Molded product determination system, molded product determination program

Abstract

To reduce the time required to determine whether a molded product is a good product.SOLUTION: This invention includes an acquisition unit that acquires measurement data for at least two or more of a plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring the plurality of measurement items that indicate the operating status of the injection molding machine, the determination unit that determines whether or not the molded product molded in the operating status detected by the detection unit is a good product based on the relationship between at least two of the two or more measurement items acquired, and determines that an abnormality has occurred in the injection molding machine, an abnormality cause analysis unit that analyzes the cause of the abnormality, an output unit that outputs the analyzed abnormality cause, a status acquisition unit that acquires the abnormality cause of the injection molding machine in which the abnormality has occurred, and a status display control unit that displays the abnormality cause of the injection molding machine in which the abnormality has occurred.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a molded product determination system Mu, Cheng and a molded product determination program.

Background Art

[0002] In recent years, plastic molded products have come to be used in all kinds of daily necessities and industrial products around us, and the demand for products by injection molding machines, which are one of the plastic molding methods, has been increasing more and more. While the generalization due to quality improvement and cost reduction is progressing, the application to high-function and high-added-value fields such as the medical field and the automotive field is increasing. Conventionally, in a pass / fail discrimination inspection for inspecting whether there are shape defects, dimensional defects, or appearance defects in a molded product, inspections using dimensional measurement inspections, appearance visual inspections by workers, or appearance automatic inspection machines have been performed. When defective products occurred, workers judged where the abnormality was during the injection molding process and took measures to deal with the problems such as adjustment of manufacturing conditions, material replacement, and countermeasures using molds. Therefore, the pass / fail determination of molded products and the analysis of the cause of abnormalities largely depended on the skill level of workers. However, in recent years, problems of labor shortage and skill transfer due to aging have become social problems, and it has become an urgent task to promote the automation and efficiency of pass / fail determination.

[0003] As a technology for automating the pass / fail determination of products, a pass / fail determination method using the Mahalanobis-Taguchi method (hereinafter sometimes referred to as the MT method) has been developed in various manufacturing fields.

[0004] Also in the field of plastic molded product manufacturing, as a pass / fail determination method using the MT method, for example, the technology shown in Patent Document 1 below has been developed.

[0005] Patent Document 1 describes a method for determining the quality of molded products of an injection molding machine. This method combines the measured values of a plurality of molding process items obtained from the injection molding machine to calculate the Mahalanobis distance (hereinafter sometimes referred to as MD) in the MT method. Then, by considering the variation in the measured values and the variation in the MD values calculated for different combinations, it is characterized by performing a quality determination with high accuracy.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] However, the quality determination method of Patent Document 1 includes complex calculation processes. Therefore, there is a problem that the calculation time is prolonged. In addition, an operator with a high level of technical proficiency can utilize past experience and knowledge to deal with the occurred abnormal state by checking the determination results for a plurality of process items. However, an operator with a low level of technical proficiency has difficulty dealing with the occurred abnormal state even if checking the determination results for a plurality of process items.

[0008] The present invention has been made in view of such circumstances, and its object is to provide a molded product determination system and a molded product determination program that can assist an operator in dealing with an occurred abnormality while shortening the time for determining a good molded product. Mu, Cheng in providing.

Means for Solving the Problems

[0009] In order to solve the above problems, a molded product determination system according to an aspect of the present invention includes an acquisition unit that acquires measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring a plurality of measurement items indicating the operating status of the injection molding machine, and among the acquired two or more measurement items, based on the relationship between at least two items, it is determined whether the molded product molded in the operating status detected by the detection unit is a good product, a determination unit that determines that an abnormality has occurred in the injection molding machine, an abnormal cause analysis unit that analyzes the cause of the abnormality, an output unit that outputs the analyzed cause of the abnormality, a state acquisition unit that acquires the cause of the abnormality of the injection molding machine in which the abnormality has occurred, and a state display control unit that displays the cause of the abnormality of the injection molding machine in which the abnormality has occurred.

[0010] Further, a molded product determination device according to an aspect of the present invention includes an acquisition unit that acquires measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring a plurality of measurement items indicating the operating status of the injection molding machine, and among the acquired two or more measurement items, based on the relationship between at least two items, it is determined whether the molded product molded in the operating status detected by the detection unit is a good product, a determination unit that determines that an abnormality has occurred in the injection molding machine, an abnormal cause analysis unit that analyzes the cause of the abnormality, and an output unit that outputs the analyzed cause of the abnormality.

[0011] Further, an aspect of the present invention is a molded product determination method executed by a computer, which includes acquiring measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring a plurality of measurement items indicating the operating status of the injection molding machine, and among the acquired two or more measurement items, based on the relationship between at least two items, it is determined whether the molded product molded in the operating status detected by the detection unit is a good product, it is determined that an abnormality has occurred in the injection molding machine, the cause of the abnormality is analyzed, and the analyzed cause of the abnormality is output.

[0012] Further, one aspect of the present invention is to obtain measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring a plurality of measurement items indicating the operating status of the injection molding machine, and among the two or more acquired measurement items, based on the relationship between at least two items, determine whether the molded product molded in the operating status detected by the detection unit is a good product, determine that an abnormality has occurred in the injection molding machine, analyze the cause of the abnormality, and cause a computer to execute outputting the analyzed cause of the abnormality. This is a molded product determination program.

Advantages of the Invention

[0013] As described above, according to the present invention, it is possible to shorten the time for determining whether a molded product is a good product and assist workers in dealing with the occurring abnormalities.

Brief Description of the Drawings

[0014]

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Embodiments for Carrying Out the Invention

[0015] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0016] (Molded Product Judgment System) FIG. 1 is a diagram showing a schematic configuration of a molded product judgment system 1 according to an embodiment of the present invention. The molded product judgment system 1 includes an injection molding device 10 (injection molding machine), an injection molded product inspection device 20, an additional sensor 30, an input device 40, a molded product judgment device 50, an output device 60, a storage device 70, and a display device 80. There are a plurality of injection molding devices 10, and each injection molding device 10 is provided with an injection molded product inspection device 20, an additional sensor 30, an input device 40, a molded product judgment device 50, and an output device 60. The injection molding apparatus 10 includes a detection unit 11.

[0017] The injection molding apparatus 10 performs a metering process of metering the required resin material, a plasticizing process of melting by kneading while heating the resin material with a screw, a filling process of injecting and filling the resin into the mold, a cooling process of cooling and solidifying the resin filled in the mold, a pressure holding process of compensating for the shrinkage of the resin due to cooling, and a mold opening process of opening the mold to take out the injection molded product, thereby injection molding the molded product.

[0018] The injection molding apparatus 10 is connected to an injection molded product inspection apparatus 20, an additional sensor 30, and a molded product determination apparatus 50. The injection molding apparatus 10 conveys the injection molded product to the injection molded product inspection apparatus 20 via a transfer mechanism or the like, and performs inspections based on molding process items for each molding shot by a plurality of sensors (detection unit 11) provided inside the injection molding apparatus 10 itself, and outputs molding process item data indicating the inspection results to the molded product determination apparatus 50. The detection unit 11 detects the operating status of the injection molding apparatus 10 by measuring a plurality of molding process items. For example, the detection unit 11 generates molding process item data including the result of detecting the operating status of the injection molding apparatus 10 for each molding shot, and transmits it to the data acquisition unit 51. In the present embodiment, as molding process items related to injection molding, time parameters, screw position parameters, filling parameters, and mold clamping parameters can be included. As the time parameters, for example, cycle time, filling time, metering time, mold closing time, and mold opening time can be used.

[0019] Here, the detection unit 11 has a function of measuring the cycle time from the start time to the end time of performing one shot by a timekeeping function for measuring time, the filling time from the start time to the end time of starting the filling of the resin on the inner peripheral side of the mold, the metering time from the start time to the end time of introducing a predetermined amount of molten resin into the barrel, the mold closing time from the start of closing the mold until it is completely closed and the mold is in close contact, and the mold opening time from the start of opening the mold until it is completely opened. In addition, the detection unit 11 has a function of measuring the screw position indicating the position of the screw, the minimum cushion position indicating the position of the resin remaining at the tip of the cylinder, and the pre-metering position indicating the position of the screw before metering. In addition, the detection unit 11 has a function of detecting the filling peak pressure, which is the peak value of the pressure when filling the resin, and the global peak pressure, which is the peak value of the pressure in the entire area from the start to the end of injection. In addition, the detection unit 11 has a function of detecting the peak mold clamping force, which is the peak value of the force for clamping the mold, and the mold clamping force at the completion of pressure holding, which indicates the mold clamping force when the pressure holding is completed. In this embodiment, as the molding process items, all 12 items of the cycle time, filling time, metering time, mold closing time, mold opening time, screw position, minimum cushion position, pre-metering position, filling peak pressure, global peak pressure, peak mold clamping force, and mold clamping force at the completion of pressure holding are used. For the molding process items, other items may be used, or a plurality of items fewer than these 12 items may be used.

