A precision injection molding CCD mold intelligent monitoring and control system based on machine vision

Abstract

The present invention belongs to the field of precision injection molding production monitoring technology, and discloses a precision injection molding CCD mold intelligent monitoring and control system based on machine vision, including a mold clamping system test module, a mold clamping system analysis module, an injection molding process status monitoring module, an injection molding process status analysis module, a product quality status monitoring module, and a product quality status analysis module. The present invention analyzes the mold clamping system test results and the injection molding process status, and reflects the quality of the precision injection mold from different aspects. This analysis method reduces the blindness of quality problem investigation, increases the possibility of quickly resolving mold quality hazards, and comprehensively reflects and guarantees the quality of precision injection molds. The present invention increases the accuracy and timeliness of mold maintenance, reduces the instability of product quality, and improves the continuity of the overall production process by conducting feedback analysis on mold quality based on the quality of the injection molded product.

Description

Technical Field

[0001] The invention belongs to the technical field of precision injection molding production monitoring, and relates to a precision injection molding CCD mold intelligent monitoring and control system based on machine vision. Background Art

[0002] Precision injection molding is an injection molding technology designed to produce plastic products with high dimensional accuracy, excellent surface quality, and stable physical properties. It places stringent demands on molds, molding equipment, raw materials, and process control, enabling the precise shaping of plastic raw materials into complex and precise product shapes. Monitoring precision injection molding processes enables real-time control of product dimensional accuracy, surface quality, and internal structure, ensuring stable product quality, optimizing the injection molding process, reducing defective and scrapped products, improving production efficiency, protecting and extending mold life, and ensuring production safety. Therefore, intelligent monitoring and control of precision injection molding CCD molds based on machine vision is of great significance.

[0003] In the prior art, there are also related solutions for precision injection molding production monitoring technology. For example, the Chinese invention patent application with publication number CN117635595A is a method for visual inspection of the surface quality of a precision injection mold base, which includes: obtaining a grayscale image, analyzing the grayscale value, gradient value and area of ​​the connected domain of the pixels in the connected domain according to the visual inspection method to obtain the characteristic factor. Then, the position change, gradient value and gradient value of the closed edge line of the boundary of the connected domain are analyzed to obtain the glossiness value. Finally, the grayscale value of the edge pixel points in the sub-region, the boundary edge line and area of ​​the sub-region are analyzed to obtain the degree of change value. Through the characteristic factor, glossiness value and degree of change value, the overall characteristic value is obtained, the defective area is determined, and the quality of the surface of the precision injection mold base is judged.

[0004] In addition, a Chinese invention patent application with publication number CN118071753A is for a method for visually detecting surface defects of an injection mold, which comprises: obtaining a grayscale image of the injection mold. Obtaining a second edge image. Obtaining an edge feature index of the edge based on the fluctuation of each edge in the second edge image. Obtaining the grayscale change consistency of the edge based on the grayscale change direction of the pixel points in the edge. Obtaining the possibility that the edge is a texture edge based on the difference in edge feature index and grayscale change consistency of different edges in the neighborhood area. Obtaining several defective edges in the second edge image. Obtaining several defective areas in the grayscale image of the injection mold based on the distance between different defective edges and the difference in edge feature index.

[0005] While the two aforementioned approaches offer some solutions for precision injection molding production monitoring, they still have certain limitations: On the one hand, existing technical solutions only judge abnormalities based on the surface features of precision injection molds, lacking real-time analysis and control of the actual production process. This analysis method reduces the accuracy of abnormality judgments, as factors such as temperature, pressure, and material flow within the mold production process have a significant impact on product quality. By simply observing surface features, problems such as internal stress concentration in the product caused by uneven cooling are difficult to detect, increasing the risk of problematic products flowing into the next process. At the same time, it also reduces the preventative nature of the production process. Since dynamic parameters such as plastic injection speed and temperature changes cannot be analyzed in real time, it is difficult to issue early warnings for possible abnormalities, increasing the probability of adverse situations such as production interruptions and resource waste, which is not conducive to ensuring efficient and stable production.

