Inspection system for molded articles and a method for inspecting molded articles

Abstract

A method for optically inspecting molded articles comprising: causing a row or a column of an array of molded articles to fall, the array having rows and columns; causing an optical device to capture an image of each molded article as each molded article of the row or the column of the array of molded articles is falling; and analysing, for each one of the molded articles, a parameter with respect to a predetermined parameter requirement. An inspection system operatively connectable to a molding system, comprising a driving system for causing a row or a column of an array of molded articles to fall in an inspection zone; and an optical system including an optical device at the inspection zone, the optical device configured to capture images of the molded articles as the molded articles are falling in the inspection zone.

Description

[0001] INSPECTION SYSTEM FOR MOLDED ARTICLES AND A METHOD FOR INSPECTING MOLDED ARTICLES

[0002] FIELD OF THE TECHNOLOGY

[0003] The present technology relates to molding systems. More specifically the present technology relates to an inspection system for inspecting molded articles from a molding system, and a method for inspecting molded articles during operation of the molding system.

[0004] BACKGROUND

[0005] Molding is a process by virtue of which a molded article can be formed from molding material by using a molding system. Various molded articles can be formed by using the molding process, such as an injection molding process. One example of a molded article that can be formed, for example, from polyethylene terephthalate (PET) material is a preform that is capable of being subsequently blown into a beverage container, such as a bottle and the like.

[0006] Broadly speaking, the cost of producing a molded article is made up of the capital cost of the molding system itself, the cost of resin, and other overheads (electricity, water supply, labour costs, etc.). In order to gamer the most profitability from the system, the molding system should be running as much as possible, and at full capacity. To extend the life of the molding system, regular inspection is important. One manner of inspecting such a machine is inspecting the molded articles produced by the machine.

[0007] In order to minimize downtime, inspection should not impede operation of the molding system, and inspection of the molded articles should take place with a minimum of delay from when they are molded, to intercept issues as quickly as possible.

[0008] SUMMARY

[0009] It is an object of the present invention to ameliorate at least some of the inconveniences present in the prior art.

[0010] According to one broad aspect of the present technology, there is provided a method for optically inspecting a plurality of molded articles, the method being executable by a processor, the method comprising: causing a row or a column of an array of molded articles to fall, the array of molded articles having a plurality of rows and a plurality of columns; causing an optical device to capture at least one image of each molded article of the row or the column of the array of molded articles, the at least one image being captured as each molded article of the row or the column of the array of molded articles is falling; and analysing, for each one of the molded articles of the row or the column of the array of molded articles, by the processor, at least one parameter with respect to a predetermined parameter requirement from the at least one captured image.

[0011] In certain implementations, in response to the at least one parameter not meeting the predetermined parameter requirement, the processor causes an execution of a corrective action.

[0012] In certain implementations, the corrective action includes causing the one of the molded articles to be directed toward a discard pile.

[0013] In certain implementations, the method further comprises determining a molding cavity in a mold of a molding system, the molding cavity being associated to the one of the molded articles of the array.

[0014] In certain implementations, the method further comprises receiving the array of molded articles in a receiving device defining an array of apertures, the array of apertures corresponding to the array of molded articles. The method may comprise causing a robot holding the array of molded articles to move towards the receiving device to dispose the array of molded articles in the receiving device. The method may comprise causing the receiving device to move towards a robot holding the array of molded articles to dispose the array of molded articles in the receiving device.

[0015] In certain implementations, the method further comprises causing the array of molded articles to move along a given plane by causing the receiving device to move along the given plane. In certain implementations, the given plane is parallel to a substantially horizontal plane. In such implementations, moving the receiving device parallel to the substantially horizontal plane causes the receiving device to be separated from a support plate at a base of the receiving device permitting the row or the column of the molded articles to fall.

[0016] In certain implementations, the given plane is parallel to the given plane, such as a substantially vertical plane. In certain implementations, moving the receiving device parallel to the substantially vertical plane causes the receiving device to be separated from a support plate of the receiving device permitting the row or the column of the molded articles to fall. In certain implementations, the receiving device and the support plate are caused to move together along a plane transverse to the given plane, such as towards a robot holding the array of molded articles.

[0017] In certain implementations, the method further comprises causing the receiving device to move along the given plane at a constant or variable speed.

[0018] In certain implementations, the array of molded articles are held by a robot, and causing the row or the column of the array of the molded articles to fall comprises causing the robot to release the molded articles of the row or the column.

[0019] In certain implementations, the optical device is a first optical device, the at least one parameter is a first parameter, and the predetermined parameter requirement is a first predetermined parameter requirement, and the method further comprises: causing a second optical device to capture at least one image of at least one molded article of the array of molded articles, the at least one image being captured as the array of molded articles is moving along the given plane; and analysing, for each one of the at least one molded articles of the array of molded articles, by the processor, a second parameter with respect to a second predetermined parameter requirement. In such implementations, the second optical device may capture the at least one image whilst the array of molded articles is being moved relative to a support plate or an extension support plate. The support plate and / or the extension support plate may comprise transparent portions through which to image the molded articles. The support plate and / or the extension support plate may comprise channels for supported base portions of the molded articles, the channels having open bases through which to image the molded articles.

[0020] In certain implementations, the fall of each one of the molded articles of the row of the array of the molded articles is at least one of a free fall, and a sliding fall.

[0021] In certain implementations, the method further comprises supporting the receiving device on a support plate, and causing the support plate to move away from the receiving device to cause the row or the column of the array of molded articles to fall.

[0022] From another aspect, there is provided an inspection system operatively connectable to a molding system, the inspection system comprising: a driving system for causing a row or a column of an array of molded articles to fall in an inspection zone; and an optical system including an optical device at the inspection zone, the optical device configured to capture at least one image of the molded articles as the molded articles are falling in the inspection zone.

[0023] In certain implementations, the inspection system further comprises a receiving device configured to house the array of molded articles, wherein the receiving device is configured to maintain a position of each of the molded articles within the array of molded articles, and wherein the driving system is configured to move the receiving device along a given plane towards the inspection zone.

[0024] In certain implementations, the receiving device defines an array of apertures corresponding to the array of molded articles.

[0025] In certain implementations, the given plane is parallel to a substantially horizontal plane.

[0026] In certain implementations, the driving system is configured to move the receiving device along the first plane at a constant or variable speed.

[0027] In certain implementations, the driving system includes a drive component which is moveable along the given plane; inter-engaging components of the drive component and the receiving device which are configured to selectively engage to selectively connect the drive component to the receiving device; and a driver configured to drive the drive component along the given plane.

[0028] In certain implementations, the inspection system further comprises a support plate selectively positionable beneath a base of the receiving device. In certain implementations, the driving system is configured to cause movement of one or both of the receiving device and the support plate along the given plane.

[0029] In certain implementations, the inter-engaging components comprise a pin and a recess configured to receive the pin.

[0030] In certain implementations, the drive component is moveable relative to guide rails so as to position the molded articles over a cavity defined between the guide rails and over the inspection zone.

[0031] In certain implementations, the support plate is moveable along a plane transverse to the given plane. In certain implementations, the inspection system further comprises inter-engaging components between the support plate and the receiving device which can be engaged when the support plate is being moved along the plane transverse to the plane and retracted to allow the drive component to be actuated along the given plane.

[0032] In certain implementations, the inter-engaging components comprise a pin and a recess configured to receive the pin.

[0033] In certain implementations, the optical device is a first optical device, and the inspection system includes a second optical device, the second optical device being configured to capture at least one of the at least one images of the molded articles as the molded articles are falling.

[0034] In certain implementations, the optical device is a first optical device, and the inspection system includes a second optical device, the second optical device being configured to capture at least one image of at least one molded article of the array of molded articles, the at least one image being captured as the array of molded articles is moving along a given plane which is parallel to a substantially horizontal plane or parallel to a substantially vertical plane.

[0035] In certain implementations, the inspection system further comprises a slide disposed generally in the inspection zone so that each molded article of the row of the array of molded articles falls in the inspection zone in a sliding manner.

[0036] In certain implementations, the inspection system further comprises a robot holding the array of molded articles, wherein the driving system is configured to move the robot towards the inspection zone.

[0037] In certain implementations, the support plate can be moved away from the receiving device along the plane transverse to the given plane.

