JPH10180848A - Quality control system of extrusion molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To discriminate overall quality without depending on a person in charge by a method wherein manufacturing process information is compared with a manufacturing condition master of a master control part, and inspection information collected with in-line and on-line inspection information collection parts is compared with a quality standard master of the master control part. SOLUTION: An in-line inspection information collection part 2 accumulates relating to a manufactured molded product, and an off-line inspection information collection part 3 collects inspection information obtained with inspection of the molded product after manufacture relating to the molded product. A master control part 4 controls a manufacturing condition master 41 and a quality standard master 42. A quality discrimination part 5 compares manufacturing process information collect with an extruder manufacturing process information part 1 with the manufacturing condition master 41 of the master control part 4, compares inspection information with the in-line inspection information collection part 2 and the off-line inspection information collection part 3 with the quality standard master 42 of the master control part 4, and discriminates quality of the molded product.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention has a long manufacturing process,
Therefore, the present invention relates to a quality management system for an extruded product that requires a plurality of pieces of information such as manufacturing process information and quality inspection information for quality determination.

[0002]

2. Description of the Related Art For example, in the field of injection molding, manufacturing conditions (mold temperature, resin temperature, cycle time, pressure, etc.)
Production information is obtained by comparing with reference values set in accordance with these conditions.

For example, in a production information management apparatus for plastic extrusion molding disclosed in Japanese Patent Application Laid-Open No. 61-130021, data (for example, heater power supply) corresponding to the operation state of various control objects in a plastic extrusion molding line is detected by a data detecting means. Time, barrel temperature, mold temperature, screw rotation speed, line speed, etc.), and processes the detected data in accordance with a predetermined procedure to obtain desired production information (eg, power consumption, unit price of power source). ,
Operating rate, yield, etc.), and the obtained production information is displayed on the display means.

[0004] In other words, when only the production information obtained based on the manufacturing conditions is displayed and the quality is determined,
It was necessary to separately determine the quality based on the obtained production information. In other words, up to the quality inspection data has not been managed as production information.

On the other hand, in the case of extrusion molding, since the manufacturing process is long, it is not possible to judge the quality accurately only by the manufacturing conditions. Therefore, comprehensive information, including in-line and off-line inspections, is needed for quality determination of extruded products.

In this case, the off-line inspection, which is a sampling inspection, cannot obtain a result until several minutes after production, and therefore, in addition to the manufacturing process information and the in-line inspection information, the person in charge of the off-line inspection enters the form. He hand-wrote and collected the forms the next day to collect and judge the quality.

[0007]

As described above, in the case of extrusion molding, the person in charge collects a form on which the quality inspection result other than the manufacturing conditions is handwritten the next day, and determines the quality by the person in charge. . Therefore, in the situation of multi-kind production, there are many kinds of quality standards, so that it takes a long time to make a judgment, and there is a problem that a judgment error easily occurs.

When the person in charge collects quality inspection data, the measurement time differs for each quality inspection item.
Since it is necessary to collect information by batch processing several times a day, there has been a problem that the collection work is complicated.

[0009] Further, since quality inspection data is stored in a form, there is also a problem that, when prompt confirmation is required, such as when a customer makes a complaint, necessary data cannot be quickly taken out.

The present invention has been made to solve such a problem, and has as its object the purpose of comprehensive quality judgment including in-line inspection information and offline inspection information without relying on the judgment of a person in charge. It is to provide a quality control system of an extruded product which can perform the above.

[0011]

In order to solve the above-mentioned problems, a quality control system for an extruded product according to claim 1 of the present invention stores information in each manufacturing process of an extruder with information on a manufactured product. The extruder manufacturing process information collection unit that collects while associating with the extruder, and the inline inspection that collects the inspection information obtained by the inspection device arranged in each manufacturing process of the extruder while associating it with the molded product to be manufactured An information collection unit, an offline inspection information collection unit that collects inspection information obtained by inspecting a molded article after manufacturing while associating the information with the molded article, and a master that manages each master of manufacturing conditions and quality standards. Management unit, a comparison between the manufacturing process information collected by the extruder manufacturing process information collection unit and the manufacturing condition master of the master management unit, the in-line inspection information collection unit By comparison with collected test information and the master management unit of the quality standards master by fine the offline inspection information collecting unit, a configuration in which a determining quality determination unit the quality of the molded article.

