WO2013145823A1 - ワイヤロープ検査装置 - Google Patents
ワイヤロープ検査装置 Download PDFInfo
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- WO2013145823A1 WO2013145823A1 PCT/JP2013/051324 JP2013051324W WO2013145823A1 WO 2013145823 A1 WO2013145823 A1 WO 2013145823A1 JP 2013051324 W JP2013051324 W JP 2013051324W WO 2013145823 A1 WO2013145823 A1 WO 2013145823A1
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- WIPO (PCT)
- Prior art keywords
- wire rope
- camera
- light source
- video
- state analysis
- Prior art date
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
- G01N21/952—Inspecting the exterior surface of cylindrical bodies or wires
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/08—Measuring arrangements characterised by the use of optical techniques for measuring diameters
- G01B11/10—Measuring arrangements characterised by the use of optical techniques for measuring diameters of objects while moving
- G01B11/105—Measuring arrangements characterised by the use of optical techniques for measuring diameters of objects while moving using photoelectric detection means
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/2433—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures for measuring outlines by shadow casting
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/30—Subject of image; Context of image processing
- G06T2207/30108—Industrial image inspection
Definitions
- the present invention relates to a wire rope inspection apparatus.
- a light projecting unit for irradiating a laser beam and a light receiving unit for receiving light that has passed through the wire rope are respectively arranged at positions facing each other with the wire rope interposed therebetween.
- An inspection device that travels and measures the diameter of the entire length of the wire rope has been proposed (for example, Patent Document 1).
- Patent Document 2 in an inspection apparatus using a method of irradiating a wire rope with light and capturing the reflected light with a camera, an operator can confirm a video recorded by imaging.
- the measurement accuracy may be lowered. That is, for example, when the surface of the wire rope is soiled with oil or the like, or when the wire rope has a metallic luster, the light reflected from the wire rope is uneven or uneven. As a result, there is a problem that it is difficult to accurately extract only the portion where the rope is reflected from the captured image.
- the fact that the wire rope has a cylindrical shape and that shadows are generated by the strands and strands constituting the wire rope also make it difficult to extract the wire rope outline. Furthermore, when an object is present at a position facing the camera across the wire rope, or when external light is present in the measurement environment, there is a problem that the accuracy of extracting the outline of the wire rope is reduced.
- the present invention has been made to solve such problems, and an object of the present invention is to provide a wire rope inspection apparatus capable of inspecting a wire rope with higher accuracy than in the past.
- the present invention is configured as follows. That is, the wire rope inspection device according to one aspect of the present invention is arranged so as to face a camera that continuously captures a moving wire rope as an image and the camera with the wire rope interposed therebetween. A surface light source that emits light, a state analysis device that analyzes the state of the wire rope from the wire rope image captured by the camera, and an analysis result display that displays the analysis result analyzed by the state analysis device And a device.
- the camera captures a shadow formed by the light irradiated from the surface light source being blocked by the wire rope. Even when there is a metal reflection or the like, the wire rope region can be stably extracted from the image of the wire rope. Therefore, the wire rope can be analyzed with higher accuracy than in the past.
- FIG. 1 It is a block diagram of the wire rope inspection apparatus by Embodiment 1 of this invention. It is a perspective view of the wire rope inspection apparatus which shows the positional relationship of the wire rope with which the wire rope inspection apparatus shown in FIG. 1 is equipped, a camera, and a surface light source. It is the schematic diagram which showed an example of the image
- FIG. 2 is a schematic diagram showing an example in which a state analysis device and an analysis result display device provided in the wire rope inspection device shown in FIG. 1 are configured by a general-purpose computer, and an analysis result is displayed by a program operating on the computer.
- It is a block diagram of the wire rope inspection apparatus by Embodiment 3 of this invention. It is the schematic diagram which showed an example of the image
- FIG. 8 is a schematic diagram showing an example in which the state analysis device and the analysis result display device provided in the wire rope inspection device shown in FIG.
- FIG. 7 are configured by a general-purpose computer, and the analysis result is displayed by a program operating on the computer.
- FIG. 16 is a schematic diagram illustrating an example in which the state analysis device and the analysis result display device included in the wire rope inspection device illustrated in FIG. 15 are configured by a general-purpose computer, and the analysis result is displayed by a program operating on the computer.
- FIG. 6 is a block diagram for explaining functions of a state analysis device provided in the wire rope inspection device according to the first to fourth embodiments of the present invention.
- wire rope inspection apparatus according to an embodiment of the present invention will be described below with reference to the drawings.
- the same or similar components are denoted by the same reference numerals.
- the wire rope inspection apparatus of each following embodiment although the wire rope in an elevator is taken as an example as an example of a wire rope, of course, it is not limited to this.
- FIG. 1 shows a configuration of a wire rope inspection apparatus 101 according to the first embodiment.
