Management device

Abstract

Provided is a management device capable of more reliably ascertaining the occurrence state of an event. The management device is used for managing at least injection molding machines (10) in equipment included in a molding unit (1), and is provided with a storage part which associates and stores image information of a region including the molding unit (1) and events of the molding unit (1).

Description

[0001] This invention is a divisional application of the Chinese patent application No. 202011557370.7, with the invention title of "Management Device", which was filed by the applicant on December 25, 2020.

[0002] This application claims priority based on Japanese Patent Application No. 2020-064638 filed on March 31, 2020. The entire content of the Japanese application is incorporated herein by reference. Technical Field

[0003] The present invention relates to a management device for managing at least an injection molding machine among the devices included in a molding unit. Background Art

[0004] For example, as shown in Patent Document 1 below, an injection molding machine that injects a molding material into a mold device is known. And, for example, as shown in Patent Document 2 below, a control device for an injection molding machine that detects an operation abnormality such as an abnormality in a mold closing operation regardless of the operator's monitoring is also known.

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2019-171818

[0006] Patent Document 2: Japanese Unexamined Patent Application Publication No. 2002-248665

[0007] In the control device as described above, when an event such as an operation abnormality occurs, the occurrence date, time, and name of the event are sometimes automatically recorded. However, it is sometimes difficult to grasp the occurrence situation of the event only by the occurrence date, time, and name of the event. Summary of the Invention

[0008] The present invention has been completed to solve the above problems, and an object thereof is to provide a management device that can more reliably grasp the occurrence situation of an event.

[0009] One of the above management devices is a management device for managing at least an injection molding machine among the devices included in a molding unit, and includes a storage unit that stores by associating image information of an area including the molding unit with an event of the molding unit.

[0010] Advantages of the Invention

[0011] According to the above management device, the storage unit stores by associating image information of an area including the molding unit with an event of the molding unit, so that the occurrence situation of the event can be more reliably grasped. Brief Description of the Drawings

[0012] Figure 1It is an explanatory diagram showing an injection molding system including a management device according to Embodiment 1 of the present invention.

[0013] Figure 2 It is Figure 1 a block diagram of a molding machine control device.

[0014] Figure 3 It is Figure 2 an explanatory diagram showing an example of a stop history stored in a storage unit.

[0015] Figure 4 It is Figure 2 an explanatory diagram showing an example of a setting change history stored in a storage unit.

[0016] Figure 5 It is Figure 2 an explanatory diagram showing an example of image information stored in association with an event by a storage unit.

[0017] Figure 6 It is Figure 2 an explanatory diagram showing an example of image information of a camera stored in association with an event of a molding unit by a storage unit.

[0018] Figure 7 It is an explanatory diagram showing an injection molding system including a management device according to Embodiment 2 of the present invention.

[0019] Figure 8 It is Figure 7 a block diagram of a molding machine management system.

[0020] Figure 9 It is Figure 1 and Figure 7 a partial cross-sectional view of an example of a mold device and an injection molding machine.

[0021] In the figure: 1 - molding unit, 10 - injection molding machine, 2 - molding machine control device (management device), 22 - storage unit, 23 - imaging control unit, 24 - image analysis unit, 4 - camera (imaging device), 6 - inspection device, 7 - molding machine management system (management device), 72 - storage unit, 73 - imaging control unit, 74 - image analysis unit. Detailed Embodiments

[0022] Hereinafter, with reference to the accompanying drawings, embodiments for implementing the present invention will be described. The present invention is not limited to each embodiment, and constituent elements can be modified and embodied without departing from the gist thereof. Further, by appropriately combining a plurality of constituent elements disclosed in each embodiment, various inventions can be formed. For example, several constituent elements can be deleted from all the constituent elements shown in the embodiment. Moreover, constituent elements of different embodiments can be appropriately combined.

[0023] Embodiment 1.

[0024] Figure 1 It is an explanatory diagram showing an injection molding system including a management device (molding machine control device 2) according to Embodiment 1 of the present invention. As Figure 1 shown, the injection molding system of the present embodiment includes a molding unit 1, a molding machine control device 2, a network 3, a camera 4 as an imaging device, an image management server 5, and an inspection device 6.

[0025] The molding unit 1 is a device unit including at least an injection molding machine 10. The injection molding machine 10 is a device for molding a molded product having a predetermined shape. The injection molding machine 10 of the present embodiment includes an injection device 100. The injection device 100 is a device for melting a predetermined amount of a molding material (such as a thermoplastic resin material) and injecting the melted molding material.

[0026] The molding unit 1 of the present embodiment can include auxiliary equipment 11. Sometimes the injection molding machine 10 and the auxiliary equipment 11 are collectively referred to as the equipment included in the molding unit 1. The auxiliary equipment 11 is equipment for assisting the operation of the injection molding machine 10. In the molding unit 1 of the present embodiment, the auxiliary equipment 11 is connected to the molding machine control device 2 (or the injection molding machine 10), and the molding machine control device 2 (or the injection molding machine 10) can monitor and control the operation of the auxiliary equipment 11.

[0027] The structure of the accessory device 11 is arbitrary, but in the accessory device 11 of the present embodiment, it includes a mold device 110, a material dryer 111, a mold temperature regulator 112, a notification device 113, and an output device 114. The mold device 110 is a device for molding a molded product by cooling and solidifying the molding material injected from the injection device 100. The material dryer 111 is a device for drying the molding material supplied to the injection device 100. The mold temperature regulator 112 is a device for adjusting the temperature of the mold device 110. The mold temperature regulator 112 can adjust the temperature of the mold device 110 by controlling the temperature of a fluid such as water or oil that circulates in the mold device 110 and the mold temperature regulator 112. The notification device 113 is a device for notifying the occurrence of an event when an event such as an abnormal operation of the injection molding machine 10 should be notified to the operator. The notification device 113 can notify the occurrence of an event by light emission and / or sound. The output device 114 is a device for outputting the molded product from the mold device 110.

