Monitoring device for machine tool and program

Abstract

To save an operation for specifying a factor of an abnormal generation of a machine tool.SOLUTION: A monitoring device 1 for monitoring an operation of a machine tool, comprises: a plurality of cameras 21, 22, and 23 for photographing the machine tool from a plurality of directions; a plurality of sensors 31, 32, and 33 that detects the operation of the machine tool; a moving image file storage part 104 that repeatedly stores a plurality of video images photographed by each of the plurality of cameras as a plurality of moving image files; a sensor signal storage part 106 that constantly stores a plurality of sensor signals detected by the plurality of sensors; an abnormality generation detection part 107 that detects the generation of an abnormality in the machine tool on the basis of the plurality of sensor signals; and an abnormal moving image file storage part 109 that stores the plurality of abnormal moving image files corresponded to all of the plurality of cameras over before and after periods at a time when the generation of the abnormality is detected from the plurality of moving image files when the generation of the abnormality is detected.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a monitoring device and a program for a machine tool. [Background technology]

[0002] Conventionally, machine tools, such as injection molding machines, use sensors to collect operational data such as screw torque, cylinder temperature, mold pressure, injection speed, mold resin temperature, and mold surface temperature, and monitor for operational abnormalities. Many injection molding machines issue an alarm when a sensor value indicates an abnormal value. Note that an abnormal value here is a value that is closer to a normal value than a value (fault value) that would cause the machine to automatically stop as a malfunction has occurred, and is referred to as a value that indicates an impending malfunction. When an abnormal value is detected, the injection molding machine continues to operate, while the manager begins to investigate the cause of the malfunction.

[0003] In some types of monitoring systems, the video of the injection molding machine captured by a camera is recorded as a video file along with the operation data. The manager can check the operation status of the machine tool at that time on the video while checking the operation data for the occurrence of an abnormality, and infer the cause of the abnormality.

[0004] This work required alternating between playing back the operation data and playing back the video, which was extremely cumbersome. In addition, there were cases where the cause of the problem was not visible on a single camera, in which case it was assumed that multiple cameras would be used to capture various locations on the machine tool, but the work of linking and playing back multiple videos would become even more cumbersome. Summary of the Invention [Problem to be solved by the invention]

[0005] The purpose is to reduce the labor required to identify the cause of abnormalities in machine tools. [Means for solving the problem]

[0006] A monitoring device for monitoring the operation of a machine tool according to an embodiment of the present invention comprises a plurality of cameras that capture images of the machine tool from a plurality of directions, a plurality of sensors that detect the operation of the machine tool, a video file storage unit that repeatedly stores a plurality of images captured by the plurality of cameras as a plurality of video files, a sensor signal storage unit that constantly stores a plurality of sensor signals detected by the plurality of sensors, an abnormality detection unit that detects the occurrence of an abnormality in the machine tool based on the plurality of sensor signals, and an abnormality video file storage unit that, when the occurrence of the abnormality is detected, stores from the plurality of video files a plurality of abnormality video files corresponding to all of the plurality of cameras spanning a period before and after the occurrence of the abnormality was detected. [Brief description of the drawings]

[0007] [Figure 1] 1 is a diagram showing a physical configuration of a machine tool monitoring device according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a perspective view showing an example of the arrangement of the sensor and the camera in FIG. 1 relative to the injection molding machine. [Diagram 3] FIG. 2 is a diagram showing a functional configuration of the information processing device in FIG. [Figure 4] 2 is a flowchart showing the procedure of the monitoring operation of the monitoring device of FIG. 1; [Diagram 5] 11 is a conceptual diagram showing how an abnormal video file is generated from a video file in this embodiment. [Figure 6] 3 is a diagram showing an example of a list display screen relating to the date and time of abnormality occurrence and the type of the abnormality by the playback control unit in FIG. 2; [Figure 7] 7 is a diagram showing an example of a playback screen of three abnormal video files corresponding to the abnormality occurrence date and time and the abnormality type selected from the list in FIG. 6; [Figure 8] 8A to 8C are diagrams showing screen transitions associated with the specification of an enlargement command in FIG. 7; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, an embodiment of the present invention will be described. Machine tools include cutting machines such as lathes, milling machines, machining centers, and grinding machines that cut metals, etc., plastic processing machines such as injection molding machines, electric discharge machines such as wire cutters, and surface polishing machines. Here, an injection molding machine will be used as an example.

