Molded product removal machine and its operation monitoring method

Abstract

To provide a molded article take-out machine and a method for monitoring a work thereof, capable of detecting a case where a troubleshooting work by a person in charge of the work is slow or insufficient when a brief interruption occurs, in a simple method.SOLUTION: A cycle time management unit 3 of a molded article take-out machine has: a cycle time measuring unit 5 for measuring a cycle time for each one cycle of taking out a molded article from an injection molding machine; a target cycle time setting storage unit 7 for setting and storing a target cycle time; a comparison unit 9 for comparing the measured cycle time and the target cycle time for each one cycle; an excess number measurement unit 11 for measuring the number of times the target cycle time is continuously exceeded after the next cycle when the measured cycle time exceeds the target cycle time as a result of comparison; and a detected signal output unit 13 for outputting a detected signal when the number of times the target cycle time is continuously exceeded exceeds n (n is 1 or a larger integer).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a molded product removal machine that removes molded products from an injection molding machine and a method for monitoring the operation thereof. [Background technology]

[0002] BACKGROUND ART Conventionally, there has been known a manufacturing line device that reports an abnormality when a cycle time is delayed compared to a reference time (for example, Japanese Patent Laid-Open No. 2013-152973 (Patent Document 1) relating to a board production line). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-152973 Summary of the Invention [Problem to be solved by the invention]

[0004] There are various possible reasons for cycle time delays, but one possible cause is that the workers are slow or inadequate in taking action when an event occurs in which the molded product removal machine stops for a short period of time and then resumes operation (commonly known as a "choco-tei" (a partial shutdown of the equipment or a shutdown due to a malfunction of the equipment's target, which can be recovered from in a short period of time [JIS Z 8141:2001]).

[0005] An object of the present invention is to provide a molded product removal machine and an operation monitoring method therefor that can easily detect cases where the operator's response to a brief stoppage is slow or insufficient. [Means for solving the problem]

[0006] The method for monitoring the operation of a molded product removal machine of the present invention includes a cycle time measurement step for measuring the cycle time required for one cycle to remove a molded product from an injection molding machine, a target cycle time setting step for setting a target cycle time acceptable to an administrator, a comparison step for comparing the measured cycle time with the target cycle time for each cycle, an excess count measurement step for measuring the number of times the measured cycle time continuously exceeds the target cycle time after the first time the target cycle time is exceeded (from the next cycle onwards) if the comparison shows that the measured cycle time exceeds the target cycle time, an excess count measurement step for measuring the number of times the measured cycle time continuously exceeds the target cycle time, and an output step for outputting a detection signal when the number of times the target cycle time is continuously exceeded exceeds n times (n is an integer greater than or equal to 1).

[0007] If the target cycle time is exceeded n times in a row, i.e., if the cycle time exceeds the target cycle time two or more times in a row, it is inferred that the operator's response to a minor stoppage due to some cause was slow or insufficient. Therefore, when the detection signal according to the present invention is output, checking the number of times and timing of occurrence of the detection signal can serve as an opportunity to check whether the operator's response was appropriate, and the manager can recognize the need for guidance and education for the operator. Note that when a detection signal is output, there is no need to take action to stop the operation of the molded product extractor based on the detection signal.

[0008] The same effect can be obtained by providing an output step that determines whether the cycle time has exceeded the target cycle time m times (m is an integer greater than or equal to 2) in succession, and outputs a detection signal when it is determined that the cycle time has exceeded the target cycle time.

[0009] It is preferable that the target cycle time be set only by the manager of the molded product removal machine, as there is a risk that a time different from the manager's standards or schedule may be set by mistake, which would defeat the purpose of work monitoring.

[0010] In the exceedance count measurement step, if the measured cycle time falls below the target cycle time before the number of times that the measured cycle time has continuously exceeded the target cycle time reaches n times, the exceedance count measurement step is reset. By doing this, if the worker's response processing is appropriate, the detection signal will not be output, and the detection signal will be output only when the target cycle time has continuously been exceeded, so the manager will not be burdened with more judgment than necessary.

[0011] After a detection signal is output, the next detection signal may not be output until the measured cycle time falls below the target cycle time. In this way, for example, by looking at the interval between the first and second detection signals, the worker's response ability can be known, and even if the manager mistakenly sets a target cycle time that is difficult to fall below, detection signals will not be output continuously, and the worker's work will not be hindered.

