Full-automatic boxing device of injection molding machine

Abstract

The invention relates to the technical field of injection molding product boxing, in particular to a full-automatic boxing device of an injection molding machine, comprising: a conveying module comprising a conveying belt for conveying products and a first visual detector; the arrangement module comprises a temporary storage table used for displaying to-be-boxed products, a mechanical arm used for stably placing the products output by the conveying belt to the temporary storage table and a second visual detector used for detecting the product defect degree of the to-be-boxed products; the boxing module comprises a box body positioning platform used for supporting a box body to be boxed and a mechanical structure used for arranging the products to be boxed into the box body to be boxed; and the control module is used for obtaining the length of the stacked products and determining the obtaining frequency of the defect degree of the products when the boxing effectiveness is insufficient, or determining the conveying power of the conveying belt according to the jamming frequency of the mechanical arm. The boxing effectiveness and continuity of the boxing device are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of packing injection products, and particularly to a full-automatic packing device for an injection molding machine. Background Art

[0002] During the production process of an injection molding machine, it is necessary to pack and remove the injection molded products (materials) from the injection molding machine using a material frame. In the prior art, the general conveying process is to place an empty material frame at the discharge port of the injection molding machine, load the injection molded products into the material frame from the discharge port, then remove the material frame and place a new empty material frame. However, the production of the injection molding material continues. Due to the time interval between removing and placing a new empty material frame, this conveying method not only causes the accumulation of injection molded products in the injection molding machine, affecting the normal operation of the injection molding machine, but also results in a low conveying efficiency of the injection molded products, and cannot well ensure the continuous working state of the injection molding machine and the material frame conveying equipment. There is no high-efficiency cooperation and coordinated work between the injection molding machine and the material frame conveying equipment, ultimately resulting in a relatively increased production cost, further reduced production efficiency and equipment utilization rate.

[0003] Chinese Patent Publication No.: CN107235165B discloses a full-automatic packing device for an injection molding machine, including an injection molding machine body, characterized in that: the full-automatic packing device for the injection molding machine further includes a packing mechanism and a transplanting mechanism. The packing mechanism is located on the side of the injection molding machine body, and the transplanting mechanism is fixed on the injection molding machine body and close to the discharge port of the injection molding machine body. Thus, the full-automatic packing device for the injection molding machine has the following problems: the operation continuity of the device decreases due to inaccurate determination of the packing effectiveness reflected by the change value of the stacking length per unit time and the operation stability of the device reflected by the vibration frequency of the robotic arm. Summary of the Invention

[0004] Therefore, the present invention provides a full-automatic packing device for an injection molding machine to overcome the problem in the prior art that the operation continuity of the device decreases due to inaccurate determination of the packing effectiveness reflected by the change value of the stacking length per unit time and the operation stability of the device reflected by the vibration frequency of the robotic arm.

[0005] To achieve the above object, the present invention provides a full-automatic packing device for an injection molding machine, including a conveying module for conveying the products produced by the injection molding machine to the corresponding packing position, including a conveying belt for conveying the products and a first vision detector disposed on the conveying belt for obtaining the stacking length of the products on the conveying belt;

[0006] An arrangement module, which is connected to the conveying module, includes a buffer table for displaying products to be packed, a temperature sensor arranged on the buffer table for detecting the ambient temperature, a robotic arm arranged above the buffer table for stably placing the products output by the conveying belt onto the buffer table, a vibration sensor connected to the robotic arm for detecting the vibration frequency of the robotic arm, and a second vision detector arranged on the buffer table for detecting the degree of product defects of the products to be packed;

[0007] A packing module, which is connected to the arrangement module, is used for packing the products to be packed output by the arrangement module, and includes a box positioning platform for supporting the box to be packed, a mechanical structure arranged above the box positioning platform for arranging the products to be packed into the box to be packed, and a lifting platform connected to the box positioning platform for moving out the box after packing is completed;

[0008] A control module, which is respectively connected to the conveying module, the arrangement module, and the packing module, is used for obtaining the length of the stacked products, determining the acquisition frequency of the degree of product defects when the packing effectiveness is insufficient, or determining the transportation power of the conveying belt according to the jamming frequency of the robotic arm.

