WO2019146010A1

WO2019146010A1 - Apparatus for detecting defect in workpiece

Info

Publication number: WO2019146010A1
Application number: PCT/JP2018/002079
Authority: WO
Inventors: 中原　崇; 牧　晃司; 見多出口; 雅寛堀; 金子　悟
Original assignee: 株式会社日立製作所
Priority date: 2018-01-24
Filing date: 2018-01-24
Publication date: 2019-08-01

Abstract

Disclosed is an apparatus which is for detecting a defect in a workpiece, and is capable of detecting, with high accuracy, a defect in a machined and molded product with a relatively simple configuration. An apparatus for detecting a defect in a workpiece according to the present invention is configured to detect a defect in a workpiece manufactured by a machining device (H1) driven by a motor (H108), the apparatus being provided with: a phase determining unit which determines an operation phase of the machining device on the basis of a current flowing in the motor; and a defect determining unit which determines whether there is a defect in the workpiece, on the basis of the angular speed of a rotor of the motor in the predetermined operation phase determined by the phase determining unit.

Description

Defect detection system for workpieces

TECHNICAL FIELD The present invention relates to a device for detecting a defect in a machined product which detects defects in a workpiece by various machining devices and molding devices.

In processing by a processing machine such as injection molding and cutting, defects such as burrs occur in a workpiece manufactured by the processing machine unless an appropriate control parameter is given. Therefore, when a defect is detected, control conditions are adjusted. For example, in injection molding, a molded article is produced by injecting material from an injector and sandwiching and holding it with a mold. However, if the conditions such as the injection speed, mold pressure, and holding pressure are not set, burrs may form on the molded article. It may occur or filling will be insufficient. However, visual inspection of the occurrence of burrs and insufficient filling is time-consuming, leading to a decrease in productivity.

On the other hand, as described in Patent Document 1, there is known a prior art that automatically detects an injection abnormality that causes burrs and insufficient filling.

In the technique described in Patent Document 1, after the injection holding process starts, the moving speed of the screw driven by the motor is detected at a predetermined point or screw position set in advance, and the detected moving speed exceeds the setting allowable range. If it is determined that the injection is abnormal.

Unexamined-Japanese-Patent No. 5-192969

In the above-mentioned prior art, installation of a sensor or detection of a sensor signal is required to detect a defect in a processed molded product. In addition, when detecting a defect in a processed and formed product, it is necessary to capture the current process state from the control device of the processing machine itself. For this reason, there is a problem that the device configuration becomes complicated and the cost increases.

Accordingly, the present invention provides a defect detection apparatus for a workpiece that can detect defects of a workpiece with high accuracy with a relatively simple configuration.

In order to solve the above problems, the defect detection device for a workpiece according to the present invention detects defects in a workpiece manufactured by a processing device driven by a motor, and based on the current flowing to the motor, A phase determination unit that determines an operation phase of a processing apparatus, and a defect determination unit that determines the presence or absence of a defect of a workpiece based on a rotor angular velocity of a motor in a predetermined operation phase determined by the phase determination unit. .

According to the present invention, defects of a processed and formed product can be detected with high accuracy by a relatively simple configuration.

Problems, configurations, and effects other than those described above will be clarified by the description of the embodiments below.

BRIEF DESCRIPTION OF THE DRAWINGS The system configuration | structure of the processing molded article defect detection system which is Example 1 of this invention is shown. The hardware constitutions of the molded article defect detection apparatus are shown. It shows the hardware configuration of the server in FIG. It is a functional block diagram of a molding defect detection device. It is a functional block diagram of a molded article defect detection unit. It is a functional block diagram of the rotor angular velocity calculation part in FIG. It is a functional block diagram of each phase determination part. It is a functional block diagram of a defect determination part. It is a functional block diagram of a defect feature-value calculation part. It is a functional block diagram of a bad threshold value judgment part. It is a functional block diagram of a burr | flash threshold-value determination part. It is a functional block diagram of the server in FIG. It is a functional block diagram of parameter learning / preservation part in a server. Fig. 5 shows a flow and sequence of processing in a workpiece molded part defect detection system. The detailed process flow and sequence of the phase determination process in FIG. 14 are shown. FIG. 15 shows a detailed processing flow and a sequence of data collection processing in FIG. FIG. 15 shows a detailed processing flow and a sequence of molded part defect detection processing in FIG. 14. The processing flow and sequence of parameter learning / preservation processing which a server performs are shown. The processing flow and sequence of parameter update processing F91 which a server performs are shown. It is a data structure of the various data with which a molded article defect detection apparatus is equipped. FIG. 21 shows a data configuration of a program temporary variable included in data for a molded part defect detection program in FIG. 20. FIG. The data structure of the temporary variable for angular velocity calculation parts in FIG. 21 is shown. The data structure of the phase determination threshold value group in FIG. 21 is shown. The data structure of the temporary variable for defect determination parts in FIG. 21 is shown. The data structure of the defect determination threshold value group in FIG. 21 is shown. FIG. 21 shows a data configuration of a defect detection result in FIG. 20. FIG. The data structure of the performance data in FIG. 20 is shown. FIG. 21 shows a data configuration of learned parameter data in FIG. 20. FIG. The data structure of the various data which the server in FIG. 1 has is shown. The screen transition of the defect detection result screen display in the display in FIG. 1 is shown. The system configuration | structure of the processing molded article defect detection system which is Example 2 of this invention is shown. It is a functional block diagram of a molding defect detection function part. It is a functional block diagram of the molded article defect detection part in FIG. It is a functional block diagram of each phase determination part in FIG. It is a functional block diagram of the defect determination part in FIG. The system configuration | structure of the processing molded article defect detection system which is Example 3 of this invention is shown. FIG. 37 is a functional block diagram of a defective feature quantity calculation unit included in the molding defect detection device in FIG. 36. FIG. 37 is a functional block diagram of a defective threshold value determination unit included in the molding defect detection device in FIG. 36.

Hereinafter, embodiments of the present invention will be described with reference to the drawings in Examples 1 to 3 below. In the drawings, those with the same reference numerals indicate components having the same configuration or similar functions.

FIG. 1 shows a system configuration of a workpiece molded product defect detection system according to a first embodiment of the present invention.

The present processing molded article defect detection system includes an injection molding machine H1, a U-phase current sensor H2, a V-phase current sensor H3, a W-phase current sensor H4, a molded article defect detection device H5, a display H6, a speaker H7, an internet H8, and a server H9. It consists of In addition, you may apply not only the internet H8 but another wired or wireless communication network.

The injection molding machine H1 generates a molded product by injecting a molten material (for example, a plastic material) into a mold, sandwiching and holding the pressure with the mold. The injection molding machine H1 includes a cylinder H100, a hopper H101, a screw H102, a mold H103, a tie bar H104, a mold clamping mechanism H105, an ejector H106, a crosshead H107, an injection motor H108, a metering motor H109, an ejector motor H110, a type A clamping motor H111, an ejection motor inverter H112, a weighing motor inverter H113, an ejector motor inverter H114, a clamping motor inverter H115, and a control device H116.

A permanent magnet synchronous motor or the like is applied as each motor. In the first embodiment, the injection motor H108 is driven by the three-phase AC power output from the injection motor inverter H112.

The hopper H101 heats the material to flow. The metering motor H109 agitates the material in a fluidized state with the hopper H101. The metering motor inverter H113 applies a voltage to the metering motor H109 to drive the metering motor 109.

The cylinder H100 injects the material in the fluid state into the mold H103. The screw H102 rotates in the cylinder H100 to push out the material. The injection motor H108 rotates the screw H102. The injection motor inverter H112 applies a voltage to the injection motor H108 to drive the injection motor H108.

The mold H103 molds a molded article. The tie bars H104 are two or more support columns for guiding the opening and closing operation of the mold H103.

The clamping mechanism H105 opens and closes the mold H103. The cross head H107 is a nut portion of a mold opening / closing ball screw. The mold clamping motor H111 interlocks with the crosshead H107 to open and close the mold. The clamping motor inverter H115 applies a voltage to the clamping motor H111 to drive the clamping motor H111.

The ejector H106 removes the molded material from the mold H103. The ejector motor H110 rotates the ejector H106. The ejector motor inverter H114 applies a voltage to the ejector motor H110 to drive the ejector motor H110.

The control device H116 sends a voltage command to the injection motor inverter H112, the weighing motor inverter H113, the ejector motor inverter H114, and the mold clamping motor inverter H115, whereby the injection molding machine H1 These inverters are controlled so that molded products can be made with high accuracy.

The operation of the injection molding machine H1 in the first embodiment is as follows. First, the plastic material is heated in the hopper H101 and stirred using the metering motor H109. Next, by driving the mold clamping mechanism H105 and the cross head H107 using the mold clamping motor 111, the two divided molds H103 are brought together. Next, the screw H102 is rotated using the injection motor H108 to inject the plastic material from the cylinder H100 into the mold H103. The mold is then held until the plastic material solidifies. Furthermore, after the mold is cooled, the mold clamping mechanism H 105 and the crosshead H 107 are driven using the mold clamping motor 111 to divide the mold into one, and the ejector motor H 110. The molded product is released from the mold H103 by driving the ejector H106 with using to eject the molded product. By repeating such an operation, a plurality of molded articles can be manufactured.

