Monitoring device

Abstract

To reduce the monitoring timing of sprue runners taken out of a mold and stored in an accommodation box.SOLUTION: A monitoring device comprises: an image capturing unit for capturing an image of a container that accommodates sprue runners taken out from a mold, and the inside of the container in which the sprue runners are accommodated; an information processing unit for determining an accumulation quantity of sprue runners inside the container on the basis of an accumulation state of the sprue runners taken in an image captured by the image capturing unit; a notification unit of, when it is determined by the information processing unit that the accumulation quantity reaches a predetermined quantity, notifying thereof. The information processing unit applies binarization processing to the image using a threshold value set according to a color of the sprue runners and the background to convert a whole image into a black and white image, and determines the accumulation quantity using a ratio of black to the whole.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a monitoring device. [Background technology]

[0002] A known device for confirming product drop for an injection molding machine includes a pattern detection means for detecting the pattern on the mold parting surface of a mold fixed to a movable platen, and a pattern comparison means for comparing the detected pattern from the pattern detection means with a set pattern, and detects that a molded product has been removed from the mold based on a matching output from the pattern comparison means (Patent Document 1).

[0003] A processing device is also known that has a processing section for performing a predetermined process on an injection molded product having a detectable portion, the processing device being provided with an injection molded product placement section on which the injection molded product is placed, a transport device that displaces the injection molded product placed in the injection molded product placement section in the rotational direction and transports it in the left-right and front-back directions, a product part placement section that is provided at or near the processing section and for placing a product part in the injection molded product, an image processing device that is provided near the transport path of the transport device and photographs the detectable part of the injection molded product transported by the transport device, and a control device that determines the deviation angle of the product part from a standard position from an image taken by the image processing device, controls the transport device based on the deviation angle to rotate the injection molded product and correct the deviation angle of the product part, and determines the distance between the position of the product part and the product part placement section from the image taken by the image processing device, and controls the transport device based on the distance to transport the injection molded product from the image taking position to the processing section and position the product part in the product part placement section (Patent Document 2). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Unexamined Patent Publication No. 62-108020 [Patent Document 2] JP 2003-181887 A Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention reduces the need to monitor the spool runner once it has been removed from the mold and stored in a container. [Means for solving the problem]

[0006] In order to solve the above problem, the monitoring device according to claim 1 comprises: an imaging unit that captures an image of the inside of a container that contains the spool runner to be removed from the die; an information processing unit that determines an amount of the spool runners accumulated in the container based on a state of the spool runners captured in an image by the imaging unit; and a notification unit that notifies the user when the information processing unit determines that the deposition amount has reached a predetermined amount. It is characterized by:

[0007] The invention described in claim 2 is the monitoring device described in claim 1, the information processing unit performs a binarization process on the image using a threshold value set according to the color of the spool runner and the background, converts the entire image into a black and white image, and determines the amount of deposition in the spool runner based on the ratio of black to the entire image. It is characterized by:

[0008] The invention described in claim 3 is a monitoring device type according to claim 1 or 2, The apparatus further includes a background panel disposed in the container rearward with respect to the imaging unit and forming a background of the spool runner as viewed from the imaging unit. It is characterized by:

[0009] The invention described in claim 4 is the monitoring device type described in claim 3, the background panel being a different color than the spool runner; It is characterized by:

[0010] The invention described in claim 5 is the monitoring device described in claim 1, the notification unit transmits an alert message together with the captured image to a mobile terminal carried by an observer observing the spool runner in the container. It is characterized by: Effect of the Invention

[0011] According to the invention recited in claim 1, it is possible to reduce the frequency of monitoring the spool runner which has been removed from the mold and stored in the container.

[0012] According to the invention recited in claim 2, accumulation on the spool runner can be reliably detected.

[0013] According to the invention as recited in claim 3, the spool runner can be detected more clearly.

[0014] According to the invention as recited in claim 4, the spool runner can be detected more clearly.

