JP6993170B2 - Mold monitoring device and mold monitoring method - Google Patents

Description

The present invention relates to a mold monitoring device and a mold monitoring method.

Generally, in a resin molding machine for manufacturing a resin product, for example, an injection molding machine, a molding cycle consisting of a mold clamping operation, an injection operation, cooling / solidification of a resin material, a mold opening operation, and a molded product projecting operation is repeatedly performed. ..
For example, Patent Document 1 describes a mold monitoring device that captures an image of a movable mold surface at a position where a mold opening operation is completed and monitors the state of the movable mold surface in a process of manufacturing a resin product by an injection molding machine. It has been disclosed. The mold monitoring device compares the monitoring image data of the movable mold surface after the completion of the mold opening operation captured by the monitoring camera with the reference image data stored in advance. As a result, in the mold monitoring device, when the mold opening operation is performed, the molded product is not held in the molding area of the movable mold surface, but is held in the fixed mold, for example, or from the molding area of the movable mold surface. Detects malfunctions such as falling off and adhering to other areas.

Japanese Patent No. 4448869

However, in the monitoring operation after the completion of the mold opening operation, it is possible to appropriately determine whether or not the molded product is held on the mold surface of the movable mold, but it is possible to detect a slight defect or deformation of the molded product. It is difficult. Therefore, if an operation abnormality occurs in which a part of the molded product remains in the fixed mold during the mold opening operation, the operation abnormality cannot be detected appropriately, and the operation of the injection molding machine is continued as it is. There is a risk that it will end up. In this case, in the mold clamping operation of the injection molding machine, the fixed mold surface or the movable mold surface may be damaged by the remaining molded product.
Therefore, it is an object of the present invention to provide a mold monitoring device and a mold monitoring method capable of appropriately detecting abnormalities generated in the process of molding in a resin molding machine.

In order to solve the above problems, one aspect of the mold monitoring device according to the present invention includes a first image acquisition unit that acquires an image of a molded product in a state where the mold of the resin molding machine is in the middle of opening operation, and the above -mentioned. A second image acquisition unit that acquires an image of the mold surface of the mold after the mold opening operation of the resin molding machine is completed, and a second image that stores a reference image related to the reference posture of the molded product in the middle of the mold opening operation. 1 storage unit, a second storage unit that stores a reference image related to the mold surface of the mold after the mold opening operation of the resin molding machine is completed, and an image acquired by the first image acquisition unit. , Acquired by the first determination unit and the second image acquisition unit, which determines whether or not an abnormality has occurred in the mold opening operation intermediate state by comparing with the reference image stored in the first storage unit. A second determination unit for determining the presence or absence of an abnormality after the completion of the mold opening operation by comparing the image with the reference image stored in the second storage unit, and the first determination. When it is determined by the unit that no abnormality has occurred during the mold opening operation, a permission command for the mold opening operation is output to the resin molding machine, and after the permission command is output, the second It is provided with a control unit that controls the determination by the determination unit .

As described above, since the mold monitoring device monitors the state of the molded product in the middle of the mold opening operation, it is possible to appropriately determine the molded product that causes defects such as defects and deformation due to the mold opening operation. If the molded product is defective due to the mold opening operation, the defective portion may remain in the mold. The mold monitoring device can appropriately detect the above-mentioned operation abnormality that occurs in the process of molding in the resin molding machine. Further, in the mold monitoring device, when the resin molding machine performs the mold opening operation, the molded product is not held in the molding area of the movable mold surface, for example, it is held in the fixed mold or the movable mold surface. It is possible to appropriately detect an operation abnormality such as falling off from the molding area of the above and adhering to another area.

Further, in the mold monitoring device, the first image acquisition unit is an image of a state in which the molded product is held by the movable mold and the fixed mold constituting the mold while the mold opening operation is in progress. May be obtained. In this case, it is possible to appropriately detect an operation abnormality that occurs in the process of mold opening operation.

Further, in the mold monitoring device, in the first determination unit, the posture of the molded product in the middle of the mold opening operation is relative to the reference posture based on the image acquired by the first image acquisition unit. It may be monitored whether or not the tilt exceeds the permissible range.
When the posture of the molded product in the middle of the mold opening operation is tilted beyond the allowable range with respect to the reference posture, defects such as defects and deformation are likely to occur in the molded product due to the mold opening operation. By monitoring the posture of the molded product in the middle of the mold opening operation, it is possible to appropriately identify the molded product that causes defects such as defects and deformation due to the mold opening operation.

Further, in the mold monitoring device, the first image acquisition unit acquires images of the molded product captured at a plurality of different timings in the middle of the mold opening operation, and the first determination unit. May determine whether or not an abnormality has occurred in the mold opening operation halfway state for each of the plurality of images acquired by the first image acquisition unit.
In this way, by monitoring a plurality of times during the mold opening operation, it is possible to more appropriately detect an operation abnormality that occurs in the mold opening operation process.

Further, in the mold monitoring device , the first image acquisition unit and the second image acquisition unit are each of the molded product by a monitoring camera fixed at a predetermined position with respect to the resin molding machine. An image and an image of the mold surface of the mold may be acquired .
In this case, for example, by using an image captured by a surveillance camera fixed above the resin molding machine, it is possible to appropriately monitor the state during the mold opening operation and the presence or absence of an abnormality after the mold opening operation is completed . Further , by using a fixed surveillance camera, a mechanism or a structure for moving the surveillance camera becomes unnecessary.

Further, in the mold monitoring device, when the first determination unit determines that an abnormality has occurred in the mold opening operation intermediate state, or the second determination unit completes the mold opening operation. If it is determined that an abnormality has occurred later, an operation control unit that controls the operation of the resin molding machine to be stopped may be further provided.
In this case, if the molded product unintentionally remains in the molding area of the injection molding machine due to an operation abnormality that occurs in the molding process of the resin molding machine, the operation of the resin molding machine is continued as it is. Can be prevented. Therefore, it is possible to prevent the mold and the like from being damaged by the remaining molded product when the mold clamping operation is performed in the resin molding machine.