[0009] 1, a monitoring device 1 according to this embodiment includes an information processing device 10. A first camera 21, a second camera 22, a third camera 23, a vibration sensor 31, a temperature sensor 32, and a microphone 33 as an acoustic sensor are connected to the information processing device 10.

[0010] The information processing device 10 constantly records the images captured by the three cameras 21, 22, and 23, and monitors the occurrence of an abnormality based on the sensor signals of the sensors 31, 32, and 33. When an abnormality is detected, the information processing device 10 extracts and stores three partial images (corresponding to an abnormal video file described later) corresponding to the three cameras 21, 22, and 23, respectively, over the same period before and after the time of the abnormality. The information processing device 10 also arranges the three partial images at the time of the abnormality specified by the user side by side on one screen and plays them synchronously, that is, plays them with the time axis aligned. Furthermore, the information processing device 10 displays at least one of a vibration time waveform, a temperature time waveform, and an acoustic time waveform (referred to as a sensor graph) on the same screen as the three partial images. A seek bar indicating the playback position on the time axis is displayed superimposed on the sensor graph, and the user can play back from any point by manually changing the position of the time bar on the time axis. The physical configuration and functional configuration of the information processing device 10, as well as details regarding the operation procedure, will be described later.

[0011] The first camera 21, the second camera 22, and the third camera 23 are arranged through open windows so that both the fixed mold and the movable mold as important moving parts of the injection molding machine 4 are within the approximately central range of the angle of view, as exemplified in FIG. 2, and continuously photograph the injection molding machine 4 from multiple directions, typically from three directions, front, back, and above, during the operation period of injection molding. The vibration sensor 31 is abutted against the fixed mold or the movable mold and directly detects vibrations generated in the mold. The temperature sensor 32 is abutted against the fixed mold or the movable mold and directly detects the surface temperature of the mold. The microphone 33 is arranged through an open window with respect to the fixed mold and the movable mold and detects operating sounds generated by the mold itself, the injection unit, and the mold clamping unit around it.

[0012] Returning to Fig. 1, the information processing device 10 has a processor 11. Connected to the processor 11 via a data / control bus 19 are a RAM (Random Access Memory) 12, a ROM (Read Only Memory) 13, a storage device 14 such as an HDD (Hard Disk Drive) or an SSD (Solid State Drive), an input device 15 such as a keyboard or a mouse, a display 16 such as a liquid crystal display, an interface (I / F) 17 connected to cameras 21-23 and sensors 31-33, and a communication unit 18 for connecting to an external cloud storage device 2 via an Internet line 3.

[0013] The processor 11 is composed of a CPU (Central Processing Unit) and a GPU (Graphics Processing Unit). The processor 11 executes a monitoring program loaded from the storage device 14 or ROM 13 into the RAM 12, and executes processes related to video recording and playback, which will be described later. The RAM 12 functions as the main memory, work area, etc., of the processor 11. The ROM 13 or the storage device 14 stores a BIOS (Basic Input Output System) executed by the processor 11, an operating system program (OS), the monitoring program according to this embodiment, various data required for these processes, etc.

[0014] 3 shows the functional configuration of the information processing device 10. The information processing device 10 has a control unit 101 as a control center, and includes a camera signal input unit 102, a video file generation unit 103, a video file storage unit 104, a sensor signal input unit 105, a sensor signal storage unit 106, an abnormality occurrence detection unit 107, an abnormal video file generation unit 108, an abnormal video file storage unit 109, a video file transmission unit 113, a playback control unit 110, a playback operation input unit 111, and a display unit 112.

[0015] The video file generating unit 103 repeatedly generates video files of a predetermined time duration, for example, five minutes, from the video signals of the cameras 21, 22, and 23 input via the camera signal input unit 102. The video files are set with attribute data including a camera identification code for identifying the cameras 21, 22, and 23 and the date and time when an abnormality was detected. The video file storage unit 104 stores the video files. As a result, video from three directions is constantly recorded.

