Test result display device and control program

Abstract

To provide technology that enables a worker, etc., to easily grasp the tendency of defects occurring to a casting mold or a model.SOLUTION: A display device (10) displays inspection results of a plurality of casting molds or a plurality of models as inspection objects. The display device (10) executes a process of classifying the plurality of inspection objects into a plurality of groups, a process of generating, for each of the plurality of groups, a heat map image that represents the spatial distribution of defect occurrence frequency from the results of defect inspection of the inspection objects classified into the group, and a process of displaying, on a display, the heat map image that corresponds to one or a plurality of groups designated by a user among the heat map images generated by the generation process.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an inspection result display device and a control program. [Background technology]

[0002] A technique for inspecting defects in castings has been proposed. For example, Patent Document 1 describes a technique for generating a map in which the surface of a case part produced by machining a rough shaped material is divided into a plurality of areas, and generating an image (defect image) showing the occurrence frequency of defects in the rough shaped material on the map. Patent Document 1 also describes a technique for displaying each area by color coding or the like according to the occurrence frequency (number of occurrences) of the defect.

[0003] Furthermore, Patent Document 2 describes an apparatus that statistically compiles defect data consisting of the location of defective parts, the details of the defects, etc. during inspection work in the manufacturing process, and outputs visual analysis results such as the defect occurrence frequency distribution for each part and the details of the defects on top of an image created from the actual product being inspected. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2012-45563 A [Patent Document 2] JP 2000-131242 A Summary of the Invention [Problem to be solved by the invention]

[0005] In the technology described in Patent Document 1, defects in the raw material found in the inspection after machining can be fed back to the raw material production process, but workers cannot grasp the tendency of defects occurring in the mold or the model (pattern) for manufacturing the mold. Defects occurring in the mold or the model vary depending on the type of model or the molding conditions. It would be ideal if workers could grasp the tendency of those defects.

[0006] One aspect of the present invention aims to provide a technique that enables workers to easily grasp trends in defects occurring in molds or models. [Means for solving the problem]

[0007] In order to solve the above problems, an inspection result display device according to a first aspect of the present invention is an inspection result display device for inspecting a plurality of molds or a plurality of models, and is equipped with a controller, which executes the following processes: classifying the inspection objects into a plurality of groups; generating, for each of the plurality of groups, a heat map image representing a spatial distribution of defect occurrence frequency from the results of defect inspection of the inspection objects classified into that group; and displaying, on a display, from the heat map images generated in the generation process, heat map images corresponding to one or more groups specified by a user.

[0008] According to the above configuration, the inspection result display device classifies the inspection objects into a plurality of groups for a plurality of molds or a plurality of models as inspection objects, and displays on the display a heat map image corresponding to one or more groups designated by the user. This makes it easy for the operator user to grasp the tendency of defects occurring in the inspection objects.

[0009] A test result display device according to a second aspect of the present invention is in accordance with the first aspect, wherein the test object is a mold.

[0010] According to the above configuration, the inspection result display device classifies the molds into a plurality of groups and displays on the display a heat map image corresponding to one or a plurality of groups designated by the user, which allows the user to easily grasp the tendency of defects occurring in the molds.

[0011] In the inspection result display device according to aspect 3 of the present invention, in the above-mentioned aspect 2, in the classification process, the controller may classify each of the plurality of molds according to the model used to make the mold.

[0012] According to the above configuration, the inspection result display device classifies the molds into a plurality of groups according to the patterns used for making the molds, and displays on the display a heat map image corresponding to one or more groups designated by the user, which allows the user to easily grasp the tendency of mold defects for each pattern.

[0013] In the inspection result display device according to aspect 4 of the present invention, in the second or third aspect, in the classification process, the controller may classify each of the multiple molds by the unit period during which the mold was inspected.

[0014] According to the above configuration, the inspection result display device classifies molds into a plurality of groups for each unit period during which the molds were inspected, and displays on the display a heat map image corresponding to one or more groups designated by the user, thereby making it easy for the user to grasp the tendency and progress of defects in the molds.

[0015] In the inspection result display device of aspect 5 of the present invention, in aspects 2 to 4, in the classification process, the controller may classify each of the multiple molds according to at least one of the molding conditions used when molding the mold and the results of the defect inspection.

[0016] According to the above configuration, the inspection result display device classifies the molds into a plurality of groups according to at least one of the molding conditions when the molds were made and the results of the defect inspection, and displays on the display a heat map image corresponding to one or more groups designated by the user. Therefore, the user can easily grasp the tendency of the mold defects for each molding condition and / or each result of the defect inspection.

[0017] In the inspection result display device of aspect 6 of the present invention, in aspect 5, the molding conditions may include at least any of the sand properties of the mold, the control parameters of the molding machine used to manufacture the mold, weather conditions, and the importance of defects.

[0018] According to the above configuration, the inspection result display device classifies molds into a plurality of groups according to molding conditions including at least one of the sand properties of the mold, the control parameters of the molding machine for manufacturing the mold, the weather conditions, and the importance of the defects, and displays a heat map image corresponding to one or more groups designated by the user on the display. Therefore, the user can easily grasp the tendency of defects occurring in the mold for each molding condition.

[0019] In the inspection result display device according to a seventh aspect of the present invention, in the fifth or sixth aspect, the result of the defect inspection may include the importance of the defect.

[0020] According to the above configuration, the inspection result display device classifies molds into a plurality of groups according to the severity of the defects, and displays on the display a heat map image corresponding to one or more groups designated by the user. This makes it easy for the user to grasp the tendency of the severity of defects occurring in the molds.

[0021] In the inspection result display device according to aspect 8 of the present invention, in any of aspects 2 to 7, in the classifying process, the controller may classify each of the plurality of molds according to whether the mold is an upper mold or a lower mold.

[0022] According to the above configuration, the inspection result display device classifies the molds into a plurality of groups depending on whether the mold is an upper mold or a lower mold, and displays on the display a heat map image corresponding to one or more groups designated by the user. Therefore, the user can easily grasp the tendency of defects when the mold is an upper mold and the tendency of defects when the mold is a lower mold.

[0023] In the test result display device according to a ninth aspect of the present invention, in any of the first to eighth aspects, in the displaying process, the controller may display an animation of the heat map images corresponding to each of the plurality of groups by switching them in sequence.