- the wire rope inspection device 101 includes a camera 120, a surface light source 130, a state analysis device 150, and an analysis result display device 160 as basic components.
- the configuration illustrated in FIG. 1 further includes a video recording device 140, a diffusion plate 135, and a louver 170. These components will be described below.
- FIG. 2 is a view showing the positional relationship between the wire rope 1, the camera 120, and the surface light source 130 provided in the wire rope inspection apparatus 101.
- the camera 120 and the surface light source 130 are provided at positions facing each other with the wire rope 1 to be inspected in between, and the surface light source 130 irradiates the wire rope 1 and the camera 120 with light. Therefore, when viewed from the camera 120 side, the surface light source 130 is located on the back side of the wire rope 1. With this arrangement, the camera 120 shoots the video while running the wire rope 1.
- the video data of the wire rope 1 photographed by the camera 120 is stored in the video recording device 140.
- the state analysis device 150 reads the video data recorded in the video recording device 140, analyzes the captured video of the wire rope 1, and analyzes the state of the wire rope 1 including the quality of the wire rope 1 as a result thereof. 160.
- the state of the wire rope 1 refers to, for example, the outer diameter of the wire rope 1, the presence or absence of rust on the surface of the wire rope 1, the presence or absence of a broken wire of the wire rope 1.
- the state analyzed by the state analyzer 150 is not limited to these physical quantities and physical phenomena, but includes general physical quantities and physical phenomena related to the strength and aging of the wire rope. These components will be described in more detail below.
- the camera 120 is in such a posture that the horizontal line in the image sensor is perpendicular to the longitudinal direction of the wire rope 1 and at an angle of view that includes the wire rope 1 and the surface light source 130 provided behind it in the field of view. Be placed. By arranging in this manner, the camera 120 simultaneously captures the shadow formed by the light irradiated from the surface light source 130 being blocked by the wire rope 1 and the light directly incident on the camera 120 from the surface light source 130. It becomes.
- a diffusion plate 135 is further arranged between the wire rope 1 and the surface light source 130 so that the light emitted from the surface light source 130 passes through the diffusion plate 135 and is applied to the wire rope 1 and the camera 120. Also good. Further, a louver 170 may be further disposed between the wire rope 1 and the diffusion plate 135 so that light emitted from the surface light source 130 passes through the louver 170 and is irradiated to the wire rope 1 and the camera 120. .
- the louver 170 is a filter for controlling the traveling direction of light, and is arranged so as to be orthogonal to the optical axis of the camera 120.
- the diffusing plate 135 and the louver 170 are preferably used at the same time, but may be configured to include only one of them.
- FIG. 3 is a schematic diagram illustrating an example of an image captured by the camera 120. Since light is irradiated from the surface light source 130 toward the wire rope 1 and the camera 120, the area 1A that is blocked by the wire rope 1 and becomes a shadow appears dark as shown in the center portion of FIG. On the other hand, the portion 130A where the light from the surface light source 130 directly enters the camera 120 appears bright as the left and right portions of FIG. 3 is a conceptual diagram when an area camera is used as the camera 120, the wire rope inspection apparatus 101 is not limited to an area camera but may be a line camera.
- FIG. 3 is a diagram when one camera 120 captures an image of one wire rope 1.
- the cameras are arranged so that a plurality of wire ropes 1 are within one field of view. 120 may be arranged, the state analysis device 150 may simultaneously analyze the plurality of wire ropes 1, and the results may be simultaneously displayed on the analysis result display device 160.
- the video recording device 140 is a device that records video data of the traveling wire rope 1 photographed by the camera 120.
- a video recording device 140 may be built in either the camera 120 or the state analysis device 150, or may be removable from the camera 120 and the state analysis device 150. Good.
- the form connected with the camera 120 and the state analysis apparatus 150 with a cable may be sufficient.
- a recording medium such as a hard disk, a non-volatile memory, an optical disk, or a video tape can be used as the video recording device 140.
- the state analysis device 150 sequentially reads the captured video data of the wire rope 1 recorded in the video recording device 140 for each frame, and performs an analysis process of the state of the wire rope 1. The result of the analysis process is displayed on the analysis result display device 160.
- the state analysis device 150 is actually implemented using a computer, and will be described in detail in the state analysis operation description part of the wire rope 1 described below.
- Software programs corresponding to each analysis function and the execution thereof are executed. It is composed of hardware such as a CPU (Central Processing Unit) and a memory.
- the computer preferably corresponds to a microcomputer incorporated in the wire rope inspection apparatus 101, but a stand-alone personal computer can also be used.
- the analysis result display device 160 is configured by the same computer as the state analysis device 150, for example, and a display of this computer can be used. Of course, a separate display may be used.
