Signal processing device

Abstract

A signal processing device (16) processes a signal that is used in a machine (12) which is capable of repeatedly executing a cycle including at least one prescribed operation process. The signal processing device (16) comprises: a counter unit (34); a count condition setting unit (40) that sets a count condition; a reset condition setting unit (42) that sets a reset condition; a signal output unit (36) that outputs a trigger signal to a prescribed output destination when the counted number reaches or exceeds a prescribed count threshold value; and an output setting unit (38) that sets a count threshold value and an output destination.

Description

signal processing device

[0001] The present invention relates to a signal processing device.

[0002] A machine can repeatedly execute a cycle including one or more predetermined operating steps. In various types of machines, peripheral devices disposed around the machine may be operated in accordance with the operating state of the machine. For example, Japanese Patent Laid-Open Publication No. 5-181514 discloses a technique for selecting a device to be operated in a certain operating step and setting a value obtained by adding a numerical value of 2 to the nth power corresponding to the selected device, thereby operating the operating device.

[0003] In Japanese Patent Laid-Open Publication No. 5-181514, although it is possible to select the equipment to be operated in each work process, it is not possible to obtain signals, etc., at the desired timing. Generally, depending on the system including the machine and its peripheral equipment, or in response to the request of the operator using the system, the program may be changed to obtain signals, etc., at the desired timing. In such cases, a relatively long time is required. Therefore, a problem has been raised regarding how to easily customize the signals to be output to peripheral equipment, etc., without changing the program.

[0004] The present invention aims to solve the above-mentioned problems.

[0005] One aspect of the present invention is a signal processing device that processes signals used in a machine that can repeatedly execute cycles including one or more predetermined operating steps, and includes a counter unit that counts the cycles, a count condition setting unit that sets the count condition selected from a plurality of count conditions defined as conditions for the counter unit to count up, a reset condition setting unit that sets the reset condition selected from a plurality of reset conditions defined as conditions for resetting the count number counted by the counter unit, a signal output unit that outputs a trigger signal to a predetermined output destination when the count number becomes equal to or greater than a predetermined count threshold, and an output setting unit that sets the count threshold and the output destination.

[0006] According to this aspect of the present invention, the count number of the counter unit can be changed according to the count condition and the reset condition. Furthermore, the output timing of the trigger signal can be changed according to the count threshold. Furthermore, the output destination of the trigger signal can be changed. As a result, the signal to be output to a peripheral device or the like can be easily customized.

[0007] FIG. 1 is a block diagram showing a signal processing system according to an embodiment. FIG. 2 is a block diagram showing the configuration of a processor. FIG. 3 is a diagram showing an example of a setting screen for setting count conditions and reset conditions. FIG. 4 is a diagram showing an example of a selection screen for selecting a selection signal. FIG. 5 is a diagram showing an example of another selection screen for selecting a selection signal. FIG. 6 is a diagram showing an example of a setting screen for setting an output destination of a trigger signal. FIG. 7 is a diagram showing an example of another setting screen for setting an output destination of a trigger signal. FIG. 8 is a diagram showing an example of a cycle diagnosis screen. FIG. 9 is a flowchart showing the flow of signal processing by the processor.

[0008] 1 is a block diagram showing a signal processing system 10 according to an embodiment. The signal processing system 10 includes a machine 12, a peripheral device 14, and a signal processing device 16. The peripheral device 14 is a device provided in the periphery of the machine 12.

[0009] The machine 12 is a device that can repeatedly execute a cycle including one or more predetermined operating steps. The following description will be given taking the case where the machine 12 is an injection molding machine as an example. The injection molding machine repeatedly executes molding cycles. A molding cycle is the unit of time from the start to the end of one injection molding process. In a molding cycle, the operating steps of mold clamping, injection, pressure holding, metering, mold opening, and molded product removal are executed.

[0010] Mold clamping is an operational process of closing a mold and applying a predetermined clamping force to the closed mold. The mold clamping operational process is performed by the mold clamping device of the injection molding machine. Injection is an operational process of injecting molding material into the mold. Pressure holding is an operational process of applying pressure (holding pressure) to the molding material injected into the mold. Metering is an operational process of metering the molding material in preparation for the next molding cycle. The operational processes of injection, pressure holding, and metering are performed by the injection device of the injection molding machine. Mold opening is an operational process of opening the mold. The mold opening operational process is performed by the mold clamping device of the injection molding machine. Molded product removal is an operational process of removing the molded product from the mold. The molded product removal operational process is performed by the ejector device of the injection molding machine.

[0011] The peripheral devices 14 are devices provided around the machine 12. The peripheral devices 14 include an alarm device 14_1, an indicator light 14_2, and an ejection device 14_3. The alarm device 14_1 is a device that issues an alarm when an abnormality or the like occurs in the machine 12. The indicator light 14_2 is a device that displays the status of the machine 12. The ejection device 14_3 is a device that ejects molded products formed by the injection molding machine to the outside of a housing that covers the injection molding machine. The peripheral devices 14 may also include an opening / closing device that opens and closes a door provided in a housing that covers the injection molding machine.