[0020] The injection molded product inspection device 20 captures an image of the molded product injection molded from the injection molding device 10 with a camera, analyzes and processes the captured image data according to an inspection algorithm to perform quality inspection, and determines whether it is a good product or a defective product. For example, the injection molded product inspection device 20 determines that it is a good product when no defect is found in any inspection item based on the presence or absence of appearance defects, shape defects, or dimensional defects in the molded product, and determines that it is a defective product in other cases. Further, the injection molded product inspection device 20 identifies the type of defect for the molded product determined to be a defective product. For example, the types of appearance defects include gate protrusion, burr, sink mark, short shot, etc. The injection molded product inspection device 20 identifies which of these types the molded product determined to have an appearance defect corresponds to according to the state of the appearance defect. The injection molded product inspection device 20 outputs quality inspection data, which is data indicating the above-mentioned quality inspection results, to the molded product determination device 50. The quality inspection data is data representing the quality result with different numbers according to the quality result, for example, 0 (good product), 1 (gate protrusion defect), 2 (burr defect), 3 (sink mark defect), 4 (short shot defect).

[0021] The additional sensor 30 is, for example, a pressure gauge, a thermometer, etc. provided inside or outside the injection molding device 10, measures various environments (such as air pressure, temperature, etc.) of the injection molding device 10 during molding, and outputs the measured values to the molded product determination device 50. In the present embodiment, the additional sensor 30 is attached to one or more of the molds of the injection molding device 10, measures at least one or more (for example, all 4 items) of the in-mold pressure, product surface temperature, mold opening and closing displacement amount, and cooling water flow rate, and outputs the measurement results as additional sensor item data. The in-mold pressure is the pressure on the inner peripheral side of the mold during injection molding (the pressure applied to the resin forming the molded product), the product surface temperature is the surface temperature of the molded product, the mold opening and closing displacement amount is the amount of displacement generated in the tie bar that guides the opening and closing of the mold when the mold is being clamped, and the cooling water flow rate is the flow rate of water used as a refrigerant to cool the mold by passing through the inside of the mold to control the temperature of the mold.

[0022] Hereinafter, the molding process items and the additional sensor items may be collectively referred to as measurement items.

[0023] The input device 40 is, for example, a keyboard, a mouse, etc., and inputs the unit space calculation conditions, MD calculation conditions, or abnormality determination conditions to the molded product determination device 50 according to the operator's operation input.

[0024] The unit space calculation conditions include the number of shots used for unit space calculation and the combination information of the measurement items. The MD calculation conditions include the combination information of the measurement items used for MD calculation.

[0025] The combination information of the measurement items indicates the combination of the measurement items used for unit space calculation / MD calculation. The combination of the measurement items includes at least two items out of the 12 molding process items in total, and further may include at least one item out of the 4 additional sensor items in total. For example, as the combination of the measurement items, two items of the minimum cushion position and the global peak pressure can be selected from the molding process items, and two items of the in-mold pressure and the mold opening / closing displacement amount can be selected from the additional sensor items. As another example of the combination, all 12 items can be selected from the molding process items.

[0026] Depending on the specifications of the molded product, it is conceivable that the statistical significance may not be satisfied when the number of shots is small. In such a case, the unit space calculation may be performed based on samples of a predetermined number of shots (for example, at least 100 shots). In this embodiment, the case where the unit space calculation is performed with the number of shots set to about 400 shots will be described.

[0027] The abnormality determination conditions include an MD value abnormality determination threshold for determining the quality of the molded product based on the calculated MD value obtained by MD calculation, a stop signal reporting threshold (first threshold) for stopping the injection molding apparatus 10 based on the frequency at which the calculated MD value exceeds the MD value abnormality determination threshold, and an alarm signal reporting threshold (second threshold) for outputting an alarm to the injection molding apparatus 10 based on the frequency at which the calculated MD value exceeds the MD value abnormality determination threshold.

[0028] The molded product determination device 50 acquires the molding process item data of the injection molding device 10, the quality inspection data of the injection molded product inspection device 20, and the additional sensor item data of the additional sensor 30 for each molding shot. Further, the molded product determination device 50 acquires the unit space calculation conditions, MD calculation conditions, or abnormality determination conditions from the input device 40.

[0029] As will be described in detail later, the molded product determination device 50 performs unit space calculation or MD calculation using the MT method, and performs a pass / fail (normal / abnormal) determination to determine whether the molded product is a good product or a defective product based on the calculated MD value obtained by the MD calculation.

[0030] When calculating the unit space, if the unit space is not calculated or the accuracy of the calculated unit space is poor (when the value indicating the accuracy is below a certain value), the molded product determination device 50 outputs a unit space calculation error to the output device 60.

[0031] When calculating the MD, the molded product determination device 50 outputs the quality inspection data, the measurement item data used for the MD calculation, and the calculated MD value to the storage device 70 for each molding shot. Further, when it is determined as a defective product (abnormal) in the pass / fail (normal / abnormal) determination result, the molded product determination device 50 outputs the contribution degree of the measurement items related to the occurrence of the defect (abnormality) to the output device 60 and the storage device 70. Here, the contribution degree is a value representing the degree of the relationship between the measurement items used to obtain the MD value and the MD value. This contribution degree may be calculated by the molded product determination device 50 (the MD calculation unit 553 described later).

[0032] The output device 60 is an external device such as a PC (computer) or a display device. When calculating the unit space, the output device 60 receives the unit space calculation error from the molded product determination device 50 and displays the error content on a display or the like. When calculating the MD, the output device 60 receives and displays the quality inspection data, the measurement item data used for the MD calculation, the calculated MD value, and the contribution degree from the molded product determination device 50.

[0033] The memory device 70 is an external device equipped with a database. The display device 80 is an information processing device such as a PC (computer), a tablet terminal, or a smartphone.

[0034] (Molded product determination device) FIG. 2 is a functional block diagram showing the configuration of a molded product determination device 50 according to an embodiment of the present invention.

[0035] The molded product determination device 50 includes a data acquisition unit 51, an input unit 52, a storage unit 53, a data selection unit 54, a data analysis unit 55, an output unit 56, an alarm unit 57, and a stop unit 58.

[0036] The data acquisition unit 51 acquires, for each molding shot, the molding process item data of the injection molding device 10, the additional sensor item data of the additional sensor 30, and the quality inspection data of the injection molded product inspection device 20, and transmits them to the storage unit 53. Note that at least two items out of all 12 items may be included in the acquired molding process item data, and at least one item out of all 4 items may be included in the acquired additional sensor item data.

[0037] The input unit 52 receives the unit space calculation conditions, the MD calculation conditions, or the abnormality determination conditions from the input device 40 and transmits them to the storage unit 53.

[0038] The storage unit 53 stores various data. For example, the storage unit 53 stores unit space data generated based on the Mahalanobis-Taguchi method for measurement data when good products are molded by the injection molding device 10 in a plurality of measurement items indicating the operating status of the injection molding device 10. The storage unit 53 can store unit space data for all combinations of a plurality of measurement items. Such a storage unit 53 is composed of a storage medium, for example, an HDD (Hard Disk Drive), a flash memory, an EEPROM (Electrically Erasable Programmable Read Only Memory), a RAM (Random Access read / write Memory), a ROM (Read Only Memory), or any combination of these storage media. This storage unit 53 can use, for example, a non-volatile memory. The data configuration of the storage unit 53 will be described with reference to FIGS. 3 to 5.

[0039] FIG. 3 is a diagram showing the data configuration of the storage unit 53. The storage unit 53 stores measurement item data 531, quality inspection data 532, good product data 533, unit space data 534, calculation conditions 535, a quality identification table 536, a measurement item identification table 537, and abnormal determination conditions 538.

[0040] As the measurement item data 531, 12 items of molding process item data and 4 items of additional sensor item data received from the data acquisition unit 51 are stored.

[0041] As the quality inspection data 532, the quality inspection data received from the data acquisition unit 51 is stored.

[0042] As the good product data 533, as will be described in detail later, the data determined to be good product data in the data selection unit 54 is stored.

[0043] As the unit space data 534, as will be described in detail later, the unit space data calculated using the good product data 533 by the MT method in the data analysis unit 55 is stored.

[0044] As the calculation conditions 535, the unit space calculation conditions or MD calculation conditions received from the input unit 52 are stored.

[0045] As the quality identification table 536, the quality type of the molded product and the corresponding quality inspection data are stored. FIG. 4 is a diagram showing an example of the quality identification table 536. For example, as shown in FIG. 4, when the value of the quality inspection data is 0, it represents a non-defective product, 1 represents a defective product with a gate protrusion, 2 represents a defective product with burrs, 3 represents a defective product with sink marks, ···, and N represents a defective product with a short shot.

[0046] As the measurement item identification table 537, the item number, item name, and item identification label of the measurement item data are stored. FIG. 5 is a diagram showing an example of the measurement item identification table 537. For example, as shown in FIG. 5, the measurement item identification table 537 stores the item numbers, item names, and item identification labels (101 to 112, 201 to 204) of 12 molding process items and 4 additional sensor items. For example, from the input device 40, at least two of the item numbers in the molding process items or external sensor items can be selected by specifying values. That is, when item numbers 1 and 5 are specified, "cycle time" and "mold opening time" are used as the items for which the unit space is sought.

[0047] As the abnormality determination condition 538, the abnormality determination condition received from the input unit 52 is stored.