[0024] According to the above configuration, the inspection result display device displays a plurality of heat map images on the display in an order according to the molding conditions, which makes it easy for a user to grasp the tendency and transition of defects according to the molding conditions.

[0025] In the examination result display device according to a tenth aspect of the present invention, in the first aspect, the examination object may be a plurality of models.

[0026] According to the above configuration, the inspection result display device classifies the models into a plurality of groups and displays on the display a heat map image corresponding to one or a plurality of groups designated by the user, which allows the user to easily grasp the tendency of defects occurring in the models.

[0027] A test result display device according to aspect 11 of the present invention is, in aspects 1 to 10, wherein the controller may include at least one processor that executes each of the processes according to a predetermined program, and at least one memory that stores the program.

[0028] According to the above configuration, the inspection result display device classifies the inspection objects, which are molds or models, into a plurality of groups and displays on the display a heat map image corresponding to one or more groups designated by the user, thereby making it easy for the user to grasp the tendency of defects occurring in the inspection objects.

[0029] A control program according to a twelfth aspect of the present invention is a control program for controlling the test result display device according to any one of the first to eleventh aspects, and is characterized in that it causes the controller to execute each of the processes.

[0030] The scope of the present invention also includes a control program according to aspect 12 and a computer-readable recording medium having the same recorded thereon. Effect of the Invention

[0031] According to one aspect of the present invention, a user can easily grasp the tendency of defects occurring in a mold or a model. [Brief description of the drawings]

[0032] [Figure 1] 1 is a configuration diagram showing a schematic configuration of a casting system according to a first embodiment of the present invention. [Diagram 2] FIG. 1 is a block diagram showing a schematic configuration of a display device according to a first embodiment of the present invention. [Diagram 3] FIG. 13 is a diagram illustrating an example of the contents of a reference image table. [Figure 4] FIG. 13 is a diagram illustrating a reference image. [Diagram 5] FIG. 13 is a diagram illustrating an example of the contents of a test result table. [Figure 6] FIG. 13 is a diagram illustrating an example of the contents of a mold management table. [Figure 7] 5 is a flowchart illustrating a flow of display processing of an examination result by the display device according to the first embodiment of the present invention. [Figure 8] FIG. 13 is a diagram illustrating an example of a heat map image. [Figure 9] FIG. 13 is a diagram illustrating an example of a heat map image. [Figure 10] FIG. 13 is a diagram illustrating an example of a display screen of a heat map image. [Figure 11] FIG. 11 is a diagram illustrating an example of a screen transition for selecting molding conditions. [Figure 12]FIG. 11 is a diagram illustrating an example of a screen transition for selecting molding conditions. [Figure 13] FIG. 11 is a diagram illustrating an example of a screen displayed on a display. [Figure 14] FIG. 13 is a diagram illustrating an example of a screen for selecting a period. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] [Embodiment 1] 1 is a schematic diagram of a casting system 1 including a display device 10 according to one embodiment of the present invention. The casting system 1 is part of a system for producing castings by pouring molten metal into multiple molds 2 transported along a transport path. The casting system 1 includes the display device 10, an inspection device 20, an input / output device 30, a molding machine 40, a line controller 50, a pouring machine 60, and a transport device 70.

[0034] The display device 10 in FIG. 1 (an example of an inspection result display device and a controller) is a device that displays the results of a defect inspection of an inspection target on a display. In this embodiment, the inspection target is the product surface (cavity surface) of a plurality of molds 2. The defect on the product surface of the mold 2 is, for example, outdated mold 2 or sand adhesion. Outdated mold means that a part of the mold 2 is chipped. Sand adhesion means that sand is attached to a part of the mold 2. The result of the defect inspection includes, for example, the outdated mold 2 or the position, size, and shape of the sand adhesion. In this embodiment 1, a case where the inspection result of outdated mold is displayed will be described. The display device 10 is, for example, a laptop or desktop personal computer. The display device 10 may be a smartphone or a tablet terminal carried by a user such as a worker.

[0035] The inspection device 20 photographs each of the multiple molds 2 transported along the transport path. The inspection device 20 includes, for example, a camera. The inspection device 20 also identifies defects in the molds 2 using image data that includes the molds 2 as subjects.

[0036] The input / output device 30 is a device that allows a user to perform various operations. The input / output device 30 includes an operation unit (not shown) that is operated by a user, and a display 31 (see FIG. 2) that displays the inspection results of the mold 2. The input / output device 30 is installed at a location that corresponds to a process that follows the location where the inspection device 20 takes photographs. In the example of FIG. 1, the input / output device 30 is installed at the core setting site A1.

[0037] The display 31 is, for example, a liquid crystal display, and displays a screen in accordance with the data supplied from the display device 10. Particularly in this embodiment, the display 31 displays the results of the defect inspection of the mold 2 in accordance with the data supplied from the display device 10. The display 31 may be provided in a device other than the input / output device 30. Also, the display device 10 may be configured to include the display 31.

[0038] The molding machine 40 is a device that manufactures a mold 2 using a pattern. The molding machine 40 receives information about the mold 2 (hereinafter referred to as "mold information") from the line controller 50, and manufactures a mold 2 indicated by a pattern code included in the received mold information. The pattern code is information that uniquely indicates a molding pattern. The molding machine 40 pours sand into a molding flask (not shown) that is set together with a pattern (not shown), and pressurizes the sand in the flask to harden it. The molding machine 40 forms a mold 2 by removing the model from the hardened sand.

[0039] The line controller 50 is a controller that performs overall control of the casting system 1. In this embodiment, the line controller 50 particularly controls the molding machine 40, the pouring machine 60, and the transport device 70. The pouring machine 60 is a device that pours molten metal into the mold 2. In accordance with a control signal transmitted from the line controller 50, the pouring machine 60 pours (pouring) molten metal into the mold 2 located in the pouring area, with the mold 2 being the pouring target.

[0040] The transport device 70 is a device that transports the molds 2 from the molding machine 40 to before the pouring machine 60. The transport device 70 has, for example, a roller conveyor (not shown) or rails (not shown), and transports a plurality of molds 2 in sequence along a transport path on the roller conveyor or rail. The transport device 70 transports the molds 2 in accordance with a control signal transmitted from the line controller 50.

[0041] A core setting station A1 is provided between the inspection device 20 and the pouring machine 60. Workers are stationed at the core setting station A1 and perform the task of setting cores in the mold 2.