[0006] On the other hand, existing technical solutions lack feedback analysis of mold quality based on the quality of the injection molded product. This analysis method reduces the timeliness of quality improvement. When quality issues such as flash and sink marks appear in the product, it is difficult to feedback the problems to the mold quality level. Hidden dangers such as poor mold clamping accuracy and abnormal cavity surface roughness are difficult to detect in time, increasing the risk of continued fluctuations in product quality. At the same time, this lack also reduces the efficiency of production operations. It is impossible to accurately optimize the mold based on the product status, resulting in an increase in repeated mold debugging and frequent rework, increasing the consumption of manpower, material resources and time costs, and hindering the company's timely delivery of qualified products. Summary of the Invention

[0007] In view of this, in order to solve the problems raised in the above background technology, a precision injection molding CCD mold intelligent monitoring and control system based on machine vision is proposed.

[0008] The purpose of the present invention can be achieved through the following technical solutions: a precision injection molding CCD mold intelligent monitoring and control system based on machine vision, including: a mold clamping system test module, which is used to test the clamping system before the injection molding operation, obtain the mold clamping data, including monitoring the gap width and monitoring the position offset distance, and analyze the tightness evaluation and positioning accuracy of the clamping system.

[0009] The mold clamping system analysis module is used to determine whether injection molding operations are allowed based on the tightness evaluation and positioning accuracy of the clamping system.

[0010] The injection molding process status monitoring module is used to monitor the injection molding process of precision injection molding, arrange temperature monitoring points on the mold to obtain several temperature monitoring points, obtain the temperature of each temperature monitoring point in real time, analyze the injection molding temperature control evaluation, and at the same time obtain the movement speed of each ejector corresponding to the ejection operation, and analyze the ejection speed control evaluation.

[0011] The injection molding process status analysis module is used to determine whether there is an abnormality in the injection molding process based on the injection molding temperature control evaluation status and the top mold speed control evaluation status corresponding to the injection molding process. If so, it further identifies the specific abnormality direction, which includes injection molding temperature control abnormality and top mold speed control abnormality.

[0012] The product quality status monitoring module is used to monitor the quality of precision injection molded products, obtain three-dimensional data of each injection molded product, analyze the dimensional accuracy evaluation of the injection molded products, and use CCD equipment to collect surface images of each injection molded product to analyze the surface quality evaluation of the injection molded products.

[0013] The product quality status analysis module is used to determine whether the injection molding product production process meets the process requirements based on the dimensional accuracy evaluation and surface quality evaluation of the injection molding product.

[0014] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention analyzes the test results of the mold clamping system and the injection process status, reflecting the quality of the precision injection mold from different aspects. This analysis method reduces the blindness of quality problem investigation and increases the possibility of quickly resolving mold quality risks. At the same time, it reduces the uncertainty of the production process. Based on real-time data, the process parameters can be reasonably set to avoid product defects and mold losses caused by improper parameters, thereby increasing the stability and efficiency of production. It also reduces the long-term operating costs of the enterprise and comprehensively reflects and guarantees the quality of the precision injection mold.

[0015] (2) The present invention conducts feedback analysis of mold quality based on the quality of the injection molded product. This analysis method increases the accuracy and timeliness of mold maintenance. This reduces the instability of product quality. Continuous feedback promotes continuous optimization of mold quality, reduces quality fluctuations between batches of products, increases the output ratio of high-quality products, improves the consistency of the overall production process, avoids frequent production interruptions due to quality issues, and ensures the production efficiency of the enterprise. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0017] Figure 1 This is a schematic diagram of the connection of various modules of the system of the present invention.

[0018] Figure 2 A flowchart for determining whether an injection molding operation is allowed corresponding to an embodiment provided by the present invention.

[0019] Figure 3 A flowchart for determining whether an abnormality exists in the injection molding process corresponding to an embodiment provided by the present invention.

[0020] Figure 4 A flowchart for determining whether the injection molding product production process corresponding to an embodiment provided by the present invention meets the process requirements. DETAILED DESCRIPTION

[0021] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only 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 efforts are within the scope of protection of the present invention.

