JP7260417B2 - Abnormality detection device for injection molding machine - Google Patents

Description

The present invention relates to an abnormality detection device for an injection molding machine.

2. Description of the Related Art Conventionally, an injection molding machine is known that manufactures a molded product by filling a resin into a cavity formed between a movable mold and a fixed mold. 2. Description of the Related Art In an injection molding machine, in order to improve production efficiency, one mold is provided with a plurality of cavities, and a large number of molded products are manufactured in one molding operation. Among these, in injection molding using a mold called a hot runner type, the runner (resin flow path) communicating with multiple cavities is heated by a heater, so the resin inside the runner can be kept in a molten state. . The hot runner type injection molding machine does not allow the resin to harden inside the runner even after one molding cycle is completed, and the resin inside the runner can be filled into the cavity in the next molding cycle, reducing waste of resin. It has the advantage of being less.

On the other hand, in hot runner type injection molding machines, the flow of resin is hindered by resin leakage from the resin outflow part of the fixed mold, and excessive resin pressure is generated during injection, resulting in damage to the mold and damage to the molded product. Molding defects may occur in the appearance. In order to solve this problem, an injection molding machine has been proposed that detects the occurrence of an abnormality by measuring the resin pressure in each cavity (see, for example, Patent Document 1). Also, an injection molding machine has been proposed in which an opening/closing means called a valve gate is provided at the resin outflow portion of the fixed mold, and the valve gate is controlled according to the supplied resin pressure to prevent resin leakage. (See, for example, Patent Document 2).

JP-A-2002-86495 JP 2010-131812 A

In the conventional injection molding machine described above, it is necessary to provide a sensor for detecting resin pressure in order to detect resin leakage from the resin outflow portion and to control the valve gate. However, in the injection molding machine of the prior art, the shape of the mold becomes complicated due to the provision of the sensor, and it may not be possible to install the sensor depending on the shape and size of the molded product. Further, when a sensor is provided for each of a plurality of cavities, it is conceivable that the resin leakage cannot be accurately detected if the detection sensitivity of each sensor varies or if some of the sensors are out of order.
Therefore, injection molding machines are desired to more reliably detect resin leakage.

One aspect of the present disclosure includes a mold comprising a fixed mold and a movable mold that is movable with respect to the fixed mold, and the mold in which the fixed mold and the movable mold are closed. An abnormality detection device for filling resin into each of a plurality of cavities formed therein and detecting an abnormality in an injection molding machine that manufactures a molded product in each cavity, wherein the stationary mold and the movable mold are being molded. an image acquisition unit that acquires an image of at least one mold surface of a mold as an image to be inspected; and an abnormality that detects the cavity in which an abnormality occurs based on a comparison between the image to be inspected and a reference image a detection unit; and a signal output unit that associates and outputs identification information of the cavity in which the occurrence of an abnormality is detected by the abnormality detection unit and an abnormality signal.

According to one aspect of the present disclosure, resin leakage from an injection molding machine can be detected more reliably.

It is a functional block diagram of injection molding system 1 in a 1st embodiment. 2 is a conceptual diagram showing the configuration of an injection molding machine 2; FIG. 4 is a conceptual diagram showing the arrangement and shape of cavities formed inside the mold 10. FIG. FIG. 4 is a diagram showing an example of reference images Gb(0) to Gb(3); FIG. 3 is a diagram showing an example of inspection target images G(0) to G(3); 4 is a flow chart showing a processing procedure of an abnormality detection program executed in the control device 3; It is a functional block diagram of injection molding system 1A in a 2nd embodiment. It is a functional block diagram of injection molding system 1B in a 3rd embodiment. It is a conceptual diagram which shows the structure of the injection molding machine 2B in 3rd Embodiment.

Embodiments of the present invention will be described below. The drawings attached to this specification are all schematic diagrams, and the shapes, scales, vertical-to-horizontal dimensional ratios, etc. of each part are changed or exaggerated from the actual ones in consideration of ease of understanding.
(First embodiment)
FIG. 1 is a functional block diagram of an injection molding system 1 according to the first embodiment. FIG. 2 is a conceptual diagram showing the configuration of the injection molding machine 2. As shown in FIG.
In this specification and the like, as shown in FIG. 2, the moving direction of the movable mold 12 (described later) is defined as the X direction. In the X direction, the direction in which the movable mold 12 separates from the fixed mold 11 is defined as the X1 direction, and the direction in which the movable mold 12 approaches the fixed mold 11 is defined as the X2 direction.