[0015] According to the invention as recited in claim 5, the accumulation state of the spool runner can be notified in an intuitive and easy-to-understand manner. [Brief description of the drawings]

[0016] [Figure 1] FIG. 2 is a functional block diagram showing an example of a monitoring device according to the present embodiment. [Diagram 2] 1 is a schematic diagram showing an example of the configuration of an injection molding system to which a monitoring device according to an embodiment of the present invention is applied; [Diagram 3] FIG. 1A is a schematic partial cross-sectional view showing a mold K for molding a green body and the green body inside the mold, and FIG. 1B is a view for explaining separation of a spool runner. [Figure 4] FIG. 1A is a diagram showing an example of a captured image, and FIG. 1B is a diagram showing an example of a captured image that has been binarized. [Diagram 5] FIG. 13 is a diagram showing an example of a captured image in which a background panel is installed. [Figure 6]FIG. 13 is a diagram illustrating an example of an alert message displayed on the mobile terminal. [Figure 7] FIG. 11 is a flowchart showing a flow of a detection process for estimating a deposition state of the spool runner in the container in the monitoring device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Next, specific examples of the embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to the following embodiments. In the following explanation using the drawings, it should be noted that the drawings are schematic and the ratios of the dimensions, etc. may differ from the actual ones, and in order to facilitate understanding, illustrations other than those of components necessary for the explanation have been omitted as appropriate.

[0018] (1) Injection molding system First, an injection molding system 100 and a spool runner SR to which a monitoring device 1 according to this embodiment is applied will be described with reference to the drawings. FIG. 2 is a schematic diagram showing an example configuration of the injection molding system 100, FIG. 3(a) is a partial cross-sectional schematic diagram showing a mold K for molding the molded body S and the molded body S within the mold K, and FIG. 3(b) is a diagram explaining the separation of the spool runner SR. The injection molding system 100 includes an injection molding machine 110, a removal device 120 that removes the molded body S from the mold K, and a container 130 that stores the spool runner SR removed from the mold K.

[0019] The injection molding machine 110 includes at least a mold clamping unit 111, an injection unit 112, a movable mold K1, a fixed mold K2, and a control unit 113. The clamping unit 111 clamps the mold by moving the movable mold K1 closer to the fixed mold K2. The injection unit 112 fills a cavity CA (see FIG. 3(a)) formed between the clamped movable mold K1 and fixed mold K2 with molten resin used to mold the molded body S. After the molten resin filled in the cavity CA has solidified, the clamping unit 111 moves the movable mold K1 away from the fixed mold K2 to open the mold.

[0020] 3(a), the molded body S has a molded body main body S1 and a spool runner SR. The spool runner SR is made up of a spool SR1 and a runner SR2. The spool SR1 extends in the movement direction of the movable mold K1 (see arrow R1 in Figure 3(a)), and its diameter gradually increases from the nozzle side to the intersection with the runner SR2, and the diameter is the same from the intersection with the runner SR2 to the bottom end. The runners SR2 extend radially outward from the spool SR1 as a center, and are provided at intervals in the circumferential direction. The radially outer ends of the runners SR2 are connected to the molded body S1 before the molded body S is ejected from the movable die K1, and are separated from the molded body S1 after the molded body S is ejected from the movable die K1.

[0021] The removal device 120 has a slide guide 121, moving parts 122 and 123, and a removal part 124. The slide guide 121 extends in a horizontal direction intersecting with the moving direction of the movable mold K1, and guides the movement of the moving part 122 in the horizontal direction (see arrow R2 in FIG. 2). The moving part 123 is vertically movable with respect to the moving part 122. The moving section 122 moves the moving section 123 and the removal section 124 horizontally by the guide of the slide guide 121, and the removal section 124 is capable of moving horizontally between a removal position above the movable mold K1 and a position (open position) outside the injection molding machine 110 where the removal section 124 separates from the movable mold K1 and releases the molded body S1 and the spool runner SR. Note that the removal device 120 is not particularly limited to the above configuration as long as it includes the removal section 124, removes the molded body S1 and the spool runner SR from the opened movable mold K1, and transports the gripped spool runner SR to the container 130.

[0022] 3(b), the ejector pin EP1, which is movably arranged in the movable mold K1, moves toward the fixed mold K2, and the molded body S is simultaneously ejected from the movable mold K1 and gate-cut, and separated into a molded body main body S1 and a spool runner SR. The molded body main body S1 separated by gate-cut is held in the removal section 124, and the spool runner SR separated by gate-cut is moved to the fixed mold K2 side by the movement of the ejector pin toward the fixed mold K2 and is held by the removal section 124. When the removal section 124 holds the molded body S1 and holds the spool runner SR, it retreats outside the injection molding machine 110 and moves above the container 130, dropping the spool runner SR into the container 130.

