Defective product sorting method and system for laptop molds, and defective product detection device

Abstract

The present invention relates to a method for sorting defective laptop molds, which obtains the working state parameters of each injection molding machine in real time and identifies its type. If it is a second state parameter, a timer is used to obtain the duration of the state, and it is compared with different preset time thresholds. If it is less than the first preset time threshold, it is determined to be a normal state. If it reaches the second preset time threshold or the third preset time threshold, it is determined to be an abnormal state, and a corresponding control instruction is generated to control a robot to throw away defective products of a corresponding preset number threshold. That is, the present invention identifies whether the injection molding machine will produce defective products based on the duration of the abnormal state, and obtains the corresponding number of defective products according to different durations, so as to control the robot to throw away the corresponding number of defective products, which greatly improves the efficiency compared to manual identification and detection of defective products. Correspondingly, the present invention also provides a defective product sorting system and detection device.

Description

Technical Field

[0001] The present invention relates to the technical field of injection molding, and in particular to a method and system for sorting defective products in the process of injection molding of a laptop mold, and a defective product detection device. Background Art

[0002] Injection molding is one of the most commonly used plastic processing technologies, which is widely used in production and life. The definition of injection molding is that after the plastic is heated to a certain temperature, the injection molding machine injects the dissolved plastic into the closed mold cavity with extremely high pressure, and then the mold is cooled and formed. After the mold is opened, the plastic product is ejected from the top plate. The characteristics of injection molding are good product consistency and stable quality during continuous and stable production, and the probability of defective products is extremely low.

[0003] However, when producing in a non-continuous stable state, such as when the production factors change, such as when the machine is just started, when the machine stops working abnormally, when the equipment fails, etc., the probability of product defects increases sharply, and the product yield rate is greatly reduced. Since the robot arm is commonly used to automatically pick up the finished injection molded parts processed by the injection molding machine to the designated area, it is difficult to prevent defective products from mixing with good products. When defective products are mixed with good products, they must be manually inspected and screened, which is time-consuming and labor-intensive. In addition, only visible defects can be identified, and non-appearance defects will escape and flow into the next process or be delivered to customers, resulting in quality degradation and customer complaints.

[0004] In order to efficiently detect defective products, various defective product detection devices have emerged in the prior art. For example, by setting a camera on the production line to shoot the appearance of the workpiece, and then performing image analysis and processing on the captured image to obtain the appearance and structural parameters of the workpiece, and compare it with the appearance and structural parameters of the standard workpiece, so as to identify defective products; and in order to be able to shoot the workpiece from multiple angles, so as to obtain the complete appearance and structural parameters of the workpiece, it is necessary to set up multiple cameras, and to set up auxiliary equipment for flipping or adjusting the angle of the workpiece on the processing equipment. Therefore, this method not only requires a major improvement to the existing processing equipment, making the structure of the processing equipment more complicated, but also because a large amount of image processing is required, the performance requirements of the main control equipment are higher, which undoubtedly greatly increases the cost of the enterprise, and is not suitable for enterprises where both the processing equipment and the main control equipment have been put into use for a long time.

[0005] The prior art also proposes a method for detecting and sorting defective products based on production cycles. For example, CN115972522A discloses a defective product control system for an injection molding machine, which identifies defective production cycles based on the time interval between two adjacent production cycles, thereby removing the injection molded products obtained from the defective production cycle. If the time interval is greater than a preset time interval, the current production cycle is determined to be a defective cycle, and then the robot is controlled to determine the finished products in the defective cycle as defective products. Summary of the invention

[0006] The object of the present invention is to provide a defective product sorting method and system for laptop molds, and a defective product detection device, which partially solve or alleviate the above-mentioned deficiencies in the prior art and can automatically sort defective products.

[0007] In order to solve the above-mentioned technical problems, the present invention specifically adopts the following technical solutions:

[0008] A first aspect of the present invention is to provide a method for sorting defective laptop computer molds, comprising the steps of:

[0009] Acquire working state parameters of each injection molding machine in real time; the working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state, and a second state parameter indicating that the injection molding machine is in an abnormal state;

[0010] When the second state parameter is identified for the first time, the timer is triggered to start timing, and when the first state parameter is identified again, the timing is stopped to obtain the timing time T; and the timing time T is compared with the first preset time threshold, the second preset time threshold and the third preset time threshold;

[0011] If the timing time T is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the robot arm corresponding to the current injection molding machine;

[0012] If the timing time T reaches the second preset time threshold, it is determined that the current injection molding machine is in the first abnormal state, and a second control instruction is generated and sent to the robot corresponding to the current injection molding machine, so that when the robot receives the second control instruction, the finished injection molded parts of the first preset number threshold output by the current injection molding machine are sorted to the defective product area; the second control instruction includes the first preset number threshold of defective products to be discarded;

[0013] If the timing time T reaches the third preset time threshold, it is determined that the current injection molding machine is in the second abnormal state, and a third control instruction is generated and sent to the robot corresponding to the current injection molding machine, so that when the robot receives the third control instruction, the finished injection molded parts with a second preset quantity threshold output by the current injection molding machine are sorted into the defective product area; the third control instruction includes the second preset quantity threshold of defective products to be discarded.

