JP2021181921A - Flaw detection device and flaw detection method - Google Patents

Flaw detection device and flaw detection method Download PDF

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JP2021181921A
JP2021181921A JP2020087335A JP2020087335A JP2021181921A JP 2021181921 A JP2021181921 A JP 2021181921A JP 2020087335 A JP2020087335 A JP 2020087335A JP 2020087335 A JP2020087335 A JP 2020087335A JP 2021181921 A JP2021181921 A JP 2021181921A
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image pickup
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JP7501093B2 (en
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雄貴 荒井
Yuki Arai
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JTEKT Corp
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Abstract

To generate a development image for suppressing defects on a cylindrical outer peripheral surface, and to use the image for flaw detection.SOLUTION: A flaw detection device 100 for generating a development image on an outer peripheral surface of an object 200 includes: an imaging element 111; an imaging apparatus 110 having an optical system 112; a rotating device 120 for relatively rotating the imaging apparatus 110 and the object 200 in a circumferential direction; an imaging part 131 for capturing an image of an outer peripheral surface of the object 200 at a predetermined time interval synchronized with relative rotation; an area locating part 142 for locating and acquiring first area data 151 in which a first predetermined surface side 231 of a projection part 210 is captured from image data captured by the imaging apparatus 110 and second area data 152 in which a second surface side 232 of the projection part 210 is captured; and an image composition part 133 for compositing the first area data 151 and the second area data 152 for generating a development image of an outer peripheral surface.SELECTED DRAWING: Figure 4

Description

本発明は、丸棒状または円筒状の部材の外周面に設けられた突出部を有する対象物の外周面の画像を生成する探傷装置、および探傷方法に関する。 The present invention relates to a flaw detection device and a flaw detection method for generating an image of the outer peripheral surface of an object having a protrusion provided on the outer peripheral surface of a round bar-shaped or cylindrical member.

特許文献１には、歯車の歯先をラインカメラにより撮像し、得られた画像を結合して歯先面の展開画像を生成し、歯車の表面を検査する技術が記載されている。 Patent Document 1 describes a technique of capturing a tooth tip of a gear with a line camera, combining the obtained images to generate a developed image of the tooth tip surface, and inspecting the surface of the gear.

特開２０１８−３６１７２号公報Japanese Unexamined Patent Publication No. 2018-36172

ところが、歯丈が長い歯車など対象物表面の突出部の突出量が大きい場合など、１台のラインカメラだけでは突出部の根元が隣接する突出部の影になるため撮像できない欠陥部分が発生する。そのため、得られた画像は対象物の表面のすべてが反映されたものではなくなり、突出部を含む外周面全域の表面状態を正しく確認することができない。 However, when the amount of protrusion on the surface of an object such as a gear with a long tooth length is large, a defect part that cannot be imaged occurs because the root of the protrusion is a shadow of the adjacent protrusion with only one line camera. .. Therefore, the obtained image does not reflect the entire surface of the object, and the surface state of the entire outer peripheral surface including the protrusion cannot be confirmed correctly.

本発明は、上記課題に鑑みなされたものであり、円筒形状の外周面の画像であって欠陥部分が抑制された画像を生成する探傷装置、および探傷方法を提供することを目的としている。 The present invention has been made in view of the above problems, and an object of the present invention is to provide a flaw detection device and a flaw detection method for generating an image of a cylindrical outer peripheral surface in which a defect portion is suppressed.

上記目的を達成するために、本発明の１つである探傷装置は、円筒状の外周面に外向きに突出する突出部を有する対象物の前記外周面の画像を生成する探傷装置であって、行列状に配置される複数の撮像画素を有する撮像素子と、前記撮像素子に像を結像する光学系を備えた撮像装置と、前記撮像装置と前記対象物とを前記対象物の周方向に相対回転させる回転装置と、前記回転装置による相対回転と同期した所定の時間間隔で前記対象物の外周面の画像を前記撮像装置に撮像させる撮像部と、前記撮像装置が撮像した画像データから、前記突出部の所定の第一面側が撮像される第一領域データ、および前記突出部の前記第一面側と逆側の第二面側が撮像される第二領域データを特定して取得する領域特定部と、前記第一領域データ、および前記第二領域データを合成して前記外周面の展開画像を生成する画像合成部と、を備える。 In order to achieve the above object, the flaw detector according to the present invention is a flaw detector that generates an image of the outer peripheral surface of an object having an outwardly protruding protrusion on the outer peripheral surface of a cylinder. An image pickup element having a plurality of image pickup pixels arranged in a matrix, an image pickup device provided with an optical system for forming an image on the image pickup element, and the image pickup device and the object in the circumferential direction of the object. From the rotating device that rotates relative to the image, the image pickup unit that causes the image pickup device to capture an image of the outer peripheral surface of the object at a predetermined time interval synchronized with the relative rotation by the rotation device, and the image data captured by the image pickup device. , The first region data in which a predetermined first surface side of the protruding portion is imaged, and the second region data in which the second surface side opposite to the first surface side of the protruding portion is imaged are specified and acquired. It includes a region specifying unit, an image synthesizing unit that synthesizes the first region data and the second region data to generate a developed image of the outer peripheral surface.