- the video recording device 140 may be omitted from the configuration shown in FIG. 1 when it is not necessary to record video from the camera 120 or to reproduce the recorded video later.
- the camera 120 is directly connected to the state analysis device 150, and the state analysis device 150 sequentially analyzes video signals transmitted from the camera 120 in real time.
- the state analysis device 150 includes a rope region extraction unit 151, a display region extraction unit 152, a travel distance information recognition unit 153, a travel distance, as shown in FIG.
- Each component includes a distance information output unit 154, a rope diameter acquisition unit 155, a rust detection unit 156, and a strand break detection unit 157.
- Such a state analysis device 150 is actually realized by using a computer as described above, and each of the components 151 to 157 includes software (program) corresponding to each function and It is comprised from hardware, such as CPU and memory for performing.
- the program includes not only a program that can be directly executed by a computer but also a program that can be executed by being read via a communication line and installed in a hard disk or the like. Also included are those that are compressed or encrypted.
- the state analysis device 150 reads the image data captured and recorded by the camera 120 from the video recording device 140 (step S11), and sequentially executes the following processing for each frame of the image data.
- the state analysis device 150 uses the rope region extraction unit 151 to capture a portion 130A (FIG. 3) in which the surface light source 130 is captured of one frame of imaging data based on the optical characteristics of the surface light source 130, and a wire. It isolate
- the optical characteristics refer to characteristic values such as the color (wavelength characteristics) of emitted light from the surface light source 130 and its intensity (luminance), for example.
- step S12 The operation of extracting the region 1A of the wire rope 1 in step S12 will be described in more detail.
- an example of processing for extracting the region 1A of the wire rope 1 based on the intensity (luminance) of light is shown.
- the rope region extraction unit 151 of the state analysis device 150 creates a luminance histogram as shown in FIG. In the created histogram, two large peaks are generated. In FIG. 5, the peak that appears in the dark portion corresponds to the portion that appears dark due to the shadow of the wire rope 1, and the peak that appears in the bright portion corresponds to the portion that appears bright due to the light emitted from the surface light source 130. Each corresponds.
- the rope region extraction unit 151 uses this histogram to calculate a threshold value for distinguishing between the region 1A of the wire rope 1 and the region 130A of the surface light source 130.
- the threshold calculation method for example, a discriminant analysis method, a mode method, or the like can be used. Then, a pixel whose luminance is higher than the obtained threshold is identified as the region 130A of the surface light source 130, and a small pixel is identified as the region 1A of the wire rope 1.
- the procedure for generating a histogram from the video and automatically determining the threshold value is exemplified, but a predetermined fixed value may be used as the threshold value.
- the state analysis device 150 measures the width of the extracted region 1A of the wire rope 1 at the rope diameter acquisition unit 155 (step S13).
- the unit for obtaining the width of the region 1A on the image is the number of pixels. Therefore, a conversion coefficient (actual dimension per pixel) between the number of pixels and the actual dimension of the rope 1 is set in the rope diameter acquisition unit 155.
- the rope diameter acquisition part 155 calculates the actual dimension of the diameter of the wire rope 1 from the extracted pixel count of the width
- the method of obtaining the actual dimension of the wire rope 1 from the number of pixels is not limited to the method using the conversion coefficient described above, and other known methods can be adopted, for example, using a table. .
- the actual dimension of the acquired diameter of the wire rope 1 is output as data (step S14).
- the output form display on a screen, storage in a file format, printing to a printer, and the like are possible.
- the diameter can be measured over the entire length of the wire rope 1 and the result can be obtained.
- the analysis result display device 160 is actually implemented using a computer as described above, and software (programs) corresponding to the following functions and a CPU (central processing unit) for executing the software (program). And hardware such as memory.
- functions of the analysis result display device 160 include a recorded video display unit 161, a video file designation unit 162, a conversion coefficient input unit 163, a wire rope diameter measurement result display unit 164, a wire rope diameter graph display unit 165, and an operation unit 166.
- a travel distance display unit 167 (Embodiment 4) and a rust ratio display unit 168 (Embodiment 4) are provided.
- FIG. 6 shows that the functions of both the state analysis device 150 and the analysis result display device 160 are configured by a single general-purpose computer, the wire rope 1 is analyzed by a software program on this computer, and the results are displayed. An example is shown. Prior to performing the analysis process, the above-described conversion coefficient between the number of pixels and the actual size is input in advance to the conversion coefficient input unit 163 in the display (analysis result display device 160).
- the video file designation unit 162 designates a video file recorded in the video recording device 140 to be analyzed. Due to this designation, the video file designation unit 162 actually reads the designated video file from the video recording device 140. The video of the read video file is reproduced and displayed by the recorded video display unit 161. Further, the wire rope diameter is measured from the read video file according to the procedure described above. The measurement result is displayed as a line graph by the wire rope diameter graph display unit 165. Further, when the operator operates the operation unit 166, the video displayed on the recorded video display unit 161 can be reproduced, paused, fast-forwarded, or rewound.
