Molded Product Manufacturing System

Abstract

A molded article production system according to the present invention comprises: a first writing unit which writes, to a readable and writable storage medium, first information pertaining to a molded article that has been molded by an injection molding machine; and a conveyance unit which associates and conveys the molded article and the storage medium in which the first information pertaining to the molded article is written.

Description

[Technical Field]

[0001] The present invention relates to a molded product manufacturing system. [Background technology]

[0002] In injection molding machines, manufacturing is not complete once a molded product is formed, but rather the product is shipped after undergoing various post-processing steps. In recent years, various proposals have been made to manage molded products produced by injection molding machines in post-processing steps. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-135986 Summary of the Invention [Problem to be solved by the invention]

[0004] Patent Document 1 describes a technology for attaching a two-dimensional code to a container when multiple molded resin bottles are placed in the container. Information about the lot is stored in the two-dimensional code. The problem with such two-dimensional codes is that it is difficult to write new information. Since various processes are performed on molded products in post-molding processes, it is preferable to be able to write the results of these processes.

[0005] One aspect of the present invention provides a technology for appropriately managing each molded product by associating the molded product with a readable / writable storage medium, thereby improving the accuracy of quality control of the molded products. [Means for solving the problem]

[0006] A molded product manufacturing system according to one aspect of the present invention includes a first writing unit that writes first information about a molded product molded by an injection molding machine to a readable and writable storage medium, and a transport unit that transports the molded product and the storage medium in which the first information about the molded product is written, in association with each other; and an arrangement unit that arranges each of the molded products molded for each cavity in each of the divided areas of a storage container having divisions corresponding to the number of cavities of the injection molding machine, wherein the first writing unit writes the first information to each of the storage media provided for each of the divided areas of the storage container, and the transport unit transports the storage container. . A molded product manufacturing system according to one embodiment of the present invention includes a first writing unit that writes first information about a molded product molded by an injection molding machine to a readable and writable storage medium, a transporting unit that transports the molded product in association with the storage medium on which the first information about the molded product is written, a first reading unit that reads the first information from the storage medium transported together with the molded product by the transporting unit, and a processing unit that performs predetermined processing on the molded product using the first information read by the first reading unit. [Effects of the Invention]

[0007] According to one aspect of the present invention, proper management is performed for each molded product, improving the accuracy of quality management of molded products. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram illustrating the configuration of a molded product manufacturing system according to an embodiment. [Figure 2] FIG. 2 is a diagram showing an example of a storage container according to the embodiment. [Figure 3] FIG. 3 is a diagram illustrating an example of an injection molding machine according to an embodiment and a peripheral configuration of the injection molding machine. [Figure 4] FIG. 4 is a diagram illustrating information read from and written to an RFID tag by an RFID reader / writer in a molding process according to the embodiment. [Figure 5] FIG. 5 is a diagram illustrating information read from and written into an RFID tag by an RFID reader / writer in the take-out / carry-out step according to the embodiment. [Figure 6] FIG. 6 is a diagram illustrating information read from and written to an RFID tag by an RFID reader / writer in an inspection step according to the embodiment. [Figure 7] FIG. 7 is a diagram illustrating information read from and written to an RFID tag by an RFID reader / writer in a packing step according to the embodiment. [Figure 8] FIG. 8 is a flowchart showing a processing procedure performed in a molding process in the manufacturing system according to the embodiment. [Figure 9] FIG. 9 is a flowchart showing the processing procedure performed in the take-out / carry-out process in the manufacturing system according to the embodiment. [Figure 10] FIG. 10 is a flowchart showing a processing procedure performed in an inspection process in the manufacturing system according to the embodiment. [Figure 11] FIG. 11 is a flowchart showing a processing procedure performed in the transfer process in the manufacturing system according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same or corresponding components are denoted by the same or corresponding reference numerals, and the description thereof may be omitted.

[0010] Fig. 1 is a diagram illustrating the configuration of a manufacturing system 1 (an example of a molded product manufacturing system) according to an embodiment. The manufacturing system 1 shown in Fig. 1 includes a management system server 2, an injection molding machine 3, a take-out robot 4, a material dryer 5, a mold temperature regulator 6, and an image inspection device 9. Furthermore, the manufacturing system 1 according to this embodiment includes a plurality of RFID readers / writers 31 to 34.

[0011] The management system server 2 is a server that manages information about each device in the manufacturing system 1. The management system server 2 is equipped with a storage device 15. The management system server 2 manages information received from each device (e.g., RFID reader / writer 34) in the storage device 15. However, some devices included in the manufacturing system 1 may not be able to connect to the network and may not be able to transmit information to the management system server 2. In contrast, the manufacturing system 1 according to this embodiment can collect information from devices that are not connected to a network by using RFID tags 55. The manufacturing system 1 according to this embodiment can collect information required for a process even from devices that are not connected to a network, and can store the information obtained in that process.

[0012] In the manufacturing system 1 according to this embodiment, various processes are performed after a molded product 10 is molded by an injection molding machine 3. The manufacturing system 1 according to this embodiment includes, as processing steps, a molding process, a removal / carry-out process, an inspection process, and a packaging process. Note that this embodiment shows only one example of processing steps, and other processes may also be included.