[0038] In certain implementations, at least a portion of the support plate is transparent. In certain implementations, the inspection system further comprises an extension support plate across which the molded articles can be caused to move, at least a portion of the extension support plate being transparent.

[0039] In certain implementations, the support plate has a plurality of channels defined therein, each channel having side walls configured to support the base portion of the molded article, and an open base through which at least a part of the base portion of the molded article can be imaged. In certain implementations, the inspection system further comprises an extension support plate across which the molded articles can be caused to move, the extension support plate having a plurality of channels defined therein, each channel having side walls configured to support the base portion of the molded article, and an open base through which at least a part of the base portion of the molded article can be imaged.

[0040] In the context of the present specification, the words “first”, “second”, “third”, etc. have been used as adjectives only for the purpose of allowing for distinction between the nouns that they modify from one another, and not for the purpose of describing any particular relationship between those nouns. Further, as is discussed herein in other contexts, reference to a “first” element and a “second” element does not preclude the two elements from being the same actual real-world element.

[0041] These and other aspects and features of non-limiting embodiments of the present technology will now become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the technology in conjunction with the accompanying drawings.

[0042] Embodiments of the present technology each have at least one of the above-mentioned object and / or aspects, but do not necessarily have all of them. It should be understood that some aspects of the present technology that have resulted from attempting to attain the above- mentioned object may not satisfy this object and / or may satisfy other objects not specifically recited herein.

[0043] Additional and / or alternative features, aspects and advantages of embodiments of the present technology will become apparent from the following description, the accompanying drawings and the appended claims.

[0044] BRIEF DESCRIPTION OF THE DRAWINGS

[0045] A better understanding of the embodiments of the present technology (including alternatives and / or variations thereof) may be obtained with reference to the detailed description of the nonlimiting embodiments along with the following drawings, in which: Figure 1 is a schematic diagram of an injection system including a molding machine, an inspection system and a processor;

[0046] Figure 2 is a schematic view of the inspection system of Figure 1 comprising a receiving device, a robot and an optical system in an inspection zone;

[0047] Figure 3 is a perspective side view of the inspection system of Figure 2;

[0048] Figure 4 is a perspective side view of the receiving device of the inspection system of Figure 3;

[0049] Figure 5 is a perspective view of a driving system of the inspection system of Figure 3, the driving system being configured to actuate the retaining device towards the inspection zone and including a support plate;

[0050] Figure 6 is a close-up view of part of the driving system of Figure 5;

[0051] Figures 7A-7F are side views of the inspection system of Figure 3 showing the receiving device in different positions relative to a support plate and an extension support plate as the receiving device actuates from the inspection zone to a receiving zone and back to the inspection zone;

[0052] Figures 8A-8C are side views of the inspection system of Figure 3 showing the receiving device in different positions as it actuates vertically towards a robot at the receiving zone;

[0053] Figures 9A-9D are close up views of the receiving device and the support plate of Figures 7A- 7F in different positions as the support plate actuates from the inspection zone to the receiving zone;

[0054] Figures 10A-10D are side views of another implementation of the inspection system of Figure 3 showing a robot in different positions as it actuates towards the receiving device at the receiving zone;

[0055] Figures 11 A-l ID are side views of another implementation of the inspection system of Figures 10A-10D in which the robot can move to different positions relative to the receiving device using a scissoring mechanism;

[0056] Figures 12A-12D are side views of another implementation of the inspection system of Figure 3 in which the receiving device and the robot do not move vertically; Figures 13A-13D are side views of another implementation of the inspection system of Figure 3 comprising a robot and an optical system;

[0057] Figure 14 is a side view of another implementation of a portion of the extension support plate of Figures 7A-7F when supporting a molded article and including an upper optical device and a light source;

[0058] Figure 15 is a side view of another implementation of the extension support plate of Figure 14 in which channels with open bases are provided through which the molded article can be imaged;

[0059] Figure 16 is a perspective view of the extension support plate of Figure 15 with a receiving device;

[0060] Figure 17A is a perspective view of the extension support plate of Figure 15;

[0061] Figure 17B is a cross-section of one channel of the extension support plate of Figure 17A through line 17b of Figure 17 A;

[0062] Figure 18A is a perspective view of another implementation of the extension support plate of Figure 15;

[0063] Figure 18B is a cross-section of one channel of the extension support plate of Figure 18A through line 18b of Figure 18 A;

[0064] Figure 18C is a plan view of the extension support plate of Figure 18A; and

[0065] Figure 19 is a schematic workflow of an implementation of a method of the present technology.

[0066] DETAILED DESCRIPTION

[0067] Reference will now be made in detail to various non-limiting embodiment(s) of a molding system and a related method for the operation thereof. It should be understood that other nonlimiting embodiment(s), modifications and equivalents will be evident to one of ordinary skill in the art in view of the non-limiting embodiment(s) disclosed herein and that these variants should be considered to be within scope of the appended claims. Furthermore, it will be recognized by one of ordinary skill in the art that certain structural and operational details of the non-limiting embodiment(s) discussed hereafter may be modified or omitted (i.e. non-essential) altogether. In other instances, well known methods, procedures, and components have not been described in detail.

[0068] Injection Molding System

[0069] With reference to Figure 1, there is depicted a non-limiting embodiment of the injection molding machine 100 which can be adapted to implement embodiments of the present technology. For illustration purposes only, it shall be assumed that the injection molding machine 100, which is part of a molding system 200, is configured to make preforms (not depicted) for subsequent blow-molding into a final shaped container.

[0070] It should be understood that in alternative non-limiting embodiments, the molding system 200 may include other types of molding systems, such as, but not limited to, compression molding systems, compression injection molding systems, transfer molding systems, metal molding systems and the like. Also, the molding system 200 could include additional machines such as a blow-molding machine (not depicted) disposed downstream from the molding machine 100 and / or a dryer disposed upstream from the molding machine 100. Alternatively, the blowmolding machine can be located separately from the molding system 200, such as being located in a different facility, be under control of a different entity, and the like.

[0071] In the non-limiting embodiment of Figure 1, the molding machine 100 includes a stationary platen 102 and a movable platen 104. The stationary platen 102 is also referred to as a fixed platen 102. In some embodiments of the present technology, the molding machine 100 may include a third non-movable platen (not depicted). Alternatively or additionally, the molding machine 100 may include turret blocks, rotating cubes, turning tables and the like (all not depicted but known to those of skill in the art).

[0072] The injection molding machine 100 further includes an injection unit 106 for plasticizing and injection of the molding material. The injection unit 106 can be implemented as a single stage or a two-stage injection unit.

[0073] In operation, the movable platen 104 is moved towards and away from the stationary platen 102 by means of stroke cylinders (not shown) or any other suitable means. Clamp force (also referred to as closure or mold closure tonnage) can be developed within the molding machine 100, for example, by using tie bars 108, 110 (typically, four tie bars 108, 110 are present in the molding machine 100) and a tie-bar clamping mechanism 112, as well as (typically) an associated hydraulic system (not depicted) that is usually associated with the tie-bar clamping mechanism 112. It will be appreciated that clamp tonnage can be generated using alternative means, such as, for example, using a column-based clamping mechanism, a toggle-clamp arrangement (not depicted) or the like.

[0074] The molding machine 100 has a mold 113 having a first mold half 114, and a second mold half 116. The first mold half 114 can be associated with the stationary platen 102 and the second mold half 116 can be associated with the movable platen 104. In the non-limiting embodiment of Figure 2, the first mold half 114 defines the mold cavities 118. The mold cavities 118 generally form an array, such that there is a given number of columns and a given number or rows. In some embodiments, there could be eight columns and twelve rows of mold cavities 118 making 96 cavities in total, but it should be noted that embodiments of the present technology are not limited to any specific cavitation number. As will be appreciated by those of skill in the art, the mold cavities 118 may be formed by using suitable mold inserts (such as a cavity insert, a gate insert and the like) or any other suitable means. As such, the first mold half 114 can be generally thought of as a “mold cavity half’.

[0075] The second mold half 116 includes mold cores 120 complementary to the mold cavities 118, such that the mold cores 120 also generally form an array similar to the array formed by the mold cavities 118, where the array formed by the mold cores 120 has the same number of columns and rows as the array formed by the mold cavities 118. As will be appreciated by those of skill in the art, the mold cores 120 may be formed by using suitable mold inserts or any other suitable means. As such, the second mold half 116 can be generally thought of as a “mold core half’. Even though not depicted in Figure 1, the first mold half 114 may be further associated with a melt distribution network, commonly known as a hot runner, for distributing molding material from the injection unit 106 to each of the mold cavities 118. Also, the second mold half 116 is provided with neck rings (not depicted) produce preforms with the neck portions of the preforms (not depicted).