- the current position display 165d in the wire rope diameter graph display unit 165 moves left and right.
- the wire rope diameter graph display unit 165 also has a function as a synchronous display unit. Further, the measurement result of the corresponding wire rope diameter is synchronously displayed by the wire rope diameter measurement result display unit 164.
- the camera 120 captures a shadow formed by the light irradiated from the surface light source 130 being blocked by the wire rope 1.
- 101 can stably extract the region 1A of the wire rope 1 from the image even if the surface of the wire rope 1 has, for example, oil stains or metallic reflections of strands. Therefore, according to the wire rope inspection apparatus 101, it is possible to execute a wire rope analysis with higher accuracy than in the past.
- the surface light source 130 when the surface light source 130 is provided with the diffusion plate 135, the surface light source 130 becomes a surface light source having a uniform brightness distribution. Therefore, in the luminance histogram of the photographed image, the respective luminance distributions of the wire rope region 1A and the background region (the portion where the surface light source is reflected) 130A are clearly separated. Therefore, by providing the diffusion plate 135, the stability of the extraction process of the wire rope region 1A can be improved.
- the louver 170 is provided between the wire rope 1 and the surface light source 130, the light emitted from the surface light source 130 toward the camera 120 becomes parallel light. Therefore, the wraparound of light generated near the boundary between the shadow of the wire rope 1 and the background is suppressed. Therefore, since an image in which the contrast between the shadow and the background of the wire rope 1 is emphasized can be taken, the louver 170 is provided in the wire rope region 1A in the same manner as the effect of the configuration including the diffusion plate 135. The stability of the extraction process can be improved.
- the surface light source 130 shown in FIG. 1 may be a monochromatic light source.
- a monochromatic light source is useful. That is, when the camera 120 captures the wire rope 1 in a state where ambient light has hit the surface of the wire rope 1, the shadow portion of the wire rope 1 appears bright, and the shadow portion and the background portion, that is, the light portion from the light source The difference between light and dark becomes smaller. As a result, there is a possibility that the accuracy of extracting the region 1A of the wire rope 1 is lowered in the processing by the state analysis device 150.
- the surface light source 130 by using monochromatic light having optical characteristics different from the reflected light due to disturbance light as the surface light source 130, the above-described possibility of a decrease in accuracy can be suppressed.
- the reflected light from the wire rope 1 is rarely green light or blue light. Therefore, as the surface light source 130, monochromatic light of green light or blue light is used. Is effective.
- the state analysis device 150 may perform the operation of extracting the region 1A of the wire rope 1 (step S12 in FIG. 4) according to the following procedure. That is, for each pixel in the frame of the captured image, the state analysis device 150 determines that the pixel is the background if the intensity of green light is sufficiently large and the intensity of red light and blue light is sufficiently small compared to the intensity of green light. On the other hand, if not, it is determined to be the region 1A of the wire rope 1. Similar to the procedure described in the first embodiment, the threshold for this determination may be automatically calculated from a histogram, or may be a predetermined fixed value.
- the state analysis device 150 can easily identify the region 1A of the wire rope 1 and the region 130A of the surface light source 130, and extract the wire rope region 1A. To improve accuracy.
- the image sensor of the camera 120 is a single-plate type with a Bayer pattern
- the number of green light receiving pixels is twice that of the red light and blue light receiving pixels, and thus the sensitivity to green light is high. Therefore, in this case, it is preferable to use a green monochromatic light source as the surface light source 130.
- the light of the surface light source 130 and the region 1A of the wire rope 1 can be photographed with high sensitivity and high resolution, and the accuracy of analysis processing in the state analysis device 150 can be improved.
- FIG. 7 shows a configuration diagram of the wire rope inspection apparatus 103 according to the third embodiment.
- the wire rope inspection apparatus 103 employs a configuration in which a display 180 is additionally arranged between the wire rope 1 and the surface light source 130 in the wire rope inspection apparatus 101 of the first embodiment.
- the display 180 is installed at a position that falls within the field of view of the camera 120 and displays information related to the travel distance of the wire rope 1. This information is, for example, the number of rotations of the electric motor that drives the wire rope 1, the elapsed time from the start of rotation, and the like.
- Other configurations are the same as those of the wire rope inspection apparatus 101, and a description thereof is omitted here.
- FIG. 8 is a schematic diagram illustrating an example of an image captured by the camera 120 in a state where the display 180 is disposed.
- the display 180 shows a case where the travel distance information of the wire rope 1 is displayed as a number, but the travel distance information may be displayed by a space code such as a barcode.
