JP4860060B2 - Die casting machine monitoring device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a die-casting machine monitoring device, and particularly to further improve monitoring accuracy.
[0002]
[Prior art]
As a die-casting machine that casts metal products with a mold, after the molten metal is cast in a mold-clamped state in which the movable-side mold is in contact with the fixed-side mold, the movable-side mold is retracted from the fixed-side mold. , A die casting machine is used in which a product attached to the movable side die and pulled out from the fixed side die is taken out by a work robot, and a casting product is efficiently manufactured by repeating subsequent casting cycles. .
[0003]
In the die-casting machine having this configuration, when the movable side mold is in the mold open state, when the cast product to be pulled out attached to the movable side mold is taken out by the work robot, for example, it seems that the cast product has failed to be taken out. If such an abnormal state occurs, there is a disadvantage that the mold is damaged or a defective product is cast.
[0004]
As a method for solving such inconvenience, when the movable side mold is in the mold open state, the state of the movable side mold and the fixed side mold is imaged by a monitoring camera, and the captured image is compared with a standard captured image. A die casting machine monitoring apparatus is used in which whether or not an abnormality has occurred is determined by determining whether or not they match (this is called primary monitoring).
[0005]
[Problems to be solved by the invention]
However, in this type of die casting machine, when the movable mold is in the mold open state and the cast product adhering to the mold is taken out by the work robot, the fog that the cast product takes out from the movable mold in the next casting cycle. Work process such as spraying the mold release agent (which can be easily removed from the movable side mold) to the movable side mold and the fixed side mold is necessary. Since the camera lens becomes dirty, there is a possibility that a clear monitoring image cannot be obtained from the monitoring camera.
[0006]
The present invention has been made in consideration of the above points, and an object of the present invention is to propose a die casting machine monitoring apparatus in which a monitoring camera is not contaminated by a release agent.
[0007]
[Means for Solving the Problems]
In order to solve such a problem, in the present invention, a mold clamping process for pressing the movable side mold to the fixed side mold, a casting process for injecting a cast metal material into a mold composed of the movable side mold and the fixed side mold, and a movable In order to make it easy to take out the cast product from the movable side mold in the mold opening process for retreating the side mold from the fixed side mold, the product takeout process for taking out the cast product adhering to the movable side mold, and the product takeout process in the next casting cycle A die casting machine main body that repeats a series of casting cycles including a mold release agent spraying process for spraying a mold release agent to the mold, and a mold in a state where a cast product is taken out from the movable mold after the mold release agent spraying process, Alternatively, an imaging unit that obtains an image output signal by capturing an image of a mold and its surrounding subject, and monitoring whether or not an abnormality has occurred in the casting cycle based on the image output signal. If it occurs, the casting cycle is stopped, and if no abnormality occurs, the monitoring means that repeats the next casting cycle is provided on the lens front surface between the lens and the mold of the television camera in the imaging means, The lens is closed from the mold to protect it from contamination by the mold release agent by closing it after the mold clamping process through the casting process, mold opening process and product takeout process. The shutter is opened from after the mold release agent spraying process until after the mold clamping process in the next casting cycle, so that the lens is exposed to the mold and imaged by the imaging means, and the shutter after the mold opening process. The timer for the shutter is started and a set time elapse output signal indicating that a predetermined time has elapsed since the start of the shutter timer is output after the release agent spraying process. By receiving al, it was provided and control means for opening the Shiyatta.
[0008]
The shutter 11F can sufficiently prevent contamination of the lens 11A of the image pickup means 11 by opening only for a short period of the casting cycle of the die casting machine main body 1, and thereby clear image data can be obtained from the image pickup means 11. By being able to obtain, abnormality determination accuracy can be increased.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.
[0010]
(1) Overall Configuration of Die Machine Monitoring Device In FIG. 1, reference numeral 1 denotes a die casting machine main body, and a casting metal material is injected through a conduit 4 in a mold clamping state in which a movable die 2 is pressed against a fixed die 3. The cast product is cast in the movable side mold 2 and the fixed side mold 3.