[0028] The molding machine control device 2 is provided in the injection molding machine 10 and is a device for monitoring and controlling the operations of the injection molding machine 10 and the accessory device 11. The molding machine control device 2 may be composed of, for example, a computer that performs arithmetic processing according to a program, a dedicated circuit, a display device such as a display, and an input device such as a keyboard. The number and position of the hardware constituting the molding machine control device 2 are arbitrary.

[0029] The molding machine control device 2 of the present embodiment manages at least the injection molding machine 10 among the devices included in the molding unit 1, and thus constitutes a management device. In addition, the management device may be built into the injection molding machine 10 or may be arranged outside the injection molding machine 10. The molding machine control device 2 may manage a part of the injection molding machine 10 and the accessory device 11 or may manage all of them.

[0030] The molding machine control device 2 will be described in detail later.

[0031] The network 3 is composed of, for example, a wired, wireless local area network, enterprise network, or the Internet. The devices included in the molding unit 1 (especially the molding machine control device 2), the camera 4, the image management server 5, and the inspection device 6 are interconnected via the network 3.

[0032] The camera 4 is a device for photographing the area including the molding unit 1. The camera 4 can continuously or intermittently photograph the area including the molding unit 1. The camera 4 can input the obtained image information into the molding machine control device 2 and the image management server 5. The image information may be either a still image or a moving image.

[0033] In the present embodiment, a camera 4 is arranged to be able to photograph the entire molding unit 1. More specifically, the camera 4 is installed on the ceiling or wall of the equipment provided with the molding unit 1, and is arranged to overlook and photograph the entire molding unit 1 from above. However, the number and position of the cameras 4 that photograph the area including the molding unit 1 are arbitrary. For example, the area including the molding unit 1 can be photographed from different angles by a plurality of cameras 4. Also, the camera 4 can photograph the molding unit 1 from a position lower than the head position of the operator, etc. In the area including the molding unit 1, in addition to the area including at least a part of the molding unit 1, it also includes the area of the operator who operates the equipment of the molding unit 1. According to the embodiment, the camera 4 can photograph in such a way as to only photograph, for example, the front of the molding machine control device 2, etc. (the equipment of the molding unit 1 is not photographed) of the operator.

[0034] The camera 4 of the present embodiment has a camera body 40, a photographing lens 41, and a support mechanism 42. The camera body 40 is a device having an imaging element such as a CCD, etc. The photographing lens 41 is installed on the camera body 40, and the photographing of the camera 4 is performed through the photographing lens 41. The photographing lens 41 can be a zoom lens capable of changing the magnification or focal length. The support mechanism 42 is a mechanism for supporting the camera 4. The support mechanism 42 of the present embodiment is configured to be able to adjust the orientation of the camera 4. The support mechanism 42 can support the camera 4 in such a way as to be able to rotate around two axes orthogonal to each other. The camera 4 can be supported by the support mechanism 42 in such a way as to be rotatable and movable around a first axis extending in the vertical direction and a second axis extending in the horizontal direction. Also, the support mechanism 42 of the present embodiment is configured to be able to adjust the position of the camera 4. By changing the orientation position of the camera 4, the angle of the camera 4 relative to the imaging object can be adjusted. The position adjustment of the camera 4 includes the adjustment of the height position. That is, the support mechanism 42 can support the camera 4 in such a way as to be able to move vertically. The support mechanism 42 can support the camera 4 in such a way that the camera 4 can be displaced along a specified track. The camera 4 can be supported by the support mechanism 42, for example, in such a way as to be able to be displaced along a track provided on the ceiling so as to surround the area including the molding unit 1.

[0035] The image management server 5 is a device for storing the image information from the camera 4. The image management server 5 can store the image information from the camera 4 non-selectively. In other words, the image management server 5 can at least temporarily store all the image information obtained by the camera 4. The image management server 5 can store the image information for a specified period such as one month, etc., and can delete the image information after the specified period. The image management server 5 can attach specific information such as the date and time or the lot number of the molded product to the image information from the camera 4. The specific information can be input from the injection molding machine 10 or the molding machine control device 2.

[0036] The inspection device 6 is a device for inspecting molded products molded by the injection molding machine 10. The inspection device 6 can detect molding defects of molded products such as shape defects. The inspection device 6 can input the detection of molding defects into the molding machine control device 2.

[0037] Next, Figure 2 represents Figure 1 a block diagram of the molding machine control device 2. As Figure 2 shown, the molding machine control device 2 of the present embodiment includes an abnormality detection unit 20, an operation input unit 21, a storage unit 22, a camera control unit 23, and an image analysis unit 24.

[0038] The abnormality detection unit 20 can detect an operation abnormality of the equipment included in the molding unit 1. When the abnormality detection unit 20 detects an operation abnormality of the equipment, it can stop the operation of the equipment included in the molding unit 1. The abnormality detection unit 20 can input information indicating the detected operation abnormality into the storage unit 22 and the camera control unit 23. The information indicating the detected abnormality includes the date and time when the operation abnormality is detected and the content of the operation abnormality. The content of the operation abnormality may include the name of the operation abnormality and information on the equipment that causes the operation abnormality.

