JP2011106909A - Visual inspection apparatus of pipe - Google Patents
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- JP2011106909A JP2011106909A JP2009260807A JP2009260807A JP2011106909A JP 2011106909 A JP2011106909 A JP 2011106909A JP 2009260807 A JP2009260807 A JP 2009260807A JP 2009260807 A JP2009260807 A JP 2009260807A JP 2011106909 A JP2011106909 A JP 2011106909A
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- 238000011179 visual inspection Methods 0.000 title claims abstract description 11
- 238000005286 illumination Methods 0.000 claims abstract description 17
- 238000003384 imaging method Methods 0.000 claims abstract description 8
- 230000003287 optical effect Effects 0.000 claims abstract description 7
- 230000001678 irradiating effect Effects 0.000 claims abstract description 3
- 238000007689 inspection Methods 0.000 claims description 64
- 230000002093 peripheral effect Effects 0.000 claims description 24
- 238000012545 processing Methods 0.000 claims description 23
- 238000012546 transfer Methods 0.000 claims description 16
- 230000007547 defect Effects 0.000 abstract description 10
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 230000001788 irregular Effects 0.000 abstract 3
- 229920003002 synthetic resin Polymers 0.000 description 9
- 239000000057 synthetic resin Substances 0.000 description 9
- 230000002950 deficient Effects 0.000 description 8
- 238000001514 detection method Methods 0.000 description 5
- 238000009792 diffusion process Methods 0.000 description 3
- 230000000007 visual effect Effects 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 230000002411 adverse Effects 0.000 description 2
- 229920003020 cross-linked polyethylene Polymers 0.000 description 2
- 239000004703 cross-linked polyethylene Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 230000005856 abnormality Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 239000003550 marker Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000004148 unit process Methods 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
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- Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
Abstract
Description
本発明は、合成樹脂製の長尺の管の外観を検査する外観検査装置に関する。 The present invention relates to an appearance inspection apparatus for inspecting the appearance of a long tube made of synthetic resin.
架橋ポリエチレン管等の合成樹脂製の管は、給水・給湯用の送水管として広く使用されている。このような合成樹脂製の管の外観不良としては、異物混入や樹脂ヤケによる炭化物の発生を原因とした外観不良や、管表面が波打った凹凸形状になる不良や丸い形状に凹む不良などがある。 Synthetic resin pipes such as crosslinked polyethylene pipes are widely used as water supply pipes for water supply and hot water supply. Examples of such defective appearance of synthetic resin pipes include poor appearance due to foreign matter contamination and the occurrence of carbides due to resin burns, defects that make the pipe surface wavy, and defects that dent into round shapes. is there.
これらの不良は、管の意匠性を損なうだけではなく、管の性能（耐圧性、耐久性など）に大きな影響を与える原因となるため、不良の管が市場に出回ることを未然に防止する必要がある。特に凹凸形状や凹み形状の外観不良については、管の厚さに影響を及ぼし、ひいては管の性能に悪影響を及ぼすことがある。 These defects not only impair the design of the pipe, but also have a major impact on the pipe performance (pressure resistance, durability, etc.), so it is necessary to prevent the defective pipe from entering the market. There is. In particular, an appearance defect such as an uneven shape or a recessed shape affects the thickness of the tube, which may adversely affect the performance of the tube.
このような外観不良の管が市場へ流出するのを防止するため、従来は、目視での全数検査が行われてきたが、検査の精度（検出能力）が低く、流出を完全に防止することはできなかった。 In order to prevent such a tube with poor appearance from flowing out to the market, the total inspection has been performed by visual inspection in the past, but the inspection accuracy (detection ability) is low and the outflow is completely prevented. I couldn't.
一方、円筒状の物体の外周面の良否を検査する装置として、円筒体の軸線に対し斜め方向から均一な光を照射し、かつ照射面を、光軸が円筒の軸線に対して垂直方向に配置されたカメラで撮像する装置が提案されている（例えば、特許文献１参照）。 On the other hand, as an apparatus for inspecting the quality of the outer peripheral surface of a cylindrical object, irradiate uniform light from an oblique direction with respect to the axis of the cylinder, and the optical surface is perpendicular to the axis of the cylinder. There has been proposed an apparatus that captures an image with an arranged camera (see, for example, Patent Document 1).
特許文献１に記載の外観検査装置は、凸状や凹状の点欠陥、傷、汚れ、異物等の異常の検出には効果を発揮する。しかし、この外観検査装置は、感光体ドラムのような平坦な外周面を有する円筒体の外観検査を行うものであり、合成樹脂製の管の表面に形成されるような形状的な外観不良の検査装置としては、必ずしも適切ではなかった。 The appearance inspection apparatus described in Patent Document 1 is effective in detecting abnormalities such as convex or concave point defects, scratches, dirt, and foreign matters. However, this appearance inspection apparatus is for inspecting the appearance of a cylindrical body having a flat outer peripheral surface such as a photosensitive drum, and has a shape appearance defect that is formed on the surface of a tube made of synthetic resin. It was not necessarily suitable as an inspection device.