[0011]
This cast product was brought to the mold opening limit position with the movable side mold 2 attached to the inner surface of the movable side mold 2 when the movable side mold 2 was separated from the fixed side mold 5 along the guide 5. After that, the pin (not shown) protrudes from the rear side of the movable mold 2 and the working robot (not shown) grips and takes out the cast product to the outside.
[0012]
The casting cycle of the die casting machine main body 1 is automatically controlled by a sequencer provided in the die casting machine main body drive control device 6.
[0013]
The casting operation of the die casting machine main body 1 is picked up by a television camera 11 as an image pickup means provided in the die casting machine monitoring device 10, and the video signal VD1 is converted into video data DATA1 by the image input circuit 12, and image processing is performed. It is input to the circuit 13 and held.
[0014]
The video data held in the image processing circuit 13 is input from the operation input unit 25 to the central processing unit (CPU) 17 that performs processing operation according to the program in the program memory 16 via the bus 15 in response to a user operation. In response to an operation command, the data is taken in at a predetermined timing and stored in the frame memory 18 via the bus 15 for each pixel.
[0015]
In this embodiment, the timing at which the CPU 17 stores the image data DATA1 in the frame memory 18 is first during the test mode before the die casting machine monitoring device 10 enters the monitoring operation, and secondly, the die casting machine main body. Reference numeral 1 denotes the primary monitoring mode in which the mold opening operation is performed.
[0016]
In the primary monitoring mode, the CPU 17 determines the presence / absence of an abnormality based on the video data DATA1 stored in the frame memory 18, and determines the determination result image data DATA2 representing the determination result via the bus 15 as an image processing circuit. 13 The image processing circuit 13 supplies the determination result image data DATA2 to the image display circuit 19 so that the image display circuit 19 superimposes it on the video signal VD1 supplied from the television camera 11 to the monitor 20 as the display image signal VD2. give.
[0017]
Thus, the monitor 20 determines the abnormal state (or normal state) determined by the CPU 17 with respect to the object currently captured by the television camera 11 based on the input video signal VD1, that is, the image of the mold 213 of the die casting machine body 1. Based on the result image data DATA2, it is possible to present to the user a monitoring screen in which an abnormality occurrence display is displayed on the image portion where the abnormality has occurred.
[0018]
The CPU 17 recognizes the timing at which the monitoring processing operation should be performed based on the monitoring control signal S1 provided from the die casting machine main body drive control device 6 via the control signal input / output unit 21, performs a determination operation, and performs the determination result. The sequence control signal S2 is given to the die casting machine main body drive control device 6 via the control signal input / output unit 21 on the basis of the above, so that the die casting machine main body 1 is operated in synchronization with the monitoring operation of the die casting machine monitoring device 10. Execute.
[0019]
Thus, the CPU 17 executes the monitoring processing operation described below while synchronizing with the operation of the casting cycle of the die casting machine body 1.
[0020]
(2) Shiyatta device television camera 11 of the television camera, as shown in FIG. 4 (A) and (B), installed in the camera housing 11B having a front opening in the lens 11A, the camera housing 11B Shi ya jitter device 11C is provided on the front opening position of.
[0021]
Shiyatta device 11C is vertically the camera housing 11 Shiyatta 11F engaged with the pair of slide grooves 11D and 11E to the left and right sides of the front opening is provided so as to extend in the vertical direction B by the air cylinder 11G , The shutter 11F is driven to the shutter closed state (FIG. 4A) at the upper slide position or to the shutter open state (FIG. 4B) slid downward.
[0022]
The air cylinder 11G is opened or closed by supplying the air from the air source 11I to the shutter closing port 11J1 or the shutter opening port 11J2 of the air cylinder 11G via the opening / closing solenoid valve 11H. In response to this, the shutter 11F is opened or closed accordingly.
