CN111610190A - Appearance inspection device for household appliances - Google Patents
Appearance inspection device for household appliances Download PDFInfo
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- CN111610190A CN111610190A CN201910878711.1A CN201910878711A CN111610190A CN 111610190 A CN111610190 A CN 111610190A CN 201910878711 A CN201910878711 A CN 201910878711A CN 111610190 A CN111610190 A CN 111610190A
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- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
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Abstract
The invention provides a household appliance appearance inspection device, comprising: a vision inspection section for photographing an appearance of an inspection object; a support frame for supporting the visual inspection part so that the visual inspection part can move in a vertical direction; and a control unit for moving the visual inspection unit along the support frame in a vertical direction to capture an image of the object to be inspected, wherein the control unit determines whether the object to be inspected is a defective product based on the image acquired by the visual inspection unit.
Description
Technical Field
The present invention relates to an appearance inspection apparatus for home appliances, and more particularly, to an apparatus for detecting appearance defects of home appliances such as a refrigerator, a washing machine, an air conditioner, etc. using a vision inspection algorithm.
Background
In general, household appliances such as refrigerators, washing machines, and air conditioners may have defects including cracks or scratches during processes or transportation, which may reduce consumer confidence in products. Therefore, an appearance inspection process of inspecting surface defects of the home appliance is required, and in general, the appearance inspection is performed by naked eyes. However, the visual inspection by naked eyes is not reliable because the workability is low and the defect cannot be inspected by mistake of an inspector.
Disclosure of Invention
The invention provides a visual inspection device for detecting appearance defects by inspecting the appearance of a household appliance. The quality of the product can be improved and an effective inspection system can be established by performing a final inspection of the product produced using the home appliance appearance inspection apparatus proposed in the present invention.
The appearance defect of the home appliance is automatically detected in the product production line, thereby minimizing the inspection time and more accurately performing the inspection of various items.
The invention also provides a household appliance appearance inspection device, which can realize additional management of product production and product record by using a database for managing and counting the inspection quantity, the defective quantity record and the like.
The invention provides a household appliance appearance inspection device, comprising: a vision inspection section for photographing an appearance of an inspection object; a support frame for supporting the visual inspection unit so that the visual inspection unit can move in a vertical direction; and a control unit for moving the vision inspection unit in a vertical direction along the support frame to photograph an appearance of the inspection target, wherein the control unit determines whether the inspection target is a defective product based on the image acquired by the vision inspection unit.
The invention provides the following home appliance appearance inspection device, the above-mentioned home appliance appearance inspection device also includes: a conveying unit for conveying the inspection object; and an identification code reader for scanning an identification code attached to the inspection object to identify the inspection object when the inspection object moves on the conveying unit, wherein the control unit loads product information related to the identified inspection object and changes the imaging setting of the vision inspection unit based on the product information.
The present invention provides the home appliance appearance inspection apparatus, wherein the control unit determines a surface metal pattern direction of the inspection target based on the product information, and the visual inspection unit operates in a horizontal scanning mode or a vertical scanning mode based on the determined surface metal pattern direction.
The present invention provides a home appliance appearance inspection apparatus, further comprising a joint part rotating the vision inspection part by 90 degrees according to a horizontal scanning mode and a vertical scanning mode, wherein the vision inspection part comprises: an image acquisition device for acquiring an image of the inspection object; an illumination unit configured to irradiate the inspection object with light; a distance measuring unit for measuring a distance between the inspection object and the vision inspection unit; and a distance adjusting unit for adjusting a distance between the inspection object and the vision inspection unit, wherein the control unit moves the vision inspection unit in a vertical direction along the support frame in a vertical scanning mode to photograph an appearance of the inspection object when the surface metal of the inspection object has a vertical pattern, and rotates the vision inspection unit by 90 degrees to move the vision inspection unit in a horizontal direction to photograph an appearance of the inspection object when the surface metal of the inspection object has a horizontal pattern.
The present invention provides a home appliance appearance inspection device, wherein the conveying part comprises: a stopper for stopping the inspection object to locate the inspection object at an inspection position; and an alignment unit for fixing and aligning the inspection object stopped by the stopper, wherein the alignment unit applies pressure to the inspection object stopped by the stopper at both sides to perform alignment.
The present invention provides a home appliance appearance inspection device, wherein the visual inspection unit comprises: a first vision unit located on the front surface of the inspection object; a second vision unit located on a left side surface of the inspection object; a third vision unit located on a right side surface of the inspection object; a fourth visual part located between the first visual part and the second visual part; and a fifth visual part located between the first visual part and the third visual part, wherein the first visual part, the second visual part and the third visual part can horizontally move left and right, and the fourth visual part and the fifth visual part can rotate at fixed positions.
The present invention provides a home appliance appearance inspection device, wherein the first to fifth vision parts comprise: an image acquisition device for acquiring an image of the inspection object; an illumination unit configured to irradiate the inspection object with light; a distance measuring unit for measuring a distance between the inspection object and the vision unit; and a distance adjusting unit for adjusting a distance between the inspection object and the vision unit, wherein the control unit controls the distance adjusting unit based on the distance measured by the distance measuring unit as the vision inspection unit moves in a vertical direction.