[0039] The operation input unit 21 receives an operation input from the operator. The operation input unit 21 may be a device such as a touch panel, a keyboard, or an operation panel. The input of the operator's operation includes an interference operation on the operation of the equipment included in the molding unit 1 and a setting change of the equipment included in the molding unit 1. The interference operation includes the stop of the equipment included in the molding unit 1 and manual steering. The stop of the equipment can be performed at the time of, for example, maintenance of the mold device 110, sampling inspection of molded products, and production preparation processes (such as material replacement). As the manual operation, an operation that causes the equipment to perform an operation different from the operation preset by a program or the like can be cited. As the setting change, for example, changes in the filling maximum pressure, injection speed, injection pressure, and nozzle temperature can be cited.

[0040] When the operation input unit 21 detects an interference operation or a setting change, it can input information indicating the detected interference operation or setting change into the storage unit 22 and the camera control unit 23.

[0041] The operation input unit 21 can accept the registration of the operator who performs the interference operation or the setting change. The molding machine control device 2 can prompt the registration of the operator who performs the interference operation or the setting change before accepting the interference operation or the setting change.

[0042] The storage unit 22 stores by associating the image information of the area including the molding unit 1 with the events of the molding unit 1. The operator can confirm the events of the molding unit 1 and the image information associated with the events by operating the molding machine control device 2. Thereby, the occurrence status of the events can be grasped more reliably.

[0043] When an event occurs, the storage unit 22 can store by associating the image information at at least one moment among before the occurrence of the event, during the occurrence of the event, and after the occurrence of the event with the event. When an event occurs, the storage unit 22 of the present embodiment stores by associating the image information at all moments among before the occurrence of the event, during the occurrence of the event, and after the occurrence of the event with the event. However, according to the embodiment, the storage unit 22 may store the image information at one or two moments among before the occurrence of the event, during the occurrence of the event, and after the occurrence of the event, such as the image information during the occurrence of the event and after the occurrence of the event.

[0044] The storage unit 22 of the present embodiment can obtain the image information to be stored from the image management server 5 when an event occurs. However, the storage unit 22 can store by associating the image information directly input from the camera 4 with the event. The storage unit 22 can also store the image information from the camera 4 during at least a specified period in a manner different from the image information stored by associating with the event.

[0045] The events of the molding unit 1 include the events for which the injection molding machine 10 leaves an operation history. The storage unit 22 can store by associating the image information of the camera 4 with the events for which the operation history of the injection molding machine 10 is left. The storage unit 22 can store by associating the image information of the camera 4 with all the events for which the operation history of the injection molding machine 10 is left, or can also store by associating the image information of the camera 4 with the events for which a specific operation history is left. For example, importance is set for each event for which an operation history is left, and the storage unit 22 can store by associating the image information of the camera 4 with the events having an importance level above a specified level, and for the events having an importance level lower than the specified level, it may not store by associating with the image information of the camera 4.

[0046] Among the events for which an operation history is left, there are included the operation abnormality of the equipment included in the molding unit 1, the interference of the operator with the operation of the equipment included in the molding unit 1, and the setting change of the equipment included in the molding unit 1. The storage unit 22 can detect the occurrence of the event through the information from the abnormality detection unit 20 and the operation input unit 21.

[0047] Moreover, the events of the molding unit 1 include the detection of abnormalities in the molded products by the inspection device 6. The storage unit 22 can store the image information of the camera 4 in association with the detection of abnormalities in the molded products by the inspection device 6. The storage unit 22 can store the image information of the camera 4 when molding a molded product in which a molding abnormality is detected by the inspection device 6. To mold a molded product, it includes: a metering process of melting a specified amount of molding material; a filling process of filling the melted molding material into the mold device 110; a holding pressure process of holding the molding material in the mold device 110 at a specified pressure; a cooling process of cooling and solidifying the molding material in the mold device 110; and an output process of outputting the molded product from the mold device 110. The storage unit 22 can detect the occurrence of an event (detection of abnormalities in the molded products) through information from the inspection device 6.

[0048] When an event of the molding unit 1 occurs, the imaging control unit 23 controls the operation of the camera 4 according to the content of the event. The control of the operation of the camera 4 by the imaging control unit 23 includes the change of the orientation and / or position of the camera 4, and the change of the magnification or focal length of the imaging lens 41. As described above, the angle can be changed by changing the orientation and position of the camera 4. The imaging control unit 23 can control the operation of the camera 4 in such a way as to magnify the area including the equipment related to the event that has occurred and perform shooting. For example, when the operation of the mold temperature regulator 112 is abnormal, the imaging control unit 23 can direct the camera 4 towards the mold temperature regulator 112 and can switch the magnification of the imaging lens 41 to be able to confirm the state of the mold temperature regulator 112.

[0049] The image analysis unit 24 analyzes the image information. The image analysis unit 24 can analyze the image information from the camera 4 and / or the image information stored in the storage unit 22. The storage unit 22 can further store the information obtained through the analysis by the image analysis unit 24 in association with the events of the molding unit 1.

[0050] The information obtained through the analysis by the image analysis unit 24 includes the information related to the operator included in the image information. The information related to the operator includes, for example, information for identifying the operator such as the facial image, name, or identification number of the operator.