[0076] The first mold half 114 can be coupled to the stationary platen 102 by any suitable means, such as a suitable fastener (not depicted) or the like. The second mold half 116 can be coupled to the movable platen 104 by any suitable means, such as a suitable fastener (not depicted) or the like. It should be understood that in an alternative non-limiting embodiment of the present technology, the position of the first mold half 114 and the second mold half 116 can be reversed and, as such, the first mold half 114 can be associated with the movable platen 104 and the second mold half 116 can be associated with the stationary platen 102. In an alternative nonlimiting embodiment of the present technology, the stationary platen 102 need not be stationary and may be movable in relation to other components of the molding machine 100.

[0077] Figure 1 depicts the first mold half 114 and the second mold half 116 in a so-called “mold open position” where the movable platen 104 is positioned generally away from the stationary platen 102 and, accordingly, the first mold half 114 is positioned generally away from the second mold half 116. For example, in the mold open position, a molded article (not depicted) can be removed from the first mold half 114 and / or the second mold half 116. In a so-called “mold closed position” (not depicted), the first mold half 114 and the second mold half 116 are urged together (by means of movement of the movable platen 104 towards the stationary platen 102) and cooperate to define (at least in part) molding cavities into which the molten plastic (or other suitable molding material) can be injected, as is known to those of skill in the art. Due to the arrangement of the mold cavities 118 and the mold cores 120, the molding cavities generally form a mold array, also referred to as molding cavity array. The molding cavity array has the same number of columns and rows as the array formed by the mold cavities 118 and the mold cores 120.

[0078] It should be appreciated that one of the first mold half 114 and the second mold half 116 can be associated with a number of additional mold elements, such as for example, one or more leader pins (not depicted) and one or more leader bushings (not depicted), the one or more leader pins cooperating with one more leader bushings to assist in alignment of the first mold half 114 with the second mold half 116 in the mold closed position, as is known to those of skill in the art.

[0079] The injection molding machine 100 can further include a robot 122, sometimes referred to as a retrieval device and / or a removal device, operatively coupled to the stationary platen 102. Those skilled in the art will readily appreciate how the robot 122 can be operatively coupled to the stationary platen 102 and, as such, it will not be described in detail herein. The robot 122 includes a mounting structure 124, an actuating arm 126 coupled to the mounting structure 124 and a take-off plate 128 coupled to the actuating arm 126. The take-off plate 128 includes a plurality of molded article receptacles 130.

[0080] Generally speaking, the purpose of the plurality of molded article receptacles 130 is to remove molded articles (such as preforms, in this example) from the one or more mold cores 120 (or the one or more mold cavities 118) and / or to implement post mold cooling of the molded articles.

[0081] The molded articles may comprise any one or more of: preforms, closures, thin-wall containers, medical appliances, and the like. The preforms may be monolayer or multilayer and generally comprise a neck portion, a gate portion and a body portion extending between the neck portion and the gate portion. The gate portion is associated with a substantially spherical shape that terminates in a vestige portion.

[0082] In the non-limiting example illustrated herein, the plurality of molded article receptacles 130 includes a plurality of cooling tubes for receiving a plurality of molded preforms. However, it should be expressly understood that the plurality of molded article receptacles 130 may have other configurations. The exact number of the plurality of molded article receptacles 130 is not particularly limited. In some instances, the number of molded article receptacles 130 corresponds to the number of mold cavities 118.

[0083] Schematically depicted in Figure 1 is the robot 122 of a side-entry type. However, it should be understood that in alternative non-limiting embodiments of the present technology, the robot 122 can be of a top-entry type. It should also be expressly understood that the term “robot” is meant to encompass structures that perform a single operation, as well as structures that perform multiple operations. In at least some embodiments, it is also contemplated that the robot 122 could be omitted and / or replaced with a differently implemented device for moving the molded articles.

[0084] It is to be noted that the robot 122 is configured to manipulate the molded articles while preserving the molding cavity array (i.e., the robot 122 does not scramble the positioning of the molded articles).

[0085] The molding machine 100 further includes a post-mold treatment device 132 operatively coupled to the movable platen 104. Those skilled in the art will readily appreciate how the post- mold treatment device 132 can be operatively coupled to the movable platen 104 and, as such, it will not be described here in any detail. The post-mold treatment device 132 includes a mounting structure 134 used for coupling the post-mold treatment device 132 to the movable platen 104. The post-mold treatment device 132 further includes a plenum 129 coupled to the mounting structure 134. Coupled to the plenum 129 is a plurality of treatment pins 133. The number of treatment pins within the plurality of treatment pins 133 generally corresponds to the number of receptacles within the plurality of molded article receptacles 130. In at least some embodiments, it is also contemplated that the post-mold treatment device 132 could be omitted and / or replaced with a differently implemented device for treating the molded articles.

[0086] The molding machine 100 further includes a computing apparatus 140, also referred to herein as a processor 140 or as a “controller”, configured to control one or more operations of the molding machine 100. As will be described below, the processor 140 is further configured to control one or more operations of the molding system 200 that the molding machine 100 is part of, and which will be described in greater detail below. As will be appreciated by those skilled in the art, the computing apparatus 140 may include a plurality of processors or computer- implemented devices operatively connected together.

[0087] The processor 140 includes a human-machine interface (not separately numbered) or an HMI, for short. The HMI of the processor 140 can be implemented in any suitable interface. As an example, the HMI of the processor 140 can be implemented in a multi-functional touch screen. An example of the HMI that can be used for implementing non-limiting embodiments of the present technology is disclosed in co-owned United States Patent 6,684,264, content of which is incorporated herein by reference, in its entirety.

[0088] Those skilled in the art will appreciate that the processor 140 may be implemented using preprogrammed hardware or firmware elements (e.g., application specific integrated circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.), or other related components. In other embodiments, the functionality of the processor 140 may be achieved using a processor that has access to a code memory (not shown) which stores computer-readable program code for operation of the computing apparatus, in which case the computer-readable program code could be stored on a medium which is fixed, tangible and readable directly by the various network entities, (e.g., removable diskette, CD-ROM, ROM, fixed disk, USB drive), or the computer-readable program code could be stored remotely but transmittable to the processor 140 via a modem or other interface device (e.g., a communications adapter) connected to a network (including, without limitation, the Internet) over a transmission medium, which may be either a non-wireless medium (e.g., optical or analog communications lines) or a wireless medium (e.g., micro wave, infrared or other transmission schemes) or a combination thereof.

[0089] In alternative non-limiting embodiments of the present technology, the HMI does not have to be physically attached to the processor 140. As a matter of fact, the HMI for the processor 140 can be implemented as a separate device. In some embodiments, the HMI can be implemented as a wireless communication device (such as a smartphone, for example) that is “paired” or otherwise communicatively coupled to the processor 140.

[0090] The processor 140 can perform several functions including, but not limited to, receiving from an operator control instructions, controlling the molding machine 100 based on the operator control instructions or a pre-set control sequence stored within the processor 140 or elsewhere within the molding machine 100, acquire one or more operational parameters associated with the molding system and the like. According to non-limiting embodiments of the present technology, the processor 140 is further configured to process one or more of the acquired operational parameters associated with the molding system 200 and output information to the operator using the HMI and the like. It is contemplated that the processor 140 may be implemented in a distributed manner over a plurality of physical machines, without departing from the scope of the present technology.

[0091] The molding machine 100 further includes a number of monitoring devices (not depicted), the monitoring devices being configured to acquire various operational parameters associated with the performance of the molding machine 100. Generally speaking, these monitoring devices are known in the art and, as such, will not be described here at any length.

[0092] Just as an example, the injection molding machine 100 may include a counter to count mold opening and closing to determine the number of cycles over a period of time and / or the cycle time of each cycle. The injection molding machine 100 may also include a number of pressure gauges to measure pressure within various components of the injection molding machine 100 (such as hydraulic fluid pressure or molding material pressure). According to non-limiting embodiments of the present technology, the processor 140 is configured to acquire a plurality of operational parameters associated with the molding machine 100. The nature of the so-acquired plurality of operational parameters can vary. How the processor 140 acquires the plurality of operational parameters will depend, of course, on the nature of the so-acquired plurality of operational parameters.