The present invention provides the household appliance appearance inspection device, wherein the household appliance appearance inspection device further comprises an inspection result output part for displaying an appearance inspection result related to the inspection object, and the control part outputs the inspection result output part at a defective position of the image display shot by the visual inspection part.
According to the present invention, a one-stop quality inspection system is introduced from a product production step to a product completion step, thereby solving the problem of the inspection quality degradation of a target product and establishing a more effective inspection support system.
According to the present invention, in the process of performing final inspection of products produced through manufacturing and production processes using the home appliance appearance inspection apparatus, inspection time and cost can be greatly reduced, thereby contributing to increase in productivity and management convenience of a process line.
According to the present invention, since the home appliance appearance inspection apparatus uses the conventional camera inspection apparatus, inspection cost can be reduced, and defects of a plurality of individual products can be easily detected in a short time. An intelligent factory can be realized by high speed and stability of inspection and by large data of production and manufacturing processes of accumulated inspection results.
Drawings
Embodiments of the present invention will be described with reference to the following illustrative figures, wherein like reference numerals refer to like structural elements, but the present invention is not limited thereto.
Fig. 1 is a perspective view schematically showing an appearance inspection apparatus for home appliances.
Fig. 2 is a perspective view schematically showing an appearance inspection apparatus for home appliances.
Fig. 3 is a diagram showing a state in which an inspection object is fixed at an inspection position.
Fig. 4 is a diagram showing a support frame that supports the visual inspection portion.
Fig. 5 is a diagram showing a detailed structure of the visual inspection unit.
Fig. 6 is a view showing a scanning direction of a vision inspection portion according to an embodiment of the present invention.
Fig. 7 is a diagram showing an appearance inspection result screen according to an embodiment of the present invention.
Fig. 8 is a flow chart of appearance inspection of the household appliance according to an embodiment of the present invention.
Fig. 9 is a diagram showing a microscopic crack detection step in a captured image.
Fig. 10 is a diagram illustrating a foreign matter inspection step in a captured image.
Fig. 11 is a view showing an image of the front surface of the home appliance determined as a good product.
Fig. 12 is a diagram showing a part of an image of the front surface of the home appliance determined as a defective product.
Fig. 13 is a view showing a visual part for photographing the left or right side of an inspection object.
Fig. 14 is a view showing a visual part for photographing the left or right corner of the inspection object.
Fig. 15 is a flow chart of an appearance inspection of a home appliance having a metal surface according to an embodiment of the present invention.
Description of reference numerals
110: the visual inspection unit 120: inspection result output unit
210: the conveying part 220: inspection object loading unit
230: the inspection object 240: identification code reader
330: the stopper 340: alignment part
420: support frames 510, 520, 530, 540, 550: visual part
552: image acquisition device 554: illumination unit
556: distance measuring part
Detailed Description
Hereinafter, specific details for carrying out the present invention will be described in detail with reference to the drawings. In the following description, only specific descriptions about well-known functions or configurations will be omitted when it is judged that the gist of the present invention is unclear.
In the drawings, the same or corresponding constituent elements may be given the same reference numerals. In the description of the following embodiments, the same or corresponding components may not be described repeatedly. However, even if the technology related to the structural elements is omitted, such structural elements are not included in the other embodiments. Terms representing relative positions may be used to describe the relationship between structures in the drawings, and the present invention is not limited to such terms.
Fig. 1 is a perspective view schematically showing an appearance inspection apparatus 100 for a home appliance. The home appliance appearance inspection apparatus 100 may include: a vision inspection part 110 for photographing the appearance of the home appliance as an inspection object; and an inspection result output unit 120 for confirming the appearance inspection result. When the inspection object reaches the inspection position, the vision inspection unit 110 moves in the vertical direction and can capture the entire appearance of the inspection object.
The home appliance appearance inspection apparatus 100 is an apparatus for inspecting the entire appearance of a home appliance, and can acquire an image photographed by a high-resolution camera at a specific position of a production line, and determine the quality or defective state of an inspection object by detecting the appearance defect of a product. In an embodiment, the home appliance appearance inspection apparatus 100 inspects the appearance of a home appliance such as a refrigerator, a washing machine, an air conditioner, etc. and may provide an inspection result. For example, defective items such as cracks, scratches, crushing, foreign substances, stains, paint peeling, play, and the like in the appearance of the home appliance can be detected.
When the inspection object moving along the product process line stops at the inspection position, the vision inspection unit 110 captures an image of the appearance of the inspection object and can determine the quality and defective state of the inspection object by a vision inspection algorithm. In one embodiment, the control unit (not shown) may move the vision inspection unit 110 in a vertical direction along the appearance of the inspection object and capture an image. The vision inspection unit 110 can move in the horizontal direction to acquire an image as needed.
The control unit (not shown) preprocesses the image of the inspection object captured by the vision inspection unit 110, and then compares the preprocessed image with a standard image stored in advance to determine the quality or defective state of the inspection object. The state of the good or defective product of the inspection object is output to the inspection result output unit 120 and confirmed by the user. As shown, the inspection result output part 120 may include at least one display.
In one embodiment, the inspection result output part 120 may display the result of the appearance of the inspection object photographed in different directions. For example, the vision inspection unit 110 may capture images of the inspection target in five directions of the front, left, right, left corner, and right corner, respectively, and the control unit (not shown) may output the captured 5 images to the inspection result output unit 120. The control unit (not shown) compares the inspection target with the standard image, and outputs the number of defects and the statistical values of the high-quality products and the defective products to the inspection result output unit 120, so that the defective positions can be displayed on the captured image. Therefore, the user can confirm the defective position displayed on the inspection result output unit 120 and easily and quickly grasp the defective position in the actual product.