[0051] In addition, the information obtained through the analysis by the image analysis unit 24 includes information related to the cause of stoppage of the equipment included in the molding unit. For example, the image analysis unit 24 can obtain information related to the cause of equipment stoppage by comparing the image information from the camera 4 and / or the image information stored in the storage unit 22 with the occurrence of events in the molding unit 1. The correlation can be information indicating that if a specified action or operation is not performed at a specified time during normal operation, the equipment stops due to a specified cause. For example, if an abnormality notification is issued by the mold temperature regulator 112 and not processed within a specified time, the image analysis unit 24 has correlation information indicating that the entire injection molding machine 10 stops. When the equipment stops after the abnormality notification of the mold temperature regulator 112 has been pending for more than the specified time in the image information from the camera 4 and / or the image information stored in the storage unit 22, the image analysis unit 24 can obtain a defective temperature regulator as the cause of equipment stoppage. Also, for example, if the material shortage is not replenished within a specified time when the material shortage is notified, the image analysis unit 24 has correlation information indicating that the entire injection molding machine 10 stops. When the equipment stops after the notification of material shortage has been pending for more than the specified time in the image information from the camera 4 and / or the image information stored in the storage unit 22, the image analysis unit 24 can obtain a material shortage as the cause of equipment stoppage.

[0052] In addition, the information obtained through the analysis by the image analysis unit 24 includes information related to the content of the processing performed by the operator after the equipment included in the molding unit stops. For example, the image analysis unit 24 has information representing the operator's actions for each processing content, and by detecting the situation where the operator takes a specific action in the image information from the camera 4 and / or the image information stored in the storage unit 22, it can perform the processing corresponding to the action and obtain the name of the processing.

[0053] The image analysis unit 24 can obtain the correlation between the image information stored in the storage unit 22 and the events in the molding unit 1 associated with the image information by learning. When the image analysis unit 24 detects a correlation in the image information to be analyzed, it notifies the detection of the correlation. The image information to be analyzed can be the image information from the camera 4. That is, the image analysis unit 24 can predict the occurrence of an event similar to a past event and notify the operator of the prediction of the event occurrence before the event occurs. The image analysis unit 24 can perform the notification through the notification machine 113. Thus, by the operator performing avoidance operations based on the notification, sudden prevention of the device can be avoided.

[0054] When the image analysis unit 24 detects a correlation in the image information from the camera 4, it can control the operations of the devices included in the molding unit. For example, when a specific operator attempts to operate the molding machine control device 2, the image analysis unit 24 can perform controls such as invalidating at least one operation (such as setting changes, etc.) performed by the operator. Also, for example, when the image analysis unit 24 detects water leakage from the mold temperature regulator 112 from the image data, it can notify the water leakage through the notification machine 113. And, for example, the image analysis unit 24 can determine the degree of fouling of the mold device 110 based on the image data of the mold device 110 and urge the staff to clean it through the notification machine 113.

[0055] Next, Figure 3 is an explanatory diagram showing Figure 2 an example of the stop history stored in the storage unit 22. As Figure 3 shown, the storage unit 22 can store the stop history of the devices of the molding unit 1. Figure 3 Each row in the table shown in

[0056] represents the stop of the devices of the molding unit 1. In the stop history, it may include the stop time, stop moment, restart moment, machine state, and content. The stop time is the difference between the stop moment and the restart moment. The stop moment and the restart moment can be obtained from the state monitoring of the device, etc. The machine state can indicate whether an abnormality has occurred or whether it has stopped normally. An abnormal stop can indicate that the device has stopped due to abnormal detection. A normal stop can indicate a stop caused by the operator's intervention, an automatic stop based on a calendar timer, and an automatic stop due to the completion of production, etc. The machine state can be created based on the information from the abnormality detection unit 20 and the operation input unit 21. The content is information indicating the stop of the device. For example, a plurality of tags or marks representing the content are pre-registered in the storage unit 22, and the content can be created by the operator selecting a plurality of tags or marks.

[0057] Next, Figure 4 is an explanatory diagram showing Figure 2 an example of the setting change history stored in the storage unit 22. As Figure 4 shown, the storage unit 22 can store the setting change history of the devices of the molding unit 1. Figure 4 Each row in the table shown in

[0058] The setting change history may include the change date and time, the molding condition name, the item name, the setting values before and after the change, and the person in charge. The change date and time are the date and time when the setting change is made. The molding condition name indicates the name of the molding condition for which the setting change is made, and the item name indicates the name of the item of the molding condition for which the setting change is made. The setting values before and after the change and the person in charge can be created based on the operator's input.

[0059] Next, Figure 5 is an explanatory diagram showing an example of the image information stored by associating with an event by the Figure 2 storage unit 22. In Figure 5 is shown the image information stored by associating with the stop history of the first row in the Figure 3 table. Figure 5 The image at the upper right end of

[0060] is the image when an event of equipment stop occurs, the two images on the left side of the upper part are the images before the event occurs, and the two images in the lower part are the images after the event occurs. Figure 5 shows the state when the equipment of the molding unit 1 operates normally (left end of the upper part), after an abnormality notification is made by the mold temperature regulator 112 (center of the upper part), until the equipment stops and a notification is made by the notification machine 113 (right end of the upper part), after operator A appears for processing (left end of the lower part), and after the piping cleaning is completed (right end of the lower part). The storage unit 22 can store a series of multiple still images or dynamic images. By selecting Figure 3 and Figure 4 one of the events (histories) shown in Figure 5 the image information (image information associated with the event) as shown in

[0061] Next, Figure 6 is an explanatory diagram showing an example of the image information of the camera 4 stored by associating with the events of the molding unit by the Figure 2 storage unit 22. As shown in Figure 6 the image information of the camera 4 can be displayed simultaneously with the list (history) of events. The arrangement of the image information and the list of events is arbitrary. For example, in Figure 6 the image information is shown above the list of events, but the list of events can also be displayed beside the image information. The displayed image information can be switched by selecting an event.

[0062] And, as shown in Figure 6 in addition to the events and the image information, the information obtained by image analysis can also be displayed. The information obtained by image analysis can be displayed together with the display of the information obtained by image analysis. In Figure 6In this case, it shows a situation where the staff (operator) who handles the abnormal stop, the cause of the stop, and the handling content can be obtained through image analysis. As Figure 6 As shown in the table in the lower part of Figure 6 , the information obtained through image analysis can be added to the table of the event list.