[0013] The manufacturing system 1 according to this embodiment writes, for each processing step, information about the processing performed in that processing step to a storage medium associated with the processed molded article 10. In this embodiment, an RFID tag 55 is used as the storage medium, but any readable and writable storage medium will do.

[0014] The RFID (Radio Frequency Identifier) ​​tag 55 is a storage medium that can read and write information by short-range (several centimeters to several meters depending on the frequency band) wireless communication using the RFID reader / writers 31 to 34 .

[0015] The RFID tag 55 of this embodiment is provided in association with the molded product 10. In this embodiment, a storage container 50 is used to associate the RFID tag 55 with the molded product 10.

[0016] Between each processing step, a belt conveyor 7 (an example of a transport unit) transports the storage container 50 storing the molded article 10. Although not shown in FIG. 1, each processing step is connected by the belt conveyor 7. Note that in this embodiment, an example using the belt conveyor 7 as an example of a transport unit will be described, but the transport unit is not limited to the belt conveyor 7, and any means can be used as long as it can transport the molded article 10 while associating the RFID tag with it between processing steps.

[0017] Fig. 2 is a diagram showing an example of a storage container 50 according to this embodiment. The storage container 50 shown in Fig. 2 has four storage areas 51A to 51D separated by partitions 52 and 53. The number of storage areas 51A to 51D in this embodiment corresponds to the number of cavities in the mold device of the injection molding machine 3. In other words, the manufacturing system 1 according to this embodiment stores all of the molded articles 10 removed from the cavities in the storage areas and transports them every time the injection molding machine 3 performs molding.

[0018] As shown in FIG. 2, the storage container 50 is provided with RFID tags 55A-55D (also referred to as RFID tag 55 if any RFID tag is used) associated with each of the storage areas 51A-51D. In this embodiment, one molded product 10 is stored in each of the storage areas 51A-51D. This allows each of the RFID tags 55A-55D to be associated with a molded product 10. Although the storage container 50 of this embodiment has been described as storing four molded products 10, the number that can be stored is not limited to four. The storage container 50 is provided with partitions or the like so that it can store the number of molded products 10 (the number of cavities) that the injection molding machine 3 will mold at one time.

[0019] 1, RFID reader / writers 31 to 34 are provided for each process step performed by manufacturing system 1. RFID reader / writers 31 to 34 read and write information from / to RFID tags 55A to 55D for each process step.

[0020] Next, the processing step will be described. The molding step is a step in which an injection molding machine 3 molds a molded product 10. The manufacturing system 1 according to this embodiment includes the injection molding machine 3, a material dryer 5, and a mold temperature regulator 6 as devices used in the molding step.

[0021] Fig. 3 is a diagram illustrating an injection molding machine 3 according to this embodiment and the peripheral configuration of the injection molding machine 3. In the example shown in Fig. 3, the peripheral configuration of the injection molding machine 3 includes a material dryer 5 and a mold temperature regulator 6. Furthermore, in the manufacturing system 1, the injection molding machine 3 and the management system server 2 are connected via a public network 8.

[0022] The material dryer 5 is a device for drying the molding material (for example, resin) that is fed into the supply port of the injection molding machine 3, and includes a communication I / F 501 and a control circuit 502.

[0023] The control circuit 502 is a device that controls the entire material dryer 5. The communication I / F 501 is an interface for communicating with the control device 700 of the injection molding machine 3. The control circuit 502 of this embodiment transmits data related to the material dryer 5 to the control device 700 via the communication I / F 501. The data related to the material dryer 5 (hereinafter also referred to as dryer data) includes the temperature set for drying and actual data on the drying temperature of the molding material.

[0024] The mold temperature regulator 6 is a device for adjusting the temperature of the mold device 800 of the injection molding machine 3, and includes a communication I / F 601, a sensor 602, and a control circuit 603. In this embodiment, an example in which the mold temperature regulator 6 includes the sensor 602 will be described, but this embodiment is not limited to an example in which the sensor 602 is provided in the mold temperature regulator 6. For example, the sensor 602 may be provided in the mold device 800.

[0025] The sensor 602 acquires the temperature of the mold device 800 of the injection molding machine 3. The control circuit 603 is a device that controls the entire mold temperature regulator 6. The communication I / F 601 is an interface for communicating with the control device 700 of the injection molding machine 3. The control circuit 603 of this embodiment adjusts the temperature of the mold device 800 based on the temperature acquired from the sensor 602. Furthermore, the control circuit 603 transmits data related to the mold temperature regulator 6 (hereinafter also referred to as temperature regulator data) to the control device 700 via the communication I / F 601. The data related to the mold temperature regulator 6 includes the temperature set for the mold device 800, actual temperature data of the mold device 800, and flow rate data of the liquid used for temperature regulation.

[0026] (injection molding machine) A description will now be given of the injection molding machine 3. Note that the manufacturing system 1 according to this embodiment is not limited to installing one injection molding machine 3, and a plurality of injection molding machines may be installed.