[0042] FIG. 2 is a block diagram showing a schematic configuration of the display device 10. As shown in FIG. 2, the display device 10 includes a processor 101, a main memory 102, an auxiliary memory 103, an input interface 104, and an output interface 105. The processor 101 is a processor that controls the display device 10, and is, for example, a microprocessor, a digital signal processor, a microcontroller, or a combination of these. The main memory 102 is, for example, a semiconductor RAM (Random Access Memory). The auxiliary memory 103 is, for example, a flash memory, a HDD (Hard Disk Drive), an SSD (Solid State Drive), or a combination of these. The auxiliary memory 103 stores a program for causing the processor 101 to execute the operation of the display device 10. The processor 101 loads the control program stored in the auxiliary memory 103 onto the main memory 102, and executes each command included in the loaded control program. The auxiliary memory 103 is an example of a memory according to the present invention.

[0043] A reference image table and an inspection result table are stored in the auxiliary memory of the inspection device 20. The reference image table is a table in which a reference image used when inspecting the mold 2 is stored for each model. The inspection result table is a table in which the results of the defect inspection of the mold 2 are stored in association with identification information that identifies the mold 2.

[0044] Fig. 3 is a diagram illustrating the contents of the reference image table. In the example of Fig. 3, the reference image table stores the items "pattern code" and "reference image folder No." in association with each other. Of these items, the "pattern code" item stores identification information for identifying the model. The "reference image folder No." item stores information indicating the storage location of the data of the reference image corresponding to the model. Note that the items included in the reference image table are not limited to those described above, and other items may be included in the reference image table.

[0045] Fig. 4 is a diagram illustrating an example of the reference image G0. In the example of Fig. 4, the reference image G0 is an image of a defect-free mold 2 captured by the inspection device 20.

[0046] FIG. 5 is a diagram illustrating an example of the contents of an inspection result table. In the example of FIG. 5, the inspection result table stores the items "mold ID," "pattern code," "inspection date and time," and "inspection result" in association with each other. Of these items, the "mold ID" item stores identification information that identifies the mold 2. The "pattern code" item stores identification information (pattern code) that identifies the model. The "inspection date and time" item stores information indicating the date and time when the defect inspection was performed. The "inspection result" item stores information indicating the result of the defect inspection.

[0047] The "Inspection Results" item includes the items "Judgment" and "Inspection Image Folder No." The "Judgment" item stores information indicating the judgment result of the defect inspection. Information indicating the judgment result is, for example, "OK," "NG," or "Fail." "OK" indicates that the mold 2 is normal. "NG" indicates that the mold 2 is abnormal (has a defect). "Fail" indicates that the inspection itself has failed. The "Inspection Image Folder No." item stores information indicating the storage location of an image showing the results of the defect inspection of the mold 2 (hereinafter referred to as "inspection image"). Note that the items included in the inspection results table are not limited to those described above, and other items may be included in the inspection results table.

[0048] Returning to the explanation of Fig. 2, the input interface 104 acquires data indicating the inspection results from the inspection device 20. The output interface 105 outputs data representing an image to the display 31. Although one input interface 104 and one output interface 105 are illustrated in Fig. 1, the display device 10 may include a plurality of input interfaces and / or a plurality of output interfaces. In this example, the processor 101 reads out and executes a control program stored in the auxiliary memory 103, thereby realizing the classification unit 12, the generation unit 13, and the display unit 14.

[0049] In this embodiment, the mold 2 is inspected for defects by the inspection device 20. The inspection device 20 inspects the molds 2 transported on the transport path for defects using images captured by the inspection device 20 and reference images registered in a reference image table. The inspection device 20, for example, generates a difference image that represents the difference between the image captured by the inspection device 20 and a reference image registered in advance, performs particle analysis on the generated difference image, and detects blobs in the difference image to identify defective portions.

[0050] The inspection device 20 stores data indicating the inspection results (hereinafter referred to as "inspection result data") in an inspection result table in association with the identification information of the mold 2. By performing defect inspection on each of the multiple molds 2, the inspection results of the multiple molds 2 are accumulated in the inspection result table.

[0051] The classification unit 12 classifies the multiple molds 2 into multiple groups. The generation unit 13 generates a heat map image representing the spatial distribution of defect occurrence frequency for each of the multiple groups based on the results of defect inspection of the molds 2 classified into that group. In this embodiment, the generation unit 13 displays the position, size, and shape of the obsolete molds in a heat map format. The generation unit 13 stores data representing the generated heat map image in the auxiliary memory 103.

[0052] The display unit 14 displays on the display 31, among the heat map images generated by the generation unit 13, heat map images corresponding to one or more groups designated by the user.

[0053] The line controller 50 is provided with a mold management table that manages mold information. The mold management table is stored, for example, in an auxiliary memory of the line controller 50. The mold information is information about the mold 2, and includes, for example, identification information that identifies the mold 2, and position information that indicates the position of the mold 2 on the transport path. That is, the mold management table stores the identification information of the mold 2 in association with the position information of the mold 2.

[0054] 6 is a diagram illustrating an example of the contents of the mold management table. The mold management table stores items such as "mold ID," "pattern code," "position," and "mold inspection results" in association with each other. Among these items, the "mold ID" item stores identification information that identifies the mold 2. The "pattern code" item stores identification information (pattern code) that identifies a model used to manufacture the mold 2 identified by the corresponding mold ID.

[0055] The "position" item stores information indicating the position on the transport path of the mold 2 identified by the corresponding mold ID (hereinafter referred to as "position information"). In this embodiment, positions P1 to P19 are set as the positions of the mold 2 on the transport path. Position P1 is located at the most upstream position in the transport direction of the transport device 70, and position information is assigned as positions P2, P3, ... moving downstream. Position P1 is the position where molding is performed by the molding machine 40. Positions P2 to P4 are positions between the molding machine 40 and the inspection device 20. Position P5 is the position where photography is performed by the inspection device 20. Positions P6 to P17 are positions between the inspection device 20 and the pouring machine 60. Position P9 is a position in front of the display 31. Position P18 is a position where pouring is performed by the pouring machine 60. Position P19 is a position where the molding flask containing the poured mold 2 is carried out.