- the information displayed on the display 180 and the wire rope 1 can be simultaneously photographed and recorded by the wire rope inspection device 103, so that the analysis result of the wire rope 1 and this The position in the wire rope 1 corresponding to the analysis result can be confirmed while associating later.
- the state analysis device 150 may automatically recognize information displayed on the display 180.
- a space code such as a bar code instead of displaying characters on the display 180 in order to facilitate the recognition process in the state analysis device 150.
- FIG. 9 shows a case where the state analysis device 150 recognizes the travel distance information displayed on the display 180 in the video in parallel with the process of measuring the diameter of the wire rope 1 in the above-described steps S12 to S14.
- the flow of processing of the state analysis device 150 is shown.
- the display area extraction unit 152 (FIG. 16) of the state analysis device 150 extracts the region where the display 180 is displayed from the frame (step S22), and the travel distance information recognition unit 153 (FIG. 16) of the state analysis device 150. 16) recognizes the travel distance information displayed on the display 180 (step S23).
- the travel distance information output unit 154 (FIG. 16) of the state analysis device 150 outputs the recognized travel distance information as data (step S24).
- FIG. 10 illustrates a display example by the analysis result display device 160 in the wire rope inspection device 103 according to the third embodiment.
- the recorded video display unit 161 displays the video of the read video file as described above, and display information on the display 180 is also displayed in this embodiment.
- FIG. 10 shows an example of a screen when the recognition result of the travel distance of the wire rope 1 is displayed in synchronization with the video of the wire rope 1 in the analysis result display device 160 in the present embodiment.
- the analysis result display device 160 is provided with a display information display unit 167 on the display 180.
- the display unit 167 displays the travel distance information of the wire rope 1 on the recorded video display unit 161. Change the display synchronously.
- the wire rope inspection apparatus 103 is configured in such a manner that the width information and the travel distance information of the wire rope 1 are assembled with each frame of the image of the wire rope 1. Can be output as electronic data. Therefore, the confirmation work when an abnormal measurement result is obtained can be easily and quickly performed.
- FIG. 11 illustrates the configuration of the wire rope inspection device 104 according to the fourth embodiment of the present invention.
- the difference from the wire rope inspection apparatus 103 in the third embodiment is that a light source 190 for irradiating light to the wire rope 1 from the camera 120 side is further provided in the vicinity of the camera 120.
- the light source 190 is arranged such that light is also applied to the side surface portion of the wire rope 1.
- the other configuration is the same as that of the wire rope inspection device 103, and the description thereof is omitted here.
- FIG. 12 is a schematic diagram showing an example of an image captured by the camera 120 in the configuration of the fourth embodiment of the present invention. Since the light source 190 is provided, light is also applied to the front surface of the wire rope 1 when viewed from the camera 120, so that the surface of the wire rope 1 can be photographed by the camera 120.
- the light source 190 emits white light and the surface light source 130 emits green light. Further, the state analysis device 150 of the wire rope inspection device 104 separates the background, that is, the green light of the surface light source 130 from the inside of the image by the same procedure as described in the second embodiment, and thereby the region of the wire rope 1. Extract 1A.
- the state analysis device 150 of the wire rope inspection device 104 is capable of analyzing the surface of the wire rope 1.
- a rust detection unit 156 that detects a rust region can be provided. For example, when irradiating the wire rope 1 with white light from the light source 190 and photographing the reflected light with the camera 120, the reflected light of the rust portion of the wire rope 1 has a reddish color. Therefore, by setting the range of the feature amount of the color determined to be rust in the rust detection unit 156 in advance, the rust detection unit 156 compares the range with the color of the reflected light, so that the rust detection unit 156 Extract the rust area.
- the state analysis device 150 of the wire rope inspection device 104 can include a strand break detection unit 157 that detects the strand break of the wire rope 1.
- FIG. 13 shows an example of an image of the wire rope 1 in which a strand break is present. In the normal wire rope 1, a regular periodic texture is obtained. On the other hand, when the strand break occurs, discontinuous points are generated as indicated by 1 c in FIG. 13. Using this, the strand break detection unit 157 analyzes the periodicity of the texture, and determines that the portion where the irregular portion is found is broken.
- FIG. 14 shows a processing flow of the state analysis device 150 in the wire rope inspection device 104 of the fourth embodiment.
- the rust detection unit 156 extracts the rust region in the region (step S33) and outputs the information on the rust position (step S34).
- the strand break detection unit 157 detects the strand break in the wire rope region 1A (step S43) and outputs information on the strand break position (step S44). .
- FIG. 15 is a diagram showing an example in which the state analysis device 150 and the analysis result display device 160 included in the wire rope inspection device 104 are configured by a general-purpose computer, and the analysis result is displayed by a program operating on the computer.