Further, the quality control system for an extruded product according to claim 2 of the present invention,
The in-line inspection information is inspection information in each inspection item such as a thickness inspection, a surface inspection, and a color inspection, and the offline inspection information is inspection information in each inspection item such as a moisture content inspection, a glossiness inspection, and an appearance inspection.

According to a third aspect of the present invention, there is provided the quality control system for an extruded product according to the first or second aspect, wherein the quality judgment data in the quality judgment unit is used as production management information as a factory host computer. To send to.

[0014]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing an electrical configuration of a quality control system for an extruded product according to the present invention.

The quality control system includes an extruder manufacturing process information collection unit 1 that collects information in each manufacturing process of an extruder while associating the information with a molded product to be manufactured, and an extruder manufacturing process. An in-line inspection information collection unit 2 that collects inspection information obtained by an arranged inspection apparatus while associating the inspection information with a molded article to be manufactured, and outputs inspection information obtained by inspecting the molded article after manufacturing to the molding apparatus. Off-line inspection information collection unit 3 that collects information while associating it with products, manufacturing condition master 41 and quality standard master 4
2, a comparison between the manufacturing process information collected by the extruder manufacturing process information collecting unit 1 and the manufacturing condition master 41 of the master managing unit 4, an in-line inspection information collecting unit 2 and an offline inspection information collection A quality judging section 5 for judging the quality of the molded article by comparing the inspection information collected by the section 3 with the quality standard master 42 of the master management section 4 is provided.

Also, as a result of the quality judgment in the quality judgment section 5,
A failure display unit 6 for displaying the result of the determination when the determination is rejected, and a data storage unit 7 for storing the quality determination data in the quality determination unit 5 are provided. The quality judgment data in the quality judgment section 5 is transmitted to the factory host computer 8 as production management information.

FIG. 2 shows a process diagram of an extrusion production line to which the quality control system having the above configuration is applied. The extrusion process 11 by an extruder, the film formation process 12, the humidification process 13, and the winding by a winder. Step 15 is a humidification step 1
3 and the winding step 15, the in-line inspection step 14
Is provided.

The extruder manufacturing process information collecting unit 1 includes an extruding process 11, a film forming process 12, a humidifying process 13, and a winding process 15.
From the respective extruding process, film forming process, humidifying process and winding process, and collects information of suction pressure, additive flow rate, line speed and interlocking ratio. ing.

The in-line inspection information collecting section 2 collects thickness inspection information, surface inspection information, and color inspection information from a thickness sensor, a foreign substance sensor, and a color sensor (not shown) provided in the in-line inspection process 14.

The off-line inspection information collecting unit 3 includes:
Glossiness and appearance are inspected, and moisture content inspection information, glossiness inspection information and appearance inspection information are collected.Specifically, emboss roughness, transmittance, moisture content, appearance, preliminary press Of each information is collected.

The master management unit 4 manages upper and lower limits of manufacturing conditions and upper and lower limits of quality standards. In particular, with respect to the quality standard master 42, by doubling the standard, it is possible to judge "O", "X", and "△".

The quality judging section 5 compares each inspection information collected by the in-line inspection information collecting section 2 and the offline inspection information collecting section 3 with the quality standard stored in the quality standard master 42 of the master management section 4. Is performed, and each quality item is determined. If all the items pass, the quality determination data is transmitted to the factory host computer 8. In the case of rejection, the quality display data of the rejected molded article is displayed on the defect display section 6.

The defect display section 6 displays quality judgment data of a molded product having a rejected quality item on a screen.
The list can be printed out, and the person in charge makes a final quality judgment by looking at the screen display or the list.

Next, information collection and quality judgment in the quality control system for an extruded product having the above-described configuration will be specifically described.

Each time the production is started, a management ID is assigned to the molded article to be produced, and the molded article is managed by the management ID until the production is completed. That is, extruder manufacturing process information, inline inspection information, offline inspection information, and the like are collected in association with the molded article management ID.

(1) Collection of Extruder Manufacturing Process Information and Judgment of Quality Every time a molded product is started to be produced, a management ID is assigned, and manufacturing process information is collected using this management ID as a key. However, the manufacturing process information needs to be collected in consideration of the time required to reach the winding process 15, and this time can be calculated based on the line speed and the total process length. Here, it is necessary that the molded product be extruded from the extruder and wound up by a winder.
It should take 0 minutes.