As shown in FIG. 1, the injection molding system 1 includes an injection molding machine 2, a control device 3, a camera 4, a display device 5 and an operation input section 6.
The injection molding machine 2 is a device that fills a cavity formed between a fixed mold 11 and a movable mold 12 (described later) with a resin to manufacture a molded product. The injection molding machine 2 includes a mold 10, a toggle mechanism device 20 and an injection device 30, as shown in FIG. The mold 10, toggle mechanism device 20, and injection device 30 are connected to the control device 3 shown in FIG. 1 via a communication medium (not shown).

As shown in FIG. 2, the mold 10 includes a fixed mold 11 and a movable mold 12. As shown in FIG. The fixed mold 11 and the movable mold 12 are connected by tie bars 15 .
The fixed mold 11 is a mold having a concave portion on the molding surface. The fixed mold 11 is provided on the X2 side of the mold 10 and supported by the fixed platen 13 . The stationary platen 13 is configured not to move along the tie bars 15 in the X (X1-X2) direction. Therefore, the fixed mold 11 does not move in the X (X1-X2) direction.

The fixed mold 11 is formed with a sprue 16 connected to a nozzle 30N of an injection device 30, which will be described later. The sprue 16 is a channel into which the resin supplied from the injection device 30 flows. A resin outflow portion 17 is formed at the end of the sprue 16 on the outlet side. The resin outflow part 17 is a part that becomes an entrance when resin is filled into the mold 10 . The resin outflow portion 17 is provided with a valve gate (not shown) as an opening/closing mechanism. In addition, in FIG. 2, in the fixed mold 11 and the movable mold 12, illustration of mold surfaces (molding surfaces) forming cavities is omitted.

The movable mold 12 is a mold having a convex portion on its molding surface. The movable mold 12 is provided on the X1 side of the mold 10 and supported by the movable platen 14 . The movable platen 14 is connected to a toggle mechanism device 20 (described later), and is configured to be movable along the tie bars 15 in the X (X1-X2) direction. Therefore, the movable mold 12 can move freely in the X (X1-X2) direction together with the movable platen . When the movable mold 12 is moved to the mold closing position on the X2 side and clamped together with the fixed mold 11, the concave mold portion and the convex mold portion described above are formed between the fixed mold 11 and the movable mold 12. Cavities C(0)-C(3) (described below) are formed. By filling resin from the injection device 30 into the cavities C(0) to C(3), a molded product can be manufactured in each of the cavities C(0) to C(3).

Here, the cavities C(0) to C(3) formed inside the mold 10 will be described.
FIG. 3 is a conceptual diagram showing the arrangement and shape of cavities formed inside the mold 10. As shown in FIG.
FIG. 4 is a diagram showing an example of reference images Gb(0) to Gb(3). FIG. 5 is a diagram showing an example of inspection target images G(0) to G(3).

In one example, when the fixed mold 11 and the movable mold 12 are closed, as shown in FIG. ) and C(3) are formed. In this embodiment, C(0), C(1), C(2) and C(3) are the identification information of each cavity. Hereinafter, the cavities C(0) to C(3) are also collectively referred to as “cavities”. A resin outflow portion 17 is opened in the central portion of each of the cavities C(0) to C(3). The resin outflow portion 17 is formed in the fixed mold 11 as shown in FIG. 2, but in FIG. It schematically shows how the

The molding surface of the fixed mold 11 on which the resin outflow portion 17 is open is imaged as images of the cavities C(0) to C(3) by the camera 4 (described later). In this embodiment, reference images Gb(0), Gb(1), Gb(2), Gb(3) and inspection target images G(0), G (1), G(2), and G(3) are imaged.
The reference images Gb(0) to Gb(3) are images captured in a normal state in which no resin leakage occurs, and are captured in advance before the injection molding work is performed. As shown in FIG. 4, the reference images Gb(0) to Gb(3) are images of the molding surface where no resin leakage occurs in the resin outflow portion 17. As shown in FIG.