Further, the mold monitoring device includes a third image acquisition unit that acquires an image of the mold surface of the mold after the molded product projecting operation of the resin molding machine is completed, and the molded product projecting operation of the resin molding machine. A third storage unit that stores a reference image related to the mold surface of the mold after completion, an image acquired by the third image acquisition unit , and a reference image stored in the third storage unit. A third determination unit for determining the presence or absence of an abnormality after the completion of the molded product projecting operation is further provided, and the control unit is provided with an abnormality after the completion of the mold opening operation by the second determination unit. If it is determined that this is not the case, a command for permitting the protrusion of the molded product is output to the resin molding machine, and after the command for permitting the protrusion of the molded product is output, the third determination unit makes a determination. You may control it.
In this case, the mold monitoring device keeps the molded product held on the movable mold surface without being released from the movable mold surface when the resin molding machine performs the molded product projecting operation. Operation abnormalities can be detected appropriately.

Further, one aspect of the mold monitoring method according to the present invention includes a first image acquisition step of acquiring an image of a molded product in a state where the mold of the resin molding machine is in the middle of opening operation, and a mold opening of the resin molding machine. The second image acquisition step of acquiring the image of the mold surface of the mold after the operation is completed, the image acquired in the first image acquisition step, and the pre-stored state in the middle of the mold opening operation. The first determination step of determining the presence or absence of an abnormality in the mold opening operation intermediate state by comparing with the reference image related to the reference posture of the molded product, and the mold opening operation intermediate state in the first determination step. When it is determined that no abnormality has occurred in the above, the control step of outputting the permission command for the full-open operation of the mold to the resin molding machine, and the second after the permission command is output in the control step. A second determination step of determining whether or not an abnormality has occurred after the completion of the mold opening operation by comparing the image acquired by the image acquisition unit of the above with the reference image stored in the second storage unit. , Including.
Further, one aspect of the mold monitoring device according to the present invention is an image acquisition unit that acquires an image of a molded product in the middle of the mold opening operation of the resin molding machine, and the molded product in the middle of the mold opening operation. The storage unit that stores the reference image related to the reference posture of the above, the image acquired by the image acquisition unit, and the reference image stored in the storage unit are compared, and the degree of matching between the two images is determined. The abnormality monitoring unit is provided with an abnormality monitoring unit that monitors the presence or absence of an abnormality in the mold opening operation intermediate state, and the abnormality monitoring unit exceeds the permissible range of the posture of the molded product in the mold opening operation intermediate state with respect to the reference posture. If it is tilted, it is determined that an abnormality has occurred during the mold opening operation.
Further, one aspect of the mold monitoring method according to the present invention is a pre-stored acquisition step of acquiring an image of a molded product in a state where the mold of the resin molding machine is in the middle of opening operation, and the acquired image. A monitoring step for monitoring the presence or absence of an abnormality in the mold opening operation state by comparing with the reference image related to the reference posture of the molded product and determining the degree of coincidence between the two images. In the monitoring step, when the posture of the molded product in the mold opening operation intermediate state is tilted beyond the allowable range with respect to the reference posture, an abnormality occurs in the mold opening operation intermediate state. It is determined that there is.
This makes it possible to appropriately detect abnormalities that occur in the process of molding in the resin molding machine.

According to the present invention, since the state of the molded product is monitored during the mold opening operation, it is possible to appropriately detect an abnormality that occurs in the molding process in the resin molding machine, which cannot be detected by monitoring after the mold opening operation is completed. Can be done.

It is a figure which shows the configuration example of the mold monitoring apparatus in this embodiment. It is a figure which shows the mold clamping state of a mold. It is a figure which shows the mold opening operation of a mold. It is a figure which shows the molded product protrusion operation. It is a figure which shows the taking-out state of a molded product. It is a block diagram which shows the hardware composition of the mold monitoring apparatus. It is a figure explaining the flow of a monitoring operation. It is a flowchart for demonstrating the monitoring operation of the mold monitoring apparatus. It is a figure explaining the primary monitoring operation. It is a time chart which shows the input / output of a signal in a mold monitoring device.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
FIG. 1 is an explanatory diagram showing the configuration of the mold monitoring device 100 in the present embodiment together with the configuration of the injection molding machine 200.
The injection molding machine 200 is a resin molding machine that manufactures a resin molded product. The injection molding machine 200 includes a mold 10. The mold 10 is composed of a fixed mold 11 and a movable mold 12, which are in a male-female relationship with each other. Further, the injection molding machine 200 includes an injection unit 20 that melts and injects a resin material, and a mold drive unit 30 that opens and compacts the mold 10. The injection unit 20 and the mold drive unit 30 are driven and controlled by the control unit 40.

The injection unit 20 includes a cylindrical cylinder 21 provided with a heater (not shown) on the outer peripheral surface thereof, and a nozzle 22 fixed to the tip end (left end in FIG. 1) of the cylinder 21. A supply port (not shown) for supplying a resin material is formed in the rear end portion of the cylinder 21. A hopper 23 into which the resin material is charged is arranged at a position on the outer peripheral surface of the cylinder 21 where the supply port is located. Further, in the cylinder 21, a screw (not shown) for kneading the resin material is arranged so as to be able to move forward and backward along the axial direction of the cylinder 21. The base end portion of the screw is attached to the screw drive mechanism 24.

The injection unit 20 retreats the screw in the cylinder 21 while rotating it to melt the resin material charged in the hopper 23 and supply the molten resin material from the rear end to the front end of the cylinder 21. Fill the inside of the front end of the cylinder 21. In this state, the injection unit 20 advances the screw in the cylinder 21. As a result, the molten resin material filled inside the front end portion of the cylinder 21 is ejected from the nozzle 22.