[0016] The sensor signal storage unit 106 constantly stores a plurality of sensor signals detected by the sensors 31 , 32 , and 33 and input via the sensor signal input unit 105 .

[0017] The abnormality occurrence detection unit 107 detects the occurrence of an abnormality in the injection molding machine based on a plurality of sensor signals. Typically, with regard to vibration, the occurrence of abnormal vibration is detected when a threshold value related to amplitude or vibration acceleration is exceeded. With regard to operating noise, the occurrence of abnormal sound is detected when a threshold value related to amplitude or decibels is exceeded. With regard to temperature, an appropriate range related to amplitude or decibels generated during steady operation is set in advance, and the occurrence of abnormal temperature is detected when the temperature deviates from the appropriate range to a high or low level.

[0018] When an abnormality (abnormal vibration, abnormal sound, abnormal temperature) is detected, the abnormal video file generating unit 108 generates three abnormal video files corresponding to the three cameras 21, 22, 23 from a plurality of video files, covering a period before and after the time when the abnormality was detected. The period, that is, the time length of the abnormal video files, is set arbitrarily by the user independently of the time length of the video files. Attributes related to the camera identification code for identifying the cameras 21, 22, 23, the date and time when the abnormality was detected, and the abnormality code for identifying the type of abnormality are set in the abnormal video file. The abnormal video file storage unit 109 stores the generated abnormal video files.

[0019] In addition, the video file generated by the video file generation unit 103, the sensor signals detected by the sensors 31, 32, 33, and the anomalous video file generated by the anomalous video file generation unit 108 are stored in memory units 104, 106, 109 corresponding to the internal storage device 14, and are also transmitted to the cloud storage device 2 by the video file transmission unit 113 and stored therein.

[0020] The playback control unit 110 creates a list of the date and time when the occurrence of the abnormality was detected and the type of the abnormality based on the attributes of the stored abnormal video file in accordance with a user command related to the abnormal video playback input from the playback operation input unit 111, and displays the list on the display unit 112. The playback control unit 110 also synchronously plays three abnormal video files of each of the three cameras 21, 22, and 23 corresponding to the date and time when the occurrence of the abnormality was detected and the abnormality code selected from the list in accordance with a user instruction via the playback operation input unit 111 on one screen of the display unit 112. The playback control unit 110 creates a sensor graph that shows the temporal fluctuation of the sensor signal in the same period as the period of the abnormal video file, and displays the sensor graph on the display unit 112 together with the three abnormal video files. A seek bar that shows the playback positions of the three abnormal video files is superimposed on the sensor graph. The position of the seek bar on the time axis is moved arbitrarily in accordance with a user instruction via the playback operation input unit 111. The three abnormal video files start to be played synchronously from the position of the seek bar operated by the user.

[0021] The procedure of the monitoring operation is shown in Fig. 4. When the main switch of the injection molding machine 4 is turned on and the operation of the injection molding machine 4 starts (step S11 "Yes"), the cameras 21, 22, 23 are activated (S12) and the sensors 31, 32, 33 are also activated (S13). Of course, the cameras 21, 22, 23 and the sensors 31, 32, 33 may be activated by turning on the main switch of the monitoring device 1 without being limited to the activated state.

[0022] Video signals from cameras 21, 22, and 23 are input via camera signal input unit 102, and as shown in Fig. 5, a moving image file MI(CA) corresponding to camera 21, a moving image file MI(CB) corresponding to camera 22, and a moving image file MI(CC) corresponding to camera 23, each having a predetermined period (time length), for example, 5 minutes, are repeatedly generated every 5 minutes by moving image file generation unit 103 (S14). In the moving image files MI(CA), MI(CB), and MI(CC), a camera identification code for identifying cameras 21, 22, and 23 and the file generation date and time are set as attribute data.

[0023] The video files MI(CA), MI(CB), and MI(CC) are stored in the video file storage unit 104 (S15), and are also transmitted to and stored in the cloud storage device 2 (S15).