[0093] The processor 140 can acquire machine variables by monitoring the operation of the molding machine 100. Just as an example, the processor 140 can acquire the cycle time by monitoring the performance of the molding machine 100. Naturally, the processor 140 can acquire some of the machine variables by either the operator entering them using the HMI or by reading a memory tag (not depicted) associated with the mold (i.e. the above described first mold half 114 and the second mold half 116) that is used in the molding machine 100. Various implementations of the memory tag (not depicted) are known in the art. Generally speaking, the memory tag (not depicted) may store information about the mold, the molded article to be produced, pre-defined control sequences, set-up sequences and the like.

[0094] For example, the operator may enter an indication of cavitation of the injection molding machine 100 using the HMI of the processor 140 (in which case, the cavitation can be considered to be an operational and supervisory variable). Alternatively, the mold (i.e. the above described first mold half 114 and the second mold half 116) may be equipped with the memory tag, which memory tag may for example store an indication of the cavitation of the mold. In those implementations, the processor 140 can acquire the cavitation by accessing the memory tag and reading the information therefrom (in which case, the cavitation can be considered to be a machine variable). In yet further embodiments, the memory tag may contain an indication of the mold cavitation of the mold (i.e. the above described first mold half 114 and the second mold half 116), but some of the mold cavities may not be operational at the time. Within those examples, the operator or the supervisor could enter the actual cavitation using the HMI (in which case, the cavitation could again be considered to be an operational and supervisory variable).

[0095] In some non-limiting embodiments of the present technology, the processor 140 can acquire the operational and supervisory variables by receiving an indication of those parameters from the operator. However, within some implementations of the molding machine 100, it is possible for the processor 140 to acquire some (or even all) of the operational and supervisory variables by monitoring performance of the molding machine 100. For example, some implementations of the molding machine 100 may include a device for weighing molded articles and / or a device to keep track of scrapped molded articles (for example, those molded articles that do not quality or weight specifications). Within those embodiments, the processor 140 can acquire the part weight and / or scrap rates by monitoring the performance of the molding machine 100. Naturally, other ways for the processor 140 to acquire some or all of these or other operational parameters are possible, some of which will be described below.

[0096] It is contemplated that different embodiments of the injection molding machine 100 could be included in the molding system 200. It is also contemplated that the molding system 200 could further include different molding equipment, such as but not limited to: a compression molding machine, injection compression molding machine, extrusion blow molding machine, transfer molding machine and the like.

[0097] Referring now to Figure 2, disclosed is an inspection system 300 operatively connected to the molding system 200 and which is configured to identify defective molded articles. Defective molded articles thus identified can be associated with a corresponding molding cavity to dynamically adjust one or more operational parameters of the molding process to limit the number of defective preforms produced. This can result in reduction of waste generation. As will become apparent from the foregoing, the adjustment of the one or more operational parameters can be done to a molding machine of the molding system 200 or, in some cases, to a device downstream from the molding machine, such as to a blow-molding machine of the molding machine, as well as a device upstream from the molding machine (such as a dryer or any other resin-conditioning device).

[0098] In prior art systems, parameters of a molded article are generally checked after the molded article exits the molding system (i.e. downstream of the molding system). However this is after the fact, and it is time consuming and typically expensive. There may be large numbers of defective molded articles produced before the molding process can be adjusted. It is to be noted that “defective molded articles” could be articles that have one or more parameters that are at least partially offset from a quality parameter or a quality range, while still being useable (i.e., defective molded articles are not necessarily destined to be scrapped). In some implementations of the present technology, “defective molded articles” could be articles destined to be scrapped. Examples of the parameters that may be offset from the quality range in a defective molded article include one or more of color deviations, texture deviations and shape deviations. When the molded articles are preforms, defective molded articles may comprise those with black specks, off-set gate nub length, and offset TSS flash / sink / ovality.

[0099] Broadly, in implementations of the present technology, the inspection system 300 comprises an inspection zone and an optical system for capturing images of molded articles moving within the inspection zone. According to certain implementations, the molded articles may be caused to move within the inspection zone by means of one or both of (i) a receiving system which transfers molded articles from the robot to the inspection zone, or from the robot to a receiving device, and (ii) a receiving system for transporting the molded articles from a receiving device to the inspection zone. In alternative non-limiting embodiments of the present technology, the molded articles may be caused to move towards or within the inspection zone by means of the robot.

[0100] With reference to Figure 2, in a first implementation of the present technology, the inspection system 300 comprises a receiving device 302 for housing the molded articles molded by the molding system 200, a receiving mechanism 304 for transferring the molded articles from the robot 122 to the receiving device 302 or from the robot 122 to an inspection zone 306, a driving system 308 for moving the receiving device 302 towards the inspection zone 306, and an optical system 310 for capturing images of the molded articles.

[0101] More specifically, and as best seen schematically in Figures 2-4, the receiving device 302 is configured to maintain the positioning of the molded articles in an array 312 that corresponds to a layout in which they were produced during molding, and to move the molded articles in a first direction 314 towards the inspection zone 306. The first direction 314 is along a first plane. At a predetermined position in the inspection zone 306, each molded article of the array 312 will be caused to fall from the receiving device 302, row-by-row, and the optical system 310 is configured to capture images of the molded articles as they fall (i.e. during the fall) in the inspection zone 306. The inspection system 300 may be configured so that the molded articles fall freely, or that they are guided as they fall (such as by a guiding surface, for example). One implementation of the inspection system 300 is depicted in Figure 3, and one implementation of the receiving device 302 is depicted in Figure 4.

[0102] Receiving device According to certain embodiments, as best seen in Figure 4, the receiving device 302 comprises a frame 316 defining apertures 318. Each aperture 318 is sized and shaped to receive a given molded article. The apertures 318 are configured in the array 312. The array 312 comprises a plurality of rows 320 and a plurality of columns 322. The configuration of the array 312 corresponds to the array of molded articles such that the array 312 of apertures 318 is configured to receive the plurality of the molded articles in the same configuration in which the molded articles were molded.

[0103] The apertures 318 are defined by a plurality of tubes 324 supported by the frame 316, each tube 324 having an open upper end 326 and an open lower end 328 with a channel 330 extending therethrough. Each channel 330 is sized and shaped to receive a given molded article therein. The upper end 326 of the tubes 324 are flared outwardly which can help in positioning the molded articles into the tube 324. The frame 316 comprises an upper component 332 and a lower component 334, each having defined therein openings 336 for receiving the tubes 324. The upper component 332 comprises a plate for supporting the tubes 324. In the embodiments shown in Figure 4, the array 312 comprises 6 rows, each row having 8 tubes defining 8 apertures. It will be appreciated that any other configuration of the array 312 and the receiving device 302 is also possible. Instead of tubes 324, there may be provided any other type of separator(s) for maintaining a spatial arrangement of the molded articles.

[0104] A support plate 348 (Figure 6) is provided beneath the receiving device 302 such that the molded articles are supported in the tubes 324 by the support plate 348. This will be further described in relation to Figure 6 and Figure 14. The support plate 348 has an upper surface 368 which is planar on which the molded articles are supported. The tubes 324 are sized and shaped so that the molded article can freely rest in a given tube 324 without any attachment. A diameter of the apertures 318 is wider than a diameter of the molded article (e.g. 2- 4 mm). The molded articles may be completely enclosed by the respective tube or have an upper portion, such as a preform neck, extending out of the tube 324.

[0105] Driving system

[0106] Turning now to Figure 5, there is shown a portion of the driving system 308 which is selectively connectable to the receiving device 302 for driving the receiving device 302 along the first direction 314 on the first plane. The first plane is substantially horizontal. The first direction 314 is towards the inspection zone 306 from a receiving zone 338 in which the molded articles are received in the receiving device 302.

[0107] The driving system 308 comprises a drive component 340 slidingly attached to a drive frame 342 of the inspection system 300 by guide rails 344. The drive component 340 is configured to detachably engage with the receiving device 302 and to pull the receiving device 302 in the first direction 314. Inter-engaging members 346 are provided on the drive component 340 and the receiving device 302 for detachably attaching the drive component 340 and the receiving device 302.

