JP4627919B2 - Molding defect monitoring system - Google Patents

Description

[0001]
[Technical field to which the invention belongs]
The present invention relates to a molding monitoring system for confirming a molding defect including a molded product taking-out operation in a remote place in a resin molding machine (hereinafter, referred to as a molding machine) equipped with a molded product taking-out machine.
[0002]
[Problems to be solved by the invention]
For example, if the mold is not open at a predetermined interval despite the improper mold temperature and the mold opening completion signal being output, the molding machine's molding failure can be caused by a protruding pin of the molded product protruding mechanism. The stroke is insufficient. When a molding defect occurs in the molding machine, a molding defect alarm is output to the molded product take-out machine.
[0003]
In addition, examples of the defective take-out of the molded product take-out machine include a molded product release failure from the mold, a holding failure due to a short stroke of the protruding pin, a suction failure of the suction member in the chuck portion, and a chuck movement failure. .
[0004]
In any case, when a molding failure occurs, the molding operation by the molding machine and the removal of the molded product by the molded product take-out machine are interrupted until the defective state is restored to the normal state.
[0005]
Conventionally, in order to monitor the molding failure of molding machines and molding product take-out and to elucidate the cause of the failure, we arranged the imaging device for each molding machine to record the molding and removal status, and when a take-out failure occurred, The recorded image data can be used to identify the cause of molding failure and removal failure.
[0006]
In the conventional monitoring system described above, when a takeout failure occurs, the inspection operator of the molding machine or the molded product takeout machine needs to go to the molding factory, identify the cause of the failure by imaging data, and take a solution. It took a long time to recover from molding defects and removal defects. When a molding failure or a take-out failure occurs, it is necessary to interrupt the molding operation until the take-out failure is resolved, and the molding work efficiency is remarkably deteriorated.
[0007]
The present invention was invented in order to solve the above-described conventional drawbacks, and the problem to be solved is to identify the cause of molding defects and take-out defects even if the operator does not go to the site. An object of the present invention is to provide a molding defect monitoring system capable of taking measures.
[0008]
Another object of the present invention is to provide a molding defect monitoring system capable of shortening the stop time of the molding operation and improving the molding operation efficiency.
[0009]
[Means for Solving the Problems]
The present invention relates to a resin molding machine that injects a synthetic resin into a mold to mold a molded product, and a molding that is attached to the resin molding machine and holds the molded product in the mold by a chuck portion and takes it out to a release position. When the molded product take-out operation is performed from the resin molding machine by performing drive control of the molded product take-out machine based on the product take-out machine and preset take-out data, and when a molded product take-out failure occurs, A take-out machine control device that outputs a molded product take-out alarm signal, and a molding alarm signal when a molding failure occurs when a molded product is molded by controlling the resin molding machine based on preset molding data. A molding machine control device that outputs the image data to the molded product take-out machine control device, an imaging means that outputs the imaging data obtained by imaging the resin molding machine and the molded product take-out device to the take-out machine control device, and stores them in the buffer storage area; Extruder controller always predetermined time at least one of the imaging data of the resin molding machine has been captured and molded product removing machine buffer storage area by the imaging means, while updating the stored resin molding machine and molded article ejection When an alarm signal is output from at least one of the machines, the imaging data for a predetermined time stored in the buffer storage area at the time of output of the alarm signal is read out, transferred to the imaging data storage area and stored, and then the imaging The imaging data stored in the data storage area is transmitted from the communication means of the take-out machine control device to the external terminal device so that the abnormal state of the resin molding machine or the molded product take-out machine can be confirmed.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below with reference to the drawings showing embodiments.
As shown in FIGS. 1 and 2, the molding machine 1 has a known structure and clamps a movable platen 7 supported by a tie bar 6 laid horizontally between a fixed side mounting platen 3 and a movable side mounting platen 5. After a movable mold (not shown) attached to the movable platen 7 is clamped to a fixed die 11 attached to the fixed side mounting plate 3 by reciprocating movement by a mold clamping member 9 such as a cylinder or a mold clamping motor. Then, the synthetic resin melted from the injection device 15 is injected between both molds to form a molded product.
