JP7011288B2 - Mixing degree judgment method and mixing degree judgment device - Google Patents

Description

The present invention relates to a mixing degree determination method and a mixing degree determination device for determining the mixing degree of a mixed material composed of a material composed of a plurality of types of powders or granules (hereinafter referred to as "powder / granular material").

For example, in the pre-stage of manufacturing a resin molded product, a treatment of mixing a plurality of types of powders and granules such as resin pellets, master batches, pulverized materials, and additives may be performed. The conventional mixing process is described in, for example, Patent Document 1. In the apparatus of Patent Document 1, a plurality of powder or granular material raw materials are weighed and blended in a predetermined blending ratio.

In the mixing treatment of a plurality of types of powders and granules, even when they are mixed at a predetermined ratio as a whole, the local uniformity (hereinafter referred to as “mixing degree”) in the mixed material may be biased. For example, in the mixing process in the pre-stage of manufacturing a resin molded product, even when the masterbatch as a colorant is mixed with the colorless resin pellets at a predetermined ratio, the mixing degree of the masterbatch is locally biased and later. Color unevenness may occur during resin molding in the process. Therefore, before charging the mixed material into the resin molding machine in the post-process, by detecting and dealing with the local unevenness of the mixing degree of the powder or granular material in the mixed material, a problem occurs during the resin molding in the post-process. It is required to suppress this. For example, Patent Document 2 describes a device for measuring a mixed state of powder.

Japanese Unexamined Patent Publication No. 2015-0754020 Japanese Unexamined Patent Publication No. 6-300682

The measuring device of Patent Document 2 converts the RGB color signal at each dot of the image obtained by copying the powder with a color video camera into a numerical value, and compares the numerical values measured for each dot to obtain the powder. Measure the degree of mixing. However, the powder particles such as resin pellets, master batches, crushed materials, and additives used in the production of resin molded products each have a certain particle size or more, and the particles between the types of these powder particles The large difference in diameter complicates the image of the mixed material. Therefore, it is difficult to determine the degree of mixing from the analysis for each dot.

The present invention has been made in view of such circumstances, and the degree of mixing of a mixed material composed of a plurality of types of powders and granules, each having a certain particle size or more and having a large difference in particle size between types. And an object of the present invention is to provide a method and an apparatus capable of determining an abnormality in a degree of mixing.

The first invention of the present application is used for manufacturing a resin molded product, and is a mixing degree determination method for determining a mixing degree which is local uniformity in a mixed material composed of a plurality of types of powders and granules having different colors. The step of supplying the mixed material to a resin molding machine, which is a subsequent device, via a transport unit having at least a part of an observation window capable of photographing the inside, and b) the step of the step a). On the way, the mixed material passing through the inside of the transport unit in a direction perpendicular to the fixed optical axis is photographed from the direction of the optical axis at predetermined time intervals through the observation window. To obtain one or more captured images, and c) select at least one type of powder or granule from the plurality of types of powder or granule, and total the number of pixels having the color of the selected powder or granule. The step of calculating the value, d) the step of calculating the ratio of the calculation result of the step c) to the total value of the number of pixels included in the whole of the one or more captured images as the measured area ratio, and e. ) A step of determining whether or not the measured area ratio calculated in the step d) is within a predetermined range, or determining the mixing degree of the powder or granules based on the calculation result of the measured area ratio in the step d). And have.

The second invention of the present invention is the mixing degree determination method of the first invention, and in the step e), the measured area ratio is determined as a numerical value indicating the mixing degree of the selected powder or granular material.

The third invention of the present application is the mixing degree determination method of the first invention, and is selected for the total number of pixels included in the whole of the one or a plurality of captured images before the step e). The result of predicting the ratio occupied by the total value of the number of pixels having the color of the powder and granules is recorded as the predicted area ratio, and based on the result of comparing the predicted area ratio and the actually measured area ratio in the step e). Then, it is determined whether or not the measured area ratio is within a predetermined range.

The fourth invention of the present application is the mixing degree determination method of any one of the first to third inventions, and in the step e), it is determined whether or not the measured area ratio is within a predetermined range, and the above-mentioned When it is determined that the invention is not within the predetermined range, further f) the step of outputting the abnormality determination information indicating the abnormality of the value of the measured area ratio is executed.

