Defective product sorting method and system for stylus electric mold and defective product detection device

Abstract

The invention relates to a defective product sorting method of a stylus electric mold, which comprises the following steps: acquiring a working state parameter of each injection molding machine in real time, identifying the type of the working state parameter, if the working state parameter is a second state parameter, acquiring the duration of the state by using a timer, comparing the duration with different preset time thresholds, and if the duration is less than a first preset time threshold, determining that the injection molding machine does not have defective products. If the time reaches a first preset time threshold value, judging the state as a normal state, if the time reaches a second preset time threshold value or a third preset time threshold value, judging the state as an abnormal state, and generating a corresponding control instruction to control the manipulator to throw away defective products of a corresponding preset number threshold value. According to the method, whether the defective products are generated or not is recognized based on the duration time of the abnormal state of the injection molding machine, the corresponding number of the defective products is obtained according to different duration time so as to control the manipulator to throw away the defective products of the corresponding number, and compared with manual recognition and detection of the defective products, the efficiency is greatly improved. Correspondingly, the invention further provides a defective product sorting system and a detection device.

Description

[0001] Divisional application This application is a divisional application of the Chinese invention patent application [Application No.: 2023118636307] [Title: Method and System for Sorting Defective Products of Laptop Molds, and Defective Product Detection Device] filed on December 29, 2023. Technical Field

[0002] The present invention relates to the technical field of injection molding processing, and particularly relates to a method and system for sorting defective products during the injection molding process of laptop molds, and a defective product detection device. Background Art

[0003] Injection molding processing is one of the most commonly used plastic processing techniques and is widely applied in production and daily life. The definition of injection molding processing is that after heating plastic to a certain temperature, an injection molding machine injects the molten plastic into a closed mold cavity at an extremely high pressure, and then the mold cools and forms. After the mold is opened, the plastic product is ejected from the top plate. The characteristics of injection molding processing are that when producing continuously and stably, the product consistency is good, the quality is stable, and the probability of producing defective products is extremely low.

[0004] However, when producing in a non - continuously stable state, such as when starting production for the first time, abnormal shutdown, equipment failure alarm and other production factor changes occur, the probability of product defects increases sharply, and the product yield is greatly reduced. Since currently common manipulators are used to automatically pick the finished injection molded parts processed by the injection molding machine to a designated area, it is difficult to prevent defective products from being mixed into good products. And when defective products are mixed into good products, manual inspection and screening are necessary, which is time - consuming and labor - intensive. Moreover, only visible appearance defects can be identified, and non - appearance defects will escape and flow into the next process or be delivered to customers, resulting in quality decline and customer complaints.

[0005] In order to be able to efficiently detect defective products, various defective product detection devices have emerged in the prior art. For example, by setting cameras on the production line to photograph the appearance of workpieces, and then performing image analysis and processing on the captured images to obtain the appearance structure parameters of the workpieces, and comparing them with the appearance structure parameters of standard workpieces to identify defective products; and, in order to be able to photograph workpieces from multiple angles to obtain complete appearance structure parameters of the workpieces, multiple cameras need to be set, and auxiliary equipment for flipping or adjusting the angle of the processed parts also needs to be added to the processing equipment. Therefore, this method not only requires a large improvement to the existing processing equipment, making the structure of the processing equipment more complex, but also because a large amount of image processing is required, the performance requirements for the main control equipment are higher, which undoubtedly greatly increases the cost of the enterprise and is not applicable to enterprises where both the processing equipment and the main control equipment have been in long - term use.

[0006] In the prior art, a method for detecting and sorting defective products based on the production cycle has also been proposed. For example, CN115972522A discloses a defective product control system for an injection molding machine, which identifies defective production cycles based on the time interval between two adjacent production cycles, and then rejects the injection molded products obtained in the defective production cycles. If it is greater than the preset time interval, it is determined that the current is a defective production cycle, and then the manipulator is controlled to determine the finished products in the defective cycle as defective products. Summary of the Invention

[0007] The purpose of the present invention is to provide a method and system for sorting defective products of a laptop mold, and a defective product detection device, which can partially solve or alleviate the above deficiencies in the prior art and can automatically sort defective products.

