing by a central information processing device (CPU) executing predetermined processing according to a program stored in a storage device and controlling various hardware as necessary. Implement the means logically.

  The molded product monitoring apparatus 100 includes a molded product image acquisition unit 101, an abnormality occurrence position specifying unit 102, a storage unit 104, a display unit 106, and a comparison unit 107.

  The molded product image acquisition unit 101 is a unit that acquires an image of a molded product molded by an injection molding machine. Typically, a camera unit can be used.

  The abnormality occurrence position specifying unit 102 performs processing for determining whether or not there is an abnormality in the molded product image acquired by the molded product image acquiring unit 101. Further, when it is determined that there is an abnormality in the molded product image, a process for specifying the position where the abnormality has occurred is performed. More specifically, the abnormality occurrence position specifying unit 102 acquires in advance a reference non-defective molded product image (reference molded product image), and the molded product acquired by the reference molded product image and the molded product image acquisition unit 101. By comparing with the image, it can be determined whether or not there is an abnormality. Alternatively, instead of the reference molded product image, a CAD drawing of the molded product may be used as the reference image.

  FIG. 2 shows an example of a method for identifying a position where an abnormality has occurred. The abnormality occurrence position specifying unit 102 arranges an image obtained by photographing a predetermined surface of the molded product on the XY coordinate plane. Then, this coordinate plane is divided into lattice regions of an arbitrary size, and the above-described determination process is performed for each lattice. As a result, the grid determined to be abnormal is specified as the position where the abnormality has occurred.

  Further, the abnormality occurrence position specifying unit 102 acquires a molded product image of at least two or more of the same type of molded product by the molded product image acquiring unit 101. Then, at least one of the number of occurrences of abnormality and the frequency of occurrence of abnormality is calculated for each position where an abnormality has occurred, and the calculation result is displayed on the display means 106. The display means 106 is typically a display unit.

  3 to 5 show display examples of the number of occurrences of abnormality or the frequency of occurrence of abnormality. The chart of FIG. 3 is an example in which a numerical value indicating the number of occurrences of an abnormality is displayed on a grid area indicating the occurrence position of the abnormality. For example, when the numerical value “4” is displayed, it indicates that the abnormality has occurred four times at that position. The chart of FIG. 4 is an example in which a numerical value indicating an abnormality occurrence frequency is displayed on a similar grid area. For example, when the numerical value “40%” is displayed on the grid, it indicates that an abnormality has occurred at that position in 40% of the molded product image acquired by the abnormality occurrence position specifying unit 102. The graph of FIG. 5 is an example in which a three-dimensional graph is generated and displayed in a coordinate space having a third axis indicating the number of occurrences of abnormality and the frequency of occurrence of abnormalities in addition to the XY axes constituting a plane including a grid area. is there. According to the example of FIG. 5, it is possible to more intuitively understand the number of occurrences of abnormality or the position where the abnormality occurrence frequency is high.

  The abnormality occurrence position specifying unit 102 may specify the abnormality occurrence position every time the molded product image is acquired, and update the abnormality occurrence frequency and the abnormality occurrence frequency at the abnormality occurrence position each time. Alternatively, the abnormality occurrence position specifying unit 102 may store the abnormality occurrence position every time the molded product image is acquired, and calculate the abnormality occurrence frequency and the abnormality occurrence frequency for each abnormality occurrence position later. . The abnormality occurrence position specifying unit 102 stores the abnormality occurrence frequency and abnormality occurrence frequency calculated for each abnormality occurrence position in the storage unit 104.

  The comparison unit 107 performs processing for comparing information regarding the number of occurrences of abnormality and the frequency of occurrence of abnormality calculated under different molding conditions. In other words, processing for comparing the number of occurrences of abnormality or the frequency of occurrence of abnormality for each abnormality occurrence position calculated in different periods is performed. Thereby, it becomes easy to verify the influence etc. by the change of molding conditions.

  Hereinafter, an operation example of the molded product monitoring apparatus 100 in the present embodiment will be described. First, the injection molding machine performs molding for the first 100 shots. The abnormality occurrence position specifying means 102 calculates the number of occurrences of abnormality and the frequency of occurrence of abnormality for each abnormality occurrence position for the 100 shots of the molded product, and the storage means 104 stores them.

  Next, the injection molding machine changes the pressure holding condition and performs molding for the next 100 shots. The abnormality occurrence position specifying means 102 also calculates the number of occurrences of abnormality and the frequency of occurrence of abnormality for each abnormality occurrence position for the 100 shots of the molded product, and the storage means 104 stores them.