[0063] In the management device (molding machine control device 2) of the present embodiment, the storage unit 22 stores the image information of the area including the molding unit 1 in association with the events of the molding unit 1, so that the occurrence status of the events can be grasped more reliably.

[0064] Moreover, when an event occurs, the storage unit 22 stores the image information at the time of the occurrence of the event, before the occurrence of the event, and after the occurrence of the event in association with the event, so that the occurrence status of the event can be grasped further reliably.

[0065] Moreover, the events of the molding unit 1 include the events for which the injection molding machine 10 leaves an operation history. Therefore, the injection molding machine 10 can confirm the image information in association with the operation history, and the management of the molding unit 1 can be carried out more reliably.

[0066] Moreover, the events of the molding unit 1 include the operation abnormalities of the equipment included in the molding unit 1. Therefore, the image information can be confirmed in association with the operation abnormalities of the equipment, and the management of the molding unit 1 can be carried out more reliably.

[0067] Moreover, the events of the molding unit 1 include the interference of the operator with the operation of the equipment included in the molding unit 1. Therefore, the image information can be confirmed in association with the interference of the operator, and the management of the molding unit 1 can be carried out more reliably.

[0068] Moreover, the events of the molding unit 1 include the setting changes of the equipment included in the molding unit 1. Therefore, the image information can be confirmed in association with the setting changes, and the management of the molding unit 1 can be carried out more reliably.

[0069] Moreover, the events of the molding unit 1 include the abnormal detection of the molded products by the inspection device 6, and this inspection device 6 is used for inspecting the molded products molded by the injection molding machine 10. Therefore, the image information can be confirmed in association with the abnormalities of the molded products, and the management of the molding unit 1 can be carried out more reliably.

[0070] Moreover, when an event of the molding unit 1 occurs, the camera control unit 23 controls the operation of the camera 4 according to the content of the event. Therefore, more suitable image information related to the event of the molding unit 1 can be obtained, and the management of the molding unit 1 can be carried out more reliably.

[0071] Further, the image analysis unit 24 analyzes the image information, and the storage unit 22 further stores the information obtained through the analysis by the image analysis unit 24 in association with the events of the molding unit 1, so that the analysis of the cause of occurrence of the events of the molding unit 1 and the like can be performed more easily.

[0072] In addition, the image analysis unit 24 obtains the information related to the operator included in the image information, so that the operator related to the event can be confirmed more easily, and the management of the molding unit 1 can be performed more reliably.

[0073] Moreover, the image analysis unit 24 obtains the information related to the cause of stoppage of the equipment included in the molding unit 1, so that the analysis of the cause of occurrence of the events of the molding unit 1 and the like can be performed more easily.

[0074] Furthermore, the image analysis unit 24 obtains the information related to the content of the processing performed by the operator after the equipment included in the molding unit 1 stops, so that the management of the molding unit 1 can be performed more reliably.

[0075] In addition, the image analysis unit 24 obtains the relevance between the image information and the occurrence of the events of the molding unit 1 by learning the image information stored in the storage unit 22 and the events of the molding unit 1 associated with the image information. When the relevance is detected in the image information to be analyzed, the detection of the relevance is notified. Therefore, the occurrence of an event similar to the event that occurred in the past can be predicted, and the prediction of the occurrence of the event can be notified to the operator before the event occurs.

[0076] Embodiment 2.

[0077] Figure 7 It is an explanatory diagram showing an injection molding system including a management device (molding machine management system 7) according to Embodiment 2 of the present invention. As Figure 7 shown, the injection molding system of the present Embodiment 2 includes a plurality of molding units 1, a plurality of molding machine control devices 2, a network 3, a plurality of cameras 4, an image management server 5, an inspection device 6, and a molding machine management system 7. Regarding the molding unit 1, the molding machine control device 2, the network 3, the camera 4, the image management server 5, and the inspection device 6, they are as described in Embodiment 1.

[0078] The molding machine management system 7 is connected to the molding unit 1, the molding machine control device 2, the network 3, the camera 4, the image management server 5, and the inspection device 6 via the network 3, and is a system for monitoring and controlling the operations of a plurality of injection molding machines 10 and auxiliary equipment 11. The molding machine management system 7 can be constituted by, for example, a device such as a computer that performs arithmetic processing according to a program and / or a dedicated circuit. The number and position of the hardware constituting the molding machine management system 7 are arbitrary.

[0079] The molding machine management system 7 of the present Embodiment 2 manages at least the injection molding machine 10 among the devices included in each of the plurality of molding units 1, and thus constitutes a management device. As in the case of the present Embodiment 2, when the molding machine management system 7 manages the plurality of molding units 1 and thus constitutes a management device, as described in Embodiment 1, the molding machine control device 2 may constitute a management device for managing one molding unit 1. For example, it may not have at least a part of the functions of a management device such as the storage unit 22.

[0080] Next, Figure 8 is a block diagram Figure 7 of the molding machine management system 7. As Figure 8 shown, the molding machine management system 7 of the present embodiment includes an abnormality detection unit 70, an operation input unit 71, a storage unit 72, a camera control unit 73, and an image analysis unit 74.

[0081] These abnormality detection unit 70, operation input unit 71, storage unit 72, camera control unit 73, and image analysis unit 74 are substantially the same as the abnormality detection unit 20, operation input unit 21, storage unit 22, camera control unit 23, and image analysis unit 24 of Embodiment 1.