本発明はこのような事情に鑑みてなされたもので、管の外周面に形成された凹凸形状や凹み形状などの形状的な外観不良を適切に検出できる外観検査装置を提供することを目的とする。 The present invention has been made in view of such circumstances, and an object thereof is to provide an appearance inspection apparatus that can appropriately detect a shape appearance defect such as an uneven shape or a recessed shape formed on the outer peripheral surface of a pipe. To do.
上記目的を達成するため本発明にかかる管の外観検査装置は、管の外周面を撮像した画像を分析することにより前記管の外観を検査する管の外観検査装置であって、
前記管の外周面に均一な拡散光を照射する照明装置と、
前記拡散光の照射により前記管の外周面に形成された陰影の濃淡画像を撮像するカメラと、を備え、
前記カメラは、その光軸が前記管の軸線に対して斜めになるように配設されていることを特徴とする。
In order to achieve the above object, a tube appearance inspection device according to the present invention is a tube appearance inspection device that inspects the appearance of the tube by analyzing an image obtained by imaging the outer peripheral surface of the tube,
An illumination device for irradiating the outer peripheral surface of the tube with uniform diffused light;
A camera that captures a shaded gray image formed on the outer peripheral surface of the tube by the irradiation of the diffused light, and
The camera is arranged such that its optical axis is inclined with respect to the axis of the tube.
本発明にかかる管の外観検査装置において、前記照明装置は、
中心部に前記管が貫通する孔が形成され、かつ内側に半球状の反射面を有するドームと、
前記ドームの開口部の内周側に形成されたリング状のフランジと、
前記フランジの内側にリング状に配設された複数の発光ダイオードとで構成されることが好ましい。
In the tube appearance inspection apparatus according to the present invention, the illumination device includes:
A dome having a hole through which the tube passes in the center and a hemispherical reflecting surface on the inside;
A ring-shaped flange formed on the inner peripheral side of the opening of the dome;
A plurality of light emitting diodes arranged in a ring shape inside the flange is preferable.
ここで、前記複数の発光ダイオードは、青色の光を発光することが好ましい。また前記カメラは、前記管の円周方向に４台、等間隔に配設されていることが好ましい。 Here, it is preferable that the plurality of light emitting diodes emit blue light. Further, it is preferable that four cameras are arranged at equal intervals in the circumferential direction of the tube.
本発明にかかる管の外観検査装置は、前記カメラで撮像した画像を処理する画像処理手段を更に備え、この画像処理手段は、前記画像に含まれる陰影の濃淡の度合を算出すると共に、その算出値をあらかじめ設定された閾値と比較して、前記管の外観の良否を判定することが好ましい。 The tube appearance inspection apparatus according to the present invention further includes image processing means for processing an image picked up by the camera, and the image processing means calculates the degree of shading of the shadow included in the image and the calculation thereof. It is preferable to compare the value with a preset threshold value to determine the quality of the tube.
また本発明にかかる管の外観検査装置は、前記管を、その軸線方向に一定の速度で移送する管移送手段を更に備え、この管移送手段は、前記管を移送するモータと、移送された前記管の位置を検出するロータリーエンコーダとを含むことが好ましい。更に、前記画像処理手段から出力された前記管の外観の良否判定結果を、前記ロータリーエンコーダにより検出された前記管の位置データと関連付けて記憶するメモリを備えることが好ましい。 The tube appearance inspection apparatus according to the present invention further includes tube transfer means for transferring the tube at a constant speed in the axial direction thereof, and the tube transfer means is transferred with a motor for transferring the tube. And a rotary encoder for detecting the position of the tube. Further, it is preferable that the apparatus further includes a memory that stores a result of the quality determination of the appearance of the tube output from the image processing unit in association with the position data of the tube detected by the rotary encoder.
本発明にかかる管の外観検査装置を用いることにより、管の外周面に形成された凹凸形状や凹み形状を適切に検出でき、不良品の市場への流出を防止できる。 By using the tube appearance inspection apparatus according to the present invention, it is possible to appropriately detect the uneven shape and the recessed shape formed on the outer peripheral surface of the tube, and prevent the outflow of defective products to the market.
以下、本発明の実施の形態にかかる管の外観検査装置について、図面を参照しながら説明する。 Hereinafter, a tube appearance inspection apparatus according to an embodiment of the present invention will be described with reference to the drawings.
図１は、本実施の形態にかかる管の外観検査装置（以降、単に「外観検査装置」という）１の主要部品の配置を示した正面図である。外観検査装置１は、通常、製造されたばかりの合成樹脂製の管１０を保管場所に移送する経路の途中や、合成樹脂管の製造ラインの途中に設置されている。管１０は、外観検査装置１の主要部品を貫通するように水平方向に移動する。 FIG. 1 is a front view showing the arrangement of main components of a tube appearance inspection apparatus (hereinafter simply referred to as “appearance inspection apparatus”) 1 according to the present embodiment. The appearance inspection apparatus 1 is usually installed in the middle of a route for transferring a synthetic resin pipe 10 just manufactured to a storage location or in the middle of a synthetic resin pipe production line. The tube 10 moves in the horizontal direction so as to penetrate the main parts of the appearance inspection apparatus 1.
