Injection molding machine quality monitoring system and method

Abstract

The invention relates to an injection molding machine quality monitoring system and method, and is applied to the field of industrial automation. The image acquisition unit is connected to the injection molding unit and is used for acquiring a product internal image and a product external image of the injection molding product; the image processing unit is connected to the image acquisition unit, and is used for receiving the product internal image and the product external image, processing the product internal image and the product external image by adopting a preset image processing algorithm, and generating a detection result; the shunting unit is connected to the image processing unit and is used for distinguishing product categories according to detection results; and the control unit is connected to the injection molding unit, the image acquisition unit, the image processing unit and the shunting unit and used for controlling the injection molding unit to normally operate and stop operating. The X-ray detection device has the technical effects that the X-ray detection is integrated, internal defects of products can be scanned and detected, and the qualified rate of the products is improved.

Description

Technical Field

[0001] The present application relates to the field of industrial automation technology, and in particular to a quality monitoring system and method for an injection molding machine. Background Art

[0002] Injection molding is one of the important processes for producing plastic products and is widely used in various industries. The traditional injection molding production process usually uses manual sampling to detect product quality. However, the manual sampling method has low detection efficiency and is easily affected by human factors, resulting in inaccurate detection results. Currently, visual inspection methods are used for quality inspection.

[0003] However, the visual inspection methods currently used are relatively simple and difficult to detect internal defects of products, resulting in unstable product quality and low production efficiency. Summary of the invention

[0004] In order to help solve the problem that the currently used visual inspection method is relatively simple and difficult to detect internal defects of products, thus leading to unstable product quality and low production efficiency, the present application provides an injection molding machine quality monitoring system and method.

[0005] In a first aspect, the present application provides an injection molding machine quality monitoring system, which adopts the following technical solution: the system comprises: an injection molding unit, an image acquisition unit, an image processing unit, a diversion unit and a control unit;

[0006] The injection molding unit is used to perform injection molding on the material;

[0007] The image acquisition unit is connected to the injection unit and is used to acquire an internal image and an external image of the injection-molded product;

[0008] The image processing unit is connected to the image acquisition unit, and is used to receive the internal image of the product and the external image of the product, process the internal image of the product and the external image of the product using a preset image processing algorithm, and generate a detection result;

[0009] The diversion unit is connected to the image processing unit and is used to distinguish product categories according to the detection results, and the product categories include qualified products and unqualified products;

[0010] The control unit is connected to the injection unit, the image acquisition unit, the image processing unit and the diversion unit, and is used to control the injection unit to run normally and stop running.

[0011] In a specific possible implementation scheme, the image acquisition unit includes an X-ray detection module and a camera module;

[0012] The X-ray detection module is connected to the injection molding unit and is used to obtain an internal image of the product;

[0013] The camera module is connected to the injection molding unit and is used to obtain an external image of the product.

[0014] In a specific possible implementation scheme, the X-ray detection module includes an X-ray transmitter and a receiver;

[0015] The X-ray emitter is used to emit X-rays;

[0016] The receiver is used to receive the X-ray and generate an internal image of the product.

[0017] In a specific implementation scheme, the diversion unit includes a diversion device, a qualified product receiving trough and a failed product receiving trough;

[0018] The diversion device is used to receive the test results and divide the products into qualified products and unqualified products according to the test results;

[0019] The qualified product receiving trough is used to receive the qualified products;

[0020] The unqualified product receiving trough is used to receive the unqualified products.

[0021] In a specific implementation scheme, the detection results generated by the image processing unit include qualified and unqualified, and the system further includes an alarm unit;

[0022] The alarm unit is connected to the control unit and the image processing unit, and is used to give an alarm when continuous unqualified products are detected.

[0023] In a specific implementation scheme, the alarm is in the form of sound and light alarm.

[0024] In a specific possible implementation manner, the alarm unit generates an alarm when two unqualified products are detected consecutively.

