Note: Descriptions are shown in the official language in which they were submitted.
H-8233-0-CA
MOLDING SYSTEM AND
METHOD FOR INSPECTING MOLDED ARTICLES
FIELD OF THE TECHNOLOGY
The present technology relates to molding systems and methods for using the
molding systems.
More specifically the present technology relates to a molding system for
producing and inspecting
molded articles, and a method for inspecting molded articles during operation
of the molding
system.
BACKGROUND
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.
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 garner the most profitability from the system, the molding
system should be
running as much as possible, at full capacity, producing molded articles that
meet specification.
In order to minimize downtime of the molding system inspection of the molded
articles may be
undertaken, downstream of the molding system, and then any required
maintenance and process
tuning is performed as required. The 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.
For multilayer preforms, where there are multiple layers of molded material
together, additional
inspection challenges are presented. Inspection by hand of the different
layers, as is commonly
done in the art, is both time-consuming and difficult.
SUMMARY
It is an object of the present invention to ameliorate at least some of the
inconveniences present in
the prior art.
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According to a first broad aspect of the present technology, there is provided
a molding system
comprising a molding machine for producing a plurality of molded articles; and
at least one
inspection device configured to inspect at least one molded article of the
plurality of molded
articles; and a computing apparatus operatively coupled to the at least one
inspection device, the
at least one inspection device comprising at least one multispectral light
source configured to
illuminate the at least one molded article; and at least one imaging system
configured to collect at
least some light reflected and scattered from the at least one molded article,
the at least one imaging
system including at least one detector configured to detect a plurality of
wavelengths in light
imaged by the at least one imaging system, the at least one detector being
communicatively
coupled to the computing apparatus, the at least one inspection device
configured to inspect the at
least one molded article between an end of a first molding cycle and prior to
a start of a second
molding cycle.
In some embodiments of the molding system, the at least one inspection device
is configured to
image the at least one molded article in a mold of the molding machine prior
to ejection of the at
least one molded article from the molding machine.
In some embodiments of the molding system, the computing apparatus and the at
least one
inspection device are configured to detect that one of the plurality of molded
articles is missing in
the molding machine.
In some embodiments of the molding system, the computing apparatus is
communicatively
.. coupled to the molding machine and the molding machine is configured to
adjust at least one
molding process variable in response to detection, by the at least one
inspection device, of at least
one defect in the at least one molded article.
In some embodiments of the molding system, the at least one molding process
variable includes
at least one of a mold opening speed profile; a mold closing speed profile; an
ejector speed profile;
a mold open dwell time; a part removal function; a transfer air assist
function; molding process
parameters such as temperature, pressure, time and a part handling device
dwell time.
In some embodiments of the molding system, the molding machine comprises a
stationary platen,
and a moveable platen; the at least one inspection device is mounted to one of
the stationary or
moveable platens; and the at least one inspection device is configured to
image mold cavities in a
first mold half associated with the stationary platen and/or mold cores in a
second mold half
associated with the moveable platen.
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In some embodiments of the molding system, the at least one inspection device
is configured to
image the plurality of molded articles during ejection from one of the first
mold half or the second
mold half.
In some embodiments of the molding system, the at least one inspection system
and the computing
apparatus are configured to produce hyperspectral images of at least one of a
portion of the
molding machine and the at least one molded article.
According to another broad aspect of the present technology, there is provided
a method for
inspecting molded articles from a molding system, the molding system including
at least one
inspection device and a molding machine. The method comprises illuminating, by
at least one light
source of the at least one inspection device, at least one molded article
produced by the molding
machine, the at least one light source providing light having a plurality of
wavelengths; imaging,
by an imaging system of the at least one inspection device, at least some
light reflected and
refracted from the at least one molded article onto a detector of the at least
one inspection device,
the detector being configured to detect at least some of the plurality of
wavelengths of illuminating
light; and determining, by a computing apparatus communicatively coupled to
the detector, at least
one attribute of the at least one molded article, the at least one attribute
being detectable using a
plurality of images of the at least one molded article, the plurality of
images being formed by at
least some of the plurality of wavelengths.
