KR100961339B1 - Mold monitoring apparatus - Google Patents

Abstract

It is an object of the present invention to provide a mold monitoring apparatus which can easily identify the cause of the occurrence of the abnormality and operate the injection molding machine as having a high throughput.

The mold monitoring apparatus includes a surveillance camera for monitoring the mold surface state of the movable mold of the injection molding machine which fills the molded article forming material in the cavity formed by clamping the movable mold and the fixed mold, and the movable mold stored in advance. And a monitoring apparatus main body for monitoring the occurrence of abnormality by comparing the reference image data of the mold surface of the mold surface with the monitoring image data of the mold surface of the movable mold obtained in the process of forming. Each time the molding process is performed, the old surveillance image data is sequentially updated with the latest monitoring image data so that the state where the monitoring image data relating to at least two molding processes of the immediately preceding molding process is stored is obtained. .

Description

Mold monitoring device {MOLD MONITORING APPARATUS}

This invention monitors the mold surface state of the metal mold | die in an injection molding machine, for example, the molding process is carried out in the state in which clamping is performed in the state which the molded product remained in the metal mold surface of a metal mold | die, or a defect has arisen in the molded product. The present invention relates to a mold monitoring apparatus for preventing the continuation from being performed.

Conventionally, in an injection molding machine for manufacturing a resin molded article, which includes a fixed mold and a movable mold having a relation to each other, for example, when both molds are clamped in a state in which a molded article is left in the movable mold, Since damage to itself causes problems such as a case where the production line may be stopped for a long time, it is necessary to monitor the mold surface state of the movable mold, for example, at a mold opening completion position. The mold of the structure which fixes a surveillance camera in the position which can image the mold surface of a movable mold in a predetermined position and a direction, and monitors the molding surface state of a movable mold based on the image data acquired by this surveillance camera. The monitoring apparatus is proposed (for example, refer patent document 1 and patent document 2).

In such a mold monitoring apparatus, in the process of performing a series of shaping | molding processes including clamping, resin material filling, cooling solidification, mold opening, and extruding of a molded article, for example, a molded article on a mold surface of a movable mold Primary reference image data which is the image data of this hold | maintain state, and secondary monitoring image data which is image data of the state in which the molded article was isolate | separated from the molded article holding surface, and acquired the reference image in each state previously acquired By comparing with the primary reference image data and the secondary reference image data, which are data, the presence or absence of abnormality occurrence related to molding is monitored.

5 is a block diagram schematically showing the configuration of a monitoring apparatus main body in an example of a conventional mold monitoring apparatus.

The monitoring apparatus main body 50 in this mold monitoring apparatus is provided with the reference image memories 51A and 51B to which the primary reference image data and the secondary reference image data are rewritable and stored, and the monitoring camera 60. By comparing the primary reference image data and the primary surveillance image data with the surveillance image memories 52A and 52B in which the primary surveillance image data and secondary surveillance image data acquired are recorded; The control unit 55 has a function of comparing the secondary reference image data with the secondary surveillance image data to determine the degree of agreement between the two image data. In the figure, reference numeral 56 denotes an I / 0 block that outputs an operation command signal to the controller 55 based on, for example, a mold opening signal transmitted from an injection molding machine, an extrusion completion signal, or the like. It is an A / D conversion block which converts image data output from the camera 60 as an analog signal, for example, into a digital signal (A / D value), and inputs it into the control part 55. FIG.

In this mold monitoring apparatus, the monitoring image data is acquired every time a molding process is performed, and the thing related to the molding process just before being recorded in the monitoring image memory is updated and recorded with the monitoring image data related to the latest molding process.

As a result of the comparison judgment of the reference image data and the monitoring image data, when it is confirmed that the two images generally coincide, it is determined that the molded article does not remain in the fixed mold but is held in the movable mold, and the process proceeds to the extrusion process of the molded article. Or it is judged that the molded article was pushed out favorably from the mold surface of the movable mold, and the following molding process (clamping process) is performed.

On the other hand, when it is confirmed that the two images do not coincide as a result of the comparison judgment between the reference image data and the monitoring image data, it is determined that part or all of the molded article remains in the fixed mold or the molded article is defective. Or, it is judged that the molded article remained in the movable mold without being pushed out well, and the injection molding machine is stopped.