また、上記目的を達成するために、本発明の他の１つである探傷方法は、円筒状の外周面に外向きに突出する突出部を有する対象物の前記外周面の画像を生成する探傷方法であって、行列状に配置される複数の撮像画素を有する撮像素子と、前記撮像素子に像を結像する光学系を備えた撮像装置と前記対象物とを前記対象物の周方向に回転装置が相対回転させ、前記回転装置による相対回転と同期した所定の時間間隔で前記対象物の外周面の画像を前記撮像装置に撮像部が撮像させ、前記撮像装置が撮像した画像データから、前記突出部の所定の第一面側が撮像される第一領域データ、および前記突出部の前記第一面側と逆側の第二面側が撮像される第二領域データを領域特定部が特定して取得し、前記第一領域データ、および前記第二領域データを合成して前記外周面の展開画像を画像合成部が生成し、前記展開画像に基づき対象物表面の傷を検出する。 Further, in order to achieve the above object, another flaw detection method of the present invention is to generate an image of the outer peripheral surface of an object having an outwardly protruding protrusion on the outer peripheral surface of the cylinder. It is a method, in which an image pickup element having a plurality of image pickup pixels arranged in a matrix, an image pickup device provided with an optical system for forming an image on the image pickup element, and the object are placed in the circumferential direction of the object. The rotating device rotates relative to each other, and the image pickup unit captures an image of the outer peripheral surface of the object at a predetermined time interval synchronized with the relative rotation by the rotating device. The region specifying unit identifies the first region data in which the predetermined first surface side of the protruding portion is imaged and the second region data in which the second surface side opposite to the first surface side of the protruding portion is imaged. The image synthesizing unit generates a developed image of the outer peripheral surface by synthesizing the first region data and the second region data, and detects scratches on the surface of the object based on the developed image.

本探傷装置、および探傷方法によれば、対象物の外周面に存在する突出部に起因した欠陥部分の発生を抑制した外周面の画像を得ることが可能となる。 According to this flaw detection device and the flaw detection method, it is possible to obtain an image of the outer peripheral surface in which the generation of defective portions due to the protrusions existing on the outer peripheral surface of the object is suppressed.

探傷装置の機構構成等を示す斜視図である。It is a perspective view which shows the mechanism composition of a flaw detector. 探傷装置の機構構成を示す側面図である。It is a side view which shows the mechanical structure of the flaw detector. 探傷装置が備える画像生成装置の機能構成を示すブロック図である。It is a block diagram which shows the functional structure of the image generation apparatus included in the flaw detection apparatus. 領域特定部が取得する領域データの関係を示す図である。It is a figure which shows the relationship of the area data acquired by the area identification part. 展開画像である合成画像を示す図である。It is a figure which shows the composite image which is a developed image. 対処物と領域データの対応関係を示す図である。It is a figure which shows the correspondence relationship between a coping object and area data.

以下に、本発明に係る探傷装置、および探傷方法の実施の形態について、図面を参照しつつ説明する。なお、以下の実施の形態で示される数値、形状、材料、構成要素、構成要素の位置関係、および接続状態、ステップ、ステップの順序などは、一例であり、本発明を限定する主旨ではない。また、以下では複数の発明を一つの実施の形態として説明する場合があるが、請求項に記載されていない構成要素については、その請求項に係る発明に関しては任意の構成要素であるとして説明している。また、図面は、本発明を説明するために適宜強調や省略、比率の調整を行った模式的な図となっており、実際の形状や位置関係、比率とは異なる場合がある。 Hereinafter, embodiments of the flaw detection device and the flaw detection method according to the present invention will be described with reference to the drawings. The numerical values, shapes, materials, components, positional relationships of the components, connection states, steps, the order of steps, etc. shown in the following embodiments are examples, and are not intended to limit the present invention. Further, in the following, a plurality of inventions may be described as one embodiment, but the components not described in the claims will be described as arbitrary components with respect to the claimed invention. ing. Further, the drawings are schematic views in which emphasis, omission, and ratio adjustment are appropriately performed in order to explain the present invention, and may differ from the actual shape, positional relationship, and ratio.