[0014] The first preset time threshold is smaller than the second preset time threshold, and the second preset time threshold is smaller than the third preset time threshold.

[0015] The first preset number threshold is smaller than the second preset number threshold

[0016] In some embodiments of the present invention, before the step of generating the second control instruction, the step further includes:

[0017] Obtain the material consumption Q0 of a single injection molding part corresponding to the current injection molding machine, and the total amount Q of melted raw materials in the material pipe of the current injection molding machine whose temperature exceeds the minimum denaturation temperature, and calculate the defective product quantity threshold S=Q / Q0 corresponding to the current injection molding machine based on the material consumption Q0 of a single injection molding part and the total amount Q of melted raw materials whose temperature exceeds the minimum denaturation temperature.

[0018] In some embodiments of the present invention, before the step of generating the third control instruction, the step is also included: obtaining the material consumption Q0 of a single injection molded part corresponding to the current injection molding machine, and the total amount V of melted raw material in the material tube, and calculating the defective product quantity threshold S = V / Q0 corresponding to the current injection molding machine based on the material consumption Q0 of the single injection molded part and the total amount V of melted raw material in the material tube.

[0019] A second aspect of the present invention is to provide a defective laptop mold sorting system, comprising:

[0020] At least one injection molding machine, used for processing injection-molded parts of the laptop mold and outputting finished injection-molded parts of the laptop mold;

[0021] A main control device, which communicates data with the at least one injection molding machine, is used to obtain the working state parameters of the injection molding machine in real time and identify the type of the working state parameters. When the working state parameters of the current injection molding machine are identified as the second state parameters for the first time, the timer is triggered to start timing, and when the first state parameters of the current injection molding machine are identified again, the timing is stopped and the timing time is obtained, and then the timing time is compared with the first preset time threshold, the second preset time threshold and the third preset time threshold respectively. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to a robot for sorting; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to a robot for sorting; the second control instruction includes a first preset number threshold for discarding defective products; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to a robot for sorting; the third control instruction includes a second preset number threshold for discarding defective products;

[0022] At least one robot, each of which is installed at a sorting station at the output position of each injection molding machine and communicates data with the main control device, and the robot is used to sort the finished injection molded parts output by the corresponding injection molding machine to the good product area when receiving the first control instruction; or, when receiving the second control instruction, sort the finished injection molded parts output by the corresponding injection molding machine with a first preset quantity threshold to the defective product area; or, when receiving the third control instruction, sort the finished injection molded parts output by the corresponding injection molding machine with a second preset quantity threshold to the defective product area.

[0023] The types of the working state parameters include the first state parameter and the second state parameter, wherein the first state parameter indicates that the injection molding machine is in a normal state; and the second state parameter indicates that the injection molding machine is in an abnormal state.

[0024] The first preset time threshold is smaller than the second preset time threshold, and the second preset time threshold is smaller than the third preset time threshold.

[0025] The first preset quantity threshold is smaller than the second preset quantity threshold.

[0026] In some embodiments of the present invention, the main control device includes:

[0027] A data acquisition module, used for acquiring the working status parameters of each injection molding machine in real time;

[0028] A state identification module, used to identify the type of working state parameters of each injection molding machine;

[0029] A trigger module, configured to trigger a timer to start timing when the state recognition module recognizes for the first time that the working state parameter of the current injection molding machine is the second state parameter, and to stop timing and obtain the timing time when the working state parameter of the current injection molding machine is recognized for the second time as the first state parameter;

[0030] An abnormality identification module is used to compare the timing time with a first preset time threshold, a second preset time threshold and a third preset time threshold, and when it is judged that the timing time is less than the first preset time threshold, it is judged that the current injection molding machine is in a normal state, and the first control instruction is generated and sent to the robot; or when it is judged that the timing time reaches the second preset time threshold, it is judged that the current injection molding machine is in a first abnormal state, and the second control instruction is generated and sent to the robot; or when it is judged that the timing time reaches the third preset time threshold, it is judged that the current injection molding machine is in a second abnormal state, and the third control instruction is generated and sent to the robot.