[Patent Document 1: Japanese Patent No. 3875486]

[Patent Document 2: Japanese Patent Application Laid-Open No. 2002-11772]

Therefore, in the conventional mold monitoring apparatus as described above, as described above, when it is detected that an abnormality has occurred in molding, the injection molding machine is stopped, that is, the molding operation is stopped, for example, the fixed mold or the movable mold. The molding operation was resumed by taking temporary measures such as removing remaining molded articles.

However, in such a countermeasure, it is difficult to identify the cause of abnormality, and since the molding operation is continuously performed without substantial improvement, the molding operation may be frequently stopped whenever an abnormality occurs. There is a problem that the throughput of the injection molding machine is lowered.

The present invention has been made on the basis of the above circumstances, and when an abnormality occurs in the process of performing a series of molding treatments, the factor can be identified very easily, and therefore, the injection molding machine has a high throughput. It is an object of the present invention to provide a mold monitoring apparatus which can be operated as a system.

The metal mold | die of the said movable mold of the injection molding machine of the injection molding machine of this invention is equipped with a movable mold and a fixed mold, and forms a molded article by filling a molded article formation material in the cavity formed by clamping the said movable mold and the said fixed mold. Security cameras to monitor surface conditions,

The primary reference image data in which the molded article is held on the mold surface of the movable mold and the secondary reference image data in which the molded article is separated from the mold surface of the movable mold are recorded and stored in advance, and the molding process is performed. Primary monitoring operation | movement which checks the difference of both image data by comparing primary monitoring image data and said primary reference image data in the state in which the molded object was hold | maintained on the metal mold | die surface of a movable mold acquired by the said monitoring camera, and a movable mold The occurrence of an abnormality in the process in which the molding process is performed by comparing the secondary monitoring image data in which the molded article is separated from the mold surface of the mold with the secondary reference image data and performing the secondary monitoring operation to confirm the difference between the two image data. It is provided with a monitoring device body for monitoring the presence,

Each time the molding process is performed so that the state of storing the primary surveillance image data and the secondary surveillance image data related to the latest molding process and at least two molding processes immediately before the molding process is stored, The primary surveillance image data and the secondary surveillance image data related to the molding process are recorded while being sequentially updated with the primary surveillance image data and the secondary surveillance image data related to the latest molding process.

In addition, in the mold monitoring apparatus of the present invention, when an external memory is detachably installed and it is confirmed that an abnormal state occurs in either one of the primary monitoring operation and the secondary monitoring operation, recording is performed in the monitoring apparatus main body. It is preferable that the surveillance image data to be transmitted is stored in the external memory.

According to the metal mold | die monitoring apparatus of this invention, the shaping | molding process old in time series so that the monitoring image data related to the shaping | molding process which an abnormality generate | occur | produced and the monitoring image data related to the shaping | molding process immediately before the said shaping | molding process are always recorded as history information. The monitoring image data related to the above is sequentially configured to be updated and stored with the monitoring image data related to the latest molding process. Thus, the monitoring image data related to the molding process in which an abnormality occurs and the monitoring image data related to the molding process immediately before an abnormality occur. As a result of comparison, it is possible to recognize the precursor of the occurrence of the abnormality. As a result, the cause of the abnormality can be identified very easily. Therefore, appropriate measures for the cause of the abnormality can be promptly taken, and the injection molding machine has a high throughput. It can be operated.

Moreover, since the external memory for transmitting and storing the surveillance image data as the history information recorded in the monitoring apparatus main body is connectable, only the external memory is removed from the monitoring apparatus main body, for example, a computer for data analysis. By connecting to, since the monitoring image data can be analyzed in parallel with the molding operation, the cause of the abnormality can be determined while preventing the throughput of the injection molding machine from decreasing.

BRIEF DESCRIPTION OF THE DRAWINGS Explanatory drawing which showed the outline of the structure of the principal part in an example of the injection molding machine with the metal mold | die monitoring apparatus of this invention in the state which both mold opened, FIG. 2 is an example of the metal mold | die monitoring apparatus of this invention. It is a block diagram schematically showing the configuration of a related monitoring apparatus body.