The extruder manufacturing process information is monitored until the production of each of the molded product 1 and the molded product 2 is completed while measuring the actual measurement value every two seconds. FIG. 3 shows a specific example of the relationship between the suction pressure data and the management ID in the extruder manufacturing process information. Data collection is also performed for the additive flow rate, line speed, interlock ratio, and the like.

In the quality judging section 5, the quality standard master 42
Are sequentially compared with the measured values collected as described above, and a pass / fail judgment is made, and the judgment result is stored in the data storage unit 7.

The method of storing data in the data storage unit 7 is as follows.
It is determined for each molded article management ID whether or not the manufacturing conditions fall between the upper limit value and the lower limit value (indicated by the alternate long and short dash line in FIG. 3) stored in the manufacturing condition master 41, as shown in FIG. Store in data format. That is, the molded article 1 (management ID = 001) is judged to be “か ら” because it falls within the upper limit value and the lower limit value in all steps, and the molded article 2 (management ID = 002) is in the final step. It is determined to be "x" because there is a portion of the portion below the lower limit.

In the storage data shown in FIG. 4, all of the flow rates of the additives, the line speed, and the interlocking ratio are judged to be “○”.

(2) Collection of Inline Inspection Information and Quality Judgment Here, an inspection using a foreign substance sensor will be described as an example.

In the foreign substance inspection, the quality is determined based on the number of foreign substances generated during the production of the molded article 1 or the molded article 2. In this example, it is assumed that the molded article 1 has no foreign matter and the molded article 2 has one foreign matter.

In the quality judging section 5, the quality standard master 42
Is compared with the number of foreign substances collected as described above to determine pass / fail.

That is, molded article 1 (management ID = 001)
Is determined to be “○” because there is no foreign matter, and is determined to be “×” since one foreign matter occurs in the molded article 2 (management ID = 002). FIG. 5 shows storage data obtained by adding the foreign matter determination data to the storage data shown in FIG.

(3) Collection of Offline Inspection Information and Quality Judgment Here, an inspection of emboss roughness will be described as an example.

In the inspection of the emboss roughness, samples are cut out after the production of the molded article 1 and after the production of the molded article 2, respectively. At this time, the emboss roughness data of the inspection result is input using the management ID as a key.

The quality judging section 5 compares the input data with the quality standard stored in the quality standard master 42 and judges pass / fail.

Here, the input data is shown in FIG.
Assuming that the data stored in the quality standard master 42 is as shown in FIG. 6B, the result of the pass / fail determination is as shown in FIG. That is, the molded product 1 (management ID = 001) has an emboss of 58, which is equal to or less than the upper limit value of 60, but exceeds the upper limit value of 55. ID = 002) has an emboss of 43, which is equal to or higher than the lower limit of 40, but is lower than the lower limit of 45, so it is determined to be “△”.

FIG. 7 shows storage data obtained by adding the emboss data to the storage data shown in FIG.

In the quality judgment section 5, based on the result of the pass / fail judgment for all items obtained in this way, the management I
A comprehensive pass / fail decision is made for each D. This determination method is a method of making a determination according to the worst determination item. That is, as shown in FIG. 8, the molded article 1 (management ID = 001)
For, since the emboss quality item is “△”, the comprehensive judgment is “と”. In addition, molded article 2 (management I
For D = 002), since the suction pressure and the quality item of the foreign matter are “×”, the comprehensive judgment is “×”.

FIG. 9A shows an example of the result of the comprehensive judgment for each management ID.

For a molded product that has passed the comprehensive determination, the quality determination data (FIG. 9B) is transmitted to the factory host computer 8. In addition, for the molded products that have failed in the comprehensive judgment, the quality judgment data [FIG. (C)] is displayed on the defect display section 6 and printed out as a list. Then, looking at this screen display or list, the person in charge performs final quality judgment.