[0009] Further, the arrangement module further includes a weight sensor connected to the robotic arm for obtaining the weight, and the robotic arm and the mechanical structure automatically switch the grasping mode after obtaining the product weight.

[0010] Further, the packing module further includes:

[0011] A laser rangefinder, which is connected to the box positioning platform for obtaining the position of the box to be packed;

[0012] An automatic clamping device, which is connected to the box positioning platform for calibrating and clamping the box to be packed according to the position of the box to be packed located by the laser rangefinder.

[0013] Further, the mechanical structure includes,

[0014] A six-axis robotic arm, which is arranged on the box positioning platform,

[0015] A vacuum suction cup group, which is connected to the six-axis robotic arm for covering the surface of the products to be packed and performing negative pressure adsorption on the products to be packed.

[0016] Further, the control module monitors the length of the products stacked on the conveying belt, calculates the change value of the stacked length per unit time, and respectively compares the change value of the stacked length per unit time with a preset first change value and a preset second change value to respectively determine the working modes of the conveying module and the arrangement module.

[0017] Further, when the change value of the stacking length per unit time is greater than the preset first change value and less than or equal to the preset second change value, the control module determines that the packing effectiveness is insufficient and determines the acquisition frequency of the product defect degree.

[0018] Further, the acquisition frequency of the product defect degree is determined according to the change value of the ambient temperature.

[0019] Further, when the change value of the stacking length per unit time is greater than the preset second change value, the control module preliminarily determines that the operation stability of the device is lower than the allowable range and acquires the vibration frequency of the robotic arm.

[0020] Further, the control module determines the transportation power of the conveyor belt according to the vibration frequency of the robotic arm.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows. In the full-automatic packing device of the present invention, the conveying module is equipped with a vision detector to detect the stacking length of products on the conveyor belt in real time, ensuring uniform distribution of materials on the conveyor belt to avoid blockage and improving the continuity of production; the arranging module identifies product defects through the vision detector and combines the stable handling of the robotic arm to ensure that only qualified products enter the packing link, improving the product qualification rate and ensuring more orderly arrangement of products during buffering, which is beneficial to the subsequent packing link; the packing module uses a mechanical structure and a lifting table to cooperate to achieve high-speed and accurate packing; the control module determines the conveying power of the conveyor belt and the detection frequency of the vision detector according to the product stacking situation, optimizing the system stability to reduce the device downtime, and improving the packing effectiveness and continuity of the packing device.

[0022] Further, in the full-automatic packing device of the present invention, by calculating the change value of the stacking length per unit time and comparing it with the preset first and second change values, the system can predict product flow anomalies in advance. Since product stacking will increase the extrusion degree between products on the conveyor belt, the possibility of product defects will increase accordingly, which will affect the subsequent packing efficiency. The control module adjusts the working modes of the conveying module, the arranging module and the packing module through dynamic monitoring of real-time data, reducing human participation and shortening the downtime inspection time, and further improving the packing effectiveness and continuity of the packing device.

[0023] Further, in the full-automatic boxing device of the present invention, when the change value of the stacking length of products on the conveyor belt is between a preset first change value and a preset second change value, the control module determines that the boxing effectiveness is insufficient, and at this time, a dynamic adjustment mechanism for the defect detection frequency is automatically triggered. By real-time monitoring the degree of product defects, the system can accurately identify defective products, avoid defective products from flowing into the boxing link, thereby improving the overall boxing qualification rate and reducing rework and material waste; due to the influence of product stacking, the friction generated by the conveyor belt increases, and the heat generated is more likely to affect the integrity of the product when the robotic arm grabs the product. During the continuous operation of the device, by detecting the ambient temperature, when the temperature fluctuates greatly, the system automatically increases the detection frequency to ensure that defective products are promptly removed, guarantee the qualification rate of products, and further improve the boxing effectiveness and continuity of the boxing device through the dual judgment of ambient temperature and stacking state.