[0056] The transport device 70 moves the multiple molds 2 sequentially on the transport path, and outputs a signal indicating that the movement is complete each time a mold 2 is moved (hereinafter referred to as a "flask transfer completion signal"). The line controller 50 updates the position information associated with the identification information of the mold 2 each time the multiple molds 2 are moved on the transport path. In this embodiment, each time a flask transfer completion signal is received from the transport device 70, the "position information" included in the mold information stored in the mold management table is advanced by one, and the new mold information is added to the mold management table. The added mold information has position information indicating position P1 stored in the "position" field. When the flask at position P19 is transferred to the flask, it is removed from the casting system 1.

[0057] The "Mold inspection results" item includes the items "Judgment" and "Pouring possible or not." The "Judgment" item stores information indicating the judgment result of the defect inspection. The information stored in the "Judgment" item is the same as the information stored in the "Judgment" item of the inspection results table of the display device 10.

[0058] The "Pouring Possible or Not" item stores information indicating whether or not pouring of molten metal will be performed (hereinafter referred to as "Pouring Possible or Not Information"). In this embodiment, the worker setting the core judges whether or not pouring of molten metal is possible for the mold 2 by visually checking the inspection results shown on the display 31 and the actual mold, and inputs the judgment result using the input / output device 30. The input / output device 30 transmits the pouring possible or not information to the line controller 50 in response to the operation of the worker. The line controller 50 stores the pouring possible or not information received from the input / output device 30 in the "Pouring Possible or Not" item of the mold management table. Note that the items included in the mold management table are not limited to those described above, and other items may be included in the mold management table.

[0059] (operation) 7 is a flowchart illustrating the flow of a display process of the test results performed by the display device 10. Note that some steps may be executed in parallel or in a different order.

[0060] In step S100, the sorting unit 12 sorts the multiple molds 2 into multiple groups. In this embodiment, the sorting unit 12 sorts each of the multiple molds 2 according to the model used to make that mold. More specifically, the sorting unit 12 sorts the molds 2 according to the pattern code associated with the mold ID of each mold 2 in the inspection result table of the inspection device 20.

[0061] In step S101, the generating unit 13 refers to the inspection results stored in the inspection result table via the input / output device 30, and generates a heat map image showing the spatial distribution of defect occurrence frequency for each of the multiple groups from the result of the defect inspection of the inspection target classified into that group. For example, the generating unit 13 counts the defect occurrence frequency for each unit area (for example, for each pixel) in the reference image corresponding to each of the multiple models, and generates a heat map image showing the defect occurrence frequency for each unit area shown by the counting result in a heat map format. The counting process is performed, for example, by the display device 10 assigning "1" to each pixel included in the inspection image if there is a defect and "0" if there is no defect, and calculating a total value for each pixel for the multiple inspection images. The display device 10 generates a heat map image in which each pixel is color-coded according to the calculated total value. The display device 10 may generate an image showing the spatial distribution of defect occurrence frequency (hereinafter referred to as "spatial distribution image") as a heat map image, or may generate an image in which the spatial distribution image is superimposed on the reference image or the inspection image as a heat map image.

[0062] In this way, information showing the inspection results for each position corresponding to an out-of-date product is accumulated in the display device 10, and the accumulated results are displayed as a heat map image. In this case, for example, when the occurrence frequency of defects is color-coded using colors expressed in RGB space, the color of the range with the highest occurrence frequency may be (r,g,b)=(255,0,0) and the color of the range with the lowest occurrence frequency may be (r,g,b)=(0,0,255), and the generation unit 13 may assign a color that forms a gradation between these two colors to each range. Note that when displaying the inspection result for sand adhesion, the display device 10 may similarly display the results as a heat map image, color-coded according to the occurrence frequency of sand adhesion.

[0063] 8 and 9 are diagrams illustrating heat map images generated by the generation unit 13. In the examples of Fig. 8 and Fig. 9, an image in which a reference image and a spatial distribution image are superimposed is generated as a heat map image. In the figures, heat map images G10 and G11 are images that represent the results of tallying up the defect occurrence frequency in pixel units in a heat map format. The generation unit 13 stores the heat map image generated for each model in the auxiliary memory 103 in association with a pattern code that identifies the model. The auxiliary memory 103 accumulates a heat map image for each model.

[0064] For example, the generation unit 13 expresses the occurrence frequency of defects in the heat map image by dividing the occurrence frequency of defects into a plurality of ranges and changing the color for each divided range. For example, when dividing the occurrence frequency of defects into colors represented by RGB space, the color of the range with the highest occurrence frequency may be (r, g, b) = (255, 0, 0), the color of the range with the lowest occurrence frequency may be (r, g, b) = (0, 0, 255), and the generation unit 13 may assign a color that is a gradation between these two colors to each range.

[0065] Now, when a user such as an operator wishes to grasp the tendency of the inspection results, he / she performs an operation of designating one or a plurality of models using the input / output device 30. Based on the user operation, the input / output device 30 transmits information indicating one or a plurality of groups designated by the user (hereinafter referred to as "designation information") to the display device 10. Upon receiving the designation information from the input / output device 30, the display device 10 executes the process of step S102 in FIG. 7.

[0066] Returning to the description of Fig. 7, in step S102, the display device 10 transmits, from among the heat map images generated in step S101, heat map images corresponding to one or more groups designated by the user to the input / output device 30, and displays them on the display 31. By the processing of step S102, the heat maps exemplified in Fig. 8 and Fig. 9 are displayed on the display 31.

[0067] According to the above configuration, the display device 10 classifies the mold 2 into a plurality of groups, and displays on the display 31 a heat map image corresponding to one or a plurality of groups designated by the user. This makes it easy for the user to grasp the occurrence trend of defects occurring in the mold 2 (tendency of occurrence location, etc.). This makes it easy for the user to analyze the cause of occurrence of defects in the mold 2.

[0068] [Variation 1] In the above embodiment, the mold 2 is molded with a flask. The molding method of the mold 2 is not limited to that shown in the above embodiment. For example, the mold 2 may be molded by flaskless molding. In the flaskless molding, the molding machine 40 molds the mold by filling sand with a match plate sandwiched between the upper and lower flasks. After molding the mold, when the match plate is retracted, a small inspection device 20' is inserted between the upper and lower molds to take images of the product surfaces of the upper and lower molds. After the images are taken, the small inspection device 20' is retracted. Then, the upper and lower molds are mated, the flaskless molding is performed, and the upper and lower molds are transported by the transport device 70'. The upper and lower molds are fitted with jackets and weights while being transported by the transport device 70', and molten metal is poured at the pouring position. The compact inspection device 20' inspects the mold for defects by comparing the captured image with a reference image, and accumulates the inspection results in an inspection result table.

