Device inspection system and device inspection method

Abstract

To provide a device inspection system and a device inspection method, capable of efficiently and appropriately inspecting a device.SOLUTION: A device inspection system includes: an acquisition part that acquires information on an object from an object detection sensor capable of detecting the object; a foreign matter determination part that determines the presence or absence of a foreign matter in the device based on the information on the object acquired by the acquisition part; a device control part that performs test run of the device when the foreign matter determination part determines that there is no foreign matter in the device; and an operation inspection part that inspects an operation status of the device that is turned into a test run state by the device control part.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to an apparatus inspection system and an apparatus inspection method.

Background Art

[0002] Patent Document 1 discloses an apparatus inspection system. This apparatus inspection system includes a component identification unit, a mobile terminal, and a computer. The component identification unit is provided on a component to be inspected or its surrounding part, and represents identification data of the component. The mobile terminal reads the component identification unit, displays an inspection screen according to the identification data, and transmits information on the inspection result input according to the inspection screen to the computer.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the apparatus inspection system described in Patent Document 1, the purpose is to have an operator perform an inspection of a corresponding component at an inspection location of the corresponding component. On the other hand, it may be time-consuming for the operator to input data into the inspection screen. Also, since it is an inspection by the operator, even if the inspection target is the same component, the inspection results may differ depending on the operator. For this reason, there may be variations in the information on the inspection results input into the inspection screen. The present disclosure provides an apparatus inspection system and an apparatus inspection method that can efficiently and appropriately inspect an apparatus.

Means for Solving the Problems

[0005] An apparatus inspection system according to an aspect of the present disclosure includes an acquisition unit that acquires information about an object from an object detection sensor capable of detecting the object within the apparatus, a foreign object determination unit that determines the presence or absence of a foreign object within the apparatus based on the information about the object acquired by the acquisition unit, an apparatus control unit that causes the apparatus to be pre-operated when the foreign object determination unit determines that there is no foreign object within the apparatus, and an operation inspection unit that inspects the operation status of the apparatus that has been brought into the pre-operation state by the apparatus control unit.

Effect of the Invention

[0006] According to the present disclosure, the apparatus can be inspected efficiently and appropriately.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0008] [Examples of Embodiments of the Present Disclosure] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. In the description of the drawings, the same reference numerals are assigned to the same elements, and redundant descriptions are omitted. The dimensional ratios in the drawings do not necessarily match those in the description. The terms “upper”, “lower”, “left”, and “right” are based on the illustrated state and are for convenience.

[0009] In the following description, the conveyance direction of the mold is referred to as the X direction, the horizontal direction perpendicular to the X direction is referred to as the Y direction, and the direction perpendicular to the X and Y directions is referred to as the Z direction. The X and Y directions are horizontal directions, and the Z direction is a vertical direction. The terms "upstream" and "downstream" are used with reference to the conveyance direction of the mold.

[0010] [Overview of the apparatus inspection system] The apparatus inspection system 10 is a system for inspecting an apparatus. The apparatus to be inspected in the apparatus inspection system 10 is not limited to apparatuses of a specific business type. The apparatus to be inspected includes, for example, machines operating in a factory. Further, the apparatus to be inspected may be an apparatus within an area accessible to workers in a factory or in the vicinity of the area.

[0011] [Application form to the casting system] FIG. 1 is a configuration diagram schematically showing an example of a casting system in which the apparatus inspection system according to the embodiment is provided. The casting system 1 shown in FIG. 1 is an example of a system for manufacturing castings. The casting system 1 of the present embodiment includes the apparatus inspection system 10. The casting system 1 further includes a sand treatment system 2, a molding machine 3, a core set device 4, a mold alignment device 5, a pouring device 6, a post-treatment device 7, a control unit 8, and a conveyance line 9. The apparatus inspection system 10 according to the present embodiment inspects the sand treatment system 2, the molding machine 3, the core set device 4, the mold alignment device 5, the pouring device 6, the post-treatment device 7, and the conveyance line 9 included in the casting system 1. The sand treatment system 2, the molding machine 3, the core set device 4, the mold alignment device 5, the pouring device 6, the post-treatment device 7, and the conveyance line 9 are an example of casting equipment.

[0012] The sand treatment system 2 stores the casting sand used in the molding machine 3 and supplies the casting sand to the molding machine 3. The sand treatment system 2 includes a storage device 2a and a kneader 2b. The storage device 2a stores the casting sand that is the material of the mold M. The storage device 2a stores the casting sand so that a predetermined lying time is ensured before supplying the casting sand to the kneader 2b.

[0013] The foundry sand is supplied from the storage device 2a to the kneader 2b. The kneader 2b manufactures the kneaded sand which is the material of the mold M. For example, the kneader 2b manufactures the kneaded sand by adding moisture, binder, other additives (such as starch and coal powder), or a combination thereof to the foundry sand and kneading. Hereinafter, the kneaded sand may sometimes be simply described as "sand".

[0014] The molding machine 3 is a device for manufacturing the mold M. The molding machine 3 forms the mold M using the mold frame F. The molding machine 3 is communicably connected to the control unit 8. When the molding machine 3 receives a molding start signal from the control unit 8, it starts manufacturing the mold M. The mold M manufactured at the molding site is, for example, an upper mold or a lower mold. The molding machine 3 puts the kneaded sand (raw molding sand) into the mold frame F in which the pattern is placed, and pressurizes and solidifies the sand in the mold frame F. The molding machine 3 has, for example, a mold removing device (not shown). The molding machine 3 forms the mold M by separating the sand solidified by the mold removing device from the pattern. The molding machine 3 transmits a molding result signal to the control unit 8. The molding result signal is a signal indicating whether the molding machine 3 has operated normally.

[0015] The conveying line 9 is a facility for conveying the mold. The conveying line 9 receives the mold M from the molding machine 3 and conveys the mold M toward the frame aligning device 5. The conveying line 9 has, for example, a roller conveyor, a rail, a carriage on which the mold M and the mold frame F are placed and which travels on the rail, a pusher device arranged on the molding machine 3 side, and a cushion device arranged on the post-processing device 7 side. The roller conveyor or the rail extends linearly from the molding machine 3 toward the post-processing device 7. The roller conveyor or the rail is not limited to extending linearly, and may extend, for example, in a stepped shape. The roller conveyor or the rail may extend in one continuous stroke between the molding machine 3 and the post-processing device 7.

[0016] The conveying line 9 sequentially conveys a plurality of molds M and mold frames F arranged at equal intervals on the roller conveyor or the rail from the molding machine 3 toward the post-processing device 7. The conveying line 9 is driven intermittently and conveys the molds M and the mold frames F by a predetermined number of frames. The predetermined number of frames may be one frame or a plurality of frames.

[0017] The transfer line 9 is communicably connected to the control unit 8. When the transfer line 9 receives a frame feed signal from the control unit 8, it transfers a plurality of molds M and mold frames F for a predetermined number of frames. When the transfer of a predetermined number of frames is completed, the transfer line 9 transmits a frame feed completion signal to the control unit 8. The transfer line 9 may transmit a frame feed completion signal to the control unit 8 when the positioning of the transferred molds M and mold frames F is completed.

[0018] The core setting device 4 is arranged on the downstream side of the molding machine 3. The core setting device 4 grips cores with a robot hand or the like (not shown) and arranges the cores in the mold M. When the core setting device 4 receives a start signal from the control unit 8 to arrange the cores, it automatically arranges the cores in the mold M being transferred on the transfer line 9. The mold M in which the cores are arranged by the core setting device 4 is transferred by the transfer line 9 toward the frame aligning device 5.

[0019] The frame aligning device 5 is arranged on the downstream side of the molding machine 3. The frame aligning device 5 is a device that aligns the mold M serving as the upper mold and the mold M serving as the lower mold among the plurality of molds M transferred by the transfer line 9. When the frame aligning device 5 receives a frame aligning start signal from the control unit 8, it automatically aligns the upper mold and the lower mold being transferred on the transfer line 9. The mold M in which the upper mold and the lower mold are aligned by the frame aligning device 5 is transferred by the transfer line 9 toward the pouring device 6.

[0020] The pouring device 6 is arranged on the downstream side of the frame aligning device 5. The pouring device 6 manufactures a casting having a shape corresponding to the shape of the cavity of the mold M by pouring molten metal into the mold M. The operation of the pouring device 6 is controlled, for example, by the control unit 8. The mold M is poured with molten metal into the mold M under conditions (such as the pouring amount and the pouring speed) according to a control signal from the control unit 8. The mold M into which the molten metal has been poured is transferred by the transfer line 9 toward the post-processing device 7.

[0021] The post-processing device 7 is a device capable of performing operations such as an extraction process of removing a casting from the mold M and a blasting process of blasting the surface of the casting. The post-processing device 7, for example, collapses the mold M, separates it into the casting and sand, and cools the casting. When the post-processing device 7 receives an extraction start signal from the line control unit, it starts the extraction process and the blasting process of the casting and sand. The casting taken out from the mold M is conveyed by the conveying line 9 toward an area for carrying out (shipping).

[0022] The control unit 8 is a computer such as a PLC (Programmable Logic Controller) equipped with a processor, a storage device, an input device, a display device, a communication device, etc., and controls the operation of the entire casting system 1. The control unit 8, for example, loads a program stored in the storage device and realizes various functions described later by executing the loaded program with the processor. In the control unit 8, an operator can perform input operations of commands and the like for managing the casting system 1 using the input device, and the operating status of the casting system 1 can be visualized and displayed by the display device.

[0023] The control unit 8 is communicably connected to the sand processing system 2, the molding machine 3, the frame aligning device 5, the pouring device 6, the post-processing device 7, and the conveying line 9. The control unit 8 sends control signals to the sand processing system 2, the molding machine 3, the frame aligning device 5, the pouring device 6, the post-processing device 7, and the conveying line 9 to control the operations of these devices.