[0023]
(3) Casting Operation The die casting machine main body drive control device 6 casts a cast product by executing a casting cycle according to the casting processing procedure RT1, as shown in FIG.
[0024]
In step SP21, the die casting machine main body drive control device 6 puts the movable die 2 of the die casting machine main body 1 into a clamped state where the fixed die 3 is pressed, and then in step SP22, the die opening limit signal is turned off and the television set is turned off. The shutter 11F is closed by turning off the shutter drive signal S3 with respect to the electromagnetic valve 11H for opening and closing of the camera 11.
[0025]
In this state, the die machine main body drive control device 6 performs a casting operation by applying a metal material through the conduit 4 in the next step SP23, and then performs a mold opening operation in step SP24.
[0026]
At this time, the movable die 2 moves away from the fixed die 3 with the cast product attached, and eventually the die casting machine main body drive control device 6 generates a die opening limit signal in step SP25 when the movable die 2 moves back to the die opening limit position. and then sent to the monitor control signal S1 as CPU 17, at this time CPU 17 via the bus 15 and provides an activation signal to Shiyatta timer 3 3.
[0027]
After mold opening limit signal is turned on in Shiyatta timer 3 3 this time, until the time to opening operation the Shiyatta 11F television camera 11 (in this embodiment 16 (seconds)) is set.
[0028]
Subsequently, the die casting machine main body drive control device 6 protrudes in the movable mold 2 in step SP26, and after taking out the product by the work robot, in step SP27, the release agent is supplied to the movable mold 2 and the fixed mold. 3 is sprayed.
[0029]
At this time, since the shutter 11F of the television camera 11 is still in the closed state, the lens of the television camera 11 is caused by contamination of the product during the product taking-out operation or the release agent spraying operation, particularly by the fog of the release agent. Protects 11A from contamination.
[0030]
Then with die-casting machine body drive control device 6 receives the set time has elapsed the output signal from the Shiyatta timer 3 3 in step SP28, by turning on operation of the Shiyatta drive signal S3 in response thereto, the opening and closing electromagnetic valve 11H operation To open the shutter 11F.
[0031]
In this way, the die casting machine main body drive control device 6 makes the CPU 17 of the die casting machine monitoring device 10 ready to receive the image data DATA1 from the television camera 11.
[0032]
Subsequently, in step SP29, the die casting machine main body drive control device 6 determines whether or not a stop signal is given from the CPU 17 of the die casting machine monitoring device 10, and when a negative result is obtained (this is the casting process). This means that no abnormality has occurred in the cycle), and the process returns to the above-mentioned step SP21 via step SP30 to enter the next casting cycle.
[0033]
On the other hand, if a positive result is obtained in step SP29, this means that the CPU 17 of the die casting machine monitoring device 10 detects an abnormality and gives a stop signal to the die casting machine main body drive control device 6 as the sequence control signal S2. At this time, the die casting machine main body drive control device 6 moves to step SP31, stops the die casting machine main body 1, and executes a reset processing operation for removing the cause of the abnormality by manual operation of the operator.
[0034]
As a result, when the abnormal operation recovers, the die casting machine main body drive control device 6 returns to the above-described step SP21 via the above-described step SP30 and executes the next casting cycle.
[0035]
The process of step SP30 means that the operator has designated the end of the casting cycle via the manual operation panel 31, and at that time, the die casting machine main body drive control device 6 ends the casting process procedure RT1 in step SP32.
[0036]
(4) Monitoring Processing Operation With respect to the casting cycle by the die casting machine main body drive control device 6 in FIG. 2, the CPU 17 of the die casting machine monitoring device 10 follows the monitoring processing procedure RT2 shown in FIG. Monitor whether or not an abnormality has occurred in relation to the mold opening operation.