[0069] The display device 10 refers to the inspection results stored in the inspection result table via the input / output device 30, and generates a heat map image for each group based on these inspection results. The process of generating the heat map image is the same as in the above-described embodiment. When classifying into groups, the display device 10 may classify each of the multiple molds 2 according to whether the mold is an upper mold or a lower mold.

[0070] In this embodiment, as in the above embodiment, the occurrence tendency of defects occurring in the mold 2 can be presented to the user by a heat map image. This makes it easier for the user to analyze the cause of the occurrence of defects in the mold 2.

[0071] [Modification 2] In the above-described embodiment, a case has been described in which the object of inspection for defect inspection is a plurality of molds 2. The object of inspection is not limited to the mold 2. The object of inspection may be a plurality of models used in molding the mold 2. In other words, the object of inspection for defect inspection is a plurality of molds 2, or a plurality of models used in molding the plurality of molds 2. When the object of inspection is a model, a defect is, for example, sand remaining in the model, chipping of the model, or wear on the model, and the results of the defect inspection include, for example, the location of sand remaining in the model, chipping of the model, or wear on the model.

[0072] In this case, the display device 10 classifies the inspection results of the model into multiple groups, and displays a heat map image corresponding to one or multiple groups designated by the user on the display 31. This makes it easy for the user to grasp the tendency of defects occurring in the model, and thus makes it easy for the user to analyze the cause of defects occurring in the model.

[0073] [Modification 3] In the above-described embodiment, the inspection device 20 performed the process of identifying defects in the mold 2 using image data including the mold 2 as a subject. The process of identifying defects may be performed by a device other than the inspection device 20. For example, the display device 10 may perform the process of identifying defects in the mold 2 using image data including the mold 2 as a subject.

[0074] [Modification 4] In the above-described embodiment, the size of the cast off part may be small relative to the surface area of ​​the mold 2. Therefore, the display device 10 may be configured to enlarge and display a part that the user wishes to enlarge. In this case, when the user performs an operation to specify a part included in the heat map image displayed on the display 31, the display device 10 may enlarge and display the heat map image of the specified part.

[0075] [Modification 5] In the above-described embodiment, when the mold is inverted or frame-transferred, sand adhering to the boundary between the outer periphery of the frame and the mold may fall onto the mold product surface. When the upper and lower molds are mated, the sand that has fallen onto the surface of the mold 2 may become trapped between them and cause defects. Therefore, the display device 10 may detect the sand that has fallen onto the surface of the mold 2 as a defect.

[0076] [Embodiment 2] Another embodiment of the present invention will be described. In the second embodiment, the contents of the classification process performed by the classification unit 12 are different from those in the first embodiment. In the second embodiment, the display device 10 classifies each of the multiple molds 2 into multiple groups in the classification process according to at least one of the type of pattern, molding conditions related to molding of the mold 2, and the results of defect inspection. The molding conditions include, for example, at least one of the period during which the mold 2 was inspected, the sand properties of the mold 2, the control parameters of the molding machine 40, and the weather conditions. The results of the defect inspection include, for example, the importance of the defect. The sand properties of the mold 2 include, for example, the CB value (compactability), moisture, air permeability, compressive strength, and sand temperature. The molding conditions may also include the presence or absence of an effect of the defects of the mold 2 on the product quality of the casting.

[0077] The control parameters refer to parameters that affect the quality of the template 2. Main examples include the following: - Aeration air pressure for filling sand into the flask -Air pressure in the sand tank - Difference between aeration air pressure and air pressure in the sand tank Squeeze pressure ·Working pressure of cylinder for leveling frame - Timing of operation of cylinder for segment type squeeze foot · Down pressure of the cylinder for the segment type squeeze foot Weather conditions include, for example, temperature and humidity.

[0078] The importance of the defect is referred to when deciding whether or not to pour molten metal. If the importance of the defect is high, control is exercised such that molten metal is not poured. On the other hand, if the importance of the defect is low, for example, the defective area can be repaired by grinding it down with a grinder or the like, and molten metal can be poured. The importance of the defect is judged, for example, by the worker who sets the core. The worker then manually inputs the judgment result. The importance also varies depending on the location where it occurs (for example, it is more important if it is near an uneven surface on the model) and the size of the defect.

[0079] The molding conditions of the mold 2 are included in the mold information stored in, for example, the mold management table. That is, the mold management table stores the molding conditions of the mold 2 in association with identification information for identifying the mold 2. Furthermore, date and time information indicating the date and time when the mold 2 was inspected is stored in the inspection result table as described above.

[0080] (Example 1) The user performs an operation for selecting a group according to the modeling conditions using the input / output device 30. The input / output device 30 displays on the display 31 a screen for selecting a group according to the modeling conditions in response to the user's operation.

[0081] 10 is a diagram illustrating a display screen of a heat map image. The screen G60 includes display areas G61 and G62. Heat map images G611 and G612 are displayed in the display areas G61 and G62, respectively. Display elements b11 to b16 are displayed in the display areas G61 and G62, respectively. The display element b11 is a button for reading out data of the heat map image stored in the auxiliary memory 103. When the display element b11 is selected by the user, the display device 10 reads out data of the heat map image from the auxiliary memory 103 in response to the user's operation, and displays a heat map image representing the read data in the display area G61 or G62.

[0082] The display element b12 is a list box for selecting a type of model (an example of a group). The user selects the type of model using the display element b12. In response to the user's operation on the display element b12, the display device 10 selects one of a plurality of types of models.

[0083] The display element b13 is a button for specifying an inspection period (an example of a group) of the mold 2. The user uses the display element b13 to select an inspection period of the mold 2. In response to an operation on the display element b13 by the user, the display device 10 selects the inspection period.

[0084] The display element b14 is a list box group for selecting one or more groups according to the molding conditions of the mold 2. The user uses the display element b14 to select a group to be used for creating a heat map image. In response to the user's operation on the display element b14, the display device 10 selects a group according to the molding conditions. Groups according to the molding conditions of the mold 2 are groups classified by, for example, period (morning, afternoon, etc.), CB value (20-30, etc.), and squeeze pressure (medium, etc.). In this way, on the screen G60, the user uses the display elements b12, b13, and b14 to select a group for classifying the mold 2.