[0012] The signal processing device 16 is a computer that controls the machine 12 and the peripheral devices 14. The signal processing device 16 may be a numerical control device. The signal processing device 16 includes an input terminal 20 and an output terminal 22. The machine 12 is connected to the input terminal 20. One or more peripheral devices 14 are connected to the output terminal 22. In this embodiment, the machine 12 connected to the input terminal 20 includes a clamping device, an injection device, an ejector device, and a sensor of an injection molding machine.

[0013] The signal processing device 16 includes a processor 24, a storage unit 26, an operation unit 28, and a display unit 30. The processor 24 may be configured with one or more CPUs. The processor 24 may also include an MPU, a GPU, etc. as components. The storage unit 26 may be configured with volatile memory and non-volatile memory. Examples of volatile memory include RAM, etc. Examples of non-volatile memory include ROM, flash memory, etc. The operation unit 28 is a device that accepts operator instructions, etc., for the processor 24. The operation unit 28 includes an operation panel, a touch panel, etc. The touch panel is provided on the display screen of the display unit 30. The display unit 30 is a device that displays information. For example, a liquid crystal display device, etc., may be used as the display unit 30.

[0014] 2 is a block diagram showing the configuration of the processor 24. The processor 24 includes a machine controller 32, a counter unit 34, a signal output unit 36, an output setting unit 38, a count condition setting unit 40, a reset condition setting unit 42, a name setting unit 44, and a display control unit 46. The machine controller 32, the counter unit 34, the signal output unit 36, the output setting unit 38, the count condition setting unit 40, the reset condition setting unit 42, the name setting unit 44, and the display control unit 46 are realized by the processor 24 executing a signal processing program. At least a portion of the machine controller 32, the counter unit 34, the signal output unit 36, the output setting unit 38, the count condition setting unit 40, the reset condition setting unit 42, the name setting unit 44, and the display control unit 46 may be realized by an integrated circuit such as an ASIC or FPGA. At least a portion of the machine controller 32, counter unit 34, signal output unit 36, output setting unit 38, count condition setting unit 40, reset condition setting unit 42, name setting unit 44, and display control unit 46 may be configured by an electronic circuit. The electronic circuit may include discrete devices.

[0015] The machine controller 32 controls the machine 12. In this embodiment, the machine controller 32 causes the injection molding machine to repeatedly execute a molding cycle based on the molding program stored in the storage unit 26. In this case, the machine controller 32 appropriately controls the mold clamping device, injection device, and ejector device included in the injection molding machine.

[0016] A cycle signal indicating the cycle of the machine 12 is input to the counter unit 34. The counter unit 34 counts the cycles of the machine 12 based on the cycle signal. In this embodiment, the counter unit 34 counts the molding cycles of the injection molding machine.

[0017] The counter unit 34 counts cycles until the reset condition set in the reset condition setting unit 42 is met. When the reset condition is met, the counter unit 34 resets the number of counts made up until the reset condition was met and then starts counting cycles again. The counter unit 34 counts cycles in accordance with the count condition set in the count condition setting unit 40. The count condition is a selection signal selected from a predefined group of signals.

[0018] At least one of the signal groups includes a status signal indicating the status of the injection molding machine. An example of this status signal is a process signal indicating at least one of the start and end of each operation process included in the molding cycle. Another example is a constantly ON signal indicating that the power to the machine 12 is on. Another example is an operation status signal indicating whether the machine is in automatic operation or manual operation. Another example is a pass / fail signal indicating that the molded product is a pass / fail product. Another example is a defective signal indicating that the molded product is a defective product. Another example is a sample signal indicating that the molded product is a sample.

[0019] At least one of the signal groups includes a status signal indicating a condition occurring independently of the molding cycle, such as an emergency stop signal indicating an emergency stop of the injection molding machine, or an alarm signal indicating an abnormality in the injection molding machine.

[0020] At least one of the signal groups includes a result of an operation performed by an operation circuit. The operation circuit is provided in the signal processing device 16. The operation circuit may be provided in the processor 24. The operation circuit operates on one or more state signals. In this case, the operation circuit operates on at least one of a logical inversion of a signal, a rising edge of a signal, a falling edge of a signal, a delay time of a signal, an output time of a signal, a logical sum of a plurality of signals, and a logical product of a plurality of signals.

[0021] The signal group is generated based on the detection results of sensors provided in the injection molding machine while the injection molding machine is in operation, and is stored in the memory unit 26. The cycle signal is generated based on sequence processing built into the injection molding machine. The counter unit 34 performs a logical operation on the selection signal stored in the memory unit 26 and the cycle signal, and counts the cycles.

[0022] The signal output unit 36 ​​compares the count number of the counter unit 34 with a predetermined count threshold value. When the count number of the counter unit 34 becomes equal to or greater than the count threshold value, the signal output unit 36 ​​outputs a trigger signal to a predetermined output destination.