[0048] The data selection unit 54 refers to the quality identification table 536 stored in the storage unit 53 and determines whether the measurement item data 531 acquired from the storage unit 53 is data at the time of forming a non-defective product (non-defective product data) or data at the time of forming a defective product (defective product data). For example, the data selection unit 54 refers to the quality identification table 536 shown in FIG. 4 and determines that the measurement item data 531 is non-defective product data when the quality inspection data 532 is 0, and determines that the measurement item data 531 is defective product data when the quality inspection data 532 is other than 0. The data selection unit 54 transmits the measurement item data determined to be non-defective product data to the storage unit 53, and the storage unit 53 stores the received measurement item data as non-defective product data 533.

[0049] The data analysis unit 55 includes an analysis mode setting unit 551, a unit space calculation unit 552, an MD calculation unit 553, a determination unit 554, and an abnormal cause analysis unit 555.

[0050] The analysis mode setting unit 551 refers to the calculation conditions 535 in the storage unit 53 to set whether to execute unit space calculation or MD calculation. When unit space calculation is set, the analysis mode setting unit 551 sends a unit space calculation instruction to the unit space calculation unit 552. When MD calculation is set, the analysis mode setting unit 551 sends an MD calculation instruction to the MD calculation unit 553. In this way, by designating either unit space calculation or MD calculation, for example, from the input device 40, the processing of the molded product determination device 50 is executed in either the unit space calculation mode or the MD calculation mode.

[0051] When the unit space calculation unit 552 receives a unit space calculation instruction from the analysis mode setting unit 551, it performs unit space calculation according to the calculation instruction. When the unit space is calculated, the unit space calculation unit 552 sends the calculated unit space data to the storage unit 53. When the unit space is not calculated, the unit space calculation error is sent to the output unit 56. Details of the unit interval calculation process will be described later.

[0052] Note that the unit space calculation unit 552 can calculate unit spaces for a plurality of combinations with different measurement items and store the calculated plurality of unit space data in the storage unit 53 respectively.

[0053] The MD calculation unit 553 obtains the Mahalanobis distance (hereinafter referred to as the MD value) based on the MT method using the measurement data of at least two items among the acquired two or more measurement items. Hereinafter, the operation in which the MD calculation unit 553 obtains the Mahalanobis distance is referred to as MD calculation. Also, the Mahalanobis distance obtained by MD calculation is referred to as the calculated MD value. When the MD calculation unit 553 receives an MD calculation instruction from the analysis mode setting unit 551, it performs MD calculation according to the calculation instruction, and transmits the measurement item data 531 used for the MD calculation and the calculated MD value to the output unit 56. Further, the MD calculation unit 553 transmits the calculated MD value to the determination unit 554. Details of the MD calculation process will be described later.

[0054] Based on the relationship between at least two of the acquired two or more measurement items, the determination unit 554 determines whether the molded product molded in the operating state detected by the detection unit 11 is a good product, and determines that an abnormality has occurred in the injection molding machine. When determining whether the molded product is a good product based on the relationship between two items, there are several methods. In this embodiment, the case of determining based on whether the MD value calculated by the MD calculation unit 553 exceeds a reference value will be described, but it may be realized by other methods. For example, a learned model is generated by having AI (artificial intelligence) learn the relationship between the measurement results of two or more measurement items and whether an abnormality has occurred. Then, the injection molding machine is actually operated, and the measurement results detected by the detection unit 11 for the operating state are input into the learned model to determine whether an abnormality has occurred. Based on whether the MD value calculated by the MD calculation unit 553 exceeds a reference value, the determination unit 554 determines whether the molded product molded in the operating state detected by the detection unit 11 is a good product. The reference value is the MD value abnormality determination threshold value stored in the storage unit 53. Based on a plurality of unit space data based on measurement items with different combinations among the plurality of measurement items, the determination unit 554 makes a determination for each combination of measurement items of the unit space data based on the plurality of unit space data and the measurement data based on the measurement items detected by the detection unit 11. The determination unit 554 can perform such determination using the measurement data detected by the detection unit obtained when each shot of the molded product is performed, every time a shot of the molded product is performed. Further, the determination unit 554 can also perform determination for each combination of all measurement items of the measurement data obtained from the detection unit 11. Based on the calculated MD value received from the MD calculation unit 553, the determination unit 554 performs a pass / fail determination (normal / abnormal determination) of the molded product. When the determination unit 554 determines that it is abnormal (fail) in the pass / fail determination result, it transmits an abnormal cause analysis instruction to the abnormal cause analysis unit 555 and transmits an alarm instruction signal for the molded product to the alarm unit 57. When the determination unit 554 determines that the MD value has exceeded the reference value, it outputs an alarm instruction signal indicating the determination result together with the measurement data determined to have exceeded the reference value. Details of the pass / fail determination process will be described later.

[0055] Further, when the determination unit 554 determines that the MD value has exceeded the reference value, it determines whether or not the frequency of the MD value exceeding the reference value has exceeded the stop signal reporting threshold. When the frequency of the MD value exceeding the reference value has exceeded the stop signal reporting threshold, the determination unit 554 determines that an abnormality has occurred in the injection molding apparatus 10, transmits a stop instruction signal instructing the stop of the injection molding apparatus 10 to the stop unit 58, and transmits abnormal occurrence data indicating that an abnormality has occurred in the injection molding apparatus 10 to the output unit 56. The abnormal occurrence data includes the date and time when the abnormality occurred, the identification information of the injection molding apparatus 10, the state "MD stop" of the injection molding apparatus 10, and the cause of the abnormality (contribution degree of the abnormal item) analyzed by the abnormal cause analysis unit 555. Further, when the determination unit 554 determines that the MD value has exceeded the reference value, it determines whether the frequency at which the MD value has exceeded the reference value has exceeded an alarm signal reporting threshold smaller than the stop signal reporting threshold. When the frequency at which the MD value has exceeded the reference value has exceeded the alarm signal reporting threshold, the determination unit 554 determines that an abnormality has occurred in the injection molding apparatus 10, transmits an alarm instruction signal of the injection molding apparatus 10 to the alarm unit 57, and transmits abnormality occurrence data to the output unit 56. The abnormality occurrence data includes the date and time when the abnormality occurred, the identification information of the injection molding apparatus 10, the state "MD alarm" of the injection molding apparatus 10, and the cause of the abnormality (contribution degree of the abnormal item) analyzed by the abnormality cause analysis unit 555. Here, the MD value abnormality determination threshold, the stop signal reporting threshold, and the alarm signal reporting threshold will be described with reference to FIG. 6.

[0056] FIG. 6 is an image diagram showing an example of a threshold setting screen displayed by the output device 60. As shown in the figure, on the threshold setting screen 600, the MD value abnormality determination threshold 601 that is a reference value for determining the quality of the molded product, the stop signal reporting threshold 602 for stopping the injection molding apparatus 10, and the alarm signal reporting threshold 603 for outputting an alarm for the injection molding apparatus 10 can be set and input from the input device 40. In the example shown in the figure, it is an input screen when "4" is set as the MD value abnormality determination threshold. In this case, the determination unit 554 determines that the molded product of the shot with the calculated MD value of "4" or more is abnormal (defective). The stop signal reporting threshold can be represented by the ratio of the number of shots for which the molded product is abnormal (defective) to the number of shots within a certain range, and in the example shown in the figure, it is "10 shots / 100 shots". Therefore, in this example, when the number of shots with the calculated MD value of "4" or more exceeds "10 shots" within the most recent "100 shots", the determination unit 554 determines that an abnormality has occurred in the injection molding apparatus 10 and outputs a stop instruction signal for stopping the injection molding apparatus 10. The alarm signal reporting threshold can be represented by the ratio of the number of shots with abnormal (or not) molded products to the number of shots within a certain range. In the illustrated example, it is "5 shots / 100 shots". Therefore, in this example, when the number of shots with an MD value of "4" or more exceeds "5 shots" among the most recent "100 shots", the determination unit 554 determines that an abnormality has occurred in the injection molding apparatus 10 and outputs an alarm instruction signal to the injection molding apparatus 10. Here, the reporting of the stop signal and the reporting of the alarm signal can be set separately.

[0057] In this embodiment, the MD value abnormality determination threshold, the stop signal reporting threshold, and the alarm signal reporting threshold are set from the input device 40 on the threshold setting screen 600 displayed on the output device 60. However, the threshold setting screen 600 may be displayed on the display device 80 so that the MD value abnormality determination threshold, the stop signal reporting threshold, and the alarm signal reporting threshold (used by each molded product determination device 50 for determination) of each injection molding apparatus 10 can be set from the display device 80.

[0058] When the abnormality cause analysis unit 555 receives an abnormality cause analysis instruction from the determination unit 554, it performs an abnormality cause analysis. Specifically, the abnormality cause analysis unit 555 calculates the contribution degrees of the measurement items used in the calculation of the MD value, selects a plurality of items with large contribution degrees from the largest ones, and uses these items as abnormal items related to the occurrence of the abnormality, and transmits the contribution degrees of the abnormal items to the output unit 56. Details of the abnormality cause analysis process will be described later.

[0059] The output unit 56 transmits the unit space calculation error, quality inspection data, measurement item data, calculated MD value, and contribution degrees of abnormal items received from the data analysis unit 55 to the output device 60. Further, the output unit 56 transmits the quality inspection data, measurement item data, calculated MD value, and contribution degrees of abnormal items received from the data analysis unit 55 to the storage device 70 as determination result data together with the identification information of the injection molding apparatus 10, the date and time of the molding shot, the order number of the molded product, and the box number. In addition, the output unit 56 transmits the abnormality occurrence data including the cause of the abnormality received from the data analysis unit 55 to the storage device 70.

