Molded article take-out machine and operation monitoring method thereof

Abstract

The present invention provides a molded product taking-out machine and a work monitoring method thereof capable of detecting a situation where a response to a work delay or insufficiency by a work performer at the time of a pause is made late or insufficient in a simple manner. The molded product taking-out machine has a cycle time management section (3) including a cycle time measuring section (5) that measures a cycle time at each cycle of taking out a molded product from an injection molding machine, a target cycle time setting storage section (7) that sets and stores a target cycle time, a comparison section (9) that compares the measured cycle time with the target cycle time at each cycle, an exceeding number measuring section (11) that measures a number of times of continuously exceeding the target cycle time after the next cycle in the case where the result of the comparison is that the measured cycle time exceeds the target cycle time, and a detection signal output section (13) that outputs a detection signal in the case where the number of times of continuously exceeding the target cycle time exceeds n times, n being an integer of 1 or more.

Description

Technical Field

[0001] This invention relates to a molded article removal machine for removing molded articles from an injection molding machine and a method for monitoring its operation. Background Technology

[0002] Previously, there were known devices for manufacturing lines that reported an anomaly when the cycle time was delayed compared to the reference time (e.g., Japanese Patent Application Publication No. 2013-152973 (Patent Document 1) as a technology related to substrate production lines).

[0003] Prior art literature

[0004] Patent Document 1: Japanese Patent Application Publication No. 2013-152973 Summary of the Invention

[0005] The technical problem that the invention aims to solve

[0006] There are various reasons for the delay in cycle time. One possible reason is the slow or inadequate response from the operator when the machine restarts after a period of inactivity (commonly referred to as a "pause" (a partial stop of equipment or a stop caused by a malfunction of the object being processed, which can be recovered in a short time [JIS Z 8141:2001]) occurs.

[0007] The purpose of this invention is to provide a molded product take-out machine and its operation monitoring method that can easily detect situations where the response to the work by the operator is slow or insufficient when a pause occurs.

[0008] Solutions for solving technical problems

[0009] The operation monitoring method for the molded article removal machine of the present invention includes: a cycle time measurement step, measuring the cycle time required for one cycle of removing the molded article from the injection molding machine; a target cycle time setting step, setting a target cycle time allowed by the manager; a comparison step, comparing the measured cycle time with the target cycle time in each cycle; an excess count measurement step, if the comparison result shows that the measured cycle time exceeds the target cycle time, measuring the number of times the measured cycle time continuously exceeds the target cycle time after it begins to exceed the target cycle time (after the next cycle); and an output step, outputting a detection signal if the number of times the measured cycle time continuously exceeds the target cycle time exceeds n times, where n is an integer greater than or equal to 1.

[0010] The term "n times" refers to consecutively exceeding the target cycle time, meaning a total of two or more consecutive instances of exceeding the target cycle time. This is presumably due to delays or inadequacies in the response actions taken by the operator during pauses caused by some reason. Therefore, by outputting the detection signal based on this invention, the frequency and timing of the detection signal can be used as an opportunity for the operator to verify the appropriateness of the response, allowing management to identify the necessity for guidance and training to the operator. It should be noted that when the detection signal is output, it is not necessary to stop the operation of the molded product extraction machine based on the detection signal.

[0011] It should be noted that if there is an output step, in which the period time is determined to exceed the target period time for m consecutive times, and a detection signal is output when it is determined to exceed the target period time for m consecutive times, where m is an integer greater than 2, the same effect can be achieved.

[0012] Preferably, the target cycle time can only be set by the manager of the finished product removal machine. This is because it is possible to mistakenly set a time that differs from the manager's baseline or plan, in which case the purpose of operation monitoring cannot be achieved.

[0013] In the over-count measurement step, if the measured cycle time is lower than the target cycle time before the number of consecutive times the measured cycle time exceeds the target cycle time reaches n, the over-count measurement step is reset. Therefore, if the operator's response is appropriate, no detection signal is output; a detection signal is only output when the target cycle time is exceeded consecutively. This avoids imposing unnecessary judgment burden on the manager.

[0014] Alternatively, after the detection signal is output, no further detection signal will be output until the measured cycle time is lower than the target cycle time. In this way, for example, by observing the generation interval between the first and subsequent detection signals, the operator's response capability can be understood. In addition, even if the manager mistakenly sets an unattainable target cycle time, the detection signal will not be continuously output, thus not hindering the operator's work.