[0023] The output setting unit 38 sets a count threshold value that is compared with the count number of the counter unit 34, and an output destination of the trigger signal that is output from the signal output unit 36. The count threshold value and the output destination can be specified by an operator.

[0024] The count condition setting unit 40 sets a count condition selected from a plurality of count conditions defined as conditions for counting up by the counter unit 34. The count condition can be selected by the operator.

[0025] The reset condition setting unit 42 sets a reset condition selected from a plurality of reset conditions defined as conditions for resetting the count number counted by the counter unit 34. The reset condition can be selected by the operator.

[0026] The name setting unit 44 sets a name for the selected combination of count and reset conditions. The name can be arbitrarily input by the operator.

[0027] The display control unit 46 displays various screens on the display unit 30 in response to operations on the operation unit 28 by the operator.

[0028] 3 is a diagram showing an example of a setting screen SC1 for setting the counting conditions and the resetting conditions. When the display control unit 46 receives an instruction to set the counting conditions and the resetting conditions from the operation unit 28, the display control unit 46 displays the setting screen SC1.

[0029] The setting screen SC1 has a count condition item IT1, a reset condition item IT2, a signal name item IT3, a current value item IT4, a set value item IT5, and an on / off icon IT6.

[0030] The count condition item IT1 displays the signal name of the signal (first selected signal) selected by the operator as the count condition.

[0031] The reset condition item IT2 displays the signal name of the signal (second selected signal) selected by the operator as the reset condition.

[0032] The signal name item IT3 displays the name (subject name) of the combination of the selection signal (first selection signal) selected as the count condition and the selection signal (second selection signal) selected as the reset condition. This name is entered arbitrarily by the operator.

[0033] The current count number counted by the counter unit 34 is displayed in the current value item IT4.

[0034] The setting value item IT5 displays a count threshold. This count threshold is input by the operator. If the operator does not input a count value, a default value prepared in advance is input as the count threshold.

[0035] The on / off icon IT6 indicates whether or not a trigger signal is being output. In Fig. 3, a state in which a trigger signal is being output is indicated by a "■", and a state in which a trigger signal is not being output is indicated by a "□". The on / off icon IT6 may be replaced with a check box, a radio button, or the like.

[0036] When there are multiple counter units 34, a setting field corresponding to each of the multiple counter units 34 is provided. FIG. 3 shows an example in which setting fields "Cnt01," "Cnt02," "Cnt03," and "Cnt04" corresponding to four counter units 34 are provided. Each setting field is provided with the above-mentioned count condition item IT1, reset condition item IT2, signal name item IT3, current value item IT4, set value item IT5, and on / off icon IT6. In other words, count-related settings can be made for each counter unit 34.

[0037] The signal name "defective product signal" is displayed in the count condition item IT1 of "Cnt01." The defective product signal is a signal that indicates that the molded product is a defective product. In this case, the count condition setting unit 40 sets the defective product signal as the count condition. With this setting, the defective product signal from the group of signals stored in the memory unit 26 is input from the memory unit 26 to the counter unit 34 as the count condition. The signal name "good product signal" is displayed in the reset condition item IT2 of "Cnt01." The good product signal is a signal that indicates that the molded product is a good product. In this case, the reset condition setting unit 42 sets the good product signal as the reset condition. With this setting, the good product signal from the group of signals stored in the memory unit 26 is input from the memory unit 26 to the counter unit 34 as the reset condition.

[0038] In the case of "Cnt01," the counter unit 34 calculates the logical AND of the defective product signal and the cycle signal, and resets the calculation result when a non-defective product signal is obtained. In other words, the counter unit 34 counts the number of consecutively molded defective products until a non-defective product is molded. To intuitively grasp the counting content, the operator can arbitrarily input an easy-to-understand name (subject name) into the signal name item IT3. In the example of "Cnt01" in FIG. 3, the name "Number of consecutive defective products" is input into the signal name item IT3. When a name is input into the signal name item IT3, the name setting unit 44 associates the name "Number of consecutive defective products" with the defective product signal and the non-defective product signal and stores the name in the memory unit 26.

[0039] Furthermore, in the case of "Cnt01," a value of "2035" is input to the setting value item IT5. In this case, the output setting unit 38 stores the value of "2035" in the memory unit 26 as a count threshold to be compared with the count number of the counter unit 34. When the count number of the counter unit 34 (the number of defective products molded consecutively) reaches 2035, the signal output unit 36 ​​outputs a trigger signal to the output destination. In this case, the display control unit 46 switches the on / off icon IT6 from "□" to "■."