The mold drive unit 30 includes a fixed platen 31 to which the fixed mold 11 is fixed and a movable platen 32 to which the movable mold 12 is fixed. The fixed platen 31 and the movable platen 32 are arranged so as to face each other in the horizontal direction.
A plurality of tie bars 33 for horizontally guiding the movable platen 32 are provided between the fixed platen 31 and the movable platen 32. Further, the movable platen 32 is connected to the mold clamping mechanism 34.

The mold driving unit 30 moves (advances) the movable platen 32 to which the movable mold 12 is fixed by the mold clamping mechanism 34 in a direction toward the fixed platen 31 along the tie bar 33, thereby performing a mold clamping operation. I do. Further, the mold driving unit 30 moves (retracts) the movable platen 32 to which the movable mold 12 is fixed by the mold clamping mechanism 34 in a direction away from the fixed platen 31 along the tie bar 33. Perform the open operation.

The injection molding machine 200 may be configured to be able to switch between automatic operation, semi-automatic operation, and manual operation. In the automatic operation, the injection molding machine 200 repeatedly executes a molding cycle including a mold clamping operation, an injection operation, cooling / solidification of a resin material, a mold opening operation, and a molded product projecting operation.
Specifically, the injection molding machine 200 performs a mold clamping operation by advancing the movable platen 32 by the mold driving unit 30. As a result, as shown in FIG. 2, the mold surface of the movable mold 12 is pressed against the mold surface of the fixed mold 11, and as a result, a molding space is formed in the mold 10. In the mold clamping state shown in FIG. 2, the injection molding machine 200 performs an injection operation by the injection unit 20. As a result, the molten resin material is filled in the molding space inside the mold 10. The resin material injected and injected into the mold 10 is cooled for a certain period of time to solidify. After the resin material is solidified, the injection molding machine 200 performs a mold opening operation by retracting the movable platen 32 by the mold driving unit 30. At this time, in the normal state, as shown in FIG. 3, the molded product 60 is held in the molding area (the area forming the molding space) on the mold surface of the movable mold 12.

Next, the injection molding machine 200 performs a molded product projecting operation in which the projecting pin 35 shown in FIG. 5 is projected from the mold surface of the movable mold 12 in the mold opening state shown in FIG. 4 when the mold opening operation is completed. As a result, the molded product 60 is projected from the mold surface of the movable mold 12 as shown in FIG. The molded product 60 is released from the movable mold 12 as shown in FIG. 5 by automatic dropping or taking out by a take-out machine such as a robot.
After the molded product 60 is taken out, the injection molding machine 200 returns the protruding pin 35 to the original position where it does not protrude from the mold surface of the movable mold 12, and advances the movable platen 32 by the mold driving unit 30 to remold the mold. Perform the tightening operation.

Returning to FIG. 1, the mold monitoring device 100 monitors the state of the mold surface of the mold 10 in the injection molding machine 200 and the state of the molded product 60 held in the molding area of the mold 10.
The mold monitoring device 100 monitors the presence or absence of an abnormality related to molding based on the monitoring camera 110 that captures the mold surface and the molding area of the movable mold 12 and the image captured by the monitoring camera 110, and is an injection molding machine. A monitoring control unit 120 that controls the operation of the 200 is provided.
The surveillance camera 110 is fixed above the injection molding machine 200, more specifically above the fixed mold 11. The surveillance camera 110 is configured to be capable of capturing a plurality of images (videos) continuously captured in time series. Here, the installation position, the imaging direction, and the imaging angle of view of the surveillance camera 110 are preset so that the mold surface and the molding area of the movable type 12 to be monitored can be imaged.

FIG. 6 is a block diagram showing a hardware configuration of the mold monitoring device 100.
As shown in FIG. 6, the monitoring control unit 120 operates the central control unit 121, the ROM 122, the RAM 123, the image acquisition unit 124, the image data processing unit 125, the storage unit 126, and the display unit 127. A unit 128 is provided.
The central control unit 121 is a CPU that comprehensively controls the operation of the monitoring control unit 120, and controls each component of the monitoring control unit 120 via a bus. The ROM 122 is a non-volatile memory for storing a control program or the like necessary for the central control unit 121 to execute a process. The RAM 123 functions as a main memory, a work area, etc. of the central control unit 121. That is, the central control unit 121 loads a program or the like required from the ROM 122 into the RAM 123 when executing the process, and executes the program or the like to realize various functional operations.

The image acquisition unit 124 acquires an image from the surveillance camera 110. The image data processing unit 125 processes the image acquired by the image acquisition unit 124, stores the processed image in the storage unit 126, and displays the processed image on the display unit 127. The image data processing unit 125 also functions as an abnormality monitoring unit that performs a monitoring operation for monitoring the presence or absence of an abnormality related to molding based on the image acquired by the image acquisition unit 124.
The image data processing unit 125 outputs the result of the monitoring operation to the central control unit 121, and the central control unit 121 controls the operation of the injection molding machine 200 based on the result of the monitoring operation input from the image data processing unit 125. do. That is, the central control unit 121 also functions as an operation control unit that controls to stop the operation of the injection molding machine 200 when it is determined by the monitoring operation by the image data processing unit 125 that there is an abnormality.
The operation unit 128 inputs an operator's operation to the mold monitoring device 100.

