Raw material verification system and raw material verification method

Abstract

To prove scientifically a ratio of raw materials contained in resin molded product, and to manage it as record information of a final product.SOLUTION: A raw material verification system used to control a quality of a resin molded product made from two or more types of raw materials includes: a raw material data acquisition part that acquires raw material data including data on analysis results of two or more types of raw materials; a material analysis data acquisition part that acquires material analysis data for the resin molded product; and a calculation processing part that performs predetermined calculation processing based on the raw material data and material analysis data. The calculation processing part compares a raw material blending ratio contained in the raw material data with a material content ratio contained in the material analysis data to determine whether it falls within the range of specifications for the resin molded product.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a raw material verification system and a raw material verification method. [Background technology]

[0002] In recent years, advances in artificial intelligence (AI) and machine learning have led to increased automation in a variety of fields. The technology for automatic and accurate processing is also advancing in the field of quality control.

[0003] Patent Document 1 discloses a dispensing system that aims to provide a dispensing system that enables automatic dispensing, and that prepares dispensing materials based on prescription information, dispenses medicine using the prepared dispensing materials, and prepares for shipment of the dispensed medicine in the dispensing department, and verifies the accuracy of the dispensed medicine based on the weight of the medicine based on the prescription information and the weight of the dispensed medicine.

[0004] Patent Document 2 discloses an injection molding condition generation system that uses a computer to generate injection molding conditions for injection molding using a resin material based on target values ​​of quality parameters related to the quality of the molded product, material characteristic values, and a predetermined relational equation, with the aim of improving the quality of injection molding. The predetermined relational equation is an equation that shows the relationship between the material characteristic values ​​of the resin material, a plurality of injection molding conditions input to an injection molding machine, and quality parameters related to the quality of the molded product molded by the injection molding machine based on the material characteristic values ​​and each injection molding condition, and is generated based on data stored in memory in which the material characteristic values ​​of the resin material, the injection molding conditions, and the quality parameters are linked. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2022-124444 A [Patent Document 2] JP 2022-141495 A Summary of the Invention [Problem to be solved by the invention]

[0006] When manufacturing resin molded products using an injection molding machine, the raw materials, recycled and virgin resin pellets, are mixed, melted, stirred, and injected into a mold for molding. In this case, the ratio of recycled and virgin materials contained in each of the resin molded products actually manufactured continuously (data included in the product data) may not match the ratio of recycled and virgin materials of the raw materials fed into the injection molding machine (data included in the manufacturing data) due to factors such as variations in the amount of recycled and virgin materials fed during mixing and unevenness when the materials are not mixed sufficiently before melting. For this reason, it is difficult to prove the amount (content) of recycled materials used in resin molded products using only manufacturing data. It is difficult to scientifically prove the content of recycled materials using only easily obtainable data such as weight.

[0007] For this reason, there are cases where a third party is asked to issue a certificate regarding the recycled material content, but in this case, issuing the certificate requires time and cost.

[0008] In Patent Document 1, dispensed medicines are subject to quality control.

[0009] In Patent Document 2, the quality of injection molding is improved by setting appropriate injection molding conditions.

[0010] The purpose of this disclosure is to scientifically prove the ratio of raw materials contained in a resin molded product and manage it as history information of the final product. [Means for solving the problem]

[0011] The raw material verification system disclosed herein is a system used for managing the quality of a resin molded product made from two or more types of raw materials, and includes a raw material data acquisition unit that acquires raw material data including data on the analysis results of two or more types of raw materials, a material analysis data acquisition unit that acquires material analysis data of the resin molded product, and a calculation processing unit that performs predetermined calculation processing based on the raw material data and the material analysis data, and the calculation processing unit compares the raw material blending ratio contained in the raw material data with the material content ratio contained in the material analysis data to determine whether it falls within the specification range of the resin molded product. Effect of the Invention

[0012] According to the present disclosure, the ratio of raw materials contained in a resin molded product can be scientifically proven and managed as history information of the final product. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a schematic diagram showing a raw material verification system according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a flow chart showing a raw material verification method according to the first embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. The examples are illustrative for explaining the present disclosure, and are omitted and simplified as appropriate for clarity of explanation. The present disclosure can be implemented in various other forms. Unless otherwise specified, each component may be singular or plural.

[0015] In order to facilitate understanding of the invention, the position, size, shape, range, etc. of each component shown in the drawings may not represent the actual position, size, shape, range, etc. Therefore, the present disclosure is not necessarily limited to the position, size, shape, range, etc. disclosed in the drawings.

[0016] As examples of various information, the various information may be described using expressions such as "table," "list," and "queue," but the various information may be expressed using data structures other than these. For example, various information such as "XX table," "XX list," and "XX queue" may be expressed as "XX information." When describing identification information, expressions such as "identification information," "identifier," "name," "ID," and "number" are used, but these are mutually interchangeable.