図１は、探傷装置の機構構成等を示す斜視図である。図２は、探傷装置の機構構成を示す側面図である。これらの図に示すように探傷装置１００は、円筒状の外周面に外向きに突出する突出部２１０を有する対象物２００の外周面の画像を生成して探傷に供する探傷装置１００であって、撮像装置１１０と、回転装置１２０と、画像生成装置１３０と、を備えている。本実施の形態の場合、探傷装置１００は、照明装置１４０を備えている。 FIG. 1 is a perspective view showing the mechanical configuration of the flaw detector. FIG. 2 is a side view showing the mechanical configuration of the flaw detector. As shown in these figures, the flaw detector 100 is a flaw detector 100 that generates an image of the outer peripheral surface of an object 200 having an outwardly projecting protrusion 210 on a cylindrical outer peripheral surface and uses the flaw detector 100 for flaw detection. It includes an image pickup device 110, a rotation device 120, and an image generation device 130. In the case of the present embodiment, the flaw detection device 100 includes a lighting device 140.

対象物２００は、探傷装置１００により得られた外周面の展開画像に基づき傷の有無が検査される検査対象であって、円筒状の外周面に外向きに突出する突出部２１０を備えている。対象物２００の種類は、特に限定されるものではなく、例えば、平歯車、ウォームシャフトなどを含む歯車、ボルト、木ネジなどを含む締結具、ホブ、エンドミルなどを含む切削工具などを例示することができる。本実施の形態の場合、対象物２００としてピニオンシャフトを例示しており、突出部２１０は、突条となっており、ピニオンシャフトの歯が対応している。 The object 200 is an inspection target for which the presence or absence of scratches is inspected based on the developed image of the outer peripheral surface obtained by the flaw detector 100, and includes a protruding portion 210 protruding outward on the cylindrical outer peripheral surface. .. The type of the object 200 is not particularly limited, and examples thereof include gears including spur gears and worm shafts, fasteners including bolts and wood screws, and cutting tools including hobs and end mills. Can be done. In the case of the present embodiment, the pinion shaft is exemplified as the object 200, and the protruding portion 210 is a protrusion, and the teeth of the pinion shaft correspond to it.

撮像装置１１０は、対象物２００の外周面を突出部２１０と共に撮像するいわゆるエリアカメラであって、撮像素子１１１（図４参照）と、光学系１１２（図４参照）とを備えている。撮像素子１１１は、光学系１１２により結像した像を二次元の画像データを取得する装置であり、行列状（マトリクス状）に配置される複数の撮像画素を有する。撮像素子１１１の種類は特に限定されるものではなく、ＣＣＤ（Ｃｈａｒｇｅ Ｃｏｕｐｌｅｄ Ｄｅｖｉｃｅｓ）タイプの撮像素子１１１、ＣＭＯＳ（Ｃｏｍｐｌｅｍｅｎｔａｒｙ Ｍｅｔａｌ Ｏｘｉｄｅ Ｓｅｍｉｃｏｎｄｕｃｔｏｒ）タイプの撮像素子１１１などを例示することができる。光学系１１２は、撮像素子１１１に結像させる単数、または複数の光学素子により形成されるものである。光学系１１２の種類は、特に限定されるものではない。本実施の形態の場合、光学系１１２は、突出部２１０の突出量（歯丈）程度の被写界深度を備え、突出部２１０の頂上部分（歯先）から突出部２１０の裾の部分（歯底）までピントが合うものとなっている。光学系１１２は、回転装置１２０に保持された対象物２００の回転軸２２２と光軸２２１とが直交するように配置されている。 The image pickup device 110 is a so-called area camera that takes an image of the outer peripheral surface of the object 200 together with the protrusion 210, and includes an image pickup element 111 (see FIG. 4) and an optical system 112 (see FIG. 4). The image pickup device 111 is a device for acquiring two-dimensional image data of an image imaged by the optical system 112, and has a plurality of image pickup pixels arranged in a matrix shape. The type of the image pickup element 111 is not particularly limited, and examples thereof include a CCD (Charge Coupled Devices) type image pickup element 111, a CMOS (Complementary Metal Oxide Semiconductor) type image pickup element 111, and the like. The optical system 112 is formed by a single or a plurality of optical elements for forming an image on the image pickup element 111. The type of the optical system 112 is not particularly limited. In the case of the present embodiment, the optical system 112 has a depth of field of about the protrusion amount (tooth length) of the protrusion 210, and has a depth of field from the top portion (tooth tip) of the protrusion 210 to the hem portion of the protrusion 210 (tooth tip). It is in focus up to the tooth bottom). The optical system 112 is arranged so that the rotation axis 222 of the object 200 held by the rotation device 120 and the optical axis 221 are orthogonal to each other.