[0027] The injection molding machine 3 has a mold clamping unit 100, an ejector unit 200, an injection unit 300, a moving unit 400, a control unit 700, and a frame 900. The control unit 700 is disposed in the internal space of the frame 900. Each component of the injection molding machine 3 will be described below.

[0028] (mold clamping device) The mold clamping unit 100 performs mold closing, pressurization, mold clamping, depressurization, and mold opening of the mold apparatus 800. The mold apparatus 800 includes a fixed mold 810 and a movable mold 820. The mold clamping unit 100 is, for example, a horizontal type, and the mold opening and closing direction is horizontal. The mold clamping unit 100 has a fixed platen 110, a movable platen 120, toggle supports 130, tie bars 140, a toggle mechanism 150, a mold clamping motor 160, a motion conversion mechanism 170, and a mold thickness adjustment mechanism 180.

[0029] The stationary platen 110 is fixed to the frame 900. A stationary mold 810 is attached to the surface of the stationary platen 110 facing the movable platen 120. The movable platen 120 is disposed so as to be movable in the mold opening / closing direction relative to the frame 900. A movable mold 820 is attached to the surface of the movable platen 120 facing the stationary platen 110. Mold closing, pressurization, mold clamping, depressurization, and mold opening of the mold device 800 are performed by moving the movable platen 120 back and forth relative to the stationary platen 110. The toggle support 130 is disposed at a distance from the stationary platen 110 and is placed on the frame 900 so as to be movable in the mold opening / closing direction. Tie bars 140 connect the stationary platen 110 and toggle support 130 at a distance in the mold opening / closing direction.

[0030] The toggle mechanism 150 is disposed between the movable platen 120 and the toggle support 130, and moves the movable platen 120 in the mold opening / closing direction relative to the toggle support 130. The toggle mechanism 150 is composed of a crosshead 151, a pair of link groups, etc. When the crosshead 151 moves back and forth relative to the toggle support 130, the link group bends and stretches, and the movable platen 120 moves back and forth relative to the toggle support 130. The mold clamping motor 160 is attached to the toggle support 130, and operates the toggle mechanism 150. The motion conversion mechanism 170 converts the rotational motion of the mold clamping motor 160 into linear motion of the crosshead 151, and operates the toggle mechanism 150.

[0031] The mold clamping unit 100 performs a mold closing process, a pressure increasing process, a mold clamping process, a pressure reducing process, a mold opening process, and the like under the control of the control device 700.

[0032] In the mold closing process, the mold clamping motor 160 is driven to move the crosshead 151 forward at a set moving speed to the mold closing completion position, thereby moving the movable platen 120 forward and bringing the movable mold 820 into contact with the fixed mold 810.

[0033] In the pressure increasing step, the mold clamping motor 160 is further driven to move the crosshead 151 further forward from the mold closing completion position to the mold clamping position, thereby generating a mold clamping force.

[0034] In the mold clamping process, the mold clamping motor 160 is driven to maintain the position of the crosshead 151 at the mold clamping position. In the mold clamping process, the mold clamping force generated in the pressure increase process is maintained. In the mold clamping process, a cavity space 801 is formed between the movable mold 820 and the fixed mold 810, and the injection device 300 fills the cavity space 801 with liquid molding material. The filled molding material is solidified to obtain the molded product 10.

[0035] In the depressurization process, the mold clamping motor 160 is driven to move the crosshead 151 back from the mold clamping position to the mold opening start position, thereby moving the movable platen 120 back and reducing the mold clamping force. The mold opening start position and the mold closing completion position may be the same position.

[0036] In the mold opening process, the mold clamping motor 160 is driven to move the crosshead 151 backward at a set moving speed from the mold opening start position to the mold opening completion position, thereby moving the movable platen 120 backward and separating the movable mold 820 from the fixed mold 810. Thereafter, the ejector device 200 ejects the molded product 10 from the movable mold 820.

[0037] When the thickness of the mold device 800 changes due to replacement of the mold device 800 or a temperature change in the mold device 800, the mold thickness is adjusted so that a predetermined clamping force is obtained during mold clamping. The mold thickness adjustment mechanism 180 adjusts the mold thickness by adjusting the gap between the fixed platen 110 and the toggle support 130. The mold thickness adjustment is performed, for example, between the end of a molding cycle and the start of the next molding cycle.

[0038] (Ejector device) The ejector unit 200 is attached to the movable platen 120 and moves forward and backward together with the movable platen 120. The ejector unit 200 performs an ejection process under the control of the control unit 700. In the ejection process, the drive mechanism 220 advances the ejector rod 210 from the standby position to the ejection position at a set movement speed, thereby advancing the movable member 830 and ejecting the molded product 10. Thereafter, the drive mechanism 220 retracts the ejector rod 210 at the set movement speed, and the movable member 830 retracts to the original standby position.