[0040] The count condition item IT1 of "Cnt02" displays the signal name "Power On." Power On means a constantly ON signal. The constantly ON signal is a signal indicating that the machine 12 is powered on. In this case, the count condition setting unit 40 sets the constantly ON signal as the count condition. With this setting, the constantly ON signal from the group of signals stored in the memory unit 26 is input from the memory unit 26 to the counter unit 34 as the count condition. The reset condition item IT2 of "Cnt02" displays the signal name "Auxiliary Button." Auxiliary Button means an auxiliary button ON signal. The auxiliary button ON signal is a signal indicating that the auxiliary button included in the operation unit 28 is pressed. In this case, the reset condition setting unit 42 sets the auxiliary button ON signal as the reset condition. With this setting, the auxiliary button ON signal from the group of signals stored in the memory unit 26 is input from the memory unit 26 to the counter unit 34 as the reset condition.

[0041] In the case of "Cnt02," the counter unit 34 calculates the logical product of the always-on signal and the cycle signal, and resets the calculation result when the auxiliary button ON signal is obtained. In other words, the counter unit 34 counts the number of cycles since power-on until the auxiliary button is pressed. To intuitively grasp the count content, the operator can arbitrarily enter an easy-to-understand name (subject name) in the signal name item IT3. In the example of "Cnt02" in FIG. 3, the name "release agent" is entered in the signal name item IT3. When a name is entered in the signal name item IT3, the name setting unit 44 associates the name "release agent" with the always-on signal and the auxiliary button ON signal and stores the name in the memory unit 26.

[0042] Furthermore, in the case of "Cnt02," a value of "100" is input to the setting value item IT5. In this case, the output setting unit 38 stores the value of "100" in the memory unit 26 as a count threshold to be compared with the count number of the counter unit 34. When the count number of the counter unit 34 (the number of cycles since power-on) reaches 100, the signal output unit 36 ​​outputs a trigger signal to the output destination. In this case, the display control unit 46 switches the on / off icon IT6 from "□" to "▪."

[0043] The count condition item IT1 of "Cnt03" displays the signal name "Weighing ON." Weighing ON refers to a weighing ON signal. The weighing ON signal is a signal indicating that the weighing operation step in the molding cycle has been performed. In this case, the count condition setting unit 40 sets the weighing ON signal as the count condition. With this setting, the weighing ON signal, which is one of the signals stored in the memory unit 26, is input from the memory unit 26 to the counter unit 34 as the count condition. The reset condition item IT2 of "Cnt03" displays "Unused." In this case, the reset condition setting unit 42 does not set a reset condition. However, when the reset button BT is pressed, the count number of the counter unit 34 is reset. The reset button BT is used by the operator to reset the count number of the counter unit 34 at any timing, regardless of the number of cycles counted. The reset button BT is provided in each setting field. Since the reset condition item IT2 in the setting field of "Cnt03" is "unused", the count number of "Cnt03" can be reset only by pressing the reset button BT.

[0044] In the case of "Cnt03," the counter unit 34 calculates the logical product of the metering ON signal and the cycle signal. When the operator presses the reset button BT, the counter unit 34 resets the calculation result. The counter unit 34 counts the number of molding cycles in which the metering operation process has been executed. To intuitively grasp the count content, the operator can arbitrarily input an easy-to-understand name (subject name) into the signal name item IT3. In the example of "Cnt03" in Figure 3, the name "screw inspection" is input into the signal name item IT3. When a name is input into the signal name item IT3, the name setting unit 44 stores the name "screw inspection" in the memory unit 26 in association with the metering ON signal and unused.

[0045] Furthermore, in the case of "Cnt03," a value of "10000" is input into the setting value item IT5. In this case, the output setting unit 38 stores the value of "10000" in the memory unit 26 as a count threshold to be compared with the count number of the counter unit 34. When the count number of the counter unit 34 (the number of molding cycles in which the metering operation process has been executed) reaches 10000, the signal output unit 36 ​​outputs a trigger signal to the output destination. In this case, the on / off icon IT6 is switched from "□" to "■" by the display control unit 46.

[0046] The count condition item IT1 of "Cnt04" displays the signal name "In automatic operation." "In automatic operation" refers to an automatic operation signal. The automatic operation signal is a signal indicating that the operation mode of the machine 12 is automatic. In this case, the count condition setting unit 40 sets the automatic operation signal as the count condition. With this setting, the automatic operation signal, which is one of the signals stored in the memory unit 26, is input from the memory unit 26 to the counter unit 34 as the count condition. The reset condition item IT2 of "Cnt04" displays "Mold opening completed." "Mold opening completed" refers to a mold opening completion signal. The mold opening completion signal is a signal indicating that the mold opening operation process of the mold by the clamping device of the injection molding machine has been completed. In this case, the reset condition setting unit 42 sets the mold opening completion signal as the reset condition. With this setting, the mold opening completion signal, which is one of the signals stored in the memory unit 26, is input from the memory unit 26 to the counter unit 34 as the reset condition.

[0047] In the case of "Cnt04," the counter unit 34 calculates the logical product of the automatic operation signal and the cycle signal. The counter unit 34 counts the number of molding cycles during automatic operation. Furthermore, in the case of "Cnt04," a value of "2" is input into the setting value item IT5. In this case, the output setting unit 38 stores the value of "2" in the memory unit 26 as a count threshold to be compared with the count number of the counter unit 34. When the count number of the counter unit 34 (the number of molding cycles during automatic operation) reaches 2, the signal output unit 36 ​​outputs a trigger signal to the output destination. In other words, in "Cnt04," the trigger signal is output to the output destination from the start of mold opening to the completion of mold opening. In this case, the display control unit 46 switches the on / off icon IT6 from "□" to "■."