In some embodiments of the method, the determining the at least one attribute
includes executing
an image recognition algorithm to analyse the plurality of images formed by
the at least some of
the plurality of wavelengths.
In some embodiments of the method, determining the at least one attribute
includes detecting at
least one defect in the at least one molded article; and further comprising,
in response to detecting
the at least one defect, causing a change in at least one molding process
variable of the molding
machine.
In some embodiments of the method, causing the change in the at least one
molding process
variable includes causing change in at least one of a mold opening speed
profile; a mold closing
speed profile; an ejector speed profile; a mold open dwell time; a part
removal function; a transfer
air assist function; and a part handling device dwell time.
In some embodiments, the method further comprises determining that the at
least one molded
article of a previous molding cycle is to be rejected.
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In some embodiments, the method further comprises determining that the at
least one molded
article of a subsequent molding cycle is to be rejected.
In some embodiments of the method, imaging the at least one molded article
includes imaging
the plurality of molded articles.
In some embodiments of the method, imaging the plurality of molded articles
includes imaging
the plurality of molded articles in the molding machine prior to ejection.
In some embodiments, the method further comprises producing a hyperspectral
image block, by
the computing apparatus, based on the imaging the plurality of molded articles
in the plurality of
wavelengths.
In some embodiments of the method, at least some of the plurality of
wavelengths are wavelengths
outside of a visible light spectrum.
According to yet another broad aspect of the present technology, there is
provided a molding
system comprising a molding machine for producing a plurality of molded
articles; and at least
one inspection device configured to inspect at least one molded article of the
plurality of molded
articles; and a computing apparatus operatively coupled to the at least one
inspection device, the
at least one inspection device comprising at least one multispectral light
source configured to
illuminate the at least one molded article; and at least one imaging system
configured to collect at
least some light reflected and scattered from the at least one molded article,
the at least one imaging
system including at least one detector configured to detect a plurality of
wavelengths in light
imaged by the at least one imaging system, the at least one detector being
communicatively
coupled to the computing apparatus.
In some embodiments, the system further comprises a display arrangement for
receiving the at
least one molded article from the molding machine; and the at least one
inspection device is
configured to image the at least one molded article in the display
arrangement.
In some embodiments of the system, the computing apparatus and the at least
one inspection device
are configured to detect at least one attribute in the at least one molded
article, the at least one
attribute being detectable using light with at least a first wavelength of the
plurality of wavelengths.
In some embodiments of the system, the first wavelength is outside a visible
spectrum.
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In some embodiments of the system, the computing apparatus is communicatively
coupled to the
molding machine; and the molding machine is configured to adjust at least one
molding process
variable in response to detection of the at least one attribute in the at
least one molded article.
In some embodiments of the system, the plurality of molded articles produced
by the molding
machine is a plurality of multilayer preforms; and each of the plurality of
multilayer preforms
includes a core layer and a skin layer enveloping the core layer.
In some embodiments of the system, the at least one inspection device is
configured to image the
skin layer and the core layer of at least one of the plurality of multilayer
preforms; and the
computing apparatus is configured to identify defects in at least one of the
skin layer and the core
layer.
In some embodiments of the system, the computing apparatus is communicatively
coupled to the
molding machine; and the molding machine is configured to adjust at least one
molding process
variable in response to identified defects in the at least one of the skin
layer and the core layer.
In some embodiments of the system, the computing apparatus is communicatively
coupled to the
molding machine; the at least one inspection device is configured to inspect
the at least one molded
article prior to ejection of the at least one molded article from the molding
machine; and the
molding machine is configured to adjust at least one molding process variable
in response to
detection, by the at least one inspection device, of at least one defect in
the at least one molded
article.
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.
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.