[0023] (2) Overall configuration of the monitoring device FIG. 1 is a functional block diagram showing an example of a monitoring device 1 according to the present embodiment. The monitoring device 1 is configured to include an imaging unit 10 that captures an image of the inside of a container 130 that contains the spool runner SR removed from the mold K, an information processing unit 20 that judges the amount of deposition in the container 130 based on the deposition state of the spool runner SR shown in the image captured by the imaging unit 10, and a notification unit 30 that notifies the information processing unit 20 that the deposition amount has reached a predetermined amount, and monitors the deposition state of the spool runner SR in the container 130. When the deposition amount reaches the predetermined amount, the notification is made together with an image, thereby reducing the number of times to monitor the spool runner SR. In this embodiment, the container 130 may be a dust box that contains waste plastics, a crusher that crushes waste plastics, or a flexcon bag that is a bag-shaped packaging material for temporarily storing and transporting waste plastics.

[0024] In the monitoring device 1, the operation control and processing control of the imaging unit 10, the information processing unit 20, and the notification unit 30 are realized by, for example, a general computer in which a processor consisting of a CPU (Central Processing Unit), a ROM (Read Only Memory), and a RAM (Random Access Memory) executes a predetermined program. In this embodiment, the control can be performed using a Raspberry Pi (registered trademark), which is a single-board computer equipped with an ARM processor, but is not limited to the Raspberry Pi.

[0025] (Imaging unit) The imaging unit 10 captures an image of the spool runner SR in the container 130 from diagonally above or from the side. The imaging unit 10 can be fixedly installed, for example, on the frame of the container 130, and in this embodiment, as shown in Fig. 2, the imaging unit 10 is installed so as to be located above an upper opening of the container 130 that receives the spool runner SR.

[0026] The imaging unit 10 is configured with a camera equipped with a CCD image sensor as an imaging device and an imaging condition adjustment function for adjusting optical conditions such as the angle of view and exposure, and captures still images or videos. In the case of capturing a video, still images extracted at regular time intervals are cut out. As for the camera, as long as it has the resolution etc. required for judgment by the information processing unit 20 and has the function of sending the captured image to the information processing unit 20 as digital data, it may be a dedicated photographing device, or it may be a general-purpose photographing device that is generally available as a peripheral device for personal computers, such as a USB camera, a web camera, or a network camera.

[0027] Further, although one imaging unit 10 is used in this embodiment, multiple imaging units 10 may be installed. The multiple imaging units 10 may separately image the spool runner SR in the container 130 (partial overlapping images may be taken), or each of the multiple imaging units 10 may image the entire inside of the container 130 from a different angle. Images captured by the multiple imaging units 10 may be synthesized to form a single image of the entire inside of the container 130, for example.

[0028] (Information Processing Department) The information processing unit 20 acquires the captured image captured by the imaging unit 10. The information processing unit 20 acquires the captured image from the imaging unit 10, for example, by wirelessly communicating with the imaging unit 10. Examples of wireless communication methods include Wi-Fi (registered trademark), Bluetooth (registered trademark), and ZigBee (registered trademark). The information processing unit 20 may acquire the captured image from the imaging unit 10 by communicating with the imaging unit 10 via a wired connection.

[0029] The information processing unit 20 may acquire a captured image from the imaging unit 10 by communicating with the imaging unit 10 via a network, for example. The network may include, for example, the Internet and a LAN (Local Area Network). The network may also include a mobile communication network. The mobile communication network may conform to, for example, any of the following communication methods: 3G (3rd Generation) communication method, LTE (Long Term Evolution) communication method, 5G (5th Generation) communication method, and 6G (6th Generation) communication method or later.

[0030] The information processing unit 20 determines the amount of deposition in the container 130 based on the deposition state of the spool runner SR shown in the captured image obtained from the imaging unit 10. Specifically, the information processing unit 20 performs binarization processing on the captured image using a threshold value Th1 set according to the color and background of the spool runner SR to convert the entire image into a black and white image, and determines the amount of deposition of the spool runner based on the ratio of black to the entire image.