[0085] When a group is selected by the user, the display device 10 receives, from the input / output device 30, designation information indicating the group selected by the user. Based on information indicating a period designated by the user (hereinafter referred to as "period information") contained in the received designation information, the display device 10 searches the inspection result table via the input / output device 30 for molds 2 inspected during the period indicated by the period information. The display device 10 transmits a request including identification information for identifying the searched mold 2 to the line controller 50. The line controller 50 searches the mold management table for the identification information contained in the request received from the display device 10. The line controller 50 transmits, to the display device 10, a response including molding conditions (CB value, etc.) of the mold 2 associated with the searched identification information. The display device 10 classifies the molds 2 inspected during the period designated by the user into multiple groups according to the molding conditions contained in the response received from the line controller 50.

[0086] For example, when a group in which the "period" is "morning" and the "CB value" is "20-30" is selected by the user, the display device 10 generates a heat map image showing the spatial distribution of defect occurrence frequency using the inspection results of a plurality of molds 2 whose inspection dates and times are in the morning and whose CB values ​​are 20-30%. The process of generating the heat map image is the same as that of the above-mentioned embodiment 1. The generated heat map image is displayed on the display 31, and is also stored in the auxiliary memory 103 in response to a user operation. The data of the heat map image stored in the auxiliary memory 103 is read out at a timing desired by the user and displayed on the display 31.

[0087] In this way, the display device 10 generates image data showing a heat map image corresponding to one or more groups selected by the user, based on a group according to the modeling conditions selected by the user. The display device 10 transmits the generated image data to the input / output device 30, which displays the image data on the display 31. The input / output device 30 receives the image data from the display device 10, and displays a heat map image represented by the received image data on the display 31. As a result, the heat map image shown in FIG. 10 is displayed on the display 31.

[0088] When the user selects a group for each of the display areas G61 and G62, a heat map image corresponding to the selected group is displayed in each of the display areas G61 and G62.

[0089] As shown in Fig. 10, the display device 10 displays a plurality of heat map images G611 and G612 generated according to the molding conditions side by side on one screen G60. The plurality of heat map images displayed are heat map images corresponding to different groups. For example, the heat map image G611 may be a heat map image of a mold 2 having a CB value of "37 to 43%", and the heat map image G612 may be a heat map image of a mold 2 having a CB value of "44 to 50%".

[0090] The number of heat map images displayed on one screen is not limited to two, and may be more or less than this. Furthermore, the display device 10 is not limited to displaying a plurality of heat map images side by side, and may display a plurality of heat map images in a superimposed manner on the display 31. When superimposing the heat map images, the display device 10 may display at least a portion of the plurality of heat map images in a semi-transparent manner.

[0091] 10 is a button for saving the data of the heat map image being displayed. When the user selects the display element b15, the display device 10 stores the data of the heat map image being displayed on the display 31 in the auxiliary memory 103. The data stored in the auxiliary memory 103 can be read out by the user selecting the display element b11.

[0092] The display element b16 is a button for performing a frame-by-frame display (animation display). The user uses the display element b16 to select a unit period that will be a division for each frame when performing the frame-by-frame display. The unit period is a unit for classifying the inspection period of the mold 2 into a plurality of groups. If the frame-by-frame display is not performed, the user selects "no selection" in the display element b16. When the user specifies a unit period for the frame-by-frame display using the display element b16, the display device 10 classifies each of the plurality of molds 2 by the unit period during which the mold 2 was inspected, and generates a heat map image for each specified unit period (each group). The display device 10 switches between heat map images corresponding to each of the plurality of groups in sequence to display an animation.

[0093] 10, when "12 / 1 to 12 / 30" is selected in display element b13 and "Every week" is selected in display element b16, display device 10 classifies the inspection results of mold 2 inspected "12 / 1 to 12 / 30" by week and generates a heat map image for each week. Display device 10 displays the heat map images for each week in the period "12 / 1 to 12 / 30" in an animation, switching between ascending and descending order.

[0094] As described above, the user can switch the heat map image displayed on the screen G60 by using the display elements b11 to b16 of the screen G60.

[0095] The display elements (display elements b12, b13, b14, etc.) for selecting a group for displaying a heat map image are not limited to those described above, and various elements may be adopted. Other examples of the screen for selecting a group will be described with reference to Figs. 11 to 13.

[0096] (Example 2) FIG. 11 is a diagram illustrating an example of screen transition for selecting a group according to molding conditions. The input / output device 30 displays a screen G21 on the display 31 in response to a user operation. The screen G21 corresponds to the display element b14 in the screen G60 of FIG. 10. The screen G21 is a screen for selecting one of the items "Pattern", "Period", "CB value", "Moisture", and "Squeeze pressure". These items are displayed on the screen G21 by scrolling. When the user selects "CB value" on the screen G21, the input / output device 30 transitions the display on the display 31 to the screen G22.

[0097] The screen G22 is a screen for specifying a range (group) of the CB value. The screen G22 is a screen for selecting one of the groups "up to 29%", "30 to 36%", "37 to 43% (within the threshold range)", "44 to 50%", and "51% or more". These groups are displayed on the screen G22 by scrolling. When the user selects "37 to 43% (within the threshold range)" on the screen G22, the input / output device 30 transitions the display on the display 31 to the screen G23. The method of specifying the range of the CB value is not limited to the method using the screen G22. For example, the input / output device 30 may display a screen for inputting an arbitrary number, and the user may input an arbitrary number to specify the range of the CB value. The user may select one group, or may select multiple groups.

[0098] The screen G23 is a screen for specifying a period. The screen G23 is a screen for selecting one of "hours", "days", "weeks", "months", and "years" and for specifying a numerical value (0, 1, 2, ...). When an operation for specifying a period (group) is performed on the screen G23, the input / output device 30 transmits, to the display device 10, specification information indicating the group specified by the user. Note that the method for specifying a period is not limited to the method using the screen G23. For example, the input / output device 30 may display an image of a calendar, and the user may perform an operation for selecting a period on the displayed calendar.