[0031] In some embodiments of the present invention, the main control device uses a single chip microcomputer integrated on the robot, and the main control device performs data communication with the injection molding machine through an integrated wireless communication module.

[0032] In some embodiments of the present invention, the main control device also includes: a defective product count calculation module, which is used to determine when the timing time reaches the second preset time threshold, or reaches the third preset time threshold, obtain the material consumption of a single injection molded part corresponding to the current injection molding machine, and calculate the defective product quantity threshold corresponding to the current injection molding machine based on the material consumption of the single injection molded part.

[0033] A third aspect of the present invention is to provide a defective product detection device for a laptop computer mold, comprising:

[0034] Timer, used for timing;

[0035] A wireless communication module, used for performing data communication with a plurality of injection molding machines to obtain working state parameters of each injection molding machine;

[0036] A state identification module, used to identify the type of the working state parameter acquired by the wireless communication module; the type of the working state parameter includes: a first state parameter characterizing that the injection molding machine is in a normal state; a second state parameter characterizing that the injection molding machine is in an abnormal state;

[0037] A trigger module, configured to trigger a timer to start timing when the state recognition module recognizes for the first time that the working state parameter of the current injection molding machine is the second state parameter, and to stop timing when the state recognition module recognizes for the second time that the working state parameter of the current injection molding machine is the first state parameter, thereby obtaining a timing time;

[0038] An abnormality identification module is used to compare the timing time with a first preset time threshold, a second preset time threshold and a third preset time threshold. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the robot; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the robot; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the robot; wherein, the second control instruction includes a first preset quantity threshold for discarding defective products; and the third control instruction includes a second preset quantity threshold for discarding defective products.

[0039] Beneficial effect: Compared with the traditional method of using a visual system, such as a camera and other auxiliary equipment to obtain the appearance and structural parameters of the processed workpiece, and then performing a large amount of image analysis and data processing, the present invention only monitors the underlying IO signals of each injection molding machine and the manipulator for finished product sorting through the Internet of Things, that is, by collecting the working state parameters of the injection molding machine, and calculating and monitoring the duration of its abnormality (such as continuously collecting the second state parameter), if it reaches the preset time threshold (for example, the second preset time threshold or the third preset time threshold; or, in other words, exceeds the minimum abnormal duration), it is finally determined to be in an abnormal state, and defective products will be produced, thereby controlling the manipulator to throw away the corresponding number of defective products. That is, the present invention triggers the detection of defective products from the perspective of the working state of the injection molding machine equipment, which greatly reduces the cost and is simpler and more effective than the defective product detection using a visual system.

[0040] On the one hand, different injection molded parts have different material consumption and different time cycles required for their production. Accordingly, the number of defective products generated under abnormal conditions (for example, shutdown conditions) will also be different. On the other hand, the duration of the abnormal condition is different, and the number of defective products generated under the abnormal condition is also different. That is, the material consumption of a single injection molded part and the duration of the abnormal condition are the key factors affecting the number of defective products. Therefore, in this application, the material consumption required for each injection molding machine to produce a single injection molded part and the duration T of its corresponding abnormal condition are used to accurately calculate the number of defective products that the injection molding machine will produce within the abnormal duration, and the robot is controlled to automatically throw them away, thereby realizing fully automatic and accurate calculation and elimination of defective products, which has a wide range of applications and low cost.

[0041] Furthermore, the present invention can also accurately calculate the number of times defective molds need to be discarded under abnormal conditions in combination with the material consumption of each injection molding machine in producing and processing a single injection molded part, thereby achieving the effect of fully automatic and complete elimination of defective products, avoiding the disadvantages of the previous technology that requires technicians to manually calculate and control the number of times defective molds are discarded, such as inaccurate calculation, uncontrollable behavior, untimely operation, and high cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, each element or part is not necessarily drawn according to the actual scale. Obviously, the drawings described below are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can also be obtained based on these drawings without paying creative labor.

[0043] Figure 1A functional module diagram of a defective laptop mold sorting system according to an exemplary embodiment of the present invention;

[0044] Figure 2 A flowchart of a method for sorting defective laptop computer molds according to an exemplary embodiment of the present invention;

[0045] Figure 3a and Figure 3b Each of them is a schematic diagram of the number of discarded defective products of each of some injection molding machines in the entire workshop detected by using a defective product sorting method according to an exemplary embodiment of the present invention. DETAILED DESCRIPTION

[0046] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0047] Herein, suffixes such as "module", "component" or "unit" used to represent elements are only used to facilitate the description of the present invention, and have no specific meanings by themselves. Therefore, "module", "component" or "unit" can be used mixedly.