回転装置１２０は、撮像装置１１０と対象物２００とを対象物２００の周方向に相対回転させる装置である。本実施の形態の場合、回転装置１２０に対し撮像装置１１０は、固定的に配置されており、回転装置１２０は、対象物２００の回転軸２２２周りに対象物２００を回転させることにより撮像装置１１０と対象物２００との相対回転を実現している。回転装置１２０の具体的な態様は、特に限定されるものではないが、本実施の形態の場合、回転装置１２０は、対象物２００の軸部２１１の周面に当接する二つのローラ１２１からなるローラ対を対象物２００の両端にそれぞれ配置し、撮像装置１１０の光軸２２１と対象物２００の回転軸２２２とが直交するように対象物２００を保持している。ローラ１２１の回転軸が対象物２００の回転軸２２２と平行になるように各ローラ１２１は配置されている。回転装置１２０のローラ１２１の少なくとも１つは、駆動装置（不図示）により回転駆動力が付与され、他のローラ１２１は、自由に回転するものとなっている。 The rotation device 120 is a device that relatively rotates the image pickup device 110 and the object 200 in the circumferential direction of the object 200. In the case of the present embodiment, the image pickup device 110 is fixedly arranged with respect to the rotation device 120, and the rotation device 120 rotates the object 200 around the rotation axis 222 of the object 200 to cause the image pickup device 110. The relative rotation between the object 200 and the object 200 is realized. The specific embodiment of the rotating device 120 is not particularly limited, but in the case of the present embodiment, the rotating device 120 includes two rollers 121 that abut on the peripheral surface of the shaft portion 211 of the object 200. A pair of rollers are arranged at both ends of the object 200, and the object 200 is held so that the optical axis 221 of the image pickup apparatus 110 and the rotation axis 222 of the object 200 are orthogonal to each other. Each roller 121 is arranged so that the rotation axis of the roller 121 is parallel to the rotation axis 222 of the object 200. At least one of the rollers 121 of the rotating device 120 is provided with a rotational driving force by a driving device (not shown), and the other rollers 121 are free to rotate.

照明装置１４０は、撮像装置１１０が対象物２００の外周面を撮像するために対象物２００の外周面に光を照射する装置である。照明装置１４０の種類は特に限定されるものではないが、本実施の形態の場合、第一光源１４１と、第二光源１４２と、保持機構１４３とを備えている。 The lighting device 140 is a device in which the image pickup device 110 irradiates the outer peripheral surface of the object 200 with light in order to image the outer peripheral surface of the object 200. The type of the lighting device 140 is not particularly limited, but in the case of the present embodiment, the first light source 141, the second light source 142, and the holding mechanism 143 are provided.

第一光源１４１は、突出部２１０の第一面側２３１に光を照射する。第二光源１４２は、第一面側２３１とは逆側の第二面側２３２に光を照射する。本実施の形態の場合、対象物２００の回転軸２２２が図中のＹ軸に沿って配置されており、Ｙ軸の負側（Ｙ−）からＹ軸の正側（Ｙ＋）に向かって時計回り（右回り）方向に法線が向く突出部２１０の面（歯面）が第一面側２３１、反時計回り（左回り）方向に法線が向く突出部２１０の面（歯面）が第二面側２３２となっている。 The first light source 141 irradiates the first surface side 231 of the protrusion 210 with light. The second light source 142 irradiates the second surface side 232 opposite to the first surface side 231 with light. In the case of the present embodiment, the rotation axis 222 of the object 200 is arranged along the Y axis in the drawing, and the clock is directed from the negative side (Y−) of the Y axis to the positive side (Y +) of the Y axis. The surface (tooth surface) of the projecting portion 210 whose normal is directed in the clockwise (clockwise) direction is 231 on the first surface side, and the surface (tooth surface) of the projecting portion 210 whose normal is directed in the counterclockwise (counterclockwise) direction is. It is 232 on the second side.

第一光源１４１、および第二光源１４２が放射する光の種類は、特に限定されるものではなく、レーザー光やＬＥＤ光などの単色光でもよく、白色光などでも構わない。また、撮像装置１１０が撮像可能であれば可視光以外でも構わない。例えば、対象物２００の外周面に蛍光を発する粉体が付着している様な場合は、蛍光物質が励起する波長を含む可視光ではない光を照射するものでもよい。第一光源１４１、および第二光源１４２は、撮像装置１１０が撮像する対象物２００の領域全体、つまり、前記領域内の突出部２１０の頂上部（歯先面）、第一面側２３１、第二面側２３２、隣り合う突出部２１０の間（歯元）をできる限り均等な照度となるように光を照射している。 The type of light emitted by the first light source 141 and the second light source 142 is not particularly limited, and may be monochromatic light such as laser light or LED light, or white light or the like. Further, as long as the image pickup device 110 can take an image, it may be other than visible light. For example, when a powder that emits fluorescence is attached to the outer peripheral surface of the object 200, it may be irradiated with light other than visible light including a wavelength excited by the fluorescent substance. The first light source 141 and the second light source 142 are the entire region of the object 200 imaged by the image pickup apparatus 110, that is, the top portion (tooth tip surface) of the projecting portion 210 in the region, the first surface side 231 and the first. Light is radiated so that the illuminance is as uniform as possible between the two-sided side 232 and the adjacent protruding portions 210 (teeth root).

