JP2004108956A - Flaw inspection device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To execute an accurate test optically for determining the presence or absence of flaws on the surface of a round bar material on which oil films are formed because of being coated with oil or the like in a manufacturing process. <P>SOLUTION: The flaw inspection device inspecting the flaws of the round bar material W which is arranged horizontally and on which a film such as an oil film is formed, is provided with a nozzle mechanism 3 which at least includes a water nozzle 21 for removing the film and an oil nozzle 23 for recreating a film on the round bar material W from which the former film is previously removed by the water nozzle 21, an area camera 2 which photographs the surface of the round bar material W from which the film is removed by the water nozzle 21, a moving mechanism 4 which moves the area camera 2 and the nozzle mechanism 3 in the axial direction of the round bar material W, and a tracking controller 5 which controls the moving mechanism 4. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a flaw inspection device for round bars. More specifically, the present invention relates to a flaw inspection apparatus for inspecting the presence or absence of flaws on the surface of a round bar using an optical sensor.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, when a round bar is manufactured by polishing or drawing, it is common to apply oil to the surface of the material mainly for rust prevention. Therefore, when inspecting the surface of a round bar manufactured by polishing or drawing, it is necessary to check the presence or absence of flaws through an oil film, and performing this visually is equivalent to detecting minute surface defects. Skill is required.
[0003]
Therefore, an optical inspection method that uses a low-cost optical sensor such as a CCD camera and detects flaws based on the captured image is preferable from the viewpoint of improving accuracy and saving labor. However, when the flaw inspection is performed by an optical method, it is necessary to make the oil film thickness uniform and to make the reflection state of the transmitted light constant in order to perform accurate flaw detection.
[0004]
However, it can be said that it is almost impossible to make the oil film thickness uniform in the round bar due to its shape.
[0005]
For this reason, in the end, in the inspection of the flaws on the surface of the round bar material, there is a problem that it is necessary to rely on the visual inspection of a skilled person, and it is difficult to simplify the inspection process.
[0006]
[Problems to be solved by the invention]
The present invention has been made in view of the problems of the related art, and inspects the presence or absence of a defect on the surface of a round bar material on which an oil film is formed by applying oil or the like in a manufacturing process, with high accuracy by an optical method. It is an object of the present invention to provide a flaw inspection device that can perform the inspection.
[0007]
[Means for Solving the Problems]
The flaw inspection apparatus of the present invention is a flaw inspection apparatus for inspecting flaws of a round bar on which a coating such as an oil film is horizontally arranged, and a coating removing unit for removing the coating, A nozzle mechanism having at least a coating forming unit for re-forming the coating on the round bar from which the coating has been removed by the removing unit, an imaging unit for imaging the surface of the round bar from which the coating has been removed by the coating removing unit, It is characterized by comprising a transfer mechanism for transferring the imaging means and the nozzle mechanism in the axial direction of the round bar, and a transfer mechanism control means for controlling the transfer mechanism.
[0008]
In the flaw inspection device of the present invention, it is preferable that the nozzle mechanism has a drying unit for drying the surface of the round bar from which the coating has been removed by the coating removing unit.
[0009]
In the flaw inspection device of the present invention, it is preferable that a rotation mechanism for rotating the round bar is provided, and the rotation mechanism rotates the round bar in synchronization with the imaging by the imaging unit.
[0010]
Further, in the flaw inspection device of the present invention, foreign matter attached to the surface of the round bar is removed by ejecting air from the nozzle mechanism and moving the round bar from the other end to one end. Is preferred.
[0011]
[Action]
Since the flaw inspection device of the present invention is configured as described above, the flaw inspection accuracy of the round bar material is improved, and the coating is re-formed at the end of the inspection. Therefore, improvement in quality and productivity is achieved.
[0012]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described based on embodiments with reference to the accompanying drawings, but the present invention is not limited to only such embodiments.
[0013]
FIG. 1 shows a schematic configuration of a flaw inspection apparatus according to an embodiment of the present invention. This flaw inspection apparatus (hereinafter, simply referred to as an apparatus) A uses an optical sensor (imaging means) to measure the surface of a round bar material. A round bar W (FIGS. 2 to 5) which is processed by a processing method in which oil is used and an oil film (coating) is formed on the material surface, such as polishing, drawing, or the like. This is a flaw inspection apparatus suitable for inspecting the surface with high accuracy and efficiency.