[0008] In order to solve the above-mentioned technical problems, the present invention specifically adopts the following technical solutions: In the first aspect of the present invention, a method for sorting defective products of a laptop mold is provided, which includes the steps of: Obtain the working state parameters of each injection molding machine in real time; the working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state, and a second state parameter indicating that the injection molding machine is in an abnormal state; When the second state parameter is first recognized, trigger a timer to start timing, and when the first state parameter is recognized again, stop timing to obtain the timing time T; and compare the timing time T with a first preset time threshold, a second preset time threshold, and a third preset time threshold; If the timing time T is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator corresponding to the current injection molding machine; If the timing time T reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the manipulator corresponding to the current injection molding machine, so that when the manipulator starts receiving the second control instruction, the first preset number threshold of injection molded product finished products successively output by the current injection molding machine are sorted into the defective product area; the second control instruction includes the first preset number threshold of defective products to be discarded; If the timing time T reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the manipulator corresponding to the current injection molding machine, so that when the manipulator starts receiving the third control instruction, the second preset number threshold of injection molded product finished products successively output by the current injection molding machine are sorted into the defective product area; the third control instruction includes the second preset number threshold of defective products to be discarded.

[0009] Wherein, the first preset time threshold is less than the second preset time threshold, and the second preset time threshold is less than the third preset time threshold.

[0010] Wherein, the first preset quantity threshold is less than the second preset quantity threshold In some embodiments of the present invention, before the step of generating the second control instruction, the following steps are further included: Obtain the material consumption Q0 of a single injection molded part corresponding to the current injection molding machine, and the total amount Q of the melted raw material in the material pipe of the current injection molding machine whose temperature exceeds the lowest denaturation temperature, and calculate the defective product quantity threshold S = Q / Q0 corresponding to the current injection molding machine according to the material consumption Q0 of a single injection molded part and the total amount Q of the melted raw material whose temperature exceeds the lowest denaturation temperature.

[0011] In some embodiments of the present invention, before the step of generating the third control instruction, the following steps are further included: Obtain the material consumption Q0 of a single injection molded part corresponding to the current injection molding machine, and the total amount V of the melted raw material in the material pipe, and calculate the defective product quantity threshold S = V / Q0 corresponding to the current injection molding machine according to the material consumption Q0 of a single injection molded part and the total amount V of the melted raw material in the material pipe.

[0012] In a second aspect of the present invention, there is provided a defective product sorting system for a laptop mold, which includes: At least one injection molding machine, which is used to process the injection molded parts of the laptop mold and output the finished injection molded parts of the laptop mold; A main control device, which performs data communication with the at least one injection molding machine, is used to obtain the working state parameters of the injection molding machine in real time, and identify the types of the working state parameters. When the working state parameters of the current injection molding machine are first identified as the second state parameters, a timer is triggered to start timing, and when the first state parameters of the current injection molding machine are identified again, the timing is stopped and the timing time is obtained, and then the timing time is compared with the first preset time threshold, the second preset time threshold, and the third preset time threshold respectively. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator for sorting; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the manipulator for sorting; the second control instruction includes a first preset quantity threshold for discarding defective products; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the manipulator for sorting; the third control instruction includes a second preset quantity threshold for discarding defective products; At least one manipulator, each of which is installed at the sorting station at the output position of each injection molding machine and communicates with the main control device for data. When receiving the first control instruction, the manipulator sorts the finished injection molded parts output by the corresponding injection molding machine to the good product area; or when receiving the second control instruction, sorts the first preset quantity threshold of the finished injection molded parts output by the corresponding injection molding machine to the defective product area; or when receiving the third control instruction, sorts the second preset quantity threshold of the finished injection molded parts output by the corresponding injection molding machine to the defective product area.

[0013] Among them, the types of the working state parameters include the first state parameter and the second state parameter. The first state parameter characterizes that the injection molding machine is in a normal state; the second state parameter indicates that the injection molding machine is in an abnormal state.

[0014] Among them, the first preset time threshold is less than the second preset time threshold, and the second preset time threshold is less than the third preset time threshold.

[0015] Among them, the first preset quantity threshold is less than the second preset quantity threshold.