[0024] The device inspection system 10 includes a control unit 8 and a plurality of detection units 11. The detection unit 11 has at least one sensor. The detection unit 11 is provided in each device. That is, the plurality of detection units 11 in the present embodiment are respectively provided in the sand processing system 2, the molding machine 3, the core set device 4, the mold alignment device 5, the pouring device 6, the post-processing device 7, and the transfer line 9. Each of the plurality of detection units 11 acquires information regarding each device. That is, the plurality of detection units 11 acquire each information regarding the sand processing system 2, the molding machine 3, the core set device 4, the mold alignment device 5, the pouring device 6, the post-processing device 7, and the transfer line 9. The detection unit 11 may be provided in at least one component of the casting system 1. The information regarding the device includes at least one of, for example, information regarding an object in the device, information regarding the startup condition of the device, and information regarding the operation status (operation information) of the device. Details will be described later.

[0025] [Overview of Molding Machine] Hereinafter, the molding machine 3 and the device inspection system 10 will be described with reference to FIG. 2. FIG. 2 is a longitudinal sectional view showing the state of the molding machine (the state at the original position) before the start of the molding operation. As shown in FIG. 2, the molding machine 3 includes a sand tank 22 (an example of a tank). The sand tank 22 stores sand 23 inside. The sand tank 22 is connected to a compressed air source (not shown) and has a filter 22a provided with air ejection holes for ejecting air on its inner surface. The lower end of the sand tank 22 is open. A nozzle 24 is provided at the lower end of the sand tank 22.

[0026] Below the sand tank 22, a casting mold F is arranged. The casting mold F forms a molding space 26 together with at least a pattern plate 25. The sand 23 stored in the sand tank 22 is guided to the molding space 26 (an example inside the casting mold F) by the nozzle 24.

[0027] At the lower end of the sand tank 22, a segment type squeeze foot 27 (an example of a squeeze mechanism) is provided adjacent to the nozzle 24. The squeeze foot 27 functions as a squeeze means for compressing the sand 23 filled in the molding space 26.

[0028] Further, the molding machine 3 includes a molding base 28. A plurality of frame set cylinders 29 are erected on the molding base 28. Further, a lifting support frame 30 is installed between the tip ends of the piston rods 29a of the frame set cylinders 29. That is, the frame set cylinders 29 are erected upward with the molding base 28 side as the retracting end. A pressure sensor PB for detecting the squeeze pressure is provided on the frame set cylinder 29.

[0029] Below one of the plurality of frame set cylinders 29, the central portion of the pattern changing device 31 is rotatably supported in a horizontal plane. At both ends of the pattern changing device 31, pattern carriers 32 on which the above-described template 25 is placed are set in a state of being lifted by a spring (not shown), and are configured to alternately carry the template 25 into and out of the upper center of the molding base 28.

[0030] The above-described sand tank 22 is suspended from the lifting support frame 30. At the upper end of the sand tank 22, a sand inlet 22b that is opened and closed by a slide gate 33 is provided. Further, as described above, filter 22a for air ejection is provided on substantially the entire inner surface of the sand tank 22. The filter 22a is a porous body provided with a large number of holes over the entire surface. A hollow chamber 22c is formed between the filter 22a and the inner surface of the sand tank 22. Compressed air is supplied to the hollow chamber 22c from a compressed air source CA that communicates via an upper side air passage 34 and a lower side air passage 35. Further, a pressure sensor PA for detecting the pressure inside the sand tank 22 is provided in the hollow chamber 22c. The sand tank 22 configured in this way fluidizes the sand 23 by ejecting compressed air from a plurality of holes provided in the filter 22a, and fills the molding space 26 with the sand 23 through the nozzle 24 while fluidizing the sand. The compressed air source CA, the sand tank 22, and the nozzle 24 are an example of an injection unit that injects sand.

[0031] The above-mentioned squeeze foot 27 and nozzle 24 form a molding space 26 together with the template 25, the casting mold F, and the flask 36. The flask 36 is arranged below the sand tank 22 and is vertically movable so as to surround the nozzle 24 and the squeeze foot 27. The flask 36 is connected to a flask cylinder 37 provided downward on the lifting support frame 30 and is vertically moved by the flask cylinder 37.

[0032] The lifting support frame 30 is provided with a frame 38 located outside the sand tank 22 and provided on the lower side, and a loading / unloading conveyor 39 (an example of the conveying line 9) for loading and unloading the casting mold F is suspended via this frame 38. The loading / unloading conveyor 39 is constituted by, for example, a roller conveyor.

[0033] Next, a molding method using the molding machine 3 as described above will be described. In the molding method, from the original position shown in FIG. 2, sand is filled, compressed, and a mold release operation is performed. This will be described in detail below.

[0034] The state in FIG. 2 is a state in which sand 23 is charged into the sand tank 22 and an empty casting mold F is loaded onto the loading / unloading conveyor 39. The plurality of frame set cylinders 29 are in a state of being extended so that the lifting support frame 30 installed between the tips of the piston rods 29a is arranged at the upper end position as the original position state. The slide gate 33 is in a state of closing the sand inlet 22b as the original position state. The flask cylinder 37 is in a state of being retracted so that the flask 36 is located on the side (upper side) of the lifting support frame 30 as the original position state. The plurality of frame set cylinders 29, the slide gate 33, and the flask cylinder 37 are, for example, hydraulic actuators.

[0035] The pattern carrier 32 is set on the pattern changing device 31 in a state lifted by a spring (not shown) and there is a gap between it and the molding base 28. Next, the entire segment-type squeeze foot 27 forms unevenness relative to the unevenness of the lower template 25. Then, the pattern carrier 32 is pressed against the molding base 28 by a clamping device (not shown).

[0036] When the sand 23 is input, the slide gate 33 operates to open the sand input port 22b. After the input of the sand 23 is completed, the slide gate 33 operates to close the sand input port 22b. Then, the frame setting cylinder 37 extends to lower the frame 36 and press it against the upper surface of the mold frame F to make it closely adhere, and at the same time, the mold set cylinder 29 contracts to make the mold frame F closely adhere to the outer periphery of the mold plate 25, forming a molding space 26.

[0037] Next, while ejecting compressed air into the sand tank 22 from a large number of holes provided in the filter 22a to make the sand 23 in the sand tank 22 float and fluidize, the sand 23 is filled into the molding space 26 formed by the lower surfaces of the mold frame F, the mold plate 25, the frame 36, the squeeze foot 27, the lower surface of the sand tank 22, etc. At this time, the compressed air during filling is exhausted from vent holes (not shown) provided in the frame 36 and the mold plate 25. At this time, the exhaust amount from the vent holes can be controlled, and thereby, the filling density of the molding sand can be partially adjusted.

[0038] Next, the mold set cylinder 29 is further contracted, and while contracting the frame cylinder 37, the lifting support frame 30 and the members supported by it are lowered, and the squeeze operation is performed by compressing the sand 23 until the entire lower surface of the segment type squeeze foot 27 becomes flat.

[0039] Next, mold removal is performed. While raising the sand tank 22, the mold frame F is lifted by the loading and unloading conveyor 39 to remove the compressed sand 23 (mold M) in the mold frame F from the mold plate 25. Then, the sand tank 22 and the loading and unloading conveyor 39 are raised so as to return to the original position shown in FIG. 2. The operation in which each member moves up and down so as to return to this original position is called the original position return operation. When the original position return operation is completed, the slide gate 33 is operated to open the sand input port 22b, and the sand 23 in the sand tank 22 is replenished.

[0040] Next, the mold frame F with the mold M already molded is horizontally carried out via the loading and unloading conveyor 39, an empty mold frame F is carried in, the pattern exchange device 31 is rotated 180 degrees, and the mold plate 25 is replaced with the one outside, and the above operations are repeated.

[0041] [Application form to molding machine] As shown in FIGS. 2 and 3, the detection unit 11 includes an object detection unit 12, a feature amount measurement unit 13, and a position measurement unit 14 for the molding machine 3. The object detection unit 12 detects foreign objects in the molding machine 3, and the feature amount measurement unit 13 and the position measurement unit 14 detect information related to the drive of each actuator of the molding machine 3. This will be described in detail below.

[0042] The object detection unit 12 has an object detection sensor capable of detecting an object in the device. The object refers to, for example, a physical object necessary for driving the device including the components of the device, and a physical object not necessary for driving the device. The object detection unit 12 detects an object located in a region where the device can interfere during the drive of the device. The object here includes foreign objects. The foreign object includes a physical object not necessary for driving the device. The foreign object includes, for example, at least one of protective gear such as helmets, gloves, masks, goggles, tools, operators, and machine parts.

[0043] The object detection unit 12 has, for example, a plurality of cameras 12a. That is, the object detection unit 12 of the present embodiment has a CCD sensor as an object detection sensor. The plurality of cameras 12a are provided in at least one of the regions inside and around the molding machine 3, and image at least a part of the inside of the molding machine 3. The inside of the molding machine 3 includes at least one of the region where the molding space 26 is formed in the molding machine 3 (the region on and above the mold plate 25) and the region where each actuator of the molding machine 3 operates. The plurality of cameras 12a image, for example, so that the region where the molding space 26 is formed enters the image. As shown in FIG. 2, the plurality of cameras 12a image the inside of the molding machine 3 from different positions. The plurality of cameras 12a are respectively arranged so that there is no dead angle that any of the plurality of cameras 12a cannot recognize with respect to the region where foreign matter can enter or be arranged inside the molding machine 3. Note that the number of cameras 12a is not limited, and may be one, or may be three or more.

[0044] The object detection unit 12 acquires a plurality of reference images that are imaged by the plurality of cameras 12a and show the state of the inside of the molding machine 3 in a state where there is no foreign matter. Further, the object detection unit 12 acquires a plurality of inspection images that are imaged by the camera 12a and show the state of the inside of the molding machine 3 before the determination of the start-up condition or before the trial operation of the molding machine 3. The object detection unit 12 outputs the plurality of reference images and the plurality of inspection images to the control unit 8.

[0045] The plurality of cameras 12a of the object detection unit 12 operate regardless of whether the molding machine 3 is started. For example, the power required for the plurality of cameras 12a to image the plurality of reference images and the plurality of inspection images is supplied from dedicated respective circuits, not from the power supply circuit provided for the operation of the molding machine 3.