[0017] When there are multiple components having the same or similar functions, they may be described by using the same reference numerals with different subscripts, or when there is no need to distinguish between these multiple components, the subscripts may be omitted.

[0018] In the embodiments, a process performed by executing a program may be described. Here, a computer executes the program using a processor (e.g., CPU, GPU), and performs the process defined by the program while using a storage resource (e.g., memory) and an interface device (e.g., communication port). Therefore, the subject of the process performed by executing the program may be the processor. Similarly, the subject of the process performed by executing the program may be a controller, device, system, computer, or node having a processor. The subject of the process performed by executing the program may be a calculation unit, and may include a dedicated circuit that performs specific processing. Here, the dedicated circuit is, for example, an FPGA (Field Programmable Gate Array), an ASIC (Application Specific Integrated Circuit), or a CPLD (Complex Programmable Logic Device).

[0019] The program may be installed in the computer from a program source. The program source may be, for example, a program distribution server or a computer-readable storage medium. When the program source is a program distribution server, the program distribution server may include a processor and a storage resource that stores the program to be distributed, and the processor of the program distribution server may distribute the program to be distributed to other computers. In addition, in the embodiment, two or more programs may be realized as one program, and one program may be realized as two or more programs. EXAMPLES

[0020] FIG. 1 is a schematic diagram showing the configuration of a raw material verification system according to an embodiment of the present invention.

[0021] In this diagram, the raw material collation system 3 includes a raw material data acquisition unit 31, a material analysis data acquisition unit 32, and a calculation processing unit 33. The raw material data acquisition unit 31 acquires raw material data and the like for the molding machine 1. The molding machine 1 is a device that molds resin, and is, for example, an injection molding machine, an extrusion molding machine, a blow molding machine, a vacuum molding machine, or the like. The material analysis data acquisition unit 32 acquires material analysis data and the like from the material analysis machine 2. Here, the raw material refers to resin pellets, which are the raw material of the resin molded product. Also, the material refers to a sample of the resin molded product to be analyzed. The resin molded product is a part, product, etc., produced by mixing two or more types of raw materials and using the molding machine 1. In this embodiment, at least one of the two or more types of raw materials is a recycled material.

[0022] The raw material data includes data on the analysis results of two or more types of raw materials. In this embodiment, the raw material data includes data on the analysis results of virgin and recycled resin materials. The analysis of virgin and recycled materials may be performed in advance by the material analysis device 2. The raw material data is included in the manufacturing data, and includes data on the content rate of recycled materials determined in the design of the resin molded product. The material analysis data is also included in the product data obtained by analyzing samples of the resin molded products that have actually been manufactured by the material analysis device 2.

[0023] In this specification, "virgin material" refers to resins manufactured using only new materials, i.e. unused and unprocessed resins. "Recycled material" refers to resin materials defined in accordance with JIS Q14021:2000, including resin materials extracted from the waste stream during the manufacturing process and resin materials recovered after consumers have used the product. It is preferable to use virgin and recycled resin materials in the form of resin pellets.

[0024] The calculation processing unit 33 acquires necessary data and the like from the raw material data acquisition unit 31 and the material analysis data acquisition unit 32, performs predetermined calculation processing, compares the raw material blending ratio calculated from the raw material data with the material content ratio calculated from the material analysis data, and transmits the result data and the like to the production management system 4. The production management system 4 stores the data received from the calculation processing unit 33 by dividing it into manufacturing data and product data. Here, the "raw material blending ratio" refers to the ratio of recycled material to virgin material in the raw materials fed into the molding machine 1. Also, the "material content ratio" refers to the ratio of recycled material to virgin material contained in each of the resin molded products actually manufactured continuously.

[0025] In addition to the raw material data, the molding machine 1 also stores data on molding conditions, operation data, etc. In addition to the material analysis data, the material analysis machine 2 also stores data on analysis conditions, analysis history, etc.

[0026] In the present embodiment, the material analyzer 2 uses fluorescence spectroscopy, which is a non-destructive measurement method, since non-destructive measurement is desirable when analyzing parts or products. By applying multivariate analysis or the like to the data obtained using fluorescence spectroscopy, the components constituting the material and their ratios can be calculated. However, other methods may also be used for material analysis, such as nuclear magnetic resonance analysis (NMR), thermal analysis such as differential scanning calorimetry (DSC), near infrared analysis (NIR), mid-infrared analysis (MIR), Raman spectroscopy, electron spin resonance (ESR), etc. Note that NMR, DSC, etc. are destructive analyses.

[0027] It is preferable that the raw material collation system 3 has a database. This database preferably stores data accumulated by learning raw material data and the like by machine learning or the like, correlations between results obtained by analyzing materials such as parts and products and other analysis results (e.g., destructive analysis), correlations between specific components or the ratio of recycled materials that make up the material and properties such as tensile strength and impact strength of the material sample, and the like.

[0028] The raw material collation system 3 may store in a database at least one of the manufacturing data and the product data stored in the production management system 4. In this case, it is preferable that at least one of the manufacturing data and the product data is stored in association with the result of collation obtained by the calculation processing unit 33.