The fifth invention of the present application is the mixing degree determination method of any one of the first to fourth inventions, and the area of the photographed image is such that 100 or more of the powder or granular materials are adjacent to each other on a plane. It has a flat area occupied by the powder or granular material when they are arranged side by side.

The sixth invention of the present application is the mixing degree determination method of any one of the first to fifth inventions, in which a plurality of the photographed images are acquired in the step b) and in the step c). The total value of the number of pixels having the color of the selected powder and granules is calculated for each captured image, and in the step d), the total number of pixels included in the entire captured image for each captured image is relative to the total value. , The ratio occupied by the calculation result of the step c) is calculated, and the average value of the calculated ratio over the plurality of captured images is calculated as the actually measured area ratio.

The seventh invention of the present application is the mixing degree determination method of the sixth invention, and is obtained by taking pictures at predetermined time intervals from the direction of the fixed optical axis calculated in g) the step d). Calculate the amount of change in the ratio of the calculation result of the step c) to the total number of pixels included in the entire captured image for each captured image over the plurality of captured images. When it is determined that the amount of change calculated in the step g) is not within a predetermined range, a step of outputting abnormality determination information indicating an abnormality in the amount of change in the measured area ratio is further executed. do.

The eighth invention of the present application is used for manufacturing a resin molded product, and is a mixing degree determination device for determining a mixing degree which is local uniformity in a mixed material composed of a plurality of types of powders and granules having different colors. A supply unit for supplying the mixed material to a resin molding machine, which is a subsequent device, via a transport unit having at least a part of an observation window capable of photographing the inside, and the inside of the transport unit . One or more captured images are acquired by photographing the mixed material passing in a direction perpendicular to the fixed optical axis through the observation window at predetermined time intervals from the direction of the optical axis. It has an image acquisition unit and an image analysis unit that analyzes the one or a plurality of captured images acquired by the image acquisition unit, and the image analysis unit is selected in advance from the plurality of types of powder or granular material. The total value of the number of pixels having the color of the specific type of the powder or granular material is calculated as the first total value, and the second total value is the total value of the number of pixels included in the whole of the one or a plurality of captured images. , The ratio occupied by the first total value is calculated as an actually measured area ratio, it is determined whether or not the actually measured area ratio is within a predetermined range, or the degree of mixing of the powder or granular material is based on the calculation result of the actually measured area ratio. Is determined.

A ninth aspect of the present invention is the mixing degree determination device of the eighth invention, in which the observation window is fitted into a through hole provided in at least a part of the transport portion and communicating with the inside and the outside of the transport portion. A transparent or translucent plate that is combined or covers the through hole.

The tenth invention of the present invention is the mixing degree determination device of the eighth invention or the ninth invention, the image acquisition unit is a camera having a lens and an image pickup element, and the observation window is the image acquisition unit. It spreads perpendicularly to the optical axis and in a plane.

The eleventh invention of the present application is the mixing degree determination device of the eighth invention or the ninth invention, the image acquisition unit is a camera having a lens and an image pickup element, and the observation window is the image acquisition unit. It spreads like a curved surface with respect to the surface perpendicular to the optical axis.

According to the first to eleventh inventions of the present application, the mixing degree of a plurality of types of powders and granules supplied to a subsequent apparatus is determined, or whether or not the mixing degree is within a predetermined range is determined in-line and in real time. be able to. This makes it possible to suppress problems in subsequent devices (injection molding machines, etc.).

In particular, according to the fourth invention of the present application, the abnormality of the mixing degree value can be immediately recognized.

In particular, according to the sixth invention of the present application, it is possible to suppress the fluctuation of the mixing degree and the determination result of the abnormality of the mixing degree.

In particular, according to the seventh invention of the present application, the abnormality of the change in the mixing degree can be immediately recognized.

It is sectional drawing which shows typically the state of determining the mixing degree of the mixed material composed of a plurality of kinds of powders and granules. It is sectional drawing which shows typically the state of determining the mixing degree of the mixed material composed of a plurality of kinds of powders and granules. It is a schematic diagram which shows the state of analyzing the photographed image schematically. FIG. 4 is a graph showing the relationship between the input ratio of the powder or granular material and the predicted area ratio. FIG. 5 is a flowchart showing a step of determining a mixing degree of a mixed material composed of a plurality of types of powders and granules and an abnormality in the mixing degree.