[0044]

According to the present invention, there is provided a quality control system for an extruded product, which collects information in each manufacturing process of an extruder while associating the information with a manufactured product. An information collecting unit, an in-line inspection information collecting unit that collects inspection information obtained by an inspection device arranged in each manufacturing process of the extruder while associating the information with a molded product to be manufactured, and an Offline inspection information collection unit that collects inspection information obtained by inspection while associating it with the molded product, master management unit that manages each master of manufacturing conditions and quality standards, and extruder manufacturing process information collection unit Of the manufacturing process information collected by the master management unit and the manufacturing process information collected by the master management unit, and the inspection collected by the inline inspection information collection unit and the offline inspection information collection unit By comparing the broadcast and master management unit of the quality standard master, it has a configuration that includes a determining quality determination unit the quality of the molded article. In-line inspection information consists of inspection information in each inspection item of thickness inspection, surface inspection, and color inspection, and offline inspection information consists of inspection information in each inspection item of moisture content inspection, glossiness inspection, and appearance inspection. I have. This makes it possible to efficiently and accurately determine the quality of a molded product that requires a plurality of pieces of information such as manufacturing process information and quality inspection information. In addition, even when the quality standards cover a wide variety of types, such as in the case of multi-product production, the determination does not take much time and no determination error occurs. In addition, by centrally managing the quality inspection data, it is possible to promptly respond to the case where prompt confirmation is required, such as when a customer makes a complaint.

In the quality control system for extruded products according to claim 3 of the present invention, the quality judgment data in the quality judgment section is transmitted to the factory host computer as production management information. Can quickly respond to the construction of an additional production schedule in response to the occurrence of

[Brief description of the drawings]

FIG. 1 is a block diagram showing an electrical configuration of a quality control system for an extruded product of the present invention.

FIG. 2 is a process diagram of an extrusion production line to which the quality control system of the present invention is applied.

FIG. 3 is a diagram showing a specific example of a relationship between suction pressure data and management ID in extruder manufacturing process information.

FIG. 4 is a table showing an example of stored data stored in a data storage unit.

FIG. 5 is a chart showing an example of storage data to which foreign matter determination data in the in-line inspection information is added.

FIGS. 6A and 6B are tables for explaining a procedure for determining emboss roughness in the offline inspection information, wherein FIG. 6A is an example of input data, FIG. 6B is a quality standard master, and FIG. The input example of the judgment data is shown below.

FIG. 7 is a chart showing an example of storage data to which emboss roughness determination data in the offline inspection information is added.

FIG. 8 shows the results of the pass / fail judgment for all items.
9 is a chart for explaining a determination method for performing comprehensive pass / fail determination for each management ID.

9A and 9B are tables showing a process of processing comprehensive judgment data, wherein FIG. 9A shows an example of a result of the comprehensive judgment for each management ID, and FIG. 9B shows a result of the overall judgment transmitted to the factory host computer. (C) shows an example of quality determination data for a molded article, which is displayed on the defect display unit, and shows an example of quality determination data for a molded article that has failed in the overall determination printed out as a list.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 Extruder manufacturing process information collection unit 2 In-line inspection information collection unit 3 Off-line inspection information collection unit 4 Master management unit 5 Quality judgment unit 6 Fault display unit 7 Data storage unit 8 Factory host computer 41 Manufacturing condition master 42 Quality standard master

Claims (3)

[Claims] 1. An extruder manufacturing process information collecting unit for collecting information in each manufacturing process of an extruder while associating the information with a molded product to be manufactured, and an inspection device arranged in each manufacturing process of the extruder. The in-line inspection information collection unit that collects the inspection information obtained by associating with the molded article to be manufactured, and associates the inspection information obtained by the inspection of the molded article with the molded article with the molded article. An off-line inspection information collecting unit that collects the data, a master managing unit that manages each master of manufacturing conditions and quality standards, a manufacturing process information collected by the extruder manufacturing process information collecting unit, and a manufacturing condition master of the master managing unit. And the inspection information collected by the in-line inspection information collection unit and the offline inspection information collection unit and the quality standard mass of the master management unit. A quality control system for an extruded product, comprising: a quality judging unit for judging the quality of the molded product by comparison with the extruder. 2. The method according to claim 1, wherein the in-line inspection information includes a thickness inspection,
The inspection information in each inspection item of a surface inspection and a color inspection, and the offline inspection information is inspection information in each inspection item of a moisture content inspection, a glossiness inspection, and a visual inspection. Quality control system for extruded products. 3. The quality judgment data in the quality judgment unit,
3. The quality management system for an extruded product according to claim 1, wherein the quality management system transmits the production management information to a factory host computer.