[0031] In the binarization process, the pixel value of each pixel in the captured image is set to 0 or 1, with a predetermined threshold value Th1 as the boundary. For example, if the luminance value is equal to or greater than the predetermined threshold value Th1, the pixel value of the pixel is set to "1" (e.g., white), and if the luminance value is less than the threshold value Th1, the pixel value of the pixel is set to "0" (e.g., black). The threshold value Th1 for the binarization process uses the brightness values ​​of the inner surface of the container 130 and the storage bag BG placed in the container 130. The brightness values ​​of the inner surface of the container 130 and the storage bag BG may be measured in advance or may be estimated from a captured image.

[0032] FIG. 4(a) is a diagram showing an example of a captured image, and FIG. 4(b) is a diagram showing an example of a captured image that has been binarized. In this embodiment, since the detection target is the spool runner SR, which is an absorbent, pixel values ​​greater than the threshold value Th1 for the binarization process are set to "1," and pixel values ​​equal to or less than the threshold value Th1 for the binarization process are set to "0." As a result, the pixel values ​​of the inner surface of the storage box 130 and the area of ​​the storage bag BG become 1 (e.g., white), and the pixel values ​​of the area of ​​the spool runner SR become 0 (e.g., black). The threshold value Th1 for the binarization process may be a differential brightness value between the inner surface of the container 130 and the storage bag BG and the spool runner SR. When the color of the spool runner SR to be detected is not black but is a light color or close to white, the threshold value Th1 can be set based on the differential brightness value, making it possible to detect the area of ​​the spool runner SR close to the reflector.

[0033] FIG. 5 shows an example of a captured image in which a background panel P is installed. A background panel P may be installed on the container 130. The background panel P is disposed behind the container 130 with respect to the imaging unit 10, and forms a background for the spool runner SR contained in the container 130. Specifically, the background panel P has a color different from that of the spool runner SR, and the outline of the boundary between the background panel P and the spool runner SR to be detected becomes clearer, making it easier for the imaging unit 10 to detect it. When a background panel P is placed, the luminance value of the background panel P is used as the threshold value Th1 for the binarization process, so that the pixel value of the area of ​​the spool runner SR becomes 0 (e.g., black), allowing the spool runner SR to be detected more clearly.

[0034] The information processing unit 20 calculates the ratio of pixel values ​​of 0 (black) in the binarized captured image to the entire binarized captured image, and determines the amount of deposition of the spool runner SR in the container 130.

[0035] (Notification Department) FIG. 6 shows an example of an alert message displayed on the mobile terminal T. When the information processing unit 20 determines that the accumulation amount of spool runner SR in the container 130 has reached a predetermined amount, the notification unit 30 sends an alert message together with the captured image to a mobile terminal T held by a monitor monitoring the injection molding system 100. The notification unit 30 links the captured image to an SNS (Social Networking Service) account such as LINE (trademark) or Twitter (trademark) used by the monitor and sends an alert message together with the captured image. For example, as shown in FIG. 6, a message indicating that the accumulation amount in the spool runner SR has reached a predetermined threshold is displayed on the LINE chat screen along with the captured image.

[0036] (3) Detection process of monitoring device 7 is a flowchart showing the flow of a detection process for estimating the accumulation state of the spool runner SR in the container 130 in the monitoring device 1. Hereinafter, the detection process for estimating the accumulation state of the spool runner SR in the container 130 in the monitoring device 1 according to this embodiment will be described with reference to the drawings.

[0037] In the monitoring device 1 of this embodiment, the imaging unit 10 is installed so as to be positioned above the upper opening that receives the spool runner SR of the container 130, and is configured to image the spool runner SR inside the container 130 from diagonally above it.

[0038] First, in step S101, the imaging unit 10 is turned on to capture an image of the inside of the container 130 to obtain the captured image (S101). The imaging interval can be set in advance and may be matched to the molding cycle of the injection molding machine 110. The captured image may be either a still image or a video, and in the case of video capture, the captured image is obtained as a frame image extracted at a fixed time interval.

[0039] Next, the captured image acquired in step S102 is subjected to a binarization process (S102). In the binarization process, the pixel value of each pixel in the captured image is set to 0 or 1 with a predetermined threshold Th1 as the boundary. For example, if the luminance value is equal to or greater than the predetermined threshold Th1, the pixel value of the pixel is set to "1" (e.g., white), and if the luminance value is less than the threshold Th1, the pixel value of the pixel is set to "0" (e.g., black). Fig. 4(a) shows an example of the captured image, and Fig. 4(b) shows an example of the captured image after the binarization process.