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
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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.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
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 non-
limiting embodiments along with the following drawings, in which:
Figure 1 is a cross-sectional view of a multilayer preform, which can be
inspected by non-limiting
embodiments of the present technology;
Figure 2 is a plan view schematic diagram of an injection molding machine,
which can be adapted
for implementation of the non-limiting embodiments of the present technology;
Figure 3 is a schematic diagram of a molding system, which can be adapted for
implementation of
the non-limiting embodiments of the present technology;
Figure 4 is a schematic diagram of another embodiment of a molding system
being implemented
in accordance with another non-limiting embodiment of the present technology;
Figure 5 is a schematic diagram of yet another embodiment of a molding system
being
implemented in accordance with another non-limiting embodiment of the present
technology; and
Figure 6 depicts a block diagram of a method executable in accordance with non-
limiting
embodiments of the present technology and executable within the system of
Figures 3 to 5.
DETAILED DESCRIPTION
With reference to Fig. 1, there is depicted, in cross-section, a non-limiting
embodiment of a molded
article produced by a molding machine of the present technology, specifically
a multi layer preform
50. The illustrated preform 50 is produced by an injection molding machine
100, described below
with reference to Fig. 2, but it is contemplated that preforms 50 could be
produced by another type
of molding machine in other non-limiting embodiments in accordance with the
present technology.
It is also contemplated that different types of molded articles could be
produced by molding
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machines according to non-limiting embodiments of the present technology,
including but not
limited to: closures, thin-wall containers, medical appliances, and the like.
The multilayer preform 50 consists of a neck portion 32, a gate portion 36 and
a body portion 34
extending between the neck portion 32 and the gate portion 36. The gate
portion 36 is associated
with a substantially spherical shape that terminates in a vestige portion 38.
The multilayer preform 50 is formed by at least two layers. On exterior sides,
the multilayer
preform 50 has a skin layer 20. The skin layer 20 can be made of various
materials. For example,
in multilayer preforms 50 for making beverage containers, the skin layer 20 is
made of virgin
polyethylene terephthalate (PET), which is approved by the FDA for use in
contact with foodstuffs.
It is contemplated that the skin layer 20 could be made of various other
materials, including any
appropriate polymer resins and thermoplastics, as will be appreciated by those
skilled in the art.
The multilayer preform 50 has a cavity identification number 25 imprinted in
the skin layer 20.
Even though the cavity identification number 25 is depicted to be located in
the neck portion 32,
this does not need to be so in alternative embodiments of the present
technology. In alternative
embodiments, the cavity identification number 25 can be located anywhere
within the gate portion
36 or the body portion 34.
As will be described below, each cavity 118 of one or more mold cavities 118
of the injection
molding machine 100 has a cavity origin insert which imprints the cavity
identification number 25
of each cavity 118, each cavity identification number 25 being unique to each
cavity 118. In some
alternative embodiments, it is contemplated that that the cavity origin insert
could be omitted.
The skin layer 20 surrounds a core layer 40, the core layer 40 being generally
made of a different
material, or a different variety of the same material, e.g. recycled PET, than
the skin layer 20. At
a top end of the preform 50, the core layer 40 begins at a leading edge 42. At
a bottom end of the
preform 50, the core layer 40 terminates at a trailing edge 44. In some
embodiments, the core layer
40 is used to impart different properties to the preforms 50. The core layer
40, in some
embodiments, can act as a barrier layer in the eventual blow-molded container
blown from the
preform 50. In such cases, the barrier layer can help to prevent transmission
of, for example,
oxygen or light into an interior of the blow-molded container. The core layer
40 can also be made
from any one of various appropriate thermoplastics and polymer resins as will
be appreciated by
those skilled in the art. It is contemplated that the core layer 40 could be
also contain various
additives, coloring, or property adjusting agents to affect different
properties of the multilayer
preform 50.
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With reference to Fig. 2, 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 makes the
multilayer preforms 50 described above that are subsequently processed by a
molding system 200
of the present technology. However, it should be understood that in
alternative non-limiting
embodiments, the injection molding machine 100 may comprise 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.
