JP7189519B2 - Manufacturing method and apparatus for resin molding - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method and apparatus for manufacturing a resin-molded product for attaching parts to a molded product body having a mounting seat.

Conventionally, there are cases where some post-processing such as assembly of separate parts is required for a molded product body manufactured by injection molding. In this case, for example, the main body of the molded product is taken out from the mold by a take-out robot or the like, held at a predetermined position while being gripped, the position of the assembly point is measured, and the part is assembled at that position. There is known a device that follows a change in the assembly position of parts due to shrinkage of the main body of the molded product (see, for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 2017-222150 (page 4, FIGS. 1-5)

However, since the main body of the molded product continues to shrink even after the injection molding and before the parts are assembled, the assembly positions of the parts change every second. Therefore, it is desired to be able to stably assemble the parts to the molded product body even if the time between processes after injection molding and mounting of the parts changes. In addition, when the parts are automatically attached to the main body of the molded product, it is desired that defects such as missing parts are less likely to occur.

The present invention has been devised in view of these points, and provides a method and apparatus for manufacturing a resin molded product that can stably attach a part to a mounting seat of a molded product body and that can guarantee a high level of quality. intended to provide

A method of manufacturing a resin molded product according to claim 1 is a method of manufacturing a resin molded product in which parts are attached to a molded product body provided with a mounting seat, comprising: a removing step of removing the molded product body from the mold; a recognition step of recognizing positions of a plurality of markers positioned apart from each other on the molded product body as measured positions when the molded product body is in a region where the dimensional change after molding is moderate; indexing step of indexing the positions of the respective mounting seats based on the position data of and mutual positional relationship data prepared in advance including the position data of the mounting seats; and a mounting step for mounting the component, measuring the engagement reaction force of the component during the mounting step, and determining whether or not the component is engaged with the mounting seat within a predetermined engagement reaction force characteristic range. In the mounting step, in accordance with the elapsed time from molding of the molded product body to mounting of the part to the position of the mounting seat, indexed in the indexing step It corrects the position of each of the mounting seats .

According to a second aspect of the present invention, there is provided a method for manufacturing a resin molded product according to the first aspect, wherein at least one of the markers is one of the plurality of mounting seats.

The apparatus for manufacturing a resin molded product according to claim 3 is an apparatus for manufacturing a resin molded product for attaching parts to a molded product body having a mounting seat, comprising: a take-out device for taking out the molded product body from the mold; a recognition device for recognizing positions of a plurality of markers positioned apart from each other on the molded product body taken out from the mold as measured positions; the measured positions, position data of the markers, and position data of the mounting seat. an indexing device for indexing the position of each mounting seat based on mutual positional relationship data prepared in advance including The mounting device has an inspection device that measures an engagement reaction force of the component and inspects whether or not the component is engaged with the mounting seat within a predetermined engagement reaction force characteristic range , The position of each mounting seat indexed by the indexing device is corrected in accordance with the elapsed time from molding of the molded product body to mounting of the component on the position of the mounting seat .

According to a fourth aspect of the present invention, there is provided an apparatus for manufacturing a resin molded product according to the third aspect, wherein the recognizing device detects a plurality of markers when the main body of the molded product is in a region where the dimensional change after molding is moderate. position is recognized as the measured position.

According to the method of manufacturing a resin molded product according to claim 1, the measured positions of the plurality of markers measured when the molded product main body removed from the mold is in a region where the dimensional change after molding is moderate, and the positions of the markers The position of each mounting seat is determined based on the data and mutual positional relationship data prepared in advance including the position data of the mounting seat, and the position of the determined mounting seat is shifted from the molding of the molded product main body to the position of the mounting seat. By correcting according to the elapsed time until the part is installed, and engaging the part with the mounting seat and mounting it, the part can be stably and accurately mounted on the mounting seat of the molded product body. By measuring the engagement reaction force of the part when mounting the part and inspecting whether or not the part is engaged with the mounting seat within a predetermined engagement reaction force characteristic range, the lack of the part can be detected. A high level of quality assurance can be achieved by suppressing product defects and the like.