[0037]
The CPU 17 of the die-casting machine monitoring apparatus 10 shown in FIG. 3 is synchronized with the casting processing procedure RT1 of the die-casting machine main body 1 described above with reference to FIG. 2 when the user designates the monitoring processing mode via the operation input unit 25. Such a monitoring processing procedure RT2 is executed.
[0038]
When entering the monitoring processing procedure RT2, the CPU 17 uses the first casting cycle operation of the die casting machine body 1 to execute the test mode processing in steps SP1 to SP3.
[0039]
That is, the CPU 17 waits for the mold opening limit signal to be turned on in step SP1.
[0040]
When the movable die 2 of the die casting machine main body 1 is retracted from the fixed die 3 to the die opening limit position, this die opening limit signal is sent from the die casting machine main body drive control device 6 as a monitoring control signal S1 as a control signal input / output unit. 21. Thus, the CPU 17 is in a state in which the movable die 2 of the die casting machine body 1 is retracted to the casting product take-out position, and therefore the die casting machine monitoring device 10 is in a state to enter a monitoring operation. Is notified to the CPU 17.
[0041]
At this time CPU17 drives the image data take-in timer 3 2 proceeds to step SP2.
[0042]
The image data acquisition timer 3 2 receives a timer activation instruction via the bus 15 from the CPU 17, and starts the time counting operation, the image input command to the CPU 17 via the bus 15 after a lapse of a subsequent predetermined measurement time give.
[0043]
At this time, the CPU 17 moves to step SP3, takes in the primary monitoring image from the image processing circuit 13, and registers it in the frame memory 18.
[0044]
Timed time of the image data take-in timer 3 2, die casting and machine body 1 is turned to the mold open state, after the cast product has been removed, until the die preparative machine monitoring apparatus 10 is in a state to be the monitoring operation (For example, 17 [seconds]).
[0045]
Thus, when the die machine body 1 executes the first casting cycle, the CPU 17 has registered the monitoring image at that time in the frame memory 18 as a reference registered image (IG1 (FIG. 5A)). As a result, it is determined that an abnormality has occurred in the casting cycle in which a change has occurred in comparison with the registered supervision image IG2 (FIG. 5B) based on the registered image memory and image data obtained in the subsequent casting cycle.
[0046]
When the die casting machine main body drive control device 6 enters the casting cycle, the CPU 17 waits for the mold opening limit signal to be turned on in step SP4. When an affirmative result is obtained in step SP4, the process proceeds to step SP5. The built-in timer 32 is started.
[0047]
This image data capturing timer 32 is set to a time (in this embodiment, 17 [seconds]) from when the mold opening limit signal is turned on until the die casting machine main body 1 enters a monitoring state. During the time measured by the image data taking-in timer 32, the die-casting machine main body 1 performs the protrusion and robot product take-out process in step SP26 of the above-described casting process procedure RT1, and the release agent spraying operation in step SP27. An operation of opening the shutter 11F in step SP28 is executed.
[0048]
Thus, in the next step SP6, the CPU 17 executes a process of inputting the primary monitoring image at a timing when the set time has elapsed by the image data capturing timer 32.
[0049]
At this time, since the shutter 11F of the television camera 11 is open, the image data DATA1 obtained based on the video signal VD1 is taken into the CPU 17 as the operation result of the die casting machine body 1 in the current casting cycle.
[0050]
At this time, the CPU 17 executes a monitoring process in step SP7, whereby the captured monitoring image IG2 captured in SP6 (FIG. 5B) is registered, and the registered image IG1 captured in the above-described step SP3 (FIG. 5A). ) And a process of comparing each dot pattern.
[0051]
When the monitoring process is thus completed, the CPU 17 proceeds to step SP8 to determine whether or not the monitoring process result is abnormal (whether it is NG), and when a negative result is obtained (this is not abnormal). CPU 17 returns to the above-mentioned step SP4 via step SP9.
[0052]
In this way, the CPU 17 ends the casting cycle in which the die casting machine main body 1 casts one casting product and enters the next casting cycle, so that the mold opening limit signal of step SP4 is turned on again accordingly. Start waiting processing.