[0040] In step S103, the ratio (black ratio BR) of pixel values ​​of 0 (black) in the binarized captured image to the entire captured image that has been binarized to a black and white two-tone image is calculated (S103). Then, in step S104, it is determined whether the amount of the spool runner SR deposited in the container 130 has reached a predetermined amount (S104). Specifically, it is determined whether the black ratio BR calculated in step S103 has reached a predetermined threshold value Th2. If the black ratio BR exceeds the predetermined threshold value Th2 (S104; Yes), the notification unit 30 transmits an alert message together with a captured image to the mobile terminal T carried by the monitor (S105). If the black ratio BR has not reached the predetermined threshold value Th2 (S104; No), the process returns to step S101, and an image of the inside of the storage box 130 is captured to obtain the captured image (S101).

[0041] (4) Effects of monitoring devices The monitoring device 1 according to this embodiment captures an image of the inside of the container 130 that contains the spool runners SR removed from the mold K, and judges the accumulation amount of the spool runners SR in the container 130 based on the accumulation state of the spool runners SR shown in the captured image. When it is determined that the accumulation amount of the spool runners SR in the container 130 has reached a predetermined amount, it transmits an alert message together with the captured image to the mobile terminal T carried by the monitor.

[0042] The spool runners SR stored in the container 130 have been monitored by an observer and processed as they are received. The shapes of the spool runners SR discharged into the container 130 vary depending on the mold K, and the way in which they accumulate in the container 130 also varies. According to the monitoring device 1 of this embodiment, when it is determined that the amount of spool runners SR accumulated in the container 130 has reached a predetermined amount, an alert message is sent together with a captured image to the mobile terminal T held by the observer, thereby reducing the number of times the observer must monitor the container 130.

[0043] The information processing unit 20, which determines the amount of deposition in the container 130 based on the deposition state of the spool runner SR shown in the image captured by the imaging unit 10, performs binarization processing on the captured image using a threshold value set according to the color and background of the spool runner SR, converts the entire image into a black and white image, and determines the amount of deposition of the spool runner SR based on the ratio BR of black to the entire image. This allows the deposition of the spool runner SR to be clearly detected. By disposing a background panel that has a different color from the spool runner SR and forms a background of the spool runner SR as seen by the imaging unit 10 at the rear of the container 130 relative to the imaging unit 10, the spool runner SR can be detected more clearly. When the information processing unit 20 determines that the amount of spool runners SR accumulated in the container 130 has reached a predetermined amount, the notification unit 30 transmits an alert message together with a captured image to the mobile terminal T carried by the monitor monitoring the spool runners SR in the container 130. This makes it possible to notify the monitor of the accumulation state of the spool runners SR in an intuitive and easy-to-understand manner, and also to reduce the timing of monitoring the spool runners SR that have been removed from the mold K and stored in the container 130. [Explanation of symbols]

[0044] 1...Monitoring device 10 imaging unit, 20 information processing unit, 30 notification unit 100 injection molding system, 110 injection molding machine, 120 removal device, 130 container K···Mold, K1···Movable side mold, K2···Fixed side mold S···Molded body, SR···Spool runner, T···Mobile terminal

Claims

1. an imaging unit that captures an image of the inside of a container that contains the spool runner to be removed from the die; an information processing unit that determines an amount of the spool runners accumulated in the container based on a state of the spool runners captured in an image by the imaging unit; and a notification unit that notifies the user when the information processing unit determines that the deposition amount has reached a predetermined amount. A monitoring device comprising:

2. the information processing unit performs a binarization process on the image using a threshold value set according to the color and background of the spool runner to convert the entire image into a black and white image, and determines the amount of deposition based on the ratio of black to the entire image.

2. The monitoring device according to claim 1.

3. The apparatus further includes a background panel disposed in the container rearward with respect to the imaging unit and forming a background of the spool runner as viewed from the imaging unit.

3. The monitoring device according to claim 1 or 2.

4. the background panel being a different color than the spool runner; 4. The monitoring device according to claim 3.

5. the notification unit transmits an alert message together with the captured image to a mobile terminal carried by an observer observing the spool runner in the container.

2. The monitoring device according to claim 1.

Images