[0022] See also Figure 1 As shown, the present invention provides a precision injection molding CCD mold intelligent monitoring and control system based on machine vision, including a mold clamping system testing module, a mold clamping system analysis module, an injection molding process status monitoring module, an injection molding process status analysis module, a product quality status monitoring module and a product quality status analysis module, wherein the mold clamping system testing module is connected to the mold clamping system analysis module, the mold clamping system analysis module is connected to the injection molding process status monitoring module, the injection molding process status monitoring module is connected to the injection molding process status analysis module, the injection molding process status analysis module is connected to the product quality status monitoring module, and the product quality status monitoring module is connected to the product quality status analysis module.

[0023] The mold clamping system test module is used to test the clamping system before the injection molding operation, obtain the mold clamping data, including monitoring the gap width and monitoring the position offset distance, and analyze the tightness evaluation and positioning accuracy of the clamping system.

[0024] It should be noted that the reason for testing the clamping system before the injection molding operation is: on the one hand, it effectively guarantees product quality. If the clamping system has problems such as uneven clamping force, the mold cavity cannot be closed tightly during injection molding, and the plastic melt seeps out, causing flash and burrs on the product, affecting dimensional accuracy and surface finish. Testing in advance can discover and resolve hidden dangers to ensure the production of qualified products. On the other hand, this is an effective protection for the mold. Given that the mold is subjected to high force during injection molding, if there is a problem with the template parallelism or guide components of the clamping system, forced injection will cause excessive force on the local part of the mold, accelerated wear or even damage. Testing can eliminate risks and extend the life of the mold. Furthermore, it can greatly improve production efficiency. If a clamping system failure is discovered in the middle of injection molding, downtime for maintenance and scrapping of semi-finished products will cost a lot of money. Testing and troubleshooting in advance can ensure smooth injection molding and reduce interruptions.

[0025] In a preferred embodiment of the present invention, the tightness evaluation situation requires constructing a tightness evaluation index of the mold clamping system, and the specific method is as follows: extract the monitoring gap width of the mold, and then calculate the difference with the preset reference gap width to obtain the absolute value to obtain the monitoring gap width deviation of the mold clamping system, calculate the ratio of the monitoring gap width deviation of the mold clamping system to the preset reference gap width, and then take the inverse to obtain the tightness evaluation index of the mold clamping system.

[0026] It should be noted that the reasons for choosing to monitor the gap width as an influencing factor in evaluating the tightness of the mold clamping system are: First, it can intuitively display the mold clamping effect. The gap width directly quantifies the mold closing state. Excessive width will cause melt leakage, causing product flash and overflow, affecting the appearance and precision. Accurate monitoring can determine the tightness of the mold clamping. Second, it is related to product quality. Uneven gaps will cause uneven melt filling, causing product deformation and warping. Monitoring it can eliminate quality risks in advance. Third, it can provide early warning of mold wear. Long-term wear and tear of the mold will change the gap width. Monitoring can detect it in time and facilitate preventive maintenance. Fourth, it helps to optimize the process. According to the actual gap width, the mold clamping parameters can be adjusted in a targeted manner to improve production efficiency and competitiveness.

[0027] In a preferred embodiment of the present invention, the positioning accuracy situation requires constructing a positioning accuracy index of the mold clamping system, and the specific method is as follows: extracting the monitoring position offset distance of the mold, and then performing a difference calculation with a preset position offset distance threshold to obtain the monitoring position offset distance anomaly of the mold clamping system, performing a ratio calculation between the monitoring position offset distance anomaly of the mold clamping system and the preset position offset distance threshold, and then taking the inverse to obtain the positioning accuracy index of the mold clamping system.

[0028] It should be explained that the reason for choosing the monitoring position offset distance as an influencing factor of the positioning accuracy of the mold clamping system is: on the one hand, it can ensure product quality. The mold clamping position offset will cause inaccurate docking between the cavity and the core, uneven product wall thickness, and easy breakage. Monitoring can correct errors in advance to ensure reliability. On the other hand, it is beneficial to protect the mold. Inaccurate positioning causes uneven force on the parts, accelerating wear and deformation. Real-time monitoring can adjust the mold clamping status and reduce maintenance costs. Furthermore, it stabilizes the production process. Offset will cause problems such as poor melt flow and incomplete filling, interfering with production continuity. Monitoring helps maintain efficient production. In addition, it can also optimize process parameters. According to the monitoring results, the mold clamping parameters can be accurately adjusted to meet different needs and improve the process level.