In one embodiment, the home appliance appearance inspection apparatus 100 may include 1 master computer (master-pc) and 3 slave computers (slave-pc). The master computer stores various kinds of information including standard images of respective products, and the 3 slave computers can store image data of the front, left, right, left corner, and right corner of the inspection object photographed by the vision inspection part 110, respectively.
Fig. 2 is a perspective view schematically showing an appearance inspection apparatus 200 for home appliances. The home appliance appearance inspection apparatus 200 may include: a conveyor belt section 210; an inspection object loading unit 220 for loading and transferring an inspection object 230 on the conveyor belt; an identification code reader 240 for identifying an identification code of the inspection object 230; a setting unit 250 for changing the inspection setting; a process display unit 260 for displaying the current process state; an emergency stop button 270 and a visual inspection unit 280. In one embodiment, the inspection object 230 may be a floor air conditioner.
The conveyor unit 210 can sequentially transfer the inspection objects 230 to the inspection position of the home appliance appearance inspection apparatus 200. Before the inspection object 230 is transferred to the inspection position, the home appliance appearance inspection apparatus 200 may scan the identification code attached to the inspection object 230 using the identification code reader 240 to identify the inspection object. Specifically, the home appliance appearance inspection apparatus 200 may identify what an inspection object is using the identification code reader 240, and may load product information related to a corresponding product.
In one embodiment, the home appliance appearance inspection apparatus 200 automatically sets the photographing setting of the visual inspection part 280 to be suitable for the inspection object 230 based on the loaded product information. For example, the home appliance appearance inspection apparatus 200 changes inspection setting values of the visual inspection unit 280 such as an illumination value, a camera position, a focus, and a scanning mode (a horizontal scanning mode and a vertical scanning mode) based on product information. The home appliance appearance inspection apparatus 200 compares the image of the home appliance appearance inspection apparatus 200 captured by the visual inspection unit 280 with the standard image included in the loaded product information, and determines whether or not the inspection target 230 is a defective product. With the above-described structure, the home appliance appearance inspection apparatus 200 can implement customized type inspection for various products. Also, the inspection record can be stored per product and an intelligent factory can be realized through big data.
When the product information of the inspection object 230 is recognized by the identification code reader 240, the setting unit 250 may output the inspection setting of the visual inspection unit 280 set to match the inspection object 230. The user can manually change the inspection setting values automatically set by the setting unit 250 as necessary. For example, the user can change the inspection setting values of the illumination value, the camera position, the focus, the scanning mode (horizontal scanning mode, vertical scanning mode), and the like as necessary. In one embodiment, the setting part 250 may include a touch screen.
The process display unit 260 displays the operation state of the home appliance appearance inspection apparatus 200, and can display the operation state, failure, and the like of the home appliance appearance inspection apparatus 200. For example, when the inspection object 230 is loaded on the conveyor unit 210 and transported, the current state of the home appliance appearance inspection apparatus 200 is notified to the user by an orange electric lamp display, when the inspection object 230 is located at the inspection position and the visual inspection unit 280 photographs the inspection object 230, a blue electric lamp display, and when the inspection of the inspection object 230 is completed, a green electric lamp display, and when an error occurs in the home appliance appearance inspection apparatus 200 or the home appliance appearance inspection apparatus is inoperable due to an abnormal factor, a red electric lamp display. In the inspection process, when the home appliance appearance inspection apparatus 200 is stopped due to an error or a trouble, the user stops the inspection process using the emergency stop button 270.
Fig. 3 is a diagram showing a state in which the inspection object 320 is fixed at the inspection position. The inspection object 320 is loaded on the inspection object loading unit 310 and transferred along the conveying unit 300. The conveying unit 300 may be configured to transfer the inspection objects 320 to the inspection position, and may be configured to accurately align and fix the inspection objects 320 at the inspection position.
In an embodiment, the conveying part 300 may include: a stopper 330 for stopping the advance of the inspection target loading unit 310 when the inspection target loading unit reaches the inspection position; an alignment part 340 for aligning the positions and directions of the inspection object loading parts 310; and a motor (not shown) for generating power for transferring the inspection target loading unit 310 on the conveying unit 300. The inspection object loading unit 310 stably transfers the home appliance to the inspection position and easily aligns the home appliance. For example, the inspection object loading unit 310 may be a rectangular tray that is easily aligned in units of lines, and has a shape and material that supports the inspection object 320 flatly and stably moves on the conveying unit 300.
Before the inspection object loading unit 310, which loads the inspection object 320 transferred by the transfer unit 300, reaches the inspection position, the stopper 330 is raised to prevent the inspection object loading unit 310 from advancing beyond the inspection position. For this, the stopper 330 may include a position sensor or a proximity sensor for grasping the position of the inspection object loading unit 310. In one embodiment, the conveying unit 300 may be stopped when the inspection object 320 is stopped at the inspection position by the stopper 330. Fig. 3 shows that the stopper 330 has a flat floor shape on which the inspection object loading unit 310 is placed in the forward direction, but is not limited thereto, and may have various shapes.