The U-phase current sensor H2 measures the U-phase current of the injection motor H108. The V-phase current sensor H3 measures the V-phase current of the injection motor H108. The W-phase current sensor H4 measures the W-phase current of the injection motor H108. As these current sensors, a current transformer (CT) or the like is applied. The motor current used to control the injection motor inverter H112 for driving the injection motor H108 is an independent current different from the U-phase current sensor H2, the V-phase current sensor H3 and the W-phase current sensor H4. It is detected by a sensor (not shown).

Preferably, clamp-type or clip-type CT is applied. These types of CTs are detachably attached to a cable connecting between the injection motor H108 and the output of the injection motor inverter H112. Therefore, it is possible to provide the current sensor for the molding defect detection device without changing the device configuration of the drive device of the injection molding device including the injection motor H108 and the injection motor inverter H112.

The molded product defect detection device H5 detects whether or not the molded product has a defect using the U-phase current, V-phase current and W-phase current of the injection motor H108, and the defect detection result is the control device H116 of the injection molding machine H1. Send to or feedback. The display H6 displays a molded product defect detection result screen generated by the molded product defect detection device H5. The speaker H7 outputs a voice to notify the occurrence of a defect when a defect is detected in the molded product by the molded product defect detection device H5.

The Internet H8 is a communication path for performing data communication between the molded article defect detection device H5 and the server H9. The server H9 is configured by a computer system, reads operation performance data of the injection molding machine H1 from the molded product defect detection device H5, and finds parameters to be used for molded product defect detection by learning processing based on the read operation performance data. The determined parameters are transmitted to the molded article defect detection device H5.

FIG. 2 shows the hardware configuration of the molded article defect detection device H5.

As shown in FIG. 2, the molded article defect detection device H5 includes a central processing unit (CPU), a graphic processing unit (GPU), a sound function, a random access memory (RAM), a recording device, and interfaces (1 to 5). ing.

The CPU executes arithmetic processing in accordance with a program for detecting a molded article defect.

The GPU generates screen data to be displayed on the display H6 from the molded article defect detection result, and outputs the generated screen data to the display H6 via the interface 3.

The sound function generates audio data to be output to the speaker H7 at a timing when a molded article defect is detected, and outputs the generated audio data to the display H7 via the interface 4.

The RAM temporarily stores data in a program for detecting a molding defect.

The recording device H50 records a program, data, and the like for detecting a molding defect. A hard disk drive, a flash memory drive or the like is applied as the recording device H50.

The recording apparatus H50 stores a molded article defect detection program, a defect detection result transmission program, a defect detection result display program, a defect detection buzzer output program, a server data transmission / reception program, and various data H500. These computer programs (hereinafter referred to as "programs") are executed by the CPU.

The molded article defect detection program is a program for detecting a defect in a molded article of the injection molding machine H1 from the U-phase current, the V-phase current and the W-phase current.

The defect detection result transmission program is a program for transmitting the defect detection result to the injection molding machine H1 via the interface 2.

The defect detection result display program is a program for generating screen data from the molded article defect result using the GPU, and outputting the generated screen data to the display H6 via the interface 3.

The defect detection buzzer output program is a program for generating voice data using a sound function at a timing when a molded article defect is detected, and outputting the generated voice data to the speaker H7 via the interface 4.

The server data transmission / reception program is a program for transmitting operation record data (hereinafter referred to as “result data”) to the Internet H8 via the interface 5 and receiving learned parameters from the Internet H8.

The various data H90 is data used in a program executed by the molded article defect detection device H5.

The molded article defect detection device H5 takes in the signals from the U-phase current sensor H2, the V-phase current sensor H3 and the W-phase current sensor H4 via the interface 1.

FIG. 3 shows the hardware configuration of the server H9 in FIG.

As shown in FIG. 3, the server H 9 includes a central processing unit (CPU), a graphic processing unit (GPU), a random access memory (RAM), a recording device, an operation console, and an interface 1. According to this configuration, the server H9 learns various parameters used for detection of molded article failure using the actual data received from the Internet H8, and sends it to the Internet H8 as a learned parameter.

The CPU executes arithmetic processing in accordance with various programs described later.

The operation console displays a screen prompting the operator of the server H 9 to make an input, and receives an input from the operator regarding parameter learning execution and parameter update.

The GPU generates screen data to be displayed on the operation console, and outputs the generated screen data to the operation console.

The RAM temporarily stores data when executing various programs.

The recording device H90 records various programs and data executed by the server (CPU). A hard disk drive, a flash memory drive or the like is applied as the recording device H90.

The recording device H90 stores an actual data reception program, a learned parameter transmission program, a parameter learning program, and various data H900.

The achievement data reception program is a program for receiving achievement data from the Internet H8 via the interface 1 and recording the received achievement data in the recording device H90.

The parameter learning program is a program for learning various parameters used for molded article defect detection using actual data and storing the parameters in the recording device H90 as learned parameters.

The learned parameter transmission program is a program for transmitting the learned parameters stored in the recording device H90 to the Internet H8 via the interface 1.

Various data H900 is data used by various programs executed by the server H9.

FIG. 4 is a functional block diagram of the molded article defect detection device H5.

As shown in FIG. 4, the molded article defect detection device H5 has a molded article defect detection unit B50, a defect detection result transmission unit B51, a defect detection result display unit B52, a defect detection buzzer output unit B53, and a server data transmission unit B54. .

Molded product defect detection unit B50 detects U-phase current, V-phase current and W-phase detected by U-phase current sensor H2, V-phase current sensor H3 and W-phase current sensor H4, respectively, according to a molded product defect detection program (FIG. 2). The phase current is used to detect a defect in the molded article of the injection molding machine H1.

The defect detection result transmission unit B51 transmits the defect detection result from the molded product defect detection unit B50 to the injection molding machine H1 in accordance with the defect detection result transmission program (FIG. 2).

Defect detection result display unit B 52 generates screen data according to a molding defect result from molding defect detection unit B 50 using a GPU according to a defect detection result display program (FIG. 2), and displays the generated screen data Output to H6.

The defect detection buzzer output unit B53 generates voice data using the sound function at the timing when the molding defect is detected by the molding defect detection unit B50 according to the defect detection buzzer output program (FIG. 2), and the generated voice is generated The data is output to the speaker H7.

The server data transmission / reception unit B54 transmits the result data to the Internet H8 according to the server data transmission / reception program (FIG. 2) and receives the learned parameters from the Internet H8.

FIG. 5 is a functional block diagram of the molded article defect detection unit B50.

As shown in FIG. 5, the molded article defect detection unit B50 includes a rotor angular velocity calculation unit B500, each phase determination unit B501, a defect determination unit B502, a learning result decomposition unit B503, and a data aggregation unit B504.

The rotor angular velocity B500 uses the U-phase current, the V-phase current, and the W-phase current detected by the U-phase current sensor H2, the V-phase current sensor H3, and the W-phase current sensor H4, respectively. The rotor angular velocity is calculated, and the d-axis current and the q-axis current in the rotational coordinates are calculated from the U-phase current, the V-phase current and the W-phase current.

Each phase determination unit B501 is based on the d-axis current and the q-axis current calculated by the rotor angular velocity B500, the injection phase start time in the injection molding machine H1 (FIG. 1), the pressure phase start time, the cooling phase start time In order. The start time of each phase is also the end time of the immediately preceding phase.

Defect determination unit B 502 is a defect in the molded article of injection molding machine H 1 (presence or absence of defect, type based on the rotor angular velocity calculated by rotor angular velocity calculation unit B 500 and each phase start time determined by each phase determination unit Etc.).

The learning result disassembling unit B 503 uses the learned parameters sent from the server data transmitting / receiving unit B 54, a rotor angular velocity calculation coefficient used to calculate the rotor angular velocity, and a phase determination threshold group used to determine each phase start time And the defect determination threshold value group used for the determination of defects.

The data aggregation unit B 504 integrates the rotor angular velocity, the d-axis current and the q-axis current, the phase feature quantity serving as an index for determining each phase, and the defect feature quantity serving as an index for determining whether it is defective or not. Summarize as data.

FIG. 6 is a functional block diagram of rotor angular velocity calculation unit B 500 in FIG.

As shown in FIG. 6, the rotor angular velocity calculation unit B500 includes an αβ conversion unit, a rotor angular velocity estimation unit, and a dq conversion unit.

The αβ conversion unit is a current in the U-phase current direction (α-axis) from U-phase current, V-phase current and W-phase current respectively detected by U-phase current sensor H2, V-phase current sensor H3 and W-phase current sensor H4. The α-axis current which is the component and the β-axis current which is the current component in the direction (β-axis) perpendicular to the U-phase current direction are calculated. That is, the αβ conversion unit performs so-called three-phase / two-phase conversion.