- the position where rust is detected is rounded as shown by 11b, and the position where the broken wire is detected is highlighted by being circled as shown by 11c.
- the ratio of the rust detection region to the entire wire rope region 1A is displayed as a line graph 165b and the broken wire detection position is displayed as a circle like 165c.
- the ratio of the rust detection area is numerically displayed on the rust ratio display portion 168 in synchronization with the reproduction of the video.
- the ratio of rust is the ratio of the size (number of pixels) of the rust detection region to the size (number of pixels) of the wire rope region 1A in the frame.
- the recorded image of the wire rope 1 can be reproduced later, and the state of the surface of the wire rope 1 can be visually confirmed. Furthermore, it is possible to easily check the occurrence of rust and wire breakage of the wire rope 1 by video analysis.
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Abstract
Description
しかしながら、特許文献2のような方式でワイヤロープの径を計測した場合、計測精度が低下する場合がある。即ち、例えばワイヤロープの表面が油などで汚れている場合や、ワイヤロープの素線で金属光沢が存在する場合には、ワイヤロープからの反射光に明暗のむらや、ばらつきが発生する。その結果、撮像した映像の中から、ロープが写っている部分のみを精度良く抽出することが困難となるという問題がある。
即ち、本発明の一態様におけるワイヤロープ検査装置は、走行するワイヤロープを映像として連続撮影するカメラと、前記ワイヤロープを間に挟んで前記カメラに対向して配置され、ワイヤロープ及びカメラに向けて光を照射する面光源と、前記カメラにて撮像されたワイヤロープの映像からワイヤロープの状態の解析を行う状態解析装置と、前記状態解析装置で解析された解析結果を表示する解析結果表示装置と、を備えたことを特徴とする。
図1は、実施の形態1によるワイヤロープ検査装置101の構成を示している。ワイヤロープ検査装置101は、基本的構成部分として、カメラ120と、面光源130と、状態解析装置150と、解析結果表示装置160と、を備える。図1に示す構成では、これらの構成に加えてさらに、映像記録装置140、拡散板135、及びルーバー170を備えている。これらの構成部分について、以下に説明を行う。尚、図2は、ワイヤロープ検査装置101に備わるワイヤロープ1、カメラ120、及び面光源130の位置関係を示した図である。
検査対象であるワイヤロープ1を間に挟んで、カメラ120と面光源130とがそれぞれ対向する位置に設けられており、面光源130は、ワイヤロープ1及びカメラ120に向かって光を照射する。よって、カメラ120側から見ると面光源130は、ワイヤロープ1の背面側に位置する。このような配置にて、ワイヤロープ1を走行させながら、カメラ120は、その映像を撮影する。カメラ120により撮影されたワイヤロープ1の映像データは、映像記録装置140に保存される。状態解析装置150は、映像記録装置140に記録された映像データを読み出してワイヤロープ1の撮影映像を解析し、その結果であるワイヤロープ1の品質を含むワイヤロープ1の状態を解析結果表示装置160に表示する。ここでワイヤロープ1の状態とは、例えば、ワイヤロープ1の外径、ワイヤロープ1の表面の錆の有無、ワイヤロープ1の素線切れの有無などを指す。状態解析装置150が解析する状態は、これらの物理量や物理現象に限定されるものではなく、ワイヤロープの強度や経年劣化に関係する物理量や物理現象全般を含む。
これらの構成部分について、さらに詳しく以下に説明する。
また、ワイヤロープ1と拡散板135との間にルーバー170を更に配置し、面光源130から発せられた光がルーバー170を通って、ワイヤロープ1及びカメラ120へ照射されるようにしてもよい。ここで、ルーバー170は、光の進行方向をコントロールするためのフィルタであり、カメラ120の光軸と直交するように配置される。拡散板135及びルーバー170は、同時に使用することが好ましいが、どちらか一方のみを備えた構成であってもよい。