[0014]
The apparatus A specifically includes an inspection apparatus main body (hereinafter, referred to as a main body) 1, a camera 2, a nozzle mechanism 3, and a transfer mechanism 4 (more specifically, the camera 2 is transferred along the bar W). A camera transfer mechanism 4a, a nozzle mechanism transfer mechanism 4b for transferring the nozzle mechanism 3 along the bar W, and a camera transfer mechanism 4 (more specifically, a camera transfer for transferring the camera 2 along the bar W). A mechanism 4a and a tracking control section (transfer mechanism control means) 5 for controlling a nozzle mechanism transfer mechanism 4b for transferring the nozzle mechanism 3 along the bar W are provided as main components, and chucks 6A and 6B (FIG. 2). , See FIG. 3), the surface of the bar W gripped at both ends is imaged by the camera 2, and the surface of the bar W is inspected so as to detect flaws based on the captured image.
[0015]
At this time, at the same time as the flaw inspection, in a predetermined sequence, the oil film (coating) is removed in order to improve accuracy, and the removed oil film (coating) is formed again, for example, for rust prevention. The pre-processing and post-processing are omitted or simplified, and the flaw inspection can be efficiently performed.
[0016]
Hereinafter, each component of the device A will be described.
[0017]
The main body 1 of the device A is composed of a general-purpose computer into which various kinds of software can be incorporated, such as a personal computer, and includes a control unit 11, a flaw detection processing unit 12, and a flaw site database 13 which are incorporated into the main body 1 as such software. ing.
[0018]
The camera 2 is, for example, a CCD area camera, is disposed above the round bar W by a predetermined distance, captures an image of the surface of the round bar W over a predetermined range, and outputs the captured image to the main body 1.
[0019]
As shown in FIGS. 2 and 3, the nozzle mechanism 3 is provided with oil film removal water (eg, fine cleaner 4328A (trade name, manufactured by Nippon Parkerizing Co., Ltd.)) so as to remove the oil film on the surface of the bar W. A water nozzle (film removing portion) 21 for spraying a film removing agent (hereinafter, simply referred to as water) on the surface of the bar W, and drying the water sprayed by the water nozzle 21 and adhering to the surface of the bar W An air nozzle (drying unit) 22 for injecting air to remove the foreign matter removed, and an oil nozzle (film forming unit) 23 for spraying oil so as to apply oil to the surface of the bar W again after the end of imaging. .
[0020]
The arrangement relationship of the nozzles 21, 22, and 23 is such that at the start of the inspection shown in FIG. 2A, the oil nozzles 23, the water nozzles 21, and the air nozzles 22 are arranged in this order from the front in the traveling direction indicated by the arrow B in the figure. Then, while maintaining this arrangement, the distance between them is variably controlled as described later, and the reciprocating movement is performed by the transfer mechanism.
[0021]
The transfer mechanism 4 reciprocates the camera 2 and the nozzle mechanism 3 in the axial direction of the bar W in a predetermined sequence. More specifically, the camera transfer mechanism 4a causes the camera 2 to reciprocate in the axial direction of the bar W in a predetermined sequence, and the nozzle mechanism transfer mechanism 4b causes the nozzles 21, 22, and 23 of the nozzle mechanism 3 to move in a predetermined sequence. To reciprocate in the axial direction of the bar W.
[0022]
The tracking control unit 5 operates the transfer mechanism 4, that is, the camera transfer mechanism 4a and the nozzle mechanism transfer mechanism 4b, in accordance with an instruction from the control unit 11 so that the camera 2 and the nozzle mechanism 3 always move while facing the round bar W. Control.
[0023]
Hereinafter, each part of the main body 1 will be described in detail.
[0024]
The control unit 11 sends a predetermined instruction to the camera 2, the nozzle mechanism 3, and the tracking control unit 5 so that the inspection is performed in a predetermined sequence.