According to the method for manufacturing a resin molded product according to claim 2, in addition to the effect of the method for manufacturing a resin molded product according to claim 1, any one of the plurality of mounting seats can be used as at least one of the markers. , there is no need to form a separate marker on the main body of the molded product, and the process can be simplified.

According to the apparatus for manufacturing a resin molded product according to claim 3 , a mutual positional relationship prepared in advance including the actually measured positions of the plurality of markers on the molded product main body, the position data of the markers, and the position data of the mounting seats Based on the data, the position of each mounting seat is determined, and the determined position of the mounting seat is corrected according to the elapsed time from molding of the molded product body to mounting of the part to the position of the mounting seat. By engaging the part with the mounting seat by using the By inspecting whether or not the part is engaged with the mounting seat within the range of the predetermined engagement reaction force characteristic, it is possible to suppress defective parts, etc., and ensure a high level of quality assurance. .

According to the apparatus for manufacturing a resin molded product according to claim 4 , in addition to the effects of the apparatus for manufacturing a resin molded product according to claim 3 , the molded product main body taken out from the mold is in a region where the dimensional change after molding is moderate. By actually measuring the position of the marker when it is at , it is possible to suppress errors due to post-molding shrinkage of the molded product body when determining the position of the mounting seat.

BRIEF DESCRIPTION OF THE DRAWINGS (a) is a perspective view which shows typically the manufacturing apparatus of the resin molding of one embodiment of this invention, (b) is a perspective view which expands and shows a part of (a). (a) is a perspective view showing an example of a resin molded product manufactured by the same manufacturing apparatus, and (b) is a perspective view showing an enlarged part of (a). It is a graph which shows an example of the engagement reaction force of components with respect to a resin molding same as the above. (a) is a graph showing an example of a time change of post-molding shrinkage of a resin molded product, and (b) is a graph enlarging a part of (a).

A configuration of an embodiment of the present invention will be described below with reference to the drawings.

In FIGS. 1(a) and 1(b), 10 is a manufacturing apparatus. This manufacturing apparatus 10 manufactures a resin molded product 11 as a work. In the present embodiment, the resin molded product 11 will be described by exemplifying a vehicle interior material, that is, a garnish. The resin molded product 11 has, for example, a molded product main body 12 and parts 13 attached to the molded product main body 12, as shown in FIG. 2(b). The molded product body 12 shown in FIGS. 2( a ) and 2 ( b ) has a body portion 15 and a mounting seat 16 . The main body portion 15 is formed according to the shape of a mounting portion (not shown) such as a vehicle body panel covered with the resin molded product 11 . For example, the body portion 15 of the present embodiment is elongated and formed in a planar shape, but is not limited to this shape. Also, the body portion 15 may be integrally formed with other members by, for example, insert molding. The mounting seat 16 protrudes from the back side of the body portion 15, that is, the side opposite to the design surface side. For example, a plurality of mounting seats 16 protrude from the body portion 15 . These mounting seats 16 are arranged at different positions. For example, in the case of the molded product main body 12 of the present embodiment, the mounting seats 16 are arranged at both ends of the main body portion 15 in the longitudinal direction, between them, and at the edges in the lateral direction. Each mounting seat 16 integrally includes a base portion 17 protruding from the main body portion 15 and a mounting portion 18 further protruding from the base portion 17 . The mounting portion 18 is formed in a plate-like shape having a thickness in a direction intersecting the projecting direction from the base portion 17, and a locking hole 18a is formed through the mounting portion 18 in the thickness direction.

The part 13, which can also be called a clip, is click-engaged with and integrally fixed to the separate molded product main body 12, and engages when the resin molded product 11 is attached to the mounting part. It serves as a stopping part. Each part 13 is made of a member such as elastically deformable synthetic resin. Each component 13 has an insertion portion 20 inserted into a mounting hole (not shown) formed in the mounting portion. The insertion portion 20 is composed of a pair of insertion pieces 21, 21 positioned with the mounting portion 18 of the mounting seat 16 interposed therebetween. The sides are spaced apart from one another and are formed, as it were, in an inverted V shape. The insertion pieces 21, 21 are provided with projections 21a, 21a to be engaged with the mounting holes, protruding outside the insertion pieces 21, 21, that is, at positions opposite to the mounting portion 18. As shown in FIG. Each part 13 has a pair of locking portions 23, 23 formed on the side of the insertion pieces 21, 21 facing the mounting portion 18 of the mounting seat 16, sandwiching the mounting portion 18 therebetween. A claw portion 23a to be locked in the locking hole 18a is formed at the tip of each locking portion 23. By locking these claw portions 23a in the locking hole 18a, the component 13 can be secured. It is attached and fixed to the mounting seat 16 .