This injection molding machine is connected to the fixed mold 11 fixed to the fixed platen 10, the movable platen 10 and the tie bar 15, and a movable plate 11 provided to be movable in and out of the fixed mold 11. It is provided in the cavity (molding space) provided with the movable mold 21 fixed to the tongue 20, and formed by being in a clamping state (the movable mold 21 is in close contact with the fixed mold 11). While the injection mechanism including the nozzle 13 for filling the resin material thus prepared is provided in the stationary platen 10, the movable mold 21 is moved in a direction away from the stationary mold 11 so that the pin member ( A pushing mechanism for separating the molded article from the mold surface 21A of the movable die 21 by pressing the pusher 24 is provided on the movable platen 20.

The mold monitoring device of the present invention is a monitoring camera 25 for capturing the state of the mold surface 21A of the movable mold 21 which is a monitoring surface to acquire image data, and the monitoring image acquired by the monitoring camera 25. The monitoring device main body 30 is provided with the display means 31 which monitors the state of the metal mold surface 21A of the movable mold 21 based on data, and displays the acquired image data, and clamps in an injection molding machine. In the process of performing a series of shaping | molding processes including a process, a resin material filling process, a cooling solidification process, a mold opening process, and the extrusion process of a molded article, a molded article is made to die surface 21A of the movable die 21, for example. The primary surveillance image data which is the image data of the hold | maintain state, and the secondary surveillance image data which is image data of the state in which the molded article was isolate | separated from the metal mold surface 21A of the movable die 21 were acquired previously, and are movable Gold in mold 21 By comparing the primary reference image data with the molded article held on the mold surface 21A and the secondary reference image data with the molded article separated from the mold surface 21A of the movable mold 21, the occurrence of abnormality related to molding Monitor for presence

At this time, the primary reference image data is actually obtained by selecting, for example, a state in which a defect or a crack does not occur in the molded article among a plurality of image data obtained by repeatedly performing a series of molding processes.

Moreover, similarly about secondary reference image data, it is acquired by selecting the thing of the state in which the molded article (resin material) is not attached to 21 A of mold surfaces of the movable metal mold 21 among several image data.

The monitoring device main body 30 relates to a reference image memory area 35 having reference image memories 35A and 35B in which primary reference image data and secondary reference image data are rewritably recorded, and associated with one molding process. A control unit 32 having a surveillance image memory area in which primary surveillance image data and secondary surveillance image data are recorded, and a function of reading the reference image data and the surveillance image data and comparing and determining whether or not both image data match each other. And an I / 0 block 34 for outputting an operation command signal to the control unit 32 on the basis of a command signal transmitted from the display means 31 and a mold opening signal, an extrusion completion signal, and the like transmitted from the injection molding machine; And an A / D conversion block 33 for converting image data output as, for example, an analog signal from the surveillance camera 25 into a digital signal (A / D value) and inputting it to the control unit 32. And there.

The monitoring apparatus main body 30 in this embodiment has three monitoring image memory areas 40, 41, 42, for example, and includes three consecutive images including the monitoring image data related to the latest molding process. Surveillance image data related to the molding process is recorded as history information.

That is, when the molding process is newly performed while the monitoring image data relating to the preceding molding process is recorded in each of the three monitoring image memory areas 40, 41, and 42, the oldest molding process is performed in time series. The related monitoring image data is sequentially updated and recorded with the monitoring image data related to the latest molding process.

When the update method of monitoring image data is demonstrated concretely, when the latest primary surveillance image data and secondary surveillance image data concerning the Nth molding process are acquired, the primary monitoring of the 3rd surveillance image memory area | region 42 will be carried out. The primary surveillance image data and the secondary surveillance image data related to the oldest (N-3) th time molding process recorded in the image memory 42A and the secondary surveillance image memory 42B are erased. Primary surveillance image data and secondary surveillance relating to the (N-2) th molding process recorded in the primary surveillance image memory 41A and the secondary surveillance image memory 41B of the two surveillance image memory regions 41. The image data is transferred to the primary surveillance image memory 42A and the secondary surveillance image memory 42B of the third surveillance image memory region 42, and the primary surveillance image memory of the first surveillance image memory region 40. 40A and secondary surveillance image memo The primary surveillance image data and secondary surveillance image data related to the (N-1) th molding process recorded in the second 40B are stored in the primary surveillance image memory 41A of the second surveillance image memory region 41 and The latest primary surveillance image data and secondary surveillance image data, which are transmitted to the secondary surveillance image memory 41B and are related to the N-th molding process, are respectively stored in the primary surveillance image memory area 40 of the primary surveillance image memory region 40 ( 40A) and secondary surveillance image memory 40B.