<1. Preferable Embodiment of the present invention>
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view schematically showing how to determine the mixing degree of a mixed material 50 composed of a plurality of types of powders and granules. FIG. 2 is a cross-sectional view schematically showing how the mixing degree of the mixed material 50 composed of a plurality of types of powders and granules is determined when viewed from a direction different from that of FIG. The mixing degree determination device 1 shown in FIGS. 1 and 2 is a device for determining an abnormality in the mixing degree and mixing degree of at least two types of powders and granules in the mixed material 50 in which a plurality of types of powders and granules are mixed. .. The mixing degree determination device 1 has a supply unit 2, a transport unit 3, an image acquisition unit 4, and an image analysis unit 5. The supply unit 2, the transport unit 3, the image acquisition unit 4, and the image analysis unit 5 are fixed to a common frame.

The supply unit 2 is a device that stores the mixed material 50 inside and discharges the mixed material 50 downward by an opening / closing structure (not shown) at the lower part. The supply unit 2 has a storage tank 20 and a discharge unit 21. The storage tank 20 is a container for internally storing the mixed material 50. The lower part of the storage tank 20 has a funnel-shaped shape that gradually converges toward the bottom. The storage tank 20 is formed of, for example, a metal such as SUS (stainless steel). The details of the discharge unit 21 will be described later.

In the storage tank 20, a mixed material 50 in which two types of powder or granular material, the first powder or granular material 51 and the second powder or granular material 52, are mixed is stored. The first powder or granular material 51 is a colorless and transparent resin pellet which is a main raw material of a resin molded product. The second powder or granular material 52 is a master batch used as a colorant for coloring a resin molded product. The first powder or granular material 51 and the second powder or granular material 52 are different in color and particle size from each other. The second powder or granular material 52 may be a powder or granular material such as a pulverized material or an additive that is added before the resin molded product is manufactured. Further, the mixed material 50 may be composed of three or more kinds of powders and granules. In the following, as an example, the second powder or granular material 52, which is a masterbatch, is selected in advance from the two types of powder or granular material, and the mixing degree and the abnormality of the mixing degree of the second powder or granular material 52 in the mixed material 50 are determined. I decided to.

The first powder or granular material 51 and the second powder or granular material 52 are weighed in advance to a predetermined weight or volume in an external supply source (not shown) of the mixing degree determination device 1, respectively, and have a predetermined weight ratio or a predetermined weight ratio. It is mixed in a volume ratio and prepared as a mixing material 50. Hereinafter, the weight ratio or volume ratio of the second powder or granular material 52 selected in advance in the mixed material 50 will be referred to as “input ratio R”. The mixed material 50 prepared at the supply source is, for example, manually charged into the storage tank 20 by an operator. However, the mixed material 50 may be charged into the storage tank 20 by mechanically connecting the supply source and the storage tank 20 and transporting the storage tank 20. Further, in the storage tank 20, the first powder or granular material 51 and the second powder or granular material 52, which have been previously weighed to a predetermined weight or volume, are mixed in a predetermined weight ratio or volume ratio to form a mixing material. 50 may be prepared.

The discharge unit 21 includes an opening provided at the lower end of the storage tank 20 and a discharge valve (not shown) for opening and closing the opening. The discharge valve is driven manually or by automatic control. Below the opening, a transport section 3 described later is continuously provided. When the opening is opened, the mixed material 50 stored inside the storage tank 20 is supplied to the resin molding machine 6 which is a subsequent device via the inside of the transport unit 3.

The transport unit 3 is a hollow member extending in the vertical direction. When the above-mentioned opening is open, the internal space of the transport unit 3 communicates with the internal space of the storage tank 20. Further, the internal space of the transport unit 3 communicates with the internal space of the resin molding machine 6. As shown in FIGS. 1 and 2, the upper portion of the transport portion 3 gradually becomes smaller in diameter upward. The lower part of the transport portion 3 gradually becomes smaller in diameter downward. Further, the central portion of the transport portion 3 has a rectangular parallelepiped three-dimensional shape having a rectangular cross section. The outer peripheral surface of the central portion of the transport unit 3 is composed of a pair of first surfaces 31 facing each other and a pair of second surfaces 32 facing each other. The area of the first surface 31 is larger than the area of the second surface 32. However, the shape of the transport unit 3 is not limited to this. For example, the shape of the cross section of the transport portion 3 may be partially circular.