[0082] However, the abnormality detection unit 70 of the molding machine management system 7 can detect an operation abnormality of the devices included in each molding unit 1. The operation input unit 71 can accept an input of an operation of the devices of each molding unit 1 by an operator.

[0083] The storage unit 72 can store image information in association with the events of each molding unit 1. By operating the molding machine management system 7, the operator can confirm the events of any molding unit 1 and the image information associated with the events. Thereby, the occurrence status of the events can be grasped more reliably and easily.

[0084] When an event occurs in any one of the molding units 1, the camera control unit 73 controls the operation of the camera 4 that captures the area including the molding unit 1 according to the content of the event.

[0085] The image analysis unit 74 analyzes the image information. The storage unit 72 can store the information obtained by the analysis of the image analysis unit 74 in association with the events of each molding unit 1. Other configurations are the same as those of Embodiment 1.

[0086] In this way, the management of the plurality of molding units 1 can be performed by the molding machine management system 7 (management device).

[0087] Next, Figure 9 is a partial cross-sectional view Figure 1 showing an example Figure 7 of the mold device 110 and the injection molding machine 10.Figure 1 and Figure 7 the mold device 110 and the injection molding machine 10 as shown in Figure 9 can adopt the structure shown.

[0088] In the illustrated example, the mold device 110 has a fixed mold 110a, a movable mold 110b, and a movable member 110c. The fixed mold 110a and the movable mold 110b are molds that partition and form a cavity inside (between each other) in the mold-closed state. The movable mold 110b is arranged to be displaceable in a direction approaching the fixed mold 110a and a direction away from the fixed mold 110a. The movable member 110c is composed of an ejector pin or the like that is displaced by an ejector device 400 described later and extrudes the molded product for output. This mold device 110 can be called a two-plate mold mainly divided into two parts, the fixed mold 110a and the movable mold 110b, but it can also be made into a three-plate mold having a slide mold or a slide core or a stripper plate and divided into three parts. The mold device 110 can be appropriately installed on the injection molding machine 10 according to the shape of the molded product to be manufactured and the like, and can be replaced. Here, the mold device 110 is not regarded as a part of the injection molding machine 10.

[0089] The injection molding machine 10 has an injection device 100, a moving device 200, a mold-closing device 300, and an ejector device 400.

[0090] (Injection device)

[0091] The injection device 100 is a device for melting the molding material and injecting it into the mold device 110. The injection device 100 mainly includes a cylinder 101, a screw 102, a heater 103, and a motor box 104.

[0092] Hereinafter, the terms of the front side and the rear side are sometimes used to explain the positions of the respective structures. These terms of the front side and the rear side are terms based on the fixed platen 301a described later, with the orientation approaching the fixed platen 301a being set as the front side and the orientation away from the fixed platen 301a being set as the rear side. For example, if observing the injection device 100 located on the right side of the fixed platen 301a in Figure 9 then the left orientation approaching the fixed platen 301a becomes the front side, and the right orientation away from the fixed platen 301a is the rear side.

[0093] The cylinder block 101 is a cylindrical member extending toward the mold device 110. The cross-sectional shape of the cylinder block 101 is preferably circular, but it can also be set to other shapes. A supply port 101a and a nozzle 101b are provided in the cylinder block 101. The supply port 101a is an opening where a hopper for injecting a molding material into the cylinder block 101 can be installed. The supply port 101a can be arranged on the rear side of the cylinder block 101 and in front of the motor box 104. A water-cooled cylinder 101c based on water cooling or the like can be provided near the supply port 101a. The nozzle 101b is an opening provided at the front end portion close to the mold device 110. The cross-sectional area of the nozzle 101b is set to be smaller than the cross-sectional area of the rear side of the cylinder block 101.

[0094] The screw 102 is a long member inserted through the inside of the cylinder block 101. The central axis of the screw 102 preferably extends parallel to the central axis of the cylinder block 101. Threads are provided in a spiral around the screw 102. The molding material can be conveyed to the front end portion of the cylinder block 101 according to the rotation of the screw 102.

[0095] An intermediate reduced-diameter portion with a locally reduced outer diameter is provided on the front end side of the screw 102. A check ring 102a that can move forward and backward together with the screw 102 is arranged around the intermediate reduced-diameter portion. The check ring 102a can prevent the molding material conveyed to the front side of the cylinder block 101 from flowing backward to the rear side. For example, the check ring 102a can move forward and backward relative to the screw 102 according to the pressure received from the molding material located on the front side or the rear side of the check ring 102a, and thus only allows the molding material to flow from the rear side to the front side.

[0096] The heater 103 is arranged around the outer periphery of the cylinder block 101. The heater 103 is arranged around the cylinder block 101 including the periphery of the nozzle 101b. The heater 103 can adopt a shape such as a strip. The heater 103 can be formed integrally in the axial direction, but as shown in the figure, it can also have a plurality of heater portions separated from each other in the left-right direction ( Figure 9 in the axial direction). The inside of the cylinder block 101 can be heated at different temperatures according to each position of the heater portion. Temperature sensors 103a can be provided in each heater portion.

[0097] The motor box 104 is arranged on the rear side of the cylinder block 101 and the screw 102. Although not shown in the figure, the following are arranged in the motor box 104: a metering motor that rotates the screw 102 around the central axis to fill a predetermined amount of molding material into the front end portion of the cylinder block 101; an injection motor that moves the screw 102 forward and backward in each direction toward and away from the mold device 110; and a pressure detection sensor that detects the pressure received by the screw 102 from the molding material.

[0098] In addition, the injection molding machine 10 is a coaxial screw type injection molding machine, but it can also be a screw pre-plasticizing type injection molding machine that is structurally and functionally separated into a plasticizing cylinder, a plasticizing screw, an injection cylinder, and an injection plunger.