The dq conversion unit is configured to use the injection motor H108 according to the rotor angle (provisional value in FIG. 6) estimated by the rotor angular velocity estimation unit described later from the α-axis current and β-axis current calculated by the αβ conversion unit. D axis current which is a current component of the magnetic flux direction (d axis) of the rotating magnetic field of the stator and q axis current which is a current component of a direction (q axis) perpendicular to the magnetic flux direction of the stator The current and the q-axis current are transmitted to each phase determination unit B501 and data aggregation unit B504. That is, the dq conversion unit converts the α-axis current and the β-axis current in the stationary coordinate system into the d-axis current and the q-axis current in the rotating coordinate system. In the case of a synchronous motor or the like, the magnetic flux direction of the rotor may be d axis, and the direction perpendicular to the magnetic flux direction of the rotor may be q axis.

The rotor angular velocity estimation unit rotates based on the learning result decomposition unit B 503 based on the α axis current and β axis current calculated by the αβ conversion unit, or the d axis current and q axis current calculated by the dq conversion unit. The rotor angle and the rotor angular velocity are calculated using the child angular velocity calculation coefficient, and the calculated rotor angular velocity is transmitted to defect determination unit B 502 and data aggregation unit B 504. Further, the rotor angular velocity estimation unit outputs the calculated rotor angle (provisional value) to the dq conversion unit.

FIG. 7 is a functional block diagram of each phase determination unit B501.

As shown in FIG. 7, each phase determination unit B 501 includes a phase feature amount calculation unit and a phase threshold determination unit.

The phase feature quantity calculation unit is a phase feature quantity indicating the feature of the operation phase (injection, holding pressure, cooling) of the injection molding machine H1 based on the d-axis current and the q-axis current calculated in the rotor angular velocity determination unit B500. Is calculated, and the calculated phase feature amount is output to the phase threshold value determination unit. Further, the phase feature amount calculation unit transmits the calculated phase feature amount to the data aggregation unit B 504. Here, the phase feature value is, for example, the frequency at which the absolute value of the magnitude of the frequency component obtained by applying FFT (Fast Fourier Transform) to the d-axis current is maximum, or per unit time or in a predetermined period. It is the difference between the maximum value and the minimum value of the axis current.

The phase threshold determination unit acquires a phase determination threshold group indicating switching of the injection phase, the pressure holding phase, and the cooling phase from the learning result decomposition unit B 503, and performs threshold determination of the phase feature amount calculated by the phase feature amount determination unit. It is determined whether the time when the determination is made is the start time of each phase, and if it is the start time, the time when the determination is made is transmitted to the defect determination unit B 502 and the data aggregation unit B 504 as the start time of each phase. Do.

FIG. 8 is a functional block diagram of the defect determination unit B502.

As shown in FIG. 8, the defect determination unit B 502 includes a defect feature amount calculation unit B 5020 and a defect threshold determination unit B 5021.

Defect feature quantity calculation unit B5020 calculates a defect feature quantity based on the rotor angular velocity acquired from rotor angular velocity calculation unit B500 and each phase start time output by each phase determination unit B501, and the calculated defect feature The amount is output to the defect threshold value determination unit B5021 and is also transmitted to the data aggregation unit B504. Here, the defect feature amount is a parameter having a correlation with the defect of the molded product, for example, a peak value of the rotor angular velocity at the time of holding pressure and a decay of the rotor angular velocity, which are correlated with burr generation and insufficient filling. Time constant, the rotational movement of the rotor, etc.

The defect threshold determination unit B5021 acquires a defect determination threshold group from the learning result decomposition unit B503, performs threshold determination of the defect feature amount calculated by the defect feature amount calculation unit B5020, and determines the determination result as a defect detection result. While transmitting to transmission part B51, defect detection result display part B52, and defect detection buzzer output part B53, it transmits also to data aggregation part B504.

FIG. 9 is a functional block diagram of the defect feature quantity calculation unit B5020.

As shown in FIG. 9, the defect feature quantity calculation unit B5020 includes a pressure holding phase extraction unit, a pressure holding angular velocity extraction unit, an angular velocity peak value calculation unit, an attenuation time constant calculation unit, a rotor movement amount calculation unit, and a defect feature amount. It has an integrated part.

The pressure holding phase extraction unit extracts a pressure holding (phase) start time and a pressure holding (phase) end time, that is, a cooling (phase) start time, from each phase start time acquired from each phase determination unit B 501, and extracts it. The pressure holding start time and the cooling start time are output to the pressure holding angular velocity extraction unit.

The pressure holding angular velocity extraction unit extracts the pressure holding angular velocity from the rotor angular velocity calculated by the rotor angular velocity calculation unit B500 between the pressure holding start time and the cooling start time extracted by the pressure holding phase extraction unit. Then, the extracted rotor angular velocity is output to the angular velocity peak value calculation unit, the attenuation time constant calculation unit, and the rotor movement amount calculation unit. The pressure holding angular velocity extraction unit sets the rotor angular velocity to 0 before the pressure holding start time and after the cooling start time.

The angular velocity peak calculation unit calculates an angular velocity peak value as a defect feature based on the pressure holding angular velocity extracted by the pressure holding angular velocity extraction unit. At the time of pressure holding, the rotor angular velocity drops once due to pressure holding, but after rising due to the return of the material, it falls again. The peak value at the time of such a rise is the angular velocity peak value determined by the angular velocity peak calculation unit.

The damping time constant calculating unit calculates a damping time constant of the rotor angular velocity as a defect feature based on the pressure holding angular velocity extracted by the pressure holding angular velocity extracting unit. At the time of holding pressure, the rotor angular velocity attenuates after the peak value. The damping time constant calculating unit calculates a time constant _Tc when the angular velocity ω (t) at the time of such damping is expressed by equation (1).

In equation (1), t represents time (s), ω _peak represents the angular velocity peak value (rad / s), and T _peak represents the value of time t when the value of the angular velocity ω (t) reaches the peak value. In equation (1), t ≧ _Tpeak .

The rotor movement amount calculation unit calculates the movement amount of the rotor as a defective feature amount by performing time integration calculation of the pressure holding time angular velocity extracted by the pressure holding time angular velocity extraction unit.

The defect feature amount aggregating unit integrates the angular velocity peak value, the attenuation time constant, and the rotor movement amount calculated respectively by the angular velocity peak value calculation unit, the attenuation time constant calculation unit, and the rotor movement amount calculation unit, and integrates them. The defect feature amount is output to the defect threshold value determination unit B5021 and transmitted to the data aggregation unit B504.

FIG. 10 is a functional block diagram of the defective threshold value determination unit B5021.

As shown in FIG. 10, the defective threshold judgment unit B5021 is a burr threshold judgment unit B50210, an overfill threshold judgment unit B50211, a void / sink threshold judgment unit B50212, a deformation / warp threshold judgment unit B50213, a color change · WL (weld line ) A threshold determination unit B50214 and a defect detection result aggregation unit B50215.

The flash threshold determination unit B50210 uses the defect feature amount calculated by the failure feature amount calculation unit B5020 and a threshold for determining the presence or absence of a flash included in the failure determination threshold value group acquired from the learning result decomposition unit B503. The presence or absence of a burr of a molded product is determined by thresholding, and the determination result is output to the defect detection result collecting unit B 50215.

The filling excess / deficiency threshold determination unit B50211 is a threshold for determining the excess / deficiency of the filling included in the defect determination threshold value group acquired by the defect feature amount calculation unit B5020 and the defect determination threshold value group acquired from the learning result decomposition unit B503. Is used to determine the filling excess or deficiency of the molded product as a threshold, and the determination result is output to the defect detection result aggregating unit B 50215.

The void / sink threshold determination unit B50212 determines the presence or absence of the void / sink included in the defect determination threshold value group acquired by the defect feature amount calculation unit B5020 and the defect determination threshold value group acquired from the learning result decomposition unit B503. The threshold value is used to determine the presence or absence of voids and sink marks in the molded product using the threshold value, and the determination result is output to the defect detection result aggregation unit B 50215.

The deformation / warpage threshold determination unit B 50213 determines the presence or absence of the deformation / warpage included in the failure feature amount calculated by the failure feature amount calculation unit B 5020 and the failure determination threshold group acquired from the learning result decomposition unit B 503. The threshold value is used to determine the presence or absence of deformation or warpage of the molded product using the threshold value, and the determination result is output to the defect detection result aggregation part B50215.

For determining the occurrence of the color change / weld line included in the failure feature amount calculated by the color change / WL threshold value determination unit B50214 and the failure feature amount calculation unit B5020 and the failure determination threshold value group acquired from the learning result decomposition unit B503 The threshold value is used to determine the occurrence of discoloration and weld line of the molded product using the threshold value, and the determination result is output to the defect detection result aggregation unit B50215.