[0029] The mold clamping system analysis module is used to determine whether the injection molding operation is allowed based on the tightness evaluation and positioning accuracy of the clamping system.

[0030] In a preferred embodiment of the present invention, please refer to Figure 2 As shown, the specific analysis method for determining whether the injection molding operation is allowed is as follows: extract the tightness evaluation index and positioning accuracy index of the clamping system, and then sum them up according to the weights to obtain the clamping system test evaluation index of the clamping system, and then compare it with the pre-set clamping system test evaluation index threshold.

[0031] Exemplarily, the weights corresponding to the tightness evaluation index and the positioning accuracy index are 0.6 and 0.4 respectively.

[0032] It should be noted that the weights corresponding to the tightness evaluation index and positioning accuracy index are set based on the following: On the one hand, based on the degree of impact on product quality, poor tightness can easily cause product flash and burrs, affecting appearance and dimensional accuracy; insufficient positioning accuracy can cause uneven product wall thickness or even cracking. If high-precision appearance parts are produced, the tightness weight is increased, and the factor with the greatest impact on quality has a higher weight. On the other hand, considering the correlation between mold loss, poor tightness accelerates wear of mold sealing parts, and inaccurate positioning can easily cause local deformation and cracking. When mold costs are high and durability requirements are high, the weight of factors that have a greater impact on mold loss is increased, so as to reasonably distribute the weights and ensure production.

[0033] If the mold clamping system test evaluation index is greater than the mold clamping system test evaluation index threshold, it is determined that the injection molding operation is allowed; otherwise, it is determined that the injection molding operation is not allowed.

[0034] Exemplarily, the mold clamping system test evaluation index threshold is 0.85.

[0035] The injection molding process status monitoring module is used to monitor the injection molding process of precision injection molding, arrange temperature monitoring points on the mold to obtain several temperature monitoring points, obtain the temperature of each temperature monitoring point in real time, analyze the injection molding temperature control evaluation situation, and at the same time obtain the movement speed of each ejector corresponding to the ejection operation, and analyze the ejection speed control evaluation situation.

[0036] It's important to clarify the reasons for monitoring the precision injection molding process: First, it affects product quality. Uneven mold temperature distribution can alter the flow characteristics of the plastic melt in the cavity, resulting in defects such as sink marks, bubbles, and flow marks, affecting both the product's appearance and internal quality. By deploying temperature monitoring points and conducting real-time monitoring, the temperature control strategy can be adjusted promptly to ensure perfect product molding. Second, it protects the mold. During injection molding, the mold is subjected to high temperatures and high pressures. If the temperature gets out of control, local overheating can accelerate mold wear and deformation, shortening the mold life. Real-time temperature monitoring can provide early warnings and prevent mold damage. Third, it optimizes production efficiency. Accurately controlling the injection temperature and ejection speed allows for flexible adjustment of process parameters based on actual conditions, reducing the defective rate, shortening the injection molding cycle, and ensuring efficient and smooth production. Furthermore, monitoring the ejector pin's movement speed prevents damage to the product due to improper ejection operation, ensuring product demolding quality.

[0037] In a preferred embodiment of the present invention, the analysis of injection temperature control evaluation requires the construction of an injection temperature control evaluation index corresponding to the injection molding process. The specific method is as follows: extract the temperature of each temperature monitoring point, respectively denoted as T i , where i represents the number of the temperature monitoring point, i=1,2......I, and I represents the number of temperature monitoring points.

[0038] Using the formula The injection temperature control evaluation index ZTCi corresponding to the injection molding process is obtained by analysis, where T0 represents the preset reference temperature, ΔT represents the allowable difference between the preset reference temperature and the temperature corresponding to the temperature monitoring point, and max() represents the maximum value.