[0060] The alarm unit 57 has a function of outputting an alarm when the MD value exceeds the reference value in the determination result of the determination unit 554. For example, it is an alarm or the like having a function of emitting an alarm sound as an alarm. When the alarm unit 57 receives an alarm instruction signal from the data analysis unit 55, it emits an alarm sound notifying the occurrence of an abnormality. The alarm unit 57 may emit different warning sounds depending on whether the received alarm instruction signal is for the molded product or for the injection molding apparatus 10. The alarm unit 57 outputs an alarm when the frequency at which the MD value exceeds the reference value exceeds the alarm signal reporting threshold in the determination result of the determination unit.

[0061] The stop unit 58 stops the injection molding apparatus 10 when the frequency at which the MD value exceeds the reference value exceeds the stop signal reporting threshold in the determination result of the determination unit 554. Specifically, when the stop unit 58 receives a stop instruction signal from the data analysis unit 55, it transmits a stop signal to the injection molding apparatus 10 to stop the injection molding apparatus 10.

[0062] (Unit space calculation process) The unit space calculation process will be described with reference to FIG. 7. FIG. 7 is a flowchart explaining the flow of the unit space calculation process.

[0063] The input unit 52 receives the unit space calculation conditions from the input device 40 and transmits them to the storage unit 53. The storage unit 53 receives the unit space calculation conditions and stores them as calculation conditions 535 (step S100).

[0064] The analysis mode setting unit 551 refers to the calculation conditions 535 in the storage unit 53 and transmits a unit space calculation instruction to the unit space calculation unit 552 (step S101).

[0065] When the unit space calculation unit 552 receives a unit space calculation instruction from the analysis mode setting unit 551 in step S102, it refers to the calculation conditions 535 and acquires the non-defective data 533 used for unit space calculation from the storage unit 53 (step S102). Specifically, the unit space calculation unit 552 refers to the combination information of measurement items included in the calculation conditions 535 and acquires the non-defective data 533 of the items constituting this combination. For example, when this combination is composed of two items, the minimum cushion position and the global peak pressure, the unit space calculation unit 552 acquires the non-defective data 533 of these two items from the storage unit 53. Also, the unit space calculation unit 552 refers to the number of shots included in the calculation conditions 535 and acquires the non-defective data 533 for the number of shots. For example, when the number of shots is 400, the unit space calculation unit 552 randomly acquires data for 400 shots from the non-defective data 533.

[0066] The unit space calculation unit 552 determines whether there is a defect in the non-defective data 533 (step S103). For example, if the data for the 100th shot among the acquired non-defective data 533 for all 400 shots was not measured due to a failure of a sensor or the like, it is determined that there is a defect. If there is a defect (step S103 - No), the unit space calculation unit 552 does not perform unit space calculation and returns to step S102.

[0067] If there is no defect (step S103 - Yes), the unit space calculation unit 552 performs unit space calculation based on the MT method (step S104).

[0068] When the unit space is calculated (step S105 - Yes), the unit space calculation unit 552 transmits the calculated unit space data to the storage unit 53, and the storage unit 53 stores the received unit space data as unit space data 534 (step S106).

[0069] On the other hand, if a calculation error (for example, a multicollinearity error, etc.) occurs during the unit space calculation process, the unit space is not calculated (step S105 - No), and the unit space calculation unit 552 transmits the calculation error to the output unit 56 (step S107). The operator refers to the content of the calculation error transmitted from the output unit 56 to the output device 60, modifies the unit space calculation conditions, and inputs them into the input device 40. The input device 40 transmits the modified unit space calculation conditions to the input unit 52, and the input unit 52 updates the calculation conditions 535 in the storage unit 53. Thereby, the unit space calculation unit 552 can perform unit space calculation using the modified unit space calculation conditions.

[0070] Note that the above-described data acquisition unit 51, input unit 52, data selection unit 54, data analysis unit 55, output unit 56, alarm unit 57, and stop unit 58 may be configured by a processing device such as a CPU (central processing unit) or a dedicated electronic circuit.

[0071] (Molded Product Judgment Process) The molded product judgment process will be described with reference to FIG. 8. FIG. 8 is a flowchart explaining the flow of the molded product judgment process.

[0072] The input unit 52 transmits the MD calculation conditions received from the input device 40 to the storage unit 53, and the storage unit 53 stores the received MD calculation conditions as the calculation conditions 535 (step S200).

[0073] The analysis mode setting unit 551 refers to the calculation conditions 535 in the storage unit 53 and transmits an MD calculation instruction to the MD calculation unit 553 (step S201).

[0074] When the MD calculation unit 553 receives the MD calculation instruction, it refers to the calculation conditions 535 in the storage unit 53 and acquires the unit space data 534 used for MD calculation from the storage unit 53 (step S202). Here, the combination of measurement items constituting the unit space must match the combination of measurement items used for MD calculation. For example, consider a case where a combination composed of four items, namely, measurement time, minimum cushion position, global peak pressure, and filling peak pressure, is specified in the combination information of the measurement items included in the calculation conditions 535. In this case, the MD calculation unit 553 acquires the unit space data 534 calculated using the above four items from the plurality of unit space data stored in the unit space data 534 from the storage unit 53.

[0075] The MD calculation unit 553 refers to the combination information of measurement items included in the calculation condition 535, and acquires the measurement item data 531 of the items constituting this combination (step S203).

[0076] Furthermore, the MD calculation unit 553 determines whether there is a defect in the acquired measurement item data 531 (step S204).

[0077] When it is determined that there is a defect (step S204 - No), the MD calculation unit 553 does not perform MD calculation in the current shot. When a new shot is performed, the MD calculation unit 553 returns to step S203 to perform processing.

[0078] When it is determined that there is no defect (step S204 - Yes), the MD calculation unit 553 performs MD calculation (step S205), and transmits the calculated MD value and the measurement item data used for MD calculation to the output unit 56 (step S206). The output device 60 receives the calculated MD value and the measurement item data from the output unit 56, and displays them on a display or the like for each shot. Further, the storage device 70 receives the calculated MD value and the measurement item data from the output unit 56, and stores them as determination result data.

[0079] The determination unit 554 performs a pass / fail determination (normal / abnormal determination) of the molded product based on the calculated MD value received from the MD calculation unit 553 (step S207). Specifically, the determination unit 554 determines that it is a defective product (abnormal) when the calculated MD value is equal to or greater than the MD abnormal determination threshold, and a non-defective product (normal) when it is less than the MD abnormal determination threshold.

[0080] When it is determined to be normal in the pass / fail determination result (step S207 - Yes), the molded product determination process in the current shot ends.

[0081] When it is determined that there is an abnormality in the pass / fail determination result (step S207 - No), the determination unit 554 transmits an alarm instruction signal indicating the determined abnormal result together with the measurement data determined to be abnormal to the alarm unit 57 (step S208). The alarm unit 57 outputs an alarm sound according to the alarm instruction signal and displays the measurement data at the time of determining the abnormality on a screen such as a display screen. As a result, the operator can know in real time that there is an abnormality in the molded product that has been shot, and can take necessary countermeasures (adjustment of various setting values, etc.) from the time when the abnormality occurs. Furthermore, the determination unit 554 transmits an abnormality cause analysis instruction to the abnormality cause analysis unit 555 (step S209).

[0082] When the abnormality cause analysis unit 555 receives the abnormality cause analysis instruction from the determination unit 554, it performs an abnormality cause analysis (step S209). Specifically, the abnormality cause analysis unit 555 calculates the contribution degree of the measurement item data used for MD calculation for each item, and selects several items with a large contribution degree from the largest one. The abnormality cause analysis unit 555 regards the selected items with a large contribution degree as abnormal items related to the occurrence of the abnormality, and outputs the contribution degree of the abnormal items to the output unit 56 (step S210). The output device 60 displays the contribution degree of the abnormal items received from the output unit 56. By checking the contribution degree of the abnormal items, the operator can obtain knowledge about which measurement items are related to the occurrence of the abnormality. In addition, the storage device 70 receives the contribution degree of the abnormal items from the output unit 56 and stores it as determination result data.

[0083] Subsequently, the determination unit 554 determines whether or not the frequency at which the calculated MD value is equal to or greater than the MD abnormality determination threshold (that is, the molded product is determined to be a defective product (abnormal)) exceeds the stop signal reporting threshold (step S211).

[0084] When the determination unit 554 determines that the frequency at which the calculated MD value is equal to or greater than the MD abnormality determination threshold exceeds the stop signal reporting threshold (step S211 - Yes), it determines that an abnormality has occurred in the injection molding apparatus 10, transmits a stop instruction signal to the stop unit 58, and outputs abnormality occurrence data to the output unit 56 (step S212). When the stop unit 58 receives a stop instruction signal from the data analysis unit 55, it stops the injection molding apparatus 10. On the other hand, the output unit 56 transmits the received abnormality occurrence data to the output device 60 and the storage device 70. Thereafter, the molded product determination process in the current shot ends. When the output device 60 receives the abnormality occurrence data, it displays that an abnormality has occurred and the injection molding apparatus 10 has stopped, as well as the cause of the abnormality. As a result, the operator can know that an abnormality has occurred and the injection molding apparatus 10 has stopped, as well as the cause of the abnormality. Further, the storage device 70 receives the abnormality occurrence data from the output unit 56 and stores it.