[0015] Alternatively, it may also include a storage step, in which, when a detection signal is output, the storage of the cycle time before the output detection signal that is lower than the target cycle time, and the cycle time before the output detection signal that exceeds the target cycle time. In this way, the manager can not only confirm the history of the cycle time when the detection signal is output, but also confirm the time elapsed before the cycle time exceeded (the time required to handle the task), which can be used by the manager to confirm the necessity of guidance and training to the task handler.

[0016] The present invention can also be controlled (or manifested) as a molded product take-out machine with a cycle time management unit, which can set a target cycle time required for one cycle of taking out a molded product from the injection molding machine.

[0017] The cycle time management unit of the molded article taking-out machine of the present invention includes: a cycle time measuring unit that measures the cycle time in each cycle; a target cycle time setting and storage unit that sets and stores a target cycle time; a comparison unit that compares the measured cycle time with the target cycle time in each cycle; an exceedance measurement unit that, when the result of the comparison by the comparison unit is that the measured cycle time exceeds the target cycle time, measures the number of times the measured cycle time exceeds the target cycle time after it begins to exceed the target cycle time (after the next cycle); and a detection signal output unit that outputs a detection signal when the number of times the measured cycle time exceeds the target cycle time exceeds n times, where n is an integer greater than or equal to 1.

[0018] It should be noted that if the cycle time management unit has: an over-time measurement unit that measures the number of times the measured cycle time exceeds the target cycle time when the result of comparison by the comparison unit is that the measured cycle time exceeds the target cycle time; and a detection signal output unit that outputs a detection signal when the measured cycle time exceeds the target cycle time for m consecutive times, where m is an integer greater than 2, the same effect can be obtained.

[0019] Alternatively, the cycle time management unit may also have a history storage unit that stores at least the history of the date and time of the detection signal's generation. Alternatively, when a detection signal is output, the history storage unit may store the cycle time before the output of the detection signal that is lower than the target cycle time, and the cycle time before the output of the detection signal that is higher than the target cycle time.

[0020] Preferably, the target cycle time setting storage unit is configured so that it can only be set by the operator of the molded product removal machine. This is because it is possible to mistakenly set a time that differs from the operator's baseline or plan, in which case the purpose of work monitoring cannot be achieved.

[0021] Preferably, the system also includes an alarm generator that outputs an alarm driven by a detection signal. With such an alarm generator, administrators can easily recognize when a detection signal has been output. Alternatively, the system may also include a display unit that shows the detection signal when it is output. This allows for easy recognition of the output detection signal by checking the display unit.

[0022] Preferably, after the detection signal is output, the detection signal output unit does not output the next detection signal until the measured period time is lower than the target period time. Attached Figure Description

[0023] Figure 1 This is a block diagram showing the main structure of the control device provided in the molded article extraction machine according to an embodiment of the present invention.

[0024] Figure 2 This is a flowchart illustrating the processing flow, including a flowchart of the program used when implementing the main parts of the control device for the molded article extraction machine of this embodiment using a computer.

[0025] Figure 3 This is an example of a pop-up display and warning icon shown on the display panel.

[0026] Figure 4 This is an example of displaying a resume on the display screen.

[0027] Figure 5 This is an example of a timing diagram of the signals output during the automatic operation of a molded part removal machine.

[0028] Explanation of reference numerals in the attached figures

[0029] 1. Control device for the molded product removal machine

[0030] 3. Cycle Time Management Department

[0031] 5. Periodic Time Measurement Department

[0032] 7. Target cycle time setting storage unit

[0033] 9. Comparison Section

[0034] 11. Exceeding the number of measurement units

[0035] 13 Detection signal output unit

[0036] 15. Resume Storage Department

[0037] 17 Alarm Generator

[0038] 19 Display Control Department

[0039] 21 Display Department. Detailed Implementation

[0040] Hereinafter, embodiments of the molded article removal machine and its operation monitoring method of the present invention will be described in detail with reference to the accompanying drawings.

[0041] Figure 1 This is a block diagram showing the main structure of the control device provided in the molded article extraction machine according to an embodiment of the present invention.

[0042] In this embodiment, the molded article removal machine is installed on or adjacent to an injection molding machine (not shown). It removes the molded article from the mold of the injection molding machine, performs gate cutting, and places it in a designated location. The operation of the molded article removal machine is controlled by a control device 1.

[0043] like Figure 1 As shown, the control device 1 includes a cycle time management unit 3, which can set a target cycle time required for one cycle of removing the molded part from the injection molding machine. The cycle time management unit 3 includes a cycle time measuring unit 5, a target cycle time setting storage unit 7, a comparison unit 9, an overrun measurement unit 11, a detection signal output unit 13, and a history storage unit 15. It should be noted that the molded part removal machine, for teaching purposes, for setting cycle times and other prescribed parameters, and for displaying various information, includes an alarm generator 17 and a display unit 21 that displays images on a screen under the control of the display control unit 19.