[0012] The method may further include a storage step of storing, when a detection signal is output, the cycle times that are shorter than the target cycle time before the detection signal is output and the cycle times that exceed the target cycle time before the detection signal is output. In this way, the manager can check not only the cycle time history when the detection signal is output, but also the time that has passed until the cycle time is exceeded (the time required for the corrective work), which can be used by the manager to confirm the need for guidance and education for the workers.

[0013] The present invention can also be understood (or expressed) as a molded product removal machine having a cycle time management unit that can set a target cycle time required for one cycle of removing a molded product from an injection molding machine.

[0014] The cycle time management unit of the molded product removal machine of the present invention includes a cycle time measurement unit that measures the cycle time for each cycle, a target cycle time setting and storage unit that sets and stores a target cycle time, a comparison unit that compares the measured cycle time with the target cycle time for each cycle, an excess count measurement unit that, if the comparison unit finds that the measured cycle time exceeds the target cycle time as a result of the comparison, counts the number of times that the measured cycle time continuously exceeds the target cycle time after the first time that the target cycle time is exceeded (from the next cycle onwards), and a detection signal output unit that outputs a detection signal when the number of times that the measured cycle time continuously exceeds the target cycle time exceeds n times (n is an integer equal to or greater than 1).

[0015] In addition, if the cycle time management unit is equipped with an excess count measurement unit that measures the number of times the measured cycle time exceeds the target cycle time in succession when the comparison by the comparison unit shows that the measured cycle time exceeds the target cycle time, and a detection signal output unit that outputs a detection signal when the measured cycle time exceeds the target cycle time in succession m times (m is an integer of 2 or more), the same effect can be obtained.

[0016] The cycle time management unit may further include a history storage unit that stores at least a history of the dates and times when the detection signal is generated. When the detection signal is output, the history storage unit may store cycle times that are shorter than the target cycle time before the detection signal is output, and cycle times that exceed the target cycle time before the detection signal is output.

[0017] The target cycle time setting storage unit is preferably configured so that it can be set only by the manager of the workers who operate the molded product remover, because there is a risk that a time different from the manager's standards or schedule may be set by mistake, which would defeat the purpose of work monitoring.

[0018] It is preferable that the device further includes an alarm generator that is driven by the detection signal to output an alarm. With such an alarm generator, the administrator can easily know that the detection signal has been output. The device may also include a display unit that displays a detection indication when the detection signal is output. In this way, the output of the detection signal can be easily known by checking the display unit.

[0019] It is preferable that, after outputting a detection signal, the detection signal output unit does not output the next detection signal until the measured cycle time falls below the target cycle time. [Brief explanation of the drawings]

[0020] [Figure 1] 2 is a block diagram showing the main configuration of a control device provided in the molded product removal machine according to the embodiment of the present invention. FIG. [Figure 2] 10 is a flowchart showing a processing flow including a flowchart of a program used when the main part of the control device of the molded product removal machine of the present embodiment is realized using a computer. [Figure 3] 10 is an example of a pop-up display and a warning icon displayed on the display unit. [Figure 4] This is an example of a case where the history is displayed on the display unit. [Figure 5] 10 is an example of a timing chart of signals output during automatic operation of the molded product removal machine. DETAILED DESCRIPTION OF THE INVENTION

[0021] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the molded product remover and the operation monitoring method therefor of the present invention will be described in detail with reference to the drawings.

[0022] FIG. 1 is a block diagram showing the main configuration of a control device provided in a molded product remover according to an embodiment of the present invention.

[0023] The molded product remover of this embodiment is installed on or adjacent to an injection molding machine (not shown), and removes a molded product from the mold of the injection molding machine, performs gate cutting, and places it in a predetermined location. The operation of the molded product remover is controlled by a control device 1.

[0024] As shown in Figure 1, the control device 1 has a cycle time management unit 3 that can set a target cycle time, which is the cycle time required for one cycle to remove a molded product from the injection molding machine. The cycle time management unit 3 includes a cycle time measurement unit 5, a target cycle time setting and storage unit 7, a comparison unit 9, an excess count measurement unit 11, a detection signal output unit 13, and a history storage unit 15. The molded product removal machine also includes an alarm generator 17 and a display unit 21 that displays information on a display screen under the control of a display control unit 19, in order to perform teaching, set predetermined settings such as the cycle time, and display various information.