In the present embodiment, the mold monitoring device 100 is used three times between the time when the mold 10 starts the mold opening operation in the injection molding machine 200 and the time when the molded product 60 is taken out and the mold clamping operation is started. Perform monitoring operation.
Specifically, as shown in FIG. 7, the mold monitoring device 100 is in a state between the start of the mold opening operation and the mold opening operation state (during the mold opening operation). , Performs a primary monitoring operation for monitoring the state of the molded product held in the molding area of the mold 10. Further, the mold monitoring device 100 performs a secondary monitoring operation for monitoring the mold surface of the movable mold 12 in the mold opening state after the mold opening operation is completed. Further, the mold monitoring device 100 performs a tertiary monitoring operation for monitoring the mold surface of the movable mold 12 in a state where the molded product is projected and the molded product is taken out.
In each monitoring operation, the mold monitoring device 100 compares the monitoring image captured by the monitoring camera 110 with the reference image stored in advance, and determines whether or not an abnormality has occurred based on the degree of matching between the two images. .. The reference image is stored in advance in the storage unit 126 of FIG. 6, for example.

Hereinafter, the monitoring operation executed by the mold monitoring device 100 will be specifically described.
FIG. 8 is a flowchart for explaining the monitoring operation executed by the mold monitoring device 100.
First, in S1, the mold monitoring device 100 determines whether or not a primary monitoring trigger signal has been input. Here, the primary monitoring trigger signal is a mold opening start signal indicating that the mold opening operation has been started in the injection molding machine 200, and is input from the injection molding machine 200. In this S1, the mold monitoring device 100 waits until the primary monitoring trigger signal is input, and then shifts to S2 when the primary monitoring trigger signal is input.

In S2, the mold monitoring device 100 acquires the image captured by the monitoring camera 110 as the primary monitoring image data. Here, the primary monitoring image data is the data of the monitoring image obtained by capturing the molding area on the mold surface of the mold 10 in the middle of the mold opening operation. Specifically, the primary monitoring image data is image data in a state where the molded product 60 is held in the movable mold 12 and the fixed mold 11 of the injection molding machine 200 in the middle of the mold opening operation.
The mold monitoring device 100 is, for example, a plurality of images captured by the monitoring camera 110 from the input of the primary monitoring trigger signal (mold opening start signal) to the elapse of the monitoring time T1 set in advance in the timer. The image can be acquired as primary surveillance image data. The number of primary surveillance image data can be set arbitrarily. For example, the mold monitoring device 100 uses a single image captured by the monitoring camera 110 as primary monitoring image data after a predetermined time has elapsed since the primary monitoring trigger signal (mold opening start signal) was input. You may get it.

In S3, the mold monitoring device 100 performs a primary monitoring operation based on the primary monitoring image data acquired in S2. In the primary monitoring operation, the mold monitoring device 100 compares the primary monitoring image data acquired in S2 with the primary reference image data stored in the storage unit 126 of FIG.
Here, the primary reference image data is image data obtained by imaging the molded product 60 in the molding area in the normal state in the middle of the mold opening operation of the injection molding machine 200. This primary reference image data is an image obtained by taking an image of a molded product 60 held by a fixed mold 11 and a movable mold 12 which are separated from each other in a state during the mold opening operation. The primary reference image data can be an image of a molded product taken in the middle of the mold opening operation of the molding process in which a good product is molded, among the molding processes executed in advance by the injection molding machine 200.

The primary reference image data includes position data and brightness data for each of a plurality of pixels (for example, 640 pixels × 480 pixels) constituting the image from the surveillance camera 110. In this luminance data, the luminance of each pixel is shown by a relative value by an integer of 0 to 255, for example.
In the primary monitoring operation, the mold monitoring device 100 has all the differences between each of the luminance data in the primary surveillance image data and each of the luminance data in the primary reference image data within a preset allowable range. Judge whether or not. Then, the mold monitoring device 100 determines that the primary monitoring image data and the primary reference image data match when all of the above differences are within the allowable range. On the other hand, the mold monitoring device 100 determines that the primary monitoring image data and the primary reference image data are different when at least one of the above differences is out of the permissible range.

For example, as shown in FIG. 9, when the posture of the molded product 60 in the middle of the mold opening operation is tilted with respect to the reference posture 61 shown by the broken line and the tilt amount exceeds the allowable range, the mold is formed. The monitoring device 100 can determine that the primary monitoring image data and the primary reference image data are different from each other.
As described above, when the posture of the molded product 60 is tilted beyond the allowable range with respect to the reference posture 61 during the mold opening operation, the tip portion of the molded product 60 is tilted from the fixed mold 11 during the mold opening operation. It does not separate, and an operation abnormality occurs such that a part of the molded product 60 remains in the fixed mold 11. Then, when the operation of the injection molding machine 200 is continued in a state where such an operation abnormality occurs and the injection molding machine 200 performs the mold clamping operation, a part of the remaining molded product 60 causes the mold surface of the fixed mold 11 to be formed. The mold surface of the movable mold 12 may be damaged. The mold monitoring device 100 can appropriately monitor the presence or absence of the above-mentioned operation abnormality by the primary monitoring operation in the middle of the mold opening operation.

Returning to FIG. 8, the mold monitoring device 100 determines the result of the primary monitoring operation in S4, determines that the operation of the injection molding machine 200 will be continued if there is no abnormality, and shifts to S5. If it is determined that there is an abnormality, the process proceeds to S16.
In S5, the mold monitoring device 100 outputs a mold fully open operation permission command indicating that the movable mold 12 may be in the mold open state to the injection molding machine 200. As a result, the injection molding machine 200 continues the mold opening operation.

In S6, the mold monitoring device 100 determines whether or not a secondary monitoring trigger signal has been input. Here, the secondary monitoring trigger signal is a mold opening signal indicating that the mold opening operation has been completed in the injection molding machine 200 and the movable mold 12 has reached the mold opening position, and is input from the injection molding machine 200. To. In this S6, the mold monitoring device 100 waits until the secondary monitoring trigger signal is input, and when the secondary monitoring trigger signal is input, the process proceeds to S7.