[0016] In some embodiments of the present invention, the main control device includes: A data acquisition module for real-time acquisition of the working state parameters of each injection molding machine; A state recognition module for recognizing the types of the working state parameters of each injection molding machine; A trigger module for triggering a timer to start timing when the state recognition module first recognizes that the working state parameter of the current injection molding machine is the second state parameter, and stopping the timing and obtaining the timing time when it recognizes again that the working state parameter of the current injection molding machine is the first state parameter; An abnormality recognition module for comparing the timing time with the first preset time threshold, the second preset time threshold, and the third preset time threshold, and when it is determined that the timing time is less than the first preset time threshold, determining that the current injection molding machine is in a normal state, generating the first control instruction and sending it to the manipulator; or when it is determined that the timing time reaches the second preset time threshold, determining that the current injection molding machine is in a first abnormal state, generating the second control instruction and sending it to the manipulator; or when it is determined that the timing time reaches the third preset time threshold, determining that the current injection molding machine is in a second abnormal state, generating the third control instruction and sending it to the manipulator.

[0017] In some embodiments of the present invention, the main control device uses a single-chip microcomputer integrated in the manipulator, and the main control device performs data communication with the injection molding machine through an integrated wireless communication module.

[0018] In some embodiments of the present invention, the main control device further includes: a defective product mold times calculation module, configured to, when it is determined that the timing time reaches the second preset time threshold or the third preset time threshold, obtain the material consumption of a single injection molded part corresponding to the current injection molding machine, and calculate the defective product quantity threshold corresponding to the current injection molding machine according to the material consumption of the single injection molded part.

[0019] In a third aspect of the present invention, there is provided a defective product detection device for a laptop mold, which includes: A timer for timing; A wireless communication module for performing data communication with multiple injection molding machines to obtain the working state parameters of each injection molding machine; A state recognition module for recognizing the types of the working state parameters obtained by the wireless communication module; the types of the working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state; a second state parameter indicating that the injection molding machine is in an abnormal state; A trigger module for, when the state recognition module first recognizes that the working state parameter of the current injection molding machine is the second state parameter, triggering the timer to start timing, and stopping timing when it recognizes again that the working state parameter of the current injection molding machine is the first state parameter, to obtain the timing time; An abnormality recognition module for comparing the timing time with a first preset time threshold, a second preset time threshold, and a third preset time threshold. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the manipulator; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the manipulator; wherein, the second control instruction includes a first preset quantity threshold for discarding defective products; the third control instruction includes a second preset quantity threshold for discarding defective products.

[0020] Beneficial effects: Compared with the traditional method of using a vision system, such as a camera and other auxiliary devices, to obtain the appearance structure parameters of the processed workpiece and then performing a large amount of image analysis and data processing, the present invention only monitors the underlying IO signals of each injection molding machine and the manipulator for finished product sorting through the Internet of Things, that is, by collecting the working state parameters of the injection molding machine and calculating and monitoring the duration of its abnormal state (such as continuously collecting the second state parameter). If the preset time threshold is reached (for example, the second preset time threshold or the third preset time threshold; or, exceeding the minimum abnormal duration), it is finally determined that it is in an abnormal state and defective products will be produced. Thus, the manipulator is controlled to discard the corresponding number of defective products. That is, the present invention triggers the detection of defective products from the perspective of the working state of the injection molding machine equipment. Compared with the method of using a vision system for defective product detection, the cost is greatly reduced and it is also simpler and more effective.

[0021] On the one hand, the material consumption of different injection molded parts is different, and the required production time cycle is also different. Correspondingly, the number of defective products produced in an abnormal state (such as a shutdown state) will also be different. On the other hand, the duration of the abnormal state is different, and the number of defective products produced in the abnormal state is also different. That is, the material consumption of a single injection molded part and the duration of the abnormal state are the keys affecting the number of defective products. Therefore, in this application, according to the material consumption required for each injection molding machine to produce a single injection molded part finished product and the duration T of its corresponding abnormal state, the number of defective products that the injection molding machine will produce during this abnormal duration is accurately calculated, and the manipulator is controlled to automatically discard them, realizing the full-automatic and accurate calculation and elimination of defective products, with a wide application range and low cost. Furthermore, the present invention can also accurately calculate the number of defective product mold times required to be discarded in an abnormal state by combining the material consumption of each injection molding machine for producing a single injection molded part, so as to achieve the effect of fully automatic and complete elimination of defective products, avoiding the disadvantages of inaccurate calculation, uncontrollable behavior, untimely operation, and high cost in the past when technicians needed to manually calculate and control the number of defective product mold times to be discarded. Description of the Drawings

[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale. Obviously, the following-described drawings are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0023] Figure 1 It is a functional module diagram of a defective product sorting system for a laptop mold according to an exemplary embodiment of the present invention; Figure 2 A flowchart of a method for sorting defective products of a laptop mold according to an exemplary embodiment of the present invention; Figure 3a and Figure 3b are both schematic diagrams of the number of defective products discarded by respective injection molding machines in a part of the entire workshop detected by using the defective product sorting method according to an exemplary embodiment of the present invention. Detailed implementation manners

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0025] In this article, suffixes such as "module", "component", or "unit" used to represent elements are only for the convenience of describing the present invention, and they have no specific meaning in themselves. Therefore, "module", "component", or "unit" can be used interchangeably.

