Vent hole cleaning diagnostic system

Abstract

To provide a vent hole cleaning diagnostic system that can automatically perform not only vent hole cleaning but also diagnosis as to whether the vent hole sticks due to foreign substances after cleaning.SOLUTION: The vent hole cleaning diagnostic system 100 comprises cleaning equipment 50 that performs ultrasonic cleaning by applying vibrations in an ultrasonic region to a plurality of vent holes 102 formed in a mold 101, vibration sensors 60 to detect the elastic waves emitted from the mold 101 during ultrasonic cleaning, and a processing unit 80 that acquires the elastic wave data from the vibration sensor 60 and diagnoses whether or not each of the vent holes 102 sticks based on the physical quantity obtained from the acquired elastic wave data.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] This specification discloses a vent hole cleaning diagnostic system. [Background technology]

[0002] In a mold for vulcanizing rubber products such as tires, a plurality of vent holes may be formed to allow air in the mold and gas generated from the rubber material to escape to the outside. Fragments of the rubber material and foreign matter such as solidified gas accumulate in the vent holes. The following Patent Document 1 discloses a vent hole cleaning device that automatically cleans the vent holes with ultrasonic vibrations to remove foreign matter in the vent holes. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-128013 A Summary of the Invention [Problem to be solved by the invention]

[0004] The applicant's intention is to provide a vent hole cleaning diagnostic system that can not only clean the vent hole, but also automatically diagnose whether the vent hole after cleaning is stuck due to foreign matter or the like. [Means for solving the problem]

[0005] The vent hole cleaning diagnosis system disclosed in this specification includes a cleaning device that applies vibrations in the ultrasonic range to multiple vent holes formed in a mold to perform ultrasonic cleaning, a vibration sensor that detects elastic waves emitted from the mold during the ultrasonic cleaning, and a processing device that acquires data on the elastic waves from the vibration sensor and diagnoses whether or not each of the multiple vent holes is stuck based on physical quantities obtained from the acquired elastic wave data. Effect of the Invention

[0006] This vent hole cleaning diagnostic system can not only clean the vent hole, but also automatically diagnose whether the vent hole is stuck due to foreign matter or the like after cleaning. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a schematic side view of the vent hole cleaning diagnostic system. [Diagram 2] FIG. 2 is a schematic front view of the cleaning diagnosis area. [Diagram 3] FIG. 3 is a block diagram of the control system of the vent hole cleaning diagnostic system. [Figure 4] FIG. 4 is a flow diagram of the diagnostic program. [Diagram 5] FIG. 5 is a diagram illustrating an example of an elastic wave. [Figure 6] FIG. 6 is a scatter plot of the correlation between the maximum amplitude and energy of the elastic wave. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, preferred embodiments will be described in detail with reference to the drawings as appropriate.

[0009] (Overall system configuration) First, the overall configuration of a vent hole cleaning diagnostic system (hereinafter simply referred to as the "system") 100 will be described. FIG. 1 is a schematic side view of the system 100. The system 100 automatically cleans and diagnoses a plurality of vent holes 102 formed in a mold 101. Note that the mold 101 in this embodiment is a mold used when vulcanizing tires, but it may be a mold used when vulcanizing rubber products other than tires.

[0010] The vent holes 102 formed in the mold 101 serve to release gas generated within the mold 101 to the outside. Foreign matter accumulates in the vent holes 102 when a tire is vulcanized, and so the foreign matter must be removed from the vent holes 102 by cleaning. In addition, the vent holes 102 of this embodiment are provided with vent plugs containing springs therein to prevent spews from being formed on the outer surface of the tire. Foreign matter is particularly likely to accumulate in these vent plugs, and vent holes 102 provided with vent plugs are particularly likely to become stuck. However, the vent holes 102 do not necessarily have to be provided with vent plugs.

[0011] As shown in Fig. 1, the system 100 includes three areas: an imaging area 11, a cleaning diagnosis area 12, and a repair area 13. Fig. 2 is a schematic front view of the cleaning diagnosis area 12 out of the three areas.

[0012] 1 and 2, the system 100 includes a transport device 20 that transports a mold 101, an imaging device 30 located in an imaging area 11, a support device 40 located in a cleaning diagnosis area 12, a cleaning device 50 and a vibration sensor 60, and a display device 70 located in a repair area 13. These components will be described in order below.