One of the pair of first surfaces 31 is provided with a through hole 30 that penetrates the transport portion 3 in a direction perpendicular to the first surface 31. The through hole 30 communicates the internal space and the external space of the transport portion 3. A colorless and transparent resin plate is fitted in the through hole 30. As a result, the observation window 35 is formed. As a result, the mixed material 50 passing through the inside of the transport unit 3 can be visually recognized and photographed from the outside through the observation window 35. The observation window 35 may be formed by covering the through hole 30 with a colorless and transparent plate. Further, the plate used for the observation window 35 may be translucent. Further, the plate used for the observation window 35 may be a member other than resin (for example, a member made of glass). Further, the observation window 35 may be provided on at least a part of the first surface 31, and the position, size, and number are not limited.

The observation window 35 expands vertically and in a plane with respect to the optical axis 40 of the image acquisition unit 4, which will be described later. As a result, as will be described later, an image of the mixed material 50 passing through the inside of the transport unit 3 can be taken in a plane. As a result, it is possible to suppress an error during image analysis. However, the observation window 35 may expand in a curved surface with respect to the surface perpendicular to the optical axis 40 of the image acquisition unit 4.

The image acquisition unit 4 is a device for photographing the mixed material 50 passing through the inside of the transport unit 3 from the outside through the observation window 35. The image acquisition unit 4 is a camera having a lens and an image pickup element. The image acquisition unit 4 is fixed to the transport unit 3 via the frame 74. The optical axis 40 of the image acquisition unit 4 intersects the observation window 35 perpendicularly with the image acquisition unit 4 fixed to the transport unit 3. The frame 74 has a bottom portion 741 and a light shielding portion 742. The image acquisition unit 4 is fixed to the bottom portion 741. The light-shielding portion 742 extends from the bottom portion 741 in the optical axis 40 direction and is connected to the transport portion 3 at the peripheral edge portion of the observation window 35. Further, the light-shielding portion 742 is formed of black paper, black resin, or the like, and covers the periphery of the lens of the image acquisition portion 4. As a result, the entry of light from the outside into the image acquisition unit 4 is blocked. However, the light-shielding portion 742 may be any as long as it can block the ingress of light from the outside, and the color is not limited to black.

The image acquisition unit 4 photographs the mixed material 50 passing through the inside of the transport unit 3 at predetermined time intervals, and acquires a plurality of captured images 53. The time interval for shooting is set in advance, for example, every 0.1 seconds or every 5 minutes, and is stored in the image acquisition unit 4. Further, the number of captured images 53 to be acquired is set in advance as, for example, 3 images, 1000 images, or the like, and is stored in the image acquisition unit 4. However, the number of captured images to be acquired may be only one.

The image analysis unit 5 is a device that analyzes a plurality of captured images 53 acquired by the image acquisition unit 4. The image analysis unit 5 is composed of, for example, a computer that can operate according to a program. The image analysis unit 5 stores in advance the data of the color (black in this embodiment) of the second powder or granular material 52 selected in advance as the analysis target. FIG. 3 is a schematic diagram schematically showing how the acquired captured image 53 is analyzed. As shown in FIG. 3, the image analysis unit 5 first calculates the luminance values of the plurality of pixels 54 included in the acquired plurality of captured images 53 and compares them with each other to obtain the color of each pixel 54. Index. Then, the image analysis unit 5 first determines the total number of pixels having the color (black) of the second powder or granular material 52 in the entire plurality of captured images 53 based on the result of determining the color of each pixel 54. Calculated as the total value D1. Next, the image analysis unit 5 calculates the total value of the number of pixels included in the entire plurality of captured images 53 as the second total value D2. Then, the image analysis unit 5 calculates the ratio occupied by the calculation result of the first total value D1 to the calculation result of the second total value D2 as the actually measured area ratio C. If the second total value D2 is known before it is calculated by the image analysis unit 5, it may be stored in the image analysis unit 5 in advance.

Further, the image analysis unit 5 determines or outputs a numerical value indicating the mixing degree of the second powder or granular material 52 based on the calculation result of the actually measured area ratio C. At this time, the image analysis unit 5 may determine or output the calculation result itself of the actually measured area ratio C as a numerical value indicating the mixing degree of the second powder or granular material 52.