[0026] In this article, terms such as "upper", "lower", "inner", "outer", "front", "rear", "one end", "the other end", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be construed as a limitation of the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0027] In this article, unless otherwise clearly defined and limited, terms such as "installed", "provided with", "connected", etc. shall be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, a direct connection, or an indirect connection through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0028] In this article, "and / or" includes any and all combinations of one or more of the listed related items.

[0029] In this article, "a plurality of" means two or more, that is, it includes two, three, four, five, etc.

[0030] Embodiment 1: Refer to Figure 1, which is a functional module diagram of a defective product sorting system for an injection molding machine according to an exemplary embodiment of the present invention. Specifically, the system includes: At least one injection molding machine, which is used to process injection molded parts of laptop molds and output finished injection molded parts; The main control device communicates with at least one injection molding machine for data, and is used to obtain the working state parameters of each injection molding machine in real time and identify the types of the working state parameters; when it is first identified that the working state parameter of the current injection molding machine is the second state parameter, the timer is triggered to start timing, and when it is identified again that the working state parameter of the current injection molding machine is the first state parameter, the timing is stopped and the timing time is obtained, and then the timing time is compared with the first preset time threshold, the second preset time threshold and the third preset time threshold respectively. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator for sorting; if the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the manipulator for sorting, and the second control instruction includes the first preset quantity threshold for discarding defective products; if the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the manipulator for sorting, and the third control instruction includes the second preset quantity threshold for discarding defective products; At least one manipulator, each manipulator is installed at the sorting station at the output position of each injection molding machine and communicates with the above-mentioned main control device for data. The manipulator is used to move between the good product area and the defective product area at the sorting station under the control of the main control device, so as to sort the finished injection molded parts output by the processing device into the good product area or the defective product area; specifically, it is used to sort the finished injection molded parts successively output by the current injection molding machine into the good product area when receiving the first control instruction; or, when receiving the second control instruction, sort the first preset quantity threshold of the finished injection molded parts successively output by the current injection molding machine into the defective product area; or, when receiving the third control instruction, sort the second preset quantity threshold of the finished injection molded parts successively output by the current injection molding machine into the defective product area.

[0031] In some embodiments, the above-mentioned first abnormal state means that the injection molding machine is in a short-term temporary shutdown state, that is, the shutdown time reaches or exceeds the second preset time threshold (for example, 3 min); the above-mentioned second abnormal state means that the injection molding machine is in a long-term shutdown state, that is, the shutdown time reaches or exceeds the third preset time threshold (5 min). Preferably, for the same injection molding machine, the first preset quantity threshold is less than the second preset quantity threshold.

[0032] In some embodiments, the master device uses a single-chip microcomputer integrated on the robot arm, and the master device communicates with the injection molding machine through the integrated wireless communication module. Specifically, the master device includes: A data acquisition module for real-time acquisition of the working state parameters of each injection molding machine; A state recognition module for identifying the type of the working state parameters currently acquired by the data acquisition module; A trigger module for triggering the timer to start timing when the state recognition module first recognizes that the working state parameter of the current injection molding machine is the second state parameter, and stopping the timing and obtaining the timing time when it recognizes again that the working state parameter of the current injection molding machine is the first state parameter (that is, when it recognizes that the working state parameter of the current injection molding machine changes from the second state parameter to the first state parameter); An abnormality recognition module for comparing the above-mentioned timing time with a first preset time threshold, a second preset time threshold, and a third preset time threshold. If it is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the robot arm for sorting; if it reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the robot arm for sorting; if it reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is generated and sent to the robot arm for sorting.

[0033] In some embodiments, the above-mentioned second control instruction includes a first preset quantity threshold of defective products to be discarded obtained by pre-calculation; the third control instruction includes a second preset quantity threshold of defective products to be discarded obtained by pre-calculation.