[0013] <Transportation equipment> The transport device 20 is a device that transports the mold 101. The transport device 20 transports the mold 101 from the imaging area 11 to the cleaning diagnosis area 12, and transports it from the cleaning diagnosis area 12 to the repair area 13. The transport device 20 of this embodiment transports the mold 101 using a conveyor, but the configuration of the transport device 20 is not limited to this. Furthermore, the transport device 20 of this embodiment transports the mold 101 placed on the placement table 21 together with the placement table 21. However, the transport device 20 may transport only the mold 101.

[0014] <Imaging device> The imaging device 30 is a device that captures an image of the mold 101. The imaging device 30 is located in the imaging area 11. The imaging device 30 may include a 2D or 3D image sensor. The imaging device 30 captures an image of the entire mold 101 such that all of the vent holes 102 are included in the imaging range.

[0015] <Support device> The support device 40 is a device that supports the mold 101. The support device 40 is located in the cleaning diagnosis area 12. As shown in Fig. 2, the support device 40 has a main body 41 and a support member 42 that can be raised and lowered relative to the main body 41. The support member 42 lifts the mold 101 together with the placement table 21, and can support the mold 101 in the lifted state. Ultrasonic cleaning, which will be described later, is performed in a state in which the mold 101 is lifted by the support device 40.

[0016] <Cleaning equipment> The cleaning device 50 is a device for cleaning the vent holes 102 of the mold 101. The cleaning device 50 is located in the cleaning diagnosis area 12. As shown in FIG. 2, the cleaning device 50 has a robot arm 51 and a probe 52 provided at the tip of the robot arm 51. The robot arm 51 can move the probe 52 toward the vent hole 102 and bring the probe 52 into contact with the vent hole 102. The probe 52 can apply vibration in the ultrasonic range (for example, 20 to 50 kHz) to the vent hole 102 that it has come into contact with, thereby performing ultrasonic cleaning. In this embodiment, ultrasonic cleaning is performed on each vent hole 102 in sequence and individually. However, ultrasonic cleaning may be performed on multiple vent holes 102 at once.

[0017] By performing ultrasonic cleaning using the cleaning device 50, foreign matter accumulated in the vent holes 102 can be removed. However, some of the vent holes 102 that have been subjected to ultrasonic cleaning may be stuck with foreign matter or the like. In the system 100 according to this embodiment, it is possible to automatically diagnose whether the vent holes 102 are stuck. The diagnosis of whether the vent holes 102 are stuck will be described later.

[0018] <Vibration sensor> The vibration sensor 60 is a sensor that detects elastic waves emitted from the mold 101. Incidentally, "elastic waves" refer to wave motion that propagates through an elastic body. The vibration sensor 60 in this embodiment is provided on the support member 42 of the support device 40. When vibration is applied to the vent hole 102 by the probe 52 of the cleaning device 50, an elastic wave is emitted from the mold 101. The vibration sensor 60 can detect the elastic waves emitted from the mold 101 via the placement table 21 and the support member 42. That is, in this embodiment, the elastic waves emitted from the mold 101 are detected without directly attaching the vibration sensor 60 to the mold 101.

[0019] Moreover, the vibration sensor 60 of this embodiment is an AE (acoustic emission) sensor. Acoustic emission refers to a phenomenon in which a material releases the strain energy stored inside as an elastic wave when the material is deformed or a crack occurs. The AE sensor is a sensor that detects this elastic wave, and is configured to detect waves in the ultrasonic range (for example, several tens of kHz to several MHz). Since the elastic waves emitted from the mold 101 are waves in the ultrasonic range, if an AE sensor is used as the vibration sensor 60, the elastic waves emitted from the mold 101 can be detected.

[0020] <Display device> As described below, each vent hole 102 is diagnosed as being stuck or not. The display device 70 is a device that displays the location of a vent hole 102 that has been diagnosed as being stuck (hereinafter referred to as a "faulty vent hole"). The display device 70 is located in the repair area 13.

[0021] The display device 70 of this embodiment displays the location of the defective vent hole by projecting a predetermined image onto the mold 101. That is, the display device 70 displays the location of the defective vent hole using projection mapping technology. For example, the display device 70 projects an image onto the mold 101 in which the portion overlapping the defective vent hole is colored red. This allows the worker to recognize that the vent hole 102 that appears red is the defective vent hole.