Defect detection result aggregating part B50215 includes burr presence / absence by each of burr threshold judgment part B50210, filling excess / minus threshold judgment part B50211, void / sink threshold judgment part B50212, deformation / warpage threshold judgment part B50213, discoloration / WL threshold judgment part B50214 Judgment result, filling over / under judgment result, void / sinking judgment result, deformation / warp judgment result, discoloration / weld line judgment result are collected as defect detection results, and the collected defect detection results are shown in defect detection result transmitting portion B51, defect It transmits to the detection result display part B52, the defect detection buzzer output part B53, and the data collection part B504.

FIG. 11 is a functional block diagram of the flash threshold determination unit B50210. Note that the overfill threshold determination unit B50211, the void / sink threshold determination unit B50212, the deformation / warp threshold determination unit B50213, and the deformation / weld line threshold determination unit B50214 also have the same functional configuration as the burr threshold determination unit B50210, The description of these determination units is omitted.

As shown in FIG. 11, the flash threshold judgment unit B 50210 has a defective feature amount division unit, a defective threshold judgment group division unit, a peak value threshold judgment unit, a time constant threshold judgment unit, a movement threshold judgment unit, and a logical operation unit. doing.

The defect feature quantity dividing unit divides the defect feature quantity acquired from the defect feature quantity calculation unit B 5020 into an angular velocity peak value, an attenuation time constant, and a rotor movement amount, and the peak value threshold judgment unit, time constant threshold judgment unit, movement Output to the amount threshold determination unit.

The defect threshold judgment group dividing unit divides the defect judgment threshold value group acquired from the learning result decomposing unit B 503 into the peak value threshold for burr judgment, the time constant threshold for burr judgment, and the movement amount threshold for burr judgment, and peak value threshold judgment respectively. It outputs to the unit, the time constant threshold determination unit, and the movement amount threshold determination unit. Further, the defective threshold value judgment group dividing unit outputs logical expression information to the logical operation unit.

The peak value threshold determination unit performs the threshold determination using the peak value threshold for burr determination acquired from the defect threshold determination group division unit based on the peak value acquired from the defect feature amount division unit, and the angular velocity peak value determination result Output

The time constant threshold determination unit performs threshold determination using the time constant threshold for flash determination acquired from the failure threshold determination group division unit based on the attenuation time constant acquired from the failure feature amount division unit, and the time constant determination result Output

The movement amount threshold determination unit performs the threshold determination using the movement threshold for burr determination acquired from the defect threshold determination group division unit based on the rotor movement amount acquired from the defect feature amount division unit, and the movement amount determination result Output

The logical operation unit is based on the peak value determination result output from the peak value threshold determination unit, the time constant threshold determination unit, and the movement amount threshold determination unit, the time constant determination result, and the movement amount determination result. The logical expression information to be acquired is used to determine the presence or absence of a burr by logical operation, and the determination result is transmitted to the defect feature amount aggregating unit B 50215.

For example, the peak value judgment result is R _P (0 or 1), the time constant judgment result is R _T (0 or 1), and the movement amount judgment result is R _M (0 or 1) (1 when the threshold is exceeded If it does not exceed 0, the burr presence / absence judgment result R _B (0 (without burr) or 1 (with burr)) is expressed by a logical expression such as expression (2).

Here, C _PXX , C _XTX , C _XXM , C _PTX , C _PXM , C _XTM , and C _PTM are coefficients in respective logic terms, and take a value of 0 or 1. The equation (2) is also applied to the overfill threshold determination unit B50211, the void / sink threshold determination unit B50212, the deformation / warp threshold determination unit B50213, and the deformation / weld line threshold determination unit B50214, and the value of each coefficient is And is appropriately set according to each determination unit.

FIG. 12 is a functional block diagram of the server H9 in FIG.

As shown in FIG. 12, the server H 9 receives and saves actual data from the Internet H 8 and stores it in a server. The actual data receiving / storing unit B 90 learns and stores parameters used for molding defect determination using the actual data. Parameter learning / storing unit B91, learning parameter reading / sending unit B92 for reading the learned parameters and sending it to the Internet H8, receiving an operation from the operator via the operation console and outputting a learning command to the parameter learning / storing unit B91 It has an operation reception unit B93.

FIG. 13 is a functional block diagram of the parameter learning / storage unit B91 in the server H9.

As shown in FIG. 13, the parameter learning / storage unit B 91 includes an actual data decomposition unit, a rotor angular velocity calculation coefficient learning unit, a phase determination threshold value group learning unit, a failure determination threshold value group learning unit, and a learned parameter aggregation / storage unit. Have.

The actual data disassembling unit allows the actual data to be used in each learning unit, so that the rotor angular velocity, the d-axis current, the q-axis current, the phase feature, the injection start time, and the pressure holding start time And the cooling start time, the defect feature amount, and the defect determination result.

The rotor angular velocity calculation coefficient learning unit calculates a rotor angular velocity calculation coefficient so as to improve estimation accuracy of the rotor angular velocity based on actual data of the rotor angular velocity, d-axis current and q-axis current, and calculates a calculated value It outputs as a learning value of a rotor angular velocity calculation coefficient. For example, the rotor angular velocity calculation coefficient learning unit performs rotation when the magnitude of the difference between the rotor angular velocity calculated based on the d-axis current and the q-axis current and the rotor angular velocity of the actual data is larger than a predetermined value. The child angular velocity calculation coefficient is adjusted, and if it does not exceed the predetermined value, the rotor angular velocity calculation coefficient is not changed and maintained at the current set value.

The phase determination threshold value group learning unit determines the phase determination threshold value group (injection phase determination threshold value, storage pressure phase determination threshold value, cooling phase determination, based on the phase feature amount and the actual data of injection start time, pressure holding start time, and cooling start time. The threshold value and the in-shot phase determination threshold value are calculated, and the calculated value is output as a learning value of the phase determination threshold value group. For example, the phase determination threshold value group learning unit records the case where the injection start time, the pressure holding start time, and the cooling start time are extremely long or short, that is, when they are longer or shorter than a predetermined value. The variance of the phase feature quantity per unit time is calculated, and in the part where there is a step in the variance, an intermediate value of the values before and after the step, that is, before and after the change of the phase feature quantity is calculated. The “in-shot determination threshold” described in FIG. 13 is a threshold for determining whether or not a molded product is being generated.

The defect determination threshold value group learning unit calculates the defect determination threshold value group based on the defect feature amount and the actual result data of the defect determination result, and outputs the calculated value as a learning value. For example, the defect determination threshold value group learning unit calculates defect determination threshold value groups using so-called clustering. In this case, the defect determination threshold value group learning unit calculates a defect determination threshold value such that the cluster boundary that classifies the defect feature amount into a cluster with defect generation and a cluster without defect generation can classify the existence of defects with high probability. Do.

The learned parameter aggregating / storage unit is a parameter output by the rotor angular velocity calculation coefficient learning unit, the phase determination threshold value group learning unit, and the defect determination threshold value group learning unit, that is, the rotor angular velocity calculation coefficient, the phase determination threshold group The phase determination threshold, the pressure holding phase determination threshold, the cooling phase determination threshold, the in-shot phase determination threshold), and the defect determination threshold group are collected and stored. The learned parameter reading / transmitting unit B 92 reads the parameters stored by the learned parameter aggregation / storage unit.

FIG. 14 shows the flow and sequence of processing in the system for detecting a defect in a formed molded article according to the first embodiment.

First, the molded product defect detection device H5 acquires values of the U-phase current, the V-phase current, and the W-phase current that are detected by the U-phase current sensor H2, the V-phase current sensor H3, and the W-phase current sensor H4, respectively.

Next, using the phase determination unit B 501 (FIG. 5), the molded article defect detection device H 5 determines whether the current phase is injection, holding pressure, or cooling, and whether a shot is in progress. A phase determination process F50 is performed. If the shot is in progress, the molded article defect detection device H5 performs data collection, and then returns to the process of acquiring the values of the U-phase current, the V-phase current, and the W-phase current. When the shot is not in progress, the molded article defect detection device H5 returns to acquisition processing of the values of U-phase current, V-phase current and W-phase current if the previous shot is not in shot, and if the previous shot is in shot The process F52 is executed.

After executing the detection process F52, the molded article defect detection device H5 transmits the defect detection result to the injection molding machine H1. The injection molding machine H1 changes control setting values such as an injection speed setting value, a holding pressure setting value, and a mold pressure setting value according to the defect detection result received from the molded article defect detection device H5. Further, the molded article defect detection device H5 transmits the result data to the Internet H8, and transmits it to the server H9 (not shown in FIG. 14) via the Internet H8.

Next, the molded article defect detection device H5 creates a defect detection screen and an audio output (buzzer output) based on the result of the defect detection, and transmits them to the display H6 and the speaker H7, respectively. The display H8 displays a defect detection result screen from the molded article defect detection device H5, and the speaker H7 is a buzzer sound indicating that the molded article defect is detected when the voice output from the molded article defect detection device H5 is received. Output

After the molded article defect detection device H5 executes the above-described series of processes, the process returns to the current acquisition process.