[0044] The cycle time measuring unit 5 measures the cycle time for each cycle in which the molded part is removed from the injection molding machine by the molded part removal machine. The cycle time measuring unit 5 utilizes a known analog or digital timer that counts from the start time of a start signal and stops counting with an end signal. In the case of the molded part removal machine, "cycle time" refers to the time from the start of movement from the standby position, to the removal of the molded part from the mold, to the release position, and back to the initial standby position. The cycle time measuring unit 5 measures the cycle time based on the start signal output from the injection molding machine side at the start and the end signal output from the molded part removal machine side at the end.

[0045] The target cycle time setting storage unit 7 sets and stores the target cycle time required for one cycle of removing the molded part from the injection molding machine. The target cycle time setting storage unit 7 is configured with a password so that the operator of the molded part removal machine cannot set the target cycle time, and only a manager who knows the password can set the target cycle time. This setting is performed from the setting screen displayed on the display unit 21.

[0046] In each cycle, the comparison unit 9 compares the cycle time measured by the cycle time measurement unit 5 with the target cycle time stored in the target cycle time setting storage unit 7.

[0047] If the comparison result from the comparison unit 9 indicates that the measured cycle time exceeds the target cycle time, the over-count measurement unit 11 will measure the number of times the measured cycle time continuously exceeds the target cycle time after it begins to exceed the target cycle time (after the next cycle). If the measured cycle time is lower than the target cycle time before the number of measurements reaches n, the over-count measurement unit 11 will reset the over-count measurement. Therefore, if the operator's response is appropriate, no detection signal will be output; a detection signal will only be output when the target cycle time is continuously exceeded, thus avoiding placing undue judgment burden on the manager.

[0048] The detection signal output unit 13 outputs a detection signal when the number of times the measured period time exceeds the target period time exceeds n (n is an integer greater than or equal to 1). In this embodiment, n is set to 2, and the detection signal is output when the measured period time exceeds the target period time a total of 3 times consecutively.

[0049] The detection signal output unit 13 can also repeatedly output a detection signal after the detection signal is output, until the measured cycle time is lower than the target cycle time; alternatively, it can continuously output a detection signal. It should be noted that the detection signal output unit 13 can also refrain from outputting a next detection signal after the detection signal is output, until the measured cycle time is lower than the target cycle time. In this way, the manager can, for example, understand the operator's response capability by observing the generation interval between the first and subsequent detection signals.

[0050] In this embodiment, an alarm is generated by driving the alarm generator 17 through a detection signal. It should be noted that alarm generation is not a necessary requirement in the method of the present invention.

[0051] The history storage unit 15 stores the history of the date and time of the detection signal generation, the period before the output of the detection signal that was less than the target period time, and the period before the output of the detection signal that was more than the target period time. The stored information in the history storage unit 15 can be viewed on the display screen of the display unit 21 by the administrator entering a password. It should be noted that the history storage unit 15 can also be configured to store the period before the output of the detection signal that was less than the target period time, and the period before the output of the detection signal that was more than the target period time, when the detection signal is output. In this way, the administrator can not only view the history of the period time when the detection signal is output, but also view the time elapsed before the period time was exceeded (the time required to handle the operation), which can be used by the administrator to confirm the necessity of guidance and training for the operator.

[0052] The display screen of the aforementioned display unit 21 also functions as a touch panel, serving not only as a display screen showing the status of the molded product take-out machine, cycle time, etc., but also as an input unit used for setting target cycle time, etc. In this embodiment, when a detection signal is output, the pop-up display PW and warning icon WI, described later, are displayed on the display screen of the display unit 21 as a detection display.

[0053] 〔flow chart〕

[0054] Figure 2 It is a flowchart representing the process (steps of the method), including a flowchart of the program used when the main part of the control device 1 of the molded article take-out machine of this embodiment is implemented using a computer.

[0055] Before the operation begins, the molded part removal machine is first taught (step ST1), and the manager sets the allowable target cycle time (step ST2).