The images G(0) to G(3) to be inspected are images captured before the fixed mold 11 and the movable mold 12 are closed in one molding cycle. One molding cycle refers to one continuous process from mold closing, injection (resin filling), mold opening, molding product removal, and mold closing. The images G(0) to G(3) to be inspected are captured in each molding cycle. In the example of inspection target images G(0) to G(3) shown in FIG. 5, the resin leakage (in FIG. The resin that has been exposed is indicated by a dot pattern) is generated.

The ranges of the reference images Gb(0) to Gb(3) and the inspection target images G(0) to G(3) are specified by the positions from the origin (0) of the coordinate axes XY as shown in FIG. be.
The reference image Gb(0) and the inspection target image G(0) are images of a range surrounded by coordinates (10, 110) and coordinates (90, 190).
The reference image Gb(1) and the inspection target image G(1) are images of a range surrounded by coordinates (110, 110) and coordinates (190, 190).
The reference image Gb(2) and the inspection target image G(2) are images of a range surrounded by coordinates (10, 10) and coordinates (90, 90).
The reference image Gb(3) and the inspection target image G(3) are images of a range surrounded by coordinates (110, 10) and coordinates (190, 90).
In FIG. 3, for convenience of explanation, the left-right direction and the up-down direction of the paper surface are the directions of the coordinate axes XY.

The configuration of the injection molding system 1 will be described with reference to FIGS. 1 and 2 again.
An ejector device (not shown) is connected to the movable mold 12 . The ejector device is a device that ejects the molded product manufactured by the mold 10 from the movable mold 12 . The ejector device projects an ejector pin (not shown) from the molding surface of the movable mold 12 toward the X2 side to eject the molded product from the molding surface of the movable mold 12 .

The toggle mechanism device 20 is a device that opens and closes the mold (mold closing, mold opening), mold clamping, etc. by moving the movable mold 12 in the X (X1-X2) direction with respect to the fixed mold 11. be. The toggle mechanism device 20 has a servomotor 21 (see FIG. 1) as a power source for moving the movable platen 14 . The servomotor 21 is a motor whose rotation direction and rotation amount are controlled by a movable part control section 40 (control device 3), which will be described later. The servomotor 21 is driven by a mold closing signal sent from the movable part control part 40, and moves the movable platen 14 along the tie bars 15 in a direction (X2 direction) approaching the stationary platen 13. FIG. Also, the servomotor 21 is driven by a mold opening signal sent from the movable part control part 40 to move the movable platen 14 along the tie bars 15 in the direction away from the fixed platen 13 (X1 direction).

The injection device 30 is a device that fills the closed mold 10 with molten high-temperature resin. The injection device 30 is configured as a hot runner type injection device in which heaters (not shown) are provided in runners communicating with the cavities C(0) to C(3). As shown in FIG. 2, the injection device 30 has a tip nozzle 30N connected to a sprue 16 provided on the fixed mold 11. As shown in FIG. The injection device 30 has a servomotor 31 , and the fixed mold 11 (the mold 10 ) has a servomotor 32 and a heater 33 .

The servomotor 31 is a motor driven by an injection control signal transmitted from the movable part controller 40 . The molten resin is supplied toward the mold 10 by driving the servomotor 31 to advance a screw mechanism (not shown) provided in the cylinder of the injection device 30 .

The servomotor 32 is a motor that is driven by a valve gate control signal sent from the movable part controller 40 . By driving the servomotor 32 to open a valve gate (not shown) provided in the resin outflow portion 17, the inside of the mold 10 is filled with resin. Also, by driving the servomotor 32 to close the valve gate, filling of the mold 10 with resin is stopped.

The heater 33 is a device that heats the resin outflow portion 17 of the stationary mold 11 . A heater 33 is provided in each of the resin outflow portions 17 of the cavities C(0) to C(3). The temperature of the resin filled in each of the cavities C( 0 ) to C( 3 ) from the resin outflow portion 17 is adjusted by the temperature control signal sent from the movable portion control portion 40 to the heater 33 .