[0024] Further, in the full-automatic boxing device of the present invention, when the change value of the stacking length per unit time exceeds the preset second change value, the system can accurately determine that the operating stability of the device exceeds the allowable range, and promptly trigger the adjustment mechanism to effectively prevent the risk of system collapse caused by material stacking. This predictive control based on real-time data greatly reduces the equipment failure rate and unexpected downtime; due to the influence of product stacking, the friction generated by the conveyor belt increases, and the possibility of debris appearing due to the continuous operation of the device also increases. Debris will affect the device performance and reduce the operating stability of the device. By monitoring the vibration frequency of the robotic arm and adjusting the transportation power of the conveyor belt, the smooth operation of the device is ensured, and the boxing effectiveness and continuity of the boxing device are further improved. Description of the Drawings

[0025] Figure 1 It is a schematic diagram of the overall structure of the full-automatic boxing device of the injection molding machine according to the embodiment of the present invention;

[0026] Figure 2 It is a block diagram of the overall structure of the full-automatic boxing device of the injection molding machine according to the embodiment of the present invention;

[0027] Figure 3 It is a block diagram of the specific structure of the arrangement module of the full-automatic boxing device of the injection molding machine according to the embodiment of the present invention;

[0028] Figure 4 It is a block diagram of the specific structure of the boxing module of the full-automatic boxing device of the injection molding machine according to the embodiment of the present invention.

[0029] In the figure, 1, conveyor belt; 2, first vision detector; 3, robotic arm, 4, six-axis robotic arm; 5, vacuum suction cup group; 6, second vision detector; 7, laser rangefinder; 8, automatic clamping device; 9, lifting platform; 10, box body positioning platform; 11, temperature sensor; 12, buffer table. Detailed implementation manners

[0030] In order to make the objectives and advantages of the present invention more clearly understood, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0031] The preferred implementation manners of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these implementation manners are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0032] Please refer to Figure 1 、 Figure 2 、 Figure 3 and Figure 4 as shown, which are respectively the overall structural schematic diagram, overall structural block diagram, specific structural block diagram of the arrangement module, and specific structural block diagram of the packing module of the full-automatic packing device of the injection molding machine according to the embodiments of the present invention. A full-automatic packing device for an injection molding machine of the present invention includes:

[0033] A conveying module for conveying the products produced by the injection molding machine to the corresponding packing positions, including a conveying belt 1 for conveying products and a first vision detector 2 provided on the conveying belt 1 for obtaining the stacking length of the products on the conveying belt 1;

[0034] An arrangement module connected to the conveying module, including a buffer table 12 for displaying the products to be packed, a temperature sensor 11 provided on the buffer table 12 for detecting the ambient temperature, a robotic arm 3 provided above the buffer table 12 for smoothly placing the products output from the conveying belt 1 onto the buffer table 12, a vibration sensor (not shown in the figure) connected to the robotic arm 3 for detecting the vibration frequency of the robotic arm, and a second vision detector 6 provided on the buffer table 12 for detecting the product defect degree of the products to be packed;

[0035] A packing module connected to the arrangement module for packing the products to be packed output by the arrangement module, including a box body positioning platform 10 for supporting the box body to be packed, a mechanical structure provided above the box body positioning platform 10 for arranging the products to be packed into the box body to be packed, and a lifting platform 9 connected to the box body positioning platform 10 for moving out the box body after packing;

[0036] A control module respectively connected to the conveying module, the arrangement module, and the packing module for obtaining the stacking length of the products and determining the acquisition frequency of the product defect degree when the packing effectiveness is insufficient, or determining the transportation power of the conveying belt according to the vibration frequency of the robotic arm.