The display means 31 acquires the primary reference image data and the secondary reference image data, records them in the primary reference image memory 35A and the secondary reference image memory 35B of the reference image memory area 35, The state of the mold surface 21A of the movable mold 21 is monitored by comparing the setting mode for performing the setting operation to be stored with each reference image data stored in advance and each monitoring image data obtained in the process of performing a series of molding processes. It has a touch panel (not shown) in which an icon for selecting a monitoring mode for performing a monitoring operation is displayed, and has a function of outputting an operation command signal corresponding to the selected operation mode to the control unit 32.

The setting mode is used not only for acquiring and storing the primary reference image data and the secondary reference image data, but also for updating each reference image data already stored in the reference image memory area 35 with a new one.

Hereinafter, the method of monitoring the state of the metal mold surface 21A of the movable metal mold 21 by the said metal mold | die monitoring apparatus is demonstrated with reference to FIG.

First, when the setting mode is selected on the touch panel of the output by the display means 31 ("N" in the judging section of FIG. 3), the angles already recorded in the reference image memory area 35 as necessary. After the reference image data is erased, a molding process (a clamping process, a filling process of a resin material, a cooling solidification process) is started in the injection molding machine, and when the molding process is completed, the movable mold 21 is moved to the stationary mold 11. It moves in the direction of separation and becomes a mold opening state.

And if it is confirmed that the movable mold 21 is in the predetermined monitoring position ("Y" in the judgment part (b) of FIG. 3), the mold surface (of the movable mold 21 in which the molded article is hold | maintained) 21A) state is photographed by the monitoring camera 25, and primary reference image data is acquired and recorded in primary reference image memory 35A.

Next, when the extrusion process is performed in an injection molding machine, and it is confirmed that the molded product is separated from the mold surface 21A of the movable mold 21 ("Y" in the judgment part (c) of FIG. 3), the movable mold The state of the mold surface 21A of (21) is photographed by the monitoring camera 25, so that secondary reference image data is acquired and recorded in the secondary reference image memory 35B.

And this process is repeatedly performed as needed, and each reference image data judged to be optimal is stored.

On the other hand, when the monitoring mode is selected on the touch panel of the display means 31 in the state where each reference image data is acquired ("Y" in the judgment part of FIG. 3), the molding process (resin) in the injection molding machine is performed. When filling of the material and solidification of cooling) are started and the molding process is completed, the movable mold 21 is moved in a direction away from the stationary mold 11 to enter the mold opening state.

And when it is confirmed that the movable mold 21 is in the predetermined monitoring position ("Y" in the judgment part (d) of FIG. 3), the metal mold surface of the movable mold 21 in which the molded article is hold | maintained ( 21A) state is photographed by the surveillance camera 25, and primary surveillance image data is acquired and recorded in a surveillance image memory. At this time, as a series of molding processes are performed, when the surveillance image data has already been recorded in each of the surveillance image memory areas 40, 41, and 42, as described above, it is related to the oldest molding process in time series. The surveillance image data is erased, and the primary surveillance image data related to the latest molding process is updated and recorded.

The primary surveillance image data thus obtained is compared with the primary reference image data to determine whether the primary reference image data and the primary surveillance image data match or not (conformity of both images). Is done.

If it is judged that the primary monitoring image data and the primary reference image data substantially coincide ("Y" in the determination unit (e) of FIG. 3), the molded article is removed from the mold surface 21A of the movable mold 21. An extrusion process for separating is performed. At this time, "substantially coincident" means that a certain standard of error is determined to determine whether the obtained molded product is a good product or a defective product in order to prevent a decrease in throughput of the injection molding machine. Is set to an allowed state.

On the other hand, if it is determined that the primary monitoring image data and the primary reference image data do not coincide (“N” in the determination unit (e) of FIG. 3), it is determined that an abnormality has occurred in the molding process, and an alarm is generated. Together with the injection molding machine is forcibly stopped. In addition, the state judged that the abnormality generate | occur | produced in the shaping | molding process is mentioned later.