[0108] In the embodiment illustrated in Figure 4, the drive component 340 comprises a left drive member 340a and a right drive member 340b which are spaced apart from one another, and the guide rails 344 comprise a left guide rail 344a and a right guide rail 344b which are spaced from one another. As can be seen in Figure 6, the inter-engaging members 346 comprise pins 346a extending from the drive component 340 and corresponding recesses 346b formed in the frame 316 of the receiving device 302 in which the pins 346a are received (Figure 6). The pins 346a and the recesses 346b extend substantially transversely to the first direction 314 such that they remain engaged during movement thereby pulling the receiving device 302 in the first direction 314. In other embodiments, the configuration of the drive component 340 and the inter-engaging members 346 may differ.

[0109] The guide rails 344, attached to the drive frame 342, are configured to guide the movement of the drive component 340 in the first direction 314. The guide rails 344 extend from the receiving zone 338 towards the inspection zone 306. As best seen in Figure 6, the support plate 348, connected to the drive frame 342 and vertically moveable thereto in this implementation, is disposed between the guide rails 344 at the receiving zone 338. When the drive component 340 is at the receiving zone 338, the molded articles housed in the tubes 324 of the receiving device 302 will rest on the support plate 348. More specifically, when the molded articles are preforms, domes of the preforms will rest on the support plate 348 when the molded articles are housed in the tubes 324. The tubes are sized and shaped such that the preforms are housed in the tubes 324 such that they can freely fall when the support plate 348 is no longer supporting them.

[0110] As best seen in Figure 7A, an extension support plate 350 is provided adjacent the support plate 348 and disposed between the guide rails 344. The extension support plate 350 is fixed to the drive frame 342. The surface 368 of the support plate 348 and a surface 369 of the extension support plate 350 he on the same plane as each other while the receiving device 302 is caused to move in the first direction 314. Beyond the extension support plate 350, a cavity is defined between the guide rails 344 above the inspection zone 306.

[0111] A driver 352 is provided for causing the movement of the drive component 340. The driver 352 may be configured to move the drive component 340 at a constant speed. In other embodiments, the driver 352 may be configured to move the drive component 340 at a variable speed. The variable speed may comprise a predetermined acceleration or deceleration. The driver 352 may comprise a motor or any other suitable mechanism. The driver 352 may be operatively coupled to the processor 140. As such, the driver 352 can be controlled by the processor 140, and can synchronize the movement of the receiving device 302 with a movement of the robot 122.

[0112] In operation, and as best seen in Figures 7A-7F, when the drive component 340 moves towards the inspection zone 306, the receiving device 302 is also caused to move due to engagement of the inter-engaging members 346. The molded articles which are resting on the support plate 348 will glide along the support plate 348 in the first direction 314 onto the extension support plate 350. Further actuation of the receiving device 302 beyond the extension support plate 350, whose position is fixed, will cause the molded articles to fall into the cavity towards the inspection zone 306, row-by-row, and to be imaged as they fall by the optical system 310. Once all the tubes 324 are empty, the receiving device 302 will be caused to return to the receiving zone 338, for receiving a next batch of molded articles.

[0113] Optical system

[0114] The optical system 310 comprises an optical device 354 for capturing images of the molded articles as they fall. The optical device 354 may comprise a camera for capturing still images or moving images. The camera may have any suitable orientation for capturing images of a desired angle or part of the molded article. The optical device 354 may comprise a sensor such as an infra-red sensor. One or more additional optical devices 354 may be provided, such as one optical device for capturing images of a side of the molded article, and another optical device for capturing images of a top of the molded article. When the molded articles comprise preforms, one optical device positioned above the falling preforms can capture images of a neck finish of the preform, and another optical device positioned to a side of the falling preforms can capture images of the side of the preform. In certain implementations, the optical devices 354 are both positioned in the inspection zone 306. This is best shown in relation to the implementation of Figures 13A-13D, but can also be equally applied to any of the other embodiments described herein.

[0115] In certain implementations, and as best seen in Figures 7, 10, 11 and 12, an upper optical device 355 is provided, which upper optical device 355 is disposed above the support plate 148 and / or the extension support plate 150. The upper optical device 355 can be used to image a top part of the molded articles whilst they are supported in the receiving device 302 and before they are caused to fall in the inspection zone 306. The upper optical device 355 can also be used to image inside a base portion of the molded articles. A plurality of upper optical devices 355 may be provided.

[0116] In certain implementations (figures 14 and 15), a lower optical device 356 is provided, which lower optical device 356 is disposed below the extension support plate 150. A plurality of upper optical devices 355 may be provided. In certain implementations, the lower optical device 356 may be disposed in the inspection zone (figure 2).

[0117] Optionally, the optical system may comprise one or more light sources 353 (Figures 2, 14, 15) for illuminating the molded articles which can assist image capture and inspection (e.g. optical device can capture a clearer image). In some embodiments, the light source could be one or more of: a multispectral light source, and an array of multispectral light sources. In some embodiments, the inspection zone could be backlit by the light source. The light source 353 may be disposed above or below the extended support plate 150 (figures 14 and 15). The light source 353 may also be disposed in the inspection zone (figure 2). The light source 353 may be used to backlight the molded articles.

[0118] A slide (not shown) may be provided in the inspection zone along which the molded articles will slide downwardly. When the slide is present, the light source may be disposed on a back side of the slide. An angle of the slide may be selected so as to follow a free-fall profile of the molded articles.

[0119] The optical system 310 and the processor 140 are operatively coupled to one another. As such, the processor 140 may be configured to process the captured images and identify any defects in the molded articles. The optical device 354 can be controlled by the processor 140, and can transfer information and / or indications to the processor 140 for controlling the molding process, i.e. one or more operating parameters of one or more of the molding machine 100 and / or the molding system 200 and / or other equipment associated with the molding process.

[0120] Receiving mechanism

[0121] Turning now to the receiving mechanism for transferring the molded articles from the robot 122 to the receiving device 302 or from the robot 122 to the inspection zone. Different implementations of the receiving system will be described below with reference to Figures 8- 9, 10, 11, 12 and 13.

[0122] Receiving device moves up to meet robot

[0123] In the implementation of Figures 8 and 9, the receiving mechanism 304 comprises a vertical driver 351 for moving the support plate 348 along a second plane 358 in a second direction. The second plane is perpendicular to the first plane. The second plane is substantially vertical. The second direction is upwardly 358a. In other implementations, the driver for the first and second direction actuation may be the same driver. A stop component may be provided beneath the support plate 348 to limit a vertical actuation thereof. A vertical guide rail may be provided to guide the vertical actuation.

[0124] Inter-engaging members 360 for vertical actuation are provided between the support plate 348 and the receiving device 302 (compare with the inter-engaging members 346 for horizontal actuation being provided between the drive component 340 and the receiving device 302).

[0125] When the support plate 348 is caused to move upwardly, the inter-engaging members 346 for horizontal actuation are disengaged. However, the inter-engaging members 360 for vertical actuation remain engaged enabling the receiving device 302 to be actuated vertically with the support plate 348.

[0126] As best seen in Figures 9A-9D, the inter-engaging members 360 for vertical actuation comprise pins 360a extending from the support plate 348 and corresponding recesses 360b formed in the frame 316 of the receiving device 302. The pins 360a and the recesses 360b extend substantially parallel to the second direction 358. Before vertical actuation can begin, the inter-engaging members 360 for vertical actuation are engaged (Figure 9A). As the receiving device 302 moves upwardly (Figures 8A, 8B), a release of the molded articles from the robot 122 is synchronized by the processor 140 so that the molded articles are caused to drop into the apertures 318 to be received in the tubes 324 of the receiving device 302. The release of the molded articles may comprise a release of a vacuum.

[0127] Once the molded articles are received in the receiving device, the receiving device 302 moves downwardly 358b along the second plane (Figure 8C). The robot 122 may be caused to move out of the way. The inter-engaging members 346 of the horizontal actuation engage together as the receiving device 302 and the support plate 348 move downwardly.

[0128] Before horizontal actuation can begin, the pins 360a of the inter-engaging members 360 of the vertical actuation are caused to be removed from their corresponding recesses 360b (Figures 9B-9D). A plate from which the pins 360a extend move upwardly and downwardly to selectively connect and retract the pins from the corresponding recesses 360b. The receiving device 302 can then be moved in the first direction in the manner described above.