[0022] Furthermore, the display device 70 may display the position of the defective vent hole by projecting light onto the mold 101. For example, the display device 70 projects a laser beam onto the defective vent hole. This allows the worker to recognize that the vent hole 102 onto which the laser beam is projected is the defective vent hole.

[0023] In this way, if display device 70 displays the position of the defective vent hole by projecting an image or projecting light onto mold 101, the worker can easily recognize the defective vent hole. However, display device 70 may be a monitor and display the position of the defective vent hole on the screen.

[0024] (System control configuration) Next, the configuration of the control system of the system 100 will be described. Fig. 3 is a block diagram of the control system of the system 100. As shown in Fig. 3, the system 100 includes a processing device 80 that controls the entire system 100. The processing device 80 includes a processor, a volatile memory, a non-volatile memory, an I / O interface, and the like. Various programs including a diagnostic program described below and various data are stored in the non-volatile memory of the processing device 80, and the processor performs arithmetic processing using the volatile memory based on each program.

[0025] The processing device 80 is electrically connected to the imaging device 30 and the vibration sensor 60. The processing device 80 can acquire image data of the mold 101 from the imaging device 30, and can acquire data of elastic waves emitted from the mold 101 from the vibration sensor 60. The processing device 80 is also electrically connected to the conveying device 20, the supporting device 40, the cleaning device 50, and the display device 70. The processing device 80 can control these devices by transmitting control signals to these devices.

[0026] (Processing of processing equipment) Next, a description will be given of the processing performed by the processing device 80. In the following, the processing performed by the processing device 80 will be described for each of the cases when the mold 101 is located in the imaging area 11, when the mold 101 is located in the cleaning diagnosis area 12, and when the mold 101 is located in the repair area 13.

[0027] <Image capture area> When the mold 101 is located in the imaging area 11, the processing device 80 acquires image data of the mold 101 from the imaging device 30 that has captured an image of the mold 101. The processing device 80 then identifies the positions of the vent holes 102 in the mold 101 based on the acquired image data. For example, if an edge filter is applied to the image of the mold 101 and image processing is performed, the vent holes 102 can be recognized, and the positions of the vent holes 102 can be identified.

[0028] <Cleaning diagnosis area> Next, when the mold 101 is located in the cleaning diagnosis area 12, the processing device 80 transmits a control signal to the cleaning device 50 to perform ultrasonic cleaning on each vent hole 102 in sequence and individually. The processing device 80 performs ultrasonic cleaning based on the position of each vent hole 102 identified by image data of the mold 101. Therefore, ultrasonic cleaning can be performed on a different type of mold 101 having a different position of the vent hole 102, or on a mold 101 whose installation position is shifted from the planned position. However, if the type of mold 101 is clear and the mold 101 is accurately installed, the processing device 80 may perform ultrasonic cleaning based on the position data of the vent hole 102 stored in advance.

[0029] Furthermore, the processing device 80 performs diagnostic processing in parallel with the ultrasonic cleaning. Specifically, the processing device 80 executes a diagnostic program in parallel with the ultrasonic cleaning. Figure 4 is a flow diagram of the diagnostic program. The diagnostic program is executed for each vent hole 102.

[0030] As shown in Fig. 4, when the diagnostic program is executed, first, the processing device 80 acquires elastic wave data from the vibration sensor 60 (step S1). Specifically, the processing device 80 acquires data on elastic waves emitted from the mold 101 while ultrasonic cleaning is being performed from the vibration sensor 60. Fig. 5 is a diagram showing an example of elastic waves emitted from the mold 101.

[0031] After step S1, the processing device 80 calculates the maximum amplitude and energy of the elastic wave based on the elastic wave data acquired in step S1 (step S2). In this embodiment, the maximum amplitude and energy of the elastic wave are calculated for each unit time (e.g., 10 ms). The energy of the elastic wave is the integral value of the elastic wave (the area of ​​the shaded portion in FIG. 5).

[0032] After step S2, the processing device 80 judges whether or not the maximum amplitude and energy value of the elastic wave calculated in step S2 are included in an abnormal region (step S3). Specific explanation will be given below.

[0033] Fig. 6 is a correlation scatter diagram of the maximum amplitude and energy of the elastic wave. Fig. 6(a) is a correlation scatter diagram when the vent hole 102 is normal, that is, when the vent hole 102 is not stuck. Fig. 6(b) is a correlation scatter diagram when the vent hole 102 is abnormal, that is, when the vent hole 102 is stuck. The vertical axis is the value of the energy of the elastic wave, and the horizontal axis is the value of the maximum amplitude of the elastic wave. In this embodiment, the values ​​of the maximum amplitude and energy of the elastic wave are calculated for each unit time, and each value calculated for each unit time is indicated by one dot in the diagram.