＜外観検査装置の主要部品の配置＞
図１に示す外観検査装置１では、矢印で示した管１０の移動方向に対し、上流側から順に、ガイドローラ６ａ、照明装置３、カメラユニット４、ガイドローラ６ｂ、および管移送ユニット５が配置されている。なお図１には表示されていないが、外観検査装置１の主要部品として、これ以外に、検査ユニット７（図３参照）と、照明装置３やカメラユニット４、管移送ユニット５等に必要な電力を供給する電源（図示せず）がある。
<Arrangement of main parts of visual inspection equipment>
In the appearance inspection apparatus 1 shown in FIG. 1, a guide roller 6a, an illuminating device 3, a camera unit 4, a guide roller 6b, and a tube transfer unit 5 are arranged in order from the upstream side with respect to the moving direction of the tube 10 indicated by an arrow. Has been. Although not shown in FIG. 1, it is necessary for the inspection unit 7 (see FIG. 3), the illumination device 3, the camera unit 4, the tube transfer unit 5, and the like as main components of the appearance inspection device 1. There is a power supply (not shown) that supplies power.
照明装置３は、移送中の管１０に、斜め方向から均一な拡散光を照射するもので、床２に固定された支柱３０にドーム３１が取り付けられている。照明装置３による均一な拡散光の生成については、後に図２を用いて詳述する。 The illumination device 3 irradiates the tube 10 being transferred with uniform diffused light from an oblique direction, and a dome 31 is attached to a support column 30 fixed to the floor 2. The generation of uniform diffused light by the illumination device 3 will be described in detail later with reference to FIG.
カメラユニット４は、照明装置３によって照明されることにより管１０の外周面に形成された陰影を撮像するもので、異なる位置に配置された４台のカメラ４１〜４４（カメラ４４はカメラ４２の陰に隠れている）で構成されている。４台のカメラ４１〜４４は、床２に固定され、かつ中心部に管１０が通過する孔（図示せず）が形成された支持板４０に取り付けられている。 The camera unit 4 captures shadows formed on the outer peripheral surface of the tube 10 by being illuminated by the illumination device 3, and the four cameras 41 to 44 (camera 44 is the camera 42) arranged at different positions. Concealed in the shade). The four cameras 41 to 44 are fixed to the floor 2 and attached to a support plate 40 in which a hole (not shown) through which the tube 10 passes is formed at the center.
それぞれのカメラ４１〜４４は、管１０を囲むように円周上に等間隔に、すなわち９０度毎に配置されている。またカメラ４１〜４４は、それぞれ管１０の軸線に対して光軸が斜めになる状態で支持板４０に取り付けられている。このように管１０の円周方向に４台のカメラを配置することにより、管１０を回転させることなく、管の全周にわたって外観を検査できる。 The cameras 41 to 44 are arranged at equal intervals on the circumference so as to surround the tube 10, that is, every 90 degrees. The cameras 41 to 44 are each attached to the support plate 40 in a state where the optical axis is inclined with respect to the axis of the tube 10. By arranging four cameras in the circumferential direction of the tube 10 in this way, the appearance can be inspected over the entire circumference of the tube without rotating the tube 10.
管移送ユニット５は、管１０を矢印方向に一定速度で移送するものであり、後述の図３に示すようにモータ５１とロータリーエンコーダ５２が内蔵されている。 The pipe transfer unit 5 transfers the pipe 10 at a constant speed in the direction of the arrow, and includes a motor 51 and a rotary encoder 52 as shown in FIG.
ガイドローラ６ａおよび６ｂは、共に、支柱６０の上部に複数のローラ６１が回転可能に支持されたものであり、管１０が矢印方向に移送されるときに、管１０の軸線が水平方向および垂直方向に変位しないように規制している。 Each of the guide rollers 6a and 6b has a plurality of rollers 61 rotatably supported on the upper portion of the support column 60. When the tube 10 is transferred in the arrow direction, the axis of the tube 10 is horizontal and vertical. It is restricted so as not to be displaced in the direction.
＜外観検査の原理＞
次に、図２を参照して、外観検査装置１における外観検査の原理について説明する。図２は、図１に示した主要部品のうち照明装置３とカメラ４１の配置を示す断面図である。
<Principle of appearance inspection>
Next, the principle of appearance inspection in the appearance inspection apparatus 1 will be described with reference to FIG. FIG. 2 is a cross-sectional view showing the arrangement of the illumination device 3 and the camera 41 among the main components shown in FIG.