[0046] The feature measurement unit 13 measures the feature quantities of the power medium used in the actuator provided in the apparatus. The power medium in the present embodiment is the hydraulic oil used in each actuator of the molding machine 3. The feature measurement unit 13 measures the hydraulic pressure as the feature quantity of the hydraulic oil. The feature measurement unit 13 has, for example, a plurality of hydraulic oil detectors 13a, 13b, and 13c. The plurality of hydraulic oil detectors 13a, 13b, and 13c detect the pressure (hydraulic pressure) and the flow rate (oil quantity) of the hydraulic oil. The plurality of hydraulic oil detectors 13a, 13b, and 13c are respectively connected to the actuators of the molding machine 3. The plurality of hydraulic oil detectors 13a, 13b, and 13c are respectively connected to, for example, a plurality of frame setting cylinders 29, a slide gate 33, and a flask cylinder 37.

[0047] The hydraulic oil detector 13a measures the hydraulic pressure, oil quantity, and oil temperature in the plurality of frame setting cylinders 29. The hydraulic oil detector 13b measures the hydraulic pressure, oil quantity, and oil temperature in the slide gate 33. The hydraulic oil detector 13c measures the hydraulic pressure, oil quantity, and oil temperature in the flask cylinder 37. The plurality of hydraulic oil detectors 13a, 13b, and 13c output the measured hydraulic pressure, oil quantity, and oil temperature to the control unit 8.

[0048] The feature measurement unit 13 further measures the feature quantities of the supply medium of the apparatus. The supply medium in the present embodiment is the compressed air supplied from the compressed air source CA to the sand tank 22 via the upper side air passage 34 and the lower side air passage 35. The feature measurement unit 13 measures, as the feature quantities of the compressed air, the pressure of the compressed air flowing through the upper side air passage 34 and the lower side air passage 35, and the volume for detecting the sound of the leakage of the compressed air from the upper side air passage 34 and the lower side air passage 35. The feature measurement unit 13 has, for example, a plurality of gas detectors 13d, 13d. One gas detector 13d is provided in the upper side air passage 34, and the other gas detector 13d is provided in the lower side air passage 35. The plurality of gas detectors 13d, 13d output the measured pressure and volume to the control unit 8.

[0049] Among the feature measurement units 13, at least a plurality of hydraulic fluid detectors 13a, 13b, 13c operate regardless of whether the molding machine 3 is started. For example, the power required when the plurality of hydraulic fluid detectors 13a, 13b, 13c measure hydraulic pressure, oil quantity, and oil temperature is supplied not from the power supply circuit provided for the operation of the molding machine 3 but from dedicated individual circuits. The power required when the plurality of hydraulic fluid detectors 13a, 13b, 13c measure the oil quantity, and the power required when the plurality of gas detectors 13d, 13d measure pressure and temperature may be supplied not from the power supply circuit provided for the operation of the molding machine 3 but from dedicated individual circuits.

[0050] The position measurement unit 14 measures the position of an actuator provided in the device. The position measurement unit 14 has, for example, a plurality of proximity switches 14a, 14a, 14b, 14c, 14c. The plurality of proximity switches 14a, 14a, 14b, 14c, 14c are respectively provided on the actuator of the molding machine 3. The plurality of proximity switches 14a, 14a, 14b, 14c, 14c are provided, for example, on a plurality of frame setting cylinders 29, slide gates 33, and mold frame cylinders 37.

[0051] The pair of proximity switches 14a, 14a receive a signal when the plurality of frame setting cylinders 29 are in the home position. The pair of proximity switches 14a, 14a do not receive a signal when the plurality of frame setting cylinders 29 are retracted by a predetermined distance from the home position. The proximity switch 14b receives a signal when the slide gate 33 is in the home position. The proximity switch 14b does not receive a signal when the slide gate 33 is opened by a predetermined distance from the home position. The pair of proximity switches 14c, 14c receive a signal when the mold frame cylinder 37 is in the home position. The pair of proximity switches 14c, 14c do not receive a signal when the mold frame cylinder 37 is extended by a predetermined distance from the home position.

[0052] In this way, the plurality of proximity switches 14a, 14a, 14b, 14c, 14c output the measured signals to the control unit 8 for the configuration in which they are located at the original positions. Note that each signal measured by the plurality of proximity switches 14a, 14a, 14b, 14c, 14c is output to the control unit 8 so as to be distinguishable from each other.

[0053] Among the position measurement units 14, the plurality of proximity switches 14a, 14a, 14b, 14c, 14c operate regardless of whether the molding machine 3 is started or not. For example, the power required when the plurality of proximity switches 14a, 14a, 14b, 14c, 14c receive and output signals is supplied not from the power supply circuit provided for the operation of the molding machine 3 but from dedicated respective circuits.

[0054] Referring to FIG. 3, the functions of the control unit 8 according to the apparatus inspection system 10 will be described. As shown in FIG. 3, the control unit 8 includes an acquisition unit 81, a foreign matter determination unit 82, a start condition determination unit 83, an apparatus control unit 84, an operation inspection unit 85, a storage unit 86, and a notification unit 87.

[0055] The foreign matter determination unit 82 determines the presence or absence of foreign matter in the molding machine 3 based on the information acquired by the acquisition unit 81. The start condition determination unit 83 determines whether the molding machine 3 satisfies the start conditions based on the information acquired by the acquisition unit 81. The apparatus control unit 84 causes the molding machine 3 to be test-run when the foreign matter determination unit 82 determines that there is no foreign matter in the molding machine 3 and the start condition determination unit 83 determines that the molding machine 3 satisfies the start conditions. The operation inspection unit 85 inspects the operation status of the test run of the molding machine 3 by the apparatus control unit 84. The storage unit 86 stores the reference image and threshold value necessary for the above-described determination. The notification unit 87 notifies each of the above-described determination results. Details will be described below.

[0056] The acquisition unit 81 acquires information about an object from an object detection sensor capable of detecting the object. The acquisition unit 81 acquires information about the object in the molding machine 3 from the detection unit 11. The information about the object includes the detection result of the object by the object detection sensor. The acquisition unit 81 acquires a plurality of reference images and a plurality of inspection images from the object detection unit 12 as information about the object in the molding machine 3.

[0057] Also, the acquisition unit 81 acquires, as information about the startup condition of the molding machine 3, the characteristic amount of the power medium used for the actuator of the molding machine 3 and information about the position of the actuator of the molding machine 3. The acquisition unit 81 acquires, as the characteristic amount of the power medium of the molding machine 3, the hydraulic pressure, the oil volume, and the oil temperature in each actuator of the molding machine 3 from the characteristic amount measurement unit 13. The acquisition unit 81 acquires, as information about the position of the actuator of the molding machine 3, a signal output by the proximity switches 14a, 14a, 14b, 14c, 14c, which is a signal related to the configuration located at the original position in each actuator of the molding machine 3, from the position measurement unit 14. When the position measurement unit 14 does not receive a signal from the proximity switches 14a, 14a, 14b, 14c, 14c when each actuator of the molding machine 3 is not in the original position, the acquisition unit 81 acquires, as information about the position of the actuator of the molding machine 3, a signal from the position measurement unit 14 indicating that the position measurement unit 14 has not received a signal from the proximity switches 14a, 14a, 14b, 14c, 14c.

[0058] Furthermore, the acquisition unit 81 acquires the pressure and volume of the upper air passage 34 and the lower air passage 35 from the characteristic amount measurement unit 13 as information about the operating status of the molding machine 3. Also, the acquisition unit 81 acquires the oil volume for each actuator of the molding machine 3 from the characteristic amount measurement unit 13 as information about the operating status of the molding machine 3.

[0059] The foreign object determination unit 82 determines the presence or absence of foreign objects in the apparatus based on the information regarding the object acquired by the acquisition unit 81. In the present embodiment, the foreign object determination unit 82 determines the presence or absence of foreign objects in the molding machine 3 based on a plurality of reference images and a plurality of inspection images acquired by the acquisition unit 81. Here, in the object detection unit 12, by using the same camera 12a, images with the same focal length and angle of view can be obtained. For this reason, when there are no foreign objects inside the molding machine 3 during the imaging of the inspection image by the camera 12a, the inspection image and the reference image show the same content. The same content includes physical objects necessary during the driving of the apparatus.

[0060] The foreign object determination unit 82 generates a difference image showing the difference between the reference image and the inspection image captured for each camera 12a. The difference image represents the change in the image from the time the reference image is captured to the time the inspection image is captured. The foreign object determination unit 82 performs particle analysis on the generated difference image and detects blobs in the difference image.

[0061] For example, when a blob with a size of a predetermined number of pixels or more appears in the generated difference image, the foreign object determination unit 82 determines that there are foreign objects in the molding machine 3. When no blob with a size of a predetermined number of pixels or more appears in each of the plurality of difference images showing the differences between the plurality of reference images and the plurality of inspection images acquired from all the cameras 12a, the foreign object determination unit 82 determines that there are no foreign objects in the molding machine 3.

[0062] When the foreign object determination unit 82 determines that there are no foreign objects in the apparatus, the startup condition determination unit 83 determines whether the apparatus satisfies the startup conditions. When the foreign object determination unit 82 determines that there are no foreign objects in the molding machine 3, the startup condition determination unit 83 determines whether the molding machine 3 satisfies the startup conditions based on the information acquired by the feature amount measurement unit 13 and the position measurement unit 14.

[0063] The startup condition determination unit 83 determines whether the characteristic quantity of the power medium is within a predetermined threshold range as a determination of whether the device satisfies the startup conditions. The startup condition determination unit 83 determines whether the hydraulic pressure, oil quantity, and oil temperature of the plurality of frame set cylinders 29, the slide gate 33, and the mold frame cylinder 37 are within the respective predetermined threshold ranges as a determination of whether the molding machine 3 satisfies the startup conditions.

[0064] When the hydraulic pressure, oil quantity, and oil temperature in the plurality of frame set cylinders 29 acquired by the acquisition unit 81 from the hydraulic oil detector 13a are within the respective predetermined threshold ranges, the startup condition determination unit 83 determines that the plurality of frame set cylinders 29 satisfy the startup conditions. When the hydraulic pressure, oil quantity, and oil temperature in the slide gate 33 acquired by the acquisition unit 81 from the hydraulic oil detector 13b are within the respective predetermined threshold ranges, the startup condition determination unit 83 determines that the slide gate 33 satisfies the startup conditions. When the hydraulic pressure, oil quantity, and oil temperature in the mold frame cylinder 37 acquired by the acquisition unit 81 from the hydraulic oil detector 13c are within the respective predetermined threshold ranges, the startup condition determination unit 83 determines that the mold frame cylinder 37 satisfies the startup conditions.