[0034] As shown in (a) of Fig. 6, when the vent hole 102 is normal, no dots are present in the region (region surrounded by dashed lines) where the maximum amplitude number of the elastic wave is large and the energy is high. On the other hand, as shown in (b) of Fig. 6, when the vent hole 102 is abnormal, many dots are present in the region surrounded by dashed lines. If a region in which dots exist only when the vent hole 102 is abnormal is defined as an abnormal region, in step S3, the processing device 80 determines whether the values ​​of the maximum amplitude and energy of the elastic wave calculated in step S2 are included in this abnormal region.

[0035] In step S3, if the processing device 80 determines that the maximum amplitude and energy values ​​of the elastic waves are not within the abnormal region (YES in step S3), it diagnoses that the vent hole 102 being ultrasonically cleaned is not stuck (step S4). On the other hand, in step S3, if the processing device 80 determines that the maximum amplitude and energy values ​​of the elastic waves are within the abnormal region (NO in step S3), it diagnoses that the vent hole 102 being ultrasonically cleaned is stuck (step S5). Note that for a vent hole 102 diagnosed as stuck (a defective vent hole), the cleaning time or the number of cleanings may be extended and ultrasonic cleaning may be repeated.

[0036] The above is an explanation of the diagnostic process performed by the processing device 80. As described above, according to this embodiment, it is possible to automatically diagnose whether or not each vent hole 102 is stuck. Moreover, since the diagnosis is performed by applying vibrations in the ultrasonic range to the vent hole 102 in ultrasonic cleaning, efficient diagnosis is possible.

[0037] <Repair area> Subsequently, when the mold 101 is located in the repair area 13, the processing device 80 transmits a control signal to the display device 70 to display the position of the defective vent hole. As described above, the display device 70 of this embodiment displays the position of the defective vent hole by projecting an image onto the mold 101. Furthermore, when displaying the position of the defective vent hole, the processing device 80 identifies the position of the defective vent hole based on the position of each vent hole 102 identified by the image data of the mold 101.

[0038] In the repair area 13, the defective vent hole is repaired. The repair of the vent hole 102 is performed manually by a worker. For example, the worker replaces a vent plug installed in the defective vent hole or re-cleans the defective vent hole. As described above, according to the system 100 of this embodiment, the cleaning and diagnosis of the vent hole 102 can be performed automatically, thereby reducing the workload of the worker.

[0039] (Modification) Although the system 100 according to the embodiment has been described above, the specific configuration of the system 100 is not limited to the above. For example, in the above embodiment, the vibration sensor 60 is provided in the support device 40, but the vibration sensor 60 may be provided in the robot arm 51 of the cleaning device 50. Even in this case, the elastic wave emitted from the mold 101 can be detected without directly attaching the vibration sensor 60 to the mold 101. Note that, when the vibration sensor 60 is provided in the cleaning device 50, it is not necessary to lift the mold 101 during ultrasonic cleaning.

[0040] In the above-described embodiment, the processing device 80 diagnoses whether the vent hole 102 is stuck based on both the amplitude and energy values ​​of the elastic wave emitted from the mold 101, but it may diagnose whether the vent hole 102 is stuck based on one of the amplitude and energy values ​​of the elastic wave emitted from the mold 101. For example, it may be diagnosed that the vent hole 102 is stuck when the amplitude or energy value of the elastic wave is equal to or greater than a threshold. Furthermore, it may be diagnosed whether the vent hole 102 is stuck based on physical quantities obtained from the elastic wave emitted from the mold 101 other than the amplitude and energy values.

[0041] (Disclosure items) <Item 1> A vent hole cleaning diagnostic system comprising: a cleaning device that applies vibrations in the ultrasonic range to a plurality of vent holes formed in a mold to perform ultrasonic cleaning; a vibration sensor that detects elastic waves emitted from the mold during the ultrasonic cleaning; and a processing device that acquires data on the elastic waves from the vibration sensor and diagnoses whether or not each of the plurality of vent holes is stuck based on physical quantities obtained from the acquired elastic wave data.

[0042] <Item 2> The vent hole cleaning diagnostic system according to Item 1, wherein the vibration sensor is an AE sensor capable of detecting elastic waves in the ultrasonic range.