[0048] In this document, the terms "upper", "lower", "inner", "outer", "front", "back", "one end", "the other end" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0049] In this document, unless otherwise clearly specified and limited, the terms "installed", "provided with", "connected", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0050] Herein, "and / or" includes any and all combinations of one or more of the listed related items. Herein, "plurality" means two or more, that is, it includes two, three, four, five, etc.

[0051] Example 1: See Figure 1 , is a functional module diagram of a defective product sorting system for an injection molding machine according to an exemplary embodiment of the present invention. Specifically, the system includes:

[0052] At least one injection molding machine, used to process injection molded parts of laptop molds and output finished injection molded parts;

[0053] A main control device, which communicates data with at least one injection molding machine, is used to obtain the working state parameters of each injection molding machine in real time and identify the type of the working state parameters; when the working state parameter of the current injection molding machine is identified as the second state parameter for the first time, the timer is triggered to start timing, and when the working state parameter of the current injection molding machine is identified as the first state parameter again, the timing is stopped and the timing time is obtained, and then the timing time is compared with the first preset time threshold, the second preset time threshold and the third preset time threshold respectively. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to a robot for sorting; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the robot for sorting, and the second control instruction includes a first preset number threshold for discarding defective products; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the robot for sorting, and the third control instruction includes a second preset number threshold for discarding defective products;

[0054] At least one robot, each robot is installed at a sorting station at the output position of each injection molding machine and communicates data with the above-mentioned main control device, and the robot is used to move between the good product area and the bad product area at the sorting station under the control of the main control device, so as to sort the finished injection parts output by the processing equipment into the good product area or the bad product area; specifically, when receiving a first control instruction, sorting the finished injection parts output successively by the current injection molding machine into the good product area according to the first control instruction; or, when receiving a second control instruction, sorting the finished injection parts of a first preset number threshold value output successively by the current injection molding machine into the bad product area; or, when receiving a third control instruction, sorting the finished injection parts of a second preset number threshold value output successively by the current injection molding machine into the bad product area.

[0055] In some embodiments, the first abnormal state refers to that the injection molding machine is in a short-term temporary shutdown state, that is, the shutdown time reaches or exceeds the second preset time threshold (for example, 3 minutes); the second abnormal state refers to that the injection molding machine is in a longer shutdown state, that is, the shutdown time reaches or exceeds the third preset time threshold (5 minutes). Preferably, for the same injection molding machine, the first preset quantity threshold is less than the second preset quantity threshold.

[0056] In some embodiments, the main control device uses a single chip microcomputer integrated on the robot, and the main control device communicates data with the injection molding machine through an integrated wireless communication module. Specifically, the main control device includes:

[0057] Data acquisition module, used to obtain the working status parameters of each injection molding machine in real time;

[0058] A state identification module, used to identify the type of working state parameters currently acquired by the data acquisition module;

[0059] A trigger module is used to trigger the timer to start timing when the state recognition module recognizes for the first time that the working state parameter of the current injection molding machine is the second state parameter, and to stop timing when the working state parameter of the current injection molding machine is recognized again as the first state parameter (that is, when it is recognized that the working state parameter of the current injection molding machine changes from the second state parameter to the first state parameter), and obtain the timing time;

[0060] An abnormality identification module is used to compare the above-mentioned timing time with a first preset time threshold, a second preset time threshold and a third preset time threshold. If it is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to a robot for sorting; if the second preset time threshold is reached, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to a robot for sorting; if the third preset time threshold is reached, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to a robot for sorting.

[0061] In some embodiments, the second control instruction includes a pre-calculated first preset quantity threshold of defective products to be discarded; and the third control instruction includes a pre-calculated second preset quantity threshold of defective products to be discarded.

[0062] In some embodiments, the main control device also includes: a defective product count calculation module, which is used to determine when the timing time reaches a second preset time threshold, or reaches a third preset time threshold, to obtain the material consumption of a single injection molded part corresponding to the current injection molding machine, and calculate the defective product quantity threshold S = Q / Q0 corresponding to the current injection molding machine based on the material consumption Q of a single injection molded part and the total amount Q of melted raw materials that have deteriorated within the timing time T, for example, the above-mentioned first preset quantity threshold and the second preset quantity threshold.