FIG. 15 shows a detailed processing flow and sequence of the phase determination processing F50 in FIG.

First, in the molded article defect detection unit B50 included in the molded article defect detection device H5, the rotor angular velocity calculation unit B500 requests the learning result decomposition unit B503 for a rotor angular velocity calculation coefficient. The learning result decomposition unit B 503 transmits the rotor angular velocity calculation coefficient to the rotor angular velocity calculation unit B 500. The rotor angular velocity calculating unit B500 reads the U-phase current _{I u} and the V-phase current _{I v} and the W-phase current _{I w,} running αβ conversion by equation (3), alpha -axis current I _alpha and β-axis current I Calculate _β .

The rotor angle estimation unit (FIG. 6) in the rotor angle calculation unit estimates the rotor angular velocity based on the α axis current and the β axis current. Here, assuming that the sampling period is ΔT and time is t = k × ΔT, rotation is performed using equation (4) from α-axis current I _α (k) and β-axis current I _β (k) calculated at time t The child angle (provisional value) θ _d (k) is calculated.

Next, the rotor angular velocity calculation unit B500 calculates the equation (5) based on the α axis current I _α (k), the β axis current I _β (k) and the rotor angle (provisional value) θ _d (k). The dq conversion is performed to calculate the d-axis current I _d (k) and the q-axis current I _q (k).

The rotor angle estimation unit (FIG. 6) in the rotor angle calculation unit uses the equation (6) based on the calculated d-axis current I _d (k) and q-axis current I _q (k). The updated value θ _u (k) of the angle is calculated.

The rotor angle estimation unit (FIG. 6) determines whether the absolute value of the difference between the calculated updated value θ _u (k) of the rotor angular velocity and the temporary value θ _d (k) is equal to or greater than a predetermined threshold value. If the threshold value is greater than or equal to the threshold value, the temporary value θ _d (k) is recalculated by the equation (7), and the updated value θ _u is again calculated by the equations (5) and (6) using the recalculated value. Calculate (k).

In Formula (7), C _u is one of the rotor angular velocity calculation coefficients included in the learned parameters transmitted from the server H 9 (FIG. 12), and the absolute value of C _u is 0 or more and less than 1 is there.

If the absolute value of the difference between the updated value θ _u (k) and the temporary value θ _d (k) is less than a predetermined threshold, the rotor angle estimation unit (FIG. 6) determines the rotor angular velocity according to equation (8) ω (k) is calculated and output as an estimated value of the rotor angle and stored. Note that θ _u (k−1) is the updated value of the rotor angle that was calculated and stored one sampling period earlier.

Further, when the absolute value of the difference between the update value θ _u (k) and the temporary value θ _d (k) is less than a predetermined threshold, the rotor angular velocity calculation unit B500 sends the d-axis current to each phase determination unit B501. And each value (I _d (k), I _q (k)) of the q-axis current.

When receiving each value of the d-axis current and the q-axis current, each phase determination unit B 501 requests the phase determination threshold group to the learning result decomposition unit B 503. In response to this request, the learning result disassembly unit B 503 transmits the phase determination threshold value group to each phase determination unit B 501. When each phase determination unit B501 receives the phase determination threshold value group, each phase determination unit B501 stores the current phase number (identification number assigned to each operation phase (injection, holding pressure, cooling)) stored in each phase determination unit B501 or the like. Read and calculate phase feature quantities. When the calculated phase feature amount exceeds the phase threshold, each phase determination unit B501 determines that the operation phase is shifted from the operation phase indicated by the current phase number to the next phase, and saves the phase. Update the current phase number.

FIG. 16 shows a detailed process flow and sequence of the data collection process F51 in FIG.

First, the defect determination unit B 502 in the molded article defect detection unit B 50 requests the rotor angular velocity calculation unit B 500 to transmit the rotor angular velocity, the d-axis current, and the q-axis current. In response to this request, the rotor angular velocity calculation unit B500 transmits the rotor angular velocity, the d-axis current, and the q-axis current to the defect determination unit B502 and the data aggregation unit B504.

Next, the defect determination unit B 502 requests each phase determination unit B 501 to transmit the phase feature amount and each phase start time. In response to this request, each phase determination unit B501 transmits the phase feature amount and each phase start time to the defect determination unit B502 and the data aggregation unit B504.

When the defect determination unit B 502 receives the phase feature amount and each phase start time, the failure determination unit B 502 acquires the current time, and transmits the acquired current time to the data aggregation unit B 504. The defect determination unit B 502 and the data aggregation unit B 504 respectively store the acquired data (rotor angular velocity, d-axis current and q-axis current, phase feature amount and time to start each phase, time).

FIG. 17 shows a detailed processing flow and sequence of the molded part defect detection processing F52 in FIG.

First, the failure feature quantity calculation unit B 5020 in the failure judgment unit B 502 reads the rotor angular velocity, the pressure holding start time, and the cooling start time, and extracts the angular velocity at pressure holding. Next, the defect feature quantity calculation unit B 5020 calculates defect feature quantities according to the number of types of defect feature quantities, aggregates the calculated feature quantities, and sets them as defect feature quantities as a defect threshold decision unit B 5021 and data aggregation unit B 504. Send to

When the defect threshold value determination unit B5021 receives the defect feature amount, the defect threshold value determination unit B5021 requests the learning result decomposition unit B503 to transmit the defect determination threshold value group. In response to this request, the learning result disassembly unit B 503 transmits a failure determination threshold value group to the failure threshold determination unit B 5021. The defect threshold value determination unit B5021 executes threshold value determination processing using defect feature amounts and defect determination thresholds for the number of types of feature amounts. After all the threshold value determinations are completed, the defect threshold value determination unit B5021 determines the presence or absence of a defect by logical operation using the above-mentioned equation (2).

After executing the above processing for the number of types of defects, the defect threshold value determination unit B5021 aggregates defect detection results and transmits the result to the data aggregation unit B504. The data aggregation unit B 504 stores the received defect detection result.

FIG. 18 shows the process flow and sequence of the parameter learning / storage process F90 executed by the server H9.

First, when receiving an operation of parameter learning execution from the operator, the operation receiving unit B 93 in the server H 9 transmits a learning command to the parameter learning / storage unit B 91.

When receiving the learning command, the parameter learning / storage unit B91 requests the actual data reception / storage unit B90 to transmit the actual data. In response to this request, the actual data reception / storage unit B90 transmits actual data to the parameter learning / storage unit B91.

The parameter learning / storage unit B 91 calculates each learning value of the rotor angular velocity calculation coefficient, the phase determination threshold group, and the failure determination threshold group based on the received actual data, and integrates these calculated learning values, Save as learned parameters.

FIG. 19 shows the process flow and the sequence of the parameter update process F91 executed by the server H9.

First, when the operation accepting unit B 93 in the server H 9 accepts an operation of parameter update execution from the operator, the operation accepting unit B 93 transmits a parameter update command to the learned parameter reading and transmitting unit B 92. When receiving the parameter update command, the learned parameter reading / sending unit B 92 requests the parameter learning / storing unit B 91 to transmit the learned parameters. In response to this request, the parameter learning / storage unit B91 transmits the learned parameters to the learned parameter learning / storage unit B92. When the learned parameter reading / transmitting unit B 92 receives the learned parameter, the learned parameter reading / transmitting unit B 92 transmits the learned parameter to the server data transmission / reception unit B 54 in the molded article defect detection device H 5 via the Internet H 8. The server data transmission / reception unit B 54 stores the received learned parameter.

FIG. 20 shows the data configuration of various data H500 included in the molded article defect detection device.

As shown in FIG. 20, various data H500 (FIG. 2) recorded in the recording device H50 in the molded article defect detection device H5 are data D50 for a molded article defect detection program, data D54 for a server data transmission / reception program, and a defect detection result It comprises data for transmission program, data for defect detection result display program, and data for defect detection buzzer output program.

Molded product defect detection program data D50 is a constant and a variable used by the molded product defect detection program, and includes setting data such as sampling cycle, temporary variable D500 for program, U-phase current value, V-phase current value, W-phase The current value includes the defect detection result D501. The setting data such as the sampling cycle is a setting value such as a sampling cycle in data collection or a coefficient used for various arithmetic processing. The program temporary variable D500 is a collection of variables whose values are changed while being used while the molding defect detection program is being executed. The U-phase current value, the V-phase current value, and the W-phase current value are digital data indicating the current values measured by the U-phase current sensor H2, the V-phase current sensor H3, and the W-phase current sensor H4, respectively. The defect detection result D501 is data relating to the presence or absence of various defects of the molded product, calculated by the molded product defect detection program.