[0034] In some embodiments, the master device further includes: a defective product mold times calculation module for obtaining the material consumption of a single injection molded part corresponding to the current injection molding machine when it is determined that the timing time reaches the second preset time threshold or the third preset time threshold, and calculating the defective product quantity threshold S = Q / Q0 corresponding to the current injection molding machine according to the material consumption Q of a single injection molded part and the total quantity Q of the melted raw materials that have deteriorated within the timing time T, for example, the above-mentioned first preset quantity threshold and second preset quantity threshold.

[0035] Generally, under the normal working condition of each injection molding machine, the temperature of the material pipe is the highest at the front nozzle of the barrel and the lowest at the rear end. Once the machine stops and continues for a period of time, the molten raw material in the material pipe will carbonize or denature, thus becoming waste. The transformation of the molten raw material into waste is related to its temperature and the duration of the machine stop, and there is a minimum denaturation temperature and a minimum duration. For example, when the temperature of the material pipe is higher than the minimum denaturation temperature and the shutdown time of the injection molding machine exceeds the minimum duration, the molten raw material in the material pipe will become waste. Therefore, within this minimum duration t0, the molten raw material will not become waste, so this minimum duration t0 is taken as the first preset time threshold. However, once the minimum duration is exceeded and the temperature of the material pipe is higher than the minimum denaturation temperature, a certain number of injection molded parts need to be discarded to remove the waste in the material pipe.

[0036] Specifically, the total volume of the molten raw material in the material pipe whose temperature exceeds the minimum denaturation temperature is Q (which can be obtained from the working state parameters of the injection molding machine), and the volume of good material consumed by the injection molding machine to produce a single injection molded part is Q0. When T > t0, S = Q / Q0 molds need to be discarded to remove the waste in the material pipe.

[0037] Furthermore, when the duration of the machine stop exceeds the third preset time threshold, the total volume V of the molten raw material in the material pipe will all become waste. Therefore, S = V / Q0 molds need to be discarded to remove the waste in the material pipe.

[0038] Embodiment 2: The present invention also provides a defective product detection device. Specifically, it includes: A timer for timing; A wireless communication module for performing data communication with each injection molding machine to obtain the working state parameters of each injection molding machine; A state recognition module for identifying the type of the working state parameters obtained by the wireless communication module; wherein, the type of the working state parameters includes: a first state parameter indicating that the injection molding machine is in a normal state; a second state parameter indicating that the injection molding machine is in a shutdown state (i.e., an abnormal state); A trigger module for triggering the timer to start timing when the state recognition module first recognizes that the working state parameter of the current injection molding machine is the second state parameter, and stopping the timing to obtain the timing time T when it recognizes again that the working state parameter of the current injection molding machine is the first state parameter; Anomaly recognition module, configured to compare the above-mentioned timing time with a first preset time threshold, a second preset time threshold, and a third preset time threshold. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the robot. If the timing time reaches the second preset time threshold, it is determined that the current injection molding machine is in a first abnormal state, and a second control instruction is generated and sent to the robot. If the timing time reaches the third preset time threshold, it is determined that the current injection molding machine is in a second abnormal state, and a third control instruction is sent to the robot.

[0039] In some embodiments, the second control instruction includes a first preset quantity threshold for discarding defective products; the third control instruction includes a second preset quantity threshold for discarding defective products.

[0040] In some embodiments, the defective product detection device further includes: a defective product mold count module, configured to, when it is determined that the timing time reaches the second preset time threshold or the third preset time threshold, obtain the material consumption of a single injection molded part corresponding to the current injection molding machine (the material consumption of a single injection molded part is one of the working state parameters of the injection molding machine), and calculate the defective product quantity threshold corresponding to the current injection molding machine (i.e., the first preset quantity threshold or the second preset quantity threshold) according to the material consumption of a single injection molded part and the timing time.

[0041] Embodiment 3: Refer to Figure 2 , which is a flowchart of a defective product sorting method according to an exemplary embodiment of the present invention. Specifically, the defective product sorting method includes the steps: S101, obtain the working state parameters of each injection molding machine in real time.

[0042] In some embodiments, the working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state, and a second state parameter indicating that the injection molding machine is in an abnormal state (for example, a shutdown state caused by a fault or other reasons).