最初に、本発明を成すに到った経緯を説明する。本発明の発明者は、合成樹脂製の管の外観検査について実験を重ねた結果、管の外周面に拡散光により形成した均一な光を照射し、その照射面を、管の軸線に対して斜めの方向から観察すると、管の表面に形成された微小な凹凸形状や凹み形状の陰影の濃淡を、明瞭に視認できることを見出した。 First, the background to the present invention will be described. As a result of repeated experiments on the appearance inspection of synthetic resin pipes, the inventor of the present invention irradiates uniform light formed by diffused light on the outer peripheral surface of the pipe, and the irradiated surface is directed to the axis of the pipe. When observed from an oblique direction, it has been found that the shading of the fine uneven shape and the concave shape formed on the surface of the tube can be clearly recognized.
本発明はこの実験結果に基づいて成されたものである。すなわち、光軸が管の軸線に対して斜めとなるように配設されたカメラで管の照射面を撮像した後、画像処理によって、管の表面に形成された凹凸形状や凹み形状の陰影の濃淡の画像を抽出する。そしてこの画像から濃淡の度合（変化の程度や密度）を算出し、その値があらかじめ設定した閾値を超えたときに、外観不良であると判定するものである。 The present invention has been made based on the experimental results. In other words, after imaging the irradiated surface of the tube with a camera arranged so that the optical axis is inclined with respect to the axis of the tube, the image processing is performed on the uneven or indented shadow formed on the surface of the tube. A gray image is extracted. Then, the degree of shading (degree of change and density) is calculated from this image, and when the value exceeds a preset threshold value, it is determined that the appearance is poor.
次に、照明装置３による均一な拡散光の生成について説明する。照明装置３のドーム３１は、中心に管１０が貫通する孔が形成され、かつ内面が半球状に形成されている。またドーム３１の開口面の内周側にリング状のフランジ３２が形成されている。そしてフランジ３２の内側には、複数の発光ダイオード（以降、「ＬＥＤ」という）３３がリング状に取り付けられている。 Next, generation of uniform diffused light by the illumination device 3 will be described. The dome 31 of the illuminating device 3 has a hole through which the tube 10 penetrates at the center, and an inner surface formed in a hemispherical shape. A ring-shaped flange 32 is formed on the inner peripheral side of the opening surface of the dome 31. A plurality of light emitting diodes (hereinafter referred to as “LEDs”) 33 are attached inside the flange 32 in a ring shape.
またドーム３１の内面には、白色の塗料が塗られて反射面３４が形成されている。反射面３４の表面には細かい凹凸があるため、ＬＥＤ３３から照射された光は、反射面３４の表面で拡散し、均一な強度の光となって点線の矢印で示す方向、すなわち管１０の軸線Ｏｔに対して斜めの方向に照射される。 The inner surface of the dome 31 is coated with white paint to form a reflecting surface 34. Since there are fine irregularities on the surface of the reflecting surface 34, the light emitted from the LED 33 diffuses on the surface of the reflecting surface 34 and becomes light of uniform intensity, ie, the direction indicated by the dotted arrow, that is, the axis of the tube 10 Irradiated in an oblique direction with respect to Ot.
ＬＥＤ３３は、発光波長が短いほど、塗膜で形成された反射面３４で拡散しやすくなる。本発明では、この性質を利用し、拡散の度合いを高めるため、発光波長が４３０ｎｍ前後の青色のＬＥＤを用いている。 The LED 33 is more easily diffused on the reflection surface 34 formed of a coating film as the emission wavelength is shorter. In the present invention, a blue LED having an emission wavelength of around 430 nm is used in order to utilize this property and increase the degree of diffusion.
なお、ＬＥＤ３３から照射され、管１０の表面で反射した光がカメラ４１に入射すると、カメラ４１で撮像した画像にＬＥＤ３３の反射光が混ざり、管１０の外周面に形成された陰影の撮像に悪影響が出る。これを防止するため、フランジ３２の幅は、管１０の表面で反射した光がカメラ４１に入射しないように設定されている。 In addition, when the light irradiated from the LED 33 and reflected by the surface of the tube 10 enters the camera 41, the reflected light of the LED 33 is mixed with the image captured by the camera 41, which adversely affects the imaging of the shadow formed on the outer peripheral surface of the tube 10. coming out. In order to prevent this, the width of the flange 32 is set so that the light reflected by the surface of the tube 10 does not enter the camera 41.
次に、カメラ４１による管１０の外周面の撮像について説明する。前述したように、管１０の製造過程において外周面に凹凸形状や凹み形状が形成されることがある。このような管１０の外周面に拡散光により形成された均一な光を照射すると、照射面に陰影の濃淡ができる。その陰影の濃淡を、光軸Ｏｃが管１０の軸線Ｏｔに対して角度θとなるように斜めに配設されたカメラ４１で撮像する。 Next, imaging of the outer peripheral surface of the tube 10 by the camera 41 will be described. As described above, an uneven shape or a recessed shape may be formed on the outer peripheral surface in the manufacturing process of the tube 10. When uniform light formed by diffused light is irradiated on the outer peripheral surface of the tube 10 as described above, shades of light and shade can be formed on the irradiated surface. The shade of the shadow is imaged by a camera 41 disposed obliquely so that the optical axis Oc is at an angle θ with respect to the axis Ot of the tube 10.