The server data transmission / reception program data D54 is a constant and a variable used by the server data transmission / reception program, and includes setting data such as communication speed, a program temporary variable, actual data D540, and a learned parameter D541. The setting data such as the communication speed is a setting value such as the communication speed in communication with the server H 9 or a value indicating the type of communication protocol. The program temporary variable is a collection of variables whose values are used while the server data transmission / reception program is being executed. The performance data D540 is operation data of the molded article defect detection device H5, and time, rotor angular velocity, d axis current and q axis current, phase feature amount, injection start time, pressure holding start time, cooling start time, defect feature Includes quantity and defect judgment results. The learned parameter is a group of various coefficients used for calculation of molded product defect detection received from the server H9, and includes a rotor angular velocity calculation coefficient, a phase determination threshold group, and a failure determination threshold group.

The defect detection result transmission program data is a constant and a variable used in the defect detection result transmission program, and includes setting data such as communication speed and a program temporary variable. The setting data such as the communication speed is a setting value such as a communication speed in communication with the injection molding machine H1 or a value indicating the type of communication protocol. The temporary variable for program is a collection of variables whose values are changed while the defect detection result transmission program is being executed.

The defect detection result display program data is a constant and a variable used by the defect detection result display program, and includes setting data such as a screen size, a program temporary variable, and display screen data. The setting data such as the screen size is a setting value such as the size and the number of colors of the screen displayed on the display H6. The program temporary variable is a collection of variables whose values are changed while the defect detection result display program is being executed. The display screen data is image data of a screen showing a defect detection result.

The defect detection buzzer output program data is a constant and a variable used by the defect detection buzzer output program, and includes setting data such as a voice type, a program temporary variable, and voice data. The setting data such as the sound type is the setting value of the type and volume of sound to be output to the speaker H7. The program temporary variable is a collection of variables whose values are changed while being used during execution of the defect detection buzzer output program. The voice data is waveform data of voice that sounds when defect detection occurs.

FIG. 21 shows a data configuration of a program temporary variable D500 included in the data for a molding defect detection program in FIG.

As shown in FIG. 21, the program temporary variable D500 for the molded part defect detection program includes data D5000 for rotor angular velocity calculation unit, time series data for rotor angular velocity, data D5001 for each phase calculation unit, each phase start time, current , The current shot number, d-axis q-axis current time-series data, and data D5002 for defect determination unit.

The rotor angular velocity calculation unit data D5000 is a variable temporarily used by the rotor angular velocity calculation unit, and includes setting data and a temporary variable D50000 for the angular velocity calculation unit. The setting data is a coefficient for calculating the rotor angular velocity, and includes a rotor angular velocity calculation coefficient, and a threshold of a difference between the updated estimated value of the rotor angle and the temporary value. The angular velocity calculation unit temporary variable D50000 is a set of variables whose values are changed while the calculation of the rotor angular velocity is being performed.

The rotor angular velocity time-series data is data in which a plurality of values of time and rotor angular velocity exist as a set.

Each phase calculation unit data D5001 is a variable temporarily used in each phase calculation unit, and includes setting data and each phase calculation unit temporary variable D50010. The setting data is a coefficient for calculating each phase start time, and includes a phase determination threshold group. The temporary variables for each phase calculation unit are a collection of variables whose values are changed while calculation processing of each phase start time is being performed.

Each phase start time includes an injection start time which is a start time of the injection phase, a pressure holding start time which is a start time of the pressure holding phase, and a cooling start time which is a start time of the cooling phase.

The current phase number indicates the current phase number among the phase numbers assigned to the shot start phase, the injection phase, the pressure holding phase, the cooling phase, and the shot end phase.

The current shot number indicates the current shot number among the shot numbers indicating the number of times the molded product has been tried since the start of operation of the molded product defect detection device H5.

The d-axis and q-axis current time-series data are data that exist in a plurality of sets of time, d-axis current and q-axis current.

The defect determination unit data D5002 is a variable used in the defect determination unit, and includes setting data D50021 and a defect determination unit temporary variable D50020. The setting data D50021 is setting data of the defect determination unit, and includes a defect determination threshold value group D500210. The failure determination unit temporary variable D50020 is a variable used temporarily by the failure determination unit.

FIG. 22 shows a data configuration of the temporary variable D 50000 for the angular velocity calculation unit in FIG.

As shown in FIG. 22, the temporary variables for the angular velocity calculation unit are α axis current value, β axis current value, d axis current value (temporary value), q axis current value (temporary value), rotor angular velocity tentative value, rotation The child angular velocity update value is included.

FIG. 23 shows a data configuration of phase determination threshold value group D50010 in FIG.

As shown in FIG. 23, the phase determination threshold group D50010 includes an injection phase determination threshold for determining an injection phase, a pressure holding phase determination threshold for determining a pressure holding phase, and an injection phase determination for determining an injection phase. The threshold value, the cooling phase determination threshold value for determining the cooling phase, and the in-shot determination threshold value for determining whether the shot is in progress are included.

FIG. 24 shows a data configuration of the failure determination unit temporary variable D50020 in FIG.

As shown in FIG. 24, the failure determination unit temporary variable D 50020 includes pressure holding angular velocity time-series data and a failure feature amount. The pressure retention time angular velocity time series data is data in which a plurality of time and pressure retention time rotor angular velocities are present as a set. The defect feature amount includes an angular velocity peak value, an attenuation time constant, and a rotor movement amount.

FIG. 25 shows a data configuration of failure determination threshold value group D500210 in FIG.

As shown in FIG. 25, the defect determination threshold group D500210 includes a burr determination threshold group, an overfill determination threshold group, an underfill determination threshold group, a sink mark determination threshold group, and a void determination threshold group (FIG. 25). (Not shown), deformation determination threshold group (not shown in FIG. 25), warpage determination threshold group (not shown in FIG. 25), color change determination threshold group (not shown in FIG. 25), weld line determination A threshold group (not shown in FIG. 25) is included.

The burr determination threshold group includes a peak value threshold, a time constant threshold, a movement amount threshold, and logical expression data. The peak value threshold indicates the boundary (threshold) of the rotor angular velocity peak value when burrs occur. The time constant threshold indicates the boundary of the decay time constant when burrs occur. The movement amount threshold indicates the boundary of the rotor movement amount when burrs occur. Logical expression data, _C PXX in equation (2) described _{_{_{_{above, C XTX, C XXM, C}}}} PTX, C PXM, C XTM, a _{C PTM.}

Note that the overfill determination threshold group, the underfill determination threshold group, the sinking determination threshold group, the void determination threshold group, the deformation determination threshold group, the warpage determination threshold group, the color change determination threshold group, for weld line determination The threshold value group also has the same data configuration as the burr judgment threshold value group.

FIG. 26 shows the data structure of the defect detection result D501 in FIG.

As shown in FIG. 26, the defect detection result D501 indicates the presence or absence of burrs indicating whether or not there are burrs in the molded product, the overfilling determination result indicating whether the molded product is overfilled or not, whether the molded product is insufficiently filled or not The result of the lack of emphasis judgment shown, the result of the void judgment showing whether or not a void is generated in the molded article, the result of a sinking judgment showing whether or not a sink mark is generated in the molded article, and whether or not the molded article has deformation. As a result of deformation determination, as a result of warpage determination indicating whether warpage occurs in the molded article, as a result of weld line determination indicating whether a weld line occurs in the molded article, whether or not stringing occurs in the formed article It includes the stringing determination result shown. As illustrated, in the first embodiment, the value of the determination result is indicated by a logical value, and is 1 when the corresponding defect occurs in the molded product, and 0 when it does not occur. is there.

FIG. 27 shows the data configuration of the performance data D 540 in FIG.

As shown in FIG. 27, the performance data is a collection of performance data per shot, and the performance data per shot is a shot number, performance time series data, each phase start time, defect feature amount, defect determination Include the results. The actual time-series data is data in which a plurality of time, rotor angular velocity, d-axis current, q-axis current, and phase feature amount exist as a set.

FIG. 28 shows the data configuration of the learned parameter data D 541 in FIG.

As shown in FIG. 28, the learned parameter data D541 includes a rotor angular velocity calculation coefficient, a phase determination threshold group D50010, and a defect determination threshold group D500210.

FIG. 29 shows a data configuration of various data H900 possessed by the server H9 in FIG.

As shown in FIG. 29, the various data H900 of the server H9 includes data for a performance data reception program, data for a learned data reception program, data for a parameter learning program, performance data D540, and a learned parameter D541.

The data for the actual data receiving program is a constant and a variable used by the actual data receiving program, and includes setting data such as communication speed and a temporary variable for the program. The program setting data is a setting value such as a communication speed in communication with the molded article defect detection device H5 or a value indicating the type of communication protocol. The temporary variable for program is a collection of variables whose values are used while the actual data receiving program is being executed.

The data for the learned data transmission program is a constant and a variable used by the learned data transmission program, and includes setting data such as communication speed and a temporary variable for the program. The program setting data is a setting value such as a communication speed in communication with the molded article defect detection device H5 or a value indicating the type of communication protocol. The program temporary variable is a collection of variables whose values are used while the learned data transmission program is being executed.