[0037] Specifically, the product stacking length is the length continuously covered by the product material on the conveyor belt 1 at the detection moment of the first vision detector 2. It can be understood that using a vision sensor to measure the product stacking length is a commonly used technical means by those skilled in the art, and will not be elaborated here.

[0038] For the fully automatic boxing device of the present invention, the conveying module is equipped with a vision detector to detect the product stacking length on the conveyor belt 1 in real time, ensuring uniform distribution of the materials on the conveyor belt to avoid blockage and improving the continuity of production; the arranging module identifies product defects through the vision detector, and combined with the stable handling of the robotic arm 3, ensures that only qualified products enter the boxing link, improving the product qualification rate while ensuring more orderly arrangement of products during caching, which is conducive to the subsequent boxing link; the boxing module uses a mechanical structure and a lifting table to cooperate to achieve high-speed and precise boxing; the control module determines the transportation power of the conveyor belt and the detection frequency of the vision detector according to the product stacking situation, optimizing the stability of the system to reduce the device downtime and improving the boxing effectiveness and continuity of the boxing device.

[0039] Please refer to Figure 1 As shown, the present invention is also provided with a sliding track (not marked in the figure) respectively connected to the robotic arm 3 and the mechanical structure to restrict the movement directions of the robotic arm 3 and the mechanical structure.

[0040] Specifically, the arranging module further includes a weight sensor (not shown in the figure) connected to the robotic arm 3 for obtaining the weight, and the robotic arm 3 and the mechanical structure automatically switch the grasping mode after obtaining the product weight.

[0041] Specifically, the boxing module further includes:

[0042] A laser rangefinder 7, which is connected to the box positioning platform 10 to obtain the position of the box to be boxed;

[0043] An automatic clamping device 8, which is connected to the box positioning platform 10 to calibrate and clamp the box to be boxed according to the position of the box to be boxed located by the laser rangefinder.

[0044] Specifically, the box positioning platform 10 is a platform with a certain inclination angle. When the boxing operation is completed, the automatic clamping device relaxes, and under the action of gravity, the box after boxing enters the lifting table to complete the blanking of the box.

[0045] Specifically, the mechanical structure includes,

[0046] A six-axis robotic arm 4, which is arranged on the box positioning platform 10,

[0047] The vacuum suction cup group 5 is connected to the six-axis robotic arm 4 and is used to cover the surface of the product to be boxed and perform negative pressure adsorption on the product to be boxed.

[0048] Specifically, the control module monitors the stacking length of the products on the conveyor belt 1, calculates the change value of the stacking length per unit time, and compares the change value of the stacking length per unit time with a preset first change value and a preset second change value respectively, and determines the working modes of the conveying module and the arranging module respectively.

[0049] Specifically, the calculation method of the change value of the stacking length per unit time is as follows:

[0050]

[0051] Wherein, A is the change value of the stacking length per unit time, L is the stacking length of the products on the conveyor belt 1 at the measurement moment, L0 is the stacking length of the products on the conveyor belt 1 at the previous measurement moment, and T is the measurement interval duration.

[0052] In implementation, the preset first change value and the preset second change value are obtained according to pre-tests or set according to production requirements. Preferably, a preset first change value A1 and a preset second change value A2 are provided here, A1 = 3 cm / min, A2 = 4.5 cm / min.

[0053] For the full-automatic boxing device of the present invention, by calculating the change value of the stacking length per unit time and comparing it with the preset first and second change values, the system can predict product flow anomalies in advance. Since product stacking will increase the extrusion degree between products on the conveyor belt 1, the possibility of product defects will increase accordingly, thereby affecting the subsequent boxing efficiency. The control module adjusts the working modes of the conveying module, the arranging module and the boxing module through dynamic monitoring of real-time data, reduces human participation and shortens the downtime inspection time, and further improves the boxing effectiveness and continuity of the boxing device.