[0039] (injection device) The injection unit 300 is disposed so as to be able to move forward and backward relative to the mold device 800. The injection unit 300 touches the mold device 800 and fills the cavity space 801 in the mold device 800 with molding material. The injection unit 300 performs a metering process, a filling process, a pressure holding process, and other processes under the control of the control device 700. The filling process and pressure holding process are collectively referred to as the injection process. In the metering process, a predetermined amount of liquid molding material is accumulated. In the filling process, the liquid molding material accumulated in the metering process is filled into the cavity space 801 in the mold device 800. In the pressure holding process, the holding pressure of the molding material is maintained at a set pressure.

[0040] (Mobile device) The moving device 400 moves the injection device 300 forward and backward relative to the mold device 800 .

[0041] (Control device) 1, the control device 700 is configured by a computer, and has a CPU (Central Processing Unit) 701, a storage medium 702 such as a memory, an input interface 703, an output interface 704, a first communication interface 705, a second communication interface 706, and a third communication interface 707. The control device 700 performs various controls by causing the CPU 701 to execute a program stored in the storage medium 702. The control device 700 also receives signals from the outside via the input interface 703 and transmits signals to the outside via the output interface 704.

[0042] The control device 700 repeatedly performs processes such as a metering process, mold closing process, pressure increase process, mold clamping process, filling process, pressure dwell process, cooling process, pressure release process, mold opening process, and ejection process, thereby repeatedly manufacturing the molded product 10. A series of operations required to obtain the molded product 10, for example, the operations from the start of a metering process to the start of the next metering process, is also called a "shot" or a "molding cycle." The time required for one shot is also called the "molding cycle time" or "cycle time."

[0043] One molding cycle includes, for example, a metering process, a mold closing process, a pressurization process, a mold clamping process, a filling process, a pressure holding process, a cooling process, a depressurization process, a mold opening process, and an ejection process, in this order. The order here refers to the order in which each process starts. The filling process, the pressure holding process, and the cooling process are performed during the mold clamping process. The start of the mold clamping process may coincide with the start of the filling process. The end of the depressurization process coincides with the start of the mold opening process.

[0044] In order to shorten the molding cycle time, a plurality of steps may be carried out simultaneously.

[0045] Note that one molding cycle may include steps other than the metering step, mold closing step, pressure increase step, mold clamping step, filling step, pressure holding step, cooling step, pressure release step, mold opening step, and ejection step.

[0046] The control device 700 is connected to an operation device 750 and a display device 760. The operation device 750 accepts an input operation by a user and outputs a signal corresponding to the input operation to the control device 700. The display device 760 displays a display screen corresponding to the input operation on the operation device 750 under the control of the control device 700.

[0047] The display screen is used for setting the injection molding machine 3. A plurality of display screens are prepared, and they are displayed by switching between them or overlapping them. The user operates the operation device 750 while looking at the display screen displayed on the display device 760 to perform settings for the injection molding machine 3 (including input of setting values).

[0048] The operation device 750 and the display device 760 may be integrated, for example, by using a touch panel 770. Although the operation device 750 and the display device 760 of this embodiment are integrated, they may also be provided independently. Furthermore, a plurality of operation devices 750 may also be provided.

[0049] The third communication interface 707 is an interface for communicating with the management system server 2 connected via the public network 8 .

[0050] The first communication interface 705 is an interface for communicating between the material dryer 5 and the mold temperature regulator 6 via a communication line.

[0051] When the first communication interface 705 receives the dryer data, the CPU 701 of the control device 700 stores the received dryer data in the storage medium 702. The dryer data is used when writing the data to the RFID tags 55A to 55D.

[0052] When the first communication interface 705 receives the temperature controller data, the CPU 701 of the control device 700 stores the received temperature controller data in the storage medium 702. The temperature controller data is used when writing the data to the RFID tags 55A to 55D.

[0053] The second communication interface 706 is an interface for communicating with the RFID reader / writer 31 via a communication line.

[0054] Then, when the molded product 10 is molded, the CPU 701 reads out the information stored in the storage medium 702 and issues a write instruction to the RFID reader / writer 31 (an example of a first writing unit) via the second communication interface 706. Next, the writing performed in the molding process will be described.

[0055] 4 is a diagram illustrating information read from and written to RFID tags 55A-55D by RFID reader / writer 31 during the molding process according to this embodiment. As shown in FIG. 4, data written to RFID tags 55A-55D during the molding process includes information for identifying the current molded product 10 and information describing the current molding status. Specifically, the data includes "molding conditions," "performance data," "lot number, date and time, product name, mold name, worker name, etc.", "temperature controller data," and "dryer data." As shown in FIG. 4, no data is read by RFID reader / writer 31 during the molding process.

[0056] "Molding conditions" indicate the conditions set by the operator for this molding, including the set temperature and cooling time set for the mold device 800, for example.

[0057] The "actual data" is information acquired by sensors (not shown) during this molding, and includes, for example, the peak filling pressure of the cylinder of the injection molding machine 3, the mold pressure inside the mold device 800, the cylinder temperature of the injection molding machine 3, and the number of shots indicating the number of times the cylinder of the injection molding machine 3 has injected.

[0058] "Lot number, date and time, product name, mold name, worker name, etc." is information for specifying the current molding, and is information that has been input to the injection molding machine 3, etc.