[0129] Robot moves down to meet receiving device

[0130] Referring now to Figure 10, in other implementations, the receiving device 302 is caused to receive the molded articles by an action of the robot 122 moving downwardly along the second plane 358 to meet the receive device 302 (as opposed to the receiving device 302 moving up to meet the robot 122 along the second plane 358 as in the implementations of Figure 8-9). As seen in Figures 10A-10D, the robot 122 moves downwardly 358a in the second plane 358 towards the receiving device 302, the molded articles are released from the robot 122 such as by releasing a vacuum and the molded articles are received in the tubes 324 of the receiving device 302 as before. After releasing the molded articles, the robot 122 moves upwardly 358a in the second plane 358. The movement of the robot 122 may be driven by a robot driver (not shown).

[0131] Robot moves down to meet receiving device

[0132] In the implementations of Figures 11A-1 ID, as with Figure 10, the molded articles are caused to move downwardly in the second direction 358b along the second plane 358 to meet the receiving device 302. However, instead of the robot 122 being actuated, an upper plate 362 of the robot 122, on which the molded articles are retained, are caused to move by a scissoring mechanism 364. The scissoring mechanism 364 expands to cause the upper plate 362 to move downwardly in the second direction 358b. The receiving device 302 does not move along the second plane 358.

[0133] Robot drops molded articles to receiving device

[0134] In the implementations of Figures 12A-12D, there is no actuation of the robot 122, an upper plate 32 of the robot nor the receiving device 302. Instead, in the implementations of Figures 12A-12D, the molded articles of the robot 122 are positioned over the receiving device 302 and the molded articles are caused to fall into the tubes 324 of the receiving device 302. The molded articles fall along the second plane 358, in the second direction 358b.

[0135] Robot drops molded articles to inspection zone

[0136] The implementations of Figures 13A-13D differ from the earlier implementations in that the inspection system 300 comprises the optical system 310 and an actuation mechanism for actuating the robot 122 in a first direction 314 over the inspection zone 306 and releasing the molded articles row-by-row or molded article by molded article so that they free fall into the inspection zone 306 and are imaged by the optical devices 354, 355. As can be seen, two optical devices 354, 355 are provided for imaging the molded articles from a side and a top thereof.

[0137] Support plate movement

[0138] In other implementations (not shown), the molded articles are caused to fall by movement of the support plate 348 along the vertical plane, away from the receiving device 302 whilst the receiving device 302 remains stationary. In certain implementations, the extension support plate may be caused to move downwardly along the vertical plane when the receiving device is positioned above the extension support plate Optionally, the optical system 354 may be linked for movement with the support plate 348.

[0139] Extended support plate configuration

[0140] Referring now to Figure 14, in certain embodiments, it may be desired to image a base 370 of one or more of the molded articles whilst they are supported by the upper surface 368 of the support plate 348 and / or the upper surface 369 of the extended support plate 350. This can permit evaluation of a quality of gate vestige, for example to identify defects termed “gate voids”.

[0141] In some examples, at least a portion of the support plate 348 and / or the extended support plate 350 is transparent to permit the imaging of the molded articles from beneath using for example the lower optical device 356. Suitable materials may comprise polymers such as acrylics, polycarbonates, polyethylene, and the like. The material from which the support plate 348 and / or the extended support plate 350 is made is not particularly limited as long as it can permit imaging of a base portion of the molded articles therethrough. The entirety of the support plate 348 and / or the extended support plate 350 may be transparent, or only portions on which the molded articles will rest are transparent. The transparent portions may comprise parallel strips.

[0142] A light source, such as the light source 353 may be positioned above the molded article, and the lower optical device 356 may be positioned beneath the molded article. In other implementations, the upper optical device 355 may be provided above the support plate 148 and / or the extended support plate 150 with the light source 353 beneath the molded article. In such embodiments, an inside of the molded article can be imaged. In other embodiments (not shown), the light source and the lower / upper optical devices may have different relative positions.

[0143] The light source 353 and the optical device 355, 356 may be aligned axially with the molded article. In certain embodiments, as a result of relative movement between the support plate 348 and / or the extended support plate 350 and the receiving device 302, the molded articles may be angled relative to the vertical, in which case axial alignment means that the light source 353 and the optical device 355, 356 are not vertically aligned.

[0144] In other embodiments, the light source 353 and the optical device 355, 356 may be misaligned axially with the molded article. For example, the light source 353 and the optical device 355, 356 may be vertically aligned, whilst the molded articles are off-set relative to a vertical axis due to relative movement between the receiving device 302 and the support plate 348 / extended support plate 350.

[0145] Referring now to Figures 15, 16, 17A and 17B, another example of the extended support plate 350 is shown in which a plurality of elongate channels 372 are defined in the extended support plate 350. The channels 372 are parallel to one another. Each channel 372 is configured to align with a row of the tubes 324 which will hold the molded articles. A spacing between the channels 372 also corresponds to a spacing between the rows of tubes 324. The channels 372 extend only partially across the extended support plate 350. The channels 372 are located at an end of the extended support plate 350 closer to the inspection zone 306. This means that the base of the molded articles will be received in the channels 372 as the receiving device 302 is translated laterally. Instead of or in addition to the channels 372 being defined in the extended support plate 350, the channels 372 may be defined in the support plate 348. In other embodiments, the channels 372 may extend fully, instead of partially, across the extended support plate 350.

[0146] As seen in Figures 15, 16, 17A and 17B, each channel 372 has inclined channel walls 374. A transverse cross-sectional shape of the channel 372 is V-shaped and has an open base 376 through which the base 370 of the molded articles can be imaged. A size of the channel 372 is such that the base 370 of the molded article is supported by the inclined channel walls 374. As the transverse cross-sectional shape of the channel 372 is different than a shape of the base 370 of the molded article, a contact between the molded article and the extended support plate 350 is minimised. This can reduce or avoid any frictional wear between the molded article and the extended support plate 350. Furthermore, any friction between the molded article and the support plate 350 will not hinder the imaging of the base 370 of the molded article through the open base 376 of the channel 373.

[0147] As shown in dotted lines in Figure 17B, the inclined channel walls 374 need not be planar and can be curved instead.

[0148] Referring now to Figures 18A, 18B and 18C, a yet further embodiment of the extended support plate 350 is shown in which the plurality of channels 372 extend along an entirety of the extended support plate 350. The channels 372 differ from those of Figures 15, 16, 17A and 17B in that the base 376 of the channel 372 is open along only a part of the channel 272 length. The open portion of the channel base 376 is provided only at the inspection zone end of the extended support plate 350. This implementation of the channel 372 may also be applied to the support plate 348.

[0149] Thus, according to the various implementations of the present technology, inspection of the molded articles can be performed without having to individually manipulate the molded articles and / or individually manipulate columns or rows of the molded articles. In some instances, while performing analysis of the quality of the molded articles, the processor 140 may determine that a quality of one of the molded articles does not meet a specification requirement. In other words, the processor 140 may determine that the one of the molded articles is a defective molded article and does not meet a predetermined parameter requirement. The parameter requirement can be a given color, a given clarity, a specific size, a presence or absence of features, such as threads on a neck portion of a preform, when the molded article is a preform.

[0150] To minimize the number of defective molded articles produced it is desirable to identify the faulty molding cavity that produced the defective molded article, so as to control at least one operating parameter associated with the faulty molding cavity in order to stop production of defective molded articles. Furthermore, in other implementations of the present technology, it is also desirable to identify the faulty molding cavity that produced the defective preform, so as to control at least one operating parameter of the molding process. According to an aspect of the present technology, a candidate molding cavity of the mold 113 of the injection molding machine 100 that produced the defective molded article can be identified.

[0151] To this end, namely to identify a candidate molding cavity that produced the defective molded article, a given column and a candidate row of the molding cavity array are determined by the processor 140. In some embodiments, such as when there is a plurality of defective molded articles, only a row or a column could be identified.

[0152] The given row or column of the molding cavity array can be identified through a determination of a position of the receiving device 302 or the robot 122 at the time that the defective molded article was imaged. Indeed, as mentioned above, the array of the molded articles is maintained as the molded articles are caused to fall in the inspection zone 306.