[0053]
On the other hand, if a positive result is obtained in step SP8, this means that an abnormality has occurred in the casting cycle. At this time, the CPU 17 performs the sequence control signal S2 via the control signal input / output unit 21 in step SP10. A stop signal is sent to the die casting machine main body drive control device 6 as follows. At this time, the die casting machine main body drive control device 6 obtains a positive result in step SP29, thereby stopping the casting operation of the die casting machine main body 1 and performing a manual reset process by the operator. (SP31)
[0054]
In accordance with this, the CPU 17 waits for the end of the reset processing in step SP11, and when the processing signal is given from the reset as the monitoring control device S1 from the die casting machine main body drive control device 6, it returns to the above-mentioned step SP4 and returns to the next step SP4. Enter the monitoring device for the casting cycle.
[0055]
(5) Synchronous operation of casting process and monitoring process In contrast to the casting process procedure RT1 (FIG. 2) of the die casting machine main body drive control device 6, the monitoring process procedure RT2 (FIG. 3) of the CPU 17 of the die casting machine monitoring device 10 is an image. Synchronous operation is performed according to the timing operation of the data acquisition timer 32 and the shutter timer 33.
[0056]
That is, in step SP25, the die casting machine main body drive control device 6 turns on the mold opening limit signal to simultaneously start the image data fetch timer 32 and the shutter timer 33. As a result, the shutter timer 33 is activated in step SP26. After the time taken out (16 [seconds] in this case) after executing the product removal process by the protruding robot and the release agent spraying process in step SP27, the shutter 11F of the television camera 11 is set in step SP28. open.
[0057]
At this time, the image data capturing timer 32 of the die casting machine monitoring apparatus 10 is driven in step SP5, and then the primary monitoring image is input by the image data capturing timer 31 being timed in step SP6.
[0058]
However the set time of the image data take-in timer 32 is a Shiyatta opening operation time in Shiyatta timer 3 3 time points after slightly (i.e. 16 (seconds) time after) (i.e. the time after 17 [sec]) Moreover, since it is set to the time immediately before mold clamping, the CPU 17 can input the primary monitoring image in step SP6 during the short time when the shutter 11F is open.
[0059]
Since the time until the mold clamping operation is completed in the next casting cycle after the shutter 11F is opened (step SP28) is sufficiently shorter than the time until the casting cycle is completed once, the television Since the time when the lens 11A of the camera 11 is exposed is short, the probability that the lens 11A is contaminated as a result can be sufficiently reduced. As a result, when the CPU 17 inputs the primary monitoring image in step SP6. A clear image is obtained as the embedded monitoring image IG2 (FIG. 5B), and the accuracy of comparison with the registered image IG1 can be increased accordingly.
[0060]
(6) Other Embodiments In the above-described embodiments, the shutter timer 33 is disposed on the die casting machine main body drive control device 6 side, and the image data image data capturing timer is disposed on the die casting machine monitoring device 10 side. 32, but instead of this, the image data image data acquisition timer 32 and the shutter timer 33 are integrated to provide a single acquisition and shutter timer for the die casting machine monitoring device 10 side or the die casting machine main body. Provided on the drive control device 6 side, set the shutter opening time and the image data acquisition time in the acquisition and shutter timers, and the shutter is opened from the point when the mold opening limit signal is turned on. Even if the time signal and the time signal for capturing image data are sequentially generated, the same effect as described above can be obtained. Can.
[0061]
In the above-described embodiment, as the shutter 11F, as shown in FIGS. 4 (A) and 4 (B), a structure that slides up and down by the air cylinder 11G is used, but the structure of the shutter 11F is as follows. Not limited to this, various configurations such as a method of sliding or turning the shutter 11F in the lateral direction, or using an electric drive motor or an electromagnetic drive device instead of an air cylinder as a shutter drive source, etc. Can apply.