[0025] In a second aspect, the present application provides a method for monitoring the quality of an injection molding machine, which adopts the following technical solution: the method is applied to a quality monitoring system for an injection molding machine, the quality monitoring system for an injection molding machine comprising an injection molding unit, an image acquisition unit, an image processing unit, a shunt unit and a control unit;

[0026] The injection molding unit receives the material and performs injection molding on the material;

[0027] The image acquisition unit receives the injection molded product and acquires an internal image and an external image of the injection molded product;

[0028] The image processing unit receives the internal image of the product and the external image of the product, processes the internal image of the product and the external image of the product using a preset image processing algorithm, and generates a detection result, wherein the detection result includes a qualified result and a unqualified result;

[0029] The diversion unit receives the detection result and classifies the injection molded products into qualified products and unqualified products according to the detection result;

[0030] The control unit controls the injection unit to run normally or stop running according to the detection result.

[0031] In a specific implementation scheme, the injection molding machine quality monitoring system further includes an alarm unit, and after the image processing unit receives the internal image of the product and the external image of the product, processes the internal image of the product and the external image of the product using a preset image processing algorithm, and generates a detection result, it further includes:

[0032] The alarm unit determines whether the number of consecutive unqualified injection molded products is greater than 1;

[0033] If the number of consecutive unqualified injection molded products is greater than 1, the alarm unit emits an audible and visual alarm;

[0034] If the number of consecutive unqualified injection molded products is not greater than 1, the alarm unit will not sound an alarm.

[0035] In a specific implementation manner, the control unit controls the injection molding unit to operate normally or stop operating according to the detection result, including:

[0036] The control unit determines whether the number of consecutive alarms of the alarm unit is greater than 1;

[0037] If the alarm unit continuously generates an alarm for more than 1 times, the control unit controls the injection molding unit to stop running;

[0038] If the number of consecutive alarms issued by the alarm unit is not greater than 1, the control unit controls the injection molding unit to operate normally.

[0039] In summary, this application has the following beneficial technical effects:

[0040] 1. Real-time quality inspection: By integrating X-ray inspection technology, the internal quality of injection molded products can be monitored online in real time. By using high-definition cameras, the external quality of injection molded products can be monitored online in real time, defects can be identified quickly, and the qualification rate and consistency of products can be improved.

[0041] 2. Automatic separation of defective products: The system automatically detects and separates defective products, reducing the workload and errors of manual inspection and improving the automation level of the production line;

[0042] 3. Intelligent control: With continuous alarm and automatic shutdown functions, it can respond to quality problems in the production process in a timely manner, reduce the production of defective products, and reduce production costs;

[0043] 4. Improve production efficiency: Reduce manual intervention, improve the stability and efficiency of the production process, and be suitable for large-scale industrial production applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a structural schematic diagram of the injection molding machine quality monitoring system in an embodiment of the present application;

[0045] Figure 2 is a schematic diagram of an X-ray detection module in an embodiment of the present application;

[0046] Figure 3 It is a flow chart of the injection molding machine quality monitoring method in an embodiment of the present application.

[0047] Figure numerals: 1. Injection molding machine; 2. Image acquisition unit; 3. Image processing unit; 4. Diversion unit; 5. Qualified product receiving trough; 6. Unqualified product receiving trough; 7. Alarm unit. DETAILED DESCRIPTION

[0048] The following is combined with Figure 1-3 This application is described in further detail.

[0049] An embodiment of the present application discloses an injection molding machine quality monitoring system, which integrates X-ray and camera detection functions. The system automatically separates defective products by real-time monitoring of the internal and external structure and quality of injection molded products, and automatically suspends production and alarms when continuous quality problems occur, thereby improving the degree of automation of the production process and the stability of product quality.

[0050] Considering that the visual inspection method used in the current quality monitoring system is relatively simple and difficult to detect defects inside the product, in order to help improve the qualification rate and stability of the product, the present application provides an injection molding machine quality monitoring system.

[0051] Reference Figure 1 ,The quality monitoring system of the injection molding machine includes an injection unit, an image acquisition unit, an image processing unit, a diversion unit and a control unit.