[0012]
The main body frame 19 of the molded product take-out machine 17 extends in a direction (left-right direction) orthogonal to the axis of the molding machine 1, and the base portion is fixed to the upper part of the fixed side mounting board 3. A traveling body 21 supported so as to be movable in the left-right direction on the main body frame 19 is provided with a front-rear frame 23 extending in the axial direction (front-rear direction) of the molding machine 1. The body 25 is movably supported.
[0013]
The front and rear traveling body 25 is provided with an upper and lower unit 31 that moves up and down an upper and lower frame 29 provided with a chuck device 27 for holding a molded product, and is moved by movement of the traveling body 21, the front and rear traveling body 25, and the upper and lower frame 29. The chuck device 27 is moved in the three-dimensional direction and the molded product is taken out.
[0014]
The traveling body 21, the front / rear traveling body 25, and the upper and lower frames 29 are moved by an electric motor (not shown) that can be numerically controlled, such as a servomotor. These electric motor drive control units are connected to a control box 33 attached to the main body frame 19 or an operation box 35 provided on the floor of the molding machine 1, and various switches, keys, LCDs provided on the operation box 35 are provided. The movement control data of the chuck device 27 and the like are input by a display device or the like to set the removal operation data of the molded product.
[0015]
A portable operating body 37 is detachably attached to the operation box 35 and is electrically connected. Similar to the operation box 35, the portable operation body 37 is provided with various switches, keys, LCDs and other display devices, and the portable operation body 37 is removed from the operation box 35 when teaching operation data for taking out a molded product is input. Thus, it is possible to perform an input operation while directly confirming the moving state of the chuck device 27 for convenience.
[0016]
Further, the portable operation body 37 is provided with an imaging device 39 such as a CCD camera. The imaging device 39 is configured such that the imaging position can be changed with respect to the portable operation body 37, and desired imaging data can be obtained. Specifically, the imaging device 39 is realized by a video camera. In addition, the portable operation body 37 is provided with an imaging switch 39a and an imaging data transfer switch 39b in association with the imaging device 39, and takes an image when the imaging switch 39a is operated other than when an extraction failure alarm is generated. When the data transfer switch 39b is operated, the imaging data is transferred to the control device 41.
[0017]
In FIG. 3, the control device 41 of the molded product take-out machine 17 is accommodated in, for example, an operation box 35 and includes a communication control unit 43. The communication control unit 43 is connected to the Internet 45 via an existing telephone line, optical fiber line or the like. In the Internet 45, for example, an external terminal device 47 installed at a service center in a manufacturing and sales company of the molded product take-out machine 17 away from the installation location of the molding machine 1 and the molded product take-out machine 17 is connected to a web connection organization (so-called provider, (Not shown). When the control device 41 of the molded product take-out machine 17 is provided with a server function, a web connection organization is not necessary. The external terminal device 47 is specifically realized by a personal computer.
[0018]
4 (The control device 41 of the molded product take-out machine 17 has a function of executing a molded product take-out operation, but for convenience of explanation, FIG. 4 shows only the configuration necessary for realizing molding monitoring described later. The CPU 51 is composed of a ROM, HDD, DVD, etc., and is composed of a program memory 53, a RAM, etc. for storing management program data, and is for a predetermined time or a predetermined molding cycle (molding) transferred from the imaging device 39. A buffer area 55a for sequentially storing imaging data (including an article removal cycle) and a monitoring imaging data area 55b for storing imaging data for a predetermined time stored in the buffer area 55a when a molded article ejection failure occurs. A work memory 55 is connected.
[0019]
An imaging control circuit 57 is connected to the CPU 51 to drive and control the imaging device 39 connected to the imaging control circuit 57 and process imaging data from the imaging device 39.
[0020]
Further, the control device 59 of the molding machine 1 is connected to the CPU 51 via the interface 61. When an alarm signal at the time of molding failure is input from the CPU 51, a failure monitoring process described later is executed. Specific examples of the molding failure include a stroke failure of the protruding pin in the ejector mechanism, a mold opening incomplete failure, a mold temperature failure, etc., although a mold opening completion signal is output. The control device 59 simply outputs an alarm signal to the CPU 51 when any of the above-described molding defects occurs in the molding machine 1 regardless of the cause of these defects.