[0039] In a preferred embodiment of the present invention, the analysis of the ejector speed control evaluation situation requires the construction of an ejector speed control evaluation index corresponding to the injection molding process. The specific method is as follows: extract the moving speed of each ejector pin corresponding to the ejector operation, and record it as V j , where j represents the number of the ejector pin, j=1,2......J, and J represents the number of ejector pins.

[0040] Using the formula The ejector speed control evaluation index DMCi corresponding to the injection molding process is obtained by analysis, where V0 represents the preset reference moving speed, and ΔV represents the allowable difference between the preset reference moving speed and the moving speed of the ejector.

[0041] The injection molding process status analysis module is used to determine whether there is an abnormality in the injection molding process based on the injection molding temperature control evaluation status and the top mold speed control evaluation status corresponding to the injection molding process. If so, the specific abnormality direction is further identified, and the abnormality direction includes injection molding temperature control abnormality and top mold speed control abnormality.

[0042] In a preferred embodiment of the present invention, please refer to Figure 3 As shown, the specific process of determining whether there is an abnormality in the injection molding process is as follows: extracting the injection molding temperature control evaluation index and the top mold speed control evaluation index corresponding to the injection molding process, and then comparing them with the pre-set temperature control evaluation index threshold and the top mold speed control evaluation index threshold respectively.

[0043] Exemplarily, the temperature control evaluation index threshold is 0.9, and the top mold speed control evaluation index threshold is 0.95.

[0044] If the injection temperature control evaluation index corresponding to the injection molding process is less than the temperature control evaluation index threshold or the top mold speed control evaluation index is less than the top mold speed control evaluation index threshold, it is judged that there is an abnormality in the injection molding process; otherwise, it is judged that there is no abnormality in the injection molding process.

[0045] In a preferred embodiment of the present invention, the specific method of identifying the specific abnormal direction is: if the injection temperature control evaluation index is less than the temperature control evaluation index threshold, the specific abnormal direction is identified as injection temperature control abnormality; if the top mold speed control evaluation index is less than the top mold speed control evaluation index threshold, the specific abnormal direction is identified as top mold speed control abnormality.

[0046] It should be noted that the specific abnormality may be one or both of an abnormality in injection temperature control and an abnormality in ejection mold speed control.

[0047] It should be noted that the present invention analyzes the mold clamping system test results and the injection process status, reflecting the quality of precision injection molds from different aspects. This analysis method reduces the blindness of quality problem investigation and increases the possibility of quickly resolving mold quality risks. At the same time, it reduces the uncertainty of the production process. Based on real-time data, process parameters can be reasonably set to avoid product defects and mold loss caused by improper parameters, thereby increasing production stability and efficiency. It also reduces the company's long-term operating costs and comprehensively reflects and guarantees the quality of precision injection molds.

[0048] The product quality status monitoring module is used to monitor the quality of precision injection molded products, obtain three-dimensional data of each injection molded product, analyze the dimensional accuracy evaluation of the injection molded products, and at the same time use CCD equipment to collect surface images of each injection molded product to analyze the surface quality evaluation of the injection molded products.

[0049] In a preferred embodiment of the present invention, the analysis of the dimensional accuracy evaluation of the injection molded products requires the construction of a dimensional accuracy evaluation index for the injection molded products. The specific method is as follows: extract the three-dimensional data of each injection molded product, and then obtain the volume and surface area corresponding to each injection molded product, which is recorded as ZV k 、ZS k , where k represents the number of the injection molded product, k=1,2......K, and K represents the number of injection molded products.

[0050] Using the formula The analysis results in the dimensional accuracy evaluation index DAei of the injection molded product, where ZV0 represents a preset reference volume, ΔZV represents the allowable difference between the preset reference volume and the volume of the injection molded product, ZS0 represents a preset reference surface area, and ΔZS represents the allowable difference between the preset reference surface area and the surface area of ​​the injection molded product.