[0052] Injection unit, also referred to Figure 1The injection molding machine is used to perform injection molding on the material. The image acquisition unit is connected to the injection molding unit and is located on the transmission path after the product is molded. It is used to acquire the internal image and external image of the injection molded product, and to perform real-time scanning of the inside and outside of the product to generate an image; wherein the image acquisition unit includes an X-ray detection module and a camera module; the X-ray detection module is connected to the injection molding unit and is used to acquire the internal image of the product; the camera module is connected to the injection molding unit and is used to acquire the external image of the product. Figure 2 The X-ray detection module includes an X-ray transmitter and a receiver; the X-ray transmitter is used to transmit X-rays; the receiver is used to receive X-rays and generate an image of the inside of the product. In the embodiment of the present application, the X-ray receiver is implemented by an X-ray film. The camera is used to collect the external image of the product. It can be set separately from the X-ray detection module, or the X-ray detection module and the camera module can be integrated. In the embodiment of the present application, the two modules are integrated, and the integrated design helps to improve the detection efficiency.

[0053] Integrating X-ray and real-time camera detection systems into the injection molding system enables the function of immediate quality inspection of injection molded products after molding. Through X-ray perspective technology, internal defects of injection molded products (such as bubbles, cracks, foreign matter, etc.) can be scanned and detected in real time. The real-time camera forms a real-time image of the external surface of the product through the camera and the receiver, which can detect abnormal defects (such as cracks, collapse, etc.) on the outside of the injection molded product, greatly improving the quality control capabilities in the production process.

[0054] The image processing unit is connected to the image acquisition unit, and is used to receive the internal image and the external image of the product, and use a preset image processing algorithm to process the internal image and the external image of the product, analyze the image and detect whether the generated product has internal defects, such as bubbles, cracks, foreign matter, etc., or external defects, such as cracks, collapse, etc., detect the quality status of the product and generate corresponding test results. The image processing unit is integrated, and it can acquire and analyze X-ray image data in real time, and quickly and accurately identify defects in injection molded products through a preset algorithm. This invention ensures the automation and efficiency of the detection process and reduces the reliance on manual detection.

[0055] The diversion unit is connected to the image processing unit and is used to distinguish product categories according to the test results, and the product categories include qualified products and unqualified products; the diversion unit includes a diversion device, a qualified product receiving trough and an unqualified product receiving trough; the diversion device is used to receive the test results and classify the products into qualified products and unqualified products according to the test results; the qualified product receiving trough is used to receive qualified products; the unqualified product receiving trough is used to receive unqualified products. The automatic diversion device can automatically separate the defective products from the qualified products according to the analysis results of the image processing unit, and guide the defective products into the receiving trough separately, thereby improving the automation level of the production line and reducing human intervention and errors.

[0056] The alarm unit is connected to the control unit and the image processing unit, and is used to sound and light alarm when two consecutive unqualified products are detected; in addition, when the equipment itself is abnormal, an alarm is issued to remind the user that the problem needs to be investigated. The control unit is connected to the injection molding unit, the image acquisition unit, the image processing unit and the diversion unit, and is used to control the normal operation and stop operation of the injection molding unit. Specifically, when defective products are detected twice in a row and an alarm is issued, the control unit automatically controls the injection molding machine to suspend production and prompts the operator to check the equipment and production process. The continuous alarm and automatic shutdown function are set in the system. When defective products are detected continuously and the alarm is issued more than twice, the control unit will automatically suspend the operation of the injection molding machine and issue an alarm signal, thereby preventing the production of large quantities of defective products as much as possible, protecting production equipment and reducing production costs.

[0057] Based on the above system, an embodiment of the present application also discloses a method for monitoring the quality of an injection molding machine.

[0058] Reference Figure 3 , the method comprises the following steps:

[0059] S10, the injection molding unit receives the material and performs injection molding on the material.

[0060] Specifically, after the injection molding unit, that is, the injection molding machine, performs injection molding on the material, the product enters the image acquisition unit through a transmission path for detection.

[0061] S20, the image acquisition unit receives the injection molded product, and acquires an internal image and an external image of the injection molded product.