[0099] Note that the screen for specifying a group according to the modeling conditions is not limited to the screens G21 to G23 exemplified in Fig. 11. For example, a configuration may be adopted in which a plurality of items are displayed in a pull-down list, and the user selects one of the displayed plurality of items.

[0100] When the display device 10 receives the designation information from the input / output device 30, it displays a heat map image corresponding to one or more groups designated by the user on the display 31 in accordance with the received designation information. Note that the molding conditions for each mold 2 are obtained from the line controller 50, as in the above-mentioned Operation Example 1.

[0101] When the molding conditions selected by the user are those exemplified in FIG. 11, the display device 10 classifies the molds 2 stored in the inspection result table into a plurality of groups according to the CB values. The display device 10 generates a heat map image showing the spatial distribution of defect occurrence frequency from the inspection results of a plurality of molds 2 included in a group having a CB value of 37 to 43%. The process of generating the heat map image is the same as that of the above-mentioned embodiment 1. Data representing the generated heat map image is stored in the auxiliary memory 103 in response to a user operation. The data of the heat map image stored in the auxiliary memory 103 is read out at a timing desired by the user and displayed on the display 31.

[0102] As described above, the display device 10 generates image data showing a heat map image corresponding to one or more groups selected by the user, based on the group according to the modeling conditions selected by the user. The display device 10 transmits the generated image data to the input / output device 30. The input / output device 30 receives the image data from the display device 10, and displays a heat map image represented by the received image data on the display 31.

[0103] (Example 3) Fig. 12 is a diagram showing another example of screen transition for selecting a group according to modeling conditions. First, the input / output device 30 displays a screen G21 on the display 31 in response to a user operation. The screen G21 is obtained by scrolling the screen G21 in Fig. 11. When the user selects "Pattern" on the screen G21, the input / output device 30 transitions the display on the display 31 to a screen G32.

[0104] Screen G32 is a screen for specifying the type (pattern) of the model. Screen G32 is a screen for specifying the type (group) of the model, such as "NO.1", "NO.2", "NO.3", "NO.4", and "NO.5". When the user selects "NO.3" on screen G32, input / output device 30 transitions the display on display 31 to screen G23. Note that the method of specifying the type of model is not limited to the method using screen G32. For example, input / output device 30 may display a screen for inputting an arbitrary number, and the user may specify the type of model by inputting an arbitrary number.

[0105] Screen G23 is a screen for specifying a period, and is similar to screen G23 in Fig. 11. When an operation for specifying a period (group) is performed in G23, input / output device 30 transmits, to display device 10, specification information indicating the group specified by the user.

[0106] When the display device 10 receives the designation information from the input / output device 30, it displays a heat map image corresponding to one or more groups designated by the user on the display 31 in accordance with the received designation information. The molding conditions for each mold 2 are obtained from the line controller 50, as in the above-mentioned Operation Example 1.

[0107] When the molding conditions selected by the user are those exemplified in FIG. 12, the display device 10 classifies the molds 2 stored in the inspection result table into multiple groups according to the patterns (models). The display device 10 generates a heat map image showing the spatial distribution of defect occurrence frequency from the inspection results of multiple molds 2 included in the group whose pattern type is "NO. 3". The display device 10 transmits the generated image data to the input / output device 30. The input / output device 30 receives the image data from the display device 10, and displays a heat map image representing the received image on the display 31.

[0108] (Example 4) Fig. 13 is a diagram showing another example of screen transition for selecting a group according to modeling conditions. First, the input / output device 30 displays a screen G21 on the display 31 in response to a user operation. The screen G21 is obtained by scrolling the screen G21 in Fig. 11. When the user selects "Period" on the screen G21, the input / output device 30 transitions the display on the display 31 to a screen G42.

[0109] The screen G42 is a screen for specifying a period (group). The screen G42 includes items for specifying periods (groups) such as "8 to 12 o'clock", "12 to 16 o'clock", "16 to 20 o'clock", "20 to 24 o'clock", and "24 to 4 o'clock". When the user selects "16 to 20 o'clock" on the screen G42, the input / output device 30 transitions the display on the display 31 to the screen G23. Note that the method of specifying a period is not limited to the method using the screen G42. For example, the input / output device 30 may display a screen for inputting an arbitrary number, and the user may specify a period by inputting an arbitrary number.

[0110] When the display device 10 receives the specification information from the input / output device 30, it displays on the display 31 a heat map image corresponding to one or more groups specified by the user in accordance with the received specification information. When the group corresponding to the molding conditions selected by the user is one exemplified in FIG. 13, the display device 10 classifies the molds 2 stored in the inspection result table into multiple groups according to the inspection date and time. The display device 10 generates a heat map image showing the spatial distribution of defect occurrence frequency from the inspection results of multiple molds 2 included in the group with the inspection date and time of "16:00 to 20:00".

[0111] The display device 10 transmits the generated image data to the input / output device 30. The input / output device 30 receives the image data from the display device 10, and displays on the display 31 a heat map image representing the received image.

[0112] According to this embodiment, the correlation between defects occurring in the mold 2 and molding conditions can be visualized, making it easy for the user to grasp the tendency of defects occurring in the mold 2. For example, by displaying a heat map image for each defect with or without an impact on product quality, it becomes easier to prioritize countermeasures against defects in the mold 2. This makes it easier for the user to efficiently take countermeasures against defects in the mold 2.

[0113] In addition, in the present embodiment, by displaying a plurality of heat map images on one screen, the user can compare the plurality of heat map images, and can easily grasp the tendency of defects occurring for each molding condition. In addition, when a plurality of heat map images are displayed in a superimposed manner, by making at least a portion of the plurality of heat map images semi-transparent, the user can easily recognize the contents of the heat map images.

[0114] In addition, in this embodiment, the heat map image for each group is animated, thereby making it possible to visualize the transition of the defect tendency (e.g., change over time) of the mold 2. This makes it easier for the user to analyze the cause of the defect in more detail. Furthermore, the user can easily identify the cause of the defect by visually checking the animation display for each molding condition and comparing the transition of the defect tendency for multiple parameters.