保持機構１４３は、第一光源１４１、および第二光源１４２の位置を対象物２００の外周面に沿って移動可能に第一光源１４１、および第二光源１４２をそれぞれ保持する部材である。本実施の形態の場合、保持機構１４３は、回転装置１２０に保持された対象物２００の回転軸２２２を中心とした円弧形状を成しており、第一光源１４１、および第二光源１４２を、回転軸２２２を中心とした円周に沿って移動させ、所定の位置で保持することができるものとなっている。また、保持機構１４３は、回転軸２２２と平行な軸周りで第一光源１４１、および第二光源１４２をそれぞれ回転可能に保持している。 The holding mechanism 143 is a member that holds the first light source 141 and the second light source 142 so that the positions of the first light source 141 and the second light source 142 can be moved along the outer peripheral surface of the object 200, respectively. In the case of the present embodiment, the holding mechanism 143 has an arc shape centered on the rotating shaft 222 of the object 200 held by the rotating device 120, and the first light source 141 and the second light source 142 are used. It can be moved along the circumference about the rotation axis 222 and held at a predetermined position. Further, the holding mechanism 143 rotatably holds the first light source 141 and the second light source 142 around an axis parallel to the rotation shaft 222.

図３は、探傷装置が備える画像生成装置の機能構成を示すブロック図である。同図に示すように、画像生成装置１３０は、撮像装置１１０と回転装置１２０とを制御して対象物２００の外周面の展開画像を生成するＥＣＵ（Ｅｌｅｃｔｒｏｎｉｃ Ｃｏｎｔｒｏｌ Ｕｎｉｔ）の１つである。本実施の形態の場合、画像生成装置１３０は、非一時的記憶媒体に記録されたプログラムを実行することにより実現する処理部として、撮像部１３１と、領域特定部１３２と、画像合成部１３３と、回転制御部１３４と、傷検出部１３５と、を備えている。 FIG. 3 is a block diagram showing a functional configuration of an image generation device included in the flaw detector. As shown in the figure, the image generation device 130 is one of the ECUs (Electronic Control Units) that control the image pickup device 110 and the rotation device 120 to generate a developed image of the outer peripheral surface of the object 200. In the case of the present embodiment, the image generation device 130 includes an image pickup unit 131, a region identification unit 132, and an image composition unit 133 as processing units realized by executing a program recorded on a non-temporary storage medium. , A rotation control unit 134, and a scratch detection unit 135.

回転制御部１３４は、回転装置１２０による撮像装置１１０と対象物２００との相対回転を制御する。本実施の形態の場合、回転制御部１３４は、回転装置１２０が備える駆動装置を制御して、等速で対象物２００を回転させる。回転制御部１３４は、対象物２００の諸元を入力することで適切な回転速度を導出しても構わない。また、所定の回転速度で対象物２００を回転させた後、指定された箇所を先の回転速度よりも遅い回転速度で対象物２００を回転させても構わない。 The rotation control unit 134 controls the relative rotation between the image pickup device 110 and the object 200 by the rotation device 120. In the case of the present embodiment, the rotation control unit 134 controls the drive device included in the rotation device 120 to rotate the object 200 at a constant speed. The rotation control unit 134 may derive an appropriate rotation speed by inputting the specifications of the object 200. Further, after rotating the object 200 at a predetermined rotation speed, the object 200 may be rotated at a designated place at a rotation speed slower than the previous rotation speed.

撮像部１３１は、回転装置１２０による対象物２００と撮像装置１１０との相対回転と同期した所定の時間間隔で対象物２００の外周面の画像を撮像装置１１０に撮像させる処理部である。撮像部１３１は、一定の時間間隔、例えば３０ｆｐｓで撮像装置１１０に撮像させてもよい。また、回転制御部１３４から取得した同期信号に基づき、または対象物２００の回転速度に対応した時間間隔で撮像装置１１０に対象物２００を撮像させても構わない。 The image pickup unit 131 is a processing unit that causes the image pickup device 110 to take an image of the outer peripheral surface of the object 200 at a predetermined time interval synchronized with the relative rotation of the object 200 and the image pickup device 110 by the rotation device 120. The image pickup unit 131 may cause the image pickup apparatus 110 to take an image at a fixed time interval, for example, 30 fps. Further, the image pickup apparatus 110 may image the object 200 based on the synchronization signal acquired from the rotation control unit 134 or at a time interval corresponding to the rotation speed of the object 200.