[0025] The cycle time measurement unit 5 measures the cycle time for each cycle in which the product remover removes a molded product from the injection molding machine. Cycle time measurement unit 5 is implemented using a known analog or digital timer that starts counting time when a start signal is received and stops counting when an end signal is received. In the case of a product remover, "cycle time" refers to the time it takes from the start of movement from the standby position, to removing the molded product from the mold, releasing the molded product at the release position, and returning to the initial standby position. Cycle time measurement unit 5 measures the cycle time based on the start signal output from the injection molding machine at the start and the end signal output from the product remover at the end.

[0026] The target cycle time setting memory unit 7 sets and stores a target cycle time, which is the cycle time required for one cycle to remove a molded product from the injection molding machine. A password is set in the target cycle time setting memory unit 7, so that the operator of the molded product removal machine cannot set the target cycle time; only an administrator who knows the password can set it. This setting is made from a setting screen displayed on the display screen of the display unit 21.

[0027] The comparison unit 9 compares the cycle time measured by the cycle time measurement unit 5 with the target cycle time stored in the target cycle time setting storage unit 7 for each cycle.

[0028] If the comparison by the comparison unit 9 shows that the measured cycle time exceeds the target cycle time, the excess count unit 11 counts the number of times that the measured cycle time has consecutively exceeded the target cycle time since the first time it exceeded the target cycle time (from the next cycle onwards). If the measured cycle time falls below the target cycle time before the number of measurements reaches n, the excess count unit 11 resets the measurement of the number of excesses. In this way, if the worker's response processing is appropriate, a detection signal is not output, and a detection signal is output only when the target cycle time is consecutively exceeded, so that the manager is not burdened with more judgment than necessary.

[0029] The detection signal output unit 13 outputs a detection signal when the number of times the target cycle time is exceeded in succession exceeds n times (n is an integer equal to or greater than 1). In this embodiment, n is set to 2, and a detection signal is output when the cycle time measured three times in succession exceeds the target cycle time.

[0030] After outputting a detection signal, the detection signal output unit 13 may repeatedly output the detection signal until the measured cycle time falls below the target cycle time, or may continue to output the detection signal. Note that after outputting a detection signal, the detection signal output unit 13 may not output the next detection signal until the measured cycle time falls below the target cycle time. In this way, the manager can know the response ability of the worker by, for example, looking at the interval between the first and second detection signals.

[0031] In this embodiment, the detection signal drives the alarm generator 17 to generate an alarm, although the generation of an alarm is not an essential requirement for the method of the present invention.

[0032] The history storage unit 15 stores the history of the date and time when a detection signal occurred, the cycle time that fell short of the target cycle time before the detection signal was output, and the cycle time that exceeded the target cycle time before the detection signal was output. The information stored in the history storage unit 15 can be viewed on the display screen of the display unit 21 by the administrator entering a password. The history storage unit 15 may be configured to store, when a detection signal is output, the cycle time that fell short of the target cycle time before the detection signal was output, and the cycle time that exceeded the target cycle time before the detection signal was output. In this way, the administrator can check not only the history of the cycle time when the detection signal was output, but also the time that elapsed until the cycle time exceeded (the time required for the corrective action), which can be used by the administrator to confirm the need for guidance and education for the workers.

[0033] The display screen of the display unit 21 described above also has a touch panel function, and functions not only as a display screen that displays the status of the molded product remover, the cycle time, etc., but also as an input unit used when setting a target cycle time, etc. In this embodiment, when a detection signal is output, a pop-up display PW and a warning icon WI, which will be described later, are displayed on the display screen of the display unit 21 as detection displays.

[0034] 〔flowchart〕 FIG. 2 is a flowchart showing the flow of processing (method steps) including a flowchart of a program used when the main parts of the control device 1 of the molded product removing machine of this embodiment are realized by a computer.

[0035] Prior to the start of work, the molding remover is first taught (step ST1), and the manager sets an allowable target cycle time (step ST2).