[0056] When automatic operation begins (step ST3), the cycle time measurement unit 5 measures the cycle time after each cycle (step ST4) (step ST5). When the measurement result is obtained, the comparison unit 9 compares the measured cycle time with the target cycle time (step ST6). If the measured cycle time does not exceed the target cycle time, a reset is determined (reset if the number of times exceeds the limit, and turn off the output of the detection signal if it is on) and the process returns to step ST3 (step ST7 → step ST8). If the measured cycle time exceeds the target cycle time, the output state of the detection signal is checked (step ST7 → step ST9). If the detection signal is on and being output, the process returns to step ST3. This is to prevent continuous output of the detection signal in cases where the administrator mistakenly sets an unattainable target cycle time. If the detection signal is off and not being output, the number of times the target cycle time is exceeded is measured by the number of times the cycle time exceeds the limit (step ST10). Steps ST3 to ST10 (step ST11) are repeated. If the measured period time exceeds the target period time for n consecutive times (2 times in this embodiment, i.e., a total of 3 times), a detection signal is output (step ST12). When the detection signal is output, if... Figure 3 As shown, a pop-up display PW and a warning icon WI are displayed on the display unit 21 (step ST13). Simultaneously, the history storage unit 15 stores the history of the date and time of the detection signal generation, the period time before the output detection signal that is lower than the target period time (i.e., the normal period time 3 periods before the detection signal output), and the period time before the output detection signal that exceeds the target period time (in this embodiment, the period time of the most recent 3 times).

[0057] It should be noted that pressing the "OK" button, which indicates confirmation, can clear the pop-up display PW from the display unit 21. However, unless the administrator performs a reset operation, the warning icon WI will continue to be displayed on the display unit 21.

[0058] Figure 4 This is an example of displaying the resume on the display screen of the display unit 21. In this example, the set target cycle time, the normal cycle time three cycles before the detection signal output, and the cycle time of the three most recent measurements are displayed.

[0059] [Specific examples based on timing diagrams]

[0060] Figure 5 This is an example of a timing diagram of signals output in control device 1 during the automatic operation of the molded product take-off machine. In this timing diagram, from top to bottom, the following signals are shown in sequence: (a) a signal indicating automatic operation is being performed; (b) a signal output when one cycle is completed; (c) a signal indicating a decision is being made; (d) a signal output when the cycle time exceeds the target cycle time (hereinafter referred to as an overrun signal); (e) a signal output when the cycle time is less than the target cycle time (hereinafter referred to as a normal signal); (f) a signal output when a detection signal is output and a pop-up display is displayed (hereinafter referred to as a pop-up signal); (g) a signal output when the button to clear the pop-up display is pressed (hereinafter referred to as a pop-up clear signal); and (h) a signal output when a detection signal is output and a warning icon is displayed (hereinafter referred to as a warning icon signal).

[0061] From the timing diagram, for example, the following items can be read:

[0062] (1) Each time a cycle is completed, the comparator 9 compares the measured cycle time with the target cycle time. When the output (d) exceeds the signal for 3 consecutive times, the comparator outputs a detection signal and outputs a pop-up signal and a warning icon signal (timing T1).

[0063] (2) When the output (g) pop-up cancellation signal is received, the pop-up display is cancelled (timing T2), but the output of the (h) warning icon signal continues.

[0064] (3) If the (d) exceedance signal is output 4 times consecutively, no detection signal or (f) pop-up signal will be output on the 4th time (timing T3).

[0065] (4) After the detection signal is output, output (e) a normal signal (timing T4), thereby resetting the judgment. Figure 2 Step ST8). After that, the (d) signal is output three more times consecutively, thereby outputting the next detection signal (timing T5).

[0066] The above embodiments are described as examples, and the present invention is not limited to these embodiments as long as they do not depart from the spirit of the invention.

[0067] For example, in the above embodiment, if the measured period time exceeds the target period time, in step ST11, a detection signal is output if the period exceeds the target period time consecutively n times. That is, excluding the initial one time exceeding the target period time, if n=1 or more, it is determined to be a continuous exceedance. Conversely, if the measured period time exceeds the target period time, the number of exceedances is also counted, including the initial one time exceeding the target period time, and if the period exceeds the target period time consecutively m times, that is, if m=2 or more, it is determined to be a continuous exceedance. In this case, when the exceedance count measurement unit 11 of the period time management unit 3 detects that the measured period time exceeds the target period time consecutively m times, the detection signal output unit 13 outputs a detection signal.

[0068] Industrial availability

[0069] According to the present invention, a molded product take-out machine and its operation monitoring method are provided, which can easily detect situations where the response operation by the operator is slow or insufficient when a pause occurs.