In S7, the mold monitoring device 100 acquires the image captured by the monitoring camera 110 as secondary monitoring image data. Here, the secondary monitoring image data is the data of the monitoring image obtained by capturing the mold surface of the movable mold 12 in the mold open state.
The mold monitoring device 100 secondarily captures an image captured by the monitoring camera 110 after the standby time T2 set in advance in the timer has elapsed after the secondary monitoring trigger signal (mold opening signal) is input. It can be acquired as surveillance image data. The mold monitoring device 100 acquires a plurality of images captured by the monitoring camera 110 as secondary monitoring image data during a predetermined period after the secondary monitoring trigger signal (mold opening signal) is input. May be good.

In S8, the mold monitoring device 100 performs a secondary monitoring operation based on the secondary monitoring image data acquired in S7. In the secondary monitoring operation, the mold monitoring device 100 compares the secondary monitoring image data acquired in S7 with the secondary reference image data stored in the storage unit 126 of FIG.
Here, the secondary reference image data is image data obtained by imaging the mold surface of the movable mold 12 in a normal state after the mold opening operation of the injection molding machine 200 is completed. This secondary reference image data is image data obtained by imaging the mold surface of the movable mold 12 in which the molded product 60 is held after the mold opening operation is completed. The secondary reference image data may be an image of the mold surface of the movable mold 12 taken after the mold opening operation of the molding process in which a good product is molded is completed among the molding processes executed in advance by the injection molding machine 200. can.

The secondary reference image data includes position data and brightness data for each of a plurality of pixels (for example, 640 pixels × 480 pixels) constituting the image from the surveillance camera 110. In this luminance data, the luminance of each pixel is shown by a relative value by an integer of 0 to 255, for example.
In the secondary monitoring operation, the mold monitoring device 100 has all the differences between each of the luminance data in the secondary surveillance image data and each of the luminance data in the secondary reference image data within a preset allowable range. Judge whether or not. Then, the mold monitoring device 100 determines that the secondary monitoring image data and the secondary reference image data match when all of the above differences are within the allowable range. On the other hand, the mold monitoring device 100 determines that the secondary monitoring image data and the secondary reference image data are different when at least one of the above differences is out of the allowable range.

For example, when the molded product 60 is not held in the molding area of the mold surface of the movable mold 12 in the mold open state, the mold monitoring device 100 determines that the secondary monitoring image data and the secondary reference image data are different. can do.
As described above, when the molded product 60 is not held in the molding area of the mold surface of the movable mold 12 in the mold open state, the molded product 60 is held by the fixed mold 11 or the mold surface of the movable mold 12. It is considered that there is an operation abnormality such as falling off from the molding area of No. 1 and adhering to other areas. Then, the operation of the injection molding machine 200 is continued in a state where such an operation abnormality occurs, and when the injection molding machine 200 performs the mold clamping operation, the mold surface of the fixed mold 11 and the movable mold 12 are formed by the remaining molded product 60. There is a risk of damage to the mold surface. The mold monitoring device 100 can appropriately monitor the presence or absence of the above-mentioned operation abnormality by the secondary monitoring operation in the mold open state.

In S9, the mold monitoring device 100 determines the result of the secondary monitoring operation, determines that the operation of the injection molding machine 200 is continued if there is no abnormality, shifts to S10, and determines that there is an abnormality. Will move to S16.
In S10, the mold monitoring device 100 outputs a molded product protrusion permission command indicating that the molded product protrusion operation may be started to the injection molding machine 200. As a result, the injection molding machine 200 starts the molded product projecting operation.

In S11, the mold monitoring device 100 determines whether or not a tertiary monitoring trigger signal has been input. Here, the tertiary monitoring trigger signal is an eject completion signal indicating that the molded product projecting operation is completed in the injection molding machine 200, and is input from the injection molding machine 200. In this S11, the mold monitoring device 100 waits until the tertiary monitoring trigger signal is input, and then shifts to S12 when the tertiary monitoring trigger signal is input.

In S12, the mold monitoring device 100 acquires the image captured by the monitoring camera 110 as the tertiary monitoring image data. Here, the tertiary monitoring image data is data of a monitoring image obtained by capturing the mold surface of the movable mold 12 in a state where the molded product projecting operation is completed.
For example, the mold monitoring device 100 performs tertiary monitoring of an image captured by the monitoring camera 110 after the standby time T3 set in advance in the timer has elapsed after the tertiary monitoring trigger signal (eject completion signal) is input. It can be acquired as image data. Even if the mold monitoring device 100 acquires a plurality of images captured by the monitoring camera 110 as tertiary monitoring image data during a predetermined period after the tertiary monitoring trigger signal (eject completion signal) is input. good.

In S13, the mold monitoring device 100 performs a tertiary monitoring operation based on the tertiary monitoring image data acquired in S12. In the tertiary monitoring operation, the mold monitoring device 100 compares the tertiary monitoring image data acquired in S12 with the tertiary reference image data stored in the storage unit 126 of FIG.
Here, the tertiary reference image data is image data obtained by imaging the mold surface of the movable mold 12 in a normal state after the molded product projecting operation of the injection molding machine 200 is completed. This tertiary reference image data is image data obtained by imaging the mold surface of the movable mold 12 in a state where the molded product 60 is released after the molded product projecting operation is completed. The tertiary reference image data shall be an image of the mold surface of the movable mold 12 taken after the completion of the molded product projecting operation of the molding process in which the non-defective product is molded, among the molding processes executed in advance by the injection molding machine 200. Can be done.