The data for the parameter learning program is a constant and a variable used by the parameter learning program, and includes setting data such as a learning coefficient and a temporary variable for the program. Setting data such as learning coefficients are setting values such as learning coefficients used for parameter learning. The program temporary variable is a collection of variables whose values are used while the parameter learning program is being executed.

FIG. 30 shows screen transition of the defect detection result screen display on the display H6 in FIG.

In FIG. 30, the shot selection screen G61 is a screen display prompting the user to select which shot of the defect detection results the defect detection result is to be displayed. The molded product defect detection result screen G60 displayed when the shot number is selected includes the shot number, the presence or absence of burrs, the presence or absence of overfilling, the presence or absence of insufficient filling, the presence or absence of voids, the presence or absence of warpage, the presence or absence of warpage, or deformation The presence or absence of threading, the presence or absence of a weld line, and a back button are displayed. When the back button is selected, the screen display returns to the shot selection screen G61.

According to the first embodiment described above, the predetermined operation phase (hold pressure phase) for determining a defect is extracted and extracted based on the motor current detected by the current sensor provided for the molding defect detection device. In the operation phase, the presence or absence of a defect of the injection molded product which is a workpiece is detected based on the rotor angular velocity of the motor estimated from the motor current. As a result, defects of the injection-molded product can be detected with high accuracy by a relatively simple device configuration. In addition, since the injection molding apparatus can be provided with a molding defect detection function without substantially changing the device configuration of the injection molding machine, it is possible to suppress an increase in cost.

FIG. 31 shows a system configuration of a workpiece molded product defect detection system according to a second embodiment of the present invention. The following mainly describes differences from the first embodiment.

The present processing molded article defect detection system includes an injection molding machine H1, a display H6, a speaker H7 (buzzer sound), the Internet H8, and a server H9.

In the injection molding machine H1, the injection motor inverter H112 includes a power generation unit H1120 that applies a voltage to the injection motor H108, and a molding defect detection function unit H1121. The power generation unit H1120 includes a main circuit unit (not shown) formed of a semiconductor switching element, and a control unit (not shown) for driving the main circuit. The molded product defect detection function unit H1121 detects the presence or absence of a defect in the molded product using the rotor angular velocity sensor value of the injection motor H108 and the U-phase current, and transmits or feedbacks the defect detection result to the control device H116. The display H6 displays a molded product defect detection result screen generated by the molded product defect detection function unit H1121. The speaker H7 outputs a voice (buzzer sound) when a defect of the molded product is detected by the molded product defect detection function unit H1121, and notifies the occurrence of the defect.

The Internet H8 is a communication path for performing data communication between the molded product defect detection function unit H1121 and the server H9. The server H9 reads the operation result data of the injection molding machine H1 from the molded part defect detection function unit H1121, obtains the parameter used for molded part defect detection by learning processing, and transmits the calculated parameter to the molded part defect detection unit H1121 Do.

FIG. 32 is a functional block diagram of the molded article defect detection function unit H1121.

As shown in FIG. 32, the molded article defect detection function unit H1121 includes a molded article defect detection unit B11210, a defect detection result transmission unit B11211, a defect detection result display unit B11212, a defect detection buzzer output unit B11213, and a server data transmission unit B11214. Have.

The molded part defect detection B11210 is detected by a sensor to control the injection motor inverter H112 according to the molded part defect detection program, and is taken in and stored in the control part of the injection motor inverter H112. Defects in the molded product of the injection molding machine H1 are detected using the rotor angular velocity and the U-phase current of the motor H108. In place of the U-phase current, a V-phase current or a W-phase current may be used.

Here, the U-phase current is detected by a current sensor (CT or the like) for control of the injection motor inverter (not shown). Of the three phases, at least two of the three-phase motor currents are detected for control of the injection motor inverter (one-phase motor current is not detected because the sum of the three-phase motor currents is zero). Calculated).

Further, the rotor angular velocity is detected by a rotation sensor (for example, a rotary encoder etc.) not shown, estimated from three-phase current of the motor as in the first embodiment, or induction voltage of the motor applying so-called sensorless control. It is estimated based on etc.

Defect detection result transmission unit B11211, defect detection result display unit B11212, defect detection buzzer output unit B11213, and server data transmission unit B11214 respectively indicate defect detection result transmission unit B51 and defect detection result display in the first embodiment (FIG. 4). It has the same function as the unit B52, the defect detection buzzer output unit B53, and the server data transmission / reception unit B54.

FIG. 33 is a functional block diagram of the molded part defect detection unit H11210 in FIG.

As shown in FIG. 33, the molded article defect detection unit B11210 includes each phase determination unit B112100, a defect determination unit B112101, a learning result decomposition unit B503, and a data aggregation unit B504.

Each phase determination unit B11210 determines each phase start time using the U-phase current of the injection motor H108 stored in the injection motor inverter H112 and the phase determination threshold group from the learning result decomposition unit B503. Do.

Defect determination unit B112101 starts the rotor angular velocity of injection motor H108 stored in injection motor inverter H112, defect determination threshold value group from learning result decomposition unit B503, and start of each phase from each phase determination unit B11210. The defect detection result is calculated using time.

The learning result decomposing unit B 503 and the data aggregation unit B 504 in FIG. 33 have the same functions as the learning result decomposition unit B 503 and the data aggregation unit B 504 in the first embodiment (FIG. 5), respectively.

FIG. 34 is a functional block diagram of each phase determination unit B 112100 in FIG.

As shown in FIG. 34, each phase determination unit B 112100 has a phase feature amount calculation unit and a phase threshold determination unit. The phase feature amount determination unit calculates a phase feature amount indicating a feature of the phase from the U-phase current sensor H2. The phase threshold determination unit in FIG. 34 has the same function as the phase threshold determination unit in the first embodiment (FIG. 7).

FIG. 35 is a functional block diagram of defect determination unit B 112101 in FIG.

As shown in FIG. 35, the defect determination unit B 112101 includes a defect feature amount calculation unit and a defect threshold determination unit. The defect determination unit calculates a defect feature amount from the rotor angular velocity of the injection motor H108 stored in the injection motor inverter H112 and each phase start time from each phase determination unit B11210. The defect threshold determination unit in FIG. 35 has the same function as the defect threshold determination unit B5021 in the first embodiment (FIG. 8).

According to the second embodiment, the control unit of the injection motor inverter for driving the injection motor is provided with a molded product defect detection function and mounted, and inverter control is performed on a predetermined operation phase (hold pressure phase) for judging a defect. In the predetermined operation phase to be extracted and extracted based on the motor current detected by the current sensor provided for the motor, based on the rotor angular velocity of the motor detected by the rotation sensor or estimated from the motor current, The presence or absence of a defect of the injection-molded product which is a workpiece is detected. As a result, defects of the injection molded product can be detected with high accuracy by a relatively simple device configuration.

Further, according to the second embodiment, the molding defect detection function is mounted on the control unit of the injection motor inverter, and the motor current and the rotor angular velocity used for controlling the inverter and motor in the control unit are used together for defect detection. By doing this, since the injection molding apparatus can be provided with a molding defect detection function without substantially changing the device configuration of the injection molding machine, the increase in cost can be suppressed.

FIG. 36 shows a system configuration of a workpiece molded part defect detection system that is Embodiment 3 of the present invention. The following mainly describes differences from the first embodiment.

This machined molded product defect detection system is from cutting machine H0, U phase current sensor H2, V phase current sensor H3, W phase current sensor H4, molded product defect detection device H5, display H6, speaker H7, Internet H8, server H9 Configured

The cutting machine H0 includes a drill H001, a cutting machine H003 on which a material H002 to be processed is placed, a drill rotation motor H004, a height direction movement motor H005, a width direction movement motor H006, and a depth direction movement motor H007. Height direction movement drive system H008, width direction movement drive system H009, depth direction movement drive system H010, drill rotation motor inverter H011, height direction movement motor inverter H012, width direction movement It comprises an inverter H013, a depth direction moving motor inverter H014, and a control device H015. The cutting machine H0 manufactures a machined product by cutting the material H002 by rotating the drill H001 with the drill rotation motor H004.

The drill H 001 processes the material H 002 into a predetermined shape by contacting the material H 002 while rotating a bladed rotary body.

The cutting machine H003 is a base on which the material H002 is placed.

The drill rotation motor H004 is a motor for rotating the drill H001. The height direction moving motor H 005, the width direction moving motor H 006, and the depth direction moving motor H 007 move the drill H 001 in the height direction, the width direction, and the depth direction by rotating the rotor.

The drive system for moving in the height direction H008, the drive system for moving in the width direction H009, and the drive system for moving in the depth direction H010 are each composed of a spindle, a gear and a reel, and each has a motor for moving in the height direction H005. The power generated by the width direction moving motor H 006 and the depth direction moving motor H 007 is transmitted in each moving direction.