[0054] Specifically, when the change value of the stacking length per unit time is greater than the preset first change value and less than or equal to the preset second change value, the control module determines that the boxing effectiveness is insufficient and determines the acquisition frequency of the product defect degree.

[0055] Specifically, the acquisition frequency of the product defect degree is determined according to the change value of the ambient temperature.

[0056] Specifically, the change value of the ambient temperature is:

[0057] X = C - C0

[0058] Wherein, X is the environmental temperature change value, C is the environmental temperature detected by the temperature sensor, and C0 is the preset room temperature.

[0059] In implementation, the present invention also sets a preset environmental temperature change value X0. The settings of the preset room temperature C0 and the preset environmental change value X0 are obtained based on several experimental tests or set according to production requirements. Preferably, the present invention provides a preset room temperature C0 and a preset environmental change value X0, where C0 = 22°C and X0 = 3°C.

[0060] If X ≥ X0, the control module adjusts the acquisition frequency H of the product defect degree to H' = H × α;

[0061] If X < X0, the control module adjusts the acquisition frequency H of the product defect degree to H' = H × β;

[0062] Wherein, α and β are respectively the preset first adjustment coefficient and the preset second adjustment coefficient set by the present invention. The values of α and β are the maximum and minimum values of the best experimental values obtained based on several experimental tests, and 1 < α < β.

[0063] For the fully automatic packing device of the present invention, when the change value of the stacking length of the products on the conveyor belt 1 is between the preset first change value and the preset second change value, the control module determines that the packing effectiveness is insufficient. At this time, the dynamic adjustment mechanism of the defect detection frequency is automatically triggered. By real-time monitoring the product defect degree, the system can accurately identify defective products, avoid defective products from flowing into the packing link, thereby improving the overall packing qualification rate and reducing rework and material waste; due to the influence of product stacking, the friction generated by the conveyor belt 1 increases, and the heat generated is more likely to affect the integrity of the products when the robotic arm 3 grabs the products. During the continuous operation of the device, by detecting the environmental temperature, the system automatically increases the detection frequency in the case of large temperature fluctuations to ensure that defective products are promptly removed and the qualification rate of the products is guaranteed. Through the dual judgment of the environmental temperature and the stacking state, the packing effectiveness and continuity of the packing device are further improved.

[0064] Specifically, when the change value of the stacking length per unit time is greater than the preset second change value, the control module preliminarily determines that the running stability of the device is lower than the allowable range and obtains the vibration frequency of the robotic arm.

[0065] Specifically, the control module determines the transportation power of the conveyor belt according to the vibration frequency of the robotic arm.

[0066] In implementation, the control module sets a preset first vibration frequency L1 and a preset second vibration frequency L2.

[0067] When U < U1, the control module determines not to adjust the transportation power of the conveyor belt, and the conveyor belt 1 operates at the original power;

[0068] When U1 ≤ U ≤ U2, the control module determines to adjust the transportation power of the conveyor belt;

[0069] When U2 < U, the control module determines a fault and issues a fault warning.

[0070] In implementation, the method for the control module to determine the transportation power of the conveyor belt is

[0071] If U1 ≤ U ≤ U2, adjust the transportation power P of the conveyor belt to P’ = P × ln(1 + e ε ), where ε < ln(e - 1).

[0072] In implementation, the preset first vibration frequency U1, the preset second vibration frequency U2, and the transportation power P of the conveyor belt are all obtained from several experiments or set according to production requirements. Preferably, a preset first vibration frequency U1, a preset second vibration frequency U2, and a transportation power P of the conveyor belt are provided here, where U1 = 22HZ, U2 = 28HZ, and P = 15kW.