The manufacturing apparatus 10 shown in FIGS. 1(a) and 1(b) has a molding die (not shown) for molding the molded product body 12. As shown in FIG. The mold is installed in a molding machine (injection molding machine). When the mold is closed, the molten synthetic resin, which is the raw material, is filled into the cavity inside the mold. The molded product main body 12 can be taken out. The molding machine is equipped with a projecting device such as a hydraulic ejector that lifts the molded product body 12 from the mold surface of the mold and releases it from the mold.

The manufacturing apparatus 10 also includes a take-out device 25 for taking out the molded product main body 12 from the mold in the open state. The take-out device 25 takes out the resin molded product 11 from the mold in conjunction with the opening and closing of the mold of the molding machine and the lifting operation of the molded product main body 12 by the extrusion mechanism. The take-out device 25 comprises holding means 27 for holding the molded product body 12 . In this embodiment, the holding means 27 is, for example, a suction holding portion that holds the molded product body 12 by suction.

Furthermore, the manufacturing apparatus 10 includes a receiving device 30 for receiving the molded product body 12 removed from the mold by the removing device 25 . In the present embodiment, the receiving device 30 is a (first) robot hand and includes an action section 31 that is a multi-link manipulator and a receiving means 32 attached to the tip of the action section 31 . In the present embodiment, the receiving means 32 is, for example, an adsorption holding portion that adsorbs and holds the molded product body 12 . In addition, a (first) camera 33 is attached to the tip of the action unit 31 of the receiving device 30 . The camera 33 is image acquisition means for capturing an image by imaging the molded product body 12 . The camera 33 can output an image to image processing means such as a computer (not shown). The image processing means performs known image processing on the image captured by the camera 33, and determines whether the molded product body 12 is molded properly. That is, the camera 33 and the image processing means constitute a judgment device 35 for judging whether the molding of the molded product body 12 is good or bad. This judging device 35 can judge, for example, whether resin filling failure of the molded product main body 12, a so-called short shot, or the like has occurred. In the vicinity of the receiving device 30, a box 36 for sorting out defective products, also called a red box, is arranged. It has become so.

The manufacturing apparatus 10 also includes a set stage (stand) 38 which is a general positioning unit on which the receiving means 32 sets the molded product body 12 determined as a non-defective product by the determining means. The set stage 38 has a receiving shape (concave shape) corresponding to the shape of the molded product main body 12 . Therefore, the molded product main body 12 is set on the set stage 38 so as to be roughly positioned. The set stage 38 is prepared in advance according to the molded product body 12 . Therefore, when manufacturing a plurality of types of resin molded products 11, a plurality of set stages 38 are prepared and can be exchanged according to the resin molded product 11 to be manufactured.