[0043] S103, identify the type of the working state parameter. If it is the first state parameter, execute step S109a; or, when it is first determined that the type of the working state parameter of the current injection molding machine is the second state parameter, execute step S105.

[0044] S105, trigger the timer to start timing, and when it is again identified that the working state parameter of the current injection molding machine is the first state parameter, stop timing and obtain the timing time, and execute step S107.

[0045] S107. Compare the above-mentioned timing times with a first preset time threshold, a second preset time threshold, and a third preset time threshold respectively. If it is less than the first preset time threshold, execute step S109a. If it reaches the second preset time threshold (that is, greater than or equal to the second preset time threshold and less than the third preset time threshold), execute step S109b. If it reaches the third preset time threshold (that is, greater than or equal to the third preset time threshold), execute step S109c.

[0046] S109a. Determine that the current injection molding machine is in a normal state, generate a first control instruction and send it to the manipulator, and execute step S111a.

[0047] Generally, when the first state parameter is continuously received, it indicates that the injection molding machine is in a normal state; or, although the second state parameter is received within a short period of time, it does not last for a long time, indicating that the corresponding abnormal situation may have been eliminated and will not affect the injection molding process, or it may be a temporary abnormality caused by equipment aging or other reasons, and this type of abnormality will not affect the injection molding process and will not produce defective products naturally.

[0048] S109b. Determine that the current injection molding machine is in a first abnormal state, generate a second control instruction and send it to the manipulator, and execute step S111b.

[0049] S109c. Determine that the current injection molding machine is in a second abnormal state, generate a third control instruction and send it to the manipulator, and execute step S1111c.

[0050] In some embodiments, the first control instruction includes a first preset quantity threshold of the number of defective products expected to be produced by the injection molding machine in the first abnormal state. Specifically, the first preset quantity threshold is calculated based on the material consumption of a single injection molded part by the current injection molding machine and the above-mentioned timing time T.

[0051] In some embodiments, the second control instruction includes a second preset quantity threshold of the number of defective products expected to be produced by the injection molding machine in the second abnormal state. Specifically, the second preset quantity threshold is calculated based on the material consumption of a single injection molded part by the current injection molding machine and the above-mentioned timing time T. Generally, for the same injection molding machine, the duration of the second abnormal state is longer than that of the first abnormal state. Therefore, the calculated second preset quantity is greater than the first preset quantity threshold. For example, see Figure 3a and Figure 3b , different injection molding machines have different material consumptions for a single injection molded part, and / or different durations of abnormal states. Therefore, the calculated quantity thresholds of defective products are different.

[0052] S111a: When the robot arm receives the first control instruction, it sorts the continuously output finished injection molded parts of the current injection molding machine to the defective product area until the working state parameter of the current injection molding machine is identified as the second state parameter again in step S103, and then step S105 is executed.

[0053] S111b: When the robot arm receives the second control instruction, it sorts the continuously output finished injection molded parts of the current injection molding machine to the defective product area until the sorting count reaches the first preset quantity threshold.

[0054] S111c: When the robot arm receives the third control instruction, it sorts the continuously output finished injection molded parts of the current injection molding machine to the defective product area until the sorting count reaches the second preset quantity threshold.

[0055] It should be noted that in this article, the terms "include", "comprise" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the phrase "including one..." does not exclude the existence of additional identical elements in the process, method, article or device including that element.

[0056] Through the description of the above embodiments, those skilled in the art can clearly understand that the above-described embodiment methods can be implemented by means of software plus a necessary general hardware platform. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation. Based on such an understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disc) and includes several instructions for causing a computer terminal (which can be a mobile phone, computer, server, or network device, etc.) to execute the methods described in various embodiments of the present invention.

[0057] The embodiments of the present invention have been described above in conjunction with the accompanying drawings. However, the present invention is not limited to the above specific embodiments. The above specific embodiments are merely illustrative and not restrictive. Under the inspiration of the present invention, those of ordinary skill in the art can also make many forms without departing from the purpose of the present invention and the scope protected by the claims. These all fall within the protection scope of the present invention.

