Machine tool monitoring device and program

Abstract

To save an operation for specifying a factor of an abnormal generation of a machine tool.SOLUTION: A monitoring device 1 for monitoring an operation of a machine tool, comprises: a plurality of cameras 21, 22, and 23 for photographing the machine tool from a plurality of directions; a plurality of sensors 31, 32, and 33 that detects the operation of the machine tool; a moving image file storage part 104 that repeatedly stores a plurality of video images photographed by each of the plurality of cameras as a plurality of moving image files; a sensor signal storage part 106 that constantly stores a plurality of sensor signals detected by the plurality of sensors; an abnormality generation detection part 107 that detects the generation of an abnormality in the machine tool on the basis of the plurality of sensor signals; and an abnormal moving image file storage part 109 that stores the plurality of abnormal moving image files corresponded to all of the plurality of cameras over before and after periods at a time when the generation of the abnormality is detected from the plurality of moving image files when the generation of the abnormality is detected.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a monitoring device and a program for a machine tool. [Background technology]

[0002] Conventionally, machine tools, such as injection molding machines, use sensors to collect operational data such as screw torque, cylinder temperature, mold pressure, injection speed, mold resin temperature, and mold surface temperature to monitor for operational abnormalities. Many injection molding machines issue an alarm when a sensor value indicates an abnormal value. Note that an abnormal value here refers to a value closer to a normal value than the value at which a malfunction is detected and the machine automatically stops (fault value), and is a value that indicates an impending malfunction. When an abnormal value is detected, the injection molding machine continues to operate, while the manager begins investigating the cause of the malfunction.

[0003] In some types of monitoring systems, video footage of the injection molding machine taken by a camera is recorded as a video file along with operational data. Managers can check the operational data to see if an abnormality has occurred, while also checking the video to see the operating status of the machine tool at the time, and infer the cause of the abnormality.

[0004] This work required alternating between playing back the operation data and the video, which was extremely cumbersome. In addition, the problem area may not be captured on a single camera, so in that case, multiple cameras may be used to capture various areas of the machine tool, but the work of linking and playing back multiple videos becomes even more cumbersome. Summary of the Invention [Problem to be solved by the invention]

[0005] The purpose is to reduce the labor required to identify the cause of abnormalities in machine tools. [Means for solving the problem]

[0006] A monitoring device for monitoring the operation of a machine tool according to an embodiment of the present invention includes a plurality of cameras that photograph the machine tool from a plurality of directions, a plurality of sensors that detect the operation of the machine tool, a video file storage unit that repeatedly stores a plurality of videos photographed by the plurality of cameras as a plurality of video files, a sensor signal storage unit that constantly stores a plurality of sensor signals detected by the plurality of sensors, an abnormality detection unit that detects the occurrence of an abnormality in the machine tool based on the plurality of sensor signals, and when the occurrence of the abnormality is detected, extracts from the plurality of video files a plurality of abnormality video files respectively corresponding to all of the plurality of cameras spanning a period before and after the time the occurrence of the abnormality is detected, Attributes relating to a camera identification code for identifying the camera, the date and time when the occurrence of the abnormality was detected, and an abnormality code for identifying the type of the abnormality are set. an abnormal video file storage unit for storing the abnormal video file; a list display unit that displays a list of the date and time when the occurrence of the abnormality was detected and the type of the abnormality on a display; and a playback unit that synchronously plays back, on one screen of the display, the plurality of abnormal video files that correspond to the date and time when the occurrence of the abnormality was detected and the abnormality code, selected from the list in accordance with a user instruction. It is equipped with: [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a diagram showing a physical configuration of a machine tool monitoring device according to an embodiment of the present invention; [Figure 2] FIG. 2 is a perspective view showing an example of the arrangement of the sensors and cameras in FIG. 1 relative to the injection molding machine. [Figure 3] FIG. 2 is a diagram showing the functional configuration of the information processing device in FIG. [Figure 4] 2 is a flowchart showing the procedure of the monitoring operation of the monitoring device of FIG. 1; [Figure 5] FIG. 10 is a conceptual diagram showing how an abnormal video file is generated from a video file in this embodiment. [Figure 6] 3 is a diagram showing an example of a list display screen relating to the date and time of occurrence of an abnormality and the type of the abnormality, displayed by the playback control unit in FIG. 2; [Figure 7] 7 is a diagram showing an example of a playback screen of three abnormal video files corresponding to the abnormality occurrence date and time and the abnormality type selected from the list of FIG. 6; [Figure 8] 8A to 8C are diagrams showing screen transitions in response to the specification of an enlargement command in FIG. 7; DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, an embodiment of the present invention will be described. Machine tools include cutting machines, such as lathes, milling machines, machining centers, and grinding machines, which are used to cut metals, etc.; plastic processing machines, such as injection molding machines; electrical discharge machines, such as wire cutters; and surface polishing machines. Here, an injection molding machine will be used as an example.