[0065] When the acquisition unit 81 determines that the hydraulic pressure, oil quantity, and oil temperature of the plurality of frame set cylinders 29, the slide gate 33, and the mold frame cylinder 37 are within the respective predetermined threshold ranges, it is determined that the molding machine 3 satisfies the startup conditions.

[0066] The startup condition determination unit 83 determines whether the actuator is located within a predetermined range as a determination of whether the device satisfies the startup conditions. The startup condition determination unit 83 determines whether the plurality of frame set cylinders 29, the slide gate 33, and the mold frame cylinder 37 are in their original positions as a determination of whether the molding machine 3 satisfies the startup conditions.

[0067] When the acquisition unit 81 does not detect signals from the pair of proximity switches 14a, 14a, the startup condition determination unit 83 determines that the startup conditions are not met, assuming that the plurality of frame set cylinders 29 are not in their original positions. When the acquisition unit 81 does not detect a signal from the proximity switch 14b, the startup condition determination unit 83 determines that the startup conditions are not met, assuming that the slide gate 33 is not in its original position. When the acquisition unit 81 does not detect signals from the pair of proximity switches 14c, 14c, the startup condition determination unit 83 determines that the startup conditions are not met, assuming that the mold frame cylinder 37 is not in its original position.

[0068] Before the startup condition determination unit 83 starts determining whether the molding machine 3 meets the startup conditions, if the acquisition unit 81 detects signals from the plurality of proximity switches 14a, 14a, 14b, 14c, 14c, the startup condition determination unit 83 determines that the plurality of frame set cylinders 29, the slide gate 33, and the mold frame cylinder 37 are each in their original positions, and determines that the molding machine 3 meets the startup conditions.

[0069] In the determination based on the hydraulic pressure, the oil quantity, and the oil temperature of each of the plurality of hydraulic oil detectors 13a, 13b, 13c of the feature amount measurement unit 13, and the signals of the plurality of proximity switches 14a, 14a, 14b, 14c, 14c of the position measurement unit 14, when the startup condition determination unit 83 determines that the molding machine 3 meets the startup conditions, the startup condition determination unit 83 determines that the entire molding machine 3 meets the startup conditions.

[0070] When the foreign object determination unit 82 determines that there is no foreign object in the device, the device control unit 84 causes the device to perform a test run. When the foreign object determination unit 82 determines that there is no foreign object in the molding machine 3 and the startup condition determination unit 83 determines that the entire molding machine 3 satisfies the startup conditions, the device control unit 84 causes the molding machine 3 to perform a test run. The test run here includes driving each actuator of the molding machine 3. The test run includes, for example, driving for one cycle from the start to the end of the production of one mold M in the molding machine 3. The test run includes what is called an idle run in which each component of the molding machine 3 is driven without using the material actually used for the production of the mold M.

[0071] The device control unit 84 executes the test run so that the device operates under the same conditions as the production conditions of the product manufactured by the device. That is, the device control unit 84 controls each component of the molding machine 3 so that it operates under the same conditions as the production conditions of the mold M manufactured by the molding machine 3. The device control unit 84 can control the sand tank 22 so as to supply compressed air (an example of a gas) and inject the sand 23 as at least a part of the process of manufacturing the product, and executes the test run so as to supply compressed air under the same conditions as the supply conditions of the compressed air in the process. Specifically, during the test run, although it is controlled so that the sand 23 is not injected from the sand tank 22, it includes making the output conditions of the compressed air used for the injection of the sand 23 the same during the test run and during the production of the mold M.

[0072] When the startup condition determination unit 83 determines that the device does not satisfy the startup conditions, the device control unit 84 adjusts the device so as to match the startup conditions and causes the device to perform a test run. The device control unit 84 adjusts each component of the molding machine 3 so as to match the startup conditions for the determination target that does not satisfy the startup conditions.

[0073] When the device control unit 84 determines that the characteristic quantity of the power medium is not within the predetermined threshold range by the startup condition determination unit 83, it adjusts the characteristic quantity so that it is within the predetermined threshold range. For example, in the determination based on the hydraulic pressure, oil quantity, and oil temperature of the hydraulic oil detector 13a of the characteristic quantity measurement unit 13, when it is determined that the molding machine 3 does not satisfy the startup condition, the device control unit 84 adjusts the hydraulic oil supplied to the plurality of frame setting cylinders 29 so that the hydraulic pressure, oil quantity, and oil temperature in the plurality of frame setting cylinders 29 are respectively within the predetermined threshold ranges. For example, in the determination based on the hydraulic pressure, oil quantity, and oil temperature of the hydraulic oil detector 13b of the characteristic quantity measurement unit 13, when it is determined that the molding machine 3 does not satisfy the startup condition, the device control unit 84 adjusts the hydraulic oil supplied to the slide gate 33 so that the hydraulic pressure, oil quantity, and oil temperature in the slide gate 33 are respectively within the predetermined threshold ranges.

[0074] For example, in the determination based on the hydraulic pressure, oil quantity, and oil temperature of the hydraulic oil detector 13c of the characteristic quantity measurement unit 13, when it is determined that the molding machine 3 does not satisfy the startup condition, the device control unit 84 adjusts the state of the hydraulic oil supplied to the flask cylinder 37 so that the hydraulic pressure, oil quantity, and oil temperature in the flask cylinder 37 are respectively within the predetermined threshold ranges. The adjustment of the above-mentioned hydraulic oil is to perform, for example, the following processes. For example, when the hydraulic pressure is greater than the upper limit value of the predetermined threshold range, the device control unit 84 lowers the hydraulic pressure. For example, when the hydraulic pressure is less than the lower limit value of the predetermined threshold range, the device control unit 84 raises the hydraulic pressure. For example, when the oil quantity is greater than the upper limit value of the predetermined threshold range, the device control unit 84 lowers the oil quantity. For example, when the oil quantity is less than the lower limit value of the predetermined threshold range, the device control unit 84 raises the oil quantity. For example, when the oil temperature is greater than the upper limit value of the predetermined threshold range, the device control unit 84 lowers the oil temperature. For example, when the oil temperature is less than the lower limit value of the predetermined threshold range, the device control unit 84 raises the oil temperature.

[0075] When the activation condition determination unit 83 determines that each actuator is not within a predetermined range, the device control unit 84 adjusts each actuator to be within the predetermined range. When the device control unit 84 determines, based on the signals from the plurality of proximity switches 14a, 14a of the position measurement unit 14, that the molding machine 3 does not satisfy the activation conditions, the device control unit 84 drives the plurality of frame setting cylinders 29 so that the plurality of frame setting cylinders 29 are positioned at their original positions. The driving of the plurality of frame setting cylinders 29 is performed when it is determined that the hydraulic pressure, the amount of oil, and the oil temperature detected by the hydraulic oil detector 13a of the feature measurement unit 13 are within a predetermined threshold range.

[0076] For example, when the device control unit 84 determines, based on the signal from the proximity switch 14b of the position measurement unit 14, that the molding machine 3 does not satisfy the activation conditions, the device control unit 84 drives the slide gate 33 so that the slide gate 33 is positioned at its original position. The driving of the slide gate 33 is performed when it is determined that the hydraulic pressure, the amount of oil, and the oil temperature detected by the hydraulic oil detector 13b of the feature measurement unit 13 are within a predetermined threshold range.

[0077] For example, when the device control unit 84 determines, based on the signals from the plurality of proximity switches 14c, 14c of the position measurement unit 14, that the molding machine 3 does not satisfy the activation conditions, the device control unit 84 drives the mold frame cylinder 37 so that the mold frame cylinder 37 is positioned at its original position. The driving of the mold frame cylinder 37 is performed when it is determined that the hydraulic pressure, the amount of oil, and the oil temperature detected by the hydraulic oil detector 13c of the feature measurement unit 13 are within a predetermined threshold range.

[0078] The operation inspection unit 85 inspects the operation status of the device that has been put into the test operation state by the device control unit 84. The operation inspection unit 85 determines whether the operation status of the molding machine 3 is appropriate based on the information acquired by the feature measurement unit 13. The operation inspection unit 85 determines whether the operation status of the molding machine 3 is appropriate based on the feature amount detected when the molding machine 3 in the test operation state is driven.

[0079] The operation inspection unit 85 determines whether the pressure obtained from the plurality of gas detectors 13d, 13d of the feature amount measurement unit 13 is within a predetermined threshold range as a determination of whether the operation status of the molding machine 3 is appropriate. When the pressures of all of the plurality of gas detectors 13d, 13d are within the predetermined threshold range, the operation inspection unit 85 determines that the operation status of the molding machine 3 is appropriate, assuming that the configuration regarding the compressed air of the molding machine 3 is operating properly.

[0080] When the pressure of at least one of the plurality of gas detectors 13d, 13d is outside the predetermined threshold range, it is presumed that at least one of the plurality of gas detectors 13d, 13d has detected a state in which compressed air is not being supplied properly. In this case, the operation inspection unit 85 determines that the operation status of the molding machine 3 is not appropriate, assuming that the configuration regarding the compressed air of the molding machine 3 (for example, at least one of the compressed air source CA, the sand tank 22, the upper air passage 34, and the lower air passage 35) is not operating properly.

[0081] Also, the operation inspection unit 85 determines whether the volume obtained from the plurality of gas detectors 13d, 13d of the feature amount measurement unit 13 is less than a predetermined threshold as a determination of whether the operation status of the molding machine 3 is appropriate. When the volumes of all of the plurality of gas detectors 13d, 13d are less than the predetermined threshold, the operation inspection unit 85 determines that the operation status of the molding machine 3 is appropriate, assuming that the configuration regarding the compressed air of the molding machine 3 is operating properly.

[0082] When the volume of at least one of the plurality of gas detectors 13d, 13d is equal to or greater than the predetermined threshold, it is presumed that at least one of the plurality of gas detectors 13d, 13d has detected a sound generated by a leak of compressed air. In this case, the operation inspection unit 85 determines that the operation status of the molding machine 3 is not appropriate, assuming that the configuration regarding the compressed air of the molding machine 3 (for example, at least one of the upper air passage 34 and the lower air passage 35) is not operating properly.