Further, the manufacturing apparatus 10 includes a mounting device 40 for mounting the component 13 on the molded product body 12. As shown in FIG. In the present embodiment, the mounting device 40 is a (second) robot hand, an action part 41 that is a multi-link manipulator, and an attachment means that is attached to the tip of the action part 41 and attaches the part 13 to the molded product main body 12. 42 and. The mounting means 42 is adapted to receive the parts 13 from a parts feeder 43 which is a supply means for supplying the parts 13 . A (second) camera 45 that is an alignment camera is attached to the attachment device 40 at the tip of the operation section 41 . The camera 45 is image acquisition means for acquiring an image by imaging the positions of a plurality of markers positioned apart from each other on the molded product main body 12, in the present embodiment, the positions of the plurality of mounting seats 16. FIG. The camera 45 can output an image to analysis means such as a computer (not shown). The analysis means determines the position of each mounting seat 16 based on the image taken by the camera 45, the actually measured position of the mounting seat 16, and the mutual positional relationship data prepared in advance including the position data of the plurality of mounting seats 16. Calculate That is, the indexing device 47 for indexing the position of the mounting seat 16 of the molded product main body 12 is constituted by the camera 45 and the analysis means. Furthermore, a force sensor 50 as a detection means is attached to the tip of the action part 41 in the attachment device 40 . The force sensor 50 is a torque sensor that measures the torque, which is the reaction force of the engagement of the component 13 with the mounting seat 16, in the present embodiment. The force sensor 50 can output the measured torque to attachment determination means such as a computer (not shown). Based on the torque measured by the force sensor 50, the attachment determination means determines whether or not the component 13 is engaged with the mounting seat 16 within the range of predetermined engagement reaction force characteristics stored in advance. . That is, the force sensor 50 and the attachment determination means constitute an inspection device 52 that inspects whether or not the component 13 is properly engaged with the attachment seat 16 . The engagement reaction force characteristic is obtained by measuring, for example, the torque when an expert attaches the part 13 to the mounting seat 16 in advance by the force sensor 50, and using this as basic data, it is stored as a torque waveform for correctly attaching the part 13. be. FIG. 3 shows an example of the engagement reaction force of this embodiment. As for the engagement reaction force characteristics, an experiment was carried out on the attachment of the part 13, and waveforms were accumulated when the part 13 was correctly attached to the mounting seat 16 and when it was not. The peculiar waveforms W2 and W3 can be obtained in advance. For example, the peculiar waveform W2 shows an example of the waveform when the part 13 is improperly seated on the mounting seat 16, and the peculiar waveform W3 shows the improper seating of the component 13 against the mounting seat 16. An example of waveforms in this case is shown.

In addition, as shown in FIG. 1(a), the manufacturing apparatus 10 includes a carry-out device 55 for carrying out the resin molded product 11, which is a non-defective product to which the parts 13 are correctly attached. The carry-out device 55 includes a carry-out conveyor 56 for carrying out the resin molded product 11, for example. Further, in the present embodiment, the carrying-out device 55 uses the receiving device 30 to transfer the resin molded product 11 having the component 13 attached thereto from the set stage 38 to the carrying-out conveyor 56. there is That is, the receiving device 30 of the present embodiment also serves as a part of the unloading device 55. As shown in FIG.

Next, a method for manufacturing the resin molded product 11 of the above embodiment will be described.

First, the molded product main body 12 is injection-molded by a molding machine (molding step). In conjunction with the opening of the mold of this molding machine, the molded product main body 12 is pushed out from the mold by the ejection device, and the ejecting device 25 sucks and holds the molded product main body 12 by the holding means 27 to form the molded product. The product body 12 is removed from the mold (extraction step). Therefore, the molded product main body 12 is held by the holding means 27 without dropping in a state of being completely protruded from the mold.

Next, the receiving device 30 moves the receiving means 32 by the action part 31 to receive the molded product body 12 from the holding means 27 of the take-out device 25 (receiving step). At the time of reception, the molded product body 12 is imaged by the camera 33, and the captured image is image-processed and analyzed by the image processing means. Judge (judgement step). The molded product body 12 determined to be defective is thrown into a defective product sorting box 36 to prevent it from being mixed with non-defective products. If a defective product occurs, the operator of the molding machine can be informed of it so that necessary measures can be taken. The molded product main body 12 determined to be non-defective is placed on the set stage 38 by the receiving device 30 (placement step). The molded product main body 12 is placed on the set stage 38 so that the mounting seat 16 faces upward. In this state, the approximate position of the molded product body 12 is determined.

Next, the operation unit 41 of the mounting device 40 moves the camera 45 to a position overlooking the entire molded product body 12 on the set stage 38, the camera 45 captures an image of the molded product body 12, and the captured image is analyzed by the analysis means. , the positions of the plurality of mounting seats 16 serving as markers are recognized as measured positions (recognition step), and the position of each mounting seat 16 is determined from the recognized measured positions (indexing step). At this time, the positions of all mounting seats 16 may be detected, or a plurality of specific mounting seats 16, for example, two positions located at both ends of the molded product body 12, in other words, the positions of the mounting seats 16 that are the most distant from each other, may be detected. may be imaged by the camera 45, and the position of the other mounting seat 16 may be calculated by the analyzing means based on this image data and mutual positional relationship data prepared in advance including the position data of the mounting seat 16. That is, if all the positional relationships of the plurality of mounting seats 16 are coordinate-registered in advance as mutual positional relationship data (if mapped), each mounting seat 16 for each molded product body 12 can be determined from two distances. It can be calculated by correcting the coordinate position (X, Y, Z, θ).