[0073] For the full-automatic boxing device described in the present invention, when the change value of the stacking length per unit time exceeds the preset second change value, the system can accurately determine that the operation stability of the device exceeds the allowable range, trigger the adjustment mechanism in time, and effectively prevent the risk of system collapse caused by material accumulation. This predictive control based on real-time data greatly reduces the equipment failure rate and unexpected downtime; due to the influence of product accumulation, the friction generated by the conveyor belt 1 increases, and the possibility of debris appearing due to the continuous operation of the device also increases. The debris will affect the device performance and reduce the operation stability of the device. By monitoring the vibration frequency of the robotic arm and adjusting the transportation power of the conveyor belt, the smooth operation of the device is ensured, and further improvement of the boxing effectiveness and continuity of the boxing device is achieved.

[0074] So far, the technical solution of the present invention has been described in combination with the preferred embodiments shown in the drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the protection scope of the present invention.

Claims

1. A fully automatic boxing device for an injection molding machine, characterized in that, Including: A conveying module for conveying the products produced by an injection molding machine to the corresponding packing position, including a conveying belt for conveying products and a first vision detector arranged on the conveying belt for obtaining the stacking length of the products on the conveying belt; An arranging module connected to the conveying module, including a buffer table for arranging the products to be packed, a temperature sensor arranged on the buffer table for detecting the ambient temperature, a robotic arm arranged above the buffer table for stably placing the products output by the conveying belt onto the buffer table, a vibration sensor connected to the robotic arm for detecting the vibration frequency of the robotic arm, and a second vision detector arranged on the buffer table for detecting the product defect degree of the products to be packed; A packing module connected to the arranging module for packing the products to be packed output by the arranging module, including a box positioning platform for supporting the box to be packed, a mechanical structure arranged above the box positioning platform for arranging the products to be packed into the box to be packed, and a lifting platform connected to the box positioning platform for moving out the box after packing; A control module connected to the conveying module, the arranging module and the packing module respectively for obtaining the stacking length of the products, determining the acquisition frequency of the product defect degree of the second vision detector when the packing effectiveness is insufficient, or determining the transportation power of the conveying belt according to the jamming frequency of the robotic arm.

2. The fully automatic packing device of the injection molding machine according to claim 1, characterized in that, The arranging module further includes a weight sensor connected to the robotic arm for obtaining the weight, and the robotic arm and the mechanical structure automatically switch the grasping mode after obtaining the product weight.

3. The fully automatic packing device of an injection molding machine according to claim 2, wherein, The packing module further includes: A laser rangefinder connected to the box positioning platform for obtaining the position of the box to be packed; An automatic clamping device connected to the box positioning platform for calibrating and clamping the box to be packed according to the position of the box to be packed located by the laser rangefinder.

4. The fully automatic packing device for an injection molding machine according to claim 3, characterized in that, The mechanical structure includes: A six-axis robotic arm arranged on the box positioning platform; A vacuum suction cup group connected to the six-axis robotic arm for covering the surface of the products to be packed and performing negative pressure adsorption on the products to be packed.

5. The fully automatic packing device for an injection molding machine according to claim 4, characterized in that, The control module monitors the stacking length of the products on the conveying belt, calculates the change value of the stacking length per unit time, and compares the change value of the stacking length per unit time with a preset first change value and a preset second change value respectively to determine the working modes of the conveying module and the arranging module respectively.

6. The fully automatic packing device of an injection molding machine according to claim 5, characterized in that, When the change value of the stacking length per unit time is greater than the preset first change value and less than or equal to the preset second change value, the control module determines that the packing effectiveness is insufficient and determines the acquisition frequency of the product defect degree.

7. The fully automatic packing device of the injection molding machine according to claim 6, characterized in that, The acquisition frequency of the product defect degree is determined according to the change value of the ambient temperature.

8. The fully automatic packing device of an injection molding machine according to claim 7, characterized in that, When the change value of the stacking length per unit time is greater than the preset second change value, the control module preliminarily determines that the operation stability of the device is lower than the allowable range and obtains the vibration frequency of the robotic arm.

9. The fully automatic packing device for an injection molding machine according to claim 8, characterized in that, The control module determines the transportation power of the conveyor belt according to the vibration frequency of the robotic arm.

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