[0085] When the determination unit 554 determines that the frequency at which the calculated MD value is equal to or greater than the MD abnormality determination threshold does not exceed the stop signal reporting threshold (step S211 - No), it determines whether the frequency at which the calculated MD value is equal to or greater than the MD abnormality determination threshold (that is, the molded product is determined to be a defective product (abnormal)) exceeds the alarm signal reporting threshold (step S213).

[0086] When the determination unit 554 determines that the frequency at which the calculated MD value is equal to or greater than the MD abnormality determination threshold exceeds the alarm signal reporting threshold (step S213 - Yes), it determines that an abnormality has occurred in the injection molding apparatus 10, transmits an alarm instruction signal to the alarm unit 57, and transmits abnormality occurrence data to the output unit 56 (step S214). The alarm unit 57 outputs an alarm sound in response to the alarm instruction signal. On the other hand, the output unit 56 transmits the received abnormality occurrence data to the output device 60 and the storage device 70. Thereafter, the molded product determination process in the current shot ends. When the output device 60 receives the abnormal occurrence data, it displays that an abnormality has occurred in the injection molding device 10 and an alarm has been output, as well as the cause of the abnormality. As a result, the operator can know that an abnormality has occurred in the injection molding device 10 and the cause of the abnormality. Further, the storage device 70 receives the abnormal occurrence data from the output unit 56 and stores it.

[0087] In step S204 - No, step S207 - Yes, step S212, step S213 - No, after step S214, the data analysis unit 55 returns to step S203 every time a new molding shot is performed, and performs the processing from step S203 to step 214. Thereby, it becomes possible to determine the quality of the molded product in real time during injection molding.

[0088] (Storage device) FIG. 9 is a functional block diagram showing the configuration of the storage device 70 according to an embodiment of the present invention. The storage device 70 includes a determination result data storage unit 71, an abnormal history storage unit 72, an event data storage unit 73, a device state storage unit 74, a corresponding method storage unit 75, and a device information storage unit 76. The determination result data storage unit 71 receives the determination result data for each molding shot transmitted from the molded product determination device 50 and stores the received determination result data. The abnormal history storage unit 72 receives the abnormal occurrence data transmitted from the molded product determination device 50 and stores the received abnormal occurrence data. Note that the abnormal history storage unit 72 may also store information indicating whether the abnormality indicated by each abnormal occurrence data has been resolved.

[0089] The event data storage unit 73 stores, as event data, the events that occurred in each injection molding apparatus 10 in association with the date and time. The events include responses (measures) to abnormalities that occurred in the injection molding apparatus 10. For example, the event data storage unit 73 receives, from the display device 80, event data indicating the response implemented for the injection molding apparatus 10 in which an abnormality occurred, and stores the received event data. For example, the event data includes the date and time when the abnormality occurred, the identification information of the injection molding apparatus 10 in which the abnormality occurred, the cause of the abnormality, the response implemented to eliminate the abnormality, and the date and time when the response was implemented.

[0090] The device state storage unit 74 stores the states of the plurality of injection molding apparatuses 10. The states include, for example, "operation" in which normal operation is being performed, "stop" in which it is stopped, "failure" in which it has failed, "MD warning" in which a warning is output by the molded product determination device 50, and "MD stop" in which it has been stopped by the molded product determination device 50. When the state of the injection molding apparatus 10 is "MD warning" or "MD stop", the device state storage unit 74 also stores the cause of the abnormality (the contribution degree of the abnormal item). For example, when the device state storage unit 74 receives abnormality occurrence data from the molded product determination device 50, it rewrites the state of the corresponding injection molding apparatus 10 to the state ("MD warning" or "MD stop") included in the received abnormality occurrence data. Further, when the device state storage unit 74 receives, from the display device 80, event data indicating that the abnormality has been eliminated by implementing a response, it rewrites the state of the corresponding injection molding apparatus 10 to "operation".

[0091] The response method storage unit 75 stores in advance the response methods for each cause of each abnormality that occurs in the injection molding apparatus 10. There may be a plurality of response methods for one cause of an abnormality. When there are a plurality of response methods, a priority order is set in advance for each response method. The device information storage unit 76 stores in advance the device information regarding each injection molding apparatus 10. For example, the device information storage unit 76 stores the model, the name of the device, the floor where it is arranged, and the arrangement position on the floor (for example, coordinates, etc.) in association with the identification information of each injection molding apparatus 10.

[0092] (Display device) FIG. 10 is a functional block diagram showing the configuration of a display device 80 according to an embodiment of the present invention. The display device 80 includes an input unit 81, a data acquisition unit 82, a data display control unit 83, a state acquisition unit 84, a state display control unit 85, and a display unit 86.

[0093] The input unit 81 is, for example, a keyboard, a mouse, a touch panel installed on the display screen of the display unit 86, etc., and receives the operator's operation input. For example, the input unit 81 receives the specified input of the conditions of the determination result data to be displayed on the display unit 86.

[0094] The data acquisition unit 82 reads and acquires the determination result data that matches the specified input conditions from the storage device 70. The data display control unit 83 displays the acquired determination result data on the display unit 86.

[0095] The state acquisition unit 84 acquires from the storage device 70 the states of each of the plurality of injection molding devices 10, the cause of the abnormality of the injection molding device 10 in which an abnormality has occurred, and the corresponding method. The state display control unit 85 uses the layout diagram showing the arrangement positions of the respective injection molding devices 10 to display on the display unit 86 the injection molding device 10 in which an abnormality has occurred in a manner that enables identification. Further, the state display control unit 85 displays on the layout diagram the states of the respective injection molding devices 10 in a distinguishable manner. Further, the state display control unit 85 displays on the display unit 86 the cause of the abnormality of the injection molding device 10 in which an abnormality has occurred. Further, the state display control unit 85 displays on the display unit 86 the corresponding method for the displayed cause of the abnormality.

[0096] The display unit 86 is a display device such as a liquid crystal display or an organic EL (Electro-Luminescence) display.

[0097] (Data display screen) FIG. 11 is an image diagram showing an example of a data display screen displayed by the display device 80. On the data display screen 1100, determination result data corresponding to specified search conditions is displayed. The data display screen 1100 has a search condition specification area 1101 for specifying search conditions, a search result display area 1103 for displaying determination result data, and an event display area 1104 for displaying event data.

[0098] In the search condition specification area 1101, conditions for the determination result data to be displayed can be specified. For example, the search condition specification area 1101 accepts date / time specification or order number specification and specification of the target device as search conditions. As the target device, the model or name of the injection molding device 10 can be specified. In the illustrated example, the box numbers "80" and "81" of the order number "A1234D" are specified. When the search execution button 1102 arranged at the lower part of the search condition specification area 1101 accepts an input, the data acquisition unit 82 reads and acquires determination result data, event data, and abnormality occurrence data that match the search conditions specified in the search condition specification area 1101 from the storage device 70.

[0099] In the search result display area 1103, determination result data that matches the search conditions is displayed. The data display control unit 83 displays the acquired determination result data in the search result display area 1103. For example, the data display control unit 83 displays a list of the determination result data in chronological order (for example, in ascending order of date / time). Also, in the event display area 1104, event content / alert history that matches the search conditions is displayed. The data display control unit 83 displays a list of event registration contents associated with the date / time as the event content / alert history based on the event data and the abnormality occurrence data. The event registration content is the content of the event (for example, the response (treatment) etc. performed for the occurred abnormality) when it is event data, and is the content of the abnormality (for example, the state of the injection molding device 10 and the cause of the abnormality) when it is abnormality occurrence data. In the illustrated example, the event registration content "material patch change" is displayed in association with the date / time "2020 / 09 / 30 17:21:50".

[0100] The event data can be registered by pressing the event registration button 1105 arranged at the lower part of the event display area 1104. When the event registration button 1105 receives an input, the data display control unit 83 displays a registration screen for registering the event data and receives the input of the event data. On the registration screen, for example, the countermeasures taken against the injection molding apparatus 10 in which an abnormality has occurred can be registered. The data display control unit 83 transmits the registered event data to the storage device 70.

[0101] In this way, on the data display screen 1100, the date and time, order number, and target device can be specified as search conditions, and the determination result data and event content / alarm history that match the specified search conditions can be displayed. Thereby, the operator can refer to the abnormality details of the injection molding apparatus 10 that occurred in the past, the countermeasures taken at that time, and the determination result data. Further, the operator can predict equipment troubles of the injection molding apparatus 10 and quality defects of molded products based on the displayed determination result data (for example, based on the number of shots at which an abnormality occurred, etc.).

[0102] (Data display process) The data display process in which the display device 80 displays the data display screen 1100 will be described with reference to FIG. 12. FIG. 12 is a flowchart for explaining the flow of the data display process.

[0103] The input unit 81 receives the specification input of the search condition in the search condition specification area 1101 of the data display screen 1100 (step S300). When the search execution button 1102 receives an input, the data acquisition unit 82 reads and acquires the determination result data, event data, and abnormality occurrence data that match the search conditions specified in the search condition specification area 1101 from the storage device 70 (step S301). The data display control unit 83 displays the acquired determination result data in a list in the search result display area 1103, and displays the event details / alarm history in the event display area 1104 based on the acquired event data and abnormal occurrence data (step S302). Then, the data display process ends.