The control device 3 is electrically connected to devices such as the toggle mechanism device 20, the injection device 30, and the mold 10 of the injection molding machine 2, and is a device that controls the operation of each of these devices. The control device 3 is composed of a microprocessor unit including a CPU (Central Processing Unit), memory and the like. Each unit constituting the control device 3 cooperates with each piece of hardware by reading out and executing an application program (for example, an injection operation program, an abnormality detection program) for controlling the operation of the injection molding machine 2 from the storage unit 90 . work to realize various functions.

The control device 3 includes a movable part control section 40, an image acquisition section 50, an abnormality detection section 60, a signal output section 70, a resin temperature control section 80, and a storage section 90, as shown in FIG. In the control device 3, the operation of the movable part control part 40 is executed according to the injection operation program. The operations of the image acquisition section 50, the abnormality detection section 60, the signal output section 70, and the resin temperature control section 80 are executed according to an abnormality detection program. The image acquisition section 50, the abnormality detection section 60, the signal output section 70, and the resin temperature control section 80 constitute an abnormality detection device for the injection molding machine 2 in this embodiment.

The movable part control part 40 controls the operation of a device (movable part) having a movable mechanism such as the toggle mechanism device 20 and the injection device 30 . Since the control of the toggle mechanism device 20, the injection device 30, etc. by the injection operation program is the same as the control of a general injection molding machine, the explanation is omitted.
In one molding cycle, the image acquisition unit 50 transmits a photographing instruction signal to the camera 4 (described later) before the fixed mold 11 and the movable mold 12 are closed, and the mold surface of the fixed mold 11 is captured. image. The images captured by the camera 4 are stored in the storage unit 90 as inspection target images G(0) to G(3).

The abnormality detection unit 60 compares the images G(0) to G(3) to be inspected obtained in each molding cycle with the reference images Gb(0) to Gb(3) captured in advance. , to detect anomalous cavities. For example, a pattern matching technique is used to check whether or not the images G(0) to G(3) to be inspected match (or are similar to) the corresponding reference images Gb(0) to Gb(3). By doing so, it is possible to determine whether or not there is an abnormality in each cavity of the images G(0) to G(3) to be inspected.

The signal output unit 70 associates the identification information C(0) to C(3) of the cavity with the determination signals a(0) to a(3) and transmits them to the resin temperature control unit 80 . The determination signal is information (flags) of "0" and "1" indicating that there is or is not an abnormality in the cavity. Specifically, the signal output unit 70 transmits the identification information of the cavities in which no abnormality has occurred in association with the determination signal with a flag of "0" indicating that there is no abnormality. For example, if there is no abnormality in the image G(0) to be inspected, the determination signal a(0)=0 is associated with the identification information C(0) of the cavity and transmitted to the resin temperature control unit 80 . On the other hand, the signal output unit 70 associates the identification information of the cavity in which an abnormality has occurred with a judgment signal (abnormality signal) with a flag of "1" indicating that there is an abnormality, and sends the signal to the resin temperature control unit 80. Send. For example, if there is an abnormality in the image G(1) to be inspected, the determination signal a(1)=1 is associated with the identification information C(1) of the cavity and transmitted to the resin temperature control unit 80 .

The resin temperature control unit 80 determines whether or not there is an abnormality in the corresponding cavity based on the determination signal associated with the identification information C(0) to C(3) of the cavity, which is transmitted from the signal output unit 70. , change the temperature of the resin filled in the cavity determined to be abnormal. Specifically, the resin temperature control unit 80 controls the temperature of the heater 33 (see FIG. 2) that heats the resin outflow part 17 that fills the resin into the cavity determined to be abnormal, thereby controlling the temperature of the resin. change. For example, when resin leakage occurs in the cavity, the temperature of the heater 33 is lowered to reduce the fluidity of the resin, thereby preventing resin leakage.

