Molding product taking-out system and teaching method thereof

Abstract

The present invention provides a teaching method for a molded product taking-out system and a molded product taking-out system, using one camera device, before lowering a fitting installed in an entry frame into a mold, visually displaying which range the fitting installed in the entry frame is lowered into, and easily correcting the position on the spot in the case of interference with the mold. Before lowering a fitting (47, 48) installed in a lifting frame (45) into a mold (7, 11), a virtual plane (IP) extending on a camera image (CI) of an opening end surface (7A, 11A) of the mold (7, 11) in a state in which the lifting frame (45) is opened by one camera device (49) is superimposed with a projection image (PI) set to project the fitting (47, 48) or a maximum size virtual projection image (MPI) of the projection image (PI). It is visually confirmed which range the fitting (47, 48) is lowered into the opened mold (7, 11).

Description

TECHNICAL FIELD

[0001] The present application relates to a teaching method of a molded product taking-out system which teaches operation of a molded product taking-out machine which takes out a molded product from a molding machine, and operation thereof. BACKGROUND

[0002] In the molded product taking-out machine, the following operation is repeatedly performed, that is, a molded product is taken out at a product taking-out position in a mold of a molding machine using a taking-out head (a fitting), and the molded product is released to a product release position outside the molding machine. The operation of the taking-out robot is taught by a so-called teaching program. At the time of sucking the product, generally, teaching is required in which the taking-out head installed at the front end of an approach frame of the molded product taking-out machine is brought close to the mold by performing positioning in three directions of a horizontal direction (a direction orthogonal to a mold opening / closing direction and an up / down direction), a pulling direction (the mold opening / closing direction), and the up / down direction. In particular, at the time of making the fitting installed at the front end of the approach frame enter the mold, if the distance between the fitting and the mold is separated, the positional relationship therebetween cannot be accurately known. Therefore, in order to know the positional relationship therebetween, it is required to confirm whether or not interference therebetween occurs by making the approach frame operate in the advancing direction to shorten the distance from the mold. For example, in the case where it is known that interference with the mold occurs when the approach frame is made to descend, it is required to make the approach frame operate in the pulling direction or the horizontal direction, and it is also required to change the teaching position coordinates just before making it descend, which takes time and effort. In addition, at the time of performing this work, the fitting and the mold are sometimes collided.

[0003] Therefore, in the past, the positional relationship between the mold and the fitting has been made to coincide by depending on the skill of the operator, or by observing the positional relationship between the mold and the fitting from the horizontal direction of the molding machine. However, in such a teaching method, whether or not the fitting is directed to the correct advancing direction is mostly dependent on the intuition of the operator, and the operation time is also lengthened. In addition, there is a problem of depending on the skill of the operator.

[0004] Therefore, in the teaching method of the molded product taking-out system described in Japanese Patent Application Publication No. 2018-114752, a plurality of imaging devices which image the surroundings of a fixed frame and the surroundings of a moving frame, and an image display device which displays a merged imaging image obtained by merging images (both moving images and still images) imaged by the plurality of imaging devices are provided, and an operator performs teaching of an operation sequence while observing the merged imaging image displayed by the image display device.

[0005] PRIOR ART

[0006] PATENT LITERATURE

[0007] Patent Literature 1: Japanese Patent Application Publication No. 2018-114752

[0008] However, in the technology described in Patent Literature 1, a plurality of cameras are required, and it is difficult to accurately grasp by vision whether the jig entering the frame interferes with the mold when the jig entering the frame is made to enter the mold while the merged camera image is observed. SUMMARY

[0009] An object of the present application is to provide a teaching method for a molded product taking-out system and a molded product taking-out system that use one camera to visually display a range in which a jig attached to an entering frame is made to descend into a mold before the jig is made to descend into the mold, and easily correct the position on the spot in the case of interference with the mold.