[0104] (Device status display screen) FIG. 13 is an image diagram showing an example of a device status display screen displayed by the display device 80. The device status display screen 1300 displays the status of each of the plurality of injection molding devices 10. The device status display screen 1300 includes a floor selection area 1301, a status display area 1302, and an abnormal history display area 1303.

[0105] In the floor selection area 1301, it is possible to select a floor for displaying the status of the injection molding device 10. The status acquisition unit 84 reads and acquires the status of each injection molding device 10 installed on the floor selected in the floor selection area 1301 and the abnormal occurrence data from the storage device 70. In the status display area 1302, the status of each injection molding device 10 on the floor selected in the floor selection area 1301 is displayed. For example, the status display control unit 85 displays a layout diagram indicating the arrangement positions of the injection molding devices 10 in the status display area 1302. At this time, the status display control unit 85 shows the actual arrangement including the block settings of each injection molding device 10 in the layout diagram. Then, the status display control unit 85 displays the model name and device name on each injection molding device 10 in the layout diagram. Thereby, the operator can easily identify each injection molding device 10 in the layout diagram. Also, the status display control unit 85 displays the status of each injection molding device 10 in color in the layout diagram. For example, the status display control unit 85 displays "operating" in green, "stopped" in gray, "fault" in "red", "MD warning" in yellow, and "MD stop" in orange. Note that at the bottom of the floor selection area 1301, a guide indicating which status each color represents is shown as a "legend". In this embodiment, the status display control unit 85 displays the status of each injection molding device 10 in color, but it is not limited to this, and other methods may be used for display as long as the status of each injection molding device 10 can be identified, such as by characters, marks, patterns, etc.

[0106] In this way, on the device status display screen 1300, by displaying the status of each injection molding device 10, the status of multiple injection molding devices 10 can be centrally managed by the display device 80. Also, by using the layout diagram to display the status of each injection molding device 10 in a color - distinguishable manner, the operator can easily grasp the status of each injection molding device 10 by referring to the layout diagram. Further, based on the relationship with the arrangement position in the layout diagram, the operator can intuitively grasp which injection molding device arranged where has an abnormality. Therefore, the operator can easily identify the injection molding device 10 with an abnormality and quickly go to the injection molding device 10 to take corresponding measures, etc.

[0107] In the abnormal history display area 1303, the history of abnormalities that occurred on the selected floor is displayed. Based on the acquired abnormality occurrence data, the state display control unit 85 associates the abnormalities (alarm contents) that occurred on the selected floor with the date and time of occurrence, the model, and the name of the device, and displays them in a list in the abnormal history display area 1303 in descending order (descending order of the date and time of occurrence) starting from the latest one. At this time, the state display control unit 85 may display only the unresolved abnormalities in the abnormal history display area 1303. Alternatively, the state display control unit 85 may display only the abnormalities that occurred most recently (for example, within 24 hours) in the abnormal history display area 1303.

[0108] When the injection molding device 10 whose state is "MD warning" or "MD stop" is selected in the state display area 1302, or when the alarm content is selected in the abnormal history display area 1303, the state display control unit 85 determines that it has received an instruction to display the alarm content, and pops up an alarm content display screen that displays the corresponding alarm content.

[0109] FIG. 14 is an image diagram showing an example of an alarm content display screen and a detailed display screen displayed by the display device 80. On the alarm content display screen 1400, "Abnormality occurred in SE〇〇", the cause of the abnormality "Error content: MT6 abnormality", a detailed button for displaying details, and a close button for closing the alarm content display screen 1400 are displayed. The cause of the abnormality displayed here is the abnormality item with the highest contribution degree. Note that when there are a plurality of abnormality items, the state display control unit 85 may display all the abnormality items as the cause of the abnormality on the alarm content display screen 1400. In this way, by displaying the cause of the abnormality of the injection molding device 10 in which the abnormality occurred, the operator can easily identify the cause of the abnormality of the injection molding device 10 in which the abnormality occurred regardless of their proficiency level. When the detailed button is input on the alarm content display screen 1400, the state display control unit 85 pops up the detailed display screen 1410.

[0110] On the detailed display screen 1410, the model "SE〇〇" of the injection molding apparatus 10 in which an abnormality has occurred, the cause of the abnormality "MT6", its value "20000035", its contribution degree "147.3", a list 1411 of response methods for the cause of the abnormality, and a close button for closing the detailed display screen 1410 are displayed. The state acquisition unit 84 reads and acquires from the storage device 70 the response method for the displayed cause of the abnormality. The state display control unit 85 displays the response methods for the cause of the abnormality in a list in descending order of priority. In the illustrated example, for the highest-priority response 1, "Check whether the suction valve is defective", for the next highest-priority response 2, "Check whether the surface of the suction valve is dirty", and for the next highest-priority response 3, "Check whether the original pressure has not decreased" are displayed. In this way, by displaying the response methods for the cause of the abnormality, the operator can easily know the response methods by referring to the display regardless of their proficiency level, and can quickly respond to the occurred abnormality. Also, by displaying the response methods based on the priority order, the operator can grasp which response method should be preferentially implemented.

[0111] Also, on the detailed display screen 1410, event data can be registered by pressing each displayed response. For example, when the operator implements method 1 among the displayed response methods and the abnormality is resolved, the operator presses method 1 displayed on the detailed display screen 1410. When the state display control unit 85 receives an input for method 1 on the detailed display screen 1410, it transmits the event data to the storage device 70 with method 1 "Check whether the suction valve is defective" as the response implemented to resolve the displayed abnormality.

[0112] (State display process) The state display process in which the display device 80 displays the device state display screen 1300 will be described with reference to FIG. 15. FIG. 15 is a flowchart explaining the flow of the state display process.

[0113] The status acquisition unit 84 reads and acquires from the storage device 70 the status and abnormality occurrence data of all the injection molding devices 10 arranged on the floor selected in the floor selection area 1301 of the device status display screen 1300 (step S400). The status display control unit 85 displays, in color, the status of each acquired injection molding device 10 on the layout diagram of the selected floor in the status display area 1302 (step S401). Based on the abnormality occurrence data, the status display control unit 85 displays the history of abnormalities that occurred on the selected floor in the abnormality history display area 1303 (step S402).

[0114] The status display control unit 85 determines whether an instruction to display alarm contents has been received on the device status display screen 1300 (step S403). If it is determined that an instruction to display alarm contents has not been received (step S403 - No), the status display control unit 85 ends the status display process. On the other hand, if it is determined that an instruction to display alarm contents has been received (step S403 - Yes), the status display control unit 85 pops up and displays the alarm content display screen 1400 and displays the cause of the abnormality (step S404).

[0115] Subsequently, the status display control unit 85 determines whether a detail button has received an input on the alarm content display screen 1400 (step S405). If it is determined that the detail button has not received an input (step S405 - No), the status display control unit 85 ends the status display process.

[0116] If it is determined that the detail button has received an input (step S405 - Yes), the status display control unit 85 pops up and displays the detailed display screen 1410 and displays the countermeasure method for the cause of the abnormality (step S406). Then, the status display process ends.

[0117] Note that the data display screen 1100 and the device status display screen 1300 may be displayed by different software. In this case, for example, by switching between the data display screen 1100 and the device status display screen 1300, the operator can consider the cause of the abnormality, the response to the abnormality, etc.

[0118] Next, the relationship between the measurement items at the time of defective product occurrence and the calculated MD value will be described with reference to FIGS. 16 to 19. FIGS. 16 to 19 are diagrams showing the temporal changes of the values of 12 molding process items and the calculated MD value at the time of actual defective product occurrence, and are diagrams showing example screens displayed on the display screen of the output device 60 or the display device 80. The output device 60 can display such a screen based on the data obtained from the output unit 56. Further, the display device 80 can display such a screen based on the determination result data acquired from the storage device 70. Here, MD calculation was performed using all 12 molding process items. In this figure, in the vertical axis direction, each of the molding process items is arranged side by side, and in the horizontal axis direction, time is represented. As shown in the figure, every time a shot is performed, the calculated MD value and each value in the molding process item are displayed in time series order.

[0119] Also, on the display screen, the threshold display line 830 is also displayed so as to overlap the display area of the MD value. The threshold display line 830 is displayed along the time series direction at a position corresponding to the MD value abnormality determination threshold (reference value) used in the determination by the determination unit 554. The operator can also easily grasp whether an abnormality has occurred by visually checking whether the MD value exceeds this threshold display line 830. Also, the operator can also grasp in advance the sign of defective product occurrence by referring to the transition of each value of the molding process item.

[0120] FIG. 16 is a diagram showing the temporal changes of the values of 12 molding process items and the calculated MD value at the time of gate convexity defect occurrence. The gate convexity defect is a phenomenon in which a gate land portion remains on the molded product or a thread is drawn and remains on the molded product. During the period when gate convexity defects occur (reference numeral 800), the calculated MD value is approximately 10 to 20, which is greater than the threshold value (here it is 4) (abnormality determination). At this time, among the 12 molding process items, three items, namely the metering time, the overall peak pressure, and the clamping force at the end of the holding pressure, increase compared to normal, and one item, the minimum cushion position, decreases compared to normal. Therefore, it is presumed that the degree of relationship (contribution degree) of these four items with the occurrence of defects is high. In response to the output from the alarm unit 57 accompanying the occurrence of this defect, an alarm sound is output. Accordingly, various adjustments in the injection molding apparatus 10 and the like are appropriately made by the operator at the time indicated by reference numeral 810. When the defect is eliminated, it is shown that in the subsequent period (reference numeral 820), the calculated MD value and the molding process items each return to normal.