発明者が実験を重ねた結果、角度θが１０度から２５度、最適には１８度であると、照明によって管１０の外周面に形成された陰影の濃淡を明瞭に撮像できることがわかった。図３（ａ）に、カメラ４１によって撮像した凹凸形状の陰影の写真の一例を示す。また図３（ｂ）に、カメラ４１によって撮像した凹み形状の陰影の写真の一例を示す。 As a result of repeated experiments by the inventor, it has been found that when the angle θ is 10 degrees to 25 degrees, and optimally 18 degrees, the shade of the shadow formed on the outer peripheral surface of the tube 10 by illumination can be clearly imaged. FIG. 3A shows an example of a photograph of uneven shadows captured by the camera 41. FIG. 3B shows an example of a photograph of a concave shadow imaged by the camera 41.
図３（ａ）、（ｂ）の写真は、照明装置３の光源として波長４３０ｎｍの青色の光を発光するＬＥＤ３３を用いて、直径１５ｍｍの合成樹脂製の管１０を照明し、その照明箇所を、１００万画素のＣＣＤカメラ４１を用いて撮像したものである。図３（ａ）、（ｂ）から分かるように、凹凸形状および凹み形状の陰影の濃淡について、鮮明な画像が得られる。 3A and 3B, the LED 33 that emits blue light having a wavelength of 430 nm is used as the light source of the illumination device 3 to illuminate the synthetic resin tube 10 having a diameter of 15 mm, and the illumination location is shown. The image was taken using a CCD camera 41 with 1 million pixels. As can be seen from FIGS. 3 (a) and 3 (b), clear images can be obtained with respect to the shading of the concavo-convex shape and the concave shape.
＜外観検査装置の動作＞
次に、図１および図４を参照して外観検査装置１の動作について説明する。図４は、外観検査装置１の駆動系および信号処理系の部品、具体的には、カメラユニット４、管移送ユニット５および検査ユニット７の構成を示すブロック図である。
<Operation of appearance inspection device>
Next, the operation of the appearance inspection apparatus 1 will be described with reference to FIGS. 1 and 4. FIG. 4 is a block diagram showing the configuration of the drive system and signal processing system parts of the appearance inspection apparatus 1, specifically, the camera unit 4, the tube transfer unit 5, and the inspection unit 7.
カメラユニット４は４台のカメラを備えている。前述したように、これらのカメラ４１〜４４は管１０の円周方向に均等に配置され、３６０度の外周面のうち、９０度で分割した４台の領域のそれぞれの画像を撮像する。撮像された画像は、検査ユニット７の画像処理部７３に入力される。 The camera unit 4 includes four cameras. As described above, these cameras 41 to 44 are arranged uniformly in the circumferential direction of the tube 10 and take images of four regions divided by 90 degrees on the outer peripheral surface of 360 degrees. The captured image is input to the image processing unit 73 of the inspection unit 7.
管１０の移送手段である管移送ユニット５は、モータ５１とロータリーエンコーダ５２を備えている。モータ５１の回転軸にはゴム製の車輪がはめ込まれており（図示せず）、その車輪を管１０の外周面に押し付けることにより、管１０を移送する。 The tube transfer unit 5 that is a transfer means for the tube 10 includes a motor 51 and a rotary encoder 52. A rubber wheel (not shown) is fitted on the rotating shaft of the motor 51, and the tube 10 is transferred by pressing the wheel against the outer peripheral surface of the tube 10.
ロータリーエンコーダ５２はモータ５１の回転軸に取り付けられており、モータ５１の回転角度を検出して検査ユニット７の制御部７２に送信する。ロータリーエンコーダ５２の回転数を計測することにより、モータ５１による管１０の移送距離を検出できる。 The rotary encoder 52 is attached to the rotation shaft of the motor 51, detects the rotation angle of the motor 51, and transmits it to the control unit 72 of the inspection unit 7. By measuring the number of rotations of the rotary encoder 52, the transfer distance of the tube 10 by the motor 51 can be detected.
検査ユニット７は、入力部７１、制御部７２、画像処理部７３およびメモリ７４を備えている。検査ユニット７は、通常、パーソナルコンピュータ（以降、「ＰＣ」という）によって実現される。その場合、入力部７１にはキーボードを用い、また制御部７２および画像処理部７３の機能は、ＰＣのハードディスクに記憶されたソフトウェアによって実現される。 The inspection unit 7 includes an input unit 71, a control unit 72, an image processing unit 73, and a memory 74. The inspection unit 7 is usually realized by a personal computer (hereinafter referred to as “PC”). In this case, a keyboard is used as the input unit 71, and the functions of the control unit 72 and the image processing unit 73 are realized by software stored in the hard disk of the PC.