The storage unit 90 is a storage device in which various programs, data, and the like executed by the injection molding machine 2 are stored. The storage unit 90 is configured by, for example, a semiconductor memory, a hard disk device, or the like. The storage unit 90 stores reference images Gb(0) to Gb(3) captured by the camera 4, inspection target images G(0) to G(3), and the like. The storage unit 90 also stores, for example, an injection operation program and an abnormality detection program as application programs.

The camera 4 is a device that takes an image of the mold surface of the fixed mold 11 . For the camera 4, for example, a digital camera equipped with a CCD or CMOS image sensor is used. The camera 4 may be installed at a location away from the mold 10 as shown in FIG. It may be installed in the hand portion of the robot (not shown) that takes it out. Camera 4 is connected to control device 3 via a communication medium (not shown). The camera 4 images the mold surface of the fixed mold 11 as images of the cavities C(0) to C(3) in accordance with the photographing instruction signal transmitted from the image acquisition unit 50 (control device 3). The images G(0) to G(3) to be inspected captured by the camera 4 are stored in the storage unit 90 of the control device 3. FIG. Note that the reference images Gb(0) to Gb(3) in which resin leakage does not occur are also captured by the camera 4 in advance.

The display device 5 is a display device capable of displaying various data, messages, graphics, and the like. For example, by causing the display device 5 to display an image of a cavity in which an abnormality has been detected by the abnormality detection section 60, the administrator can determine the type and degree of abnormality that has occurred in the corresponding cavity. The display device 5 is connected to the control device 3 via a communication medium (not shown).
The operation input unit 6 is a device with which an administrator can input various character information, numerical data, operation instructions, action instructions, and the like. The operation input unit 6 is composed of, for example, a keyboard, mouse, touch panel display, etc. (all not shown). The operation input unit 6 is connected to the control device 3 via a communication medium (not shown).

Next, the processing contents of the abnormality detection program executed by the controller 3 of the injection molding system 1 will be described based on the flowchart shown in FIG.
FIG. 6 is a flow chart showing a processing procedure of an abnormality detection program executed by the control device 3. As shown in FIG. In the injection molding system 1, the processing of the abnormality detection program is executed in parallel with the processing of the injection control program.

In step S101 shown in FIG. 6, the image acquisition unit 50 (control device 3) sets 0 to a variable i, which is the count value of the cavities C(0) to C(3).
In step S102, the image acquiring unit 50 determines whether or not the fixed mold 11 and the movable mold 12 have not yet been closed in one molding cycle. In step S102, when the image acquisition unit 50 determines that the fixed mold 11 and the movable mold 12 have not yet been closed, the process proceeds to step S103. On the other hand, in step S102, when the image acquiring unit 50 determines that the fixed mold 11 and the movable mold 12 are not before closing, the process proceeds to step S102.

In step S103 (step S102: YES), the image acquisition unit 50 determines whether or not the variable i, which is the count value of the number of cavities, is less than four. In step S103, when the image acquisition unit 50 determines that the variable i is less than 4, the process proceeds to step S104. On the other hand, when the image acquisition unit 50 determines in step S103 that the variable i exceeds 4, the process proceeds to step S111.

In step S104 (step S103: YES), the image acquisition unit 50 transmits an image capturing instruction signal to the camera 4 to capture the inspection target image G(i) of the cavity C(i). For example, if the variable i is 0, the inspection object image G(0) of the cavity C(0) is picked up. The image acquisition unit 50 causes the storage unit 90 to store the inspection target image G(i) captured by the camera 4 .

In step S105, the abnormality detection unit 60 compares the inspection target image G(i) acquired by the image acquisition unit 50 with the reference image Gb(i) to determine whether an abnormality has occurred in the cavity C(i). determine whether or not there is In step S105, when the abnormality detection unit 60 determines that there is no abnormality in the cavity C(i), the process proceeds to step S106. On the other hand, in step S105, when the abnormality detection unit 60 determines that the cavity C(i) is abnormal, the process proceeds to step S107.

In step S106 (step S105: YES), the signal output unit 70 associates the identification information C(i) of the cavity with the determination signal a(i)=0 (no abnormality) and transmits the determination signal to the resin temperature control unit 80. . For example, when cavities C(0) and C(3) are normal, as shown in FIG. , is associated with a determination signal a(i)=0 (no abnormality) and transmitted to the resin temperature control unit 80 .