[0024] Next, in step S17, it is determined whether the main switch has been turned off. If the determination is "No," that is, if the injection molding operation is continuing, the abnormality occurrence detection unit 107 individually determines whether abnormal vibration has occurred (S18), whether abnormal temperature has occurred (S19), and whether abnormal sound has occurred (S20).

[0025] When the occurrence of any of abnormal vibration, abnormal temperature, and abnormal sound is detected, as shown in Fig. 5, an abnormal video file generating unit 108 generates an abnormal video file pMI(CA) corresponding to the first camera 21 from a plurality of video files MI(CA) of the cameras 21, the abnormal video file pMI(CA) covering a predetermined period before and after the time when the abnormal vibration, abnormal temperature, or abnormal sound occurred. Typically, an abnormal video file pMI(CA) covering a predetermined period (time length) FLA centered on the time when the abnormal vibration, abnormal temperature, or abnormal sound occurred is generated (S21). For example, when the occurrence of abnormal temperature is detected at time t13, an abnormal video file pMI(CA)t13 covering the period FLA centered on time t13 is generated.

[0026] The period FLA corresponding to the anomalous video file pMI(CA) can be set by the administrator to any length of time, for example, 8 minutes, regardless of the period FLC of the video file pMI(CA), and can also be changed at any timing.

[0027] Similarly, an abnormal video file pMI(CB)t13 corresponding to the second camera 22 and spanning a predetermined period FLA around time t13 when abnormal vibration, abnormal temperature or abnormal sound occurs is generated from a plurality of video files MI(CB) of the second camera 22. Also, an abnormal video file pMI(CC)t13 corresponding to the third camera 23 and spanning a predetermined period FLA around time t13 when abnormal vibration, abnormal temperature or abnormal sound occurs is generated from a plurality of video files MI(CC) of the third camera 23.

[0028] The abnormal video files pMI(CA), pMI(CB), and pMI(CC) are set with attributes related to a camera identification code for identifying the cameras 21, 22, and 23, the date and time when the abnormality (abnormal vibration, abnormal temperature, or abnormal sound) occurred, and an abnormality code for identifying the type of abnormality.

[0029] The abnormal video file generating unit 108 generates abnormal video files pMI(CA), pMI(CB), and pMI(CC) for each of the occurrences of abnormal vibration, abnormal temperature, and abnormal sound. Therefore, as illustrated in Fig. 5, when the occurrence of abnormal vibration is detected at time t37, abnormal video files pMI(CA)t37, pMI(CB)t37, and pMI(CC)t37 for a period FLA centered on time t37 are generated, and when the occurrence of abnormal sound is detected at time t38, abnormal video files pMI(CA)t38, pMI(CB)t38, and pMI(CC)t38 for a period FLA centered on time t38 are generated, and these periods may overlap each other.

[0030] Abnormal video files pMI(CA), pMI(CB), and pMI(CC) that were generated in response to the detection of the same abnormality over the same period are stored in the video file storage unit 104 (S22), and are also transmitted to and stored in the cloud storage device 2 (S23). Then, the process returns to step S14, and the next video files MI(CA), MI(CB), and MI(CC) are generated.

[0031] When the occurrence of any of abnormal vibration, abnormal temperature, and abnormal sound is not detected ("No" in S20, S21, S22), the process returns to step S14.

[0032] Steps S14-S23 are repeated until it is determined in step S17 that the main switch has been turned off ("Yes"), that is, while the injection molding operation is continuing.

[0033] When it is determined in step S17 that the main switch is turned off ("Yes"), the cameras 21, 22, 23 and the sensors 31, 32, 33 are stopped, and the generation and storage process of the moving image files MI(CA), MI(CB), MI(CC) is terminated. Of course, the generation and storage process of the abnormal moving image files pMI(CA), pMI(CB), pMI(CC) is also terminated.

[0034] In this way, when an abnormality is detected, it triggers the generation of multiple corresponding abnormal video files for all of the multiple cameras, with the same start time, end time and duration, thereby reducing the operational burden involved in playing back the videos to identify the cause of the abnormality after the fact.