入力部７１は、外観検査装置１の運転に必要なデータ、例えば、モータ５１の回転速度、画像処理部７３における外観の良否判定の閾値などを入力する。 The input unit 71 inputs data necessary for operation of the appearance inspection apparatus 1, for example, a rotation speed of the motor 51, a threshold value for determining whether the image processing unit 73 is good or bad for appearance.
制御部７２は、検査ユニット７内の各部の制御、カメラユニット４内のカメラ４１〜４４の制御および管移送ユニット５内のモータ５１の制御を行う。 The controller 72 controls each part in the inspection unit 7, controls the cameras 41 to 44 in the camera unit 4, and controls the motor 51 in the tube transfer unit 5.
画像処理手段である画像処理部７３は、カメラ４１〜４４から送信された画像を処理して、凹凸形状や凹み形状の陰影の濃淡の画像を抽出すると共に、濃淡の度合を算出し、その値をあらかじめ設定した閾値と比較して外観の良否を判定する。これらの画像処理や判定は、市販の画像処理用のソフトウェアを用いて容易に実現できるため、ここでは説明を省略する。 The image processing unit 73 serving as an image processing unit processes the images transmitted from the cameras 41 to 44 to extract shaded and shaded images of the uneven shape and the recessed shape, and calculates the degree of the shade. Is compared with a preset threshold value to determine whether the appearance is good or bad. Since these image processing and determination can be easily realized by using commercially available image processing software, description thereof is omitted here.
メモリ７４は画像処理部７３で行われた良否の判定結果を、ロータリーエンコーダ５２から送信された管１０の位置データと関連付けて記憶する。なお、画像処理部７３で抽出した凹凸形状や凹み形状の陰影の濃淡の画像を、これらの情報と併せてメモリ７４に記憶してもよい。 The memory 74 stores the result of the quality determination performed by the image processing unit 73 in association with the position data of the tube 10 transmitted from the rotary encoder 52. Note that the shaded and shaded image of the concavo-convex shape or the dent shape extracted by the image processing unit 73 may be stored in the memory 74 together with these pieces of information.
次に、外観検査装置１による検査の手順について説明する。制御部７２からの指示信号によって管移送ユニット５のモータ５１が回転し、管１０が図１の矢印で示す方向に移送される。この際、制御部７２は、ロータリーエンコーダ５２から送信された信号に基づいてモータ５１の回転数を制御し、管１０を一定の速度で移送する。 Next, an inspection procedure by the appearance inspection apparatus 1 will be described. The motor 51 of the tube transfer unit 5 is rotated by the instruction signal from the control unit 72, and the tube 10 is transferred in the direction indicated by the arrow in FIG. At this time, the control unit 72 controls the number of rotations of the motor 51 based on the signal transmitted from the rotary encoder 52 and moves the tube 10 at a constant speed.
カメラユニット４の各カメラ４１〜４４は、照明装置３によって照明された管１０の外周面を、制御部７２からの制御信号に基づいて一定の間隔で撮像する。本実施の形態では、直径１７ｍｍの架橋ポリエチレン管１０を２５ｍ／分の速度で移送しながら、１０ｍＳ毎に撮像を行った。またカメラ４１〜４４のシャッタースピードは２０μＳに設定した。 Each camera 41 to 44 of the camera unit 4 images the outer peripheral surface of the tube 10 illuminated by the illuminating device 3 at regular intervals based on a control signal from the control unit 72. In the present embodiment, imaging was performed every 10 mS while the cross-linked polyethylene pipe 10 having a diameter of 17 mm was transferred at a speed of 25 m / min. The shutter speed of the cameras 41 to 44 was set to 20 μS.
カメラ４１〜４４で撮像された画像は画像処理部７３に送信され、ここで凹凸形状や凹み形状の陰影の濃淡の画像抽出、濃淡の度合の算出、算出値と閾値との比較、ならびに良否の判定が行われる。画像処理部７３で抽出された凹凸形状や凹み形状の陰影の濃淡の画像、および良否の判定結果は、ロータリーエンコーダ５２から送信された管１０の撮像場所の位置データと共にメモリ７４に記憶される。 The images captured by the cameras 41 to 44 are transmitted to the image processing unit 73, where the shading of the concavo-convex shape or the concave shape is extracted, the degree of shading is calculated, the calculated value is compared with the threshold value, and the quality is determined. A determination is made. The shaded and shaded image of the concavo-convex shape or the dent shape extracted by the image processing unit 73 and the quality determination result are stored in the memory 74 together with the position data of the imaging location of the tube 10 transmitted from the rotary encoder 52.