[0009] 1, a monitoring device 1 according to this embodiment includes an information processing device 10. A first camera 21, a second camera 22, a third camera 23, a vibration sensor 31, a temperature sensor 32, and a microphone 33 as an acoustic sensor are connected to the information processing device 10.

[0010] The information processing device 10 continuously records video captured by the three cameras 21, 22, and 23, and monitors for abnormalities based on sensor signals from sensors 31, 32, and 33. When an abnormality is detected, it extracts and stores three partial videos (corresponding to the abnormal video files described below) corresponding to the three cameras 21, 22, and 23, respectively, spanning the same time period before and after the abnormality. The information processing device 10 also arranges the three partial videos of the user-specified time point of the abnormality on a single screen and plays them synchronously, i.e., with the time axis aligned. Furthermore, the information processing device 10 displays at least one of a vibration time waveform, a temperature time waveform, and an acoustic time waveform (referred to as a sensor graph) on the same screen as the three partial videos. A seek bar indicating the playback position on the time axis is displayed over the sensor graph, and the user can manually adjust the position of the time bar on the time axis to start playback from any point. The physical and functional configurations of the information processing device 10, as well as the operating procedures, will be described in detail below.

[0011] As shown in FIG. 2, the first camera 21, the second camera 22, and the third camera 23 are positioned through open windows so that both the fixed mold and the movable mold, which are important moving parts of the injection molding machine 4, fit within the approximate center of their viewing angles. These cameras continuously capture images of the injection molding machine 4 from multiple directions, typically from three directions: front, back, and above, during the injection molding operation. The vibration sensor 31 is placed in contact with the fixed mold or the movable mold to directly detect vibrations generated in the mold. The temperature sensor 32 is placed in contact with the fixed mold or the movable mold to directly detect the mold surface temperature. The microphone 33 is placed through an open window relative to the fixed mold and the movable mold to detect operating sounds generated by the mold itself and the surrounding injection unit and mold clamping unit.

[0012] Returning to Figure 1, the information processing device 10 has a processor 11. Connected to the processor 11 via a data / control bus 19 are a RAM (Random Access Memory) 12, a ROM (Read Only Memory) 13, a storage device 14 such as an HDD (Hard Disk Drive) or an SSD (Solid State Drive), an input device 15 such as a keyboard or a mouse, a display 16 such as an LCD, an interface (I / F) 17 connected to cameras 21-23 and sensors 31-33, and a communication unit 18 for connecting to an external cloud storage device 2 via an internet line 3.

[0013] The processor 11 is composed of a CPU (Central Processing Unit) and a GPU (Graphics Processing Unit). The processor 11 executes a monitoring program loaded from the storage device 14 or the ROM 13 into the RAM 12, and performs processes related to video recording and playback, which will be described later. The RAM 12 functions as the main memory, work area, etc. of the processor 11. The ROM 13 or the storage device 14 stores a BIOS (Basic Input Output System), an operating system program (OS), the monitoring program according to this embodiment, various data required for these processes, etc., which are executed by the processor 11.

[0014] 3 shows the functional configuration of the information processing device 10. The information processing device 10 has a control unit 101 as its control center, and includes a camera signal input unit 102, a video file generation unit 103, a video file storage unit 104, a sensor signal input unit 105, a sensor signal storage unit 106, an abnormality occurrence detection unit 107, an abnormal video file generation unit 108, an abnormal video file storage unit 109, a video file transmission unit 113, a playback control unit 110, a playback operation input unit 111, and a display unit 112.