[0099] (Moving device)

[0100] The moving device 200 is a device for advancing / retreating the injection device 100 relative to the mold device 110. The moving device 200 is provided, for example, at the lower part of the motor box 104 of the injection device 100, etc., and is an advancing / retreating drive mechanism for advancing and retreating the injection device 100 relative to the fixed platen 301a described later.

[0101] As the advancing / retreating drive mechanism constituting the moving device 200, various mechanisms can be adopted. However, the illustrated moving device 200 includes: a hydraulic pump 201 such as a hydraulic pump; a pump working motor 202 based on electricity, etc., for operating the hydraulic pump 201; and a double-acting hydraulic cylinder 203, which supplies working fluid from the hydraulic pump 201 and causes the piston rod fixed to the fixed platen 301a at the front end to perform a pushing / pulling movement.

[0102] The moving device 200 further includes a sliding base 204 and a guide member 205. The above-mentioned hydraulic pump 201, the pump working motor 202, and the hydraulic cylinder 203 are installed on the sliding base 204. The guide member 205 is laid on the frame Fr and can guide the linear movement of the sliding base 204. The advancing / retreating displacement of the injection device 100 placed on the upper part of the sliding base 204 is realized by the sliding base 204 and the guide member 205.

[0103] By the moving device 200, the injection device 100 can be moved away from the mold device 110, or the injection device 100 can be moved closer to the mold device 110, and the so-called nozzle contact can be performed in which the nozzle 101b of the cylinder body 101 of the injection device 100 is pressed against the mold device 110 with a specified pressure.

[0104] (Mold clamping device)

[0105] The mold clamping device 300 is a device for opening or closing the mold device 110 between the mold-clamped state and the mold-opened state. The mold clamping device 300 displaces the movable mold 110b relative to the fixed mold 110a of the mold device 110 to open or close the mold device 110, and sets the mold device 110 to the mold-clamped state, the mold-closed state, or the mold-opened state.

[0106] The mold clamping device 300 of the injection molding machine 10 mainly includes a platen 301 and a platen operating mechanism 302.

[0107] The platen 301 is arranged to clamp the mold device 110 from both sides. The platen 301 includes: a fixed platen 301a, which is located between the injection device 100 and the mold device 110 and fixed to the frame Fr; and a movable platen 301b, which is located with the mold device 110 interposed therebetween and the fixed platen 301a and can be displaced closer to / farther from the fixed platen 301a. One or more connecting rods 301c for guiding the displacement of the movable platen 301b are installed on the fixed platen 301a. The fixed mold 110a of the mold device 110 is installed on the side of the fixed platen 301a. The movable mold 110b is installed on the side of the movable platen 301b.

[0108] In the position where the movable platen 301b is far from the fixed platen 301a, the movable mold 110b of the mold device 110 is in an open mold state where it is opened from the fixed mold 110a. By moving the movable platen 301b closer to the fixed platen 301a from this far position, the movable mold 110b becomes in a closed mold state where it is closed relative to the fixed mold 110a. By further moving the movable platen 301b closer to the fixed platen 301a from the closed mold state, the movable mold 110b becomes in a mold clamping state where it is pressed against the fixed mold 110a.

[0109] In addition, in Figure 9 most of the mold clamping device 300 except for the fixed platen 301a and the ejector device 400 described later are located on the left side of the fixed platen 301a. Therefore, when observing most of the mold clamping device 300 and the ejector device 400, the right orientation closer to the fixed platen 301a becomes the front side, and the left orientation farther from the fixed platen 301a becomes the rear side.

[0110] The platen operating mechanism 302 is a mechanism for operating the platen 301. The platen operating mechanism 302 includes: a rear platen 304, which is mounted on the frame Fr so as to be movable; a mold clamping motor 305, which is provided on the rear platen 304; a motion conversion mechanism 306, which converts the rotational motion of the mold clamping motor 305 into a linear motion in the displacement direction of the movable platen 301b; and a toggle mechanism 307, which increases the force transmitted to the motion conversion mechanism 306 and transmits it to the movable platen 301b.

[0111] Among them, the motion conversion mechanism 306 can be set as various mechanisms capable of converting rotational motion into linear motion. However, in this example, it is composed of a lead screw shaft 306a rotationally driven by the mold clamping motor 305 and a nut 306b screwed onto the lead screw shaft 306a. The motion conversion mechanism 306 can also be set as a ball screw.

[0112] Further, the toggle mechanism 307 that increases the transmission force from the motion conversion mechanism 306 is formed by swingably connecting a plurality of connecting members 307a to 307c that connect the rear pressure plate 304, the nut 306b, and the movable pressure plate 301b with connecting heads. The number and shape of the connecting members and the connecting heads can be appropriately changed. As Figure 9 shown, a pair of connecting member groups including the connecting members 307a to 307c located above and below the crosshead 307d are swingably connected to the crosshead 307d that is connected to the nut 306b and extends in the vertical direction.

[0113] In addition, on the rear pressure plate 304, in addition to the above-mentioned clamping motor 305, a die thickness adjusting motor 308 can also be provided. The die thickness adjusting motor 308 functions as follows: by applying a rotational driving force to the lead screw shaft and the nut connected to the extended portions of the respective connecting rods 301c of the pressure plate 301, the interval between the fixed pressure plate 301a and the rear pressure plate 304 movably arranged via a track on the frame Fr is adjusted. Thus, when replacing the mold device 110 or changing the thickness of the mold device 110 due to temperature changes, etc., the die thickness can also be adjusted so as to be able to apply the expected clamping force to the mold device 110. Although not shown, even if the fixed pressure plate side is made movable on the frame Fr and the rear pressure plate side is made fixed, the die thickness adjustment can be achieved.