In step S107 (step S105: NO), the signal output unit 70 associates the identification information C(i) of the cavity with the judgment signal a(i)=1 (abnormal), and transmits it to the resin temperature control unit 80. . For example, when cavities C(1) and C(2) are abnormal as shown in FIG. , and a determination signal a(i)=1 (abnormal) is associated with each other and transmitted to the resin temperature control unit 80 .

In step S108, the resin temperature control unit 80 determines whether the cavity C(i) is abnormal based on the determination signal a(i) associated with the identification information C(i) of the cavity, which is transmitted from the signal output unit 70. It is determined whether or not there is In step S108, when the resin temperature control unit 80 determines that the cavity C(i) is abnormal, the process proceeds to step S109. On the other hand, in step S108, when the resin temperature control unit 80 determines that there is no abnormality in the cavity C(i), the process proceeds to step S110.

In step S109 (step S108: YES), the resin temperature control unit 80 controls the temperature of the heater 33 (see FIG. 2) that heats the resin outflow part 17 that fills the resin into the cavity C(i), thereby Change to lower temperature.
In step S110, the image acquisition unit 50 sets the variable i to +1, and proceeds to step S103.

In step S111 (step S103: NO), the image acquisition section 50 determines whether or not the molding cycle being executed by the movable section control section 40 has ended. If the image acquisition unit 50 determines in step S111 that the molding cycle has ended, the processing of this flowchart ends. On the other hand, if the image acquisition unit 50 determines in step S111 that the molding cycle has not ended, the process proceeds to step S101.

According to the injection molding system 1 of 1st Embodiment mentioned above, there exist the following effects, for example.
The injection molding system 1 of the first embodiment combines inspection target images G(0) to G(3) acquired in each molding cycle and reference images Gb(0) to Gb(3) captured in advance. A cavity in which an abnormality has occurred is detected by the comparison. According to this, in the injection molding system 1 of the first embodiment, unlike the method in which the resin pressure is detected by a sensor, there is no problem that an abnormality cannot be detected due to variations in the detection sensitivity of the sensor or a failure. can be detected more reliably.

In the injection molding system 1 of the first embodiment, as shown in FIG. It is installed in the hand part of the robot (not shown) that takes it out. Therefore, the camera 4 does not affect the operation and shape of the mold 10, and the installation location is not restricted by the shape and size of the molded product. Therefore, the injection molding system 1 of the first embodiment can be easily applied to existing injection molding machines.

In the injection molding system 1 of the first embodiment, the image acquisition unit 50 acquires images of the mold surface of the fixed mold 11 as inspection target images G(0) to G(3). Therefore, in the injection molding system 1 of the first embodiment, the abnormality detection section 60 can more accurately detect the presence or absence of resin leakage in the resin outflow section 17 (see FIG. 2).

In the injection molding system 1 of the first embodiment, the image acquisition unit 50 captures the images G(0) to G(3) to be inspected before the fixed mold 11 and the movable mold 12 are closed. Get an image. Therefore, in the injection molding system 1 of the first embodiment, the abnormality detection section 60 can more quickly detect the presence or absence of resin leakage in the resin outflow section 17 after the mold 10 is filled with resin.

In the injection molding system 1 of the first embodiment, the resin temperature control section 80 controls the temperature of the heater 33 that heats the resin outflow section 17 that fills the resin into the cavity that is determined to be abnormal. to change Therefore, the injection molding system 1 of the first embodiment can more effectively suppress resin leakage and resin clogging in the resin outflow portion 17 .

(Second embodiment)
FIG. 7 is a functional block diagram of injection molding system 1A in the second embodiment.
The injection molding system 1A of the second embodiment differs from that of the first embodiment in that the controller 3 is provided with a resin supply controller 81 . In the injection molding system 1A of the second embodiment, the configuration of the injection molding machine 2 is the same as that of the first embodiment. Therefore, in the description and drawings of the second embodiment, the same reference numerals are given to the same parts as in the first embodiment, and duplicate descriptions are omitted.