[0015] The video file generator 103 repeatedly generates video files of a predetermined duration, for example, five minutes, from the video signals of the cameras 21, 22, and 23 input via the camera signal input unit 102. The video files contain attribute data including a camera identification code for identifying the cameras 21, 22, and 23 and the date and time when an abnormality was detected. The video file storage unit 104 stores the video files. This allows video from three directions to be constantly recorded.

[0016] The sensor signal storage unit 106 constantly stores a plurality of sensor signals detected by the sensors 31, 32, and 33 and input via the sensor signal input unit 105.

[0017] The abnormality detection unit 107 detects the occurrence of an abnormality in the injection molding machine based on multiple sensor signals. Typically, with regard to vibration, the occurrence of abnormal vibration is detected when a threshold value related to amplitude or vibration acceleration is exceeded. With regard to operating noise, the occurrence of abnormal noise is detected when a threshold value related to amplitude or decibels is exceeded. With regard to temperature, an appropriate range for amplitude or decibels generated during steady operation is set in advance, and the occurrence of abnormal temperature is detected when the temperature deviates from the appropriate range.

[0018] When an abnormality (abnormal vibration, abnormal sound, abnormal temperature) is detected, the abnormal video file generating unit 108 generates three abnormal video files from multiple video files, each corresponding to the three cameras 21, 22, and 23, spanning a period before and after the abnormality was detected. The period, i.e., the duration of the abnormal video files, is set by the user independently of the duration of the video files. Attributes set in the abnormal video files include a camera identification code that identifies the cameras 21, 22, and 23, the date and time the abnormality was detected, and an abnormality code that identifies the type of abnormality. The abnormal video file storage unit 109 stores the generated abnormal video files.

[0019] In addition, the video file generated by the video file generation unit 103, the sensor signals detected by the sensors 31, 32, and 33, and the abnormal video file generated by the abnormal video file generation unit 108 are stored in memory units 104, 106, and 109, which correspond to the internal storage device 14, and are also transmitted to and stored in the cloud storage device 2 by the video file transmission unit 113.

[0020] The playback control unit 110 creates a list of the dates and times when an abnormality was detected and the types of abnormalities based on the attributes of the stored abnormal video files in accordance with a user command for playing back the abnormal video input from the playback operation input unit 111, and displays the list on the display unit 112. The playback control unit 110 also synchronously plays back, on a single screen on the display unit 112, three abnormal video files from each of the three cameras 21, 22, and 23 corresponding to the dates and times when the abnormality was detected and the abnormality code selected from the list in accordance with a user instruction via the playback operation input unit 111. The playback control unit 110 creates a sensor graph representing the temporal fluctuations in the sensor signal over the same period as the period of the abnormal video files, and displays the sensor graph together with the three abnormal video files on the display unit 112. A seek bar displaying the playback positions of the three abnormal video files is superimposed on the sensor graph. The position of the seek bar on the time axis can be moved arbitrarily in accordance with a user instruction via the playback operation input unit 111. The three abnormal video files start to be played back synchronously from the position of the seek bar operated by the user.

[0021] The procedure for the monitoring operation is shown in Figure 4. When the main switch of the injection molding machine 4 is turned on and the operation of the injection molding machine 4 starts (step S11 "Yes"), the cameras 21, 22, 23 are activated (S12) and the sensors 31, 32, 33 are also activated (S13). Of course, the cameras 21, 22, 23 and the sensors 31, 32, 33 may be activated by turning on the main switch of the monitoring device 1, without being limited to the synchronous activation.

[0022] Video signals from cameras 21, 22, and 23 are input via camera signal input unit 102, and as shown in Fig. 5, a video file generation unit 103 repeatedly generates from the video signals a video file MI(CA) corresponding to camera 21, a video file MI(CB) corresponding to camera 22, and a video file MI(CC) corresponding to camera 23, each having a predetermined period (length of time), for example, five minutes, every five minutes (S14). In the video files MI(CA), MI(CB), and MI(CC), a camera identification code identifying cameras 21, 22, and 23 and the file generation date and time are set as attribute data.

[0023] The video files MI(CA), MI(CB), and MI(CC) are stored in the video file storage unit 104 (S15), and are also transmitted to and stored in the cloud storage device 2 (S15).