The tertiary reference image data includes position data and brightness data for each of a plurality of pixels (for example, 640 pixels × 480 pixels) constituting the image from the surveillance camera 110. In this luminance data, the luminance of each pixel is shown by a relative value by an integer of 0 to 255, for example.
In the tertiary monitoring operation, the mold monitoring device 100 has all the differences between each of the luminance data in the tertiary surveillance image data and each of the luminance data in the tertiary reference image data within a preset allowable range. Judge whether or not. Then, the mold monitoring device 100 determines that the tertiary monitoring image data and the tertiary reference image data match when all of the above differences are within the allowable range. On the other hand, the mold monitoring device 100 determines that the tertiary monitoring image data and the tertiary reference image data are different when at least one of the above differences is out of the permissible range.

For example, when the molded product 60 is still held in the molding area of the mold surface of the movable mold 12 in the state where the molded product projecting operation is completed, the mold monitoring device 100 uses the tertiary monitoring image data and the tertiary reference image. It can be determined that the data is different.
As described above, when the molded product 60 is held in the molding area of the mold surface of the movable mold 12 in the state where the molded product projecting operation is completed, the molded product 60 is not released from the mold surface of the movable mold 12. It is considered that such an operation abnormality has occurred. Then, the operation of the injection molding machine 200 is continued in a state where such an operation abnormality occurs, and when the injection molding machine 200 performs the mold clamping operation, the mold surface of the fixed mold 11 and the movable mold 12 are formed by the remaining molded product 60. There is a risk of damage to the mold surface. The mold monitoring device 100 can appropriately monitor the presence or absence of the above-mentioned operation abnormality by the tertiary monitoring operation in the state where the molded product projecting operation is completed.

In S14, the mold monitoring device 100 determines the result of the tertiary monitoring operation, determines that the operation of the injection molding machine 200 is continued if there is no abnormality, shifts to S15, and determines that there is an abnormality. Will shift to S16.
In S15, the mold monitoring device 100 outputs a mold clamping operation permission command indicating that the mold clamping operation may be started to the injection molding machine 200. As a result, the injection molding machine 200 starts the mold clamping operation.

In S16, the mold monitoring device 100 outputs an abnormality occurrence signal indicating that an abnormality has been detected in any of the primary monitoring operation, the secondary monitoring operation, and the tertiary monitoring operation to the injection molding machine 200. By doing so, the operation of the injection molding machine 200 is instructed to be stopped. Next, in S17, the mold monitoring device 100 operates an alarm device (not shown) or the like to notify the operator that an operation abnormality has occurred in the injection molding machine 200.

FIG. 10 is a time chart showing input / output of signals in the mold monitoring device 100. In FIGS. 10, (a) to (c) are input signals of the mold monitoring device 100, and (d) to (g) are output signals of the mold monitoring device 100.
When the mold opening start signal is input from the injection molding machine 200 (primary monitoring trigger signal ON), the mold monitoring device 100 operates a timer and performs a primary monitoring operation until a predetermined monitoring time T1 elapses. Execute. Then, when the mold monitoring device 100 determines that the primary monitoring operation is normal, that is, the posture of the molded product 60 in the middle of the mold opening operation matches the reference posture, the injection molding machine 200 is determined. Outputs the mold fully open operation permission command (mold fully open permission ON).

After that, when the mold 10 is in the mold open state in the injection molding machine 200 and the mold monitoring device 100 inputs the mold opening signal from the injection molding machine 200 (secondary monitoring trigger signal ON), the mold monitoring device 100 Activates a timer and executes a secondary monitoring operation after a predetermined standby time T2 has elapsed. Then, when the mold monitoring device 100 determines that the secondary monitoring operation is normal, that is, the state of the mold surface of the movable mold 12 in the mold opening state matches the reference state, the injection molding machine 200 A molded product protrusion permission command is output to the product (molded product protrusion permission ON).

After that, a molded product projecting operation is executed in the injection molding machine 200, and when the mold monitoring device 100 inputs an eject completion signal from the injection molding machine 200 (third monitoring trigger signal ON), the mold monitoring device 100 has a timer. Is activated, and the tertiary monitoring operation is executed after the predetermined standby time T3 has elapsed. Then, when the mold monitoring device 100 determines that the tertiary monitoring operation is normal, that is, the state of the mold surface of the movable mold 12 in the state where the molded product projecting operation is completed matches the reference state. A mold clamping operation permission command is output to the injection molding machine 200 (mold clamping permission ON).

At this time, the mold monitoring device 100 resets the input state of the input signals (primary monitoring trigger signal, secondary monitoring trigger signal and tertiary monitoring trigger signal) from the injection molding machine 200, and at the same time, sends the injection molding machine 200 to the injection molding machine 200. The output states of the output signals (molded product protrusion permission command and mold fully open operation permission command) are reset (each signal is OFF).
Upon receiving the mold clamping operation permission command from the mold monitoring device 100, the injection molding machine 200 executes the mold clamping operation, the injection operation, and the cooling / solidification of the resin material in this order. Then, when the resin material is solidified, the injection molding machine 200 outputs a mold opening start signal to the mold monitoring device 100 to start the mold opening operation. When the mold opening start signal is input from the injection molding machine 200, the mold monitoring device 100 operates a timer as described above, and executes a primary monitoring operation until a predetermined standby time T1 elapses.

At this time, as shown in FIG. 9, when the posture of the molded product 60 in the middle of the mold opening operation is inclined with respect to the reference posture 61 shown by the broken line, the mold monitoring device 100 performs this primary monitoring operation. It is determined that an abnormality has occurred in. Then, the mold monitoring device 100 outputs an abnormality generation signal to the injection molding machine 200 (abnormality generation ON), and the injection molding machine 200 that receives the abnormality generation signal stops the operation.

As described above, the mold monitoring device 100 in the present embodiment acquires an image (primary monitoring image data) of the molded product 60 in the middle of the mold opening operation of the mold 10 of the resin molding machine 200 from the monitoring camera 110. , Based on the acquired image, a primary monitoring operation is performed to monitor the presence or absence of an abnormality in the state during the mold opening operation. Specifically, the mold monitoring device 100 includes a storage unit 126 that stores a reference image (primary reference image data) related to the reference posture of the molded product 60 in the middle of the mold opening operation, and the primary monitoring image data. By comparing with the primary reference image data and determining the degree of matching between the two images, the presence or absence of an abnormality in the state during the mold opening operation is monitored.