Claims

1. A defective product detection system for a laptop mold, characterized in that, it includes: At least one injection molding machine, which is used to process the injection molded parts of the laptop mold and output the finished injection molded parts of the laptop mold; The master control device communicates with the at least one injection molding machine for data, and is used to obtain the working state parameters of the injection molding machine in real time and identify the types of the working state parameters. When it first identifies that the working state parameter of the current injection molding machine is the second state parameter, it triggers a timer to start timing. And when it identifies the first state parameter of the current injection molding machine again, it stops timing and obtains the timing time, and then compares the timing time with a first preset time threshold, the time of 3 minutes when the internal part of the material tube becomes waste, and the time of 5 minutes when all the materials in the material tube become waste respectively. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator for sorting; if the timing time exceeds the second preset time threshold, it is determined that the current injection molding machine is in a short-term temporary shutdown state, and a second control instruction is generated and sent to the manipulator for sorting; the second control instruction includes a first preset quantity threshold S1 for discarding defective products; if the timing time exceeds the third preset time threshold, it is determined that the current injection molding machine is in a long-term shutdown state, and a third control instruction is generated and sent to the manipulator for sorting; the third control instruction includes a second preset quantity threshold S2 for discarding defective products; wherein, the first state parameter refers to the temperature at the nozzle at the front end of the material tube of the injection molding machine being lower than the lowest denaturation temperature; the second state parameter refers to the temperature at the nozzle at the front end of the material tube of the injection molding machine being higher than the lowest denaturation temperature; the first preset time threshold refers to the minimum continuous duration of the shutdown of the injection molding machine; the first preset time threshold is less than 3 minutes; S1 = Q / Q 0 , S2 = V / Q 0 ; wherein, Q 0 is the material consumption of a single injection molded part corresponding to the current injection molding machine, Q is the total amount of the melted raw materials in the material tube of the current injection molding machine whose temperature exceeds the lowest denaturation temperature; V is the total amount of the melted raw materials in the material tube; At least one manipulator, each of which is installed at the sorting station at the output position of each injection molding machine and communicates with the main control device for data. The manipulator is used to move between the good product area and the defective product area at the sorting station under the control of the main control device, so as to sort the finished injection molded parts output by the processing equipment into the good product area or the defective product area. Specifically, when the manipulator receives the first control instruction, it sorts the finished injection molded parts output by the corresponding injection molding machine into the good product area; or, when it receives the second control instruction, it sorts the first preset quantity threshold of the finished injection molded parts output by the corresponding injection molding machine into the defective product area; or, when it receives the third control instruction, it sorts the second preset quantity threshold of the finished injection molded parts output by the corresponding injection molding machine into the defective product area.

2. The defective product detection system according to claim 1, characterized in that, The types of the working state parameters include the first state parameter and the second state parameter, where the first state parameter represents that the injection molding machine is in a normal state; the second state parameter represents that the injection molding machine is in an abnormal state; and / or, The first preset quantity threshold is less than the second preset quantity threshold.

3. The defective product detection system according to claim 2, characterized in that, The main control device includes: A data acquisition module, which is used to acquire the working state parameters of each injection molding machine in real time; A state recognition module, which is used to recognize the types of the working state parameters of each injection molding machine; A trigger module, which is used to trigger the timer to start timing when the state recognition module first recognizes that the working state parameter of the current injection molding machine is the second state parameter, and stop timing and obtain the timing time when it recognizes again that the working state parameter of the current injection molding machine is the first state parameter; An abnormality recognition module, which is used to compare the timing time with the first preset time threshold, the time of 3 minutes when the internal part of the material pipe becomes waste, and the time of 5 minutes when all the materials in the material pipe become waste, and when it judges that the timing time is less than the first preset time threshold, it determines that the current injection molding machine is in a normal state, generates the first control instruction and sends it to the manipulator; or when it judges that the timing time exceeds 3 minutes, it determines that the current injection molding machine is in a short-term temporary shutdown state, generates the second control instruction and sends it to the manipulator; or, when it judges that the timing time exceeds 5 minutes, it determines that the current injection molding machine is in a long-term shutdown state, generates the third control instruction and sends it to the manipulator.

4. The defective product detection system according to claim 3, characterized in that, The main control device uses a single-chip microcomputer integrated on the manipulator, and the main control device communicates with the injection molding machine through the integrated wireless communication module.