[0062] Specifically, the image acquisition unit includes product internal image acquisition and product external image acquisition. The product internal image acquisition adopts the X-ray detection method. The X-ray transmitter emits X-rays, which pass through the injection molded product and are received by the receiver to form a perspective image of the inside of the product; the product external image acquisition adopts a camera to form a real-time image of the product's external surface through the camera.

[0063] S30, the image processing unit receives the internal image of the product and the external image of the product, processes the internal image of the product and the external image of the product using a preset image processing algorithm, and generates a detection result, which includes a qualified and unqualified result.

[0064] Specifically, the image processing unit receives and analyzes the internal and external images of the product, and uses algorithms to detect whether the product has internal defects, such as bubbles, cracks, foreign matter, etc., and external defects, such as cracks, collapse, etc. If the product has defects, it is judged as an unqualified product, and if the product does not have defects, it is judged as a qualified product.

[0065] S40, the diversion unit receives the test result and classifies the injection molded products into qualified products and unqualified products according to the test result.

[0066] Specifically, the diversion device in the diversion unit guides defective products into the defective product receiving slot and the qualified products into the qualified product receiving slot according to the detection result of the image processing unit.

[0067] S50, the control unit controls the injection molding unit to run normally or stop running according to the detection result.

[0068] Specifically, when continuous defective products are detected, the control unit controls the injection molding unit, that is, the injection molding machine to stop running to avoid further production of unqualified products; if no continuous defective products are detected, the injection molding machine is controlled to operate normally.

[0069] In the present application, by integrating X-ray detection technology, the internal quality of injection molded products can be monitored online in real time, and the external quality of injection molded products can be monitored online in real time through high-definition video cameras, defects can be quickly identified, and the product qualification rate and consistency can be improved; secondly, the system automatically detects and separates defective products, reducing the workload and errors of manual inspection and improving the automation level of the production line; in addition, it reduces manual intervention, improves the stability and efficiency of the production process, and is suitable for large-scale industrial production applications.

[0070] In one embodiment, considering that an alarm is required only when continuous defects occur, the injection molding machine quality monitoring system further includes an alarm unit. After the image processing unit receives the internal image and the external image of the product, processes the internal image and the external image of the product using a preset image processing algorithm, and generates a detection result, the following steps may be performed:

[0071] The alarm unit determines whether the number of consecutive unqualified injection molded products is greater than 1; if the number of consecutive unqualified injection molded products is greater than 1, the alarm unit sends out an audible and visual alarm; if the number of consecutive unqualified injection molded products is not greater than 1, the alarm unit does not send out an alarm.

[0072] In one embodiment, the control unit controls the injection molding unit to operate normally and stop operating according to the detection result, and the steps can be specifically performed as follows:

[0073] The control unit determines whether the number of consecutive alarms from the alarm unit is greater than 1; if the number of consecutive alarms from the alarm unit is greater than 1, the control unit controls the injection molding unit to stop running; if the number of consecutive alarms from the alarm unit is not greater than 1, the control unit controls the injection molding unit to run normally.

[0074] In the present application, the continuous alarm and automatic shutdown functions can promptly respond to quality problems that occur during the production process, reduce the production of defective products, and reduce production costs.

[0075] Figure 3 FIG. 1 is a flow chart of a method for monitoring the quality of an injection molding machine in one embodiment. Figure 3 The steps in the flowchart are shown in sequence as indicated by the arrows, but the steps are not necessarily executed in the order indicated by the arrows; unless otherwise specified in this document, there is no strict order restriction for the execution of the steps, and the steps may be executed in other orders; and Figure 3 At least part of the steps may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily executed at the same time, but can be executed at different times. The execution order of these sub-steps or stages is not necessarily sequential, but can be executed in turn or alternately with other steps or at least part of the sub-steps or stages of other steps.

[0076] This specific embodiment is merely an explanation of the present invention and is not a limitation of the present invention. After reading this specification, those skilled in the art may make non-creative modifications to the present embodiment as needed. However, as long as they are within the scope of the claims of the present invention, they are protected by the patent law.