[0121] Therefore, when the molded product determination device 50 detects gate convexity defects, it outputs four items, namely the metering time, the overall peak pressure, the clamping force at the end of the holding pressure, and the minimum cushion position, as abnormal items (abnormal causes). The operator can predict that gate convexity defects are occurring because three items, namely the metering time, the overall peak pressure, and the clamping force at the end of the holding pressure, increase compared to normal, and one item, the minimum cushion position, decreases compared to normal. Alternatively, the molded product determination device 50 may determine that gate convexity defects are occurring based on the fact that three items, namely the metering time, the overall peak pressure, and the clamping force at the end of the holding pressure, increase compared to normal, and one item, the minimum cushion position, decreases compared to normal, and output it as the abnormal content. Thus, in this molded product determination system 1, gate convexity defects can be detected.

[0122] Figure 17 is a diagram showing the change over time of the values of 12 molding process items and the calculated MD value when short shots and sink marks occur. A short shot is a phenomenon in which a part of the molded product is missing, resulting in a molded product with an incomplete shape. A sink mark is an appearance defect phenomenon in which a dimple (depression) appears on the surface of the wall thickness of the molded product. Both are phenomena caused by insufficient injection volume of the resin. This figure shows an example of data when, at the normal state 1700, the holding pressure (the pressure applied to the resin to compensate for the shrinkage during cooling after resin filling into the cavity), which is one of the parameters affecting the resin injection volume, is varied to cause a short circuit defect at the time indicated by reference numeral 1710 and a sink mark defect at the time indicated by reference numeral 1730.

[0123] As shown in the figure, during the period when the short circuit defect occurs (reference numeral 1720) and the period when the sink mark defect occurs (reference numeral 1740), the pre-metering position and the minimum cushion position increase more than normal, and the calculated MD value shows an abnormality by greatly exceeding the threshold value (reference value). That is, the calculated MD value becomes high particularly due to the contribution of these two items, namely, the pre-metering position and the minimum cushion position. Therefore, it is presumed that the degree of relationship (contribution degree) between these two items and the occurrence of defects is high. After that, when the holding pressure is restored to its original value at the time indicated by reference numeral 1750 and the defect is eliminated, it is shown that in the subsequent period (reference numeral 1760), the calculated MD value and the molding process items return to normal respectively.

[0124] Therefore, when a short circuit or sink mark defect occurs, the molded product determination device 50 outputs these two items, namely, the pre-metering position and the minimum cushion position, as abnormal items (abnormal causes). Since the pre-metering position and the minimum cushion position increase more than normal, the operator can predict that a short circuit or sink mark defect has occurred. Alternatively, the molded product determination device 50 may determine that a short circuit or sink mark defect has occurred based on the fact that the pre-metering position and the minimum cushion position increase more than normal and output it as the abnormal content. In this way, in this molded product determination system 1, short circuit and sink mark defects can be detected.

[0125] Figure 18 is a diagram showing the change over time of the values of 12 molding process items and the calculated MD value when a deformation abnormality defect occurs due to the stop of the cooling water. This figure shows an example of data when one of the plurality of flow paths to the mold cooling water is stopped. As shown in the figure, during the period when the cooling water is stopped (reference numeral 1800), the pre-metering position and the minimum cushion position increase each time a shot is stacked, and the calculated MD value also increases accordingly, exceeding the threshold value (reference value) and indicating an abnormality. That is, the calculated MD value is increased by the contribution of the two items of the pre-metering position and the minimum cushion position. Therefore, it is presumed that the degree of relationship (contribution degree) between these two items and the occurrence of defects is high. After that, when the cooling water is restored at the time indicated by reference numeral 1810 and the defect is eliminated, it is shown that in the subsequent period (reference numeral 1820), the calculated MD value and the molding process items have returned to normal respectively.

[0126] Therefore, when a deformation defect occurs due to the stop of the cooling water, the molded product determination device 50 outputs the two items of the pre-metering position and the minimum cushion position as abnormal items (abnormal causes). Since the operator can see that the pre-metering position and the minimum cushion position are gradually increasing, the operator can predict that a deformation defect has occurred due to the stop of the cooling water. Alternatively, the molded product determination device 50 may determine that a deformation defect has occurred due to the stop of the cooling water based on the fact that the pre-metering position and the minimum cushion position are gradually increasing, and output it as the content of the abnormality. In this way, in the present molded product determination system 1, it is possible to detect a defect caused by a blockage (clogging of the cooling water) in the flow path.

[0127] Figure 19 is a diagram showing the change over time of the values of 12 molding process items and the calculated MD value when a defect of resin leakage occurs from the tip of the nozzle. This figure shows an example of data when resin leakage occurs from the tip of the nozzle due to a trouble in the injection molding apparatus 10. As shown in the figure, when resin leakage occurs from the tip of the nozzle, the pre-metering position and the minimum cushion position gradually decrease, and the calculated MD value exceeds the threshold value (reference value) significantly, indicating an abnormality. That is, the calculated MD value is increased by the contribution of the two items of the pre-metering position and the minimum cushion position. Therefore, it is presumed that the degree of relationship (contribution degree) between these two items and the occurrence of defects is high.

[0128] Therefore, when a defect of resin leakage occurs from the nozzle tip, the molded product determination device 50 outputs two items, the pre-metering position and the minimum cushion position, as abnormal items (abnormal causes). From the fact that the pre-metering position and the minimum cushion position are gradually decreasing, the operator can predict that a defect of resin leakage has occurred from the nozzle tip. Alternatively, the molded product determination device 50 may determine that a defect of resin leakage has occurred from the nozzle tip based on the fact that the pre-metering position and the minimum cushion position are gradually decreasing, and output it as the abnormal content. Thus, in this molded product determination system 1, it is possible to detect a defect due to resin leakage from the nozzle tip.

[0129] According to the above-described embodiment, the unit space data is calculated in advance and stored in the storage unit 53. At the timing when the shot is performed, the molding process item data is acquired, the MD value is obtained using this data, compared with the reference value, and the pass / fail determination is performed. Therefore, the calculation process is simplified, and the time required for the calculation process can be shortened. Thus, it is possible to perform the pass / fail determination of the molded product in real time even during the operation of the injection molding device 10. Therefore, in the molded product determination system of this embodiment, it is possible to detect the occurrence of defective products in real time.

[0130] Also, according to the above-described embodiment, when the frequency at which the MD value exceeds the reference value exceeds the stop signal reporting threshold, the molded product determination device 50 determines that an abnormality has occurred in the injection molding device 10, stops the injection molding device 10, and when the frequency at which the MD value exceeds the reference value exceeds the warning signal reporting threshold which is smaller than the stop signal reporting threshold, the molded product determination device 50 determines that an abnormality has occurred in the injection molding device 10, outputs a warning, analyzes and outputs the cause of the abnormality. The display device 80 acquires the cause of the abnormality of the injection molding device 10 in which the abnormality has occurred, and displays the cause of the abnormality of the injection molding device 10 in which the abnormality has occurred. Thereby, regardless of the proficiency level, the operator can easily identify the cause of the abnormality of the injection molding device 10 in which the abnormality has occurred by referring to the display of the display device 80.

[0131] In addition, the display device 80 displays a countermeasure method for the indicated cause of the abnormality. As a result, regardless of the level of skill, an operator can easily know the countermeasure method by referring to the display on the display device 80 and can quickly take measures against the occurred abnormality.

[0132] There are also a plurality of injection molding devices 10, and the display device 80 displays in a manner that enables identification of the injection molding device 10 in which an abnormality has occurred, using a layout diagram showing the arrangement positions of the respective injection molding devices 10. As a result, an operator can intuitively grasp which of the plurality of injection molding devices 10 an abnormality has occurred in by referring to the layout diagram.

[0133] Also, the display device 80 displays in a manner that enables identification of the state of each injection molding device 10 in the layout diagram. As a result, an operator can easily grasp the state of each injection molding device 10 by referring to the layout diagram.

[0134] In addition, the molded product determination device 50 outputs the determination result to the storage device 70 together with the measurement data used for the determination, and the display device 80 receives a designation input of the conditions of the determination result to be displayed, acquires the determination result and the measurement data that match the designated conditions from the storage device 70, and displays the acquired determination result and measurement data. As a result, an operator can refer to the determination result and the measurement data for an arbitrary period by designating the conditions. Therefore, an operator can analyze the cause of the abnormality based on the displayed content and can review the unit space when an alarm is output even in a normal state.

[0135] In addition, the molded product determination device 50 receives a setting input of a reference value (MD value abnormality determination threshold), a stop signal reporting threshold, or an alarm signal reporting threshold. As a result, the criteria for determining a molded product as abnormal and the criteria for stopping or outputting an alarm for the injection molding device 10 can be arbitrarily set and changed according to the molded product.

[0136] In the above-described embodiments, the MT method is used. However, the present invention is not limited to the MT method, and can be applied to methods belonging to the Mahalanobis-Taguchi system, such as the MTA method, the MTS method, the TS method, and the T method.