In the non-limiting embodiment of Fig. 2, the molding machine 100 comprises 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).
The injection molding machine 100 further comprises 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.
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 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.
A first mold half 114 can be associated with the stationary platen 102 and a
second mold half 116
can be associated with the movable platen 104. In the non-limiting embodiment
of Fig. 2, the first
mold half 114 comprises the one or more mold cavities 118. As will be
appreciated by those of
skill in the art, the one or more 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".
The second mold half 116 comprises one or more mold cores 120 complementary to
the one or
more mold cavities 118. As will be appreciated by those of skill in the art,
the one or more mold
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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 Fig. 2, 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 one or more mold cavities 118. Also, the second mold half 116 may
include neck rings
(not depicted) with which to mold neck portions 32 of preforms 50. The neck
rings may be used
to for imprinting the cavity identification number 25 on the multilayer
preforms 50.
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.
Fig. 2 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) a molding cavity (not depicted) into which the molten
plastic (or other suitable
molding material) can be injected, as is known to those of skill in the art.
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.
The injection molding machine 100 can further comprise a robot 122 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 here in any
detail. The robot 122 comprises 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 comprises a plurality of molded article receptacles 130.
Generally speaking, the purpose of the plurality of molded article receptacles
130 is to remove
molded articles 50 from the one or more mold cores 120 (or the one or more
mold cavities 118)
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and/or to implement post mold cooling of the molded articles. In the non-
limiting example
illustrated herein, the plurality of molded article receptacles 130 comprises
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.
Schematically depicted in Fig. 2 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 50.
The molding machine 100 further comprises 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
comprises 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 comprises a plenum 129 coupled to the
mounting structure
134. Coupled to the plenum 129 is a plurality of treatment pins and pickers
133. 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 50.
The molding machine 100 further comprises a computing apparatus 140, also
referred to herein as
a controller 140, configured to control one or more operations of the molding
machine 100. The
controller 140 is further configured to control one ore more operations of
molding systems 200,
300, 400 described below with respect to Figs. 3 to 5. As will be appreciated
by those skilled in
the art, the computing apparatus 140 may comprise a plurality of controllers
or computer-
implemented devices operatively connected together.
The controller 140 includes a human-machine interface (not separately
numbered) or an HMI, for
short. The HMI of the controller 140 can be implemented in any suitable
interface. As an example,
the HMI of the controller 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.
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Those skilled in the art will appreciate that the controller 140 may be
implemented using pre-
programmed 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 controller 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
controller 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.,
microwave, infrared or other transmission schemes) or a combination thereof.
In alternative non-limiting embodiments of the present technology, the HMI
does not have to be
physically attached to the controller 140. As a matter of fact, the HMI for
the controller 140 can
be implemented as a separate device. In some embodiments, the HMI can be
implemented as a
wireless communication device (such as a smai _______________________________
(phone, for example) that is "paired" or otherwise
communicatively coupled to the controller 140.
The controller 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 controller 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
controller 140 is further configured to process one or more of the acquired
operational parameters
associated with the molding system 200, 300, 400 and output information to the
operator using the
HMI and the like.
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.
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
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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
controller 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 controller 140
acquires the plurality of operational parameters will depend, of course, on
the nature of the so-
acquired plurality of operational parameters.
The controller 140 can acquire machine variables by monitoring the operation
of the molding
machine 100. Just as an example, the controller 140 can acquire the cycle time
by monitoring the
performance of the molding machine 100. Naturally, the controller 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.
For example, the operator may enter an indication of cavitation of the
injection molding machine
100 using the HMI of the controller 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
controller 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).
In some non-limiting embodiments of the present technology, the controller 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
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the controller 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 controller 140 can acquire the
part weight and/or
scrap rates by monitoring the performance of the molding machine 100.
Naturally, other ways for
the controller 140 to acquire some or all of these or other operational
parameters are possible, some
of which will be described below.