[0063] Usually, when each injection molding machine is in normal working condition, the temperature of the material tube is highest at the front nozzle and lowest at the rear end. Once the machine is shut down for a period of time, the melted raw material in the material tube will be carbonized or denatured, thus becoming waste. The transformation of the melted raw material into waste is related to its temperature and the duration of shutdown, and there is a minimum denaturation temperature and a minimum duration. For example, when the temperature of the material tube is higher than the minimum denaturation temperature, and the shutdown time of the injection molding machine exceeds the minimum duration, the melted raw material in the material tube will become waste. Therefore, within the minimum duration t0, the melted raw material will not become waste, so the minimum duration t0 is used as the first preset time threshold. However, once the minimum duration is exceeded and the temperature of the material tube is higher than the minimum denaturation temperature, a certain number of injection molded parts need to be thrown away to remove the waste from the material tube.

[0064] Specifically, the total amount of melted raw material in the material tube whose temperature exceeds the lowest denaturation temperature: the volume is Q (which can be obtained from the working status parameters of the injection molding machine), and the amount of good material consumed by the injection molding machine to produce a single injection molded part: the volume is Q0, and when T>t0, S=Q / Q0 molds need to be thrown away to remove the waste from the material tube.

[0065] Furthermore, when the downtime duration exceeds the third preset time threshold, the total amount of melted raw materials in the material tube: volume V will become waste, so the S=V / Q0 mold needs to be thrown away to remove the waste from the material tube.

[0066] Embodiment 2: The present invention also provides a defective product detection device, specifically, comprising:

[0067] Timer, used for timing;

[0068] A wireless communication module is used to communicate data with each injection molding machine to obtain working status parameters of each injection molding machine;

[0069] A state identification module, used to identify the type of the working state parameter acquired by the wireless communication module; wherein the type of the working state parameter includes: a first state parameter characterizing that the injection molding machine is in a normal state; a second state parameter characterizing that the injection molding machine is in a shutdown state (i.e., an abnormal state);

[0070] A trigger module is used to trigger the timer to start timing when the state recognition module recognizes that the working state parameter of the current injection molding machine is the second state parameter for the first time, and to stop timing when the working state parameter of the current injection molding machine is recognized as the first state parameter again, so as to obtain the timing time T;

[0071] An abnormality identification module is used to compare the above-mentioned timing time with a first preset time threshold, a second preset time threshold and a third preset time threshold. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the robot; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the robot; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the robot.

[0072] In some embodiments, the second control instruction includes a first preset quantity threshold for discarding defective products; and the third control instruction includes a second preset quantity threshold for discarding defective products.

[0073] In some embodiments, the defective product detection device also includes: a defective product count calculation module, which is used to determine when the timing time reaches a second preset time threshold, or reaches a third preset time threshold, to obtain the material consumption of a single injection molded part corresponding to the current injection molding machine (the material consumption of a single injection molded part is one of the working status parameters of the injection molding machine), and to calculate the defective product quantity threshold (i.e., the first preset quantity threshold or the second preset quantity threshold) corresponding to the current injection molding machine based on the material consumption of a single injection molded part and the timing time.

[0074] Example 3: See Figure 2 , is a flow chart of a defective product sorting method according to an exemplary embodiment of the present invention. Specifically, the defective product sorting method comprises the steps of:

[0075] S101, obtaining working status parameters of each injection molding machine in real time.

[0076] In some embodiments, the working state parameter includes: a first state parameter characterizing that the injection molding machine is in a normal state, and a second state parameter characterizing that the injection molding machine is in an abnormal state (for example, a shutdown state caused by a malfunction or the like).

[0077] S103, identifying the type of the working state parameter, if it is the first state parameter, executing step S109a; or, when it is first determined that the type of the working state parameter of the current injection molding machine is the second state parameter, executing step S105.

[0078] S105, triggering the timer to start timing, and when the working state parameter of the current injection molding machine is recognized as the first state parameter again, stopping the timing and obtaining the timing time, and executing step S107.

[0079] S107, compare the above timing time with the first preset time threshold, the second preset time threshold, and the third preset time threshold respectively. If it is less than the first preset time threshold, execute step S109a; if it reaches the second preset time threshold (that is, greater than or equal to the second preset time threshold, and less than the third preset time threshold), execute step S109b; if it reaches the third preset time threshold (that is, greater than or equal to the third preset time threshold), execute step S109c.

[0080] S109a, determining that the current injection molding machine is in a normal state, generating a first control instruction and sending it to the robot, and executing step S111a.