Here, the "input ratio R" indicating the ratio of the input amount of the second powder or granular material 52 to the above-mentioned mixed material 50 and the color (black) of the second powder or granular material 52 in the photographed image 53 of the mixed material 50 occupy. The relationship with the "area ratio" will be explained. FIG. 4 is a graph showing the relationship between the input ratio R of the powder or granular material and the area ratio in the captured image. As shown in FIG. 4, in the mixed material 50 in which a plurality of types of powders and granules are mixed at a predetermined weight ratio or volume ratio, when various powders and granules are uniformly distributed, a specific type of powder is used. The relationship between the particle input ratio R and the area ratio occupied by the color of the specific type of powder or granular material in the captured image 53 of the mixed material 50 is approximated by a linear equation. In the example of FIG. 4, when the input ratio of the second powder or granular material 52 in the mixed material 50 is 8%, the color of the second powder or granular material 52 with respect to the total number of pixels of the captured image 53 in which the mixed material 50 is photographed ( The ratio of the number of pixels having black) is about 9%.

The graph shown in FIG. 4 is created, for example, based on a plurality of actually measured values in a stage before determining the mixing degree of the powder or granular material and the abnormality of the mixing degree in actually manufacturing the product. Then, based on the input ratio R of the specific type of powder or granular material to be analyzed and the approximate expression (linear expression) shown in FIG. 4, the area ratio of the specific type of powder or granular material in the captured image 53 is predicted. It is calculated as "predicted area ratio P". For example, when the input ratio R of the second powder or granular material 52 is 8%, the predicted area ratio P is calculated as 9%. Further, the predicted photographed image 53P corresponding to the calculated predicted area ratio P is prepared as a sample image based on the data obtained at the time of the past actual measurement.

Return to FIG. The image analysis unit 5 further determines whether or not the measured area ratio C is within a predetermined range based on the result of comparing the calculated measured area ratio C with the predicted predicted area ratio P calculated in advance. For example, when the measured area ratio C of the second powder or granular material 52 in the photographed image 53 of the mixed material 50 in which the input ratio R of the second powder or granular material 52 is 8% is 10%, the predicted area ratio is 9%. There is a deviation of more than 10%. If it is preset that "if the deviation of the measured area ratio C with respect to the predicted area ratio P is 10% or less, it is determined that the measured area ratio C is within a predetermined range", the measured area ratio C is 10%. In the example, it is determined that a deviation exceeding a predetermined range has occurred.

When determining whether or not the deviation of the measured area ratio C with respect to the predicted area ratio P is within a predetermined range, the operator may visually compare the captured image 53 with the predicted captured image 53P. good. When there is a large difference between the captured image 53 and the predicted captured image 53P, the abnormality can be detected at a glance.

Further, the image analysis unit 5 outputs abnormality determination information indicating an abnormality in the value of the actually measured area ratio C when it is determined that the calculation result of the actually measured area ratio C is not within a predetermined range. As a result, the operator can immediately recognize the abnormality in the mixing degree of the powder or granular material.

As described above, the mixing degree determination device 1 determines the mixing degree and the abnormality of the mixing degree of a specific type of powder or granular material in the mixing material 50 in-line and in real time. Also, when an abnormality is determined, the abnormality determination information is output. Thereby, before charging the mixing material 50 into the apparatus in the subsequent step, it is possible to detect and deal with the bias of the local mixing degree of the powder or granular material in the mixing material 50. As a result, it is possible to suppress the occurrence of defects in the subsequent process. Further, the ratio of the total number of pixels having a specific type of powder or granular material color (first total value D1) to the total number of pixels included in the entire captured image 53 (second total value D2). Based on this, the degree of mixing and the abnormality of the degree of mixing of a specific type of powder or granular material are determined. As a result, even when the captured image becomes complicated due to the fact that the mixed material 50 is composed of a plurality of types of powders and granules each having a certain particle size or more and a large difference in particle size between the types, the mixing degree and the mixing degree and Abnormality of mixing can be determined.

FIG. 5 is a flowchart showing a step of determining the mixing degree and the abnormality of the mixing degree of the mixed material 50 composed of a plurality of types of powders and granules. As described above and as shown in FIG. 5, in the mixing degree determination method of the present embodiment, first, various conditions such as the shooting time interval of the mixed material 50, the number of captured images 53 to be acquired, and the shooting range (area) are satisfied. Make the settings (step S1). Next, one or a plurality of captured images 53 are acquired by photographing the mixed material 50 passing through the inside of the transport unit 3 through the observation window 35 (step S2). At that time, shooting is repeated until a preset number of shot images are obtained as the shot image 53 (step S3). Further, the ratio of the total number of pixels having a specific type of powder or granular material color (first total value D1) to the total number of pixels included in the entire captured image 53 (second total value D2) is set. , Calculated as the measured area ratio C (step S4). Then, it is determined whether or not the calculation result of the measured area ratio C is within the predetermined range (step S5), and if it is determined that the calculated result is not within the predetermined range, the abnormality determination information indicating the abnormality is output (step S6). However, the calculation result itself of the measured area ratio C may be determined or output as a numerical value indicating the mixing degree of a specific type of powder or granular material.