With reference to Fig. 3, there is depicted a non-limiting embodiment of the
molding system 200
which can be adapted to implement embodiments of the present technology. The
molding system
200 comprises the injection molding machine 100 for making the multilayer
preforms 50. The
molding system 200 is illustrated and will be described herein with respect to
the embodiment of
the injection molding machine 100 described above. The robot 122 and the post-
mold treatment
device 132 are excluded from the illustrations for simplicity but are
contemplated to the included
in at least some embodiments.
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.
Along with the injection molding machine 100, the molding system 200 according
to the present
technology also comprises a multispectral inspection device 250. As is
illustrated schematically in
Figure 3, the inspection device 250 and the controller 140 are operably
coupled together. As will
be described in more detail below, the inspection device 250 and the
controller 140 are
communicatively coupled to permit control of the inspection device 250 by the
controller 140, as
well transfer of information and/or indications from the inspection device 250
to the controller 140
for controlling the molding machine 100. While not illustrated herein, it is
contemplated that the
molding system 200 could include a plurality of inspection devices according
to at least some of
the embodiments set out below.
Broadly, the inspection device 250 is arranged and configured to investigate
one or more of the
molded articles 50 and/or the molding machine 100 using multispectral light.
Different materials
in the molded articles 50 and components of the molding machine 100 may have
different
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reflection, absorption, and scattering properties in one wavelength or
wavelength band in the
multispectral light than in other bands of the multispectral light. In this
way, different images
formed from different wavelengths of light can be inspected separately and
compared to determine
aspects of the molded articles 50 and/or the molding machine 100. For example,
multispectral
images from the inspection device 250 could indicate presence or absence of
one of the molded
articles 50 in the molding machine 100 after a given molding cycle. Further
example inspection
variations are described in more detail below.
In order to illuminate the molded articles, not shown, such as preforms 50
(FIG. 1), located in or
on one of the mold halves, and/or portions of the molding machine 100 in the
illustrated
embodiment of Figure 3, the inspection device 250 includes one or more
multispectral light sources
260. One light source 260 is shown schematically for ease of illustration. The
light source 260 is
configured to illuminate one or more of the molded articles in or produced by
the molding machine
100. In the embodiment of Figure 3 specifically, the light source 260 is
arranged to illuminate the
mold cavities 118 of the first mold half 114 that is associated with the
stationary platen 102, as
well as any molded articles that may be disposed therein at the time of
inspection. Similarly, in an
alternative embodiment, not shown, the location of the light source 260 may be
arranged to
illuminate the mold cores 120 of the stationary platen 102, as well as any
molded articles that may
be disposed thereon at the time of inspection
The multispectral light source 260 produces light in a plurality of
wavelengths, in order to inspect
and image the molded articles and/or portions of the molding machine 100 with
different light
wavelengths. In at least some embodiments, the light source 260 produces light
in multiple
wavelength bands. The different wavelength bands produced could include, but
are not limited to,
visible light, near infrared, infrared, ultraviolet, and portions of the x-ray
band. The light source
260, depending on the embodiment, could include a plurality of light producing
elements,
especially in embodiments producing light in large range of wavelengths or in
several wavelength
bands. The light producing elements could include, but are not limited to,
electroluminescent
sources such as light emitting diodes (LEDs), electric discharge sources
(lamps), incandescent
sources, and laser sources.
The light source 260 further includes one or more optical elements (not shown)
for projecting the
multispectral light in a generally even manner over the molding machine
portions. The particular
optical components required will depend on the exact embodiment of the light
source 260. For
example, different optical component arrangements could depend on the
particular physical
structure of the molding machine 100 and the wavelengths produced by the light
source 260.
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The inspection device 250 further includes an imaging system 270 configured to
collect at least
some light reflected and scattered from the molded articles, when the
inspection device 250 is in
operation. The imaging system 270 includes at least one detector 275
configured to detect at least
some of the wavelengths of light produced by the light source 260. In some
embodiments, the
range of wavelength bands accepted by the detector 275 could be matched
exactly to the
wavelengths produced by the light source 260. It is also contemplated that the
detector 275 could
accept and measure only a portion of the wavelengths produced by the light
source 260. It is further
contemplated that the detector 275 could comprise a plurality of detectors
configured to measure
different wavelength bands.