尚、図3は、カメラ120としてエリアカメラを使用した場合の概念図であるが、ワイヤロープ検査装置101は、エリアカメラに限らず、ラインカメラであってもよい。
ここで状態解析装置150は、後述する各実施の形態における動作も含めてその機能上、図16に示すように、ロープ領域抽出部151、ディスプレイ領域抽出部152、走行距離情報認識部153、走行距離情報出力部154、ロープ径取得部155、錆検出部156、及び素線切れ検出部157の各構成部分を有する。このような状態解析装置150は、上述のように実際にはコンピュータを用いて実現され、これらの151~157で示される各構成部分は、それぞれの機能に対応するソフトウェア(プログラム)と、これを実行するためのCPUやメモリ等のハードウェアから構成されている。また、上記プログラムは、コンピュータによって直接実行可能なものだけでなく、例えば通信線を介して読み込まれハードディスク等にインストールすることによって実行可能となるものも含む。又、圧縮されたり、暗号化されたりしたものも含まれる。
状態解析装置150は、カメラ120で撮像され記録された撮像データを映像記録装置140から読み出し(ステップS11)、撮像データのフレーム毎に、順次、以下の処理を実行する。
まず、図3のような撮影画像について、状態解析装置150のロープ領域抽出部151は、図5に示すような、輝度のヒストグラムを作成する。作成されたヒストグラムでは、大きく2つのピークが生成される。図5において、輝度が暗い部分に現れるピークは、ワイヤロープ1の影により暗く写っている部分に対応し、明るい部分に現れるピークは、面光源130から照射される光によって明るく写っている部分にそれぞれ対応する。
尚、ここでは映像からヒストグラムを生成し、閾値を自動的に決める手順を例示したが、予め定めた固定値を閾値としてもよい。
解析処理を行う前に、ディスプレイ(解析結果表示装置160)における換算係数入力部163に、上述した、画素数と実寸法との上記換算係数を予め入力しておく。
実施の形態1のワイヤロープ検査装置101において、図1に示す面光源130は、単色光源としてもよい。特に、各実施の形態におけるワイヤロープ検査装置を使用する環境に外乱光が存在する場合では、単色光源が有用である。即ち、ワイヤロープ1の表面に外乱光が当たった状態でカメラ120がワイヤロープ1を撮影した場合、ワイヤロープ1の影の部分が明るく写り、影の部分と、背景部分つまり光源からの光部分との明暗差が小さくなる。その結果、状態解析装置150での処理において、ワイヤロープ1の領域1Aを抽出する精度が低下する可能性がある。
そこで、外乱光による反射光とは異なる光学的特性を有する単色光を、面光源130として使用することで、上述の精度低下可能性を抑えることができる。例えば、自然光が外乱光として存在する場合、ワイヤロープ1からの反射光が緑色光や青色光となることは通常ほとんどないことから、面光源130として、緑色光あるいは青色光の単色光を使用するのが有効となる。
この判定のための閾値は、実施の形態1で述べた手順と同様に、ヒストグラムから自動的に算出してもよいし、予め定めた固定値であってもよい。
図7には、実施の形態3におけるワイヤロープ検査装置103の構成図が示されている。このワイヤロープ検査装置103は、実施の形態1のワイヤロープ検査装置101において、ワイヤロープ1と面光源130との間にディスプレイ180を追加配置した構成を採る。ここで、ディスプレイ180は、カメラ120の撮影視野に入る位置に設置され、ワイヤロープ1の走行距離に関する情報を表示する。この情報は、例えば、ワイヤロープ1を駆動する電動機の回転数や、回転開始時からの経過時間などである。
尚、その他の構成は、ワイヤロープ検査装置101と同じであり、ここでの説明を省略する。
まず、状態解析装置150のディスプレイ領域抽出部152(図16)は、フレーム中からディスプレイ180が表示されている領域を抽出し(ステップS22)、状態解析装置150の走行距離情報認識部153(図16)は、ディスプレイ180に表示されている走行距離情報を認識する(ステップS23)。そして、状態解析装置150の走行距離情報出力部154(図16)は、認識した走行距離情報をデータとして出力する(ステップS24)。
図11は、本発明の実施の形態4によるワイヤロープ検査装置104の構成を図示している。実施の形態3におけるワイヤロープ検査装置103との相違点は、カメラ120の近傍に、カメラ120側からワイヤロープ1に対して光を照射するための光源190をさらに備えた点である。光源190の配置は、ワイヤロープ1の側面部分にも光が照射されるようにする。
尚、その他の構成は、ワイヤロープ検査装置103と同じであり、ここでの説明を省略する。
例えば、光源190から白色光をワイヤロープ1に照射し、その反射光をカメラ120で撮影する場合、ワイヤロープ1の錆の部分の反射光は、赤みがかった色となる。そこで、錆と判定する色の特徴量の範囲を錆検出部156に予め設定することで、その範囲と反射光の色とを比較することにより、錆検出部156は、ワイヤロープ領域1Aの中の錆の領域を抽出する。
図13は、素線切れが存在するワイヤロープ1の映像の例を示している。正常なワイヤロープ1では、規則正しい周期的なテクスチャが得られるのに対し、素線切れが生じている場合には、図13において1cで示すように不連続な点が生じる。これを利用して、素線切れ検出部157は、テクスチャの周期性を解析し、不規則な部分が見つかった部分を素線切れと判定する。