[0010] A molded product taking-out system that is a teaching object of the present application includes a fixed frame, a moving frame that moves along the fixed frame, an entering frame that has a jig such as a taking-out head and is movably held in the moving frame to enter a mold of a molding machine, a motion control section that moves the moving frame and the entering frame in accordance with a pre-set motion sequence to take out a molded product from an opened mold of the molding machine, convey the taken-out molded product to a given position, and release it, a camera that takes an image of the surroundings of the mold, and an image display device that displays a camera image taken by the camera on a display screen of a display section. The motion control section includes a teaching execution section that enables an operator to change the position of the entering frame while observing the camera image displayed on the image display device to perform teaching of the motion sequence. A teaching method for the molded product taking-out system of the present application configures the camera to be able to take an image of the opened mold in an opened state and its surroundings from a direction in which the entering frame enters the mold in the opened state, and to be able to demarcate a virtual plane that extends in the camera image including an opening end surface of the opened mold. Further, based on three-dimensional position information of the jig in a state in which the jig is attached to the entering frame and three-dimensional shape information of the jig, a projection image that is set to be a projection of the jig on the virtual plane or a maximum size virtual projection image of the projection image is created. In addition, the image display device superimposes and displays the projection image or the maximum size virtual projection image on the display screen on the camera image.

[0011] Thus, before the jig attached to the entering frame is made to enter the mold, the maximum size virtual projection image that is set to be a projection of the jig or the projection image is superimposed and displayed on a virtual plane that extends in the camera image including an opening end surface of the opened mold in the opened state from the direction in which the entering frame enters the mold in the opened state, so it is possible to display in a manner that enables confirmation by vision of a range in which the jig descends into the opened mold. As a result, it is possible to correct the teaching position of the jig before the jig actually interferes with the mold.

[0012] The image display device can also be caused to display an indicator for judging the size ratio of the captured image to the projection image or the maximum size virtual projection image on the virtual plane together with the captured image. In this way, the amount of correction for the position for avoiding interference of the fitting with the mold can be roughly determined based on information obtained by observing the display of the indicator.

[0013] For example, the indicator can include a grid-like scale extending at a certain interval in the lateral direction and the longitudinal direction of the virtual plane. If such an indicator is used, the determination accuracy of the amount of correction is increased.

[0014] Further, the teaching execution section can be caused to, when the projection image or the maximum size virtual projection image is overlapped with a part of the image of the opening end surface of the mold in the opened state, issue an alarm signal and stop the action of entering the frame. In this way, interference of the mold with the fitting can be automatically prevented by the alarm signal.

[0015] The molded product taking-out system of the present application implements the method of the present application. The molded product taking-out system of the present application includes: a fixed frame; a moving frame that moves along the fixed frame; an entering frame that holds a fitting such as a take-out head, and is movably held in the moving frame to enter the mold of a molding machine; an action control section that moves the moving frame and the entering frame in accordance with a predetermined action sequence, thereby taking out a molded product from the opened mold of the molding machine, and transporting and releasing the taken-out molded product to a given position; an imaging device that images the surroundings of the mold; and an image display device that displays the captured image captured by the imaging device on a display screen of a display section. The action control section includes a teaching execution section that enables an operator to change the position of the entering frame while observing the captured image displayed on the image display device, and perform teaching of the action sequence. The imaging device is configured to image the mold in the opened state and its surroundings from a direction in which the entering frame enters the mold in the opened state, and to demarcate a virtual plane that extends to include the image of the opening end surface of the mold in the opened state in the captured image. The imaging device includes a projection image creation section that creates a projection image or a maximum size virtual projection image of the projection image when the fitting is projected on the virtual plane, based on three-dimensional position information of the fitting in the state of being fitted to the entering frame and three-dimensional shape information of the fitting. The image display device is configured to display the projection image or the maximum size virtual projection image overlapped on the captured image captured by the imaging device on the display screen. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1is a perspective view of a state in which the molded article take-out machine of the application embodiment's method is installed on a fixed platen of a molding machine.

[0017] Figure 2 is a diagram showing one example of an image captured by an imaging device.

[0018] Figure 3 (A) of shows a virtual plane extending to include an open end surface of a mold, Figure 3 (B) of is a schematic view of an imaging image of an image including the virtual plane, Figure 3 (C) of shows another pattern of an indicator.

[0019] Figure 4 is a diagram for explaining the center of an imaging range.

[0020] Figure 5 is a diagram for explaining a pair of symmetrically configured portions.

[0021] Figure 6 is a block diagram showing the structure of a control system of a molded article take-out machine used in the present embodiment.