The imaging system 270 also includes optical elements (not shown) for
optically transferring light
collected from light reflected and scattered from the molded articles to the
one or more detectors
275. Similarly to the optical elements of the light source 260, the particular
form and details of the
optical elements for imaging by the imaging system 270 vary depending on the
particular
wavelengths of light from the light source 260, the particular arrangement of
the molding machine
100, and implementational details of the one or more detectors 275.
The one or more detectors 275 is communicatively coupled to the computing
apparatus 140. In
some embodiments, the imaging system 270 could include an internal computing
apparatus for
receiving data from the detector 275 and forming images, and in turn
transmitting information
and/or images to the controller 140. In some embodiments, the controller 140
could receive
unprocessed or only partially processed data from the detector 275. Depending
on the particular
embodiment, the inspection device 250 and/or the controller 140 could produce
different types of
images. For example, compound images produced by a combination of images
formed in different
wavelengths could be computed. In at least some embodiments, it is also
contemplated that the
inspection system 250 and the controller 140 could be configured to produce
hyperspectral images
of at least one of a portion of the molding machine 100 and/or one or more of
the molded articles
50.
In the present embodiment, the inspection device 250 is mounted to the movable
platen 104. In
such an arrangement, the inspection device 250 is configured to image the mold
cores 120
associated with the stationary platen 102 and/or the molded articles 50 prior
to ejection from the
molding machine 100, as is illustrated by the example rays of Figure 3.
Specifically, the inspection
device 250 is configured to image one or more of the molded articles 50 in the
molds (i.e. the first
mold half 114 and the mold cavities 118) of the molding machine 100 prior to
ejection of the
molded articles 120 from the molding machine 100 or between an end of a first
molding cycle and
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prior to a start of a second molding cycle. It is contemplated that the
controller 140 and the
inspection device 250 could also be configured to detect that one of the
molded articles 50 is
missing in the molding machine 100 in such a case.
In the present embodiment, the inspection device 250 is mounted to the movable
platen 104. In
such a configuration, the inspection device 250 could also be used to verify
that all molded articles
50 have been properly removed from the mold cavities 118 of the first mold
half 114, that is
associated with the stationary platen 102, with opening of the mold following
a given molding
cycle and prior to the beginning of a subsequent molding cycle. In at least
some embodiments, the
inspection device 250 could also be configured to image molded articles 50
during ejection from
the mold cores 120 of the second mold half 116 that is associated with the
moveable platen 102
(further illustrated in Figure 5). In an alternative embodiment, not shown,
the inspection device
250 may be mounted to the stationary platen 102. In such a configuration, the
inspection device
250 could be used to verify that all molded articles 50 have been properly
ejected from the mold
cores 120 following a given molding cycle and prior to the beginning of a
subsequent molding
cycle.
As is noted above, the controller 140 is communicatively coupled to the
molding machine 100 for
controlling at least some operational aspects thereof. As the inspection
device 250 is further
communicatively coupled to the controller 140, the controller 240 could be
configured to control
one or more aspects of the molding machine 100 in response to information from
the inspection
device 250. It is contemplated, for example, that the molding machine could be
configured to
adjust one or more molding process variables in response to detection, by the
inspection device
250, of at least one defect in one or more of the molded articles 50. In at
least some embodiments,
as one non-limiting example, the controller 140 could detect the presence of a
molded article 50
that has not properly ejected and, in response, control the molding machine
100 to stop the
subsequent molding cycle to prevent damage due to the improperly ejected
molded article 50.
Depending on the specific embodiment of the inspection device 250 (or others)
and the molding
machine 100, it is contemplated that adjustments could be made at a variety of
molding process
variables. The mold process variables to be controlled could include, but is
not limited to: a mold
opening speed profile, a mold closing speed profile, an ejector speed profile,
a mold open dwell
time, a part removal function, a transfer air assist function, a part handling
device dwell time, and
molding process parameters such as temperature, pressure, and time.