In the secondary monitoring operation of monitoring the state of the mold surface of the mold 10 (movable mold 12) after the mold opening operation of the injection molding machine 200 is completed, whether or not the molded product 60 is properly held on the mold surface of the movable mold 12. It is difficult to detect a slight defect or deformation of the molded product 60. In the present embodiment, the mold monitoring device 100 executes the primary monitoring operation of monitoring the state of the molded product 60 in the middle of the mold opening operation before the secondary monitoring operation, so that the mold is defective or deformed due to the mold opening operation. It is possible to appropriately identify the molded product 60 that leads to such a defect.

Here, the image of the molded product 60 in the middle of the mold opening operation is an image of the state in which the molded product 60 is held by the movable mold 12 and the fixed mold 11 constituting the mold 10. Based on the image, the mold monitoring device 100 monitors whether or not the posture of the molded product 60 in the middle of the mold opening operation is tilted beyond the allowable range with respect to the reference posture 61.
Therefore, the mold monitoring device 100 can predict in advance a phenomenon in which a part of the molded product 60 is taken up by the fixed mold 11 due to the mold opening operation, and can determine that there is an abnormality. Further, since the mold monitoring device 100 determines the inclination of the molded product 60 while being held by the movable mold 12 and the fixed mold 11, it is possible to detect an abnormality with high accuracy.

Further, as shown in FIG. 1, the surveillance camera 110 is fixed above the injection molding machine 200 and at a position close to the fixed mold 11. Therefore, the distance from the surveillance camera 110 to the molded product 60 during the mold opening operation is shorter than the distance from the surveillance camera 100 to the mold surface of the movable mold 12 after the mold opening operation is completed. That is, the mold monitoring device 100 can perform the primary monitoring operation at a position closer to the monitoring target than the secondary monitoring operation. Therefore, the mold monitoring device 100 can appropriately detect even a slight inclination of the molded product 60.
Further, since the surveillance camera 110 is a fixed camera, no mechanism or structure for moving the surveillance camera 110 is required. Therefore, it is possible to avoid the increase in size and complexity of the device.

Then, the mold monitoring device 100 controls to stop the operation of the injection molding machine 200 when it is determined by the primary monitoring operation that there is an abnormality. As a result, the mold monitoring device 100 can prevent the injection molding machine 200 from being continued to operate with a part of the molded product 60 remaining in the molding area, and the mold clamping operation being performed. Therefore, it is possible to appropriately prevent the mold 10 and the like from being damaged by the remaining molded product 60 when the mold clamping operation is performed in the injection molding machine 200.

Further, in the primary monitoring operation, the mold monitoring device 100 acquires images of the molded product 60 captured at a plurality of different timings in the middle of the mold opening operation, and the acquired plurality of images are abnormal. Monitor the presence or absence of occurrence. Specifically, the mold monitoring device 100 continuously captures images of the molded product 60 from the monitoring camera 100 until a predetermined monitoring time T1 elapses after the mold opening operation is started in the injection molding machine 200. It is acquired, and the presence or absence of an abnormality is monitored for each of the acquired images.
As described above, the mold monitoring device 100 can detect an operation abnormality that occurs in the process of the mold opening operation with higher accuracy by performing monitoring a plurality of times in the state during the mold opening operation.

Further, the mold monitoring device 100 acquires an image of the mold surface of the mold 10 (movable mold 12) after the mold opening operation of the injection molding machine 200 is completed, and based on the acquired image, after the mold opening operation is completed. A secondary monitoring operation for monitoring the presence or absence of an abnormality in the above may be performed. Further, the mold monitoring device 100 acquires an image of the mold surface of the mold 10 (movable mold 12) after the molded product projecting operation of the injection molding machine 200 is completed, and based on the acquired image, the molded product projecting operation. A tertiary monitoring operation for monitoring the presence or absence of an abnormality after completion may be performed.

As described above, the mold monitoring device 100 monitors three times between the time when the mold 10 starts the mold opening operation in the injection molding machine 200 and the time when the molded product 60 is taken out and the mold clamping operation is started. The operation may be performed. This makes it possible to appropriately detect various abnormalities that occur in the process of molding in the injection molding machine 200. Further, the mold monitoring device 100 can perform the monitoring operation three times by using the monitoring image captured by the common monitoring camera 110. Therefore, it is not necessary to provide a detection mechanism corresponding to each of the three monitoring operations. Therefore, the number of parts can be reduced, and the size and complexity of the device can be avoided.

(Modification example)
In the above embodiment, a case where the mold monitoring device 100 outputs an abnormality generation signal to the injection molding machine 200 and stops the operation of the injection molding machine 200 when it is determined that there is an abnormality in each monitoring operation will be described. did. However, the operation when it is determined that there is an abnormality in each monitoring operation is not limited to the above. For example, the mold monitoring device 100 is configured to be capable of inputting a re-monitoring command by the operator after determining that there is an abnormality in the monitoring operation, stopping the injection molding machine 200, and notifying the operator of the abnormality. May be good. When the re-monitoring command is input, the mold monitoring device 100 can re-execute the monitoring operation determined to have an abnormality.

Further, in the above embodiment, the case where the mold monitoring device 100 includes the monitoring camera 110 has been described, but the monitoring camera 110 may not be included in the mold monitoring device 100. That is, the mold monitoring device 100 may be provided with means for acquiring an image captured by the monitoring camera 110.