図４は、領域特定部が取得する領域データの関係を示す図である。同図に示すように、領域特定部１３２は、撮像装置１１０の撮像素子１１１が撮像した画像データ１５０から、突出部２１０の第一面側２３１が撮像される第一領域データ１５１、および突出部２１０の第二面側２３２が撮像される第二領域データ１５２を特定して取得する。本実施の形態の場合、領域特定部１３２は、画像データ１５０から突出部２１０の頂上部が撮像される第三領域データ１５３も特定して取得している。領域特定部１３２の領域の特定の仕方は特に限定されるものではなく、作業者が画像データ１５０からなる画像を目視により確認して複数の領域を指定することにより第一領域データ１５１、第二領域データ１５２、第三領域データ１５３を特定してもよい。また、対象物２００の諸元を入力することで適切な第一領域データ１５１、第二領域データ１５２、第三領域データ１５３を特定しても構わない。 FIG. 4 is a diagram showing the relationship of the area data acquired by the area specifying unit. As shown in the figure, the region specifying unit 132 has a first region data 151 in which the first surface side 231 of the projecting portion 210 is imaged from the image data 150 imaged by the image sensor 111 of the image pickup device 110, and a protruding portion. The second region data 152 on which the second surface side 232 of the 210 is imaged is specified and acquired. In the case of the present embodiment, the region specifying unit 132 also identifies and acquires the third region data 153 in which the top of the protruding portion 210 is imaged from the image data 150. The method of specifying the area of the area specifying unit 132 is not particularly limited, and the operator visually confirms the image consisting of the image data 150 and designates a plurality of areas to specify the first area data 151 and the second area. Area data 152 and third area data 153 may be specified. Further, appropriate first region data 151, second region data 152, and third region data 153 may be specified by inputting the specifications of the object 200.

領域特定部１３２は、撮像装置１１０に指示を与えることにより第一領域データ１５１、第二領域データ１５２、第三領域データ１５３をそれぞれ取得してもよい。また、領域特定部１３２は、画像データ１５０を取得した後、得られた画像データ１５０から第一領域データ１５１、第二領域データ１５２、第三領域データ１５３をそれぞれ切り出しても構わない。 The area specifying unit 132 may acquire the first area data 151, the second area data 152, and the third area data 153, respectively, by giving an instruction to the image pickup apparatus 110. Further, the area specifying unit 132 may cut out the first area data 151, the second area data 152, and the third area data 153 from the obtained image data 150 after acquiring the image data 150.

第一領域データ１５１、第二領域データ１５２、第三領域データ１５３の幅は、撮像画素の１つから取得するデータでもよく、複数の撮像画素から取得するデータでも構わない。 The width of the first region data 151, the second region data 152, and the third region data 153 may be data acquired from one of the imaging pixels, or may be data acquired from a plurality of imaging pixels.

画像合成部１３３は、第一領域データ１５１、第二領域データ１５２、および第三領域データ１５３をそれぞれ合成して対象物２００の外周面を相互に異なる方向で撮像した展開画像である例えば図５に模式的に示すような第一合成画像１６１、第二合成画像１６２、第三合成画像１６３を生成する。画像合成部１３３は、生成した第一合成画像１６１、第二合成画像１６２、第三合成画像１６３を表示装置１７０に表示させる。画像合成部１３３は、撮像素子１１１で一度に撮像した画像の部分が並ぶように第一合成画像１６１、第二合成画像１６２、第三合成画像１６３を並べて表示させてもよい。 The image synthesizing unit 133 is a developed image obtained by synthesizing the first region data 151, the second region data 152, and the third region data 153, and capturing the outer peripheral surfaces of the object 200 in different directions, for example, FIG. The first composite image 161 and the second composite image 162 and the third composite image 163 as schematically shown in the above are generated. The image composition unit 133 causes the display device 170 to display the generated first composite image 161, second composite image 162, and third composite image 163. The image synthesis unit 133 may display the first composite image 161, the second composite image 162, and the third composite image 163 side by side so that the portions of the images captured by the image pickup element 111 at one time are lined up.

傷検出部１３５は、画像合成部１３３が生成した第一合成画像１６１、第二合成画像１６２、第三合成画像１６３に基づき、ディープラーニングなどの人工知能を用いて傷を検出する。傷検出部１３５は、検出した傷が作業者に目視で認識できるように第一合成画像１６１、第二合成画像１６２、第三合成画像１６３の対応箇所に目印を付すことができる。 The scratch detection unit 135 detects scratches using artificial intelligence such as deep learning based on the first composite image 161, the second composite image 162, and the third composite image 163 generated by the image synthesis unit 133. The scratch detection unit 135 can mark the corresponding portions of the first composite image 161 and the second composite image 162 and the third composite image 163 so that the detected scratch can be visually recognized by the operator.

本実施の形態で説明した画像生成装置１３０を備えた探傷装置１００によれば、１つの撮像装置１１０により複数のアングルから対象物２００の外周面を撮像することできるため、突出部２１０に起因した欠損部が抑制された展開画像を生成することができる。従って、対象物２００の外周面に発生した傷を見逃すことなく検出することが可能となる。 According to the flaw detection device 100 provided with the image generation device 130 described in the present embodiment, the outer peripheral surface of the object 200 can be imaged from a plurality of angles by one image pickup device 110, which is caused by the protrusion 210. It is possible to generate a developed image in which the defective portion is suppressed. Therefore, it is possible to detect scratches generated on the outer peripheral surface of the object 200 without overlooking them.