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While not illustrated herein, embodiments of the molding system 200 could also
further include
one or more conveyance devices for transporting multilayer preforms 50 between
different
portions or the molding system 200 and/or additional devices operationally
arranged with the
molding system 200. Many variations of conveyance devices can be implemented
in non-limiting
embodiments of the present technology, as will be appreciated by those skilled
in the art. As such,
specific implementation details need not be supplied here.
With reference to Figure 4, another implementation of molding system 300
according to the
present technology is illustrated. Elements of the molding system 300 that are
similar to those of
the molding system 200 retain the same reference numeral and will generally
not be described
again. The robot 122 and the post-mold treatment device 132 are excluded from
the illustrations
for simplicity but are contemplated to the included in at least some
embodiments.
The molding system 300 includes the molding machine 100, as well as another
non-limiting
embodiment of an inspection device 350. The inspection device 350 includes the
light source 260
and the imaging system 270 with the detector 275 according to one of the non-
limiting
embodiments described above.
The inspection device 350 is arranged and configured to image one or more of
the molded articles
50 when disposed on the pickers 133 of the post-mold treatment device 132. It
is also contemplated
that the inspection device 350 could be arranged to inspect the molded
articles 50 after molding at
a different point of transferring the molded articles 50 from the molding
machine 100 in some
embodiments, for example when the molded articles 50 are being held or moved
by the molded
article receptacles 130 of the take-off plate 128 (see Figure 2). It is
further contemplated that the
molding system 300 could include a display arrangement for receiving the
molded articles 50 from
the molding machine 100, for example from the take-off plate 128 and/or the
pickers 133. In such
an arrangement, the inspection device 350 could be configured to image the
molded articles 50 in
the display arrangement.
In at least some of the above described arrangements, the controller 140 and
the inspection device
250 could be configured to detect one or more attributes of the molded
articles 50. For example,
the attribute may include the presence or absence of core layer in parts of
the preform. In another
example the attribute may be the detection of an impurity in the article. A
particular impurity could
be detectable using a specific wavelength of light, the light source 250
producing the specific
wavelength amongst the multispectral light produced. In at least some
embodiments, the specific
wavelength for detecting the impurity could be outside the visible spectrum.
It is also contemplated
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that a plurality of wavelengths produced and detected by the inspection device
250 could be chosen
for detecting a plurality of impurities in the molded articles. In at least
some embodiments, the
molding machine 100 and the controller 40 could further be configured to
adjust one or more
molding process variables in response to detection of one or more impurities
in the molded articles
50. The mold process variables to be controlled could include, but is not
limited to: a mold opening
speed profile, a mold closing speed profile, an ejector speed profile, a mold
open dwell time, a part
removal function, a transfer air assist function, a part handling device dwell
time, and molding
process parameters such as temperature, pressure, and time.
In at least some embodiments, the inspection device 350 could be configured to
image the skin
layer 20 and the core layer 40 for embodiments where the molded articles 50
are preforms 50. In
some such embodiments, the controller 140 could be configured to identify
defects in the skin
layer 20 and/or the core layer 40. In at least some embodiments, the molding
machine 100 could
further be configured to adjust one or more molding process variables,
described above, in
response to identifying defects in the skin layer 20 and/or the core layer 40.
Upon detection of an attribute, such as an impurity or defect, of one of the
molded articles 50 by
the inspection device 250, the controller 140 could receive and record the
information related to
the attribute determined. In some embodiments, the controller 140 could be
configured to
determine if the attribute falls outside a pre-determined range, such as if
the attribute falls outside
of an acceptable range of values. In some embodiments, the controller 140 is
further configured to
generate an alert for the operator that the attribute falls outside the pre-
determined range. For
example, the operator may receive a visual or audio alert on the HMI that the
preforms 50 being
inspected have core layers 40 having an impurity. The controller 140 may also
be configured to
adjust at least one of the operational settings of the molding system 200, or
specifically the molding
machine 100, if the attribute falls outside the pre-determined range.