When the inspection object loading unit 310 is stopped by the stopper 330, the alignment unit 340 may align and fix the inspection object loading unit 310 and the inspection object 320 at the inspection position. In one embodiment, the alignment part 340 applies pressure to the inspection object loading part 310 at both sides to perform horizontal alignment of the inspection object 320, and the inspection object loading part 310 and the inspection object 320 may be fixed at the inspection position. The aligning part 340 adjusts the degree of pressurization according to the product information recognized by the identification code reader.
The alignment unit 340 may additionally include an alignment inspection unit (not shown) for checking the alignment between the inspection target loading unit 310 and the inspection target 320. The alignment inspection unit (not shown) measures the interval between the inspection target mounting unit 310 and the alignment unit 340 or the degree of pixel alignment, and if the condition is not met, the inspection result output unit or the setting unit may provide error information to the inspector.
After the inspection object loading part 310 and the inspection object 320 are aligned and fixed at the inspection position, the appearance inspection of the inspection object 320 based on the vision inspection part may be performed. After finishing the appearance inspection of the inspection object 320, the alignment part 340 will return to the home position, and the stopper 330 will descend. Thereafter, the transport unit 300 operates to transport the inspection object loading unit 310 and the inspection object 320 along the transport unit 300 again. In one embodiment, the inspection object 320 may be moved along a good conveyor line or a defective conveyor line according to the inspection result.
Fig. 4 is a diagram illustrating a support frame 420 supporting the vision inspection portion 410. The home appliance appearance inspection apparatus 400 may include: a vision inspection unit 410 for imaging the appearance of an inspection target; a support frame 420 for supporting the vision inspection unit 410 so that the vision inspection unit 410 moves in a vertical direction; and an inspection result output part 430 for displaying an appearance inspection result related to the inspection object. The support frame 420 may support the vision inspection unit 410 such that the vision inspection unit 410 moves in a vertical direction along the appearance of the inspection object and performs imaging.
In an embodiment, the support frame 420 may include a position adjusting part (not shown) for moving the vision inspection part 410 in a vertical direction. The position adjusting part may include a motor (not shown) generating power for vertically moving the vision inspection part 410. The support frame 420 may further include a guide rail (guide rail) for guiding the movement of the vision inspection part 410 to prevent the vision inspection part 410 from being separated from the path when vertically moving.
The vision inspection part 410 may vertically move along the support frame 420 and acquire an appearance image of the inspection object. The home appliance appearance inspection apparatus 400 detects a surface defect of an inspection object by comparing an image of the inspection object acquired by the visual inspection unit 410 with a standard image. Then, the home appliance appearance inspection apparatus 400 determines whether the inspection object is a good product or a defective product based on the detected surface defect. In one embodiment, the detected surface defect, quality and defective product determination results may be output to the inspection result output unit 430 and confirmed by the user.
Fig. 5 is a diagram showing a detailed structure of the visual inspection unit 500.
The vision inspection portion 500 may include a plurality of vision portions 510, 520, 530, 540, 550. In an embodiment, the visual inspection part 500 may include: a first vision part 510 for photographing the front of the inspection object; a second vision part 520 for photographing the right side surface of the inspection object; a third vision part 530 for inspecting a left side surface of the inspection object; a fourth vision part 540 positioned between the first vision part 510 and the second vision part 520 for photographing a right corner of the inspection object; and a fifth vision part 550 between the first vision part 510 and the third vision part 530 for photographing a left corner of the inspection object.
The first, second, and third vision parts 510, 520, and 530 may be horizontally moved left and right on a frame supporting the vision inspection part 500, and the fourth and fifth vision parts 540 and 550 may be rotated at a fixed position. The first, second, and third vision parts 510, 520, and 530 may include a motor and a rail for horizontal movement, and the fourth and fifth vision parts 540 and 550 may include a motor and a rotation plate for in-situ rotation.
Each of the vision parts 510, 520, 530, 540, 550 may include an image acquisition device, an illumination part, a distance measurement part, and a distance adjustment part. The image acquisition device 552, the illumination unit 554, the distance measurement unit 556, and the distance adjustment unit 558 included in the fifth viewing unit 550 will be described in detail below. The image acquiring device, the illuminating portion, the distance measuring portion, and the distance adjusting portion of the first through fourth viewing portions 510 through 540 operate similarly to the image acquiring device 552, the illuminating portion 554, the distance measuring portion 556, and the distance adjusting portion 558 of the fifth viewing portion 550, and thus, detailed descriptions thereof will be omitted.
The image acquisition means 552 may be means for acquiring an image of an inspection object. The image acquisition device 552 has sufficient resolution, frame rate, and linear rate required for detecting appearance defects such as cracks, scratches, crushing, foreign matter, stain, paint peeling, and play on the appearance of the inspection object. For example, the image capturing device may be a high-resolution camera having a high Field Of View (FOV) setting.
In one embodiment, the image acquiring device 552 may be a Line scan (Line scan) camera that moves to the vertical direction and photographs the inspection object. In this case, the control section combines a plurality of images captured by the image capturing apparatus 552 into one image and corrects distortion or the like. As described above, the synthesized and modified image of the inspection object can be used to inspect whether or not the inspection object is a defective product by comparing with the standard image, and output to the inspection result output section together with the inspection result.