また、複数のアングルを一つの撮像素子１１１により一度に取得するため、欠損部の少ない展開画像を高速で生成することが可能となる。例えば、対象物２００がピニオンシャフトのように、突出部２１０の根元（歯元）側の厚み（歯厚）が先端（歯先）側の厚みよりも薄い場合、一台のラインカメラでは、突出部２１０の根本（歯元）部分に撮像できない欠陥部分が発生する場合があるが、上記探傷装置１００によれば、複数台のラインカメラを必要とせず、１台の撮像装置１１０によって、突出部２１０の先端を含む第一面側２３１、および第二面側２３２を撮影することができ、得られた画像に基づき探傷を実施することができる。 Further, since a plurality of angles are acquired at once by one image sensor 111, it is possible to generate a developed image with few defects at high speed. For example, when the object 200 has a thickness (tooth thickness) on the root (tooth root) side of the protrusion 210 thinner than the thickness on the tip (tooth tip) side like a pinion shaft, it protrudes with one line camera. A defect portion that cannot be imaged may occur at the root (tooth root) portion of the portion 210, but according to the flaw detection device 100, a plurality of line cameras are not required, and a projecting portion is provided by one image pickup device 110. The first surface side 231 including the tip of 210 and the second surface side 232 can be photographed, and flaw detection can be performed based on the obtained images.

なお、本発明は、上記実施の形態に限定されるものではない。例えば、本明細書において記載した構成要素を任意に組み合わせて、また、構成要素のいくつかを除外して実現される別の実施の形態を本発明の実施の形態としてもよい。また、上記実施の形態に対して本発明の主旨、すなわち、請求の範囲に記載される文言が示す意味を逸脱しない範囲で当業者が思いつく各種変形を施して得られる変形例も本発明に含まれる。 The present invention is not limited to the above embodiment. For example, another embodiment realized by arbitrarily combining the components described in the present specification and excluding some of the components may be an embodiment of the present invention. The present invention also includes modifications obtained by making various modifications that can be conceived by those skilled in the art within the scope of the gist of the present invention, that is, the meaning indicated by the wording described in the claims, with respect to the above-described embodiment. Will be.

例えば、実施の形態では、第一領域データ１５１、第二領域データ１５２、および第三領域データ１５３を取得する場合を説明したが、図６に示すように、さらに、第四領域データ１５４、および第五領域データ１５５を取得し、第四合成画像、第五合成画像を生成しても構わない。 For example, in the embodiment, the case of acquiring the first region data 151, the second region data 152, and the third region data 153 has been described, but as shown in FIG. 6, the fourth region data 154 and the fourth region data 154 are further described. The fifth region data 155 may be acquired to generate a fourth composite image and a fifth composite image.

また、図４では、光学系１１２による焦点が対象物２００の外側に存在する場合を説明したが、焦点が対象物２００の内側に存在しても構わない。 Further, in FIG. 4, the case where the focal point by the optical system 112 exists outside the object 200 has been described, but the focal point may exist inside the object 200.

探傷装置、および探傷方法は、外周面に突起のある、歯車、ネジ、切削工具などの傷の検出に利用可能である。 The flaw detector, and flaw detector method, can be used to detect scratches on gears, screws, cutting tools, etc. with protrusions on the outer peripheral surface.

１００…探傷装置、１１０…撮像装置、１１１…撮像素子、１１２…光学系、１２０…回転装置、１２１…ローラ、１３０…画像生成装置、１３１…撮像部、１３２…領域特定部、１３３…画像合成部、１３４…回転制御部、１３５…傷検出部、１４０…照明装置、１４１…第一光源、１４２…第二光源、１４３…保持機構、１５０…画像データ、１５１…第一領域データ、１５２…第二領域データ、１５３…第三領域データ、１５４…第四領域データ、１５５…第五領域データ、１６１…第一合成画像、１６２…第二合成画像、１６３…第三合成画像、１７０…表示装置、２００…対象物、２１０…突出部、２１１…軸部、２２１…光軸、２２２…回転軸、２３１…第一面側、２３２…第二面側 100 ... flaw detector, 110 ... image pickup device, 111 ... image pickup element, 112 ... optical system, 120 ... rotation device, 121 ... roller, 130 ... image generation device, 131 ... image pickup unit, 132 ... area identification unit, 133 ... image synthesis Unit, 134 ... Rotation control unit, 135 ... Scratch detection unit, 140 ... Lighting device, 141 ... First light source, 142 ... Second light source, 143 ... Holding mechanism, 150 ... Image data, 151 ... First area data, 152 ... Second region data, 153 ... third region data, 154 ... fourth region data, 155 ... fifth region data, 161 ... first composite image, 162 ... second composite image, 163 ... third composite image, 170 ... display Device, 200 ... Object, 210 ... Projection, 211 ... Shaft, 221 ... Optical axis, 222 ... Rotating shaft, 231 ... First surface side, 232 ... Second surface side