ワイヤロープ領域1Aの抽出処理(ステップS12)を行った後、錆検出部156は、その領域内の錆領域を抽出(ステップS33)し、錆位置の情報を出力する(ステップS34)。また、この錆検出の処理と並行して、素線切れ検出部157は、ワイヤロープ領域1A内の素線切れを検出し(ステップS43)、素線切れ位置の情報を出力する(ステップS44)。
本発明は、添付図面を参照しながら好ましい実施形態に関連して充分に記載されているが、この技術の熟練した人々にとっては種々の変形や修正は明白である。そのような変形や修正は、添付した請求の範囲による本発明の範囲から外れない限りにおいて、その中に含まれると理解されるべきである。
又、2012年3月28日に出願された、日本国特許出願No.特願2012-73532号の明細書、図面、特許請求の範囲、及び要約書の開示内容の全ては、参考として本明細書中に編入されるものである。
101、103、104 ワイヤロープ検査装置、
120 カメラ、130 面光源、135 拡散板、140 映像記録装置、
150 状態解析装置、151 ロープ領域抽出部、
152 ディスプレイ領域抽出部、153 走行距離情報認識部、
154 走行距離情報出力部、155 ロープ径取得部、156 錆検出部、
157 素線切れ検出部、160 解析結果表示装置、
161 記録映像表示部、165 ワイヤロープ径グラフ表示部、
170 ルーバー。
Claims (14)
- 走行するワイヤロープを映像として連続撮影するカメラと、
前記ワイヤロープを間に挟んで前記カメラに対向して配置され、ワイヤロープ及びカメラに向けて光を照射する面光源と、
前記カメラにて撮像されたワイヤロープの映像からワイヤロープ状態の解析を行う状態解析装置と、
前記状態解析装置で解析された解析結果を表示する解析結果表示装置と、
を備えたことを特徴とするワイヤロープ検査装置。 - 前記カメラで撮像された映像を記録し、記録した映像を前記状態解析装置へ送出する映像記録装置をさらに備えた請求項1記載のワイヤロープ検査装置。
- 前記面光源は、拡散板を有する、請求項1又は2に記載のワイヤロープ検査装置。
- 前記ワイヤロープと前記面光源との間に、前記カメラの光軸と直交する姿勢で配置されるルーバーをさらに備える、請求項1から3のいずれか1項に記載のワイヤロープ検査装置。
- 前記面光源は、単色光源である、請求項1から4のいずれか1項に記載のワイヤロープ検査装置。
- 前記カメラの撮影視野内に配置され、ワイヤロープの走行位置に関する情報を表示するディスプレイをさらに備えた、請求項1から5のいずれか1項に記載のワイヤロープ検査装置。
- 前記ディスプレイは、ワイヤロープの走行位置に関する情報を空間符号化して表示する、請求項6に記載のワイヤロープ検査装置。
- 前記カメラの近傍に配置され、カメラ側からワイヤロープへの照明を行う光源をさらに備えた、請求項1から7のいずれか1項に記載のワイヤロープ検査装置。
- 前記光源は、白色光源である、請求項8記載のワイヤロープ検査装置。
- 前記状態解析装置は、前記カメラから得られる映像のフレーム毎にワイヤロープ領域を抽出する抽出部を有する、請求項1から9のいずれか1項に記載のワイヤロープ検査装置。
- 前記状態解析装置は、抽出されたワイヤロープ領域における画素数からワイヤロープ径を求めるロープ径取得部をさらに有する、請求項10に記載のワイヤロープ検査装置。
- 前記状態解析装置は、前記カメラから得られる映像のフレーム毎にワイヤロープ領域を抽出する抽出部と、
抽出された前記ワイヤロープ領域において、前記光源によるワイヤロープでの反射光における色特徴量を元にワイヤロープ表面の錆を検出する錆検出部を有する、請求項8,9,11のいずれか1項に記載のワイヤロープ検査装置。 - 前記状態解析装置は、前記カメラから得られる映像のフレーム毎にワイヤロープ領域を抽出する抽出部と、
抽出された前記ワイヤロープ領域において、前記光源によるワイヤロープでの反射光を撮影した映像からテクスチャの周期性を元にワイヤロープの素線切れを検出する素線切れ検出部を有する、請求項8,9,11,12のいずれか1項に記載のワイヤロープ検査装置。 - 前記解析結果表示装置は、前記映像記録装置に記録されたワイヤロープの映像を再生表示する再生表示部と、前記状態解析装置によるワイヤロープの解析結果を再生映像に同期して表示する同期表示部と、を有する、請求項1から13のいずれか1項に記載のワイヤロープ検査装置。
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Also Published As
Publication number | Publication date |
---|---|
KR20140123593A (ko) | 2014-10-22 |
JPWO2013145823A1 (ja) | 2015-12-10 |
TWI501914B (zh) | 2015-10-01 |
CN104185786B (zh) | 2016-06-29 |
CN104185786A (zh) | 2014-12-03 |
JP5769875B2 (ja) | 2015-08-26 |
TW201343529A (zh) | 2013-11-01 |
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