Release agent coating state detection method, release agent coating adjustment method and release agent coating state detection device

Abstract

The present invention relates to a release agent coating state detection method, a release agent coating adjustment method and a release agent coating state detection device. The release agent coating state detection method includes: a configuration step, configuring on a mold; and a coating step, after the configuration step, coating the release agent on at least a portion of the surface defining the mold cavity. It also includes: a first acquisition step, after the configuration step, for at least a portion of the surface, obtaining color information indicating the color before the release agent is applied corresponding to the position on the surface; a second acquisition step, after the coating step, for at least a portion of the surface, obtaining color information indicating the color after the release agent is applied corresponding to the position on the surface; and a calculation step, according to the difference between the color information obtained in the first acquisition step and the color information obtained in the second acquisition step, calculating the amount of release agent applied corresponding to the position included in at least a portion of the surface.

Description

Technical Field

[0001] The present invention relates to a release agent coating state detection method, a release agent coating adjustment method and a release agent coating state detection device. Background Art

[0002] It is known that a mold release agent is applied to the surface defining the cavity of a mold, which serves as a molding part, to facilitate demolding of the molded product. The mold release agent is usually white or colorless. Summary of the Invention

[0003] For example, Japanese Patent Application Laid-Open No. 2007-69217 describes a method for detecting the state of a release agent applied to a mold, using a release agent containing a fluorescent substance to visualize the amount of release agent applied. However, this is not limiting, and other technologies for detecting the state of a release agent applied are also desired.

[0004] The present disclosure has been made to solve the above-mentioned problems and can be implemented as the following aspects.

[0005] (1) According to one embodiment of the present invention, a release agent coating state detection method for detecting the state of a release agent applied to a mold is provided. The release agent coating state detection method includes: a placement step of placing a color-changing material that changes color when the release agent is attached on the mold; and a coating step of, after the placement step, coating the release agent on at least a portion of a surface defining a cavity of the mold. The method further includes: a first acquisition step of, after the placement step, acquiring, for at least a portion of the surface, color information indicating the color before the release agent is applied in the coating step, corresponding to a position on the surface; a second acquisition step of, after the coating step, acquiring, for at least a portion of the surface, color information indicating the color after the release agent is applied in the coating step, corresponding to a position on the surface; and a calculation step of calculating the amount of the release agent applied corresponding to a position included in the at least a portion of the surface, based on a difference between the color information acquired in the first acquisition step and the color information acquired in the second acquisition step.

[0006] According to this aspect, the difference in color information can be acquired according to the position on the surface of the mold, and therefore the application state of the release agent can be detected according to the position of the mold.

[0007] (2) In the above-described release agent coating state detection method, the color-changing material may be a developer or a sheet member whose color changes due to moisture.

[0008] According to this aspect, the color-changing material changes color when the release agent is applied. Therefore, the application state of the release agent can be detected according to the position of the mold.

[0009] (3) In the release agent coating state detection method of the above embodiment, the arrangement step, the first acquisition step, the coating step, the second acquisition step, and the calculation step may be sequentially performed a plurality of times with intervals therebetween.

[0010] According to this aspect, for example, deterioration of a mold or a coating portion can be detected.

[0011] (4) According to one embodiment of the present disclosure, a release agent coating adjustment method for adjusting the coating of the release agent is provided. The release agent coating adjustment method includes: a step of performing the release agent coating state detection method described above; and an adjustment step of adjusting the release agent coating in a product manufacturing process using the mold based on the release agent coating amount calculated in the calculation step.

[0012] According to such an aspect, for example, the amount of the release agent applied on the surface can be adjusted so as to be reduced in a portion where the amount of the release agent applied is larger than the expected amount.

[0013] The present disclosure can be implemented in various forms, for example, as a release agent coating state detection system, a release agent coating device including a release agent coating state detection device, and the like. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described below with reference to the accompanying drawings, in which like numerals represent like elements, and in which:

[0015] Figure 1 This is a diagram showing a schematic configuration of a release agent coating state detection device.

[0016] Figure 2 This is a flowchart showing an example of release agent coating state detection processing.

[0017] Figure 3 This is a diagram illustrating the calculation process.

[0018] Figure 4 This is a flowchart showing an example of the release agent coating adjustment process. DETAILED DESCRIPTION

[0019] A. First embodiment:

[0020] Figure 1: This is a diagram showing a schematic structure of a release agent coating state detection device in one embodiment of the present invention. The release agent coating state detection device 100 is a device that implements a release agent coating state detection method. The release agent coating state detection method is a method for detecting the state of the release agent coated on the surface (hereinafter referred to as "surface") 201 of the mold cavity that defines the molding part of the mold 200, that is, the coating amount of the release agent. The so-called coating amount of the release agent is, for example, the thickness of a film formed by the release agent per unit area on the surface 201 that is predetermined. The release agent coating state detection device 100 includes a configuration unit 10, a coating unit 20, a first acquisition unit 30, a second acquisition unit 40 and a calculation unit 50. The release agent coating state detection device 100 is composed of a microcomputer, etc., and the functions of the above-mentioned parts are realized by executing a pre-installed program by the microcomputer. The microcomputer is composed of a central processing unit (CPU), RAM, and ROM. However, part or all of the functions of the above-mentioned parts can also be realized by hardware circuits.