As shown in FIG. 7, the injection molding system 1A of the second embodiment includes a resin supply control section 81 in the control device 3. As shown in FIG. The resin supply control unit 81 determines whether or not there is an abnormality in the corresponding cavity based on the determination signal associated with the identification information C(0) to C(3) of the cavity, which is transmitted from the signal output unit 70. , change the timing of filling resin into the cavity determined to be abnormal. In the injection molding system 1 of the second embodiment, the above process is executed by the resin supply control unit 81 in step S109 of the flowchart shown in FIG.

Specifically, the resin supply control unit 81 controls the servo motor 32 (FIGS. 1 and 3) for opening and closing a valve gate (not shown) provided in the resin outflow unit 17 that fills the resin into the cavity determined to be abnormal. 2) is controlled. The resin supply control unit 81 controls the opening timing of the valve gate corresponding to the cavity determined to be abnormal, thereby suppressing resin leakage from the resin outflow portion 17 . For example, when resin leakage occurs in the cavity, the opening timing of the valve gate is too early with respect to the start of the injection operation, so the opening timing of the valve gate is delayed to suppress resin leakage.
In the injection molding system 1A of the second embodiment, the resin supply control section 81 controls the opening timing of the valve gate corresponding to the cavity determined to be abnormal. Therefore, according to the injection molding system 1A of the second embodiment, the resin leakage at the resin outflow portion 17 can be suppressed more quickly.

(Third Embodiment)
FIG. 8 is a functional block diagram of an injection molding system 1B according to the third embodiment. FIG. 9 is a conceptual diagram showing the configuration of an injection molding machine 2B according to the third embodiment.
The injection molding system 1B of the third embodiment differs from the first embodiment in that the controller 3 is equipped with a robot controller 82 and the injection molding machine 2B is equipped with a robot device 100 . Other configurations of the injection molding system 1B of the third embodiment are the same as those of the first embodiment. Therefore, in the description and drawings of the third embodiment, the same reference numerals are given to the same parts as in the first embodiment, and duplicate descriptions will be omitted.

As shown in FIG. 8, the injection molding system 1B of the third embodiment includes a robot control section 82 (discharge control section) in the control device 3. As shown in FIG. Moreover, as shown in FIG. 9, the injection molding system 1B of 3rd Embodiment equips the injection molding machine 2B with the robot apparatus 100 (discharge part).
The robot device 100 is a device that takes out a molded product from the mold 10 after molding. The robot device 100 includes a control unit, a storage unit, and a communication unit (all not shown), and is connected to the control device 3 via a communication medium (not shown). 9 schematically shows the position of the robot device 100 with respect to the mold 10. As shown in FIG.

The robot control unit 82 determines whether there is an abnormality in the corresponding cavity based on the determination signal associated with the identification information C(0) to C(3) of the cavity, which is transmitted from the signal output unit 70, The robot device 100 is controlled so as to eject the molded product manufactured in the cavity determined to be abnormal. In this embodiment, the molded product ejected by the ejector device (not shown) described above is collected as a non-defective product. Also, a molded product manufactured in a cavity in which an abnormality has occurred is discharged by the robot device 100 as a defective product.

In the injection molding system 1B of the third embodiment, the robot control unit 82 controls the robot device 100 to discharge the molded product manufactured in the cavity determined to be abnormal. Therefore, according to the injection molding system 1B of the third embodiment, it is possible to prevent defective molded products from mixing with good molded products.

Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments, and various modifications and changes are possible, such as modifications described later, which are also disclosed. included within the technical scope of Moreover, the effects described in the embodiments are merely enumerations of the most suitable effects resulting from the present disclosure, and are not limited to those described in the embodiments. Although the above-described embodiment and modified embodiments described later can be used in combination as appropriate, detailed description thereof will be omitted. Further, in the following description, the first to third embodiments are also collectively referred to as "embodiments".

(deformed form)
In the embodiment, an example in which four cavities C(0) to C(3) are formed inside the mold 10 has been described, but the number of cavities need only be two or more. Further, in the embodiment, as shown in FIG. 3, an example in which the cavities C(0) to C(3) are star-shaped has been shown. It may be of any shape, or may be of different shapes. Furthermore, the position of the resin outflow portion 17 is not limited to the central portion of the cavity.