[0022] Symbol Explanation

[0023] 1: molded article take-out machine;

[0024] 3: fixed platen;

[0025] 5: fixed mold;

[0026] 5A: open end surface;

[0027] 7: intermediate mold;

[0028] 7A: open end surface;

[0029] 9: movable platen;

[0030] 11: movable mold;

[0031] 11A: open end surface;

[0032] 13A to 13D: tie bars;

[0033] 15A to 15D: guide pins;

[0034] 23: cross rail (fixed frame);

[0035] 25: control box;

[0036] 27: puller frame (moving frame);

[0037] 28: puller relay box;

[0038] 29: runner elevating unit;

[0039] 31: lifting unit for suction of molded article;

[0040] 33, 35: traveling body;

[0041] 45: lifting frame (entry frame);

[0042] 47: reversing unit (accessory mounting portion);

[0043] 48: take-out head;

[0044] 49: imaging device;

[0045] 51: motion control portion;

[0046] 53: teaching execution portion;

[0047] 55: image display device;

[0048] 56: projected image creation portion;

[0049] 57: display portion. DETAILED DESCRIPTION

[0050] Hereinafter, embodiments of a molded article take-out system and a teaching method thereof according to the present application will be described in detail with reference to the accompanying drawings.

[0051] Figure 1 is a perspective view of a state in which a molded article take-out machine 1 to which the method of the present embodiment is applied is installed on a fixed platen 3 of a molding machine. In addition, in Figure 1 , a portion of a mold plate of the molding machine is extracted and shown as partially transparent. Figure 2 shows one example of an image captured by the imaging device 49 described later. The fixed mold 5 and the intermediate mold 7 are fixed to the fixed platen 3 of the molding machine, and the movable mold 11 is fixed to the movable platen 9. Furthermore, four tie rods 13A to 13D that guide movement of the movable platen 9 are arranged between the fixed platen 3 and the movable platen 9. The four tie rods 13A to 13D are arranged at equal intervals, and a virtual center line that passes through the centers of the four tie rods 13A to 13D passes through the centers (nozzle centers) of the fixed mold 5 and the movable mold 11. In addition, the fixed mold 5, the intermediate mold 7, and the movable mold 11 are guided by guide pins 15A to 15D, respectively. The four guide pins 15A to 15D are also arranged at equal intervals, and a virtual center line that passes through the centers of the four guide pins 15A to 15D also passes through the centers (nozzle centers) of the fixed mold 5 and the movable mold 11.

[0052] The molded product take-out machine 1 is provided with a traverse frame 23, a control box 25, a drawing frame 27, a runner elevating unit 29, and a molded product suction elevating unit 31. The traverse frame 23 has a cantilever beam structure extending in the X-axis direction orthogonal to the longitudinal direction of a not-shown molding machine. The control box 25 is supported to the traverse frame 23, and a traveling body 26 advances and retreats in the X-axis direction along the traverse frame 23 with an AC servo motor (not shown) included in a servo mechanism as a driving source. A base of the drawing frame 27 as a movable frame is attached to the traveling body 26 and extends in the Y-axis direction parallel to the longitudinal direction of the molding machine. The runner elevating unit 29 and the molded product suction elevating unit 31 are supported to the drawing frame 27 via traveling bodies 35 and 33 so as to be movable in the Y-axis direction with not-shown AC servo motors included in servo mechanisms as driving sources. A drawing relay box 28 is attached to the base of the drawing frame 27.

[0053] The runner elevating unit 29 has a structure in which an elevating frame 37 elevating in the Z-axis direction is provided to a traveling body 35 movably supported to the drawing frame 27. The traveling body 35 is driven by a not-shown AC servo motor to move in the Y-axis direction. The elevating frame 37 is elevated in the up-down direction (Z-axis direction) by an AC servo motor 39. The elevating frame 37 is provided with a chuck 41 as a fitting for holding a discarded runner.