Claims

1. A method for monitoring the operation of a molded article removal machine, characterized in that, The operation monitoring method for the molded product removal machine has the following features: Cycle time measurement steps: Measure the cycle time required for one cycle of removing the molded part from the injection molding machine; The steps for setting the target cycle time include setting the target cycle time allowed by the manager. The comparison step involves comparing the measured cycle time with the target cycle time in each cycle. In the step of exceeding the number of measurements, if the comparison result shows that the measured period time exceeds the target period time, then after the measured period time begins to exceed the target period time, the number of times the measured period time continuously exceeds the target period time is measured. as well as The output step is to output a detection signal when the number of times the measured period time exceeds the target period time exceeds n, where n is an integer greater than or equal to 1.

2. A method for monitoring the operation of a molded article removal machine, characterized in that, The operation monitoring method for the molded product removal machine has the following features: Cycle time measurement steps: Measure the cycle time required for one cycle of removing the molded part from the injection molding machine; The steps for setting the target cycle time include setting the target cycle time allowed by the manager. The comparison step involves comparing the measured cycle time with the target cycle time in each cycle. The step of exceeding the number of times to measure is to measure the number of times the measured period time exceeds the target period time. as well as The output step determines whether the measured period time exceeds the target period time for m consecutive times, and outputs a detection signal when it is determined that it exceeds the target period time for m consecutive times, where m is an integer greater than 2.

3. The operation monitoring method for the molded article removal machine according to claim 1, wherein, Only the manager of the molded product extraction machine can set the target cycle time.

4. The operation monitoring method for the molded article removal machine according to claim 1, wherein, In the over-count measurement step, if the measured period time is lower than the target period time before the number of times the measured period time exceeds the target period time consecutively reaches the nth time, the over-count measurement step is reset.

5. The operation monitoring method for the molded article removal machine according to claim 1, wherein, After the detection signal is output, no further detection signal will be output until the measured period time is lower than the target period time.

6. The operation monitoring method for the molded article removal machine according to claim 1, wherein, The operation monitoring method for the molded product extraction machine further includes a storage step, in which, when the detection signal is output, the cycle time before the output of the detection signal that is lower than the target cycle time and the cycle time before the output of the detection signal that is higher than the target cycle time are stored.

7. A molded article removal machine, comprising a cycle time management unit capable of setting a target cycle time for one cycle of removing a molded article from an injection molding machine, characterized in that... The cycle time management department has: A cycle time measuring unit that measures the cycle time in each cycle; A target cycle time setting and storage unit sets and stores the target cycle time; The comparison unit compares the measured cycle time with the target cycle time in each cycle. The number of times the measuring unit exceeds the target period time is exceeded if the result of the comparison by the comparison unit is that the measured period time exceeds the target period time. After the measured period time begins to exceed the target period time, the measuring unit measures the number of times the measured period time continuously exceeds the target period time. as well as The detection signal output unit outputs a detection signal when the number of times the measured period time exceeds the target period time exceeds n, where n is an integer greater than or equal to 1.

8. A molded article removal machine, comprising a cycle time management unit capable of setting a target cycle time for one cycle of removing a molded article from an injection molding machine, characterized in that... The cycle time management department has: A cycle time measuring unit that measures the cycle time in each cycle; A target cycle time setting and storage unit sets and stores the target cycle time; The comparison unit compares the measured cycle time with the target cycle time in each cycle. The number of times the measured period exceeds the target period is measured if the result of the comparison by the comparison unit is that the measured period time exceeds the target period time. as well as The detection signal output unit outputs a detection signal when the measured period time exceeds the target period time for m consecutive times, where m is an integer greater than or equal to 2.

9. The molded article extraction machine according to claim 7 or 8, wherein, The cycle time management unit also includes a history storage unit, which stores at least the history of the date and time of generation of the detection signal.

10. The molded article extraction machine according to claim 7 or 8, wherein, The target cycle time setting storage unit is configured so that it can only be set by the operator of the molded product extraction machine.

11. The molded article extraction machine according to claim 7 or 8, wherein, The molded product removal machine also includes an alarm generator that outputs an alarm driven by the detection signal.

12. The molded article extraction machine according to claim 7 or 8, wherein, The molded product extraction machine also includes a display unit that displays the detection signal when the detection signal is output.

13. The molded article extraction machine according to claim 7 or 8, wherein, The detection signal output unit will not output the next detection signal after the detection signal is output, until the measured period time is lower than the target period time.

14. The molded article extraction machine according to claim 9, wherein, When the detection signal is output, the history storage unit stores the period time before the detection signal is output that is lower than the target period time, and the period time before the detection signal is output that is output that is exceeded the target period time.

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