The area per image 53 set in step S1 may have a flat area occupied by the powder or granular material when 100 or more powder or granular material is arranged adjacently on a plane. desirable. Most of the mixed materials 50 used for resin molding are formed by mixing powders and granules such as a masterbatch having a weight or volume of 1% or more with the resin pellets of the main raw material. Since the captured image 53 has an area of 100 or more powder particles per image, there is a possibility that at least one different type of powder particles may be contained in one captured image 53. It gets higher. As a result, the actually measured area ratio C can be calculated more accurately.

<2. Modification example>
Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment.

In the above-described embodiment, the image analysis unit 5 is the total value of the number of pixels having the color (black) of the second powder or granular material 52 selected in advance in the whole of the plurality of captured images 53 (first total value D1). Was calculated. Then, the image analysis unit 5 calculates the ratio of the calculation result of the first total value to the total value (second total value D2) of the number of pixels included in the entire plurality of captured images 53 as the measured area ratio C. did. However, the image analysis unit 5 may calculate the total value (first total value D1b) of the number of pixels having the color (black color) of the second powder or granular material 52 selected in advance for each photographed image 53. Then, the image analysis unit 5 captures the ratio of the calculation result of the first total value D1b to the total value of the number of pixels included in the entire captured image 53 (second total value D2b) for each captured image 53. It may be calculated as the measured area ratio Cb for each image 53. Further, the image analysis unit 5 may calculate the average value of the calculated measured area ratio Cb for each captured image 53 over a plurality of captured images 53 as the average measured area ratio Ca. As a result, it is possible to suppress the fluctuation of the mixing degree of the mixed material 50 and the determination result of the abnormality of the mixing degree.

Further, the image analysis unit 5 may calculate the amount of change of the measured area ratio Cb for each photographed image 53 over a plurality of photographed images 53. Further, when it is determined that the calculated change amount of the measured area ratio Cb is not within the predetermined range, the abnormality determination information indicating the abnormality of the change amount of the measured area ratio Cb may be output. As a result, the abnormality of the change in the mixing degree of the powder or granular material can be immediately recognized. For example, it is possible to immediately grasp the situation in which the bias of the mixing degree of the powder or granular material has changed, which is useful for investigating the cause.

Further, two or more kinds of powders and granules may be selected in advance as targets for determining the mixing degree and the abnormality of the mixing degree.

Further, the detailed configuration of the mixing degree determination device may be different from the configuration shown in each figure of the present application.

Further, the elements appearing in the above-described embodiments and modifications may be arbitrarily combined as long as there is no contradiction.

1 Mixing degree judgment device 2 Supply part 3 Transport part 4 Image acquisition part 5 Image analysis part 6 Resin molding machine 20 Storage tank 21 Discharge part 30 Through hole 31 First side 32 Second side 35 Observation window 40 Optical axis 50 Mixed material 51 1st powder and granules 52 2nd powder and granules 53 Photographed image 53P Predicted image taken image 54 pixels 74 Frame 741 Bottom 742 Shading part C Measured area ratio Ca Average measured area ratio Cb Measured area ratio for each photographed image D1, D1b 1st total Value D2, D2b 2nd total value P Predicted area ratio R Input ratio

Claims (11)