[0062]
In the above-described embodiment, the occurrence of abnormality is monitored based on the image data of the movable side mold 2 and the fixed side mold 3, but instead, the state of the movable side mold and the surrounding image are displayed. You may make it monitor based on including in data.
[0063]
In the above-described embodiment, the image data is obtained based on the video signal of the television camera subject, but in short, other imaging means capable of obtaining the image data may be used.
[0064]
【Effect of the invention】
As described above, according to the present invention, a shutter is provided for the image pickup means, and the lens of the image pickup means is blocked from the subject during the casting cycle from immediately after the mold clamping process to after the mold release agent spraying process. to the the fact, effectively prevent contamination of the lens of the imaging means, it gives no monitoring process on the basis of the more clear image data, thereby increasing the accuracy of monitoring.
[Brief description of the drawings]
FIG. 1 is a block diagram showing the overall configuration of a die casting machine monitoring apparatus 10 according to the present invention.
FIG. 2 is a flowchart showing a casting process procedure of the die casting machine main body drive control device 6 of FIG. 1;
3 is a flowchart showing a monitoring processing procedure executed by a CPU 17 of the die casting machine monitoring apparatus 10 of FIG.
4A and 4B are perspective views showing a detailed configuration of the shutter device 11C of FIG.
FIGS. 5A and 5B are schematic diagrams illustrating a registered image and a capture monitoring image captured by the die casting machine monitoring apparatus 10 of FIG. 1;
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Die-casting machine main body, 2 ... Movable side type, 3 ... Fixed side type, 4 ... Conduit, 5 ... Guide, 6 ... Die-casting machine main body drive control apparatus, 10 ... Die-casting machine monitoring apparatus, 11 ... TV camera, 11A ... Lens, 11B ... Camera housing, 11C ... Shutter device, 11D, 11E ... Slide groove, 11F ... Shutter, 11G ... Air cylinder, 11H ... Solenoid valve for opening / closing , 11I …… Air source, 11J1 …… Shutter closed port, 11J2 …… Shutter open port, 12 …… Image input circuit, 13 …… Image processing circuit, 15 …… Bus, 16 …… Program memory, 17 …… Center Processing unit (CPU), 18: frame memory, 19: image display circuit, 20: monitor, 21: control signal input / output unit, 31: manual operation panel, 2 ...... image data take-in timer, 33 ...... Shiyatta timer.

Claims (1)

A mold clamping step for pressing the movable side die against the fixed side die, a casting step for injecting a cast metal material into a mold composed of the movable side die and the fixed side die, and the movable side die from the fixed side die. In order to facilitate the removal of the cast product from the movable side mold in the product opening process for removing the cast product adhering to the movable side mold, the product removing process for removing the cast product adhering to the movable side mold, and the next casting cycle. A die casting machine main body that repeats a series of casting cycles including a release agent spraying process for spraying a release agent;
An imaging means for obtaining an image output signal by imaging the mold in a state in which the cast product is taken out from the movable mold after the releasing agent spraying step, or the mold and its surrounding subjects. ,
Whether or not an abnormality has occurred in the casting cycle is monitored based on the image output signal. If an abnormality has occurred, the casting cycle is stopped, and if no abnormality has occurred, the next casting cycle is repeated. Means,
Provided on the lens front surface between the lens of the television camera and the mold in the imaging means, and after the mold clamping step in the casting cycle, the casting step, the mold opening step and the product removing step. The lens is closed until after the release agent spraying step so that the lens is blocked from the mold and protected from contamination by the release agent, and after the release agent spraying step, the next casting is performed. A shutter that exposes the lens to the mold by being released until after the mold clamping step in a cycle, and performs imaging by the imaging means ;
A shutter timer is started after the mold opening process, and a set time elapse output signal indicating that a predetermined time has elapsed since the start of the shutter timer is received from the shutter timer after the release agent spraying process. Thus , a die casting machine monitoring device having a control means for opening the shutter .

Images