The illumination portion 554 may include a light source that irradiates light to the detection object. In the visual inspection, the illumination greatly affects the inspection quality, and further, appearance defects such as cracks, scratches, crushing, foreign matter, stains, paint peeling, and play in the appearance of the inspection object are conspicuously recognized. The image can be differently captured according to the selection of the illumination portion 554, and thus, the form, wavelength, color, angle, light amount, and the like of illumination can be changed according to the inspection environment and the inspection object. In one embodiment, the illumination portion 554 may be an organic light emitting diode illumination such as a surface illumination, a bar illumination, or the like.
The distance measuring unit 556 can measure the distance between the test object and the fifth vision unit 550. In one embodiment, the distance measuring unit 556 may be a laser distance sensor. The distance adjustment unit 558 moves the fifth vision unit 550 back and forth based on the distance information measured by the distance measurement unit 556, thereby adjusting the distance between the inspection object and the fifth vision unit 550. The distance adjustment part 558 may include a motor for moving the fifth vision part 550 back and forth.
In an embodiment, in the case where the inspection object has a curvature due to Auto-Focus (Auto-Focus), the control part may adjust a distance between the fifth vision part 550 and the inspection object in real time to scan the inspection object. The auto-focus inspection is performed to correspond to the outward curvature of the product, and when the vision inspection unit 500 moves in the vertical direction to photograph the inspection target, the control unit drives the distance adjustment unit 558 in real time based on the distance information measured by the distance measurement unit 556 to maintain the distance between the fifth vision unit 550 and the inspection target at a predetermined distance.
The control part changes the inspection setting values of the first through fifth vision parts 510 through 550 based on the product information of the inspection object recognized by the identification code scanner. For example, the distance between the vision unit and the inspection target, the focal position of the image capturing device, the illumination intensity of the illumination unit, the left and right positions of the first vision unit 510, the second vision unit 520, and the third vision unit 530, the rotation angles of the fourth vision unit 540 and the fifth vision unit 550, and the like may be changed.
In one embodiment, the front image of the inspection object captured by the first vision part 510 is stored in the first slave computer, the right and left images of the inspection object captured by the second and third vision parts 520 and 530 are stored in the second slave computer, and the right and left corner images captured by the fourth and fifth vision parts 540 and 550 are stored in the third slave computer. The control unit compares the front face image, the right side image, the left side image, the right side corner image, and the left side corner image of the inspection object stored in the first slave computer to the third slave computer with the quality standard image (the front standard image, the right side standard image, the left side standard image, the right side corner standard image, and the left side corner standard image) of the object product stored in the host computer to determine whether or not there is a defect and a defect type (for example, a crack, a scratch, a crush, a foreign object, a stain, paint removal, a play, and the like).
Fig. 6 is a diagram illustrating a scanning direction of the vision inspection unit 620 according to an embodiment of the present invention. As shown, the visual inspection part 620 may include: a vision part for photographing the front of the inspection object; a vision part for photographing the right side surface of the inspection object; a vision part for inspecting the left side surface of the inspection object; a vision part for photographing the right side corner of the inspection object; and a vision part for photographing the left side corner of the inspection object. The vision inspection part 620 may be supported by the support frame 630 to be movable in a vertical direction, and may be moved in a vertical direction along the support frame 630 by the vision inspection part position adjustment part 610.
In one embodiment, after the inspection object is aligned and fixed at the inspection position by the stopper and the alignment part, the vision inspection part 620 moves from the uppermost position to the lowermost position along the support frame 630 and starts to prepare for the appearance inspection. In this case, the product appearance inspection is started in a state where the vision inspection portion 620 is located at the lower end of the product, and the vision inspection portion 620 ascends (in the arrow direction of fig. 6) along the support frame 630 and simultaneously photographs the front, left, right, left corner, and right corner of the inspection object with the vision portion of the vision inspection portion 620. For example, the vision inspection part 620 ascends along the support frame 630 for about 3 seconds and photographs the appearance of the inspection object.
When the vision inspection part 620 moves, the support frame 630 guides the vertical movement to prevent it from being detached from the path, so that the vision inspection part 620 can be supported. As shown, the support frame 630 may include 2 guide rails supporting the vision inspection part 620 on one side and guiding the vertical movement. In an embodiment, the visual inspection portion position adjustment portion 610 may include a motor generating power for vertically moving the visual inspection portion 620.
Fig. 7 is a diagram illustrating an appearance inspection result screen 700 according to an embodiment of the present invention.
The visual inspection result screen 700 may be output to an inspection result output section and may provide visual inspection results to an inspector. The first area 710 of the inspection result screen 700 may include 5-directional images (a front image, a left image, a right image, a left corner image, and a right corner image) captured through 5 vision parts. Also, the detected position 720 of the poor appearance may be displayed on the image of the inspection target. For example, the poor appearance position of the inspection object such as a crack, a foreign substance, a stain, a paint peeling, or the like can be displayed in the image of the inspection object as a red dot.
In an embodiment, the second area 730 of the inspection result screen 700 may display the numerical statistics and the final determination result related to the appearance inspection result. As shown in the drawing, the model number of the inspection target, the number of defects on the front surface of the inspection target, the number of defects on the left surface, and the number of defects in the items on the right surface are displayed in the second area 730, and the final determination result of whether the inspection target is a good product or a defective product can be displayed. For example, the model number recognized by the reader and the number of defective detections such as cracks, scratches, crushing, foreign matter, stains, paint peeling, play of the front, left and right sides are shown in detail, and the judgment result can be provided to the inspector.