  The comparison unit 107 reads information related to the number of occurrences of abnormality or the frequency of occurrence of abnormality in a plurality of different periods from the storage unit 104. In this example, the comparison unit 107 reads out the number of occurrences or frequency of abnormality for the first 100 shots and the number of occurrences or frequency of abnormality for the next 100 shots. The comparison unit 107 displays a chart or graph indicating the number of occurrences or frequency of abnormality for the first 100 shots, and a chart or graph indicating the number of occurrences or frequency of abnormality for the next 100 shots. Can be displayed (FIG. 6). Thereby, the user can grasp | ascertain the change of the defect occurrence condition by the change of molding conditions, etc. For example, if the number of occurrences of abnormality and the frequency of occurrence of abnormality are reduced in the next 100 shots compared to the first 100 shots, it can be evaluated that the pressure holding condition change is appropriate. Furthermore, instead of displaying the two charts or graphs side by side, the comparison means 107 calculates the difference between the number of occurrences of abnormality or the frequency of occurrence of abnormality for the first 100 shots and the number of occurrences of abnormality or the occurrence of abnormality for the next 100 shots. The difference may be obtained for each abnormality occurrence position, and the difference may be displayed in the form shown in the chart of FIG. 3 or FIG. 4 or the graph of FIG.

  Note that the present embodiment is not limited to the above-described example, and the comparison means 107, for example, the abnormality occurrence frequency or abnormality occurrence frequency obtained by first performing the molding for one hour and the molding for the next hour. The number of occurrences of abnormality or the frequency of occurrence of abnormality obtained in (1) may be displayed side by side. That is, the comparison unit 107 compares the number of occurrences of abnormality or the frequency of occurrence of abnormality in a plurality of arbitrarily defined different periods.

  According to the present embodiment, the molded product monitoring apparatus 100 can grasp the occurrence tendency of molding defects by statistically processing the abnormality occurrence positions of a plurality of molded products. Specifically, the number of occurrences of abnormality and the frequency of occurrence of abnormality can be calculated for each abnormality occurrence position. Thereby, for example, if the number of occurrences of abnormalities and the frequency of occurrences of abnormalities at the end position of the molded product is high, the user may speculate that this defect phenomenon is not sudden and there is a potential problem with the pressure holding conditions. become able to. Further, the molded product monitoring apparatus 100 displays information related to the number of occurrences of abnormality and the frequency of occurrence of abnormality calculated side by side under different molding conditions. Thereby, the user can verify easily the influence etc. by the change of molding conditions.

<Embodiment 2>
The molded product monitoring apparatus 100 according to the second embodiment uses a physical quantity (for example, peak injection pressure, minimum cushion amount, measurement time, molded product weight, molded product size, etc.) detected by an injection molding machine to detect abnormalities in the molded product. It has a feature in that it is stored together with the generation position. Hereinafter, an operation example of the molded product monitoring apparatus 100 in the present embodiment will be described.

  The molded product monitoring apparatus 100 according to the second embodiment includes a physical quantity acquisition unit 105. Other components are the same as those in the first and second embodiments.

  The physical quantity acquisition unit 105 acquires physical quantities (for example, peak injection pressure, minimum cushion amount, measurement time, injection speed, resin temperature, etc.) when the molded product is molded from the injection molding machine. Alternatively, the physical quantity may be acquired for each predetermined number of molding cycles. Moreover, you may acquire the physical quantity concerning a molded product (for example, molded product weight, molded product dimension, etc.) from the inspection machine which is not illustrated.

  The abnormality occurrence position specifying unit 102 stores the abnormality occurrence position of the molded product and the physical quantity acquired by the physical quantity acquisition unit 105 in the storage unit 104 as a set. FIG. 7 shows an example of data stored in the storage means by the molded product monitoring apparatus 100 of the present embodiment. Here, “Peak Pressure”, “Minimum Cushion Amount”, “Measuring Time” which are physical quantities, and the presence / absence of occurrence of abnormality for each grid area (OK = no abnormality, NG = abnormal) “Image (1, 1)” ”To“ image (10, 10) ”are stored in association with each other.