[0024] Next, in step S17, it is determined whether the main switch has been turned off. If the determination is "No," that is, if the injection molding operation is continuing, the abnormality occurrence detection unit 107 individually determines whether abnormal vibration has occurred (S18), whether abnormal temperature has occurred (S19), and whether abnormal sound has occurred (S20).

[0025] When the occurrence of any of abnormal vibration, abnormal temperature, and abnormal sound is detected, as shown in Fig. 5, the abnormal video file generating unit 108 generates an abnormal video file pMI(CA) corresponding to the first camera 21 from the multiple video files MI(CA) of the cameras 21, covering a predetermined period before and after the time when the abnormal vibration, abnormal temperature, or abnormal sound occurred. Typically, an abnormal video file pMI(CA) covering a predetermined period (length of time) FLA centered on the time when the abnormal vibration, abnormal temperature, or abnormal sound occurred is generated (S21). For example, when the occurrence of abnormal temperature is detected at time t13, an abnormal video file pMI(CA)t13 covering the period FLA centered on time t13 is generated.

[0026] The period FLA corresponding to the abnormal video file pMI(CA) can be set by the administrator to any length of time, for example, 8 minutes, regardless of the period FLC of the video file pMI(CA), and can also be changed at any timing.

[0027] Similarly, an abnormal video file pMI(CB)t13 corresponding to the second camera 22 is generated from the multiple video files MI(CB) of the second camera 22, spanning a predetermined period FLA before and after the time t13 when abnormal vibration, abnormal temperature, or abnormal sound occurs. Also, an abnormal video file pMI(CC)t13 corresponding to the third camera 23 is generated from the multiple video files MI(CC) of the third camera 23, spanning a predetermined period FLA before and after the time t13 when abnormal vibration, abnormal temperature, or abnormal sound occurs.

[0028] The abnormal video files pMI(CA), pMI(CB), and pMI(CC) are set with attributes related to the camera identification code that identifies the cameras 21, 22, and 23, the date and time when the abnormality (abnormal vibration, abnormal temperature, or abnormal sound) occurred, and the abnormality code that identifies the type of abnormality.

[0029] The abnormal video file generating unit 108 generates abnormal video files pMI(CA), pMI(CB), and pMI(CC) separately for the occurrence of abnormal vibration, abnormal temperature, and abnormal sound. Therefore, as illustrated in Fig. 5, when the occurrence of abnormal vibration is detected at time t37, abnormal video files pMI(CA)t37, pMI(CB)t37, and pMI(CC)t37 for a period FLA centered around time t37 are generated, and when the occurrence of abnormal sound is detected at time t38, abnormal video files pMI(CA)t38, pMI(CB)t38, and pMI(CC)t38 for a period FLA centered around time t38 are generated, and these periods may overlap with each other.

[0030] The abnormal video files pMI(CA), pMI(CB), and pMI(CC) that were generated in response to the detection of the same abnormality over the same period are stored in the video file storage unit 104 (S22), and are also transmitted to and stored in the cloud storage device 2 (S23). Then, the process returns to step S14, and the next video files MI(CA), MI(CB), and MI(CC) are generated.

[0031] If no abnormal vibration, temperature or sound is detected ("No" in S20, S21 and S22), the process returns to step S14.

[0032] Steps S14-S23 are repeated until it is determined in step S17 that the main switch has been turned off ("Yes"), that is, while the injection molding operation continues.

[0033] When it is determined in step S17 that the main switch has been turned off ("Yes"), the cameras 21, 22, 23 and sensors 31, 32, 33 are stopped, and the generation and storage process of the moving image files MI(CA), MI(CB), MI(CC) is terminated. Of course, the generation and storage process of the abnormal moving image files pMI(CA), pMI(CB), pMI(CC) is also terminated.

[0034] When an abnormality is detected in this way, it triggers the generation of multiple corresponding abnormal video files for all of the multiple cameras, with the same start time, end time and duration, thereby reducing the operational burden involved in playing back the videos to identify the cause of the abnormality after the fact.