[0153] Then, once the candidate molding cavity is identified, the processor 140 causes at least one operating parameter of the molding machine 100 to change so as to no longer produce defective molded articles. It is to be noted that the operating parameter could be changed at various points, such as at the corresponding mold cavity 118, at the corresponding mold core 120, and / or at the corresponding molded article receptacle 130. It is further contemplated that the processor 140 could generate a warning signal to an operator of the molding system 200. In some embodiments, the operating parameter is associated with a subset of molding cavities including the candidate molding cavity. In other embodiments, the operating parameter is associated with the candidate molding cavity.

[0154] Additionally, in a non-limiting embodiment of the present technology, where the molding process includes blow-molding the preforms (i.e., the molding system 200 includes a blow molding machine), the processor 140 causes at least one operating parameter of the molding process to change. For example, defective preforms are selectively separated from other preforms. Then, the defective preforms are blow-molded with different blow-molding conditions. As other examples, the processor 140 can cause one or more of the following:

[0155] • Adjustment to an operating parameter of the molding machine;

[0156] • Rejection of the molded article;

[0157] • Change an operating parameter of a downstream device, such as an adjustment to an operating parameter of a blow molding system such as to current colour level;

[0158] • Change an operating parameter of an upstream device, such as change material information such as recycled content; and

[0159] • Separate different molded articles (in and out of specification) into different bins.

[0160] With reference to Fig. 19, illustrated by a block diagram, a method 400, which is executable by the processor 140, and which is in accordance with non-limiting embodiments of the present technology. The method 400 will be described herein with respect to the molding system 200, described hereabove, but it is contemplated that the method could apply to other non-limiting embodiments of an injection molding system according to the present technology.

[0161] Step 410 - causing a row or a column of an array of molded articles to fall, the array of molded articles having a plurality of rows and a plurality of columns

[0162] The method 400 begins, at step 410, with causing a row or a column of an array of molded articles to fall, the array of molded articles having a plurality of rows and a plurality of columns. The molded articles may be caused to fall into an inspection zone, such as the inspection zone 306. The fall of each one of the molded articles of the row or the column of the array of the molded articles is at least one of a free fall, and a sliding fall.

[0163] In certain implementations, the molded articles are caused to fall in the inspection zone 306 by movement of a receiving device, such as the receiving device 302, housing the molded articles to move over the inspection zone 306 in the first direction 314. The receiving device 302 is configured to house the molded articles in a same array configuration in which they were molded. The receiving device 302 defines an array of apertures, the array of apertures corresponding to the array of molded articles. The method may comprise causing the receiving device 302 to move along a given plane towards the inspection zone. The receiving device may be caused to move along the given plane at a constant or a variable speed. The given plane is parallel to a generally horizontal plane.

[0164] The method may further comprise causing the receiving device 302 to receive the molded articles by one or more of (i) causing the receiving device to be actuated towards the robot 122 holding the molded articles, (ii) causing the robot 122 holding the molded articles to be actuated towards the receiving device, and (iii) causing the robot 122 holding the molded articles to drop the molded articles into the receiving device 302.

[0165] Step 420 - causing an optical device to capture an image of each molded article of the row or the column of the array of molded articles, the image being captured as each molded article of the row or the column of the array of molded articles is falling

[0166] The method then continues, at step 420, causing an optical device to capture an image of each molded article of the row or the column of the array of molded articles, the image being captured as each molded article of the row or the column of the array of molded articles is falling.

[0167] The image may be captured by one or more optical devices, such as the optical device 354 of the optical system 310.

[0168] Step 430 - analysing, for each one of the molded articles of the row or the column of the array of molded articles, by the processor, a parameter with respect to a predetermined parameter requirement

[0169] The method then continues, at step 430, with analysing, for each one of the molded articles of the row or the column of the array of molded articles, by the processor, a parameter with respect to a predetermined parameter requirement.

[0170] The method may comprise identifying whether the parameter does not meet the predetermined parameter requirement. It should be noted that the term “does not meet the predetermined parameter requirement” may mean that the produced molded article is outside of predetermined specification requirement / quality parameter. Alternatively, the term “does not meet the predetermined parameter requirement” may mean that the produced molded article is within the predetermined requirement but is not at an “ideal” point of the parameter requirement (which could be a center of a range, bookends of the range, or any other appropriate “gold standard” value for a given parameter of the molded article).

[0171] The method may comprise capturing multiple images of the molded articles using the optical device or multiple optical devices, and identifying multiple parameters to determine whether each of the multiple parameters does not meet respective predetermined parameter requirements.

[0172] In certain implementations, the optical device is a first optical device, the at least one parameter is a first parameter, and the predetermined parameter requirement is a first predetermined parameter requirement, and the method further comprises: causing a second optical device to capture at least one image of at least one molded article of the array of molded articles, the at least one image being captured as the array of molded articles is moving relative to a support plate and / or an extension support plate, such as the support plate 148 and / or the extension support plate 150. The at least one image is an image of a base portion of the molded articles whilst the base portion is being back-lit.

[0173] The method may further comprise, in response to the parameter not meeting the predetermined parameter requirement, the processor 140 causing an execution of a corrective action. The corrective action may include causing the one of the molded articles to be directed toward a discard pile.

[0174] The method may further comprise, in response to the parameter not meeting the predetermined parameter requirement, the processor 140 determining the molding cavity in the mold of the molding system 200, the molding cavity being associated to the one of the molded articles of the array.

[0175] In some embodiments of the method, the method comprises adjusting, by the processor, at least one operating parameter of the determined molding cavity. In some embodiments of the method, the molding process is an injection-blow molding process, and the adjusting includes causing changing at least one operating parameter of a blow molding machine.

[0176] In some embodiments of the method, the adjusting includes changing at least one operating parameter of at least one of the molding machine, a first device upstream of the molding machine in the molding process, and a second device downstream of the molding machine in the molding process.

[0177] In some embodiments, the method 400 terminates and / or returns to step 410.

[0178] Clauses

[0179] Clause 1. A method (400) for optically inspecting a plurality of molded articles, the method being executable by a processor (140), the method (400) comprising: causing a row or a column of an array of molded articles to fall, the array of molded articles having a plurality of rows and a plurality of columns; causing an optical device (354) to capture at least one image of each molded article of the row or the column of the array of molded articles, the at least one image being captured as each molded article of the row or the column of the array of molded articles is falling; and analysing, for each one of the molded articles of the row or the column of the array of molded articles, by the processor, at least one parameter with respect to a predetermined parameter requirement from the at least one captured image.

[0180] Clause 2. The method (400) of clause 1, wherein in response to the at least one parameter not meeting the predetermined parameter requirement, the processor (140) causes an execution of a corrective action, and optionally the corrective action includes causing the one of the molded articles to be directed toward a discard pile.

[0181] Clause 3. The method (400) of clause 1 or clause 2, further comprising determining a molding cavity in a mold of a molding system, the molding cavity being associated to the one of the molded articles of the array.

[0182] Clause 4. The method (400) of any of clauses 1-3, further comprising receiving the array of molded articles in a receiving device (302) defining an array of apertures (318), the array of apertures (318) corresponding to the array of molded articles, and optionally causing the array of molded articles to move along a given plane by causing the receiving device (302) to move along the given plane, and optionally wherein the given plane is parallel to a substantially horizontal plane and / or parallel to a substantially vertical plane.

[0183] Clause 5. The method (400) of any of clauses 1-4, wherein the optical device (354) is a first optical device, the at least one parameter is a first parameter, and the predetermined parameter requirement is a first predetermined parameter requirement, and the method further comprises: causing a second optical device to capture at least one image of at least one molded article of the array of molded articles, the at least one image being captured as the array of molded articles is moving along the given plane; and analysing, for each one of the at least one molded articles of the array of molded articles, by the processor, a second parameter with respect to a second predetermined parameter requirement.

[0184] Clause 6. The method of any of clauses 1-5, wherein the fall of each one of the molded articles of the row or the column of the array of the molded articles is at least one of a free fall, and a sliding fall.

[0185] Clause 7. An inspection system (300) operatively connectable to a molding system (200), the inspection system (300) comprising: an array of molded articles molded by the molding system (200), the array of molded articles having a plurality of rows and a plurality of columns; a driving system (308) for causing a row or a column of the array of molded articles to fall in an inspection zone (306); and an optical system (310) including an optical device (354) at the inspection zone (306), the optical device configured to capture at least one image of the molded articles as the molded articles are falling in the inspection zone.