5. A defective product detection device, It is characterized in that including: a timer for timing; a wireless communication module for performing data communication with multiple injection molding machines to obtain the working state parameters of each of the injection molding machines; a state recognition module for recognizing the types of the working state parameters obtained by the wireless communication module; the types of the working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state; a second state parameter indicating that the injection molding machine is in an abnormal state; the first state parameter means that the temperature at the nozzle at the front end of the material pipe of the injection molding machine is lower than the lowest denaturation temperature; the second state parameter means that the temperature at the nozzle at the front end of the material pipe of the injection molding machine is higher than the lowest denaturation temperature; a trigger module for triggering the timer to start timing when the state recognition module first recognizes that the working state parameter of the current injection molding machine is the second state parameter, and stopping timing when the working state parameter of the current injection molding machine is recognized as the first state parameter again to obtain the timing time; an abnormal recognition module for comparing the timing time with a first preset time threshold, the time of 3 minutes when part of the material in the material pipe becomes waste, and the time of 5 minutes when all the material in the material pipe becomes waste. If the timing time is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator; if the timing time exceeds 3 minutes, it is determined that the current injection molding machine is in a short-term temporary shutdown state, and a second control instruction is generated and sent to the manipulator; if the timing time exceeds 5 minutes, it is determined that the current injection molding machine is in a long-term shutdown state, and a third control instruction is generated and sent to the manipulator; Among them, the second control instruction includes a first preset quantity threshold S1 for discarding defective products, where S1 = Q / Q 0 , ; the third control instruction includes a second preset quantity threshold S2 for discarding defective products, where S2 = V / Q 0 ; the first preset time threshold refers to the minimum continuous duration of the injection molding machine being out of operation; the first preset time threshold is less than the second preset time threshold, and the second preset time threshold is less than 3 min; where Q 0 is the material consumption of a single injection molded part corresponding to the current injection molding machine, Q is the total amount of the molten raw material in the material pipe of the current injection molding machine whose temperature exceeds the lowest denaturation temperature; V is the total amount of the molten raw material in the material pipe.

6. A method for sorting defective products of a laptop mold It is characterized in that including the steps of: obtaining the working state parameters of each injection molding machine in real time; the working state parameters include: a first state parameter indicating that the injection molding machine is in a normal state, and a second state parameter indicating that the injection molding machine is in an abnormal state; the first state parameter means that the temperature at the nozzle at the front end of the material pipe of the injection molding machine is lower than the lowest denaturation temperature; the second state parameter means that the temperature at the nozzle at the front end of the material pipe of the injection molding machine is higher than the lowest denaturation temperature; the abnormal state includes: short-term temporary shutdown and long-term shutdown state; when the second state parameter is first recognized, triggering the timer to start timing, and when the first state parameter is recognized again, stopping timing to obtain the timing time T; and comparing the timing time T with a first preset time threshold, the time of 3 minutes when part of the material in the material pipe becomes waste, and the time of 5 minutes when all the material in the material pipe becomes waste; wherein, the first preset time threshold is the minimum continuous time of the shutdown of the injection molding machine; the first preset time threshold is less than 3 minutes; if the timing time T is less than the first preset time threshold, it is determined that the current injection molding machine is in a normal state, and a first control instruction is generated and sent to the manipulator corresponding to the current injection molding machine; If the timing time T exceeds the 3 minutes, it is determined that the current injection molding machine is in short-term temporary shutdown, and a second control instruction is generated and sent to the robot corresponding to the current injection molding machine, so that when the robot starts to receive the second control instruction, the first preset quantity threshold of the injection molded product finished products successively output by the current injection molding machine are sorted into the defective product area; the second control instruction includes the first preset quantity threshold S1 = Q / Q of the defective products to be discarded 0 , where Q 0 is the material consumption of a single injection molded product corresponding to the current injection molding machine, and Q is the total amount of the molten raw material whose temperature in the material pipe of the current injection molding machine exceeds the lowest denaturation temperature; If the timing time T exceeds 5 minutes, it is determined that the current injection molding machine is in a long-term shutdown state, and a third control instruction is generated and sent to the robot corresponding to the current injection molding machine, so that when the robot starts to receive the third control instruction, the second preset quantity threshold of the injection molded product finished products successively output by the current injection molding machine are sorted into the defective product area; the third control instruction includes the second preset quantity threshold S2 = V / Q of the defective products to be discarded 0 , where Q 0 is the material consumption of a single injection molded product corresponding to the current injection molding machine, and V is the total amount of the molten raw material in the material pipe.

7. The defective product sorting method according to claim 6 It is characterized in that For the same injection molding machine, the first preset quantity threshold is less than the second preset quantity threshold.

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