[0035] 6 shows a screen displaying a list of the dates and times when an abnormality was detected and the type of abnormality. Although not shown, when an administrator inputs a command to play an abnormal video via the playback operation input unit 111, the playback control unit 110 generates a list of the dates and times when the abnormality occurred and the type of abnormality, and displays this on the display unit 112. The playback control unit 110 accesses the abnormal video file storage unit 109 and receives attribute data of the abnormal video file triggered by, for example, the most recent predetermined number of abnormalities. From the attribute data, a list of the dates and times when the abnormality was detected and the type of abnormality is created according to the date and time when the abnormality (abnormal vibration, abnormal temperature, or abnormal sound) was detected and the abnormality code that identifies the type of abnormality.

[0036] The list is displayed on display unit 112, and the administrator selects any abnormality detection date and time and type of abnormality via playback operation input unit 111. This selection triggers playback control unit 110 to read three abnormality video files pMI(CA), pMI(CB), and pMI(CC) corresponding to the selected abnormality detection date and time and type of abnormality from abnormality video file storage unit 109, identify the video start date and time and end date and time from the attribute data of these abnormality video files, and read multiple sensor signals related to vibration, temperature, and operating sound detected by sensors 31, 32, and 33 during the relevant period from sensor signal storage unit 106. From the read sensor signals, playback control unit 110 creates graphs showing the temporal fluctuations of each.

[0037] As shown in FIG. 7, the playback control unit 110 synchronizes the three abnormal video files pMI(CA), pMI(CB), and pMI(CC), i.e., plays them with the same time axis, and simultaneously displays them in three areas CS1, CS2, and CS3, which are partitions of the screen of the display unit 120. The playback control unit 110 also displays graphs representing temporal fluctuations of one to three sensor signals over the same period as the abnormal video in area SS on the same screen as the three abnormal video files pMI(CA), pMI(CB), and pMI(CC). While FIG. 7 shows a temperature graph GT and a vibration graph GS, this is merely an example; one to three graphs arbitrarily designated by the administrator may be displayed. A playback command set for play, pause, stop, and fast forward is displayed on the screen.

[0038] A seek bar that displays the playback positions of the three abnormal video files is superimposed on the graph. The seek bar can be moved to any position on the time axis via the playback operation input unit 111. The playback control unit 110 synchronously plays back the three abnormal video files pMI(CA), pMI(CB), and pMI(CC) from the position of the moved seek bar.

[0039] A magnifying glass-shaped icon corresponding to the enlarge command is placed in each of the three areas CS1, CS2, and CS3 that display the abnormal video. By specifying an arbitrary icon, the playback control unit 110 enlarges the abnormal video displayed in one of the areas CS1, CS2, and CS3 where the specified icon is placed to display it across the entire screen, as shown in Fig. 8. By specifying the back button, the playback control unit 110 performs display control to return to the display shown in Fig. 7.

[0040] As described above, according to this embodiment, multiple video files corresponding to all of the cameras capturing images of the injection molding machine from multiple directions are stored in both the internal storage device and the external cloud storage device, thereby improving the reliability of video storage and enabling the operation of the injection molding machine to be confirmed with fewer blind spots.

[0041] Furthermore, when an abnormality is detected, multiple video files of the abnormality are recorded from multiple cameras capturing images of the injection molding machine from multiple directions, with the same start and end times and durations. Vibration, temperature, and operating sounds are also recorded. These multiple video files related to the same abnormality can be simultaneously played back by specifying them all at once, thereby reducing the operational burden of playing back the videos to identify the cause of the abnormality after the fact.

[0042] In addition, the movement of the injection molding machine can be viewed from multiple directions in a synchronized manner, making it easy to identify the cause of any abnormalities with high accuracy. Furthermore, graphs of vibration, temperature, and operating noise are displayed on the same screen as the video, along with a seek bar, so the vibration, temperature, and operating noise conditions at the time of video playback can also be checked at the same time.

[0043] As described above, according to this embodiment, it is possible to reduce the labor required to identify the cause of an abnormality occurring in a machine tool such as an injection molding machine, and also to improve the accuracy of the identification.