When it is judged that the molding process was normally performed in the primary monitoring operation, when the extrusion process is performed in the injection molding machine, and it is confirmed that the molded product is separated from the mold surface 21A of the movable mold 21 (the judging unit in FIG. 3 (bar ), The state of the mold surface 21A of the movable mold 21 is photographed by the monitoring camera 25, whereby secondary monitoring image data is acquired and primary monitoring related to the molding process is obtained. The image data is recorded in the secondary surveillance image memory in the surveillance image memory area where it is recorded.

The secondary surveillance operation which compares the secondary surveillance image data acquired in this way with the secondary reference image data and judges whether or not the secondary reference image data and the secondary surveillance image data coincide (the degree of agreement between the two images) is performed. Is done.

If it is judged that the secondary surveillance image data and the secondary reference image data substantially coincide ("Y" in the determination unit of FIG. 3), the next molding process is performed, while the primary surveillance image is performed. If it is determined that the data and the primary reference image data do not coincide ("N" in the judging unit of Fig. 3), it is determined that an abnormality has occurred in the molding process, an alarm is generated and an injection molding machine is Forcibly stopped.

As described above, as a result of the comparison judgment processing of both the image data of the reference image data and the monitoring image data, the reference image data and the monitoring image data do not coincide, that is, it is determined that an abnormality has occurred in the molding process. As, for example

(1) When the molded article is attached to and held on the mold surface 11A of the stationary mold 11 after mold opening, and it is confirmed that the molded article is not attached to and held on the mold surface 21A of the movable mold 21. ,

(2) Even after performing the extrusion operation of the molded article, when it is confirmed that the molded article remains without being separated from the mold surface 21A of the movable mold 21,

(3) When it is confirmed that the molded article is not molded to a desired shape

Etc. can be illustrated.

As a cause of "abnormality" such that the injection molding machine is stopped, for example, problems of the structure (shape or material, etc.) of the structural members constituting the mold and other injection molding machines themselves, deformation or damage of the structural members, or , (A) The molding powder is stuck to the mold surface 21A of the movable mold 21 by performing the next molding treatment while the molding powder (resin material) generated in the molding process immediately before is left in the mold. Various factors, such as the thing which acted as an adhesive and the molded article remained in 21 A of mold surfaces of the movable die 21, and the amount of the resin material filled in (B) cavity are not an appropriate quantity, are considered.

By the way, according to the said metal mold | die monitoring apparatus, it is time-series so that the state in which the monitoring image data related to three consecutive shaping | molding processes including the monitoring image data related to the shaping | molding process which an abnormality generate | occur | produced is always recorded as history information is obtained. The structure is configured to update and store sequentially from the monitoring image data relating to the old molding process, thereby comparing and comparing the monitoring image data related to the molding process in which the abnormality has occurred with the monitoring image data related to the molding process before the abnormality occurs. Recognizing the preceding signal to be generated, in other words, each surveillance image data recorded in the monitoring apparatus main body 30 can be used for the identification of the cause of the abnormality.

Specifically, for example, by comparing and comparing the monitoring image data related to the molding process in which an abnormality has occurred, the monitoring image data related to the molding process immediately before it, and also the monitoring image data related to the previous molding process, for example, In the secondary monitoring image data related to the molding process immediately before the generated molding process, molding powder is present on the mold surface 21A of the movable mold 21, or the filling amount of the resin material in the primary monitoring image data. It is possible to recognize a difference such as that a change in shape due to the change occurs, and as a result, the occurrence factor of the abnormality can be identified very easily.

In the present invention, if the monitoring image data relating to the molding process immediately before the molding process at the time of abnormality occurrence is recorded, it is expected that a sufficient effect will be obtained in practical use. Since the surveillance image data relating to the data is recorded as the history information, the cause of abnormality can be determined with high accuracy.

Therefore, appropriate measures for the cause of abnormality can be taken promptly, and the injection molding machine can be operated with a high throughput.

As mentioned above, although embodiment of this invention was described, this invention is not limited to said embodiment, A various change can be added.