[0114] The illustrated clamping device 300 is a horizontal type in which the moving direction of the movable pressure plate 301b is parallel to the horizontal direction, but it can also be made into a vertical type in which the moving direction is set to the vertical direction.

[0115] (Ejector device)

[0116] The ejector device 400 is a device for ejecting the molded product from the mold device 110 in the open mold state, and is provided on the movable pressure plate 301b. The ejector device 400 has: an ejector rod 402 that extends through the movable pressure plate 301b and is driven to advance and retreat to press a movable part 110c such as an ejector pin of the mold device 110 from the rear side; and a rod drive source 403 that includes a motion conversion mechanism such as a motor and a ball screw in order to operate the ejector rod 402.

[0117] During the output process of the molded product, the ejector rod 402 driven by the rod drive source 403 can be advanced through the ejector device 400 to eject the movable part 110c within the mold device 110 and output the molded product from the mold device 110. In addition, after ejecting the movable part 110c, the ejector rod 402 can be retracted by the rod drive source 403 and returned to the original position.

[0118] Next, regarding the use of Figure 9An example of a molding method for a molded product of the injection device 100 will be described. In the molding method of the molded product, a metering process, a filling process, a holding pressure process, a cooling process, and an ejection process are sequentially performed.

[0119] In the metering process, the molding material introduced into the interior of the cylinder 101 from the supply port 101a is melted by the heating of the heater 103 on the outer peripheral side of the cylinder 101 according to the rotation of the screw 102 driven by the metering motor, and is conveyed forward inside the cylinder 101 and filled in the front end portion of the cylinder 101. At this time, the screw 102 is retracted by the injection motor, and a space filled with the molding material is formed at the front end portion of the cylinder 101. This metering process can be performed at the time of the cooling process or the like during the previous molding. When performing this metering process, the mold device 110 is closed by the mold clamping device 300 to be in the mold clamped state.

[0120] In the filling process, the screw 102 is advanced, whereby the molding material at the front end portion of the cylinder 101 is injected into the mold device 110 via the nozzle 101b.

[0121] In the holding pressure process, the screw 102 is further advanced to hold the molding material inside the front end portion of the injection device 100 at a specified pressure. In the holding pressure process, the pressure acts on the molding material filled in the cavity of the mold device 110 through the molding material remaining at the front end portion of the cylinder 101. At this time, the molding material insufficient due to the cooling shrinkage of the molding material can be supplemented in the cavity of the mold device 110.

[0122] In the cooling process, the molding material filled in the cavity of the mold device 110 is cooled and solidified to obtain a molded product. In this cooling process, the metering process for molding the subsequent molded product can be performed.

[0123] In the ejection process, the mold device 110 is opened by using the mold clamping device 300 to be in the mold open state, and the movable part 110c is moved by the ejection device 400 to eject the molded product from the mold device 110.

[0124] In addition, in Embodiment 1 and Embodiment 2, it has been described that the molding machine control device 2 and / or the molding machine management system 7 constitute (also serve as) the management device. However, different from these molding machine control device 2 and molding machine management system 7, a management device for managing at least the injection molding machine 10 among the devices included in the molding unit 1, such as an image management server 5, may be provided. When a device different from the molding machine control device 2 and the molding machine management system 7, such as the image management server 5, constitutes the management device, when the molding machine control device 2 or the molding machine management system 7 detects the occurrence of an event, event occurrence information is sent from the molding machine control device 2 or the molding machine management system 7 to the management device. Based on this event occurrence information, the management device can associate with the event of the molding unit to store the image information of the area including the molding unit.

Claims

1. A management device for managing an injection molding machine, wherein, the management device includes an image analysis unit that analyzes image information of a molding unit including at least the injection molding machine to predict the occurrence of an event similar to a past event, and a storage unit that stores by associating the image information of the area including the molding unit with the event leaving a history of the molding unit, the image information includes image information at at least one of a time before the event occurs, when the event occurs, and after the event occurs, based on the prediction of the occurrence of an event of the molding unit, the image analysis unit causes the equipment included in the molding unit to operate with a setting different from the setting made by an operator.

2. The management device according to claim 1, wherein, when the event occurs, the storage unit stores by associating the image information at at least one of a time before the event occurs, when the event occurs, and after the event occurs with the event.

3. The management device according to claim 1 or 2, wherein, the event of the molding unit includes an event where the injection molding machine leaves an operation history.

4. The management device according to claim 1 or 2, wherein, the event of the molding unit includes an operation abnormality of the equipment included in the molding unit.

5. The management device according to claim 1 or 2, wherein, the event of the molding unit includes an operator's interference with the operation of the equipment included in the molding unit.

6. The management device according to claim 1 or 2, wherein, the event of the molding unit includes a setting change of the equipment included in the molding unit.

7. The management device according to claim 1 or 2, wherein, the event of the molding unit includes an abnormal detection of a molded product by an inspection device for inspecting the molded product molded by the injection molding machine.

8. The management device according to claim 1 or 2, wherein, it further includes a camera control unit that, when an event of the molding unit occurs, controls the operation of a camera device that captures the area including the molding unit according to the content of the event.

9. The management device according to claim 1 or 2, wherein, the storage unit further stores by associating the information obtained through the analysis by the image analysis unit with the event of the molding unit.

10. The management device according to claim 9, wherein, the image analysis unit obtains the relevance between the image information and the occurrence of an event of the molding unit by learning the image information stored in the storage unit and the event of the molding unit associated with the image information, and when the relevance is detected in the image information to be analyzed, notifies the detection of the relevance.

Images