[0059] "Temperature regulator data" is information transmitted from the mold temperature regulator 6, and includes, for example, the temperature set for the mold device 800, actual data on the temperature of the mold device 800, and flow rate data of the water used for temperature regulation.

[0060] "Dryer data" is information transmitted from the material dryer 5, and includes the temperature set for drying and actual data on the drying temperature of the molding material.

[0061] In the molding process, as described above, when the molded product 10 is molded, the CPU 701 of the control device 700 writes the above-mentioned information into each of the RFID tags 55A to 55D via the RFID reader / writer 31.

[0062] In this embodiment, an example will be described in which all information generated in the molding process is managed by RFID tags 55A-55D. However, this embodiment is not limited to a method in which all information generated in the molding process is managed by RFID tags 55A-55D. For example, only information necessary for identifying molded product 10, such as the number of shots and molding date and time, may be written to RFID tags 55A-55D, and RFID reader / writer 31 may transmit, together with the information necessary for identification, other information with a large amount of information (e.g., information on molding conditions and various performance values) to management system server 2. In this way, management system server 2 can associate the information necessary for identification with other information about injection molding machine 3 (information on molding conditions and various performance values) and manage them in storage device 15.

[0063] Returning to Fig. 1, the take-out / carry-out process is the process following the molding process, in which the molded article 10 is taken out of the injection molding machine 3 and carried out. This process is performed by a take-out robot 4.

[0064] The take-out robot 4 (an example of a placement unit) is a device for taking out the molded article 10 formed in the injection molding machine 3 and storing the taken-out molded article 10 in a storage container 50. The take-out robot 4 is equipped with an RFID reader / writer 32 on an arm that takes out and stores the molded article 10.

[0065] The take-out robot 4 according to this embodiment stores each of the molded articles 10 taken out for each cavity of the mold device 800 of the injection molding machine 3 in each of the storage areas 51A to 51D of the storage container 50.

[0066] The RFID reader / writer 32 (an example of a second writing unit) reads and writes data from and to each of the RFID tags 55A to 55D. The arm of the take-out robot 4 of this embodiment stores the molded article 10 in each of the storage areas 51A to 51D of the storage container 50. When the arm stores the molded article 10, the RFID reader / writer 32 provided on the arm reads and writes information about the molded article 10 to be stored from the RFID tags 55A to 55D corresponding to the storage areas 51A to 51D where the molded article 10 is to be stored.

[0067] When the take-out robot 4 of this embodiment stores the molded article 10 in the storage container 50, the RFID reader / writer 32 reads and writes information about the molded article 10 from and to each of the RFID tags 55A to 55D.

[0068] 5 is a diagram illustrating information read from and written into RFID tags 55A to 55D by RFID reader / writer 32 in the take-out / carry-out process according to this embodiment. As shown in FIG. 5, in the take-out / carry-out process, RFID reader / writer 33 reads, for example, the "number of shots," "lot number," and "molding date and time" from RFID tags 55A to 55D.

[0069] The take-out robot 4 according to this embodiment generates "identification information" for identifying the molded product 10 based on the read information "number of shots," "lot number," and "molding date and time," and the number indicating the cavity of the mold device 800. The "identification information" is information that can uniquely identify one molded product 10 by combining information related to the current molding with information indicating the cavity.

[0070] In the removal / carry-out process, the data written to the RFID tags 55A to 55D includes information indicating the molded product 10 to be stored. Specifically, the information indicating the molded product 10 includes the "mold cavity number," "product temperature," "product load," and "identification information."

[0071] The "mold cavity number" is a number indicating the cavity of the mold device 800 from which the molded product 10 was taken out.

[0072] "Product temperature" indicates the temperature of the molded product 10 that has been removed. "Product load" indicates the load of the molded product that has been removed. "Product temperature" and "product load" are values ​​detected by a sensor (not shown) provided on the take-out robot 4 when the take-out robot 4 takes out the product.

[0073] The "identification information" is a unique number for each molded product 10 produced by the "shot number," "lot number," "molding date and time," and "mold cavity number."

[0074] In the removal / carry-out process, as described above, when the removal robot 4 stores the molded product 10 in the storage container 50, the RFID reader / writer 32 reads the "number of shots," "lot number," and "molding date and time" from the RFID tags 55A to 55D, and writes the "mold cavity number," "product temperature," "product load," and "identification information" to the RFID tags 55A to 55D.

[0075] Returning to FIG. 1, the inspection process is the process that follows the removal / carry-out process, and is a process in which inspection is performed on the molded product 10. This process is performed by an image inspection device 9. The image inspection device 9 according to this embodiment is not connected to the public network 8. Therefore, in this embodiment, the inspection results are written to RFID tags 55A to 55D in order to transfer the inspection results to a subsequent process.

[0076] That is, in a process after molding of the molded product 10, depending on the situation in the factory, not all devices in the factory may be connected to the public network 8. In this way, in this embodiment, by using the RFID tags 55A to 55D, information can be exchanged without connecting to the public network 8.