[0043] <Item 3> The vent hole cleaning diagnostic system according to item 1 or 2, wherein the processing device diagnoses whether each of the plurality of vent holes is stuck or not based on the values ​​of both or one of the amplitude and energy of the elastic wave.

[0044] <Item 4> A vent hole cleaning diagnostic system according to any one of items 1 to 3, further comprising a support device that supports the mold during the ultrasonic cleaning, the vibration sensor being attached to the support device.

[0045] <Item 5> The vent hole cleaning diagnostic system according to any one of items 1 to 3, wherein the vibration sensor is attached to the cleaning device.

[0046] <Item 6> The vent hole cleaning diagnostic system of any one of Items 1 to 5, further comprising an imaging device that images the mold, wherein the processing device acquires image data of the mold from the imaging device and identifies positions of the plurality of vent holes based on the acquired image data of the mold, and the cleaning device performs the ultrasonic cleaning based on the positions of the plurality of vent holes identified by the processing device.

[0047] <Item 7> The vent hole cleaning diagnostic system according to Item 6, wherein the processing device identifies a position of a vent hole diagnosed as stuck based on the identified positions of the plurality of vent holes.

[0048] <Item 8> The vent hole cleaning diagnostic system according to any one of items 1 to 7, further comprising a display device that displays the position of a vent hole diagnosed as stuck by the processing device.

[0049] <Item 9> The vent hole cleaning diagnostic system according to Item 8, wherein the display device projects an image or shines light onto the mold to display the position of a vent hole diagnosed as stuck by the processing device.

[0050] <Item 10> The vent hole cleaning diagnostic system according to any one of items 1 to 9, wherein the cleaning device performs ultrasonic cleaning on the plurality of vent holes individually and in sequence. [Explanation of symbols]

[0051] 11 Imaging area 12 Cleaning diagnostic area 13 Repair Area 20. Conveyor 21 Stand 30 Imaging device 40 Support device 41 Main unit 42 Support member 50 Cleaning Equipment 51 Robot Arm 52 Probe 60 Vibration Sensor 70 Display device 80 Processing Equipment 100 Vent hole cleaning diagnostic system 101 Mold 102 Vent Hole

Claims

1. A cleaning device that performs ultrasonic cleaning by applying vibrations in the ultrasonic range to a plurality of vent holes formed in a mold; a vibration sensor that detects elastic waves emitted from the mold during the ultrasonic cleaning; a processing device that acquires elastic wave data from the vibration sensor and diagnoses whether or not each of the plurality of vent holes is stuck based on physical quantities obtained from the acquired elastic wave data.

2. 2. The vent hole cleaning diagnostic system according to claim 1, wherein the vibration sensor is an AE sensor capable of detecting elastic waves in the ultrasonic range.

3. 2. The vent hole cleaning diagnostic system according to claim 1, wherein the processing device diagnoses whether each of the plurality of vent holes is stuck or not based on values ​​of both or one of an amplitude and an energy of the elastic wave.

4. The ultrasonic cleaning device further includes a support device for supporting the mold during the ultrasonic cleaning. The vent hole cleaning diagnostic system of claim 1 , wherein the vibration sensor is attached to the support device.

5. The vent hole cleaning diagnostic system of claim 1 , wherein the vibration sensor is attached to the cleaning device.

6. Further, an imaging device for imaging the mold is provided, The processing device acquires image data of the mold from the imaging device, and identifies positions of the plurality of vent holes based on the acquired image data of the mold; The vent hole cleaning diagnostic system according to claim 1 , wherein the cleaning device performs the ultrasonic cleaning based on positions of the plurality of vent holes identified by the processing device.

7. The vent hole cleaning diagnostic system according to claim 6 , wherein the processing device identifies a position of a vent hole diagnosed as stuck based on the identified positions of the plurality of vent holes.

8. The vent hole cleaning diagnostic system according to claim 1 , further comprising a display device that displays the location of a vent hole diagnosed as stuck by the processing device.

9. 9. The vent hole cleaning diagnosis system according to claim 8, wherein the display device displays a position of the vent hole diagnosed as stuck by the treatment device by projecting an image or shining light onto the mold.

10. The vent hole cleaning diagnostic system according to claim 1 , wherein the cleaning device performs ultrasonic cleaning on the plurality of vent holes individually and sequentially.

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