The inspection statistics for the products produced in the production line are displayed in the third area 740 of the inspection result screen 700. For example, the number of good products, the good product ratio, the number of defective products, and the defective ratio of products inspected in the production line are displayed, and the process state of the production line can be confirmed. The third area 740 may show the states of the respective devices such as the image capturing device, the illumination unit, the distance measuring unit, and the identification code reader. For example, a green circle is displayed when each device is in a normal state, and a red circle is displayed when each device is in a defective state.
The system login is displayed in the fourth area 750 of the inspection result screen 700. In one embodiment, the appearance inspection history registered as the system, the setting change contents of the visual part, the occurrence time, and the like are stored and displayed.
Fig. 8 is a flow chart of appearance inspection of the household appliance according to an embodiment of the present invention. In an embodiment, the inspection object may be a home appliance such as a refrigerator, a washing machine, an air conditioner. The appearance inspection of the home appliance may be started by putting the inspection object into a storage of the conveying unit and identifying the inspection object by the identification code reader (step 810). In an embodiment, the identification code may be an optical identification code such as a bar code, which may be attached to the appearance of the inspection object. A control unit of the inspection apparatus loads product information relating to the inspection object identified by the identification code reader, and can change the imaging setting of the visual inspection unit based on the loaded product information.
When the inspection object enters the inspection position, the inspection object can be aligned and fixed at the inspection position by the stopper and the aligning unit (step 820). For this purpose, the inspection apparatus may include one or more sensors for detecting the approach of the inspection object to the inspection position, and the stopper may be raised to stop the advance of the inspection object when the inspection object approaches the inspection position. When the inspection object loading unit is stopped by the stopper, the alignment unit applies pressure to both side surfaces of the inspection object loading unit to align the inspection object loading unit, accurately aligns the inspection object loading unit at the inspection position, and fixes the inspection object loading unit.
When the inspection object is fixed at the inspection position, the vision inspection unit measures a distance from the inspection object to adjust the position of each vision unit so as to match the adjustment shooting setting of the inspection setting based on the identified product information. In addition, the camera can rotate in situ under the condition of shooting the visual parts at the left side corner and the right side corner, so that the corner side shooting angle can be changed according to the appearance of the product.
When the inspection preparation is completed, the vision inspection unit moves in the vertical direction along the support frame to capture the appearance of the inspection object (step 830). In one embodiment, the visual inspection part moves from the lower end toward the upper end and photographs the appearance of the inspection object. In order to photograph the appearance of the inspection object moving vertically up and down, the visual inspection part may include a plurality of line scanning cameras. For example, the visual inspection unit vertically moves up and down to photograph the front, left side, right side, left side corner, and right side corner of the inspection object.
The control unit compares the image captured by the visual inspection unit moving in the vertical direction with the standard image to detect a defective appearance of the inspection target (step 840). In one embodiment, the control unit compares the captured front image, left side image, right side image, left corner image, and right corner image with a front standard image, left side standard image, right side standard image, left corner standard image, and right corner standard image stored in advance for the inspection object, respectively, to detect surface defects such as cracks, scratches, crushing, foreign matter, stains, paint peeling, play, and the like. The control unit determines whether the product is a good product or a defective product based on the detected surface defect.
If the inspection is completed, the inspection result is output to the user, and the object can be checked out of the warehouse (step 850). In one embodiment, the photographed images of the front, left side, right side, left corner, and right corner of the inspection object are output to the inspection result output unit, and the exact position of the appearance defect is displayed on each photographed image. Further, the statistics of the respective defective forms and the determination results of the high-quality products or the defective products can be displayed. The inspection result is stored in the database, thereby realizing record management of the inspection quantity and the defective quantity, and product production record management and additional management using the database.
Fig. 9 is a diagram showing a microscopic crack detection step in a captured image. Fig. 9 (a) shows an external view image of the inspection object captured by the visual inspection unit. Part (b) of fig. 9 shows the result of performing softening (soften) processing after emphasizing the difference in brightness of an image by adjusting the Contrast (Contrast) of a captured appearance image. In the case of an image with contrast adjusted, there is a possibility of afterimage, and therefore, softening processing for softening the image edge is performed to remove the afterimage.
Fig. 9 (c) shows a result of performing binarization by calculating a local binary high variable in an image in which contrast is emphasized and an afterimage is removed. The local binary high variable can be automatically calculated according to the position of the image. Then, the fracture defect can be judged by calculating the area of the binary large object (blob) of the binary image. Among them, the crack defect detection size can be set.
Fig. 10 is a diagram illustrating a foreign matter inspection step in a captured image. Part (a) of fig. 10 shows an appearance image of the inspection object captured by the visual inspection unit. Part (b) of fig. 10 shows the result of applying the softening process after emphasizing the difference in brightness of the image by adjusting the brightness contrast of the captured appearance image. In the case of an image with contrast adjusted, there is a possibility of afterimage, and therefore, softening processing for softening the image edge is performed to remove the afterimage.