[0081] Usually, when the first status parameter is received continuously, it indicates that the injection molding machine is in a normal state; or, although the second status parameter is received in a short time, it does not last for a long time, which means that the corresponding abnormal situation may have been eliminated and will not affect the injection molding process, or it may be a temporary abnormality caused by equipment aging or other reasons, and this type of abnormality will not affect the injection molding process, and naturally no defective products will be produced.

[0082] S109b, determining that the current injection molding machine is in the first abnormal state, generating a second control instruction and sending it to the robot, and executing step S111b.

[0083] S109c, determining that the current injection molding machine is in the second abnormal state, generating a third control instruction and sending it to the robot, and executing step S1111c.

[0084] In some embodiments, the first control instruction includes a first preset quantity threshold value of the number of defective products expected to be produced by the injection molding machine in the first abnormal state. Specifically, the first preset quantity threshold value is calculated based on the material consumption of the current injection molding machine producing a single injection molded part and the above-mentioned timing time T.

[0085] In some embodiments, the second control instruction includes a second preset number threshold value of the number of defective products expected to be produced by the injection molding machine in the second abnormal state. Specifically, the second preset number threshold value is calculated based on the material consumption of the current injection molding machine in producing a single injection molded part and the above-mentioned timing time T. Generally, for the same injection molding machine, the duration of the second abnormal state is longer than that of the first abnormal state. Therefore, the calculated second preset number is greater than the first preset number threshold value. For example, see Figure 3a and Figure 3b Different injection molding machines have different calculated thresholds for the number of defective products because of different material consumption of a single injection molded part and / or different duration of abnormal status.

[0086] S111a, when the robot receives the first control instruction, it sorts the finished injection molded parts successively output by the current injection molding machine into the defective product area, until the working state parameter of the current injection molding machine is again identified as the second state parameter in step S103, and then executes step S105.

[0087] S111b, when the robot receives the second control instruction, it sorts the finished injection molded parts successively output by the current injection molding machine into the defective product area until the sorting count reaches a first preset quantity threshold.

[0088] S111c, when the robot receives the third control instruction, it sorts the finished injection molded parts output successively by the current injection molding machine into the defective product area until the sorting count reaches the second preset quantity threshold.

[0089] It should be noted that, in this article, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprises a ..." does not exclude the existence of other identical elements in the process, method, article or device including the element.

[0090] Through the description of the above implementation methods, those skilled in the art can clearly understand that the above-mentioned embodiment methods can be implemented by means of software plus a necessary general hardware platform, and of course by hardware, but in many cases the former is a better implementation method. Based on such an understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product, which is stored in a storage medium (such as ROM / RAM, a magnetic disk, or an optical disk), and includes a number of instructions for a computer terminal (which can be a mobile phone, a computer, a server, or a network device, etc.) to execute the methods described in each embodiment of the present invention.

[0091] The embodiments of the present invention are described above in conjunction with the accompanying drawings, but the present invention is not limited to the above-mentioned specific implementation modes, which are merely illustrative rather than restrictive. Under the guidance of the present invention, ordinary technicians in this field can also make many forms without departing from the scope of protection of the present invention and the claims, all of which are within the protection of the present invention.

Claims

1. A method for sorting defective laptop molds, characterized in that: Includes steps: Acquire the working state parameters of each injection molding machine in real time; the working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state, and a second state parameter indicating that the injection molding machine is in an abnormal state; the first state parameter means that the temperature at the nozzle at the front end of the material tube of the injection molding machine is lower than the lowest denaturation temperature; the second state parameter means that the temperature at the nozzle at the front end of the material tube of the injection molding machine is higher than the lowest denaturation temperature; When the second state parameter is identified for the first time, the timer is triggered to start timing, and when the first state parameter is identified again, the timing is stopped to obtain the timing time T; and the timing time T is compared with the first preset time threshold, the second preset time threshold and the third preset time threshold; wherein the first preset time threshold refers to the minimum duration of the injection molding machine shutdown; the second preset time threshold refers to the time when part of the material in the material pipe becomes waste; the third preset time threshold refers to the time when all the material in the material pipe becomes waste; the first preset time threshold is less than the second preset time threshold, and the second preset time threshold is less than the third preset time threshold; If the timing time T is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the robot arm corresponding to the current injection molding machine; If the timing time T reaches the second preset time threshold, it is determined that the current injection molding machine is in the first abnormal state, and the material consumption Q0 of a single injection molding part corresponding to the current injection molding machine and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature in the material pipe of the current injection molding machine are obtained, and the first preset quantity threshold S=Q / Q0 of the number of defective products corresponding to the current injection molding machine is calculated according to the material consumption Q0 of a single injection molding part and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature; and a second control instruction is generated and sent to the manipulator corresponding to the current injection molding machine, so that when the manipulator receives the second control instruction, the finished injection molding parts of the first preset quantity threshold outputted successively by the current injection molding machine are sorted into the defective product area; the second control instruction includes the first preset quantity threshold S=Q / Q0 of defective products to be discarded; If the timing time T reaches the third preset time threshold, it is determined that the current injection molding machine is in the second abnormal state, and the material consumption Q0 of a single injection molding part corresponding to the current injection molding machine and the total amount V of melted raw materials in the material tube are obtained. The second preset quantity threshold S= V / Q0 of the number of defective products corresponding to the current injection molding machine is calculated based on the material consumption Q0 of a single injection molding part and the total amount V of melted raw materials in the material tube, and a third control instruction is generated and sent to the manipulator corresponding to the current injection molding machine, so that when the manipulator receives the third control instruction, the finished injection molding parts of the second preset quantity threshold output by the current injection molding machine are sorted into the defective product area; the third control instruction includes the second preset quantity threshold S= V / Q0 of defective products to be discarded.