[0021] Figure 2 This is a flowchart illustrating an example of release agent application status detection processing. The release agent application status detection processing uses the release agent application status detection device 100 to detect the amount of release agent applied to the surface 201. This processing is performed, for example, when the release agent does not achieve the desired function or for spot checks.

[0022] In step S100, the configuration unit 10 configures a color-changing material that changes color when a release agent is attached to the mold 200. The configuration unit 10 is composed of a CPU of the release agent coating state detection device 100 and a robot. This process is also called a "configuration process". The color-changing material is, for example, a developer or a sheet member whose color changes due to moisture. In this embodiment, the configuration unit 10 uses a developer as the color-changing material. The so-called developer is, for example, liquid water containing fine powdered silicate powder or alcohol containing calcium carbonate. The configuration unit 10 uses a robot to move the nozzle relative to the surface 201 that defines the mold cavity to apply the developer to the surface 201. In addition, the coating unit 20 can configure the color-changing material on the entire surface 201, or can configure the color-changing material only on the portion where the release agent coating state is to be detected. For example, the color-changing material can be configured only on the portion of the surface 201 where sintering or wear occurs during the manufacture of the product using the mold 200.

[0023] In step S110, the first acquisition unit 30 acquires color information representing the color before the release agent is applied, corresponding to the position of at least a portion of the surface 201. More specifically, the first acquisition unit 30 acquires color information representing the color of at least a portion of the surface 201 after the process in step S100. This process is also referred to as the "first acquisition process." In this embodiment, the first acquisition unit 30 comprises the CPU of the release agent coating state detection device 100 and a 3D color scanner. The first acquisition unit 30 acquires color information from the 3D color scanner. More specifically, the first acquisition unit 30 acquires color information representing the color at each position based on the position information detected by the laser and the image captured by the camera. Position information is, for example, information represented by xyz coordinates. Color information is, for example, information represented by numerical values, such as RGB values, L*a*b* values, brightness, and combinations thereof. In this embodiment, the first acquisition unit 30 acquires grayscaled RGB values ​​as color information. Color information indicating the color before the release agent is applied is also referred to as “first color information”.

[0024] In step S120, the coating unit 20 applies a release agent to at least a portion of the surface 201. The coating unit 20 is composed of the CPU of the release agent coating state detection device 100 and a robot. This process is also referred to as the "coating process." In this embodiment, the coating unit 20 uses a robot to move the nozzle to apply the release agent to the surface 201. Application of the release agent is not limited to spraying; for example, application using a brush is also possible.

[0025] In step S130, the second acquisition unit 40 acquires color information indicating the color after the release agent is applied, corresponding to the position, for at least a portion of the surface 201. More specifically, the second acquisition unit 40 acquires color information indicating the color after the release agent is applied, corresponding to the position, for at least a portion of the surface 201 after the processing of step S120. This process is also referred to as a "second acquisition process." In the present embodiment, the second acquisition unit 40 is composed of a CPU and a 3D color scanner of the release agent application state detection device 100. In addition, in the present embodiment, the first acquisition unit 30 and the second acquisition unit 40 acquire color information corresponding to the position from the same 3D color scanner. The color information indicating the color after the release agent is applied is also referred to as "second color information."

[0026] In step S140, the calculation unit 50 calculates the amount of release agent applied, corresponding to at least a portion of the position included in the surface 201, based on the difference in color information obtained in steps S110 and S130. This step is also referred to as a "calculation step." More specifically, the calculation unit 50 calculates the amount of release agent applied based on a mapping or function that predefines the relationship between the amount of application and the amount of change in color information at corresponding positions on the surface 201. The amount of change in color information is the value obtained by subtracting the color information obtained in step S110 from the color information obtained in step S130.

[0027] Figure 3 This is a diagram illustrating the calculation process. The calculation unit 50 determines the amount of change in color information based on the difference between the color information obtained in the first acquisition step before the release agent is applied in the coating step and the color information obtained in the second acquisition step after the release agent is applied in the coating step. The calculation unit 50 calculates the amount of release agent applied based on the amount of change in color information.

[0028] In step S150 ( Figure 2 ), the release agent coating state detection device 100 stores the color information obtained in steps S110 and S130 and the release agent coating amount calculated in step S150 in a predetermined storage area in correspondence with the position included in at least a portion of the surface 201. In addition, this processing may be omitted.

[0029] According to the release agent coating state detection method of the present embodiment described above, it is possible to obtain a difference in color information corresponding to a position on the surface 201 defining the cavity of the mold 200. Therefore, in the calculation step, the calculation unit 50 can detect the release agent coating state corresponding to the position of the mold 200 based on the difference in color information.