[0048] To intuitively grasp the count content, the operator can arbitrarily enter an easy-to-understand name (subject name) in the signal name item IT3. In the example of "Cnt04" in Fig. 3, the name "Air Cylinder Start" is entered in the signal name item IT3. When a name is entered in the signal name item IT3, the name setting unit 44 associates the name "Air Cylinder Start" with the automatic operation signal and the mold open completion signal and stores the name in the storage unit 26.

[0049] Next, a case where an arbitrary signal is selected as a selection signal from among a plurality of signal groups will be described. In this embodiment, the signal group used to select the selection signal (first selection signal) as the count condition and the signal group used to select the selection signal (second selection signal) as the reset condition are the same. FIG. 4 is a diagram showing an example of a selection screen SC2 for selecting a selection signal. When the count condition item IT1 (FIG. 3) or the reset condition item IT2 (FIG. 3) is selected, the display control unit 46 displays the selection screen SC2.

[0050] The selection screen SC2 displays signal names corresponding to a plurality of predefined signal groups in a tree view format. The selection screen SC2 has a hierarchical display section 60 and a signal name display section 62.

[0051] A plurality of folders and folder names are displayed in the hierarchical display section 60. One or more subfolders and folder names belonging to a selected folder among the plurality of folders are displayed in a branched state from the selected folder. A signal name display section 62 displays the signal names of one or more signals belonging to the lowest folder.

[0052] When a signal name to be displayed in the signal name display section 62 is selected, the display control section 46 displays the selected signal name in the count condition item IT1 (FIG. 3) or the reset condition item IT2 (FIG. 3).

[0053] The display control unit 46 may display the signal names corresponding to a plurality of predefined signal groups in a format other than the tree view format. Fig. 5 is a diagram showing an example of another selection screen SC3 for selecting a selection signal.

[0054] The selection screen SC3 displays signal names corresponding to a plurality of predefined signal groups in a button view format. The selection screen SC3 has a button display section 64 and a signal name display section 66.

[0055] The button display section 64 displays a plurality of category buttons and category names. The signal name display section 66 displays the signal names of one or more signals belonging to a selected category button. FIG. 5 shows an example in which 12 category buttons are provided. FIG. 5 also shows an example in which the category button "1. During cycle, during operation" is selected, and the signal name corresponding to the selected category button is displayed in the signal name display section 66.

[0056] For example, when the selection is changed from the category button "1. During cycle, during operation" to the category button "12. Other," the signal name display unit 66 switches from displaying the signal name belonging to the category button "1. During cycle, during operation" to displaying the signal name belonging to the category button "12. Other."

[0057] Next, setting of the output destination of the trigger signal will be described. Fig. 6 shows an example of a setting screen SC4 for setting the output destination of the trigger signal.

[0058] When the display control unit 46 receives an instruction from the operation unit 28 to set the peripheral device 14, which is an external device connected to the output terminal 22, as the output destination of the trigger signal, the display control unit 46 displays the setting screen SC4.

[0059] The setting screen SC4 has a plurality of symbols IT10, a plurality of output condition items IT11, and a plurality of valid / invalid items IT12. Each symbol IT10 is associated with an output condition item IT11 and a valid / invalid item IT12. Each symbol IT10 indicates an output terminal 22 provided in the signal processing device 16. For example, in FIG. 6, "Y20.0" indicates the output terminal 22 to which the extraction device 14_3 is connected.

[0060] The output condition item IT11 displays the name (subject name) set for the combination of count and reset conditions, selectable, for example, in a pull-down menu. This name is input by the operator using the setting screen SC1 (FIG. 3) and set by the name setting unit 44 (FIG. 2).

[0061] The valid / invalid item IT12 displays "ON" or "Off", for example, in a pull-down format. When "ON" is displayed in the valid / invalid item IT12, it means that the output of the trigger signal to the output destination is valid. On the other hand, when "Off" is displayed in the valid / invalid item IT12, it means that the output of the trigger signal to the output destination is invalid.

[0062] In FIG. 6, "Cnt02: Release Agent" is displayed in the output condition item IT11 corresponding to "Y20.0." In this case, the output setting unit 38 stores, in the memory unit 26, for example, the take-out device 14_3 connected to the output terminal 22 of "Y20.0" as the output destination. Also in FIG. 6, "ON" is displayed in the enable / disable item IT12 corresponding to "Y20.0." In this case, when the count number of the counter unit 34, which is counted based on the count condition of "Cnt02" on the setting screen SC1 (FIG. 3), reaches the count threshold value (100) set for "Cnt02," the signal output unit 36 ​​outputs a trigger signal to the take-out device 14_3 via the output terminal 22.