[0077] The image inspection device 9 inspects the molded articles 10 based on image data obtained by capturing images of each of the molded articles 10 stored in each of the storage areas 51A to 51D of the storage container 50 using an imaging unit (not shown). The inspection may involve, for example, inspecting the appearance of the molded articles 10 to determine whether there are any defects in the appearance.

[0078] The image inspection device 9 is connected to the RFID reader / writer 33. The RFID reader / writer 33 reads information from the RFID tags 55A to 55D when the image inspection device 9 performs an appearance inspection.

[0079] 6 is a diagram illustrating information read from and written to RFID tags 55A to 55D by RFID reader / writer 33 in the inspection process according to this embodiment. As shown in Fig. 6, in the inspection process, RFID reader / writer 33 (an example of a first reading unit) reads, for example, "molding conditions," "performance data," "lot number, date and time, product name, mold name, worker name, etc.", "temperature controller data," "dryer data," "product temperature," and "product load" from RFID tags 55A to 55D.

[0080] The image inspection device 9 (an example of a processing unit) according to this embodiment generates a judgment criterion indicating whether or not a product is defective based on the read information. The image inspection device 9 then judges whether or not the molded product 10 is defective based on the generated judgment criterion. In this manner, this embodiment performs an appearance inspection of the molded product 10, taking into consideration the environment in which the molded product 10 was molded. This allows for highly accurate appearance inspection. This embodiment is an example of generating a judgment criterion based on read information, but the present invention is not limited to a method of reading data from RFID tags 55A-55D to generate the judgment criterion; for example, the judgment criterion may be fixed.

[0081] After the inspection is completed, the image inspection device 9 writes the inspection results to each of the RFID tags 55A to 55D using the RFID reader / writer 33 (an example of a second writing unit). In this embodiment, the inspection results performed for each molded article 10 are written to the RFID tags 55A to 55D corresponding to that molded article 10.

[0082] In the inspection process, the RFID reader / writer 33 writes the "inspection result" and the "inspector name" into the RFID tags 55A to 55D.

[0083] "Inspection results" is information indicating the inspection results by the image inspection device 9. If the image inspection device 9 determines that an inspection is required, the result of that determination is also included. "Inspection operator name" indicates the name of the operator who performed the work using the image inspection device 9.

[0084] As a result, the inspection results in the inspection process are written to the RFID tags 55A to 55D. As a result, in this embodiment, even if the image inspection device 9 is not connected to a network, the inspection results can be passed on to a subsequent process.

[0085] Returning to Fig. 1, the packing process is the process that follows the inspection process and involves packing the molded article 10 for shipment. This process may be performed by a packing machine or by an operator. If the process is performed by an operator, when the operator packs the molded article 10, the operator uses an RFID reader / writer 34 to read the information written in the previous processes from the RFID tags 55A to 55D that identify the molded article 10 to be packed.

[0086] FIG. 7 is a diagram illustrating information read and written to RFID tags 55A-55D by RFID reader / writer 34 during the packaging process according to this embodiment. As shown in FIG. 7 , during the packaging process, RFID reader / writer 34 (an example of a second reading unit) reads, for example, "molding conditions," "performance data," "lot number, date and time, product name, mold name, operator name, etc.", "temperature controller data," "dryer data," "product temperature," "product load," "inspection results," "inspector name," and "identification information" from RFID tags 55A-55D. In the example shown in FIG. 7 , no data is written by RFID reader / writer 34 during the packaging process, but data may be written as needed. Examples of data that may be written include the results of secondary inspections. In such a case, the process may proceed by writing data during the packaging process and then reading all data.

[0087] The worker checks the information written in the "inspection results" and, if there is a molded article 10 that is determined to require a secondary inspection, performs the necessary secondary inspection on that molded article 10.

[0088] The RFID reader / writer 34 (an example of a transmitter) is equipped with a communication I / F (not shown). The RFID reader / writer 34 then transmits all of the read information to the management system server 2 via the public network 8. The management system server 2 writes the received information into the storage device 15.

[0089] In this embodiment, an operator packs each molded article 10 into a packing bag. In addition, in order to associate the packed molded articles 10 with the information managed by the management system server 2, a two-dimensional code representing identification information (which uniquely identifies the molded article 10) read by the RFID reader / writer 34 may be attached to the packing bag 70 in which the molded articles 10 are packed. This makes it possible to trace the entire situation from when the molded article 10 is molded to after shipping, even after shipping.

[0090] Next, a description will be given of the processing procedure performed in the molding process of the manufacturing system 1 according to this embodiment. Fig. 8 is a flowchart showing the processing procedure performed in the molding process of the manufacturing system 1 according to this embodiment. Note that information such as molding conditions, lot number, date and time, product name, mold name, and worker name is stored in advance in the storage medium 702.

[0091] First, the injection molding machine 3 starts molding (S801). Next, the CPU 701 of the control device 700 of the injection molding machine 3 acquires data (dryer data, temperature controller data) related to the peripheral devices (e.g., the material dryer 5 and the mold temperature controller 6) via the first communication interface 705 (S802).

[0092] Furthermore, the CPU 701 writes the acquired information to the storage medium 702 (S803).