Claims

1. An injection molding machine quality monitoring system, characterized in that: The system comprises: an injection unit, an image acquisition unit, an image processing unit, a flow diversion unit and a control unit; The injection molding unit is used to perform injection molding on the material; The image acquisition unit is connected to the injection unit and is used to acquire an internal image and an external image of the injection molded product; The image processing unit is connected to the image acquisition unit, and is used to receive the internal image of the product and the external image of the product, process the internal image of the product and the external image of the product using a preset image processing algorithm, and generate a detection result; The diversion unit is connected to the image processing unit and is used to distinguish product categories according to the detection results, and the product categories include qualified products and unqualified products; The control unit is connected to the injection unit, the image acquisition unit, the image processing unit and the diversion unit, and is used to control the injection unit to run normally and stop running.

2. The injection molding machine quality monitoring system according to claim 1, characterized in that: The image acquisition unit includes an X-ray detection module and a camera module; The X-ray detection module is connected to the injection molding unit and is used to obtain an internal image of the product; The camera module is connected to the injection molding unit and is used to obtain an external image of the product.

3. The injection molding machine quality monitoring system according to claim 1, characterized in that: The X-ray detection module includes an X-ray transmitter and a receiver; The X-ray emitter is used to emit X-rays; The receiver is used to receive the X-ray and generate an internal image of the product.

4. The injection molding machine quality monitoring system according to claim 1, characterized in that: The diversion unit includes a diversion device, a qualified product receiving trough and a unqualified product receiving trough; The diversion device is used to receive the test results and divide the products into qualified products and unqualified products according to the test results; The qualified product receiving trough is used to receive the qualified products; The unqualified product receiving trough is used to receive the unqualified products.

5. The injection molding machine quality monitoring system according to claim 1, characterized in that: The detection results generated by the image processing unit include qualified and unqualified, and the system also includes an alarm unit; The alarm unit is connected to the control unit and the image processing unit, and is used to give an alarm when continuous unqualified products are detected.

6. The injection molding machine quality monitoring system according to claim 5, characterized in that: The alarm mode is sound and light alarm.

7. The injection molding machine quality monitoring system according to claim 5, characterized in that: The alarm unit generates an alarm when two unqualified products are detected consecutively.

8. A method for monitoring the quality of an injection molding machine, characterized in that: The method is applied to an injection molding machine quality monitoring system, which includes an injection molding unit, an image acquisition unit, an image processing unit, a shunt unit and a control unit; The injection molding unit receives the material and performs injection molding on the material; The image acquisition unit receives the injection molded product and acquires an internal image and an external image of the injection molded product; The image processing unit receives the internal image of the product and the external image of the product, processes the internal image of the product and the external image of the product using a preset image processing algorithm, and generates a detection result, wherein the detection result includes a qualified result and a unqualified result; The diversion unit receives the detection result and classifies the injection molded products into qualified products and unqualified products according to the detection result; The control unit controls the injection unit to run normally or stop running according to the detection result.

9. The method for monitoring the quality of an injection molding machine according to claim 8, characterized in that: The injection molding machine quality monitoring system further includes an alarm unit, and after the image processing unit receives the internal image of the product and the external image of the product, processes the internal image of the product and the external image of the product using a preset image processing algorithm, and generates a detection result, it further includes: The alarm unit determines whether the number of consecutive unqualified injection molded products is greater than 1; If the number of consecutive unqualified injection molded products is greater than 1, the alarm unit emits an audible and visual alarm; If the number of consecutive unqualified injection molded products is not greater than 1, the alarm unit will not sound an alarm.

10. The method for monitoring the quality of an injection molding machine according to claim 9, characterized in that: The control unit controls the injection unit to operate normally and stop operating according to the detection result, including: The control unit determines whether the number of consecutive alarms of the alarm unit is greater than 1; If the alarm unit continuously generates an alarm for more than 1 times, the control unit controls the injection molding unit to stop running; If the number of consecutive alarms issued by the alarm unit is not greater than 1, the control unit controls the injection molding unit to operate normally.

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