[0021]
Further, the control device 41 detects an extraction failure of the molded product extraction machine 17 and outputs an alarm signal. Specific examples of the takeout failure include abnormal operation (stop) of the chuck portion, poor gripping of a molded product by the chuck portion (insufficient suction pressure, air leakage due to damage to the suction member), and the like.
[0022]
The above-described communication control unit 43 is connected to the CPU 51. The communication control unit 43 has an automatic dial function for automatically connecting to the Internet 45.
[0023]
Next, a molding monitoring method will be described.
At the time of a molding operation including a molded product take-out operation, the imaging device 39 provided in the portable operating body 37 takes an image of a desired location of the molding machine 1 and the molded product take-out machine 17, for example, inside a mold that has been opened. In this way, the imaging direction, the focus, etc. are set.
[0024]
In the above state, the imaging device 39 continuously captures the operating states of the molding machine 1 and the molded product take-out machine 17 and sequentially stores the imaging data in the buffer area 55a. The buffer area 55a has a capacity for storing imaging data for a predetermined time, for example, 30 minutes, or a capacity corresponding to a predetermined number of extraction cycles.
[0025]
When the alarm signal from the control device 59 or the control device 41 detects a take-out failure of the molded product take-out machine 17 due to a molding failure of the molding machine 1 during the molding operation, the CPU 51 takes out the molding machine 1 and the molded product. A disconnection signal is output to the machine 17 to interrupt the molding operation and the removal operation.
[0026]
Further, the CPU 51 monitors the imaging data for the predetermined time or the predetermined number of extraction cycles stored in the buffer area 55a based on the alarm signal from the molding machine 1 or the detection of the extraction failure in the molded product extraction machine 17, and the monitoring imaging data area 55b. Transfer to and memorize. As a result, the imaging data for a predetermined time before the occurrence of the molding defect is stored in the monitoring imaging data area 55b.
[0027]
Note that when the alarm signal is input or when a take-out failure is detected, the imaging device 39 may continue to image the molding machine 1 and the molded product take-out machine 17 or may interrupt the subsequent imaging.
[0028]
Next, after connecting to the Internet 45 based on provider information and server information registered in advance, the communication control unit 43 captures imaging data for a predetermined time or a predetermined extraction cycle before the occurrence of an alarm read from the monitoring imaging data area 55b. Is transferred to a predetermined address of a storage device in the web connection organization and stored.
[0029]
When the control device 41 has a server function, the above-described Internet connection process is not necessary. Further, the communication control unit 43 automatically dials the service center of the manufacturing and sales company of the molding machine 1 or the molded product take-out machine 17 registered in advance separately from the above-described Internet connection processing, and the molding machine 1 or the molded product take-out machine 17 You may alert | report that it is a shaping | molding defect. If automatic notification is not performed, an on-site worker at the factory where the molding machine 1 and the molded product take-out machine 17 are installed should contact the service center and that the molding machine 1 and the molded product take-out machine 17 are in a poorly molded state. To inform.
[0030]
An inspection worker at the service center connects the external terminal device 47 to the Internet 45, takes out the imaging data for a predetermined time stored in a predetermined address of the storage device in the web connection engine, and displays it on the display device of the external terminal device 47 Then check the molding failure or removal failure status.
[0031]
When the control device 41 has a server function, the external terminal device 47 is directly connected to the control device 41 via the Internet 45, and the image pickup data stored in the monitoring image pickup data area 55b is extracted and displayed. Check for molding defects and removal defects.
[0032]
When the inspection worker cannot identify the cause of the molding failure or the removal failure from the imaging data for a predetermined time stored in the monitoring imaging data area 55b, the inspection worker directly contacts the field worker and takes the imaging data of the location that seems to be the cause of the failure. Is displayed on the external terminal device 47.
[0033]
That is, the field worker removes the imaging device 39 from the portable operation body 37, and then operates the imaging switch 39a in the state where the imaging device 39 is directed to the required location according to the instruction of the inspection worker, Are stored in the buffer area 55a. Next, when the field worker operates the imaging data transfer switch 39b, the CPU 51 transfers the imaging data stored in the buffer area 55a to the monitoring imaging data area 55b, and then automatically connects to the Internet 45 in the same manner as described above. It is transferred to a predetermined address of the storage device in the engine and manually stored. Then, the inspection worker connects the external terminal device 47 to the Internet 45 to take out and display the imaged data so that the location where the defect has occurred can be confirmed.