[0093] Then, molding by the injection molding machine 3 is completed (S804). The CPU 701 acquires performance data from a sensor or the like (not shown) (S805). Note that the acquisition of performance data from a sensor or the like shown in S805 may be performed before molding by the injection molding machine 3 is completed, and the data may be written to the storage medium 702 according to the procedure of S806 described below.

[0094] The CPU 701 reads information from the storage medium and instructs the RFID reader / writer 31 to write the information read from the storage medium 702 and the performance data to all of the RFID tags 55A to 55D (S806). In response to this instruction, the RFID reader / writer 31 writes the information read from the storage medium 702 and the performance data to the RFID tags 55A to 55D.

[0095] Furthermore, the CPU 701 transmits the information read from the storage medium 702 and the performance data to the management system server 2 (S807), thereby completing the molding process.

[0096] In the molding process of this embodiment, by performing the above-described processing procedure, information related to the molding process is written to the RFID tags 55A to 55D. Furthermore, the information is also transmitted to the management system server 2, making it possible to manage the status of the molding process.

[0097] Next, a description will be given of the processing procedure performed in the take-out / carry-out process in the manufacturing system 1 according to this embodiment. Fig. 9 is a flowchart showing the processing procedure performed in the take-out / carry-out process in the manufacturing system 1 according to this embodiment.

[0098] First, the take-out robot 4 takes out the molded article 10 from the mold device 800 of the injection molding machine 3 (S901). In this embodiment, the arm of the take-out robot 4 may simultaneously take out multiple molded articles 10 molded for each cavity, or the arm may take out the molded articles 10 molded for each cavity one by one.

[0099] The take-out robot 4 acquires information (product temperature, product weight) about the taken-out molded product 10 from a sensor (not shown) (S902).

[0100] The take-out robot 4 stores each of the taken-out molded articles 10 in each of the storage areas divided so as to correspond to the number of cavities (S903).

[0101] When the take-out robot 4 stores the molded article 10, the RFID reader / writer 32 reads information about the molded article 10 from the RFID tags 55A to 55D associated with the storage area (S904).

[0102] The take-out robot 4 generates identification information based on the read information (S905).

[0103] The take-out robot 4 writes the generated identification information, the mold cavity number from which the molded article 10 was taken out, and information about the molded article 10 (product temperature, product weight) from the RFID reader / writer 32 to the RFID tags 55A to 55D (S906).

[0104] When the storage of the molded articles 10 in the storage container 50 is completed, the belt conveyor 7 starts transporting the storage container 50 in accordance with an instruction from the take-out robot 4 (S907), thereby completing the take-out and carry-out process.

[0105] Next, a description will be given of the processing procedure performed in the inspection process of the manufacturing system 1 according to this embodiment. Fig. 10 is a flowchart showing the processing procedure performed in the inspection process of the manufacturing system 1 according to this embodiment. In this embodiment, the storage containers 50 are transported by the belt conveyor 7 from the removal / transport process to the inspection process.

[0106] First, image inspection device 9 uses RFID reader / writer 33 to read information used as inspection criteria, such as molding conditions and performance values, from RFID tags 55A to 55D (S1001).

[0107] The image inspection device 9 inspects each molded product 10 in accordance with the judgment criteria corresponding to each molded product 10 based on the read information (S1002).

[0108] The image inspection device 9 uses the RFID reader / writer 33 to write the inspection results and the like for each molded article 10 into the RFID tags 55A to 55D corresponding to the molded article 10 (S1003).

[0109] When inspection of each molded article 10 stored in the storage container 50 is completed, the belt conveyor 7 transports the storage container 50 in accordance with instructions from the image inspection device 9 or operations by the inspection operator (S1004), thereby completing the inspection process.

[0110] Next, a description will be given of the processing procedure performed in the transport process of the manufacturing system 1 according to this embodiment. Fig. 11 is a flowchart showing the processing procedure performed in the transport process of the manufacturing system 1 according to this embodiment. In this embodiment, from the inspection process to the transport process, the storage containers 50 are transported by the belt conveyor 7.

[0111] First, the RFID reader / writer 34 reads all information from the RFID tags 55A to 55D corresponding to the molded product 10 in accordance with an operation by an operator (S1101).

[0112] The worker determines whether a secondary inspection is necessary based on the "inspection result" displayed as information read by the RFID reader / writer 34 (S1102).

[0113] If it is determined that a secondary inspection is necessary (S1102: Yes), processing is performed to perform the secondary inspection (S1103), and the processing ends. Note that if the molded product is determined to be a non-defective product as a result of the secondary inspection, the processing may proceed to the packaging processing in S1104. The results of the secondary inspection may also be written to the RFID tags 55A to 55D. When the results of the secondary inspection, etc., are written to the RFID tags 55A to 55D, the RFID reader / writer 34 may read all the information again.

[0114] On the other hand, if it is determined that secondary inspection is not necessary (S1102: Yes), packaging processing is performed (S1104). After that, a two-dimensional code representing identification information is printed from a printing device connected to the RFID reader / writer 34 (S1105). The worker attaches the printed two-dimensional code to the packaging bag 70.