A mixing degree determination method for determining the degree of local uniformity in a mixed material used in the production of resin molded products and composed of a plurality of types of powders and granules having different colors.
a) A step of supplying the mixed material to a resin molding machine, which is a subsequent device, via a transport unit having at least a part of an observation window capable of photographing the inside.
b) In the middle of the step a), the mixed material passing through the inside of the transport portion in a direction perpendicular to the fixed optical axis is observed at predetermined time intervals from the direction of the optical axis. The process of acquiring one or more captured images by shooting through a window, and
c) A step of selecting at least one type of powder or granular material from the plurality of types of powder or granular material and calculating the total number of pixels having the color of the selected powder or granular material.
d) A step of calculating the ratio of the calculation result of the step c) to the total value of the number of pixels included in the whole of the one or a plurality of captured images as the measured area ratio.
e) It is determined whether or not the measured area ratio calculated in the step d) is within a predetermined range, or the mixing degree of the powder or granular material is determined based on the calculation result of the measured area ratio in the step d). Process and
A method for determining the degree of mixing. The mixing degree determination method according to claim 1.
In the step e), a mixing degree determination method for determining the measured area ratio as a numerical value indicating the mixing degree of the selected powder or granular material. The mixing degree determination method according to claim 1.
Prior to the step e), the ratio of the total number of pixels having the color of the selected powder or granular material to the total number of pixels included in the whole of the one or a plurality of captured images was predicted. Record the results as a predicted area ratio and
A mixing degree determination method for determining whether or not the actually measured area ratio is within a predetermined range based on the result of comparing the predicted area ratio and the actually measured area ratio in the step e). The mixing degree determination method according to any one of claims 1 to 3.
In the step e), it is determined whether or not the measured area ratio is within a predetermined range, and when it is determined that the measured area ratio is not within the predetermined range, f) abnormality determination information indicating an abnormality in the value of the measured area ratio is output. A mixing degree determination method for executing the steps to be performed. The mixing degree determination method according to any one of claims 1 to 4.
The area of the photographed image is a mixing degree determination method having a flat area occupied by the powder or granular material when 100 or more of the powder or granular material are arranged adjacent to each other on a plane. The mixing degree determination method according to any one of claims 1 to 5.
In the step b), a plurality of the photographed images are acquired, and the photographed images are acquired.
In the step c), the total value of the number of pixels having the color of the selected powder or granular material is calculated for each photographed image.
In the step d), the ratio occupied by the calculation result of the step c) to the total value of the number of pixels included in the entire captured image for each captured image is calculated, and the plurality of shots of the calculated ratio are further calculated. A mixing degree determination method for calculating an average value over an image as the measured area ratio. The plurality of images obtained by photographing the mixture degree determination method according to claim 6 at predetermined time intervals from the direction of the fixed optical axis calculated in g) the step d). It has a step of calculating the amount of change over the plurality of captured images in the ratio of the calculation result of the step c) to the total value of the number of pixels included in the entire captured image for each captured image. ,
A mixing degree determination method for executing a step of outputting abnormality determination information indicating an abnormality in the change amount of the measured area ratio when it is determined that the change amount calculated in the step g) is not within a predetermined range. .. It is a mixing degree determination device that determines the degree of local uniformity in a mixed material that is used in the production of resin molded products and is composed of a plurality of types of powders and granules having different colors.
A supply unit for supplying the mixed material to a resin molding machine, which is a subsequent device, via a transport unit having at least a part of an observation window capable of photographing the inside .
By photographing the mixed material passing through the inside of the transport unit in a direction perpendicular to the fixed optical axis at predetermined time intervals from the direction of the optical axis through the observation window , 1 Or an image acquisition unit that acquires multiple captured images,
An image analysis unit that analyzes the one or more captured images acquired by the image acquisition unit, and an image analysis unit.
Have,
The image analysis unit
The total value of the number of pixels having the color of the specific type of the powder or granular material selected in advance from the plurality of types of powder or granular material is calculated as the first total value.
The ratio occupied by the first total value to the second total value, which is the total value of the number of pixels included in the whole of the one or a plurality of captured images, is calculated as the measured area ratio.
A mixing degree determination device that determines whether or not the measured area ratio is within a predetermined range, or determines the mixing degree of the powder or granular material based on the calculation result of the measured area ratio. The mixing degree determination device according to claim 8.
The observation window is a transparent or translucent plate fitted in or covers a through hole provided in at least a part of the transport portion to communicate the inside and the outside of the transport portion. , Mixing degree judgment device. The mixing degree determination device according to claim 8 or 9.
The image acquisition unit is a camera having a lens and an image pickup device.
The observation window is a mixing degree determination device that extends perpendicularly and planarly to the optical axis of the image acquisition unit. The mixing degree determination device according to claim 8 or 9.
The image acquisition unit is a camera having a lens and an image pickup device.
The observation window is a mixing degree determination device that expands in a curved surface with respect to a surface perpendicular to the optical axis of the image acquisition unit.

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