Fig. 10 (c) shows a result of performing binarization by calculating a local binary low variable in an image in which contrast is emphasized and an afterimage is removed. Wherein, the local binary low variable can be automatically calculated according to the position of the image. Then, the area is distinguished in the binarized image to extract the blob and calculate the area of the blob, thereby determining the presence or absence of a foreign object. In this case, the foreign matter defect detection size can be set.
Fig. 11 is a diagram showing an image 1100 of the front surface of the home appliance determined as a good product. As shown in the figure, it was confirmed that no cracks, scratches, crushing, foreign matter, stains, paint peeling, play, etc. were present on the front surface of the high-quality product. Fig. 12 is a diagram illustrating a part 1200 of an image of the front surface of the home appliance determined as a defective product. As shown in the figure, surface defects such as scratches 1210 and cracks 1220 were present on the front surface of the defective product. The home appliance appearance inspection apparatus of the present invention compares a captured image with a standard image to detect the surface defect described above or can detect the surface defect in the image by the image processing or the like described with reference to fig. 9 and 10.
Fig. 13 is a view showing a visual part for photographing the left or right side of an inspection object. As shown, the vision portion 1310 may include an image acquisition device 1312, an illumination portion 1314, a distance measurement portion 1316, and a distance adjustment portion 1318. The functions and operations of the image acquisition device 1312, the illumination unit 1314, the distance measurement unit 1316, and the distance adjustment unit 1318 may be the same as those of the image acquisition device 552, the illumination unit 554, the distance measurement unit 556, and the distance adjustment unit 558 shown in fig. 5.
As shown, the vision part 1310 may move left and right on the frame 1320 of the vision inspection part. In one embodiment, the vision portion 1310 may be additionally provided with a sub motor (not shown) and a decelerator (not shown) for moving left and right along the frame 1320. The vision unit 1310 moves to the left and right on the frame 1320 using a sub motor and a decelerator, and moves to a position suitable for photographing an inspection object.
In one embodiment, a joint (not shown) for rotating the visual portion 1310 by 90 degrees may be additionally provided to the visual portion 1310. In this case, the vision part 1310 rotates by 90 degrees through the joint part and horizontally moves left and right along the frame 1320 as necessary to photograph the inspection object. As described above, a phenomenon in which the vision part 1310 horizontally moves left and right and photographs an inspection object may be referred to as a horizontal scan mode. Fig. 13 is an explanation of a vision unit 1310 for photographing the left or right side of an inspection object, and a sub motor, a reduction gear, and a joint unit are similarly provided in the vision unit for photographing the front surface of the inspection object, so that the front surface of the inspection object can be photographed in a transverse scanning mode.
Fig. 14 is a view showing a visual portion 1410 that captures the left or right corner of the inspection object. As shown, the vision unit 1410 may include an image acquisition device 1412, an illumination unit 1414, a distance measurement unit 1416, and a distance adjustment unit 1418. The functions and operations of the image acquisition device 1412, the illumination unit 1414, the distance measurement unit 1416, and the distance adjustment unit 1418 in the vision unit 1410 may be the same as those of the image acquisition device 552, the illumination unit 554, the distance measurement unit 556, and the distance adjustment unit 558 shown in fig. 5.
As shown, the vision portion 1410 is rotatably fixed to a frame 1420 of the vision inspection portion. In an embodiment, the vision unit 1410 may be additionally provided with a sub-motor (not shown) and a reducer (not shown) for rotation. In this case, the vision part 1410 may be rotated in place using a sub motor and a decelerator, and thus, may be disposed at an appropriate position for photographing a left corner or a right corner according to an inspection object.
Fig. 15 is a flow chart of an appearance inspection of a home appliance having a metal surface according to an embodiment of the present invention. The appearance inspection may be performed by conveying the belt-in-storage inspection object (step 1510). The inspection object is put into the appearance inspection apparatus, and the identification code reader can identify the identification code applied to the inspection object put into the storage. In one embodiment, the warehousing inspection object may be a household appliance having a metal surface. For example, the inspection object may be a household refrigerator, and a metal pattern in which fine concave portions and convex portions extending in a long manner are repeatedly arranged is formed on the front surface.
The control unit of the appearance inspection apparatus can determine whether the surface metal of the inspection object has a vertical pattern or a horizontal pattern based on the identification code (step 1520). In the case of performing appearance photographing in a direction orthogonal to the surface metal pattern of the inspection object, an image in an overexposed state is photographed due to the influence of light reflected by the surface metal pattern (concave portion and convex portion) of the inspection object, and thus the appearance inspection cannot be normally performed. Therefore, along the direction of the surface metal pattern of the inspection object, the appearance photographing direction of the inspection object may not be the same.
When the control unit determines that the surface metal of the inspection object has a vertical pattern, the vision inspection unit may acquire an external appearance image of the inspection object in a vertical scanning mode (step 1530). That is, as shown in fig. 6, in a state where a plurality of vision portions are arranged in the horizontal direction, the vision inspection portion vertically moves along the support frame and images the inspection object. The image captured by the control unit is compared with a standard image (quality image) stored in the past to detect surface defects and determine whether the quality and the defect exist (step 1540).