  According to the present embodiment, since the relationship between the physical quantity of the injection molding machine and the abnormality occurrence position is clarified, it is possible to further facilitate the countermeasure against molding defects. Specifically, a molding cycle in which a predetermined physical quantity exceeds a predetermined range and a molding cycle within a predetermined range are extracted from a set of abnormal positions and physical quantities of the molded product stored in the storage unit 104. The number of occurrences of abnormality and the frequency of occurrence of abnormality are calculated and stored for each abnormality occurrence position. Then, the molded product monitoring apparatus 100 displays the chart or graph indicating the number of occurrences of abnormality or the frequency of occurrence of abnormality in the molding cycle in which the predetermined physical quantity exceeds the predetermined range, and the number of occurrences of abnormality or the frequency of occurrence of abnormality in the molding cycle within the predetermined range. If the chart or graph shown is displayed side by side, it is possible to easily grasp how the abnormality occurrence position changes depending on whether or not the physical quantity is within a predetermined range.

  Note that the present invention is not limited to the above-described embodiment, and changes such as replacement, omission, addition, and rearrangement of constituent elements can be made without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 100 Molded article monitoring apparatus 101 Molded product image acquisition means 102 Abnormality generation position specification means 104 Storage means 105 Physical quantity acquisition means 106 Display means 107 Comparison means

Claims (11)

Molded product image acquisition means for acquiring an image of a molded product molded by an injection molding machine;
In the molded product monitoring device comprising: an abnormality occurrence position specifying means for determining whether or not there is an abnormality in the molded product based on the image, and specifying the abnormality occurrence position when there is an abnormality.
The molded product image acquisition means acquires the images of at least two or more molded products,
The abnormality occurrence position specifying means calculates at least one of the number of occurrences of abnormality and the frequency of occurrence of abnormality for each abnormality occurrence position,
A molded product monitoring apparatus, comprising: a comparison unit configured to generate a graph indicating the number of occurrences of abnormality or the frequency of occurrence of abnormality for each abnormality occurrence position in a plurality of different periods. The abnormality occurrence position specifying means displays , instead of the graph, a numerical value indicating the abnormality occurrence frequency or the abnormality occurrence frequency for each abnormality occurrence position on a plane indicating the abnormality occurrence position for each different period. The molded product monitoring apparatus according to claim 1, wherein the molded product monitoring device is displayed on a means. The abnormality occurrence position specifying means is a three-dimensional graph in a space including a plane indicating the abnormality occurrence position and an axis indicating the number of occurrences of abnormality or the frequency of occurrence of abnormality for each abnormality occurrence position for each different period. Is displayed on the display means. The molded article monitoring apparatus according to claim 1, wherein: The comparison means obtains a difference between the number of occurrences of abnormality or the frequency of occurrence of abnormality between the different periods instead of the graph for each abnormality occurrence position , and sets a numerical value indicating the difference on a plane indicating the abnormality occurrence position. The molded article monitoring apparatus according to claim 1, wherein the molded article monitoring apparatus displays the information on display means. The comparison means obtains a difference between the number of occurrences of abnormality or the frequency of occurrence of abnormality between the different periods for each abnormality occurrence position, and three-dimensionally in a space including a plane indicating the abnormality occurrence position and an axis indicating the difference The molded article monitoring apparatus according to claim 1, wherein a graph is displayed on the display means. The molded product monitoring apparatus according to claim 1, wherein the different period is a period in which a predetermined number of molding cycles is molded or a predetermined time. A physical quantity acquisition means for acquiring a physical quantity of the injection molding machine for each molding cycle;
The molded article monitoring apparatus according to claim 1, wherein the abnormality occurrence position specifying unit stores the physical quantity and the abnormality occurrence position in association with each other in a storage unit. Physical quantity acquisition means for acquiring the physical quantity of the molded product for each molding cycle;
The molded article monitoring apparatus according to claim 1, wherein the abnormality occurrence position specifying unit stores the physical quantity and the abnormality occurrence position in association with each other in a storage unit. The abnormality occurrence position specifying means is configured to calculate at least one of the abnormality occurrence frequency and the abnormality occurrence frequency for each abnormality occurrence position calculated when the physical quantity is within a predetermined range and outside the predetermined range, The molded article monitoring apparatus according to claim 7 or 8 , wherein the display means displays the case within a predetermined range and the case outside the predetermined range. The abnormality occurrence position specifying means stores in advance a reference molded product image that is a reference for determining abnormality of the molded product, and the molded product has an abnormality by comparing the reference molded product image with the image. The molded article monitoring apparatus according to claim 1, wherein it is determined whether or not. The molded product monitoring apparatus according to claim 10, wherein the reference molded product image is acquired in advance by the molded product image acquisition unit.