[0083] Furthermore, as a determination of whether the operation status of the molding machine 3 is appropriate, the operation inspection unit 85 determines whether each oil quantity acquired from the plurality of hydraulic oil detectors 13a, 13b, and 13c of the feature quantity measurement unit 13 is within a predetermined threshold range. When each oil quantity of the plurality of hydraulic oil detectors 13a, 13b, and 13c is within the predetermined threshold range, the operation inspection unit 85 determines that the operation status of the molding machine 3 is appropriate, assuming that each actuator of the molding machine 3 is appropriately driven.

[0084] When at least one value of the oil quantities acquired from the plurality of hydraulic oil detectors 13a, 13b, and 13c is outside the predetermined threshold range, it is presumed that the amount of oil leakage occurring in at least one actuator in which the oil quantity is detected to be outside the threshold range is being detected. In this case, the operation inspection unit 85 determines that the operation status of the molding machine 3 is not appropriate, assuming that the configuration related to the hydraulic oil of the molding machine 3 (for example, at least one of the plurality of frame set cylinders 29, the slide gate 33, and the flask cylinder 37) is not operating appropriately.

[0085] When the operation inspection unit 85 determines that the operation status of the molding machine 3 is appropriate in the determination based on the pressure and volume of each of the plurality of gas detectors 13d, 13d and the determination based on the oil quantity of each of the plurality of hydraulic oil detectors 13a, 13b, and 13c, the operation inspection unit 85 determines that the operation status of the entire molding machine 3 is appropriate.

[0086] The storage unit 86 stores information that serves as the criteria for the determinations of the foreign object determination unit 82, the startup condition determination unit 83, and the operation inspection unit 85. The storage unit 86 stores a reference image that is captured by the plurality of cameras 12a of the object detection unit 12 and is used during the determination by the foreign object determination unit 82. The storage unit 86 stores threshold ranges that are used during the determination by the startup condition determination unit 83, specifically, threshold ranges for the hydraulic pressure, oil volume, and oil temperature of each actuator of the molding machine 3. The storage unit 86 stores threshold ranges that are used during the determination by the operation inspection unit 85, specifically, threshold ranges for the pressure of the upper air passage 34 and the lower air passage 35, the upper limit value for the volume, and threshold ranges for the oil volume of each actuator of the molding machine 3. Further, the storage unit 86 may store a device inspection program for causing the device inspection system 10 to execute the device inspection method described later.

[0087] The storage unit 86 may store the inspection results by each component. The storage unit 86 may store the inspection images captured by the object detection unit 12, the hydraulic pressure, oil volume, and oil temperature of each actuator of the molding machine 3 measured by the feature amount measurement unit 13, and the pressure and volume of the upper air passage 34 and the lower air passage 35 measured by the feature amount measurement unit 13. The storage unit 86 stores the determination results in the foreign object determination unit 82, the startup condition determination unit 83, and the operation inspection unit 85.

[0088] When the foreign object determination unit 82 determines that there is a foreign object, when the startup condition determination unit 83 determines that the startup conditions are not satisfied, or when the operation inspection unit 85 determines that the operation status of the molding machine 3 is inappropriate, the notification unit 87 notifies of an abnormality. The notification unit 87 outputs a signal to a display device (not shown), for example, to visually display that there is an abnormality. The control unit 8 may have a buzzer (not shown). The notification unit 87 outputs a signal to the buzzer to emit a sound or voice indicating that there is an abnormality.

[0089] [Device Inspection Method] FIG. 4 is a flowchart showing an example of a device inspection method by the device inspection system according to the embodiment. The device inspection method shown in FIG. 4 is executed by the device inspection system 10 of the present embodiment. The device inspection method is executed before the start of work in a factory or the like, before the operation of each component of the factory, and before the manufacture of a product. The device inspection method starts in a state where a reference image, a threshold value, and a threshold value range used for the determination of each functional unit are stored in the storage unit 86 in advance. Hereinafter, an example in which the device inspection system 10 is applied to the molding machine 3 will be described.

[0090] First, as an acquisition step (S10), the acquisition unit 81 acquires information (detection result of an object) regarding an object in the molding machine 3 from an object detection sensor capable of detecting the object. The inspection image is an image captured by the camera 12a (CCD sensor) of the object detection unit 12 and shows information about the object in the molding machine 3. The acquisition unit 81 acquires a plurality of inspection images captured by the plurality of cameras 12a from the object detection unit 12 as information regarding the object.

[0091] Subsequently, as a foreign matter determination step (S11), the foreign matter determination unit 82 determines the presence or absence of a foreign matter in the molding machine 3 based on the information regarding the object in the molding machine 3 acquired by the acquisition unit 81. The foreign matter determination unit 82 generates a difference image based on the reference image and the inspection image acquired from each camera 12a. When no object having a size equal to or larger than a predetermined number of pixels is reflected in each of the plurality of difference images, the foreign matter determination unit 82 determines that there is no foreign matter in the molding machine 3 (S11: YES). When an object having a size equal to or larger than a predetermined number of pixels is reflected in any of the plurality of difference images, the foreign matter determination unit 82 determines that there is a foreign matter in the molding machine 3 (S11: NO).

[0092] When it is determined that there is no foreign matter in the molding machine 3 (S11: YES), as a first feature amount measurement step (S12), the feature amount measurement unit 13 measures the feature amount of the hydraulic oil used for the actuator provided in the molding machine 3. The feature amount measurement unit 13 measures the hydraulic pressure, the amount of oil, and the oil temperature of each actuator of the molding machine 3. The acquisition unit 81 acquires the hydraulic pressure, the amount of oil, and the oil temperature measured by the feature amount measurement unit 13.

[0093] Subsequently, as the position measurement step (S13), the position measurement unit 14 measures the position of the actuator provided in the molding machine 3. The acquisition unit 81 acquires a signal indicating that the position is the original position output by the plurality of proximity switches 14a, 14a, 14b, 14c, 14c, or a signal indicating that no signal is received from the plurality of proximity switches 14a, 14a, 14b, 14c, 14c from the position measurement unit 14.

[0094] Subsequently, as the start condition determination step (S14), the start condition determination unit 83 determines whether the molding machine 3 satisfies the start conditions. When the start condition determination unit 83 determines that each hydraulic pressure, each oil quantity, and each oil temperature detected in the first feature quantity measurement step (S12) are within the threshold range, and signals from the plurality of proximity switches 14a, 14a, 14b, 14c, 14c are received in the position measurement step (S13), it is determined that the entire molding machine 3 satisfies the start conditions (S14: YES). When the start condition determination unit 83 determines that each hydraulic pressure, each oil quantity, or each oil temperature detected in the first feature quantity measurement step (S12) is not within the threshold range, or when it is determined that signals from at least one of the plurality of proximity switches 14a, 14a, 14b, 14c, 14c are not received in the position measurement step (S13), it is determined that the entire molding machine 3 does not satisfy the start conditions (S14: NO).

[0095] When it is determined that the entire molding machine 3 does not satisfy the start conditions (S14: NO), as the adjustment step (S15), the device control unit 84 adjusts the molding machine 3 so as to match the start conditions. The device control unit 84 adjusts, for example, so that each hydraulic pressure, each oil quantity, and each oil temperature of the hydraulic oil used for each actuator of the molding machine 3 are within the threshold range. The device control unit 84 drives, for example, the actuator to be positioned at the original position. After the execution of the adjustment, the device inspection system 10 executes the steps again from the first feature quantity measurement step (S13) as the device inspection method.

[0096] When it is determined that the entire molding machine 3 satisfies the startup conditions (S14: YES), as a test operation process (S16), the device control unit 84 causes the molding machine 3 to perform a test operation. The device control unit 84 executes a test operation including an operation of supplying compressed air to the sand tank 22 so as to be the same conditions as the supply conditions of the compressed air in the process of controlling the sand tank 22 to inject the sand 23.

[0097] Subsequently, as a second feature amount measurement step (S17), the feature amount measurement unit 13 measures the feature amount of the medium related to the molding machine 3. The feature amount measurement unit 13 measures the feature amount of the compressed air as the supply medium supplied to the sand tank 22. The feature amount measurement unit 13 measures the pressure and volume of the compressed air in the upper air passage 34 and the lower air passage 35. Further, as a second feature amount measurement step (S16), the feature amount measurement unit 13 measures the feature amount of the power medium used for the actuator provided in the molding machine 3. The feature amount measurement unit 13 measures the oil amount of each actuator of the molding machine 3. The acquisition unit 81 acquires the pressure, volume, and oil amount of the compressed air measured by the feature amount measurement unit 13.

[0098] Subsequently, as an operation status determination step (S18), the operation inspection unit 85 determines whether the operation status of the molding machine 3 is appropriate. The operation inspection unit 85 makes a determination based on each pressure related to the compressed air measured by the plurality of feature amount measurement units 13 and each volume, and a determination based on each oil amount of the actuator measured by the plurality of hydraulic oil detectors 13a, 13b, 13c. When it is determined that the operation status of the molding machine 3 is appropriate, the operation inspection unit 85 determines that the operation status of the entire molding machine 3 is appropriate (S18: YES). In this case, the device inspection method ends.

[0099] When the operation inspection unit 85 determines that the operation status of the molding machine 3 is not appropriate in the determination based on each pressure related to the compressed air measured by the plurality of feature amount measurement units 13 or each volume, or the determination based on each oil amount of the actuator measured by the plurality of hydraulic oil detectors 13a, 13b, 13c, the operation inspection unit 85 determines that the operation status of the entire molding machine 3 is not appropriate (S18: NO).

[0100] When it is determined that there is a foreign object in the molding machine 3 in the foreign object determination step (S11) (S11: NO), or when it is determined that the operating status of the entire molding machine 3 is inappropriate in the operating status determination step (S18) (S18: NO), as the notification step (S19), the notification unit 87 notifies of an abnormality. The notification unit 87 notifies separately of the notification of the foreign object in the foreign object determination step (S11) and the notification of the abnormality of the operating status in the operating status determination step (S18). In this case, the apparatus inspection method is terminated. The operator can remove the foreign object or inspect the abnormal part based on the determination result.