In the embodiment, an example in which one camera 4 is provided in the injection molding machine 2 has been described, but a configuration in which a plurality of cameras 4 are provided may be employed. According to this configuration, the inspection target images G(0) to G(3) can be acquired more quickly in the image acquisition unit 50 (see FIG. 1). Alternatively, the images G(0) to G(3) to be inspected may be obtained by capturing images of four cavities at once with one camera and then dividing the images.

In the embodiment, an example in which an image of the mold surface of the fixed mold 11 where resin leakage may occur is used as an image to be inspected has been described. The image obtained by imaging the mold surface of 1 may be used as the image to be inspected. Also, an image obtained by capturing the mold surfaces of both the fixed mold 11 and the movable mold 12 may be used as the image to be inspected. In this case, the images of the fixed mold 11 and the movable mold 12 taken in normal times with no abnormality may be stored as reference images.

In the injection molding system 1B of the third embodiment, the robot device 100 may collectively discharge molded products manufactured in a molding cycle in which an abnormality has been detected as defective products. Further, in the injection molding system 1B of the third embodiment, the control device 3 may be provided with the resin temperature control section 80 (first embodiment) to perform control to change the temperature of the resin. may be provided with a resin supply control unit 81 (second embodiment) to perform processing for controlling the opening timing of the valve gate.

1, 1A, 1B: injection molding system, 2, 2B: injection molding machine, 3: control device, 4: camera, 10: mold, 11: fixed mold, 12: movable mold, 17: resin outflow part, 30: injection device, 40: movable part control unit, 50: image acquisition unit, 60: abnormality detection unit, 70: signal output unit, 80: resin temperature control unit, 81: resin supply control unit, 82: robot control unit, 90: storage unit, 100: robot device

Claims (6)

A mold comprising a fixed mold having a resin outflow part and a movable mold movable relative to the fixed mold, wherein the fixed mold and the movable mold are closed and placed inside the mold. An abnormality detection device that detects an abnormality in an injection molding machine that fills each of a plurality of cavities to be formed with resin from the resin outflow portion and manufactures a molded product in each cavity,
An image including the resin outflow portion of the mold surface of the fixed mold during molding is acquired as an inspection target image , and an image including the resin outflow portion of the mold surface of the fixed mold in which resin leakage does not occur. as a reference image ; and
an abnormality detection unit that detects the cavity in which an abnormality has occurred based on a comparison between the image to be inspected and the reference image;
an abnormality detection unit that detects the cavity in which an abnormality has occurred based on a comparison between the image to be inspected and the reference image;
a signal output unit that associates and outputs identification information of the cavity in which the occurrence of an abnormality has been detected by the abnormality detection unit and an abnormality signal;
An abnormality detection device for an injection molding machine. 2. The abnormality detection device for an injection molding machine according to claim 1, wherein said identification information of said cavity is position information of said cavity on a mold surface of said fixed mold. 3. The abnormality detection device for an injection molding machine according to claim 1, wherein said image to be inspected is an image acquired before said fixed mold and said movable mold are closed in one molding cycle. The resin for specifying the cavity in which the occurrence of the abnormality is detected based on the identification information associated with the abnormality signal output from the signal output unit, and changing the temperature of the resin filled in the specified cavity. 4. The abnormality detection device for an injection molding machine according to any one of claims 1 to 3, comprising a temperature control section. Resin supply for specifying the cavity in which the occurrence of the abnormality is detected based on the identification information associated with the abnormality signal output from the signal output unit, and changing the timing of supplying resin to the specified cavity. The abnormality detection device for an injection molding machine according to any one of claims 1 to 3, comprising a control section. a discharge unit for discharging the molded product from the one or more cavities;
The cavity in which the occurrence of an abnormality has been detected is identified based on the identification information associated with the abnormality signal output from the signal output unit, and the molded product manufactured in the identified cavity is discharged. The abnormality detection device for an injection molding machine according to any one of claims 1 to 3, further comprising a discharge control section that controls the discharge section.

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