With reference to Figure 5, yet another implementation of molding system 400
according to the
present technology is illustrated. Elements of the molding system 400 that are
similar to those of
the molding system 200 retain the same reference numeral and will generally
not be described
again. The robot 122 and the post-mold treatment device 132 are excluded from
the illustrations
for simplicity but are contemplated to the included in at least some
embodiments.
The molding system 400 includes the molding machine 100, as well as another
non-limiting
embodiment of an inspection device 350. The inspection device 350 includes the
light source 260
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and the imaging system 270 with the detector 275 according to one of the non-
limiting
embodiments described above.
In the illustrated embodiment, the inspection device 450 is arranged to image
in the space between
the movable platen 104 and the stationary platen 102 when the machine 100 is
in the open position.
In such a position, the inspection device 450 is configured to image molded
articles on one or both
of the first mold half 114 and the second mold half 116, or even molded during
ejection.
A technical effect associated with embodiments of the present technology may
include the ability
to minimize down time of the molding machine 100 by performing regular,
automated inspection
of molded articles 50 or by monitoring clearance of the molded articles 50
from the molding
machine 100. Another technical effect associated with embodiments of the
present technology
may include the ability to image defect or other attributes of the molded
articles 50 which may not
be detectable at only a single wavelength or within a given wavelength band.
With reference to Figure 6, illustrated by a block diagram, a method 500 is
executable in
accordance with non-limiting embodiments of the present technology. The method
500 will be
described herein with respect to the molding system 200, detailed above, but
it is contemplated
that the method applies equally to the molding systems 300, 400 as well as
other non-limiting
embodiments of an injection molding system according to the present
technology.
Step 510 ¨ illuminating at least one molded article produced by the molding
machine
The method 500 begins, at step 510, with illuminating, by the light source
260, one or more of the
molded articles and/or portions of the molding machine with light having a
plurality of
wavelengths.
Step 520 - imaging at least some light reflected and refracted from the at
least one molded
article onto the detector
The method 500 then continues, at step 520, with imaging, by the imaging
system 270, at least
some of the light reflected and refracted from the molded articles and/or
portions of the molding
machine 100 onto the detector 275. As is noted above, the detector 275 is
configured to detect at
least some of wavelengths of illuminating light.
In at least some embodiments, imaging the molded articles 50 includes imaging
the molded articles
50 in the molding machine 100 prior to ejection. It is also contemplated that
the method 500 could
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further include producing a hyperspectral image block, by the controller 140,
based on the imaging
the plurality of molded articles 50 in the plurality of wavelengths.
Step 530 ¨ determining at least one attribute of the at least one molded
article
The method 500 then terminates, at step 530, with determining, by the
controller 140, at least one
attribute of the one or more molded articles. The controller 140 determines
the attribute(s) through
detection using a plurality of images of the molded article(s) formed at
different wavelengths.
In at least some embodiments, determining the attribute(s) includes executing
an image
recognition algorithm to analyse the images formed at least some of the
plurality of wavelengths
produced by the light source 260.
In some embodiments, determining the attribute(s) includes detecting at least
one defect in one of
the molded articles 50. In such a case, the method 500 could further include,
in response to
detecting the defect, causing a change in at least one molding process
variable of the molding
machine 100. It is contemplated that causing the change in the molding process
variable could
include causing change in a mold opening speed profile, a mold closing speed
profile, an ejector
speed profile, a mold open dwell time, a part removal function, a transfer air
assist function, and/or
a part handling device dwell time.
In some embodiments, the method 500 could further include determining that one
or more of the
molded articles 50 of a previous molding cycle should be rejected. The method
500 could also
include, in some embodiments, determining that one or more of the molded
articles of a subsequent
molding cycle should be rejected.
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.
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
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that modifications and enhancements are possible without departing from the
concepts as
described.
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