In contrast, when the control unit determines that the surface metal of the inspection object has a horizontal pattern, the vision inspection unit may acquire an external view image of the inspection object in a horizontal scanning mode (step 1550), that is, after the joint unit rotates the vision unit by 90 degrees, the vision unit may move horizontally and photograph the inspection object in a state in which the vision units are vertically aligned. The control unit compares the captured image with a standard image (quality image) stored in the past to detect surface defects and can determine whether the quality or the quality is good or not (step 1560). When the imaging of the inspection object in the landscape imaging mode or the portrait imaging mode and the determination of the quality and the quality of the inspection object are completed, the appearance inspection step is stopped and the inspection object is taken out of the warehouse (step 1570).
In the present specification, the present invention has been described with reference to a part of the embodiments, and various modifications and alterations can be made without departing from the scope of the present invention as understood by those skilled in the art. Such modifications and variations are within the scope of the invention as claimed in the present specification.
Claims (8)
1. An appearance inspection device for household appliances, which is characterized in that,
the method comprises the following steps:
a vision inspection section for photographing an appearance of an inspection object;
a support frame for supporting the visual inspection unit so that the visual inspection unit can move in a vertical direction;
a control part for moving the visual inspection part along the support frame in the vertical direction and shooting the appearance of the inspection object,
the control unit determines whether or not the inspection target is a defective product based on the image acquired by the visual inspection unit.
2. The appearance inspection device of home appliances according to claim 1,
further comprising:
a conveying unit for conveying the inspection object; and
an identification code reader for scanning an identification code attached to the inspection object to identify the inspection object when the inspection object moves on the conveying unit,
the control unit loads product information related to the identified inspection target and changes the imaging setting of the vision inspection unit based on the product information.
3. The appearance inspection apparatus for home appliances according to claim 2, wherein the control unit determines a surface metal pattern direction of the inspection object based on the product information, and causes the vision inspection unit to operate in a horizontal scanning mode or a vertical scanning mode based on the determined surface metal pattern direction.
4. The appearance inspection device of a home appliance according to claim 3,
further comprises a joint part which rotates the visual inspection part by 90 degrees according to a transverse scanning mode and a longitudinal scanning mode,
the vision inspection unit includes:
an image acquisition device for acquiring an image of the inspection object;
an illumination unit configured to irradiate the inspection object with light;
a distance measuring unit for measuring a distance between the inspection object and the vision inspection unit; and
a distance adjusting part for adjusting the distance between the inspection object and the vision inspection part,
the control part makes the visual inspection part move along the support frame in the vertical direction under the vertical scanning mode to shoot the appearance of the inspection object when the surface metal of the inspection object has a vertical pattern,
when the surface metal of the inspection object has a transverse pattern, the control unit causes the joint unit to rotate the vision inspection unit by 90 degrees, and causes the vision inspection unit to move in a horizontal direction to photograph the appearance of the inspection object.
5. The appearance inspection device of home appliances according to claim 2,
the conveying part comprises:
a stopper for stopping the inspection object to locate the inspection object at an inspection position;
an alignment part for fixing and aligning the inspection object stopped by the stopper part,
the alignment unit applies pressure to the inspection object stopped by the stopper on both sides to align the inspection object.
6. The appearance inspection device of home appliances according to claim 1,
the vision inspection unit includes:
a first vision unit located on the front surface of the inspection object;
a second vision unit located on a left side surface of the inspection object;
a third vision unit located on a right side surface of the inspection object;
a fourth visual part located between the first visual part and the second visual part; and
a fifth visual part located between the first visual part and the third visual part,
the first visual part, the second visual part and the third visual part can horizontally move left and right,
the fourth visual portion and the fifth visual portion are capable of rotating and moving at fixed positions.
7. The appearance inspection device of a home appliance according to claim 6,
the first to fifth visual parts include:
an image acquisition device for acquiring an image of the inspection object;
an illumination unit configured to irradiate the inspection object with light;
a distance measuring unit for measuring a distance between the inspection object and the vision unit; and
a distance adjusting part for adjusting the distance between the inspection object and the vision part,
the control unit controls the distance adjustment unit based on the distance measured by the distance measurement unit as the vision inspection unit moves in the vertical direction.
8. The appearance inspection device of home appliances according to claim 1,
further comprises an inspection result output part for displaying the appearance inspection result related to the inspection object,
the control unit outputs the image captured by the vision inspection unit to the inspection result output unit at a display failure position.
Applications Claiming Priority (2)
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| KR10-2019-0022358 | 2019-02-26 | ||
| KR1020190022358A KR102121142B1 (en) | 2019-02-26 | 2019-02-26 | Home appliance surface inspection apparatus |
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| CN111610190A true CN111610190A (en) | 2020-09-01 |
| CN111610190B CN111610190B (en) | 2023-11-14 |
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| KR (1) | KR102121142B1 (en) |
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| JP7486715B1 (en) | 2023-01-27 | 2024-05-20 | ダイトロン株式会社 | Appearance inspection device and appearance inspection method |
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| KR102321444B1 (en) * | 2021-04-29 | 2021-11-04 | (주)티에이치엔 | Wiring product inspection support apparatus |
| KR20240030907A (en) | 2022-08-29 | 2024-03-07 | (주)휴넷가이아 | Automatic Detection System for Surface Defects of Test Subjects Based on Machine Vision |
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| CN111610190B (en) | 2023-11-14 |
| KR102121142B1 (en) | 2020-06-10 |
| WO2020175752A1 (en) | 2020-09-03 |
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