[0029] Furthermore, the raw material verification system 3 may also have the configuration and functions of the production management system 4.

[0030] FIG. 2 is a flow chart showing the raw material verification method of this embodiment.

[0031] In this diagram, when the raw material collation system 3 in Fig. 1 starts collation (step S20), the raw material data acquisition unit 31 acquires raw material data, etc. from the molding machine 1 (step S21). Then, the material analysis data acquisition unit 32 acquires material analysis data, etc. from the material analysis machine 2 (step S22).

[0032] Next, the arithmetic processing unit 33 calculates the raw material blending ratio from the raw material data (step S23). The arithmetic processing unit 33 also calculates the material content ratio from the material analysis data (step S24). Note that when the raw material data includes the raw material blending ratio or when the material analysis data includes the material content ratio, steps S23 and S24 can be omitted.

[0033] Thereafter, the calculation processing unit 33 compares the raw material blending ratio with the material content ratio and judges whether the material content ratio is within the range of the specifications of the resin molded product (step S25). At least one of the comparing step and the judging step may be performed using artificial intelligence (AI).

[0034] If the result of the judgment is that it is within the range of the specifications of the resin molded product, the judgment result is sent to the production management system 4 (step S26). On the other hand, if it is not within the range of the specifications of the resin molded product, it is processed as a molding error (step S27). In step S27, the judgment result is also sent to the production management system 4.

[0035] If the material content ratio is not within the range of the predetermined specifications for the resin molded product, that is, if it is outside the range of the specifications, the production management system 4 transmits a signal to the manufacturing equipment of the molding machine 1 that molds the raw material to stop production. This signal may be transmitted from the raw material verification system 3 in step S27.

[0036] The effects of the ingredient verification system and ingredient verification method according to the present disclosure will be summarized below.

[0037] According to the present disclosure, the ratio of raw materials contained in a resin molded product can be proven on scientific grounds.

[0038] Furthermore, the manufacturing data or product data stored in association with the collation results can be managed as history information of the final product.

[0039] Furthermore, since the raw material blend ratio or material content ratio of a resin molded product can be easily confirmed in-house, there is an advantage that there is no need to request it from a third party. [Explanation of symbols]

[0040] 1: molding machine, 2: material analysis machine, 3: raw material collation system, 4: production management system, 31: raw material data acquisition unit, 32: material analysis data acquisition unit, 33: calculation processing unit.

Claims

1. A system for managing the quality of a resin molded product made from two or more types of raw materials, comprising: a raw material data acquisition unit that acquires raw material data including data on the analysis results of the two or more types of raw materials; a material analysis data acquisition unit for acquiring material analysis data of the resin molded product; a calculation processing unit that performs a predetermined calculation process based on the raw material data and the material analysis data, The calculation processing unit compares the raw material blending ratio contained in the raw material data with the material content ratio contained in the material analysis data to determine whether it is within the range of the specifications of the resin molded product.

2. 2. The raw material collation system according to claim 1, wherein at least one of the two or more raw materials is a recycled material.

3. Further comprising a database; 2. The raw material collation system according to claim 1, wherein the database stores the production data including the raw material data in association with the result of the collation performed by the arithmetic processing unit.

4. Further comprising a database; 2. The raw material verification system according to claim 1, wherein said database stores the product data including said material analysis data in association with the result of verification obtained by said arithmetic processing unit.

5. 2. The raw material verification system according to claim 1, further comprising a signal for stopping production of said resin molded product to a production device of said resin molded product when said material content ratio is outside a range of said predetermined specifications of said resin molded product.

6. A method for controlling the quality of a resin molded product made from two or more types of raw materials, comprising: a raw material data acquisition unit acquiring raw material data including data on the analysis results of the two or more types of raw materials; A material analysis data acquisition unit acquires material analysis data of the resin molded product; A calculation processing unit performs a predetermined calculation process based on the raw material data and the material analysis data, The raw material verification method includes a step of verifying whether the raw material blending ratio contained in the raw material data is within a range of specifications for the resin molded product, the calculation processing including a step of verifying a raw material blending ratio contained in the raw material data and a material content ratio contained in the material analysis data, and determining whether the raw material blending ratio is within a range of specifications for the resin molded product.

7. 7. The raw material verification method according to claim 6, wherein at least one of the two or more raw materials is a recycled material.

8. 7. The raw material collation method according to claim 6, further comprising a step of storing in a database production data including the raw material data in association with the result of the collation obtained by the arithmetic processing unit.

9. 7. The raw material verification method according to claim 6, further comprising a step of storing in a database product data including said material analysis data in association with the result of verification obtained by said arithmetic processing unit.

10. 7. The raw material verification method according to claim 6, further comprising the step of transmitting a signal to a manufacturing device for the resin molded product to stop manufacturing the resin molded product when the material content ratio is outside a predetermined range of the specifications for the resin molded product.

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