[0036] When automatic operation starts (step ST3), the cycle time measurement unit 5 measures the cycle time (step ST5) after each cycle is completed (step ST4). When the measurement result is available, the comparison unit 9 compares the measured cycle time with the target cycle time (step ST6). If the measured cycle time does not exceed the target cycle time, the judgment is reset (the number of times the cycle has exceeded the target cycle time is reset, and if the detection signal is ON, the output of the detection signal is turned OFF), and the process returns to step ST3 (step ST7 → step ST8). If the measured cycle time exceeds the target cycle time, the output state of the detection signal is checked (step ST7 → step ST9). If the detection signal is output in the ON state, the process returns to step ST3. This is to prevent the detection signal from being output continuously in cases where the administrator has mistakenly set a target cycle time that is difficult to fall below. If the detection signal is not output in the OFF state, the excess count measurement unit 11 measures the number of times the target cycle time has been exceeded continuously (step ST10). Steps ST3 to ST10 are repeated (step ST11), and if the measured cycle time exceeds the target cycle time n times consecutively (twice in this embodiment, i.e., three times in total), a detection signal is output (step ST12). When the detection signal is output, a pop-up display PW and a warning icon WI are displayed on the display unit 21, as shown in FIG. 3 (step ST13). Additionally, the history storage unit 15 stores the history of the date and time when the detection signal occurred, the cycle time that was shorter than the target cycle time before the detection signal was output (i.e., the normal cycle time three cycles before the detection signal was output), and the cycle time when the target cycle time before the detection signal was output was exceeded (in this embodiment, the cycle times for the most recent three cycles).

[0037] The pop-up display PW can be removed from the display unit 21 by pressing the "OK" button indicating confirmation, but the warning icon WI will remain displayed on the display unit 21 unless the administrator performs a reset operation.

[0038] 4 shows an example of the history displayed on the display screen of the display unit 21. In this example, the set target cycle time, the normal cycle time three cycles prior to the time the detection signal was output, and the most recent three cycle times are displayed.

[0039] [Specific example based on timing chart] 5 is an example of a timing chart of signals output within the control device 1 during automatic operation of the molded product removal machine. This timing chart shows, from the top to the bottom, (a) a signal indicating that automatic operation is being performed, (b) a signal output when one cycle is completed, (c) a signal for executing a judgment, (d) a signal output when the cycle time exceeds the target cycle time (hereinafter referred to as an "excess signal"), (e) a signal output when the cycle time falls below the target cycle time (hereinafter referred to as a "normal signal"), (f) a signal output when a detection signal is output and a pop-up display is displayed (hereinafter referred to as a "pop-up signal"), (g) a signal output when a button to turn off the pop-up display is pressed (hereinafter referred to as a "pop-up clear signal"), and (h) a signal output when a detection signal is output and a warning icon is displayed (hereinafter referred to as a "warning icon signal").

[0040] From the timing chart, for example, the following can be read: (1) Each time one cycle is completed, the comparison unit 9 compares the measured cycle time with the target cycle time. If the (d) excess signal is output three times in a row, a detection signal is output, and a (f) pop-up signal and a (h) warning icon signal are output (timing T1). (2) The pop-up display disappears when the (g) pop-up clear signal is output (timing T2), but the (h) warning icon signal continues to be output. (3) If the (d) excess signal is output four times in a row, the fourth time, the detection signal is not output, and the (f) pop-up signal is not output (timing T3). After the (4) detection signal is output, the (e) normal signal is output (timing T4), which resets the judgment (step ST8 in FIG. 2). After that, the (d) excess signal is output three times in a row again, which causes the next detection signal to be output (timing T5).

[0041] The above-described embodiment has been described as an example, and the present invention is not limited to this embodiment unless it deviates from the gist of the present invention.

[0042] For example, in the above embodiment, when the measured cycle time exceeds the target cycle time, a detection signal is output in step ST11 if the measured cycle time has exceeded the target cycle time n times in a row. That is, it is determined that the cycle time has exceeded the target cycle time continuously when n=1 or more, excluding the first time that it has exceeded the target cycle time. However, it is of course possible to measure the number of times that the cycle time has exceeded the target cycle time, including the first time that it has exceeded the target cycle time, and determine that the cycle time has exceeded the target cycle time continuously when m times that it has exceeded the target cycle time, that is, when m=2 or more. In this case, the detection signal output 13 outputs a detection signal when the excess count counting unit 11 of the cycle time management unit 3 has counted that the measured cycle time has exceeded the target cycle time m times in a row. [Industrial Applicability]

[0043] According to the present invention, it is possible to provide a molded product removal machine and an operation monitoring method therefor that can easily detect cases where the response work by the operator when a brief stoppage occurs is slow or insufficient. [Explanation of symbols]

[0044] 1. Control device for molding remover 3. Cycle Time Management Department 5 Cycle time measurement section 7 Target cycle time setting memory 9 Comparison section 11 Excess count measurement unit 13 Detection signal output section 15 History memory section 17 Alarm Generator 19 Display control unit 21 Display section