For example, as shown in FIG. 4, the external memory 45 is detachably provided with respect to the monitoring apparatus main body 30, and as shown in the flowchart shown in FIG. 3, the primary monitoring is performed. When it is confirmed that an abnormality has occurred in either of the operation and the secondary monitoring operation, the monitoring image data recorded in the monitoring image memory areas 40, 41, 42 related to each molding process of the monitoring apparatus main body 30 ( The primary surveillance image data and the secondary surveillance image data) can be transferred to the external memory 45 and stored.

According to the metal mold | die monitoring apparatus of such a structure, only the external memory 45 is removed from the monitoring apparatus main body 30, and it connects to the computer for data analysis, for example, and analyzes monitoring image data separately from a shaping | molding operation (abnormal | Since it is possible to carry out the lifesaving of the cause, it is possible to carry out the lifesaving of the abnormality while preventing the throughput of the injection molding machine from decreasing.

In the mold monitoring apparatus of the present invention, the number of surveillance image memory regions is not particularly limited.

In addition, the abnormality occurrence factor recognized by comparing the some surveillance image data recorded as history information is not limited to what was illustrated above.

BRIEF DESCRIPTION OF THE DRAWINGS It is explanatory drawing which shows the outline of the structure of the principal part in an example of the injection molding machine with the metal mold | die monitoring apparatus of this invention in the state which both mold opened.

2 is a block diagram schematically showing the configuration of a monitoring apparatus main body according to an example of a mold monitoring apparatus of the present invention.

3 is a flow chart for explaining the operation of the mold monitoring apparatus of the present invention.

4 is a block diagram schematically showing a configuration of another example of the monitoring apparatus main body related to the mold monitoring apparatus of the present invention.

5 is a block diagram schematically showing the configuration of a monitoring apparatus main body in an example of a conventional mold monitoring apparatus.

<Explanation of symbols for the main parts of the drawings>

10: fixed platen 11: fixed mold

11A: mold face of fixed mold 13: nozzle

15: tie bar 20: movable platen

21: movable mold 21A: mold surface of the movable mold

23: pin 24: pushing out

25: surveillance camera 30: surveillance device body

31 display means 32 control unit

33: A / D conversion block 34: I / O block

35: reference picture memory area 35A: primary reference picture memory

35B: Secondary reference picture memory 40: First surveillance picture memory area

41: second surveillance image memory area 42: third surveillance image memory area

40A, 41A, 42A: Primary Surveillance Image Memory

40B, 41B, 42B: Secondary Surveillance Image Memory

45: external memory 50: the main body of the monitoring device

51A: primary reference picture memory 51B: secondary reference picture memory

52A: Primary Surveillance Image Memory 52B: Secondary Surveillance Image Memory

55 control unit 56 I / O block

57: A / D conversion block 60: surveillance camera

Claims (2)

A surveillance camera having a movable mold and a stationary mold and monitoring a mold surface state of the movable mold of an injection molding machine for filling a molded article forming material into a cavity formed by clamping the movable mold and the fixed mold to form a molded article; , The primary reference image data in which the molded article is held on the mold surface of the movable mold and the secondary reference image data in which the molded article is separated from the mold surface of the movable mold are recorded and stored in advance, and the molding process is performed. Primary monitoring operation | movement which checks the difference of both image data by comparing primary monitoring image data and said primary reference image data in the state in which the molded object was hold | maintained on the metal mold | die surface of a movable mold acquired by the said monitoring camera, and a movable mold The occurrence of an abnormality in the process in which the molding process is performed by comparing the secondary monitoring image data in which the molded article is separated from the mold surface of the mold with the secondary reference image data and performing the secondary monitoring operation to confirm the difference between the two image data. It is provided with a monitoring device body for monitoring the presence, Each time the molding process is performed so that the state of storing the primary surveillance image data and the secondary surveillance image data related to the latest molding process and at least two molding processes immediately before the molding process is stored, The primary surveillance image data and the secondary surveillance image data related to the molding process are sequentially recorded while being updated with the primary surveillance image data and the secondary surveillance image data related to the latest molding process, And monitoring image data relating to a molding process in which an abnormality has occurred and monitoring image data related to a molding process before the occurrence of abnormality are compared and contrasted. The method according to claim 1, External memory is installed detachably, When it is confirmed that an abnormal state occurs in either of the primary monitoring operation and the secondary monitoring operation, the monitoring device for a mold is transferred to and stored in the external memory. .

Images