[0034]
The inspection worker specifies the cause of the molding failure or the removal failure from the imaging data displayed on the external terminal device 47, and then notifies the site worker of the restoration procedure to troubleshoot the molding machine 1 or the molded product take-out device 17. Restore.
[0035]
Needless to say, if the cause of the failure cannot be identified only by the above-described imaging data, the inspection worker goes to the factory to identify the cause of the failure and recover the failure.
[0036]
In the present embodiment, the cause of the defect is identified by displaying the imaging data before the occurrence of the defect through the external terminal device 47 provided at a location away from the installation site of the molding machine 1 and the molded product take-out machine 17, and the failure is recovered. Therefore, the restoration time can be shortened and the molding work efficiency can be improved as compared with the case where the inspection worker goes directly to the site and tries to restore the failure.
◎
0000
In the above description, the imaging device 39 is provided on the portable operating body 37 that is detachably attached to the operation box 35 to image the molding machine 1 and the molded product take-out device 17, but in the present invention, the imaging device is used. 39 is provided, for example, on a stand installed on the floor surface on the operation side or the non-operation side of the molding machine, the fixed side mounting plate 3 or the movable side mounting plate of the molding machine 1, and the main body frame of the molding machine below the mold. The molding machine and the molded product take-out machine may be provided at any location where an image can be taken, and the technical scope of the present invention is not limited by the installation position.
[0037]
In the above description, the communication control unit 43 and the external terminal device 47 of the control device 41 are connected to the Internet 45. However, a device that connects to the Internet 45 using a telephone having a data transmission / reception function may be adopted. Good. In this case, there is a telephone connection organization with the Internet 45.
[0038]
【The invention's effect】
The present invention can identify the cause of molding failure or take-out failure without taking the operator to the site and take measures to solve it. In addition, the molding operation efficiency can be improved by shortening the stop time of the molding operation.
[Brief description of the drawings]
FIG. 1 is an overall perspective view showing an outline of a molding machine equipped with a molded product take-out machine.
FIG. 2 is a perspective view of an operation box.
FIG. 3 is an explanatory diagram of a molding monitoring system.
FIG. 4 is an electrical block diagram.
[Explanation of symbols]
1-Molding machine, 17-Molded product take-out machine, 35-Operation box, 37-Portable operation body, 39-Imaging device, 45-Internet, 47-External terminal device

Claims (4)

A resin molding machine that injects synthetic resin into the mold to form a molded product;
A molded product take-out machine that is attached to the resin molding machine and holds the molded product in the mold by the chuck portion and takes it out to the release position;
The molded product take-out machine is driven and controlled based on preset take-out data to execute the molded product take-out operation from the resin molding machine, and when a molded product take-out failure occurs, a molded product take-out alarm signal is generated. An unloader control device that outputs
Resin molding machine control that drives and controls the above resin molding machine based on preset molding data to mold a molded product and outputs a molding alarm signal to a molded product take-out machine controller when a molding failure occurs Equipment,
Imaging means for outputting image data obtained by imaging the resin molding machine and the molded product take-out machine to the take-out machine control device and storing them in the buffer storage area;
The take-out machine control device always stores at least one of the imaging data of the resin molding machine and the molded product take-out machine imaged by the imaging means while updating the buffer storage area for a predetermined time,
When an alarm signal is output from at least one of the resin molding machine and the molded product take-out machine, the imaging data for a predetermined time stored in the buffer storage area is read out and transferred to the imaging data storage area when the alarm signal is output. After the image is stored, the imaging data stored in the imaging data storage area is transmitted from the communication means of the take-out machine control device to the external terminal device so that the abnormal state of the resin molding machine or the molded product take-out machine can be confirmed. Monitoring system. 2. The molding defect monitoring system according to claim 1, wherein the communication means displays imaging data on an external terminal device via the Internet. 2. The molding defect monitoring system according to claim 1, wherein the communication means displays the imaging data on the external terminal device via a telephone line. 2. The molding defect monitoring system according to claim 1, wherein the imaging means is a CCD camera.

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