[0054] Further, the traveling body 33 included in the molded product suction elevating unit 31 is moved in the Y-axis direction on the drawing frame 27 by a not-shown AC servo motor. The molded product suction elevating unit 31 is provided with an elevating frame 45 as an entry frame elevating in the up-down direction (Z-axis direction) by an AC servo motor 46, and a reverse unit 47 as a fitting attachment portion constituting a posture control device provided to the lower end of the elevating frame 45. A take-out head 48 shown by a dashed line is attached to the reverse unit 47. In the present embodiment, the reverse unit 47 (fitting attachment portion) and the take-out head 48 constitute a fitting. The drawing frame 27 is moved in the lateral direction (X-axis direction) along the traverse frame 23 extending in the lateral direction. Further, the elevating frames 37 and 45 moving in the front-rear direction (Y-axis direction) orthogonal to the up-down direction (Z-axis direction) and the lateral direction are attached to the drawing frame 27 so as to be movable in the front-rear direction.

[0055] In the present embodiment, a camera 49 as a monitoring camera is provided to the lower surface of the traveling body 33. The camera 49 is configured to be able to take an image of a mold (5, 7, 11) in an open state and its surroundings from a direction in which the elevating frames 37 and 45 (entry frame) enter the mold (5, 7, 11) in the open state, and to be able to demarcate a virtual plane IP extending in the image including an opening end surface (5A, 7A, 11A) of the mold in the open state in the camera image.Figure 3 (A) a virtual plane IP extending to include the open end surface (5A, 7A, 11A) of the mold, Figure 3 (B) is a schematic view of a captured image CI of an image including the virtual plane IP. In Figure 3 In (B) of the above, on the display virtual plane IP along with the captured image CI, a display indicator IG constituted of a grid-like scale extending at intervals in the lateral direction W and the longitudinal direction D of the virtual plane IP is displayed. If such an indicator IG is displayed, it is easy to judge the size ratio of the captured image CI to the projected image PI or the maximum size virtual projected image MPI. Furthermore, according to the information obtained by observing the display of the indicator IG, it is possible to roughly determine the amount of correction of the position for avoiding interference of the fitting with the mold. Figure 3 (C) shows another pattern of the indicator. In this pattern, it is possible to simply recognize the degree of inclination of the projected image PI with respect to the captured image of the mold.

[0056] In Figure 3 In the example of (A) of the above, the imaging device 49 is located directly above the mold, but even in the case where the imaging device 49 is shifted from directly above the mold and captures from an inclined direction, it is possible to demarcate the virtual plane IP extending to include the image of the open end surface (5A, 7A, 11A) of the mold in the opened state in the captured image CI. In addition, Figure 3 (A) of the above and Figure 3 (B) of the above are different from the present embodiment, and are described taking two-plate molds (7, 11) as an example.

[0057] In the present embodiment, for example, based on the three-dimensional position information of the fitting (47, 48) in the state of being fitted to the lifting frame 45 (entry frame) and the three-dimensional shape information of the fitting (47, 48), the projected image PI when the fitting (47, 48) is projected to the virtual plane IP or the maximum size virtual projected image MPI of the projected image PI is created. On this basis, the projected image PI or the maximum size virtual projected image MPI is superimposed and displayed on the captured image CI. In addition, in Figure 3 The state where the maximum size virtual projected image MPI is superimposed and displayed on the captured image CI is shown in (B) of the above. Figure 4 Examples of the state where the projected image PI of the fitting (47, 48) and the maximum size virtual projected image MPI (image on the frame shown by a broken line) are superimposed and displayed on the captured image CI projected to the virtual plane IP are shown. Actually, one of the projected image PI and the maximum size virtual projected image MPI is displayed on the virtual plane IP.

[0058] Here, the three-dimensional position information of the fitting (47, 48) used for creating the projected image PI and the maximum size virtual projected image MPI isFigure 3 The dimensions L (position of camera device 49) and the position information M of the virtual plane IP are obtained, for example, using an optical position sensor or an encoder. Furthermore, M can be obtained through prior measurement. Additionally, the angle θ between camera device 49 and the virtual plane IP can be calculated based on a pre-measured initial value and the position information of camera device 49. Furthermore, the three-dimensional shape information of the accessories (47, 48) can be obtained from the design information or CAD information of the reversing unit 47 (accessory mounting section) and the extraction head 48. By obtaining this information in advance, a projected image PI or a maximum-size virtual projected image MPI displayed on the aforementioned virtual plane IP can be created using known computer graphics techniques.