[0101] [Summary of the Embodiment] In the apparatus inspection system 10 and the apparatus inspection method, based on the information regarding the object in the molding machine 3 automatically acquired by the camera 12a of the object detection unit 12 by the acquisition unit 81, the presence or absence of a foreign object in the molding machine 3 is determined by the foreign object determination unit 82. Thereby, it is possible to efficiently determine the presence or absence of a foreign object in the molding machine 3 without going through the inspection work by the operator. For example, when the operator performs the inspection work of the molding machine, there may be variations in the quality of the inspection by the operator. Further, when the operator inputs the content and the inspection result of the inspection work of the molding machine to the control unit or the like, there is a possibility of erroneously inputting at least one of the input content and the inspection result. On the other hand, according to the apparatus inspection system 10 of the present embodiment, the object can be detected with a certain quality by the object detection unit 12, and the presence or absence of a foreign object can be determined with a certain quality by the foreign object determination unit 82. Therefore, the apparatus inspection system 10 can eliminate the variations in the inspection results by the operator for the foreign object in the molding machine 3 and can detect it with a certain quality.

[0102] Further, it is determined by the start condition determination unit 83 whether or not the start condition is satisfied. Thereby, it is possible to efficiently determine whether or not each actuator of the molding machine 3 is in an appropriate state without going through the inspection work by the operator. The apparatus inspection system 10 can eliminate the variations in the inspection results by the operator for the start condition of the molding machine 3 and can inspect it with a certain quality.

[0103] In addition, with no foreign matter in the molding machine 3, the apparatus control unit 84 can execute a test run of the molding machine 3. Further, by the test run of the molding machine 3, the operation inspection unit 85 can inspect the operation status of the molding machine 3. Thereby, the molding machine 3 can be appropriately inspected up to the operation status of the molding machine 3. Also, regarding the operation status of the molding machine, as in the above case, when an operator inspects, there is a possibility of erroneously inputting at least one of the input content and the inspection result. On the other hand, according to the apparatus inspection system 10 of the present embodiment, the operation inspection unit 85 can inspect the operation status with a certain quality. For this reason, the apparatus inspection system 10 can eliminate variations in inspection results by an operator regarding the operation status of the molding machine 3 and can inspect with a certain quality. Thus, the apparatus inspection system 10 can inspect foreign matter without starting the molding machine 3 before manufacturing the mold M by the molding machine 3, start the molding machine 3 to perform a test run, and also inspect the operation status of the molding machine 3.

[0104] Also, when it is determined by the start condition determination unit 83 that the start condition is not satisfied, the apparatus control unit 84 adjusts the molding machine 3 to meet the start condition. Thereby, since there is no need for an operator to perform an inspection operation and an adjustment operation before the operation of the molding machine 3 including the test run, the labor of inspection can be significantly reduced, and the apparatus can be efficiently inspected. Also, unlike the inspection result by an operator, since an inspection result with no variation can be obtained, the apparatus control unit 84 can appropriately maintain the molding machine 3 in an operable state based on the inspection result with no variation.

[0105] Also, apparatuses related to casting facilities such as the sand treatment system 2, the molding machine 3, the core set device 4, the alignment device 5, the pouring device 6, the post-treatment device 7, and the transfer line 9 in the casting system 1 are efficiently and appropriately inspected by the apparatus inspection system 10 before and during the start of the apparatuses. Thereby, cast products can be efficiently produced with a certain quality.

[0106] In addition, since the feature measurement unit 13 measures the feature quantities of the power media used in the respective actuators of the molding machine 3, the apparatus inspection system 10 can accurately and collectively acquire the feature quantities via the acquisition unit 81. Therefore, the apparatus inspection system 10 can quickly determine whether the molding machine 3 satisfies the startup conditions. Further, since the feature quantities of the power media are adjusted by the apparatus control unit 84 to be within a predetermined threshold range, the molding machine 3 is efficiently maintained in an operable state.

[0107] In addition, since the position measurement unit 14 measures the positions of the respective actuators of the molding machine 3, the apparatus inspection system 10 can accurately and collectively acquire information regarding the positions via the acquisition unit 81. Therefore, the apparatus inspection system 10 can quickly determine whether the molding machine 3 satisfies the startup conditions. Since the positions of the actuators are adjusted by the apparatus control unit 84 to be within a predetermined range, the molding machine 3 is efficiently maintained in an operable state.

[0108] In addition, since the molding machine 3 is test-run under the same conditions as the manufacturing conditions of the mold M (product), it is possible to appropriately inspect the operating status of the components necessary for manufacturing the mold M in comparison with the manufacturing conditions, and the molding machine 3 is efficiently and appropriately maintained in an operable state.

[0109] In addition, in the sand injection, the apparatus control unit 84 test-runs each component so as to be the same as the supply conditions of compressed air (an example of a gas) to the sand tank 22 during the manufacture of the mold M. Therefore, it is possible to appropriately inspect the operating status of the sand tank 22 necessary for manufacturing the mold M in comparison with the supply conditions of the compressed air during the manufacture of the mold M, and the compressed air source CA, the upper air passage 34, the lower air passage 35, and the sand tank 22 are efficiently and appropriately maintained in an operable state.

[0110] In addition, the storage unit 86 stores the inspection results and determination results for each component. Therefore, the device inspection system 10 can collect inspection results and determination results of a certain quality without obtaining incorrect inspection results and incorrect determination results. Furthermore, the notification unit 87 can notify an abnormality based on the determination results of the foreign object determination unit 82 and the operation inspection unit 85. As a result, the operator can efficiently grasp the inspection results (determination results) by the device inspection system 10.

[0111] [Modification Example] As described above, various exemplary embodiments have been described. However, the present disclosure is not limited to the above-described embodiments, and various omissions, substitutions, and changes may be made.

[0112] The object detection unit 12 does not necessarily have a CCD sensor as an object detection sensor. That is, the object detection unit 12 does not necessarily have a plurality of cameras 12a. The object detection unit 12 may have at least one beacon sensor and at least one scanner as an object detection sensor. The beacon sensor and the scanner are object detection devices using position information. The beacon sensor is, for example, a sensor equipped with a position identification technology using LPS (Local Positioning System) or GPS (Global Positioning System). The beacon sensor is attached to an operator who enters and exits the molding machine 3 and the belongings of the operator.

[0113] At least one scanner is provided in at least one of the regions inside and around the molding machine 3, and detects a beacon sensor existing in at least a part of the inside of the molding machine 3. When the object detection unit 12 has a plurality of scanners, the plurality of scanners are arranged so that there is no blind spot where none of the plurality of scanners can recognize a region where a foreign object can enter or be placed inside the molding machine 3.

[0114] When the beacon sensor is detected within the molding machine 3, the plurality of scanners output a scan result indicating the detection to the control unit 8. When the beacon sensor is not detected within the molding machine 3, the plurality of scanners output a scan result indicating non-detection to the control unit 8. As an acquisition step (S10), the acquisition unit 81 acquires the scan result from the object detection unit 12 as information regarding the object within the molding machine 3.

[0115] As a foreign object determination step (S11), when it is indicated in the scan result that the beacon sensor has been detected within the molding machine 3, the foreign object determination unit 82 determines that there is a foreign object within the molding machine 3. As a foreign object determination step (S11), when it is indicated in the scan result that the beacon sensor has not been detected within the molding machine 3, the foreign object determination unit 82 determines that there is no foreign object within the molding machine 3.

[0116] Further, the object detection unit 12 may include at least one temperature sensor as an object detection sensor. The temperature sensor is an object detection device using temperature information. The temperature sensor detects an operator entering and exiting the molding machine 3. The temperature sensor may detect an object with heat other than the molding machine 3.

[0117] The temperature sensor is provided in at least one of the regions inside and around the molding machine 3, and detects an operator present in at least a part of the inside of the molding machine 3. When the object detection unit 12 has a plurality of temperature sensors, the plurality of temperature sensors are arranged so that there is no blind spot that none of the plurality of temperature sensors can recognize with respect to the region where a foreign object can enter or be placed inside the molding machine 3.

[0118] When an operator (heat source) is detected within the molding machine 3, the plurality of temperature sensors output a detection result indicating the detection to the control unit 8. When an operator is not detected within the molding machine 3, the temperature sensor outputs a detection result indicating non-detection to the control unit 8. As an acquisition step (S10), the acquisition unit 81 acquires the detection result from the object detection unit 12 as information regarding the object within the molding machine 3.

[0119] As a foreign object determination step (S11), when it is shown in the detection result that an operator has been detected inside the molding machine 3, the foreign object determination unit 82 determines that a foreign object is present inside the molding machine 3. As a foreign object determination step (S11), when it is shown in the detection result that an operator has not been detected inside the molding machine 3, the foreign object determination unit 82 determines that no foreign object is present inside the molding machine 3.

[0120] The gas detector 13d of the feature amount measurement unit 13 may be provided in a nozzle 24 that injects sand 23 provided in the sand tank 22, and measures the flow rate of compressed air injected through the nozzle 24. In this case, in the trial operation step (S16), the apparatus control unit 84 causes compressed air to be injected from the sand tank 22 through the nozzle 24, and in the second feature amount measurement step (S17), the gas detector 13d measures the flow rate of compressed air as the injection force of the sand 23. The operation inspection unit 85 may determine based on the flow rate acquired from the gas detector 13d of the feature amount measurement unit 13 whether or not the operation status of the molding machine 3 in the operation status determination step (S18) is appropriate. For example, when the flow rate acquired from the gas detector 13d is within a predetermined threshold range from the reference flow rate stored in advance in the storage unit 86, the operation inspection unit 85 determines that the injection force of the sand 23 of the molding machine 3 is appropriate and that the operation status of the molding machine 3 is appropriate. When the flow rate acquired from the gas detector 13d is not within a predetermined threshold range from the reference flow rate stored in advance in the storage unit 86, the operation inspection unit 85 determines that the injection force of the sand 23 of the molding machine 3 is not appropriate and that the operation status of the molding machine 3 is not appropriate.

[0121] Further, the operation inspection unit 85 may determine whether the operation status of the molding machine 3 in the operation status determination step (S18) is appropriate based on the hydraulic pressures acquired from the plurality of hydraulic oil detectors 13a, 13b, and 13c of the feature amount measurement unit 13. For example, when each of the hydraulic pressures acquired from the hydraulic oil detectors 13a, 13b, and 13c is within a predetermined threshold range from each of the reference hydraulic pressure values stored in advance in the storage unit 86, the operation inspection unit 85 determines that the configuration related to each actuator of the molding machine 3 is operating appropriately, and thus determines that the operation status of the molding machine 3 is appropriate. For example, when any of the hydraulic pressures acquired from the hydraulic oil detectors 13a, 13b, and 13c is not within a predetermined threshold range from each of the reference hydraulic pressure values stored in advance in the storage unit 86, the operation inspection unit 85 determines that the configuration related to any actuator of the molding machine 3 is not operating appropriately, and thus determines that the operation status of the molding machine 3 is not appropriate.