Claims (5)

円筒状の外周面に外向きに突出する突出部を有する対象物の前記外周面の画像を生成する探傷装置であって、
行列状に配置される複数の撮像画素を有する撮像素子と、前記撮像素子に像を結像する光学系を備えた撮像装置と、
前記撮像装置と前記対象物とを前記対象物の周方向に相対回転させる回転装置と、
前記回転装置による相対回転と同期した所定の時間間隔で前記対象物の外周面の画像を前記撮像装置に撮像させる撮像部と、
前記撮像装置が撮像した画像データから、前記突出部の所定の第一面側が撮像される第一領域データ、および前記突出部の前記第一面側と逆側の第二面側が撮像される第二領域データを特定して取得する領域特定部と、
前記第一領域データ、および前記第二領域データを合成して前記外周面の展開画像を生成する画像合成部と、
を備える探傷装置。 A flaw detector that produces an image of the outer peripheral surface of an object having an outwardly projecting protrusion on the outer peripheral surface of a cylinder.
An image pickup device having a plurality of image pickup pixels arranged in a matrix, an image pickup device provided with an optical system for forming an image on the image pickup element, and an image pickup device.
A rotating device that relatively rotates the image pickup device and the object in the circumferential direction of the object, and
An image pickup unit that causes the image pickup device to take an image of the outer peripheral surface of the object at a predetermined time interval synchronized with the relative rotation by the rotation device.
From the image data captured by the image pickup apparatus, the first region data in which the predetermined first surface side of the protrusion is imaged, and the second surface side opposite to the first surface side of the protrusion is imaged. The area identification part that identifies and acquires the two area data, and
An image synthesizing unit that synthesizes the first region data and the second region data to generate a developed image of the outer peripheral surface.
A flaw detector equipped with. 前記回転装置による前記撮像装置と前記対象物との相対回転を制御する回転制御部を備える
請求項１に記載の探傷装置。 The flaw detection device according to claim 1, further comprising a rotation control unit that controls relative rotation between the image pickup device and the object by the rotation device. 前記突出部の前記第一面側に光を照射する第一光源と、前記第二面側に光を照射する第二光源と、前記第一光源、および前記第二光源の位置を前記外周面に沿って移動可能に前記第一光源、および前記第二光源を保持する保持機構を備える照明装置を備える
請求項１または２に記載の探傷装置。 The positions of the first light source that irradiates the first surface side of the protrusion, the second light source that irradiates the second surface side, the first light source, and the second light source are the outer peripheral surfaces. The flaw detection device according to claim 1 or 2, further comprising a lighting device including a holding mechanism for holding the first light source and the second light source so as to be movable along the same. 前記画像合成部から取得した展開画像に基づき人工知能を用いて対象物表面の傷を検出する傷検出部を備える
請求項１から３のいずれか一項に記載の探傷装置。 The flaw detection device according to any one of claims 1 to 3, further comprising a scratch detection unit that detects scratches on the surface of an object using artificial intelligence based on a developed image acquired from the image synthesis unit. 円筒状の外周面に外向きに突出する突出部を有する対象物の前記外周面の画像を生成する探傷方法であって、
行列状に配置される複数の撮像画素を有する撮像素子と、前記撮像素子に像を結像する光学系を備えた撮像装置と前記対象物とを前記対象物の周方向に回転装置が相対回転させ、
前記回転装置による相対回転と同期した所定の時間間隔で前記対象物の外周面の画像を前記撮像装置に撮像部が撮像させ、
前記撮像装置が撮像した画像データから、前記突出部の所定の第一面側が撮像される第一領域データ、および前記突出部の前記第一面側と逆側の第二面側が撮像される第二領域データを領域特定部が特定して取得し、
前記第一領域データ、および前記第二領域データを合成して前記外周面の展開画像を画像合成部が生成し、
前記展開画像に基づき対象物表面の傷を検出する
探傷方法。 A flaw detection method for generating an image of the outer peripheral surface of an object having an outwardly projecting protrusion on the outer peripheral surface of a cylinder.
An image pickup device having an image pickup element having a plurality of image pickup pixels arranged in a matrix, an image pickup device provided with an optical system for forming an image on the image pickup element, and the object are rotated relative to each other in the circumferential direction of the object. Let me
The image pickup unit causes the image pickup device to take an image of the outer peripheral surface of the object at a predetermined time interval synchronized with the relative rotation by the rotation device.
From the image data captured by the image pickup apparatus, the first region data in which the predetermined first surface side of the protrusion is imaged, and the second surface side opposite to the first surface side of the protrusion is imaged. Two area data is specified and acquired by the area identification part,
The image synthesizing unit generates a developed image of the outer peripheral surface by synthesizing the first region data and the second region data.
A flaw detection method for detecting scratches on the surface of an object based on the developed image.
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