Further, in the above embodiment, the case where the injection molding machine 200 is a horizontal molding machine has been described, but the injection molding machine 200 may be a vertical molding machine. Further, the resin molding machine monitored by the mold monitoring device 100 is not limited to the injection molding machine, and may be, for example, an insert molding machine.

10 ... mold, 11 ... fixed mold, 12 ... movable mold, 60 ... molded product, 100 ... mold monitoring device, 110 ... surveillance camera, 120 ... monitoring control unit, 121 ... central control unit, 124 ... image acquisition unit, 125 ... Image data processing unit, 126 ... Storage unit, 200 ... Injection molding machine

Claims (10)

A first image acquisition unit that acquires an image of a molded product during the mold opening operation of the resin molding machine, and
A second image acquisition unit that acquires an image of the mold surface of the mold after the mold opening operation of the resin molding machine is completed, and
A first storage unit that stores a reference image related to the reference posture of the molded product in the middle of the mold opening operation, and a first storage unit.
A second storage unit that stores a reference image related to the mold surface of the mold after the mold opening operation of the resin molding machine is completed, and a second storage unit.
A first method of determining whether or not an abnormality has occurred in the mold opening operation state by comparing the image acquired by the first image acquisition unit with the reference image stored in the first storage unit. Judgment unit and
A second method of determining whether or not an abnormality has occurred after the mold opening operation is completed by comparing the image acquired by the second image acquisition unit with the reference image stored in the second storage unit. Judgment unit and
When it is determined by the first determination unit that no abnormality has occurred during the mold opening operation, a permission command for the mold opening operation is output to the resin molding machine, and after the permission command is output. , A mold monitoring device including a control unit that controls the determination by the second determination unit . The first image acquisition unit is
The mold monitoring device according to claim 1, wherein an image of a state in which the molded product is held in a movable mold and a fixed mold constituting the mold is acquired in the middle of the mold opening operation. The first determination unit is
When the posture of the molded product in the middle of the mold opening operation is tilted beyond the allowable range with respect to the reference posture, it is determined that an abnormality has occurred in the middle of the mold opening operation. The mold monitoring device according to claim 1 or 2. The first image acquisition unit is
Images of the molded product taken at a plurality of different timings in the middle of the mold opening operation are acquired.
The first determination unit is
The invention according to any one of claims 1 to 3, wherein for each of the plurality of images acquired by the first image acquisition unit, it is determined whether or not an abnormality has occurred during the mold opening operation . Mold monitoring device. The first image acquisition unit and the second image acquisition unit each have an image of the molded product and an image of the mold surface of the mold by a monitoring camera fixed at a predetermined position with respect to the resin molding machine. The mold monitoring device according to any one of claims 1 to 4, wherein the mold monitoring device is obtained. When the first determination unit determines that an abnormality has occurred during the mold opening operation, or the second determination unit determines that an abnormality has occurred after the mold opening operation is completed. The mold monitoring device according to any one of claims 1 to 5, further comprising an operation control unit for controlling the operation of the resin molding machine to be stopped. A third image acquisition unit that acquires an image of the mold surface of the mold after the molded product projecting operation of the resin molding machine is completed, and
A third storage unit that stores a reference image related to the mold surface of the mold after the molded product projecting operation of the resin molding machine is completed, and a third storage unit.
A third determination for determining the presence or absence of an abnormality after the completion of the molded product projecting operation by comparing the image acquired by the third image acquisition unit with the reference image stored in the third storage unit. With more parts,
When the second determination unit determines that no abnormality has occurred after the mold opening operation is completed, the control unit outputs a permission command for projecting the molded product to the resin molding machine, and the control unit outputs the permission command for projecting the molded product. The mold monitoring device according to any one of claims 1 to 6 , wherein after the output of the permission command for projecting the molded product, the determination is controlled by the third determination unit . An image acquisition unit that acquires an image of a molded product during the mold opening operation of a resin molding machine, and an image acquisition unit.
A storage unit that stores a reference image related to the reference posture of the molded product in the middle of the mold opening operation, and a storage unit.
By comparing the image acquired by the image acquisition unit with the reference image stored in the storage unit and determining the degree of coincidence between the two images, the presence or absence of an abnormality in the state during the mold opening operation is monitored. Equipped with an abnormality monitoring unit
The abnormality monitoring unit determines that an abnormality has occurred in the mold opening operation halfway state when the posture of the molded product is tilted beyond the allowable range with respect to the reference posture. Mold monitoring device characterized by The first image acquisition step of acquiring an image of a molded product in the middle of the mold opening operation of the resin molding machine, and
A second image acquisition step of acquiring an image of the mold surface of the mold after the mold opening operation of the resin molding machine is completed, and
By comparing the image acquired in the first image acquisition step with the pre-stored reference image relating to the reference posture of the molded product in the mold opening operation intermediate state, an abnormality in the mold opening operation intermediate state is performed. The first determination step for determining the presence or absence of the occurrence of
In the first determination step, when it is determined that no abnormality has occurred in the mold opening operation intermediate state, a control step of outputting a mold full opening operation permission command to the resin molding machine and a control step.
After the permission command is output in the control step, the mold opening operation is completed by comparing the image acquired by the second image acquisition unit with the reference image stored in the second storage unit. A mold monitoring method comprising a second determination step of determining whether or not an abnormality has occurred later . The acquisition process to acquire an image of the molded product in the middle of the mold opening operation of the resin molding machine, and the acquisition process.
The acquired image is compared with the pre-stored reference image related to the reference posture of the molded product in the mold opening operation state, and the degree of coincidence between the two images is determined to be in the mold opening operation state. Including a monitoring process to monitor the presence or absence of abnormalities,
In the monitoring step, when the posture of the molded product in the middle of the mold opening operation is tilted beyond the allowable range with respect to the reference posture, it is determined that an abnormality has occurred in the middle of the mold opening operation. A mold monitoring method characterized by this.

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