[0122] Also, for example, the acquisition unit 81 may acquire the hydraulic pressure from the hydraulic oil detectors 13a, 13b, and 13c for a predetermined time determined in advance by the operator. In the operation status determination step (S18), when the waveform of the hydraulic pressure for each actuator calculated based on the hydraulic pressure acquired for the predetermined time is within a predetermined range from the reference waveform of the hydraulic pressure stored in advance in the storage unit 86, the operation inspection unit 85 determines that the configuration related to the actuator of the molding machine 3 is operating appropriately, and thus determines that the operation status of the molding machine 3 is appropriate. In the operation status determination step (S18), when any of the waveforms of the hydraulic pressure for each actuator calculated based on the hydraulic pressure acquired for the predetermined time is not within a predetermined range from each of the reference waveforms of the hydraulic pressure stored in advance in the storage unit 86, the operation inspection unit 85 determines that the configuration related to any actuator of the molding machine 3 is not operating appropriately, and thus determines that the operation status of the molding machine 3 is not appropriate.

[0123] When the molding machine 3 (device) is in a test run by the device control unit 84, the operation inspection unit 85 may calculate the cycle time (time) required for manufacturing (one cycle) per one mold M (product). For example, the operation inspection unit 85 may calculate the cycle time based on the positions of the respective actuators measured by the position measurement unit 14. For example, the operation inspection unit 85 may use, as the cycle time, the time from when the position measurement unit 14 measures that all the actuators are in their original positions until the position measurement unit 14 measures again that all the actuators are in their original positions. For example, the operation inspection unit 85 may use, as the cycle time, the time from when the position measurement unit 14 measures that at least one actuator is in its original position until the position measurement unit 14 measures again that the at least one actuator is in its original position. In the operation status determination step (S18), the operation inspection unit 85 may make a determination based on the calculated cycle time in determining whether the operation status of the molding machine 3 is appropriate. For example, in the operation status determination step (S18), when the cycle time of the molding machine 3 falls within a predetermined threshold range from the reference cycle time pre-stored in the storage unit 86, the operation inspection unit 85 determines that the operation status of the molding machine 3 is appropriate, assuming that the configuration regarding each actuator of the molding machine 3 is operating properly. For example, in the operation status determination step (S18), when the cycle time of the molding machine 3 does not fall within a predetermined threshold range from the reference cycle time pre-stored in the storage unit 86, the operation inspection unit 85 determines that the operation status of the molding machine 3 is not appropriate, assuming that the configuration regarding any one of the actuators of the molding machine 3 is not operating properly.

[0124] In addition, the plurality of frame set cylinders 29, slide gates 33, and mold frame cylinders 37 in the molding machine 3 do not necessarily have to be, for example, hydraulic actuators. At least a part of each actuator included in the molding machine 3 may be a pneumatic actuator. In this case, the feature amount measurement unit 13 may have a gas detector instead of the hydraulic oil detectors 13a, 13b, and 13c. In this case, in the first feature amount measurement step (S12) and the second feature amount measurement step (S17), the gas detector may measure at least one value of air pressure, flow rate, and operation time instead of hydraulic pressure, oil quantity, and oil temperature. In the operation status determination step (S18), the operation inspection unit 85 may determine whether the operation status of the molding machine 3 is appropriate based on the air pressure, flow rate, and operation time.

[0125] In addition, at least a part of each actuator included in the molding machine 3 may be an electric actuator. In this case, the feature amount measurement unit 13 may have an ammeter and a voltmeter instead of the hydraulic oil detectors 13a, 13b, and 13c. In this case, in the first feature amount measurement step (S12) and the second feature amount measurement step (S17), the gas detector may measure at least one of the current value and the voltage value instead of the hydraulic pressure, oil quantity, and oil temperature. In the operation status determination step (S18), the operation inspection unit 85 may determine whether the operation status of the molding machine 3 is appropriate based on the current value and the voltage value.

[0126] Also, in the operation status determination step (S18), when it is determined by the operation inspection unit 85 that the operation status of the entire molding machine 3 is not appropriate (S18: NO), the device control unit 84 may adjust the supply of compressed air so that the pressure related to the configuration of the compressed air of the molding machine 3 falls within a predetermined threshold range. Further, for example, the device control unit 84 may adjust the supply of compressed air so that the volume related to the configuration of the compressed air of the molding machine 3 is less than a predetermined threshold value. The adjustment of the supply of compressed air described above is, for example, to perform the following processing. For example, when the pressure is greater than the upper limit value of the predetermined threshold range or the volume is greater than the predetermined threshold value, the device control unit 84 lowers the set pressure of the compressed air. For example, when the pressure is less than the lower limit value of the predetermined threshold range, the device control unit 84 raises the set pressure of the compressed air.

[0127] The position measurement unit 14 may have at least one encoder. The position measurement unit 14 has a plurality of encoders, and each encoder may be provided on a plurality of frame set cylinders 29, slide gates 33, and mold frame cylinders 37. The position measurement unit 14 may have an encoder instead of the plurality of proximity switches 14a, 14a, 14b, 14c, 14c.

[0128] In this case, in the position measurement step (S13), the encoder measures the displacement amount of the position of the actuator provided in the device. Subsequently, as the start condition determination step (S14), the start condition determination unit 83 determines whether the molding machine 3 satisfies the start conditions. When the start condition determination unit 83 determines that each hydraulic pressure, each oil volume, and each oil temperature detected in the first feature amount measurement step (S12) are within the threshold range, and the displacement amounts measured by the plurality of encoders in the position measurement step (S13) are within the threshold range, it is determined that the entire molding machine 3 satisfies the start conditions (S14: YES). When the start condition determination unit 83 determines that each hydraulic pressure or each oil temperature detected in the first feature amount measurement step (S12) is not within the threshold range, or at least one of the displacement amounts of the plurality of encoders in the position measurement step (S13) is not within the threshold range, it is determined that the entire molding machine 3 does not satisfy the start conditions (S14: NO).

[0129] The position measurement unit 14 may include a plurality of proximity switches 14a, 14a, 14b, 14c, 14c and a plurality of encoders. In this case, as the start condition determination step (S14), the start condition determination unit 83 determines that each hydraulic pressure, each oil quantity, and each oil temperature detected in the first feature amount measurement step (S12) are within the threshold range, and signals from the plurality of proximity switches 14a, 14a, 14b, 14c, 14c are received, and when it is determined that the displacement amounts measured by the plurality of encoders in the position measurement step (S13) are within the threshold range, it is determined that the entire molding machine 3 satisfies the start conditions (S14: YES). When at least one of the hydraulic pressures or the oil temperatures detected in the first feature amount measurement step (S12) is not within the threshold range, when it is determined that signals from at least one of the plurality of proximity switches 14a, 14a, 14b, 14c, 14c are not received, or when it is determined that the displacement amount of at least one of the plurality of encoders in the position measurement step (S13) is not within the threshold range, the start condition determination unit 83 determines that the entire molding machine 3 does not satisfy the start conditions (S14: NO).

[0130] [Aspects included in the present disclosure] The present disclosure includes the aspects described in the following clauses.

[0131] (Clause 1) An apparatus inspection system according to an aspect of the present disclosure includes an acquisition unit that acquires information about an object from an object detection sensor capable of detecting the object within the apparatus, a foreign object determination unit that determines the presence or absence of a foreign object within the apparatus based on the information about the object acquired by the acquisition unit, an apparatus control unit that test-drives the apparatus when the foreign object determination unit determines that there is no foreign object within the apparatus, and an operation inspection unit that inspects the operation status of the apparatus that has entered the test-driving state by the apparatus control unit.

[0132] In the device inspection system according to Item 1, based on the information about the object inside the device automatically acquired by the acquisition unit, the presence or absence of foreign matter inside the device is determined by the foreign matter determination unit. As a result, it is possible to efficiently determine the presence or absence of foreign matter inside the device without going through the inspection work by the operator. Further, when there is no foreign matter inside the device, the device control unit can execute a test run of the device. Furthermore, by the test run of the device, the operation status of the device can be inspected by the operation inspection unit. As a result, the device can be appropriately inspected up to the operation status of the device. Therefore, this device inspection system can inspect the device efficiently and appropriately.

[0133] (Item 2) In the sensor module according to Item 1, when the foreign matter determination unit determines that there is no foreign matter inside the device, it further includes a startup condition determination unit that determines whether the device satisfies the startup conditions, and when the device control unit is determined by the startup condition determination unit that the device does not satisfy the startup conditions, the device may be adjusted so as to match the startup conditions and the device may be test-run. When the startup condition determination unit determines that the startup conditions are not satisfied, the device control unit adjusts the device so as to match the startup conditions. As a result, since there is no need for the operator to perform inspection work and adjustment work before the operation of the device including the test run, the labor of inspection can be significantly reduced, the device can be efficiently inspected, and the device can be prepared in an operable state.

[0134] (Item 3) The device inspection system according to one aspect of the present disclosure includes an acquisition unit that acquires information about an object from an object detection sensor capable of detecting an object inside the device, a foreign matter determination unit that determines the presence or absence of foreign matter inside the device based on the information about the object acquired by the acquisition unit, a startup condition determination unit that determines whether the device satisfies the startup conditions when the foreign matter determination unit determines that there is no foreign matter inside the device, and a device control unit that adjusts the device so as to match the startup conditions when the startup condition determination unit determines that the device does not satisfy the startup conditions.

[0135] In the apparatus inspection system according to Item 3, based on the information regarding foreign matter in the apparatus automatically acquired by the acquisition unit, the presence or absence of foreign matter in the apparatus is determined by the foreign matter determination unit. As a result, it is possible to efficiently determine the presence or absence of foreign matter in the apparatus without going through the inspection work by the operator. Further, when it is determined by the start condition determination unit that the start condition is not satisfied, the apparatus is adjusted by the apparatus control unit so as to meet the start condition. As a result, since there is no need for the operator to perform inspection work and adjustment work before the operation of the apparatus including the trial operation, the labor of inspection can be significantly reduced, the apparatus can be efficiently inspected, and the apparatus can be prepared in an operable state. Therefore, this apparatus inspection system can efficiently and appropriately inspect the apparatus.