[0030] Furthermore, the release agent coating status detection method stores color information and coating amount as numerical data corresponding to positions on surface 201 during the storage process. This allows for quantitative evaluation of the past release agent coating status, compared to simply storing a photograph of surface 201 coated with release agent. For example, by sequentially performing the placement process, the first acquisition process, the coating process, the second acquisition process, and the calculation process multiple times at intervals, i.e., by repeatedly performing the release agent coating status detection process, degradation of mold 200 or coating unit 20 can be detected.

[0031] B. Second embodiment:

[0032] In the second embodiment, the release agent coating state detection device 100 implements a release agent coating adjustment method. This release agent coating adjustment method differs from the release agent state detection method of the first embodiment in that the release agent coating is adjusted. The structure of the release agent coating state detection device 100 of the second embodiment is the same as that of the first embodiment, and therefore, a description of the release agent coating state detection device 100 will be omitted.

[0033] Figure 4 This is a flowchart showing an example of a release agent coating adjustment process. The release agent coating adjustment process is a process for adjusting the coating of the release agent applied to the surface 201 using the release agent coating state detection device 100. This process is performed, for example, when the type of release agent or the amount of release agent applied is changed, to adjust the amount of release agent applied. The difference between the release agent coating adjustment process and the release agent state detection process is that, in step S160, the release agent application in the product manufacturing process using the mold 200 is adjusted based on the release agent application amount calculated in the calculation process of S140. The other processes are the same as the release agent state detection process.

[0034] In the adjustment step, the coating unit 20 performs adjustment so as to reduce the amount of the release agent applied to the surface 201 where the amount of the release agent applied is larger than the expected amount, for example.

[0035] According to the release agent application adjustment method of the present embodiment described above, the application of the release agent can be adjusted based on the calculated application amount of the release agent.

[0036] C. Other implementation methods:

[0037] (C1) In the above embodiment, the release agent coating state detection device 100 includes the placement unit 10 and the coating unit 20. Alternatively, the release agent coating state detection device 100 may include only the first acquisition unit 30, the second acquisition unit 40, and the calculation unit 50, with the placement unit 10 and the coating unit 20 being provided by other devices.

[0038] (C2) In the above embodiment, the dispensing unit 10 uses a developer as the color-changing material. This is not limiting. The dispensing unit 10 may also use water-sensitive paper as the color-changing material. Water-sensitive paper is a thin paper sheet with a chemical applied to one side. Water-sensitive paper changes color when water droplets adhere to the coated surface. Furthermore, the material is not limited to water; a chemical that reacts with a component of the release agent, or a sheet coated with a chemical that reacts with a component of the release agent, may also be used.

[0039] (C3) In the above embodiment, the placement step is performed by a robot. Alternatively, the placement step may be performed manually by placing the color-changing material on the mold 200. Furthermore, in the above embodiment, the coating step is also performed by a robot. Alternatively, the coating step may be performed manually by applying a release agent to the surface 201 of the mold 200.

[0040] (C4) In the above embodiment, the first acquisition unit 30 and the second acquisition unit 40 acquire color information at each position based on the position information detected by the laser and the image captured by the camera. This is not limiting. The first acquisition unit 30 and the second acquisition unit 40 may also acquire color information at each position based on the image captured by the camera.

[0041] The present disclosure is not limited to the above-mentioned embodiments and can be implemented in various structures within the scope of the main purpose of the present disclosure. For example, in order to solve the above-mentioned problems, or to achieve part or all of the above-mentioned effects, the technical features in the embodiments corresponding to the technical features in the various methods described in the "Summary of the Invention" column can be appropriately replaced or combined. In addition, if the technical feature is not described as a necessary technical feature in this specification, it can be appropriately deleted.

Claims

1. A method for detecting the state of a release agent applied to a mold, wherein: include: A disposing step of disposing a color-changing material that changes color when a release agent is attached to the mold on the mold; and a coating step of coating a mold release agent on at least a portion of a surface defining a cavity of the mold after the arranging step; The release agent coating state detection method further comprises: a first acquisition step of acquiring, after the arrangement step, color information indicating a color before the release agent is applied in the application step, corresponding to a position on the surface, for the at least a portion of the surface; a second acquisition step of acquiring, after the coating step, color information indicating a color after the release agent is applied in the coating step, corresponding to a position on the surface, for the at least a portion of the surface; and a calculation step of calculating the amount of the release agent to be applied based on a mapping or function obtained by predefining a relationship between an amount of change in color information before and after application of the release agent and an amount of the release agent applied at a corresponding position on the surface, according to a difference between the color information obtained in the first acquisition step and the color information obtained in the second acquisition step, corresponding to the position included in the at least a portion of the surface; The arrangement step, the first acquisition step, the coating step, the second acquisition step, and the calculation step are sequentially performed a plurality of times with intervals.

2. The release agent coating state detection method according to claim 1, wherein: The color-changing material is a developer or a sheet member whose color changes due to moisture.

3. A method for adjusting the coating of a release agent, wherein the coating of the release agent is adjusted, include: A step of performing the release agent coating state detection method according to claim 1 or 2; and The adjusting step is to adjust the application of the release agent in a product manufacturing step using the mold based on the application amount of the release agent calculated in the calculating step.

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