Here, as an example is shown in FIG. 4(a), the molded product body 12 is in a region where post-molding shrinkage is steep until a predetermined time T, for example, a little over 10 seconds, elapses after the mold starts to open. After that, the post-molding shrinkage follows a gentle curve and continues for about 24 hours or more, and shrinks completely in about 48 hours. Therefore, in the indexing step of the present embodiment, the molded product body 12 is placed in a region where the dimensional change due to post-molding shrinkage is steep after a predetermined time T has passed since the mold was opened, as shown in FIG. 4(b). Then, an image is taken by the camera 45 when the dimensional change shifts to a region where the dimensional change is gentler than that region, and the position of the mounting seat 16 is determined based on the image. To suppress errors due to post-molding shrinkage of the main body 12 . The predetermined time T is determined in advance according to the type and grade of the resin forming the molded product main body 12, and is set, for example, after the timing when the shrinkage rate S becomes approximately 1/2 or more of the shrinkage rate of the resin. In other words, the predetermined time T is after the timing at which the curvature of post-molding shrinkage changes from large to small by a predetermined amount or more within a predetermined short time. Further, the position of each mounting seat 16 indexed in the indexing process may be corrected according to the elapsed time from molding of the molded product body 12 to mounting of the component 13 to the position of the mounting seat 16. .

Thereafter, in the mounting device 40, the mounting means 42 picks up the parts 13 from the parts feeder 43, and the mounting means 42 moved to the indexed positions of the mounting seats 16 by the operation part 41 are directed toward the mounting seats 16, respectively. Click-engage part 13 (mounting step). In this mounting process, the inspection device 52 measures the engagement torque of the part 13 to the mounting seat 16 by the force sensor 50, and based on the measured torque, the mounting determination means determines the pre-stored engagement reaction force characteristics. It is inspected whether or not the part 13 is engaged with the mounting seat 16 within the range (inspection step). Then, resin molded products 11 with normal waveform W1 are determined as non-defective products, and other resin molded products 11 with specific waveforms W2, W3, etc. are determined as defective products, and defective products are carried out. After that, the non-defective products are transported by the transport conveyor 56 and stored in a shipping container.

Thus, in the above-described embodiment, the plurality of markers actually measured when the molded product main body 12 removed from the molding die is in a region where the dimensional change due to shrinkage after molding is moderate. The position of each mounting seat 16 is determined based on the measured positions of 16 and mutual positional relationship data prepared in advance including the position data of the mounting seat 16, and the part 13 is engaged with the determined position of the mounting seat 16. to install. For this reason, the change in the position of the mounting seat 16 caused by the shrinkage of the thermoplastic resin is estimated and corrected in real time according to the time that has elapsed since molding, and the time from molding the molded product main body 12 to mounting the part 13 temporarily changes. Also, the part 13 can be automatically and stably attached to the mounting seat 16 of the molded product main body 12 corresponding to the placement position of the molded product main body 12 .

For example, in the present embodiment, a series of measurements is started 15 seconds after the mold is opened (demolded), and the mounting process of the component 13 is completed 35 seconds later. Since 10 seconds, which is the predetermined time T at which the shrinkage curve of the molded product body 12 after molding gradually changes, has passed for 5 seconds, there is a dimensional error when the part 13 is attached to the mounting seat 16 based on the mutual positional relationship data. is at a level that poses no problem. Moreover, the 15 seconds elapsed after the mold is opened (demolded) is substantially equal to the total time taken to remove the molded product body 12 from the mold and set it on the set stage 38, so no waiting time is required. Therefore, since the parts 13 are automatically assembled in synchronization with the molding cycle of the molded product body 12, it is labor-saving and fast, and it is possible to eliminate the stagnation of in-process products during manufacturing.