[0051] It's important to clarify the reasons for selecting volume and surface area as factors influencing the dimensional accuracy evaluation index for injection molded products: First, they are related to product function. For example, in injection molded containers, volume determines liquid capacity, while surface area affects interaction with the outside world; large deviations can lead to malfunction. Second, they are related to mold design and manufacturing. Product dimensional accuracy is affected by the mold cavity. Volume and surface area can reflect cavity changes, and monitoring them can infer mold problems and facilitate timely maintenance. Third, based on the convenience of quality control, volume and surface area are easier to measure than complex three-dimensional dimensions. They can be quickly obtained using simple tools and methods, making them convenient for spot checks on the production line or in the laboratory, ensuring stable product quality.

[0052] In a preferred embodiment of the present invention, the surface quality evaluation of the injection molded product needs to be analyzed to construct a surface quality evaluation index for the injection molded product. The specific method is as follows: extract the surface image of each injection molded product collected by the CCD device, and then locate the position of each defect corresponding to the surface image of each injection molded product, and calculate the number of surface defects of each injection molded product, which is recorded as QX k , and use image processing software to obtain the surface defect area of ​​each injection molded product, recorded as QS k .

[0053] It should be noted that an embodiment of locating the position of each defect corresponding to the surface image of each injection-molded product corresponds to an analysis method: extracting the surface image of each injection-molded product collected by a CCD device, and then performing grayscale processing to obtain a grayscale image corresponding to each injection-molded product, obtaining the grayscale value of each pixel point in the grayscale image corresponding to each injection-molded product, performing difference calculation between the grayscale value of each pixel point in the grayscale image corresponding to each injection-molded product and the pre-set reference grayscale value corresponding to each defect to obtain the grayscale value deviation corresponding to each pixel point and each defect, and then performing ratio calculation with the corresponding reference grayscale value of each defect and taking the inverse to obtain the grayscale value similarity between each pixel point and each defect.

[0054] The grayscale similarity between each pixel and each defect on each injection-molded product is compared with a preset grayscale similarity threshold. If the grayscale similarity between a pixel and a defect exceeds the grayscale similarity threshold, the pixel is identified as a defective pixel, and a binary image corresponding to each injection-molded product is obtained. Regions are marked on the binary image, and each connected defective pixel is labeled as a defect region, thus determining the location of each defect on each injection-molded product.

[0055] For example, the defects may be flow marks, silver streaks, shrinkage marks, bubbles, scratches, etc.

[0056] It should be noted that the reason for selecting the number and area of ​​surface defects as factors influencing the surface quality evaluation index of injection molded products is: on the one hand, the number of surface defects directly reflects the stability of quality. For precision electronic and medical products, even small flaws can affect function, aesthetics, or safety. Fluctuations in the number of surface defects are associated with process issues. A sudden increase in the number of surface defects indicates abnormalities in parameters such as injection molding and mold temperature, which can help to promptly adjust and maintain stability. On the other hand, the area of ​​surface defects has different impacts on product performance and appearance. Large-area defects seriously damage the quality of optical and interior products. It is also used to measure the severity of defects and the cost of repair. Large-area defects are difficult to repair and costly. Statistical analysis can help companies control quality and reduce losses.

[0057] Using the formula The surface quality evaluation index SQei of the injection molded product is obtained by analysis, where QX0 represents the preset number of reference defects and QS0 represents the surface area of ​​the injection molded product.

[0058] The product quality status analysis module is used to determine whether the injection molding product production process meets the process requirements based on the dimensional accuracy evaluation and surface quality evaluation of the injection molding product.

[0059] In a preferred embodiment of the present invention, please refer to Figure 4As shown, the specific method for judging whether the injection molding product production process meets the process requirements is as follows: extracting the dimensional accuracy evaluation index and surface quality evaluation index of the injection molding product, and then summing them up according to the weights to obtain the injection molding product production process evaluation index, and then comparing it with the pre-set injection molding product production process evaluation index threshold.

[0060] Exemplarily, the dimensional accuracy evaluation index and the surface quality evaluation index have corresponding weights of 0.55 and 0.45, respectively.