[0186] Clause 8. The inspection system (300) of clause 7, further comprising a receiving device (302) configured to house the array of molded articles, wherein the receiving device (302) is configured to maintain a position of each of the molded articles within the array of molded articles, and wherein the driving system (308) is configured to move the receiving device (302) along a given plane towards the inspection zone (306), and optionally wherein the receiving device (302) defines an array of apertures (318) corresponding to the array of molded articles.

[0187] Clause 9. The inspection system (300) of clause 7 or clause 8, wherein the driving system (308) includes: a drive component (340) which is moveable along a given plane; inter-engaging components of the drive component (340) and the receiving device (302) which are configured to selectively engage to selectively connect the drive component to the receiving device; and a driver (352) configured to drive the drive component along the given plane.

[0188] Clause 10. The inspection system (300) of clause 9, further comprising a support plate (348) selectively positionable beneath a base of the receiving device (302), and optionally wherein the driving system is configured to cause movement of one or both of the receiving device and the support plate along the given plane.

[0189] Clause 11. The inspection system (300) of clause 9 or clause 10, wherein the inter-engaging components comprise a pin and a recess configured to receive the pin.

[0190] Clause 12. The inspection system (300) of clause 11, wherein the drive component is moveable relative to guide rails (344) so as to position the molded articles over a cavity defined between the guide rails (344) and over the inspection zone (306).

[0191] Clause 13. The inspection system (300) of clause 10, wherein the support plate (348) is moveable along a plane transverse to the given plane, and optionally further comprising interengaging components between the support plate (348) and the receiving device which can be engaged when the support plate is being moved along the plane transverse to the given plane and which can be retracted to allow the drive component to be actuated in the given direction.

[0192] Clause 14. The inspection system (300) of any of clauses 7-13, wherein the optical device is a first optical device (354), and the inspection system includes a second optical device (355), the second optical device being configured to capture at least one of the at least one images of the molded articles as the molded articles are moving relative to a support plate and / or extension support plate. Clause 15. The inspection system (300) of any of clauses 7-14, further comprising a slide disposed generally in the inspection zone so that each molded article of the row or the column of the array of molded articles falls in the inspection zone in a sliding manner.

[0193] Clause 16. The inspection system (300) of any of clauses 7-15, further comprising an extension support plate, and wherein at least a portion of the support plate and / or the extension support plate is transparent.

[0194] Clause 17. The inspection system (300) of any of clauses 7-15, further comprising an extension support plate, and wherein the support plate and / or the extension support plate has a plurality of channels defined therein, each channel having: side walls configured to support the base portion of the molded article; and an open base through which at least a part of the base portion of the molded article can be imaged.

[0195] Modifications and improvements to the above-described embodiments of the present technology may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present technology is therefore intended to be limited solely by the scope of the appended claims.

[0196] The description of the embodiments of the present technology provides only examples of the present technology, and these examples do not limit the scope of the present technology. It is to be expressly understood that the scope of the present technology is limited by the claims only. The concepts described above may be adapted for specific conditions and / or functions and may be further extended to a variety of other applications that are within the scope of the present technology. Having thus described the embodiments of the present technology, it will be apparent that modifications and enhancements are possible without departing from the concepts as described.

Claims

CLAIMSWhat is claimed is1. A method for optically inspecting a plurality of molded articles, the method being executable by a processor, the method comprising: causing a row or a column of an array of molded articles to fall, the array of molded articles having a plurality of rows and a plurality of columns; causing an optical device to capture at least one image of each molded article of the row or the column of the array of molded articles, the at least one image being captured as each molded article of the row or the column of the array of molded articles is falling; and analysing, for each one of the molded articles of the row or the column of the array of molded articles, by the processor, at least one parameter with respect to a predetermined parameter requirement from the at least one captured image.

2. The method of claim 1, wherein in response to the at least one parameter not meeting the predetermined parameter requirement, the processor causes an execution of a corrective action.

3. The method of claim 2, wherein the corrective action includes causing the one of the molded articles to be directed toward a discard pile.

4. The method of claim 1, further comprising: determining a molding cavity in a mold of a molding system, the molding cavity being associated to the one of the molded articles of the array.

5. The method of claim 1, further comprising: receiving the array of molded articles in a receiving device defining an array of apertures, the array of apertures corresponding to the array of molded articles.

6. The method of claim 5, further comprising: causing the array of molded articles to move along a given plane by causing the receiving device to move along the given plane, the given plane being parallel to a substantially horizontal plane or being parallel to a substantially vertical plane.

7. The method of claim 6, wherein causing the receiving device to move along the given plane comprises causing the receiving device to move along the given plane at a constant or a variable speed.

8. The method of claim 1, wherein the array of molded articles are held by a robot, and causing the row or the column of the array of the molded articles to fall comprises causing the robot to release the molded articles of the row or the column.

9. The method of claim 6, wherein the optical device is a first optical device, the at least one parameter is a first parameter, and the predetermined parameter requirement is a first predetermined parameter requirement, and the method further comprises: causing a second optical device to capture at least one image of at least one molded article of the array of molded articles, the at least one image being captured as the array of molded articles is moving along the given plane; and analysing, for each one of the at least one molded articles of the array of molded articles, by the processor, a second parameter with respect to a second predetermined parameter requirement.

10. The method of claim 1, wherein the fall of each one of the molded articles of the row or the column of the array of the molded articles is at least one of a free fall, and a sliding fall.

11. The method of claim 5, further comprising: supporting the receiving device on a support plate; causing the support plate to move away from the receiving device to cause the row or the column of the array of molded articles to fall.

12. An inspection system operatively connectable to a molding system, the inspection system comprising: a driving system for causing a row or a column of an array of molded articles to fall in an inspection zone; and an optical system including an optical device at the inspection zone, the optical device configured to capture at least one image of the molded articles as the molded articles are falling in the inspection zone.

13. The inspection system of claim 12, further comprising a receiving device configured to house the array of molded articles, wherein the receiving device is configured to maintain a position of each of the molded articles within the array of molded articles.

14. The inspection system of claim 13, wherein the receiving device defines an array of apertures corresponding to the array of molded articles.

15. The inspection system of claim 14, further comprising a support plate selectively positionable beneath a base of the receiving device.

16. The inspection system of claim 15, wherein the driving system is configured to cause movement of one or both of the receiving device and the support plate along a given plane.

17. The inspection system of claim 13, wherein the driving system includes: a drive component which is moveable along a given plane; inter-engaging components of the drive component and the receiving device which are configured to selectively engage to selectively connect the drive component to the receiving device; and a driver configured to drive the drive component in the given plane.

18. The inspection system of claim 17, wherein the inter-engaging components comprise a pin and a recess configured to receive the pin.

19. The inspection system of claim 17, wherein the drive component is moveable relative to guide rails so as to position the molded articles over a cavity defined between the guide rails and over the inspection zone.

20. The inspection system of claim 16, wherein the support plate is moveable along a plane transverse or parallel to the given plane.

21. The inspection system of claim 20, further comprising inter-engaging components between the support plate and the receiving device which can be engaged when the support plate is being moved along the plane transverse to the given plane and which can be retracted to allow the drive component to be actuated along the given plane.

22. The inspection system of claim 21, wherein the inter-engaging components comprise a pin and a recess configured to receive the pin.

23. The inspection system of claim 12, wherein the optical device is a first optical device, and the inspection system includes a second optical device, the second optical device being configured to capture at least one image of at least one molded article of the array of molded articles, the at least one image being captured as the array of molded articles is moving along a given plane which is parallel to a substantially horizontal plane or parallel to a substantially vertical plane .

24. The inspection system of claim 12, further comprising a slide disposed generally in the inspection zone so that each molded article of the row or the column of the array of molded articles falls in the inspection zone in a sliding manner.

25. The inspection system of claim 12, further comprising a robot holding the array of molded articles, wherein the driving system is configured to move the robot towards the inspection zone.

26. The inspection system of claim 15, further comprising an extension support plate, and wherein at least a portion of the support plate and / or the extension support plate is transparent.

27. The inspection system of claim 15, further comprising an extension support plate, and wherein the support plate and / or the extension support plate has a plurality of channels defined therein, each channel having: side walls configured to support the base portion of the molded article; and an open base through which at least a part of the base portion of the molded article can be imaged.

Images