2. The defective product sorting method according to claim 1, characterized in that: The first preset quantity threshold is smaller than the second preset quantity threshold.

3. A defective product detection system for laptop molds, characterized in that: include: At least one injection molding machine, used for processing injection-molded parts of the laptop mold and outputting finished injection-molded parts of the laptop mold; A main control device, which communicates data with the at least one injection molding machine, is used to obtain the working state parameters of the injection molding machine in real time and identify the type of the working state parameters. When the working state parameters of the current injection molding machine are identified as the second state parameters for the first time, the timer is triggered to start timing, and when the first state parameters of the current injection molding machine are identified again, the timing is stopped and the timing time is obtained, and then the timing time is compared with the first preset time threshold, the second preset time threshold and the third preset time threshold respectively. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the robot for sorting; If the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in the first abnormal state, the material consumption Q0 of a single injection molding part corresponding to the current injection molding machine and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature in the material tube of the current injection molding machine are obtained, and the first preset quantity threshold S= Q / Q0 of the number of defective products corresponding to the current injection molding machine is calculated based on the material consumption Q0 of a single injection molding part and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature; and a second control instruction is generated and sent to the robot for sorting; the second control instruction includes a first preset quantity threshold for discarding defective products; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in the second abnormal state, the material consumption Q0 of a single injection molding part corresponding to the current injection molding machine and the total amount V of melted raw materials in the material tube are obtained, and the second preset quantity threshold S= V / Q0 of the number of defective products corresponding to the current injection molding machine is calculated based on the material consumption Q0 of a single injection molding part and the total amount V of melted raw materials in the material tube. Q0, and generate a third control instruction and send it to the robot for sorting; the third control instruction includes a second preset quantity threshold for discarding defective products; wherein, the first state parameter refers to the temperature at the front end nozzle of the injection molding machine's material tube being lower than the lowest denaturation temperature; the second state parameter refers to the temperature at the front end nozzle of the injection molding machine's material tube being higher than the lowest denaturation temperature; the first preset time threshold refers to the minimum duration of the injection molding machine's shutdown; the second preset time threshold refers to the time when part of the material in the material tube becomes waste; the third preset time threshold refers to the time when all the material in the material tube becomes waste; the first preset time threshold is less than the second preset time threshold, and the second preset time threshold is less than the third preset time threshold; At least one robot, each of which is installed at a sorting station at the output position of each injection molding machine and communicates data with the main control device, and the robot is used to sort the finished injection molded parts output by the corresponding injection molding machine to the good product area when receiving the first control instruction; or, when receiving the second control instruction, sort the finished injection molded parts output by the corresponding injection molding machine with a first preset quantity threshold to the defective product area; or, when receiving the third control instruction, sort the finished injection molded parts output by the corresponding injection molding machine with a second preset quantity threshold to the defective product area.

4. The defective product detection system according to claim 3, characterized in that: The type of the working state parameter includes the first state parameter and the second state parameter, wherein the first state parameter indicates that the injection molding machine is in a normal state; the second state parameter indicates that the injection molding machine is in an abnormal state; and / or, The first preset quantity threshold is smaller than the second preset quantity threshold.