[0061] It should be noted that the corresponding weightings for the dimensional accuracy evaluation index and surface quality evaluation index are based on the following: For dimensional accuracy, weighting is determined based on functional impact and assembly compatibility. For example, dimensional deviations in precision gears can disrupt mechanical operation, and electronic product housings that are not properly sized cannot be tightly assembled. Therefore, the dimensional accuracy of key products is given a high weighting. Regarding surface quality, appearance-driven products, such as high-end electronic housings, where minor flaws can undermine competitiveness, should be given a high weighting. Similarly, for injection molded medical and food packaging products, surface defects can easily harbor dirt and pose a safety hazard, so the weighting should not be low. The sum of the two weights yields the production process evaluation index, which is then compared with the threshold to strictly control injection molding quality.

[0062] If the injection molding product production process evaluation index is less than the injection molding product production process evaluation index threshold, it is judged that the injection molding product production process does not meet the process requirements; otherwise, it is judged that the injection molding product production process meets the process requirements.

[0063] It should be noted that this invention utilizes feedback analysis of mold quality based on the quality of the injection molded product. This analysis method increases the accuracy and timeliness of mold maintenance. This reduces product quality instability. Continuous feedback promotes continuous optimization of mold quality, reduces quality fluctuations between batches, increases the proportion of high-quality product output, improves the consistency of the overall production process, avoids frequent production interruptions due to quality issues, and ensures the company's production efficiency.

[0064] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the described specific embodiments or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they should all fall within the scope of protection of the present invention.

Claims

1. A precision injection molding CCD mold intelligent monitoring and control system based on machine vision, characterized in that: include: The mold clamping system test module is used to test the clamping system before the injection molding operation, obtain the mold clamping data, including monitoring the gap width and position offset distance, and analyze the tightness evaluation and positioning accuracy of the clamping system; The mold clamping system analysis module is used to determine whether the injection molding operation is allowed based on the tightness evaluation and positioning accuracy of the clamping system; The injection molding process status monitoring module is used to monitor the injection molding process of precision injection molding. It arranges temperature monitoring points on the mold to obtain several temperature monitoring points, obtains the temperature of each temperature monitoring point in real time, analyzes the injection molding temperature control evaluation, and obtains the movement speed of each ejector corresponding to the ejection operation to analyze the ejection speed control evaluation; The injection molding process status analysis module is used to determine whether there is an abnormality in the injection molding process based on the injection molding temperature control evaluation and the top mold speed control evaluation corresponding to the injection molding process. If there is an abnormality, it further identifies the specific abnormality direction, which includes injection molding temperature control abnormality and top mold speed control abnormality; The product quality status monitoring module is used to monitor the quality of precision injection molded products, obtain the three-dimensional data of each injection molded product, analyze the dimensional accuracy evaluation of the injection molded product, and construct the dimensional accuracy evaluation index of the injection molded product. At the same time, CCD equipment is used to collect surface images of each injection molded product, analyze the surface quality evaluation of the injection molded product, and construct the surface quality evaluation index of the injection molded product. ; Extract the three-dimensional data of each injection molded product, and then obtain the volume and surface area of ​​each injection molded product, which are recorded as 、 ,in Indicates the number of the injection molded product. , Indicates the number of injection molded products; ,in Indicates the preset reference volume, Indicates the permissible difference between the preset reference volume and the volume of the injection molded product. represents the preset reference surface area, Indicates the permissible difference between the preset reference surface area and the surface area of ​​the injection molded product; Extract the surface image of each injection molded product collected by the CCD device, and then locate the position of each defect corresponding to the surface image of each injection molded product. Count the number of surface defects of each injection molded product, which is recorded as , and use image processing software to obtain the surface defect area of ​​each injection molded product, recorded as ; ,in Indicates the preset reference defect quantity, Indicates the surface area of ​​the injection molded product; The product quality status analysis module is used to determine whether the injection molding product production process meets the process requirements based on the dimensional accuracy evaluation and surface quality evaluation of the injection molding product; extract and , and then calculate the injection molding product production process evaluation index by summing up the weights, and then compare it with the pre-set injection molding product production process evaluation index threshold; If the injection molding product production process evaluation index is less than the injection molding product production process evaluation index threshold, it is judged that the injection molding product production process does not meet the process requirements; otherwise, it is judged that the injection molding product production process meets the process requirements.