[0136] (Item 4) The apparatus inspection system according to any one of Items 1 to 3 may include the casting equipment in the apparatus. In this case, by efficiently and appropriately inspecting the casting equipment before and during startup, it is possible to efficiently produce cast products with a certain quality.

[0137] (Item 5) The device inspection system according to any one of Items 1 to 4 further includes a feature quantity measurement unit that measures a feature quantity of a power medium used for an actuator provided in the device. The acquisition unit acquires the feature quantity of the power medium used for the actuator from the feature quantity measurement unit. The startup condition determination unit determines whether the feature quantity of the power medium is within a predetermined threshold range based on the feature quantity acquired by the acquisition unit as a determination of whether the device satisfies the startup condition. The device control unit may adjust the feature quantity so that it is within the predetermined threshold range when the startup condition determination unit determines that the feature quantity of the power medium is not within the predetermined threshold range. In this case, since the feature quantity measurement unit measures the feature quantity of the power medium used for the actuator of the device, the device inspection system can accurately and collectively acquire the feature quantity via the acquisition unit. Therefore, the device inspection system can quickly determine whether the device satisfies the startup condition. In addition, since the device control unit adjusts the feature quantity of the power medium so that it is within the predetermined threshold range, the device is efficiently prepared in an operable state.

[0138] (Item 6) The device inspection system according to any one of items 1 to 5 further includes a position measurement unit that measures the position of an actuator provided in the device. The acquisition unit acquires information regarding the position of the actuator from the position measurement unit. As a determination as to whether or not the device satisfies the startup condition, the startup condition determination unit determines whether or not the actuator is positioned within a predetermined range based on the information regarding the position acquired by the acquisition unit. When the startup condition determination unit determines that the actuator is not positioned within the predetermined range, the device control unit may adjust the actuator so that it is positioned within the predetermined range. In this case, since the position measurement unit measures the positions of the respective actuators of the molding machine, the device inspection system can accurately and collectively acquire information regarding the positions via the acquisition unit. Therefore, the device inspection system can quickly determine whether or not the molding machine satisfies the startup condition. Since the device control unit adjusts the position of the actuator so that it is positioned within the predetermined range, the device is efficiently prepared in an operable state.

[0139] (Item 7) The device inspection system according to any one of items 1 to 6 may execute a test run so that the device control unit operates under the same conditions as the manufacturing conditions of the product manufactured by the device. Since the device performs a test run under the same conditions as the manufacturing conditions of the product, it is possible to appropriately inspect the operating status of the configuration required during the manufacture of the product in comparison with the manufacturing conditions, and the device is efficiently and appropriately prepared in an operable state.

[0140] (Item 8) The apparatus inspection system according to any one of Items 1 to 7, wherein the apparatus includes an injection unit that injects sand, and the apparatus control unit can control the injection unit to inject the sand by supplying gas as at least a part of the process of manufacturing the product, and a trial operation may be executed to supply the gas under the same conditions as the gas supply conditions in the process. In this case, in the injection of sand, since the apparatus control unit performs a trial operation of each component so as to be the same as the gas supply conditions during the manufacture of the product, the operation status of the injection unit required during the manufacture of the product can be appropriately inspected in comparison with the gas supply conditions during the manufacture of the product, and the injection unit can be efficiently and appropriately maintained in a state where it can operate properly.

[0141] (Item 9) The apparatus inspection method according to one aspect of the present disclosure includes a step of obtaining information about an object from an object detection sensor capable of detecting the object in the apparatus, a step of determining the presence or absence of foreign matter in the apparatus based on the information about the object obtained in the obtaining step, a step of performing a trial operation of the apparatus when it is determined that there is no foreign matter in the apparatus in the step of determining the presence or absence of foreign matter, and a step of inspecting the operation status of the apparatus in the trial operation state in the step of performing the trial operation.

[0142] In the apparatus inspection method described in Item 9, the same operational effects as those of the apparatus inspection system described in Item 1 are achieved.

[0143] (Item 10) In the apparatus inspection method described in Item 9, when it is determined that there is no foreign matter in the apparatus in the step of determining the presence or absence of foreign matter, a step of determining whether the apparatus satisfies the startup conditions, and when it is determined that the apparatus does not satisfy the startup conditions in the step of determining whether the apparatus satisfies the startup conditions, a step of adjusting the apparatus to meet the startup conditions and performing a trial operation of the apparatus may be further included. In the apparatus inspection method described in Item 10, the same operational effects as those of the apparatus inspection system described in Item 2 are achieved.

[0144] (Item 11) The device inspection method according to one aspect of the present disclosure includes: a step of acquiring information about an object from an object detection sensor capable of detecting the object inside the device; a step of determining whether there is a foreign object inside the device based on the information about the object acquired in the acquiring step; a step of determining whether the device satisfies a startup condition when it is determined in the step of determining whether there is a foreign object that there is no foreign object inside the device; and a step of adjusting the device to match the startup condition and performing a test run of the device when it is determined in the step of determining whether the device satisfies the startup condition that the startup condition is not satisfied.

[0145] The device inspection method according to Clause 11 has the same operational effects as the device inspection system according to Clause 3.

Explanation of Signs

[0146] 1... casting system, 2... sand treatment system, 2b... kneader, 3... molding machine (an example of a device), 4... core setting device, 5... mold alignment device, 6... pouring device, 7... post-treatment device, 8... control unit, 9... conveying line, 10... device inspection system, 11... detection unit, 12... object detection unit, 12a... camera (an example of an object detection sensor), 13... feature measurement unit, 14... position measurement unit, 22... sand tank, 23... sand, 24... nozzle, 81... acquisition unit, 82... foreign object determination unit, 83... startup condition determination unit, 84... device control unit, 85... operation inspection unit, 86... storage unit, 87... notification unit, CA... compressed air source, M... mold (an example of a product).

Claims

1. An acquisition unit that acquires information about the object from an object detection sensor capable of detecting the object within the device; A foreign object determination unit that determines the presence or absence of a foreign object within the device based on the information about the object acquired by the acquisition unit; A device control unit that test-runs the device when the foreign object determination unit determines that there is no foreign object within the device; An operation inspection unit that inspects the operation status of the device that has entered the test-run state by the device control unit; A device inspection system comprising the above.

2. Further comprising a startup condition determination unit that determines whether the device satisfies the startup conditions when the foreign object determination unit determines that there is no foreign object within the device; The device control unit adjusts the device to meet the startup conditions and test-runs the device when the startup condition determination unit determines that the device does not satisfy the startup conditions. The device inspection system according to Claim 1.

3. An acquisition unit that acquires information about the object from an object detection sensor capable of detecting the object within the device; A foreign object determination unit that determines the presence or absence of a foreign object within the device based on the information about the object acquired by the acquisition unit; A startup condition determination unit that determines whether the device satisfies the startup conditions when the foreign object determination unit determines that there is no foreign object within the device; A device control unit that adjusts the device to meet the startup conditions when the startup condition determination unit determines that the device does not satisfy the startup conditions; A device inspection system comprising the above.

4. The device includes casting equipment. The device inspection system according to any one of Claims 1 to 3.

5. Further comprising a feature quantity measurement unit that measures a feature quantity of a power medium used for an actuator provided in the device; The acquisition unit acquires the feature quantity of the power medium used for the actuator from the feature quantity measurement unit; The startup condition determination unit determines whether the feature quantity of the power medium is within a predetermined threshold range based on the feature quantity acquired by the acquisition unit as a determination of whether the device satisfies the startup conditions; The device control unit adjusts the feature quantity to be within the predetermined threshold range when the startup condition determination unit determines that the feature quantity of the power medium is not within the predetermined threshold range. The device inspection system according to Claim 2 or 3.

6. The apparatus further includes a position measurement unit that measures the position of an actuator provided in the apparatus. The acquisition unit acquires information regarding the position of the actuator from the position measurement unit. The startup condition determination unit determines whether or not the actuator is located within a predetermined range based on the information regarding the position acquired by the acquisition unit, as a determination as to whether or not the apparatus satisfies the startup condition. The apparatus control unit adjusts the actuator so that it is located within the predetermined range when the startup condition determination unit determines that the actuator is not located within the predetermined range, for the apparatus inspection system according to claim 2 or 3.

7. The apparatus control unit executes a test run so that the apparatus operates under the same conditions as the manufacturing conditions of the product manufactured by the apparatus, for the apparatus inspection system according to any one of claims 1 to 3.

8. The apparatus includes an injection unit that injects sand. The apparatus control unit can control the injection unit to inject the sand by supplying gas as at least part of the process of manufacturing the product, and executes a test run so as to supply the gas under the same conditions as the gas supply conditions in the process. For the apparatus inspection system according to claim 7.

9. A step of acquiring information regarding the object from an object detection sensor capable of detecting an object within the apparatus; A step of determining the presence or absence of a foreign object within the apparatus based on the information regarding the object acquired in the step of acquiring; A step of performing a test run on the apparatus when it is determined in the step of determining the presence or absence of the foreign object that there is no foreign object within the apparatus; A step of inspecting the operating status of the apparatus in the test run state in the step of performing the test run; An apparatus inspection method including the above steps.

10. A step of determining whether or not the apparatus satisfies the startup condition when it is determined in the step of determining the presence or absence of the foreign object that there is no foreign object within the apparatus; A step of adjusting the apparatus so as to meet the startup condition and performing a test run on the apparatus when it is determined in the step of determining whether or not the startup condition is satisfied that the startup condition is not satisfied; The apparatus inspection method according to claim 9, further including the above steps.

11. A step of acquiring information regarding the object from an object detection sensor capable of detecting an object within the apparatus; A step of determining the presence or absence of foreign matter in the device based on the information about the object obtained in the step of obtaining; A step of determining whether the device satisfies the startup conditions when it is determined that there is no foreign matter in the device in the step of determining the presence or absence of foreign matter; A step of adjusting the device to meet the startup conditions and performing a test run of the device when it is determined that the startup conditions are not satisfied in the step of determining whether the startup conditions are satisfied; A device inspection method including the above steps.

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