The drill rotation motor H011, the height direction movement motor inverter H012, the width direction movement motor inverter H013, and the depth direction movement motor inverter H014 are respectively the drill rotation motor H004 and the height direction movement. A voltage is applied to the motor H 005, the width direction moving motor H 006, and the depth direction moving motor H 007 to drive.

The other components (H2 to H9) shown in FIG. 36 have the same functions as in the first embodiment (FIG. 1).

FIG. 37 is a functional block diagram of a defect feature amount calculation unit B 5020 included in the molding defect detection device in FIG. 36 (see FIG. 9 for Example 1).

As shown in FIG. 37, the defective feature quantity calculation unit B5020 includes a contact phase extraction unit, an angular velocity extraction unit at contact time, an angular velocity peak value calculation unit, an attenuation time constant calculation unit, a rotor movement amount calculation unit, and a defective feature quantity aggregation unit Have.

The contact phase extraction unit extracts the contact start time and the contact end time of the drill H001 and the material H002 from each phase start time from each phase determination unit B501, and extracts the contact start time and the contact end time when contacting the angular velocity Send to department

The contact angular velocity extraction unit extracts the rotor angular velocity of the drill rotation motor H 004 at the time of contact from the rotor angular velocity from the rotor angular velocity calculation unit B 500 and the contact start time and contact end time from the contact phase extraction unit. Do. The contact angular velocity extraction unit sets these values to 0 for the rotor angular velocity before the contact start time and after the contact end time.

The angular velocity peak time calculation unit, the attenuation time constant calculation unit, the rotor movement amount calculation unit, and the defect feature amount aggregation unit in FIG. 37 are the angular velocity peak time calculation unit and the attenuation time constant in Example 1 (FIG. 9), respectively. It has the same function as the calculation unit, the rotor movement amount calculation unit, and the defect feature amount aggregation unit.

FIG. 38 is a functional block diagram of a defective threshold value determination unit B5021 included in the molding defect detection device in FIG. 36 (see FIG. 10 for Example 1).

As shown in FIG. 38, the defect threshold judgment unit B5021 is a breakage threshold judgment unit B50216, a substrate burr threshold judgment unit B50217, a dimension accuracy failure threshold judgment unit B50218, a chip clogging threshold judgment unit B50219, and a cutting surface roughness threshold judgment unit B5021A. , And a defect detection result aggregation part B50215.

The breakage threshold determination unit B 50216 uses the defect feature amount from the defect feature amount calculation unit B 5020 and the defect determination threshold value group from the learning result decomposition unit B 503 to determine whether there is a defect in the processed product due to breakage of the drill H 001. Then, the determination result is transmitted to the defect detection result aggregating unit B 50215.

The substrate burr threshold determination unit B 50217 uses the defect feature amount from the defect feature amount calculation unit B 5020 and the defect determination threshold value group from the learning result decomposition unit B 503 to threshold the presence or absence of a burr generated on the substrate of the processed molded article. It judges and transmits a judgment result to defect detection result intensive part B50215.

The dimensional accuracy defect threshold determination unit B 50218 uses the defect feature amount from the defect feature amount calculation unit B 5020 and the defect determination threshold value group from the learning result decomposition unit B 503 to determine whether there is a deviation in the dimensional accuracy of the processed product. Then, the determination result is transmitted to the defect detection result aggregating unit B 50215.

The chip clogging threshold determination unit B 50219 uses the defect feature amount from the defect feature amount calculation unit B 5020 and the defect determination threshold value group from the learning result decomposition unit B 503 to threshold the presence or absence of a defect in the processed product due to chipping. It judges and transmits a judgment result to defect detection result intensive part B50215.

The cutting surface roughness threshold determination unit B5021A uses the defect feature amount from the defect feature amount calculation unit B5020 and the defect determination threshold value group from the learning result decomposition unit B503 to threshold the presence or absence of roughening on the cutting surface of the processed product. It judges and transmits a judgment result to defect detection result intensive part B50215.

The defect detection result aggregating part B 50215 uses the judgment results of each judgment part, that is, the breakage presence / absence judgment result, the substrate burr presence / absence judgment result, the dimensional accuracy defect judgment result, the chip clogging judgment result, the cutting surface roughness judgment result as a defect detection result It gathers and it transmits to defect detection result transmission part B51, defect detection result display part B52, defect detection buzzer output part B53, and data aggregation part B504.

According to the third embodiment, the predetermined operation phase (contact phase) for determining a failure is extracted based on the motor current detected by the current sensor provided for the molding failure detection device, and the predetermined operation is extracted. In the phase, based on the rotor angular velocity of the motor estimated from the motor current, it is detected whether or not there is a defect in the machined product which is a workpiece. As a result, defects can be detected with precision with a relatively simple device configuration. In addition, since the mechanical device can be provided with a molding defect detection function without substantially changing the device configuration of the cutting machine, the increase in cost can be suppressed.

In the third embodiment, as in the second embodiment described above, the molding defect detection function may be mounted on the control unit of the drill rotation motor inverter.

The present invention is not limited to the embodiments described above, but includes various modifications. For example, the embodiments described above are described in detail in order to explain the present invention in an easy-to-understand manner, and are not necessarily limited to those having all the configurations described. In addition, it is possible to add, delete, and replace another configuration for part of the configuration of each embodiment.

H001: drill, H002: material, H003: cutting machine,
H004: Motor for drill rotation, H005: Motor for moving in the height direction,
H006: Width direction movement motor, H007: Depth direction movement motor,
H008: Drive system for moving in the height direction,
H009: Drive unit for moving in the width direction,
H010: Drive system for moving in the depth direction
H011: Inverter for drill rotation motor,
H012: Motor inverter for moving in the height direction
H013: Inverter for width direction movement motor,
H014: Inverter for moving motor in depth direction,
H100: cylinder, H101: hopper, H102: screw,
H103: mold, H104: tie bar, H105: clamping mechanism,
H106: Ejector, H107: Crosshead,
H108: Ejection motor, H109: Weighing motor H110: Ejector motor, H111: Clamping motor,
H112: Inverter for motor for injection,
H113: Motor for measuring motor,
H114: Motor for ejector motor,
H115: Motor for clamping motor

Claims

A defect detection device for detecting defects in a workpiece manufactured by a processing device driven by a motor, comprising:
A phase determination unit that determines an operation phase of the processing apparatus based on the current flowing through the motor;
A defect determination unit that determines the presence or absence of a defect of the workpiece based on a rotor angular velocity of the motor in the predetermined operation phase determined by the phase determination unit;
An apparatus for detecting defects in a workpiece, comprising:
The apparatus for detecting defects in a workpiece according to claim 1, wherein
The apparatus for detecting a defect in a workpiece according to claim 1, wherein the phase determination unit calculates a phase feature amount indicating the operation phase from the current, and determines the operation phase based on the calculated phase feature amount.
The apparatus for detecting defects in a workpiece according to claim 2, wherein
The apparatus for detecting a defect in a workpiece, wherein the phase feature quantity is a frequency component of a d-axis current calculated from the current flowing through the motor or a difference between a maximum value and a minimum value of the d-axis current.
The apparatus for detecting defects in a workpiece according to claim 1, wherein
The defect determination unit calculates a defect feature amount indicating the defect of the workpiece from the rotor angular velocity, and determines the defect of the workpiece based on the calculated defect feature amount. Defect detection device for workpieces.
The apparatus for detecting defects in a workpiece according to claim 4, wherein
The defect detection device for a workpiece according to claim 1, wherein the defect feature amount is any one of a peak value of the rotor angular velocity, an attenuation time constant of the rotor angular velocity, and a rotor movement amount.
The apparatus for detecting defects in a workpiece according to claim 1, wherein
The current flowing through the motor is detected by a current sensor,
An apparatus for detecting defects in a workpiece, comprising a rotor angular velocity calculation unit that calculates the rotor angular velocity based on the detected current.
The apparatus for detecting defects in a workpiece according to claim 1, wherein
An inverter for driving the motor;
The phase determination unit and the failure determination unit are mounted on a control unit of the inverter,
An apparatus for detecting a defect in a workpiece, wherein the current flowing through the motor is used by the control unit to control the inverter.
The apparatus for detecting defects in a workpiece according to claim 7, wherein
The apparatus for detecting a defect in a workpiece is characterized in that the rotor angular velocity is detected by a rotation sensor provided in the motor.
The apparatus for detecting defects in a workpiece according to claim 1, wherein
The processing device is an injection molding machine,
The workpiece is an injection molded article,
The defect is any of burr, overfill, underfill, void, sink marks, warp, deformation, discoloration, stringing, and weld line,
An apparatus for detecting defects in a workpiece, wherein the predetermined operation phase is a pressure holding period.
The apparatus for detecting defects in a workpiece according to claim 1, wherein
The processing device is a cutting machine,
The workpiece is a machined product,
The defect is any one of breakage, burrs, dimensional error, chip clogging, and rough cutting surface,
An apparatus for detecting defects in a workpiece, wherein the predetermined operation phase is a contact period.