Therefore, by previously inputting the positional coordinates of the design mounting seat 16 and creating an operation program for the manufacturing apparatus 10, it is possible to complete the operation program in a short period of time without the need for teaching using a teaching pendant or the like. Moreover, even when a new resin molded product 11 is added, it can be easily and automatically manufactured by inputting mutual positional relationship data in advance.

Further, when the component 13 is attached, the engagement reaction force of the component 13 is measured, and whether or not the component 13 is engaged with the mounting seat 16 within a predetermined engagement reaction force characteristic range is determined. Each 16 is inspected to confirm that the part 13 is securely seated on the mounting seat 16, and if the engagement reaction force is abnormal, it is distinguished when the product is carried out, and only good products are carried out. A high level of quality assurance is possible by suppressing defects such as missing items.

Furthermore, by using any one of the plurality of mounting seats 16 as at least one of the markers for measuring the actual position, there is no need to separately form a marker on the molded product main body 12, and the process can be simplified.

Further, by correcting the indexed position of each mounting seat 16 according to the elapsed time from molding of the molded product body 12 to mounting of the part 13 to the position of the mounting seat 16, Position indexing accuracy can be further improved.

In the above embodiment, in the indexing step, the positions of a plurality of optional markers other than the mounting seat 16 formed on the molded product body 12 may be actually measured. In this case, for example, mutual positional relationship data including marker position data and mounting seat 16 position data is prepared in advance, so that the position of each mounting seat 16 can be determined based on this mutual positional relationship data and the actually measured positions. can be assigned.

INDUSTRIAL APPLICABILITY The present invention can be suitably used, for example, as an apparatus and method for manufacturing a resin molded product that serves as an interior material for vehicles such as automobiles.

10 Manufacturing equipment
11 Resin molded products
12 Molded product body
13 parts
16 Mounting seat as a marker
25 Extractor
40 Mounting device
47 indexer
52 Inspection equipment

Claims (4)

A method for manufacturing a resin molded product in which a part is attached to a molded product body having a mounting seat,
a removing step of removing the molded product body from the mold;
a recognition step of recognizing positions of a plurality of markers positioned apart from each other on the molded product body as measured positions when the molded product body is in a region where the dimensional change after molding is moderate;
an indexing step of determining the position of each of the mounting seats based on the measured positions and mutual positional relationship data prepared in advance including position data of the markers and position data of the mounting seats;
a mounting step of engaging and mounting the component at the indexed position of the mounting seat,
an inspection step of measuring an engaging reaction force of the component during the mounting step, and inspecting whether or not the component is engaged with the mounting seat within a predetermined engagement reaction force characteristic range; ,
In the mounting step, the position of each mounting seat indexed in the indexing step is corrected according to the elapsed time from molding of the molded product body to mounting of the component to the position of the mounting seat.
A method for manufacturing a resin molded product, characterized by: 2. The method of manufacturing a resin molded product according to claim 1, wherein at least one of the markers is one of the plurality of mounting seats . A manufacturing apparatus for a resin molded product that attaches parts to a molded product body that has a mounting seat,
a take-out device for taking out the molded product body from the mold;
a recognition device that recognizes positions of a plurality of markers positioned apart from each other on the molded product body taken out from the mold as measured positions;
an indexing device for determining the position of each mounting seat based on the measured position and mutual positional relationship data prepared in advance including position data of the marker and position data of the mounting seat;
a mounting device that engages and mounts the component at the indexed position of the mounting seat,
The mounting device has an inspection device that measures an engagement reaction force of the component and inspects whether or not the component is engaged with the mounting seat within a predetermined engagement reaction force characteristic range , The position of each mounting seat indexed by the indexing device is corrected in accordance with the elapsed time from molding of the molded product body to mounting of the part to the position of the mounting seat.
A manufacturing apparatus for a resin molded product characterized by: 4. The apparatus for manufacturing a resin molded product according to claim 3 , wherein the recognition device recognizes the positions of the plurality of markers as the actually measured positions when the molded product main body is in a region where the dimensional change after molding is moderate.

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