制御部７２は、外観検査装置１による検査の終了後に、作業者の指示に従い、メモリ７４に格納されたデータ、すなわち凹凸形状や凹み形状の陰影の濃淡画像および良否の判定結果を読み出してモニタ８に表示する。作業者は、モニタ８に表示された画像により、不良と判断された箇所の凹凸形状や凹み形状を確認し、最終的にその箇所を廃棄するか否かを決定する。 After the inspection by the appearance inspection apparatus 1 is completed, the control unit 72 reads out the data stored in the memory 74, that is, the shaded image of the uneven shape or the recessed shape, and the determination result of pass / fail according to the operator's instruction, and the monitor 8 To display. The operator confirms the concave / convex shape or the concave shape of the portion determined to be defective from the image displayed on the monitor 8 and finally determines whether or not to discard the portion.
なお、外観の良否の判定結果をメモリ７４に記憶せず、代わりに管移送ユニット５の下流にインクジェット印刷装置等のマーカを設置し、検査ユニット７で不良と判断された管１０の外周面にマークを印刷するようにしても良い。このようにすれば、作業者が不良箇所を目視で確認できるため、外観の良否判定結果などのデータをメモリ７４に記憶する必要がなくなる。 In addition, the determination result of the quality of the appearance is not stored in the memory 74. Instead, a marker such as an ink jet printer is installed downstream of the tube transfer unit 5, and the outer surface of the tube 10 determined to be defective by the inspection unit 7 is provided. You may make it print a mark. In this way, since the operator can visually confirm the defective portion, it is not necessary to store data such as the appearance quality determination result in the memory 74.
＜検査結果＞
次に、あらかじめ準備した外観不良の管について、本発明の外観検査装置を用いて検査した結果と、比較のため目視により検査した結果とを表１に示す。表１の左欄に示すように、「混入異物」、「炭化物」、「凹凸形状」および「凹み形状」の外観不良サンプルを各３０個用意した。ここで、「混入異物」とは管の表面に管自体の色とは異なる色の異物が混入したもの、「炭化物」とは管の表面に炭化物が混入したものである。
<Inspection result>
Next, Table 1 shows the results of inspecting the pipes with poor appearance prepared in advance using the visual inspection apparatus of the present invention and the results of visual inspection for comparison. As shown in the left column of Table 1, 30 samples with poor appearance of “mixed foreign matter”, “carbide”, “uneven shape”, and “dent shape” were prepared. Here, “contaminating foreign matter” means that the foreign matter having a color different from the color of the tube itself is mixed on the surface of the tube, and “carbide” means that the carbide is mixed on the surface of the tube.
なお、この検査では、各サンプルを静止させた状態で外観の検査を行った。しかし、カメラのシャタースピードは管の移送速度に比べて極めて速いため（２０μＳ程度）、管１０を移送しながら検査を行う場合と同等の結果が得られると考えて差し支えない。 In this inspection, the appearance was inspected while each sample was stationary. However, since the shutter speed of the camera is extremely high compared with the transfer speed of the tube (about 20 μS), it can be considered that the same result as that in the case where the inspection is performed while the tube 10 is transferred can be obtained.
表１の右欄に、本発明の外観検査装置を用いて抽出した不良サンプルの数と、目視により抽出した不良サンプルの数を示す。表１から明らかなように、「混入異物」と「炭化物」については、目視と比較して、本発明の外観検査装置の検出精度は低い。これに対し「凹凸形状」および「凹み形状」については、本発明の外観検査装置は全てのサンプルについて不良の検出に成功しており、目視と比べて検出精度の高さが際立っている。 The right column of Table 1 shows the number of defective samples extracted using the appearance inspection apparatus of the present invention and the number of defective samples extracted visually. As can be seen from Table 1, the detection accuracy of the appearance inspection apparatus of the present invention is low for “mixed foreign matter” and “carbide” as compared with visual observation. On the other hand, with respect to the “concave / convex shape” and “dent shape”, the appearance inspection apparatus of the present invention succeeded in detecting defects for all samples, and the detection accuracy is conspicuous compared with visual observation.
従って、「混入異物」や「炭化物」の検出精度の高い特許文献１に記載の外観検査装置と、本発明の外観検査装置を組み合わせて用いれば、管の外観不良をほぼ完全に検出できる。 Therefore, if the appearance inspection apparatus described in Patent Document 1 having high detection accuracy of “contaminated foreign matter” and “carbide” is used in combination with the appearance inspection apparatus of the present invention, it is possible to almost completely detect the appearance defect of the pipe.
以上説明したように、本発明にかかる外観検査装置によれば、管の外周面にできた微小な凹凸形状や凹み形状を高精度に検出でき、また検出結果に基づいて、外観の良否判断を行うことができるため、従来の目視による外観検査に比較して検査時間を大幅に短縮できる。しかも、本発明の外観検査装置は、管を移送させながら検査を行うことができるため、管を出荷するまでに要する時間の大幅な短縮化と製造コストの大幅な削減を実現できる。 As described above, according to the appearance inspection apparatus according to the present invention, it is possible to detect a minute uneven shape and a recessed shape formed on the outer peripheral surface of the pipe with high accuracy, and to determine the quality of the appearance based on the detection result. Since it can be performed, the inspection time can be greatly shortened as compared with the conventional visual appearance inspection. Moreover, since the appearance inspection apparatus of the present invention can perform inspection while transferring the tube, it can realize a significant reduction in the time required to ship the tube and a significant reduction in manufacturing cost.