[0137] The molded product determination device 50, the output device 60, the storage device 70, or the display device 80 in the above-described embodiments may be realized by a computer. In that case, a program for realizing this function may be recorded on a computer-readable recording medium, and the program recorded on this recording medium may be read into a computer system and executed to realize it. Here, the "computer system" is assumed to include hardware such as an OS and peripheral devices. Further, the "computer-readable recording medium" refers to a portable medium such as a flexible disk, a magneto-optical disk, a ROM, a CD-ROM, or the like, or a storage device such as a hard disk built into a computer system. Furthermore, the "computer-readable recording medium" also includes a medium that dynamically holds a program for a short time, such as a communication line when transmitting a program via a network such as the Internet or a communication line such as a telephone line, and a volatile memory inside a computer system that becomes a server or a client in that case, which holds a program for a certain period of time. Also, the above program may be for realizing a part of the above-described functions, and may further be realized in combination with a program already recorded in a computer system for realizing the above-described functions, or may be realized using a programmable logic device such as an FPGA (Field Programmable Gate Array).

[0138] As described above, the embodiments of the present invention have been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and designs and the like within the scope not departing from the gist of the present invention are also included.

[0139] According to the present embodiment described above, instead of performing appearance evaluation after a defect occurs due to a conventional inspection, a quality assurance system from the upstream process can be realized by capturing a sign (abnormality) of a defect occurring by utilizing the process data log during manufacturing. Further, since the relationship between the molding process items and the change over time of the calculated MD value is output, even an operator with low proficiency can refer to this output and grasp the relationship and change status between the defect occurrence period and the data (e.g., waveform) of the molding process items during that period. Furthermore, by using these output contents as clues, it becomes easier to consider countermeasures when a quality abnormality occurs.

Explanation of Signs

[0140] 1…Molded product determination system, 10…Injection molding apparatus, 11…Detection unit, 20…Injection molded product inspection apparatus, 30…Additional sensor, 40…Input device, 50…Molded product determination device, 51…Data acquisition unit, 52…Input unit, 53…Storage unit, 54…Data selection unit, 55…Data analysis unit, 56…Output unit, 57…Alarm unit, 58…Stop unit, 60…Output device, 70…Storage device, 71…Determination result data storage unit, 72…Abnormality history storage unit, 73…Event data storage unit, 74…Device state storage unit, 75…Corresponding method storage unit, 76…Device information storage unit, 80…Display device, 81…Input unit, 82…Data acquisition unit, 83…Data display control unit, 84…State acquisition unit, 85…State display control unit, 86…Display unit, 551…Analysis mode setting unit, 552…Unit space calculation unit, 553…MD calculation unit, 554…Determination unit, 555…Abnormality cause analysis unit

Claims

1. An acquisition unit that acquires measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring a plurality of measurement items indicating the operating status of the injection molding machine; A determination unit that determines whether or not a molded product molded in the operating status detected by the detection unit is a good product based on the relationship between at least two of the acquired two or more measurement items, and determines whether or not an abnormality has occurred in the injection molding machine; An abnormality cause analysis unit that analyzes the cause of the abnormality; An output unit that outputs the analyzed cause of the abnormality; A state acquisition unit that acquires the cause of the abnormality of the injection molding machine in which the abnormality has occurred; A state display control unit that displays the cause of the abnormality of the injection molding machine in which the abnormality has occurred; and the determination unit makes a determination using the measurement data detected by the detection unit obtained when each shot of the molded product is performed, every time the shot of the molded product is performed Molded product determination system.

2. The state display control unit displays a countermeasure method for the displayed cause of the abnormality The molded product determination system according to claim 1.

3. There are a plurality of the injection molding machines, The state display control unit uses a layout diagram showing the arrangement positions of the respective injection molding machines to display the injection molding machine in which the abnormality has occurred in an identifiable manner, and to display the states of the respective injection molding machines in the layout diagram in an identifiable manner The molded product determination system according to claim 1 or claim 2.

4. An acquisition unit that acquires measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring a plurality of measurement items indicating the operating status of the injection molding machine; A determination unit that determines whether or not a molded product molded in the operating status detected by the detection unit is a good product based on the relationship between at least two of the acquired two or more measurement items, and determines whether or not an abnormality has occurred in the injection molding machine; An abnormality cause analysis unit that analyzes the cause of the abnormality; An output unit that outputs the analyzed cause of the abnormality; A state acquisition unit that acquires the cause of the abnormality of the injection molding machine in which the abnormality has occurred; A state display control unit that displays the cause of the abnormality of the injection molding machine in which the abnormality has occurred; and There are a plurality of the injection molding machines, The state display control unit uses a layout diagram showing the arrangement positions of the respective injection molding machines to display the injection molding machine in which the abnormality has occurred in an identifiable manner Molded product determination system.

5. The state display control unit displays the states of the respective injection molding machines in the layout diagram in a distinguishable manner. The molded product determination system according to claim 4.

6. An acquisition unit that acquires measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating status of an injection molding machine by measuring a plurality of measurement items indicating the operating status of the injection molding machine; A determination unit that determines whether or not a molded product molded in the operating status detected by the detection unit is a non-defective product based on the relationship between at least two of the acquired two or more measurement items, and determines whether or not an abnormality has occurred in the injection molding machine; An abnormality cause analysis unit that analyzes the cause of the abnormality; An output unit that outputs the analyzed cause of the abnormality; A state acquisition unit that acquires the cause of the abnormality of the injection molding machine in which the abnormality has occurred; A state display control unit that displays the cause of the abnormality of the injection molding machine in which the abnormality has occurred; A storage unit that stores unit space data generated based on the Mahalanobis-Taguchi method (hereinafter referred to as the MT method) for measurement data obtained when non-defective products are molded by the injection molding machine in a plurality of measurement items indicating the operating status of the injection molding machine; An MD calculation unit that calculates a Mahalanobis distance (hereinafter referred to as an MD value) based on the MT method using measurement data of at least two of the acquired two or more measurement items; having The determination unit determines whether or not a molded product molded in the operating status detected by the detection unit is a non-defective product based on whether or not the calculated MD value exceeds a reference value, and when the frequency at which the MD value exceeds the reference value exceeds a predetermined threshold, it is determined that an abnormality has occurred in the injection molding machine Molded product determination system.

7. The output unit outputs the determination result of the determination unit to a storage device together with the measurement data used for the determination, The molded product determination system is An input unit that specifies the conditions for the determination result to be displayed; A data acquisition unit that acquires the determination result and the measurement data that match the specified conditions from the storage device; A data display control unit that displays the acquired determination result and the measurement data; The molded product determination system according to claim 6, having

8. The molded product determination system is When the frequency at which the MD value exceeds the reference value in the determination result of the determination unit exceeds a first threshold, the injection molding machine is stopped, or When the frequency at which the MD value exceeds the reference value exceeds the second threshold value in the determination result of the determination unit, an alarm is output. The molded product determination system according to any one of claims 6 or 7.

9. The determination unit Among the plurality of measurement items, using a plurality of unit space data based on measurement items with different combinations, and based on the plurality of unit space data and the measurement data based on the measurement items detected by the detection unit, determination is performed for each combination of the measurement items of the unit space data. The molded product determination system according to any one of claims 6 to 8.

10. An acquisition unit that acquires measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating state of an injection molding machine by measuring a plurality of measurement items indicating the operating state of the injection molding machine; A determination unit that determines whether or not a molded product molded in the operating state detected by the detection unit is a non-defective product based on the relationship between at least two of the acquired two or more measurement items, and determines whether or not an abnormality has occurred in the injection molding machine; An abnormal cause analysis unit that analyzes the cause of the abnormality; An output unit that outputs the analyzed cause of the abnormality; A state acquisition unit that acquires the cause of the abnormality of the injection molding machine in which the abnormality has occurred; A state display control unit that displays the cause of the abnormality of the injection molding machine in which the abnormality has occurred; The measurement items include at least any one of the in-mold pressure, product surface temperature, mold opening / closing displacement amount, and cooling water flow rate measured by an additional sensor provided in the injection molding machine. Molded product determination system.

11. A computer that stores unit space data generated based on the Mahalanobis-Taguchi method (hereinafter referred to as the MT method) for measurement data when a non-defective product is molded by the injection molding machine in a plurality of measurement items indicating the operating state of the injection molding machine. Acquire measurement data of at least two or more of the plurality of measurement items from a detection unit that detects the operating state of the injection molding machine by measuring a plurality of measurement items indicating the operating state of the injection molding machine. Among the acquired two or more measurement items, based on the relationship between at least two items, determine whether or not the molded product molded in the operating state detected by the detection unit is a non-defective product, and determine whether or not an abnormality has occurred in the injection molding machine. Analyze the cause of the abnormality. Output the analyzed cause of the abnormality. This is a molded product determination program that causes the above to be executed. The molded product determination program is as follows: Among the two or more measurement items obtained, it includes calculating the Mahalanobis distance (hereinafter referred to as MD value) based on the MT method using the measurement data of at least two items. Determining whether or not the abnormality has occurred is as follows: Based on whether or not the calculated MD value exceeds a reference value, it is determined whether or not the molded product molded in the operating state detected by the detection unit is a non-defective product. When the frequency at which the MD value exceeds the reference value exceeds a predetermined threshold, it is determined that an abnormality has occurred in the injection molding machine. A molded product determination program including the above.

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