2. The machine vision-based intelligent monitoring and control system for precision injection molding CCD molds according to claim 1, characterized in that: The tightness evaluation situation requires the construction of a tightness evaluation index for the clamping system, and the specific method is as follows: The monitoring gap width of the mold is extracted, and then the difference between it and the preset reference gap width is calculated and the absolute value is taken to obtain the monitoring gap width deviation of the clamping system. The monitoring gap width deviation of the clamping system is calculated by ratio with the preset reference gap width and the inverse is taken to obtain the tightness evaluation index of the clamping system.

3. The machine vision-based intelligent monitoring and control system for precision injection molding CCD molds according to claim 2, characterized in that: The positioning accuracy situation requires the construction of the positioning accuracy index of the mold clamping system, and the specific method is as follows: The monitoring position offset distance of the mold is extracted, and then the difference between it and the preset position offset distance threshold is calculated to obtain the monitoring position offset distance anomaly of the mold clamping system. The monitoring position offset distance anomaly of the mold clamping system is calculated by ratio with the preset position offset distance threshold, and the inverse is taken to obtain the positioning accuracy index of the mold clamping system.

4. The machine vision-based intelligent monitoring and control system for precision injection molding CCD molds according to claim 3, characterized in that: The specific analysis method for determining whether the injection molding operation is allowed is as follows; Extract the tightness evaluation index and positioning accuracy index of the mold clamping system, and then calculate the mold clamping system test evaluation index by summing them according to the weights, and then compare them with the pre-set mold clamping system test evaluation index threshold; If the mold clamping system test evaluation index is greater than the mold clamping system test evaluation index threshold, it is determined that the injection molding operation is allowed; otherwise, it is determined that the injection molding operation is not allowed.

5. The machine vision-based precision injection molding CCD mold intelligent monitoring and control system according to claim 1, characterized in that: The analysis of the injection molding temperature control evaluation situation requires the construction of an injection molding temperature control evaluation index corresponding to the injection molding process, and the specific method is as follows: Extract the temperature of each temperature monitoring point and record it as ,in Indicates the number of the temperature monitoring point, , Indicates the number of temperature monitoring points; Using the formula Analyze and obtain the injection temperature control evaluation index corresponding to the injection molding process ,in Indicates the preset reference temperature. Indicates the allowable difference between the preset reference temperature and the temperature corresponding to the temperature monitoring point. Indicates taking the maximum value.

6. The machine vision-based intelligent monitoring and control system for precision injection molding CCD molds according to claim 5, characterized in that: The analysis of the top mold speed control evaluation situation requires the construction of a top mold speed control evaluation index corresponding to the injection molding process, and the specific method is as follows: Extract the moving speed of each ejector pin corresponding to the ejection operation and record it as ,in Indicates the number of the ejector pin. , Indicates the number of ejector pins; Using the formula Analyze and obtain the top mold speed control evaluation index corresponding to the injection molding process ,in Indicates the preset reference moving speed, Indicates the allowable difference between the preset reference moving speed and the moving speed of the ejector.

7. The machine vision-based intelligent monitoring and control system for precision injection molding CCD molds according to claim 6, characterized in that: The specific process of determining whether there is an abnormality in the injection molding process is as follows: Extracting the injection temperature control evaluation index and the ejection mold speed control evaluation index corresponding to the injection molding process, and then comparing them with the preset temperature control evaluation index threshold and the ejection mold speed control evaluation index threshold respectively; If the injection molding temperature control evaluation index corresponding to the injection molding process is less than the temperature control evaluation index threshold or the top mold speed control evaluation index is less than the top mold speed control evaluation index threshold, it is determined that the injection molding process is abnormal; otherwise, it is determined that the injection molding process is not abnormal; The specific method of identifying the specific abnormal direction is: If the injection temperature control evaluation index is less than the temperature control evaluation index threshold, the specific abnormality is identified as injection temperature control abnormality. If the top mold speed control evaluation index is less than the top mold speed control evaluation index threshold, the specific abnormality is identified as top mold speed control abnormality.

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