[0063] In this embodiment, the output destination of the trigger signal can be set to an output destination device external to the signal processing device 16, as well as an output destination device internal to the signal processing device 16. Fig. 7 is a diagram showing an example of another setting screen SC5 for setting the output destination of the trigger signal.

[0064] When the display control unit 46 receives an instruction from the operation unit 28 to set an alarm device provided inside the signal processing device 16 as the output destination of the trigger signal, the display control unit 46 displays the setting screen SC5.

[0065] The setting screen SC5 is a screen for setting an alarm device provided inside the signal processing device 16 as an output destination of the trigger signal. The setting screen SC5 has an enable / disable item IT20, an output form item IT21, an output time item IT22, a plurality of output condition items IT23, and a counter setting item IT24.

[0066] The enable / disable item IT20 displays "ON" or "Off", for example, in a pull-down format. When "ON" is displayed in the enable / disable item IT20, it means that the output of a trigger signal to the alarm device inside the signal processing device 16 is enabled. On the other hand, when "Off" is displayed in the enable / disable item IT20, it means that the output of a trigger signal to the alarm device inside the signal processing device 16 is disabled.

[0067] The output form item IT21 displays a plurality of predefined output forms, for example in a pull-down format. The output forms include "continuous" for continuously outputting the trigger signal and "intermittent" for intermittently outputting the trigger signal.

[0068] The operator inputs the time from when the count reaches the count threshold value to when the trigger signal is to be output in the output time item IT22. When the output time item IT22 is "0", the output is continuous.

[0069] In each output condition item IT23, the signal name selected from the selection screen SC2 (FIG. 4) or the selection screen SC3 (FIG. 5) is displayed.

[0070] The counter setting item IT24 displays names (subject names) set for combinations of count conditions and reset conditions in a selectable manner, for example, in a pull-down menu. When a name is displayed in the counter setting item IT24, the output setting unit 38 sets an alarm device provided inside the signal processing device 16 as the output destination of the trigger signal.

[0071] 7, "ON" is displayed in the enable / disable item IT20, and "Cnt01: Number of consecutive defective products" is displayed in the counter setting item IT24. In this case, the signal output unit 36 ​​outputs a trigger signal to an alarm device provided inside the signal processing device 16 based on the count condition of "Cnt01" on the setting screen SC1 (FIG. 3). That is, when the count number of the counter unit 34 (the number of consecutively molded defective products) reaches 2035, the signal output unit 36 ​​outputs a trigger signal to activate the alarm device provided inside the signal processing device 16.

[0072] 7, "continuous" is displayed in the output mode item IT21, and "0" seconds is displayed in the output time item IT22. In this case, the signal output unit 36 ​​does not limit the output time of the trigger signal from the point in time when the count number of the counter unit 34 reaches the count threshold, and outputs the trigger signal continuously from that point in time. If a value other than "0" seconds is set, the time for which the signal output unit 36 ​​outputs the trigger signal is the time from the point in time when either the condition in the output condition item IT23 or the counter setting item IT24 is met until the time set in the output time item IT22 has elapsed.

[0073] The above description has been given with reference to an example in which the output destination device in the signal processing device 16 that outputs the trigger signal is an alarm device. However, the output destination device in the signal processing device 16 that outputs the trigger signal is not limited to an alarm device. For example, the output destination device in the signal processing device 16 that outputs the trigger signal may be the machine controller 32 or an indicator light.

[0074] The setting screen for setting the machine controller 32 as the output destination of the trigger signal is equivalent to the setting screen SC5 shown as an example in Fig. 7. That is, the setting screen for the machine controller 32 has an enable / disable item IT20, an output format item IT21, an output time item IT22, multiple output condition items IT23, and a counter setting item IT24. When a name is displayed in the counter setting item IT24, the output setting unit 38 sets the machine controller 32 provided inside the signal processing device 16 as the output destination of the trigger signal. In this case, when the count number of the counter unit 34 reaches the count threshold, the signal output unit 36 ​​outputs a trigger signal to the machine controller 32 to activate a specific sequence.

[0075] The setting screen for setting the indicator light as the output destination of the trigger signal is also equivalent to setting screen SC5 shown as an example in Fig. 7. That is, the setting screen for the indicator light has an enable / disable item IT20, an output form item IT21, an output time item IT22, multiple output condition items IT23, and a counter setting item IT24. When a name is displayed in counter setting item IT24, the output setting unit 38 sets the indicator light provided inside the signal processing device 16 as the output destination of the trigger signal. In this case, when the count number of the counter unit 34 reaches the count threshold, the signal output unit 36 ​​outputs a trigger signal to the indicator light to activate the indicator light.

[0076] 8 is a diagram showing an example of the cycle diagnosis screen SC6. The cycle diagnosis screen SC6 is a screen that shows the time for each of a plurality of operating steps executed in a cycle (molding cycle) of the machine 12. The cycle diagnosis screen SC6 has a bar graph section 68, a time display section 70, and a ratio display section 72.