[0115] Then, the RFID reader / writer 34 transmits all the information read from the RFID tags 55A to 55D to the management system server 2 (S1106).

[0116] The above-described processing procedure makes it possible to manage all post-molding information in the management system server 2, and since a two-dimensional code is attached to the packaging bag 70, the entire status of the molded product 10 from molding to shipping can be grasped even after shipping.

[0117] Furthermore, after the conveying process is completed, the storage container 50 is used again from the molding process. As in this embodiment, the storage container 50 and the RFID tags 55A to 55D affixed to the storage container 50 are used to associate another molded product 10 after the associated molded product 10 has been shipped. In this way, in this embodiment, the storage container 50 and the RFID tags 55A to 55D affixed to the storage container 50 are reusable, thereby reducing costs.

[0118] In this embodiment, an example has been described in which the identification information is generated in the take-out / carry-out process, but the generation of the identification information for identifying the molded product 10 is not limited to the take-out / carry-out process, and it may be generated before all the information is transmitted to the management system server 2. For example, in the packing process, the identification information may be generated at the stage when all the information is read from the RFID tags 55A to 55D.

[0119] In the above-described embodiment, the image inspection device 9 that performs visual inspection has been described as an example of the processing unit. However, in this embodiment, the processing unit is not limited to the image inspection device 9, and may be any means that performs processing based on the read information indicating the molded product 10.

[0120] In the above-described embodiment, an example has been described in which an RFID tag is associated with each molded article 10. However, the above-described embodiment is not limited to an example in which an RFID tag is associated with each molded article 10. For example, when the injection molding machine 3 molds multiple molded articles 10 at a time, one RFID tag may be associated with each of the multiple molded articles 10 for management.

[0121] In the above-described embodiment, an example has been described in which the storage container 50 is used to associate each of the RFID tags 55A to 55D with the molded article 10. This embodiment does not limit the shape of the storage container for storing the molded article 10, and it may be, for example, bag-shaped. In this case, the molded article 10 may be stored in a bag or the like to which an RFID tag is attached, and the RFID tag and the molded article 10 may be associated and managed. Furthermore, the method is not limited to using a storage container, and an RFID tag may be attached directly to the molded article 10.

[0122] In the above-described embodiment, an example has been described in which an RFID tag is used as a storage medium associated with the molded product 10. Using an RFID tag makes it possible to read and write information via near-field wireless communication. Therefore, even if there are multiple processing steps as described above, each processing step is in a different environment, and reading and writing is required for each processing step, the ease of reading and writing information can reduce the burden on each processing step.

[0123] Furthermore, in the above-described embodiment, an RFID tag is associated with each molded article 10 in the post-molding process, and the molded articles 10 are managed accordingly. By reading and writing information about the molded articles 10 in each processing step, appropriate management of each molded article 10 can be achieved. Furthermore, the accuracy of quality control of the molded articles 10 can be improved.

[0124] Furthermore, in the above-described embodiment, each molded product 10 is managed in association with a mold cavity number (information that identifies the cavity). This allows for identification of the cavity in which the defect occurred if a defective molded product 10 is discovered during inspection. This makes it possible to analyze whether a particular cavity is prone to defects during the analysis stage. This allows for identification of molded products 10 that are prone to defects, thereby improving quality control.

[0125] Although the embodiments of the molded product manufacturing system of the present invention have been described above, the present invention is not limited to the above embodiments. Various changes, modifications, substitutions, additions, deletions, and combinations are possible within the scope of the claims. These naturally also fall within the technical scope of the present invention.

[0126] This application claims priority based on Japanese Patent Application No. 2021-062364, filed on March 31, 2021, the entire contents of which are incorporated herein by reference. [Explanation of symbols]

[0127] 1 Manufacturing system 2 Management system server 3 Injection molding machine 4 Take-out robot 5 Material dryer 6 Mold temperature controller 7 Belt conveyor 8 Public network 9 Image inspection device 10 Molded product 31-34 RFID reader / writer 50 Storage container 55A-55D RFID tag

Claims

1. a first writing unit that writes first information related to a molded product molded by the injection molding machine into a readable and writable storage medium; a transport unit that transports the molded product and the storage medium on which the first information of the molded product is written in association with each other; an arrangement unit that arranges each of the molded products molded for each cavity in each of the divided areas in a storage container having divisions corresponding to the number of cavities of the injection molding machine, the first writing unit writes the first information to each of the storage media provided in each of the partitioned areas of the storage container; The transport unit transports the storage container. Molded product manufacturing system.

2. A first writing unit that writes first information about a molded product molded by an injection molding machine to a readable and writable storage medium; a transport unit that transports the molded product and the storage medium on which the first information of the molded product is written in association with each other; a first reading unit that reads the first information from the storage medium transported together with the molded product by the transport unit; a processing unit that performs a predetermined process on the molded product using the first information read by the first reading unit; A molded product manufacturing system comprising:

3. a second reading unit that reads the first information from the storage medium transported together with the molded product by the transport unit; a transmitting unit that transmits the first information read by the second reading unit to a server that manages information on the molded product via a network; The molded product manufacturing system according to claim 1 or 2, further comprising:

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