なお本実施の形態では、ＬＥＤから発光された光をドームの反射面で拡散させて均一な照明光を生成したが、これに限定されない。例えば、複数のＬＥＤがリング状に配置された光源の前面に半透明の拡散板を設置し、ＬＥＤからの光を拡散板で拡散することによって均一な照明光を生成するようにしてもよい。 In the present embodiment, the light emitted from the LED is diffused by the reflecting surface of the dome to generate uniform illumination light, but the present invention is not limited to this. For example, a semi-transparent diffusion plate may be installed in front of a light source in which a plurality of LEDs are arranged in a ring shape, and uniform illumination light may be generated by diffusing light from the LEDs with the diffusion plate.
本発明にかかる外観検査装置は、合成樹脂製の管の外観検査ばかりでなく、諸々の材料で作られた長尺の管の外観検査に広く適用できるものである。 The appearance inspection apparatus according to the present invention can be widely applied not only to the appearance inspection of a tube made of synthetic resin but also to the appearance inspection of a long tube made of various materials.
１ 外観検査装置
２ 床
３ 照明装置
４ カメラユニット
５ 管移送ユニット
６ａ、６ｂ ガイドローラ
７ 検査ユニット
８ モニタ
３１ ドーム
３２ フランジ
３３ ＬＥＤ
３４ 反射面
４１〜４４ カメラ
５１ モータ
５２ ロータリーエンコーダ
７１ 入力部
７２ 制御部
７３ 画像処理部
７４ メモリ
DESCRIPTION OF SYMBOLS 1 Appearance inspection apparatus 2 Floor 3 Illumination apparatus 4 Camera unit 5 Pipe transfer unit 6a, 6b Guide roller 7 Inspection unit 8 Monitor 31 Dome 32 Flange 33 LED
34 Reflecting surface 41 to 44 Camera 51 Motor 52 Rotary encoder 71 Input unit 72 Control unit 73 Image processing unit 74 Memory
Claims (7)
前記管の外周面に均一な拡散光を照射する照明装置と、
前記拡散光の照射により前記管の外周面に形成された陰影の濃淡画像を撮像するカメラと、を備え、
前記カメラは、その光軸が前記管の軸線に対して斜めになるように配設されていることを特徴とする管の外観検査装置。 An external appearance inspection apparatus for a pipe that inspects the external appearance of the pipe by analyzing an image obtained by imaging the outer peripheral surface of the pipe,
An illumination device for irradiating the outer peripheral surface of the tube with uniform diffused light;
A camera that captures a shaded gray image formed on the outer peripheral surface of the tube by the irradiation of the diffused light, and
The tube visual inspection apparatus, wherein the camera is disposed so that an optical axis thereof is inclined with respect to an axis of the tube.
中心部に前記管が貫通する孔が形成され、かつ内側に半球状の反射面を有するドームと、
前記ドームの開口部の内周側に形成されたリング状のフランジと、
前記フランジの内側にリング状に配設された複数の発光ダイオードと、で構成されることを特徴とする、請求項１に記載の管の外観検査装置。 The lighting device includes:
A dome having a hole through which the tube passes in the center and a hemispherical reflecting surface on the inside;
A ring-shaped flange formed on the inner peripheral side of the opening of the dome;
The tube visual inspection device according to claim 1, comprising a plurality of light emitting diodes arranged in a ring shape inside the flange.
この画像処理手段は、前記画像に含まれる陰影の濃淡の度合を算出すると共に、その算出値をあらかじめ設定された閾値と比較して、前記管の外観の良否を判定することを特徴とする、請求項１ないし４のいずれかに記載の管の外観検査装置。 Image processing means for processing an image captured by the camera;
The image processing means calculates the degree of shading of the shadow included in the image and compares the calculated value with a preset threshold value to determine whether the appearance of the tube is good or bad. The pipe appearance inspection apparatus according to any one of claims 1 to 4.
前記管を移送するモータと、
移送された前記管の位置を検出するロータリーエンコーダと、を含むことを特徴とする、請求項１ないし５のいずれかに記載の管の外観検査装置。 The apparatus further comprises a pipe transfer means for transferring the pipe at a constant speed in the axial direction thereof.
A motor for transferring the tube;
The pipe visual inspection apparatus according to claim 1, further comprising: a rotary encoder that detects a position of the transferred pipe.
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| JP2015081838A (en) * | 2013-10-23 | 2015-04-27 | 東洋製罐株式会社 | Inspection apparatus for can with dent or buckling |
| CN109089411A (en) * | 2018-07-26 | 2018-12-25 | 江苏传艺科技股份有限公司 | A kind of scissor assembling property detection method and automatic checkout system |
| JP2023075014A (en) * | 2021-11-18 | 2023-05-30 | 株式会社クボタ | Defect determination device of steel pipe outer surface |
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