[0059] Here, the so-called maximum size virtual projection image MPI of the accessory is a virtual frame or rectangular image with the maximum size of the projection image PI of the accessory (47, 48) in the state of being assembled in the lifting frame 45 (entering the frame) projected onto the virtual plane IP, and the size of each side SD1 to SD4 of the projection image PI on the virtual plane IP is the size of the horizontal W and vertical D of the projection image PI.

[0060] like Figure 5 As shown, before the accessories (47, 48) mounted on the lifting frame 45 enter the open molds (7, 11), if a virtual projection image MPI, which is the maximum size of the projected image when the accessories (47, 48) are projected, is displayed overlaid on a virtual plane IP extending from the camera image CI of the open end faces 7A, 11A of the molds 7, 11 obtained by a camera device 49, then the extent to which the accessories (47, 48) descend into the open molds 7, 11 can be visually confirmed. As a result, the taught position of the accessories (47, 48) can be corrected before the accessories (47, 48) actually interfere (collide) with the molds 7, 11.

[0061] [Control System Block Diagram]

[0062] Figure 6is a block diagram showing the structure of a control system of the molded product taking-out machine used in the present embodiment. As shown in the figure, the control system includes the imaging device 49, the action control section 51, and the image display device 55 including the display section 57. The action control section 51 sends control instructions to the control box 25 and the drawing relay box 28 in accordance with the action sequence. Further, the action control section 51 of the present embodiment includes the teaching execution section 53, which enables the operator to change the position of the lifting frame 45 constituting the entry frame while observing the imaging image displayed on the display section 57 of the image display device 55 and to perform teaching of the action sequence. Further, the image display device 55 includes the projected image creation section 56, which creates the projected image PI set to be projected on the virtual plane IP when the fittings (the reversing unit 47 and the taking-out head 48 as the fitting mounting section) in the state of being fitted to the lifting frame 45 (entry frame) or the maximum size virtual projected image MPI of the projected image PI based on the three-dimensional position information of the fittings (47, 48) in the state of being fitted to the lifting frame 45 (entry frame) and the three-dimensional shape information of the fittings. On this basis, the image display device 55 is configured to overlap and display the projected image PI or the maximum size virtual projected image MPI on the imaging image CI taken by the imaging device 49 on the display screen.

[0063] In the case where the method of the present application is implemented using such a system, before the fittings (47, 48) mounted to the lifting frame 45 (entry frame) are caused to enter the mold (7, 11), the virtual plane IP extending on the imaging image CI of the opening end surface (7A, 11A) of the mold (7, 11) in the state of being opened in the direction of entry of the lifting frame 45 toward the mold (7, 11) in the opened state is overlaid with the projected image PI set to be projected on the fittings (47, 48) or the maximum size virtual projected image MPI of the projected image PI. Then, it is visually confirmed in which range of the opened mold (7, 11) the fittings (47, 48) are lowered. Through this confirmation, when it is determined that the fittings (47, 48) interfere (collide) with the mold 7, 11, the teaching position of the fittings (47, 48) is corrected. This correction is performed by the teaching execution section 53. In addition, other teaching is also performed by the teaching execution section 53.

[0064] [Modified Example]

[0065] In the above-described embodiment, the present application is applied to the molded product taking-out system for taking out the molded product in the up-down direction, but of course, the present application can be applied to the molded product taking-out system of the type for taking out the molded product in the lateral direction of the molding machine.

[0066] Further, the camera 49 can be provided in an existing molded product taking-out machine, and an existing controller or a portable communication terminal can be used as the image display device. Thus, the method of the present application can be applied to the existing molded product taking-out machine.

[0067] The camera 49 can be provided so as to be detachable or so as to be capable of changing the installation position. Thus, in the case where the camera becomes an obstacle, the camera can be detached or the position can be adjusted. Further, the camera can be tilted in the pulling direction all at once after the teaching is completed, for monitoring the surroundings.

[0068] [Industrial applicability]

[0069] According to the method of the present application, the virtual plane extending on the camera image of the opening end surface of the mold in the direction of entry of the mold from the entry frame toward the opened state is overlaid with the maximum dimension virtual projection image of the projection image of the fitting when projected or the projection image, and thus the display can be performed in such a manner that it can be visually confirmed which range of the opened mold the fitting has descended to. As a result, the teaching position of the fitting can be corrected before the fitting actually interferes with the mold.