Claims

1. a cycle time measurement step of measuring a cycle time required for one cycle of removing a molded product from the injection molding machine; a target cycle time setting step in which an administrator sets an allowable target cycle time; a comparison step of comparing the measured cycle time with the target cycle time for each cycle; an exceedance count measuring step of measuring the number of times that the measured cycle time has consecutively exceeded the target cycle time since the first time the measured cycle time exceeded the target cycle time, if the result of the comparison shows that the measured cycle time has exceeded the target cycle time; an output step of outputting a detection signal when the number of times that the measured cycle time continuously exceeds the target cycle time exceeds n times (n is an integer of 1 or more); The method for monitoring the operation of a molded product removal machine, wherein the target cycle time can be set only by the manager of the molded product removal machine.

2. a cycle time measurement step of measuring a cycle time required for one cycle of removing a molded product from the injection molding machine; a target cycle time setting step in which an administrator sets an allowable target cycle time; a comparison step of comparing the measured cycle time with the target cycle time for each cycle; an exceedance count measuring step of measuring the number of times that the measured cycle time has consecutively exceeded the target cycle time as a result of the comparison; An operation monitoring method for a molded product removal machine, characterized by including an output step of determining whether the cycle time has exceeded the target cycle time m times (m is an integer of 2 or more) consecutively, and outputting a detection signal when it is determined that the cycle time has exceeded the target cycle time.

3. 2. The operation monitoring method for a molded product removal machine according to claim 1, wherein, in the exceedance count measurement step, if the measured cycle time falls below the target cycle time before the number of times that the measured cycle time continuously exceeds the target cycle time reaches n times, the exceedance count measurement step is reset.

4. 2. The method for monitoring the operation of a molded product takeout machine according to claim 1, wherein after the detection signal is output, the next detection signal is not output until the measured cycle time falls below the target cycle time.

5. The method for monitoring the operation of a molded product removal machine according to claim 1, further comprising a storage step of storing, when the detection signal is output, a cycle time that falls below the target cycle time before the detection signal is output, and a cycle time that exceeds the target cycle time before the detection signal is output.

6. A molded product removal machine having a cycle time management unit capable of setting a target cycle time required for one cycle of removing a molded product from an injection molding machine, The cycle time management unit a cycle time measurement unit that measures the cycle time for each cycle; a target cycle time setting storage unit that sets and stores the target cycle time; a comparison unit that compares the measured cycle time with the target cycle time for each cycle; an excess count counting unit that, when the measured cycle time exceeds the target cycle time as a result of the comparison by the comparing unit, counts the number of times that the measured cycle time continuously exceeds the target cycle time after the first time that the measured cycle time exceeds the target cycle time; a detection signal output unit that outputs a detection signal when the number of times the target cycle time is exceeded in succession exceeds n times (n is an integer of 1 or more), The molded product removal machine is characterized in that the target cycle time setting storage section is configured so that it can be set only by a manager who is an operator operating the molded product removal machine.

7. A molded product removal machine having a cycle time management unit capable of setting a target cycle time required for one cycle of removing a molded product from an injection molding machine, The cycle time management unit a cycle time measurement unit that measures the cycle time for each cycle; a target cycle time setting storage unit that sets and stores the target cycle time; a comparison unit that compares the measured cycle time with the target cycle time for each cycle; an excess count measuring unit that measures the number of times that the measured cycle time continuously exceeds the target cycle time when the measured cycle time exceeds the target cycle time as a result of the comparison by the comparing unit; a detection signal output unit that outputs a detection signal when the measured cycle time exceeds the target cycle time m times in succession (m is an integer of 2 or more).

8. 8. The molded product remover according to claim 6, wherein the cycle time management unit further comprises a history storage unit that stores at least a history of the dates and times when the detection signals are generated.

9. 8. The molded product remover according to claim 6, further comprising an alarm generator that is driven by the detection signal to output an alarm.

10. 8. The molded product remover according to claim 6, further comprising a display unit that displays a detection indication when the detection signal is output.

11. 8. The molded product remover according to claim 6, wherein the detection signal output unit does not output the next detection signal until the measured cycle time falls below the target cycle time after outputting the detection signal.

12. The molded product removal machine according to claim 8, wherein, when the detection signal is output, the history memory unit stores a cycle time that is shorter than the target cycle time before the detection signal is output, and a cycle time that exceeds the target cycle time before the detection signal is output.

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