[0035] 6 shows a screen displaying a list of the dates and times when an abnormality was detected and the types of abnormality. Although not shown, when an administrator inputs a command to play an abnormal video via the playback operation input unit 111, the playback control unit 110 generates a list of the dates and times when an abnormality occurred and the types of abnormality, and displays it on the display unit 112. The playback control unit 110 accesses the abnormal video file storage unit 109 and receives attribute data of an abnormal video file triggered by, for example, the most recent predetermined number of abnormalities. A list of the dates and times when an abnormality was detected and the types of abnormality is created according to the attribute data, based on the dates and times when an abnormality (abnormal vibration, abnormal temperature, or abnormal sound) was detected and the abnormality code that identifies the type of abnormality.

[0036] The list is displayed on the display unit 112, and an administrator selects any abnormality occurrence detection date and time and type of abnormality via the playback operation input unit 111. This selection causes the playback control unit 110 to read out three abnormality video files pMI(CA), pMI(CB), and pMI(CC) corresponding to the selected abnormality occurrence detection date and time and type of abnormality from the abnormality video file storage unit 109, identify the video start date and time and end date and time from the attribute data of the abnormality video files, and read out multiple sensor signals related to vibration, temperature, and operating sound detected by the sensors 31, 32, and 33 during the relevant period from the sensor signal storage unit 106. From the read sensor signals, the playback control unit 110 creates a graph showing the respective temporal variations.

[0037] As shown in FIG. 7, the playback control unit 110 plays three abnormal video files pMI(CA), pMI(CB), and pMI(CC) in a synchronous manner, i.e., plays them with the time axis aligned, and arranges them in three areas CS1, CS2, and CS3, which are obtained by dividing one screen of the display unit 120, and displays them simultaneously. The playback control unit 110 also displays graphs showing the temporal fluctuations of one to three sensor signals in the same period as the abnormal video in an area SS on the same screen as the three abnormal video files pMI(CA), pMI(CB), and pMI(CC). Note that although a temperature graph GT and a vibration graph GS are displayed in FIG. 7, these are merely examples, and one to three graphs arbitrarily designated by the administrator are displayed. A playback command set relating to play, pause, stop, and fast forward is displayed on the screen.

[0038] A seek bar indicating the playback positions of the three abnormal video files is superimposed on the graph. The seek bar can be moved to any position on the time axis via the playback operation input unit 111. The playback control unit 110 synchronously plays back the three abnormal video files pMI(CA), pMI(CB), and pMI(CC) from the position of the moved seek bar.

[0039] A magnifying glass-shaped icon corresponding to the enlarge command is arranged in each of the three areas CS1, CS2, and CS3 that display the abnormal video. By designating an arbitrary icon, the playback control unit 110 enlarges the abnormal video displayed in one of the areas CS1, CS2, and CS3 where the designated icon is arranged, to the entire screen, as shown in Fig. 8. By designating the back button, the display is returned to that of Fig. 7 by the display control of the playback control unit 110.

[0040] As described above, according to this embodiment, multiple video files corresponding to all of the multiple cameras that capture the injection molding machine from multiple directions are stored in both the internal storage device and the external cloud storage device, so the reliability of video storage can be improved. Also, the operation of the injection molding machine can be confirmed with fewer blind spots.

[0041] In addition, when an abnormality is detected, the system uses that as a trigger to record multiple abnormality video files corresponding to each of the multiple cameras that capture the injection molding machine from multiple directions, with the same start time, end time, and duration. At the same time, vibration, temperature, and operating sounds are also recorded. These multiple abnormality video files related to the same abnormality can be synchronously played back by specifying them all at once, which reduces the operational burden of playing back the videos to identify the cause of the abnormality after the fact.

[0042] In addition, the movement of the injection molding machine can be viewed from multiple directions in a synchronized state, making it easy to identify the cause of an abnormality with high accuracy. Furthermore, graphs of vibration, temperature, and operating noise are displayed on the same screen as the video, along with a seek bar, so the vibration, temperature, and operating noise conditions at the time the video is played can also be checked at the same time.

[0043] As described above, according to this embodiment, it is possible to reduce the labor required for identifying the cause of an abnormality occurring in a machine tool such as an injection molding machine, and also to improve the accuracy of the identification.