[0044] The present invention is not limited to the above-described embodiments, and various modifications can be made in the implementation stage without departing from the spirit of the invention. Furthermore, the embodiments may be implemented in appropriate combinations, in which case the combined effects can be obtained. Furthermore, the above-described embodiments include various inventions, and various inventions can be extracted by combining the disclosed multiple constituent elements. For example, if the problem can be solved and the desired effect can be obtained even if some constituent elements are deleted from all the constituent elements shown in the embodiments, the configuration from which these constituent elements are deleted can be extracted as an invention. [Explanation of symbols]

[0045] 1...monitoring device, 10...information processing device, 21...first camera, 22...second camera, 23...third camera, 31...vibration sensor, 32...temperature sensor, 33...microphone, 101...control unit, 102...camera signal input unit, 103...video file generation unit, 104...video file storage unit, 105...sensor signal input unit, 106...sensor signal storage unit, 107...abnormality occurrence detection unit, 108...abnormal video file generation unit, 109...abnormal video file storage unit, 110...playback control unit, 111...playback operation input unit, 120...display unit.

Claims

1. A monitoring device for monitoring operation of a machine tool, a plurality of cameras for photographing the machine tool from a plurality of directions; a plurality of sensors for detecting the operation of the machine tool; a moving image file storage unit that repeatedly stores a plurality of images captured by the plurality of cameras as a plurality of moving image files; a sensor signal storage unit that constantly stores a plurality of sensor signals detected by the plurality of sensors; an abnormality detection unit that detects the occurrence of an abnormality in the machine tool based on the plurality of sensor signals; an abnormality video file storage unit that, when the occurrence of the abnormality is detected, selects from the plurality of video files a plurality of abnormality video files corresponding to all of the plurality of cameras over a period before and after the time when the occurrence of the abnormality is detected, and stores the selected abnormality video files by setting attributes related to a camera identification code that identifies the camera, a date and time when the occurrence of the abnormality is detected, and an abnormality code that identifies the type of the abnormality; a list display unit that displays a list of the date and time when the occurrence of the abnormality was detected and the type of the abnormality on a display; a playback unit that synchronously plays back, on one screen of the display, the plurality of abnormal video files corresponding to the date and time when the occurrence of the abnormality was detected and the abnormality code selected from the list in accordance with user instructions.

2. The monitoring device according to claim 1 , wherein the playback unit displays, on the display, a graph representing the temporal fluctuation of the sensor signal for the same period as the period of the abnormal video file, together with the plurality of abnormal video files.

3. a seek bar indicating a playback position of the plurality of abnormal video files is superimposed on the graph showing the temporal variation of the sensor signal; The monitoring device according to claim 2 , wherein the playback unit starts playing back the plurality of abnormal video files in synchronization with each other from the position of the seek bar operated by the user.

4. The monitoring device according to claim 1 , further comprising a transmission unit that transmits the video file and the abnormal video file to a cloud storage device via an Internet line.

5. The plurality of sensors include: a vibration sensor that converts mechanical vibrations of the machine tool into an electrical vibration signal; a temperature sensor that converts the temperature of the machine tool into an electrical temperature signal; 2. The monitoring device according to claim 1, further comprising a microphone for converting the operating sound of the machine tool into an electrical sound signal.

6. 6. The monitoring device according to claim 5, wherein the abnormality video file storage section generates the abnormality video file separately for occurrence of an abnormality related to the vibration, the temperature, and the operating sound.

7. A computer as a monitoring device that monitors the operation of machine tools, a means for repeatedly storing a plurality of images of the machine tool taken by a plurality of cameras from a plurality of directions as a plurality of video files in a storage unit; a means for storing a plurality of sensor signals detected by a plurality of sensors for detecting the operation of the machine tool in the storage unit; means for detecting the occurrence of an abnormality in the machine tool based on the plurality of sensor signals; a means for storing, when the occurrence of the abnormality is detected, a plurality of abnormal video files corresponding to the plurality of cameras, respectively, from the plurality of video files, with attributes set regarding a camera identification code for identifying the camera, a date and time when the occurrence of the abnormality was detected, and an abnormality code for identifying the type of the abnormality, in the storage unit; a means for displaying on a display a list of the date and time when the occurrence of the abnormality was detected and the type of the abnormality; A program for functioning as a means for synchronously playing back on one screen of the display the plurality of abnormal video files corresponding to the date and time when the occurrence of the abnormality was detected and the abnormality code selected from the list in accordance with user instructions.

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