[0077] The bar graph section 68 displays the time of each operation step in chronological order using bars. The time display section 70 displays the time of each operation step using numbers. The ratio display section 72 displays the ratio of the operation step time to the cycle time. In the display example of FIG. 8 , multiple operation steps are arranged vertically on the display screen. Also, in the display example of FIG. 8 , information regarding the time of the operation step is displayed from the operation step to the right of the display screen in the order of the bar graph section 68, the time display section 70, and the ratio display section 72.

[0078] When the display control unit 46 receives an instruction to display the cycle diagnosis screen SC6 from the operation unit 28, it displays the cycle diagnosis screen SC6 on the display unit 30. In this case, the display control unit 46 displays the output time of the trigger signal on the cycle diagnosis screen SC6. In the display example of Fig. 8, it can be seen that the trigger signal by "Cnt04: Air cylinder activation" is output from the start of mold opening to the completion of mold opening.

[0079] Next, a description will be given of the signal processing method of the signal processing device 16. Fig. 9 is a flowchart showing the flow of signal processing by the processor 24. This signal processing is executed after the count condition, reset condition, count threshold value, and output destination are set.

[0080] In step S1, the counter unit 34 determines whether the count condition is satisfied based on the selection signal selected as the counter condition. If the count condition is satisfied, the signal processing proceeds to step S2. If the count condition is not satisfied, the signal processing proceeds to step S3.

[0081] In step S2, the counter unit 34 increments the count number of cycles based on the cycle signal by 1. Once the count number is incremented, the signal processing proceeds to step S3.

[0082] In step S3, the counter unit 34 determines whether or not a reset condition is satisfied. If the reset condition is satisfied, the signal processing proceeds to step S4. If the reset condition is not satisfied, the signal processing proceeds to step S5.

[0083] In step S4, the counter unit 34 resets the current count number. After the current count number is reset, the signal processing returns to step S1.

[0084] In step S5, the counter unit 34 compares the current count with a count threshold. If the current count is less than the count threshold, the signal processing returns to step S1. On the other hand, if the current count is equal to or greater than the count threshold, the signal processing proceeds to step S6.

[0085] In step S6, the signal output unit 36 ​​outputs a trigger signal to a predetermined output destination. When the output of the trigger signal is completed, the signal processing is completed.

[0086] The invention and its effects that can be understood from the above description will be described below.

[0087] (1) The present invention provides a signal processing device (16) for processing signals used in a machine (12) capable of repeatedly executing cycles including one or more predetermined operating steps, the device comprising: a counter unit (34) for counting the cycles; a count condition setting unit (40) for setting the count condition selected from a plurality of count conditions defined as conditions for the counter unit to count up; a reset condition setting unit (42) for setting the reset condition selected from a plurality of reset conditions defined as conditions for resetting the count number counted by the counter unit; a signal output unit (36) for outputting a trigger signal to a predetermined output destination when the count number becomes equal to or greater than a predetermined count threshold; and an output setting unit (38) for setting the count threshold and the output destination.

[0088] This allows the count number of the counter unit to be changed according to the count and reset conditions. It also allows the output timing of the trigger signal to be changed according to the count threshold. Furthermore, it allows the output destination of the trigger signal to be changed. As a result, it is possible to easily customize the signal to be output to peripheral devices, etc.

[0089] (2) The present invention may be a signal processing device, in which the count condition is a selection signal selected from a predefined group of signals, and the counter unit may perform a logical operation on the selection signal and a cycle signal indicating the cycle. This makes it possible to count a number correlated with the selection signal selected from the group of signals. For example, if the selection signal is a defective product signal indicating that a molded product molded by an injection molding machine is defective, the number of defective products can be counted. Furthermore, the number of cycles can be counted according to the selection signal to be logically operated without changing the program.

[0090] (3) In the signal processing device of the present invention, at least one of the signal groups may include a result of calculating at least one of a logical inversion of a signal, a rising edge of a signal, a falling edge of a signal, a delay time of a signal, an output time of a signal, a logical sum of a plurality of signals, and a logical product of a plurality of signals. This allows the selection signal to include not only signals commonly provided in machines, but also signals derived from signals commonly provided in machines. As a result, the number of cycle count variations can be expanded, making it easier to meet the needs of operators.

[0091] (4) In the signal processing device of the present invention, the group of signals may include at least one of a constantly ON signal indicating that the machine is powered on, a pass signal indicating that the molded product is a pass product, a defective signal indicating that the molded product is a defective product, and a sample signal indicating that the molded product is a sample. This makes it easier to meet the needs of operators.

[0092] (5) The present invention may be a signal processing device, wherein the output destination is an alarm device (14_1) or an indicator light (14_2), and the signal output unit outputs the trigger signal for activating the alarm device or the indicator light. This enables the alarm device or the indicator light to be activated when the count number that satisfies the selected count condition reaches a count threshold.