[0044] The present invention is not limited to the above-mentioned embodiment, and various modifications can be made in the implementation stage without departing from the gist of the invention. The embodiments may be implemented in appropriate combination, and in that case, the combined effect can be obtained. Furthermore, the above-mentioned embodiment includes various inventions, and various inventions can be extracted by combinations selected from the multiple constituent elements disclosed. For example, if the problem can be solved and the effect can be obtained even if some constituent elements are deleted from all the constituent elements shown in the embodiment, the configuration from which the constituent elements are deleted can be extracted as an invention. [Explanation of symbols]

[0045] 1...monitoring device, 10...information processing device, 21...first camera, 22...second camera, 23...third camera, 31...vibration sensor, 32...temperature sensor, 33...microphone, 101...control unit, 102...camera signal input unit, 103...video file generation unit, 104...video file storage unit, 105...sensor signal input unit, 106...sensor signal storage unit, 107...abnormal occurrence detection unit, 108...abnormal video file generation unit, 109...abnormal video file storage unit, 110...playback control unit, 111...playback operation input unit, 120...display unit.

Claims

1. A monitoring device for monitoring an operation of a machine tool, comprising: A plurality of cameras for photographing the machine tool from a plurality of directions; A plurality of sensors for detecting the operation of the machine tool; a moving image file storage unit that repeatedly stores a plurality of images captured by the plurality of cameras as a plurality of moving image files; a sensor signal storage unit that constantly stores a plurality of sensor signals detected by the plurality of sensors; an abnormality detection unit that detects the occurrence of an abnormality in the machine tool based on the plurality of sensor signals; a monitoring device comprising an abnormality video file storage unit which, when the occurrence of the abnormality is detected, stores from the plurality of video files a plurality of abnormality video files corresponding to all of the plurality of cameras, the plurality of video files covering a period before and after the occurrence of the abnormality.

2. The monitoring device according to claim 1 , wherein attributes related to a camera identification code for identifying the camera, a date and time when the occurrence of the abnormality was detected, and an abnormality code for identifying a type of the abnormality are set in the abnormality video file.

3. a list display unit that displays on a display a list of the date and time when the occurrence of the abnormality was detected and the type of the abnormality; The monitoring device according to claim 2, further comprising a playback unit that synchronously plays, on one screen of the display, the plurality of abnormality video files corresponding to the date and time when the occurrence of the abnormality was detected and the abnormality code selected from the list in accordance with a user instruction.

4. 4. The monitoring device according to claim 3, wherein the playback unit displays, on the display, a graph showing the temporal fluctuation of the sensor signal for the same period as a period of the anomalous video file, together with the plurality of anomalous video files.

5. a seek bar indicating a playback position of the abnormal video files is superimposed on the graph showing the temporal variation of the sensor signal; The monitoring device according to claim 4 , wherein the playback unit starts playing back the abnormal video files in synchronization with each other from a position of the seek bar operated by a user.

6. The monitoring device according to claim 1 , further comprising a transmission unit that transmits the video file and the abnormal video file to a cloud storage device via an Internet line.

7. The plurality of sensors include: a vibration sensor that converts mechanical vibrations of the machine tool into an electrical vibration signal; a temperature sensor for converting the temperature of the machine tool into an electrical temperature signal; 2. The monitoring device according to claim 1, further comprising a microphone for converting the operating sound of the machine tool into an electrical sound signal.

8. 8. The monitoring device according to claim 7, wherein the abnormality video file storage section generates the abnormality video file separately for occurrence of an abnormality relating to the vibration, the temperature, and the operating sound.

9. A computer as a monitoring device for monitoring the operation of a machine tool, a means for repeatedly storing a plurality of images of the machine tool taken by a plurality of cameras from a plurality of directions as a plurality of video files in a storage unit; a means for storing a plurality of sensor signals detected by a plurality of sensors for detecting the operation of the machine tool in the memory unit; a means for detecting an occurrence of an abnormality in the machine tool based on the plurality of sensor signals; A program for functioning as a means for storing in the memory unit, when the occurrence of the abnormality is detected, a plurality of abnormal video files corresponding to the plurality of cameras from the plurality of video files, spanning the period before and after the occurrence of the abnormality.

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