5. The defective product detection system according to claim 4, characterized in that: The main control device comprises: A data acquisition module, used for acquiring the working status parameters of each injection molding machine in real time; A state identification module, used to identify the type of working state parameters of each injection molding machine; A trigger module, configured to trigger a timer to start timing when the state recognition module recognizes for the first time that the working state parameter of the current injection molding machine is the second state parameter, and to stop timing and obtain the timing time when the working state parameter of the current injection molding machine is recognized for the second time as the first state parameter; An abnormality identification module is used to compare the timing time with a first preset time threshold, a second preset time threshold and a third preset time threshold, and when it is judged that the timing time is less than the first preset time threshold, it is judged that the current injection molding machine is in a normal state, and the first control instruction is generated and sent to the manipulator; or when it is judged that the timing time reaches the second preset time threshold, it is judged that the current injection molding machine is in a first abnormal state, and the second control instruction is generated and sent to the manipulator; or when it is judged that the timing time reaches the third preset time threshold, it is judged that the current injection molding machine is in a second abnormal state, and the third control instruction is generated and sent to the manipulator; The defective product number calculation module is used to determine that when the timing time reaches the second preset time threshold, or reaches the third preset time threshold, obtain the material consumption of a single injection molded part corresponding to the current injection molding machine, and calculate the defective product number threshold corresponding to the current injection molding machine based on the material consumption of the single injection molded part; specifically, if the timing time reaches the second preset time threshold, obtain the material consumption Q0 of a single injection molded part corresponding to the current injection molding machine, and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature in the material pipe of the current injection molding machine, and calculate the first preset number threshold S of the number of defective products corresponding to the current injection molding machine based on the material consumption Q0 of the single injection molded part and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature. Q0; if the timing time reaches the third preset time threshold, obtain the single injection molded part material consumption Q0 corresponding to the current injection molding machine and the total amount V of melted raw material in the material tube, and calculate the second preset quantity threshold S= V / Q0 of the number of defective products corresponding to the current injection molding machine based on the single injection molded part material consumption Q0 and the total amount V of melted raw material in the material tube.

6. The defective product detection system according to claim 5, characterized in that: The main control device adopts a single chip microcomputer integrated on the robot, and the main control device performs data communication with the injection molding machine through an integrated wireless communication module.

7. A defective product detection device, characterized in that: include: Timer, used for timing; A wireless communication module, used for performing data communication with a plurality of injection molding machines to obtain working state parameters of each of the injection molding machines; A state identification module, used to identify the type of the working state parameter acquired by the wireless communication module; The types of working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state; a second state parameter indicating that the injection molding machine is in an abnormal state; the first state parameter means that the temperature at the nozzle at the front end of the material tube of the injection molding machine is lower than the minimum denaturation temperature; the second state parameter means that the temperature at the nozzle at the front end of the material tube of the injection molding machine is higher than the minimum denaturation temperature; A trigger module, configured to trigger a timer to start timing when the state recognition module recognizes for the first time that the working state parameter of the current injection molding machine is the second state parameter, and to stop timing when the state recognition module recognizes for the second time that the working state parameter of the current injection molding machine is the first state parameter, thereby obtaining a timing time; An abnormality identification module is used to compare the timing time with a first preset time threshold, a second preset time threshold and a third preset time threshold. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the manipulator; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the manipulator; wherein, the second control instruction includes a first preset quantity threshold for discarding defective products; the third control instruction includes a second preset quantity threshold for discarding defective products; the first preset time threshold refers to the minimum duration of the injection molding machine shutdown; the second preset time threshold refers to the time when part of the material in the material pipe becomes waste; the third preset time threshold refers to the time when all the material in the material pipe becomes waste; the first preset time threshold is less than the second preset time threshold, and the second preset time threshold is less than the third preset time threshold; The defective product number calculation module is used to determine that when the timing time reaches the second preset time threshold, or reaches the third preset time threshold, obtain the material consumption of a single injection molded part corresponding to the current injection molding machine, and calculate the defective product number threshold corresponding to the current injection molding machine based on the material consumption of the single injection molded part; specifically, if the timing time reaches the second preset time threshold, obtain the material consumption Q0 of a single injection molded part corresponding to the current injection molding machine, and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature in the material pipe of the current injection molding machine, and calculate the first preset number threshold S of the number of defective products corresponding to the current injection molding machine based on the material consumption Q0 of the single injection molded part and the total amount Q of melted raw materials with a temperature exceeding the minimum denaturation temperature. Q0; if the timing time reaches the third preset time threshold, obtain the single injection molded part material consumption Q0 corresponding to the current injection molding machine and the total amount V of melted raw material in the material tube, and calculate the second preset quantity threshold S= V / Q0 of the number of defective products corresponding to the current injection molding machine based on the single injection molded part material consumption Q0 and the total amount V of melted raw material in the material tube.

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