[0115] [Variation 1] In the above-mentioned operation example 1 of the second embodiment, the user sets the unit period of the animation display using the display element b16, and displays the heat map image for each set unit period in animation. The method of setting the display conditions for the animation display is not limited to that shown in the above-mentioned embodiment. For example, the user may set the unit period of the animation display using the screen G42 of FIG. 13, and specify the entire period for the animation display using the screen G51 illustrated in FIG. 14. The user uses the screen G51 to select the entire period for displaying the heat map image (for example, the most recent "month"). The display device 10 sequentially switches between heat map images for each unit period included in the selected period in response to the user's selection, and displays the animation. Specifically, for example, the display device 10 sequentially switches between heat map images for each week to display one month's worth of heat map images.

[0116] [Embodiment 3] Another embodiment of the present invention will be described. In the third embodiment, the contents of the classification process performed by the classification unit 12 are different from those in the first embodiment. In the third embodiment, in the display process of the heat map image, the display device 10 displays the heat map images corresponding to each of the multiple groups in sequence as an animation.

[0117] The multiple groups are groups classified according to molding conditions, for example, by inspection period, CB value, and squeeze pressure. When classified by CB value, the molds 2 are classified into five groups, for example, CB values ​​of "0-29%", "30-36%", "37-43%", "44-50%", and "51-". The display device 10 generates a heat map image for each of the five groups. The display device 10 sequentially switches between the five generated heat map images to display them as animation. For example, the display device 10 switches the displayed heat map image every unit time in the following order: a heat map image with a CB value of "0-29%," a heat map image with a CB value of "30-36%,", a heat map image with a CB value of "37-43%,", a heat map image with a CB value of "44-50%," and a heat map image with a CB value of "51-".

[0118] As another example, when classifying the molds 2 into a plurality of groups according to the squeeze pressure, the display device 10 classifies the molds 2 into a plurality of groups according to the squeeze pressure, and generates a heat map image for each of the plurality of groups. The display device 10 sequentially switches between the generated heat map images to display them as an animation.

[0119] According to this embodiment, it is possible to visualize the transition of the defect tendency of the mold 2. For example, the transition of the defect tendency as the CB value increases is shown by an animation image displayed on the display 31. The user can easily identify the cause of the defect by visually checking the animation display of the heat map image for each group according to the molding conditions and comparing the transition of the defect occurrence tendency for a plurality of molding conditions.

[0120] [Software implementation example] The control blocks of the display device 10 (particularly the defect inspection unit 11, the classification unit 12, the generation unit 13, and the display unit 14) may be realized by a logic circuit (hardware) formed in an integrated circuit (IC chip) or the like, or may be realized by software.

[0121] In the latter case, the display device 10 includes a computer that executes instructions of a program, which is software that realizes each function. The computer includes, for example, one or more processors, and a computer-readable recording medium that stores the program. The object of the present invention is achieved by the processor reading the program from the recording medium and executing it in the computer. The processor may be, for example, a CPU (Central Processing Unit). The recording medium may be a "non-transient tangible medium," such as a ROM (Read Only Memory), tape, disk, card, semiconductor memory, programmable logic circuit, or the like. The display device may further include a RAM (Random Access Memory) that expands the program. The program may be supplied to the computer via any transmission medium (such as a communication network or broadcast waves) that can transmit the program. Note that one aspect of the present invention may also be realized in the form of a data signal embedded in a carrier wave, in which the program is embodied by electronic transmission.

[0122] [Additional Notes] The present invention is not limited to the above-described embodiment, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the individual technical means included in the above-described embodiment are also included in the technical scope of the present invention. [Explanation of symbols]

[0123] 1 Casting System 2. Mold 10 Display device 11 Defect Inspection Department 12 Classification section 13 Generation part 14 Display section 20 Inspection Equipment 30 Input / Output Devices 31 Display 40 Molding machine 50 Line Controller 60 Pouring machine 70 Transport Equipment 101 Processor 102 Main Memory 103 Auxiliary Memory 104 Input Interface 105 Output Interface

Claims

1. An inspection result display device for inspecting a plurality of molds, A controller is provided. The controller: A process of classifying the plurality of molds into a plurality of groups using a combination of at least two items among the type of pattern used in molding the mold, molding conditions related to molding the mold, and results of defect inspection of the mold; generating a heat map image representing a spatial distribution of defect occurrence frequency for each of the plurality of groups based on the results of the defect inspection of the molds classified into that group; A process of acquiring designation information indicating a combination of at least two items designated by a user, among the type of pattern used in molding the mold, molding conditions related to the molding of the mold, and results of defect inspection of the mold; and displaying, on a display, a heat map image of a group corresponding to the specified information among the heat map images generated in the generating process.

13. A test result display device comprising:

2. The molding conditions include meteorological conditions related to molding of the mold, The mold inspection result includes information indicating whether or not molten metal can be poured into the mold. The test result display device according to claim 1 .

3. In the acquiring process, the controller receives the designation information corresponding to a plurality of groups, In the display process, the controller displays the heat map images corresponding to the plurality of groups side by side on one screen. The test result display device according to claim 1 or 2.

4. In the classifying process, the controller classifies each of the plurality of molds according to a pattern used to mold the mold.

4. The test result display device according to claim 1, wherein the display device is a display device for displaying a test result.

5. In the classification process, the controller classifies each of the plurality of molds by a unit period during which the mold was inspected.

5. The test result display device according to claim 1, wherein the display device is a display device for displaying test results.

6. In the classification process, the controller classifies each of the plurality of molds according to at least one of molding conditions related to molding of the mold and the result of the defect inspection.

6. The test result display device according to claim 1, wherein the display device is a display device for displaying test results.

7. The molding conditions include at least one of the sand properties of the mold and the control parameters of a molding machine for manufacturing the mold.

7. The test result display device according to claim 6.

8. The result of the defect inspection includes a severity of the defect.

8. The test result display device according to claim 6 or 7.

9. In the classifying process, the controller classifies each of the plurality of molds according to whether the mold is an upper mold or a lower mold.

9. The test result display device according to claim 1, wherein the display device is a display device for displaying a test result.

10. In the process of displaying, the controller displays the heat map images corresponding to the plurality of groups in sequence by switching the heat map images.

10. The test result display device according to claim 1, wherein the test result display device is a display device for displaying a test result of a test performed by a tester.

11. The controller: At least one processor that executes each of the processes according to a predetermined program; At least one memory storing the program.

11. The test result display device according to claim 1, wherein the test result display device is a display device for displaying a test result of a test performed by a tester.

12. 12. A control program for controlling the test result display device according to claim 1, the control program causing the controller to execute each of the processes.

Images