[0093] (6) The present invention is a signal processing device, wherein the output destination is a machine controller (32) that controls the machine, and the signal output unit may output the trigger signal to the machine to start a predetermined sequence. This allows a specific sequence to be started when the count number that satisfies the selected count condition becomes equal to or greater than a count threshold.

[0094] (7) The present invention may be a signal processing device including a display control unit (46) that displays a setting screen for setting the count condition and the reset condition, and the display control unit may display the count conditions so that one of the count conditions can be selected, and may display the reset conditions so that one of the reset conditions can be selected, thereby allowing an operator to arbitrarily select the count condition and the reset condition.

[0095] (8) In the signal processing device of the present invention, the display control unit may display the plurality of count conditions or the plurality of reset conditions in a tree view format. This allows an operator to understand the system of the plurality of count conditions or the plurality of reset conditions. As a result, the operator can easily find any one of the plurality of count conditions or the plurality of reset conditions.

[0096] (9) In the signal processing device of the present invention, the display control unit may display the time at which the trigger signal was output on a cycle diagnosis screen (SC6) that shows the time for each of the plurality of operation steps executed in the cycle. This allows the operator to understand the relationship between the time for each of the plurality of operation steps and the time at which the trigger signal was output. In addition, the operator can confirm the setting status of the count condition, reset condition, count threshold, and output destination from the time at which the trigger signal was output.

[0097] (10) The present invention may be a signal processing device including a name setting unit (44) that sets a name for a selected combination of the count condition and the reset condition, thereby enabling an operator to easily understand the meaning and role of the number counted by the counter unit.

[0098] (11) In the signal processing device of the present invention, the output setting unit may be capable of individually setting an output destination device provided inside the signal processing device and an output destination device provided outside the signal processing device as the output destination. This allows for a greater variety of operations of a system including a machine and peripheral devices, making it easier to meet the needs of operators.

[0099] The present invention is not limited to the above disclosure, and various configurations can be adopted without departing from the gist of the present invention.

[0100] REFERENCE SIGNS LIST 10: Signal processing system 12: Machine 14: Peripheral equipment 16: Signal processing device 24: Processor 26: Memory section 28: Operation section 30: Display section 32: Machine controller 34: Counter section 36: Signal output section 38: Output setting section 40: Count condition setting section 42: Reset condition setting section 44: Name setting section 46: Display control section

Claims

1. 1. A signal processing device for processing a signal for use in a machine capable of repeatedly executing a cycle including one or more predetermined operation steps, comprising: A counter unit that counts the cycles; a count condition setting unit that sets a count condition selected from a plurality of count conditions defined as conditions for the counter unit to count up; a reset condition setting unit that sets a reset condition selected from a plurality of reset conditions defined as conditions for resetting the number counted by the counter unit; a signal output unit that outputs a trigger signal to a predetermined output destination when the count number becomes equal to or greater than a predetermined count threshold; an output setting unit that sets the count threshold and the output destination; A signal processing device comprising:

2. 2. The signal processing device according to claim 1, the count condition is a selection signal selected from a predefined group of signals; The counter unit executes a logical operation on the selection signal and a cycle signal indicating the cycle.

3. 3. The signal processing device according to claim 2, A signal processing device, wherein at least one of the signal groups includes a result of calculating at least one of a logical inversion of a signal, a rising edge of a signal, a falling edge of a signal, a delay time of a signal, an output time of a signal, a logical OR of a plurality of signals, and a logical AND of a plurality of signals.

4. 4. The signal processing device according to claim 3, A signal processing device, wherein the group of signals includes at least one of an always-on signal indicating that the machine is powered on, a pass signal indicating that the molded product is a pass, a fail signal indicating that the molded product is a fail, and a sample signal indicating that the molded product is a sample.

5. 2. The signal processing device according to claim 1, the output destination is an alarm device or an indicator light, The signal output unit outputs the trigger signal for activating the alarm device or the indicator light.

6. 2. The signal processing device according to claim 1, the output destination is a machine controller that controls the machine, A signal processing device, wherein the signal output unit outputs the trigger signal for starting a predetermined sequence to the machine.

7. 2. The signal processing device according to claim 1, a display control unit that displays a setting screen for setting the count condition and the reset condition, The display control unit displays the plurality of count conditions so that one of the plurality of count conditions can be selected, and displays the plurality of reset conditions so that one of the plurality of reset conditions can be selected.

8. 8. A signal processing device according to claim 7, The signal processing device, wherein the display control unit displays the plurality of count conditions or the plurality of reset conditions in a tree view format.

9. 8. A signal processing device according to claim 7, The display control unit displays the time when the trigger signal was output on a cycle diagnosis screen that indicates the time of each of the plurality of operation steps executed in the cycle.

10. 2. The signal processing device according to claim 1, The signal processing device includes a name setting unit that sets a name for a selected combination of the count condition and the reset condition.

11. A signal processing device according to any one of claims 1 to 10, The signal processing device, wherein the output setting unit is capable of individually setting, as the output destination, an output destination device provided inside the signal processing device and an output destination device provided outside the signal processing device.