Claims

1. A teaching method of a molded article taking-out system, the molded article taking-out system comprising: a fixed frame; a moving frame that moves along the fixed frame; an entry frame that has a taking-out head fitting, is movably held in the moving frame, and enters a mold of a molding machine; a movement control section that moves the moving frame and the entry frame in accordance with a movement sequence set in advance, thereby taking out a molded article from an opened mold of a molding machine, transporting the taken-out molded article to a given position, and releasing the molded article; an imaging device that images a periphery of the mold; and an image display device that displays an imaging image imaged by the imaging device on a display screen of a display section, wherein the movement control section includes a teaching execution section that enables an operator to change a position of the entry frame while observing the imaging image displayed on the image display device, thereby teaching the movement sequence, and wherein the teaching method of the molded article taking-out system is characterized in that the imaging device is configured to image the mold and the periphery thereof from a direction in which the entry frame enters the mold in an opened state, and to demarcate a virtual plane that extends in the imaging image so as to include an opening end surface of the mold in the opened state, the movement control section creates a projection image in which the fitting is projected on the virtual plane or a maximum-size virtual projection image of the projection image based on three-dimensional position information of the fitting in a state in which the fitting is attached to the entry frame and three-dimensional shape information of the fitting, and the image display device superimposes the projection image or the maximum-size virtual projection image on the imaging image and displays the projection image or the maximum-size virtual projection image on the display screen.

2. The teaching method of the molded article taking-out system according to claim 1, wherein the image display device displays an indicator on the virtual plane together with the imaging image, the indicator indicating a size ratio of the imaging image to the projection image or the maximum-size virtual projection image.

3. The teaching method of the molded article taking-out system according to claim 2, wherein the indicator includes a grid-like scale that extends at a certain interval in a lateral direction and a longitudinal direction of the virtual plane.

4. The teaching method of the molded article taking-out system according to any one of claims 1 to 3, wherein the teaching execution section issues an alarm signal and stops movement of the entry frame if the projection image or the maximum-size virtual projection image overlaps a part of an image of the opening end surface of the mold in the opened state when the projection image or the maximum-size virtual projection image is superimposed and displayed on the imaging image.

5. A molded article taking-out system comprising: a fixed frame; a moving frame that moves along the fixed frame; an entry frame that has a taking-out head fitting, is movably held in the moving frame, and enters a mold of a molding machine; ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ an action control section that moves the moving frame and the entry frame in accordance with a predetermined action sequence, thereby taking out a molded product from an open mold of a molding machine, transporting the taken-out molded product to a given position, and releasing the molded product; an imaging device that images the surroundings of the mold; and an image display device that displays an imaging image imaged by the imaging device on a display screen of a display section, the action control section includes a teaching execution section that enables a worker to change the position of the entry frame while observing the imaging image displayed on the image display device, thereby teaching the action sequence, the molded product taking-out system is characterized in that the imaging device is configured to image the mold in an open state and its surroundings from a direction in which the entry frame enters the mold in the open state, and to demarcate a virtual plane that extends to include an image of an open end surface of the mold in the open state in the imaging image, the image display device includes a projection image creation section that creates a projection image that is set when the fitting is projected on the virtual plane or a maximum size virtual projection image of the projection image, based on three-dimensional position information of the fitting in a state in which the fitting is fitted to the entry frame and three-dimensional shape information of the fitting, the image display device is configured to superimpose the projection image or the maximum size virtual projection image on the imaging image imaged by the imaging device and display the projection image or the maximum size virtual projection image on the display screen.

6. The molded product taking-out system according to claim 5, characterized in that the image display device further includes an indicator display section that displays an indicator on the virtual plane together with the imaging image, the indicator being used to judge a size ratio of the imaging image to the projection image or the maximum size virtual projection image.

7. The molded product taking-out system according to claim 6, characterized in that the indicator includes a grid-like scale that extends at a certain interval in a lateral direction and a longitudinal direction of the virtual plane.

8. The molded product taking-out system according to any one of claims 5 to 7, characterized in that the teaching execution section is configured to issue an alarm signal and stop the action of the entry frame when the projection image or the maximum size virtual projection image overlaps a part of the image of the open end surface of the mold in the open state while the projection image or the maximum size virtual projection image is superimposed on the imaging image and displayed on the display screen.

Images