[0025]
The flaw detection processing unit 12 performs various image processing such as binarization processing and thinning processing on output image data of the camera 2 and detects flaws on the surface of the bar W based on the image-processed data. Perform detection processing. This flaw detection processing is based on a known method utilizing the fact that the brightness of the flaw portion is darker than the surrounding brightness.
[0026]
The flaw site database 13 stores information (for example, a lot number, a coin number, etc.) specifying the bar W in which the flaw is detected, and accumulates information on the content and position of the detected flaw. For example, it is possible to analyze the cause of occurrence of defective products.
[0027]
Thus, in the apparatus A having such a configuration, the flaw inspection is performed in the following sequence.
[0028]
This sequence includes a forward process and a return process. That is, in this sequence, the flaw inspection is performed by moving the camera 2 and the nozzle mechanism 3 back and forth in the axial direction over the entire length of the bar W. At this time, when shifting from the forward process to the return process, the bar W is rotated by 180 degrees by a motor (not shown) provided on at least one of the chucks 6A and 6B. That is, the half circumference of the bar W is inspected in the outward process, and the remaining half circumference is inspected in the return process.
[0029]
FIG. 2 shows an execution mode of the outward process. FIG. 3A shows the arrangement of the camera 2 and the nozzle mechanism 3 at the start of the outward process, and FIG. 3B shows the operation of the camera 2 and the nozzle mechanism 3 during the forward process. Hereinafter, the outward process will be described.
[0030]
(1) The rod W is moved from one end (the chuck 6B side) to the other end (the chuck 6A side) while spraying water from the water nozzle 21. Thus, oil is removed from the surface of the bar W.
[0031]
(2) The rod W is moved from one end side to the other end side while ejecting drying air from the air nozzle 22 so as to follow the water nozzle 21. Thereby, the surface of the bar W is dried.
[0032]
(3) While moving the camera 2 from one end of the bar W to the other end so as to follow the air nozzle 22, oil is removed by water spray from the water nozzle 21 and air jet from the air nozzle 22 to dry the oil. The surface of the bar W in the state of being performed is imaged, and the flaw detection processing unit 13 detects a flaw on the surface of the bar W based on the captured image.
[0033]
(4) The oil nozzle 23 simply moves the bar W from one end to the other end without spraying oil.
[0034]
FIG. 3 shows an execution mode of the return process. FIG. 3A shows the arrangement of the camera 2 and the nozzle mechanism 3 at the start of the return process, and FIG. 3B shows the operation of the camera 2 and the nozzle mechanism 3 during the return process. Hereinafter, the return process will be described.
[0035]
(11) The rod W is moved from the other end to one end while ejecting air from the air nozzle 22. This removes foreign matter (dust and the like) attached to the surface of the bar W.
[0036]
(12) The surface of the bar W is imaged while moving the camera 2 from the other end to the one end of the bar W so as to follow the air nozzle 22, and the flaw detection processing unit 13 uses the flaw detection processing unit 13 based on the captured image. A flaw on the surface of the material W is detected.
[0037]
(13) The rod W is moved from the other end to the one end while spraying oil from the oil nozzle 23 so as to follow the camera 2. Thereby, an oil film is formed again on the surface of the bar W.
[0038]
(14) The water nozzle 21 is simply moved from the other end of the bar W to one end without spraying water.
[0039]
As described above, in the flaw inspection apparatus A according to the present embodiment, the optical sensor (camera 2) uses the optical sensor (camera 2) to inspect the surface of the round bar manufactured by a processing method in which oil adheres to the material, such as grinding and drawing. When imaging the surface of the material W, the nozzle mechanism 3 removes an oil film from the surface of the bar W immediately before the imaging, and performs oiling again immediately after the imaging. The cleaning, drying, and oiling of the bar, which has been performed as described above, can be performed simultaneously with the inspection, so that the inspection process can be simplified and efficiently and accurately performed.
[0040]
As described above, the present invention has been described with reference to one embodiment. However, the present invention is not limited to such an embodiment, and various modifications are possible. For example, in the present embodiment, the camera 2 is an area camera, but this may be configured as a line sensor.
[0041]
For example, as shown in FIG. 4, a camera 2A composed of a line sensor and a nozzle mechanism 3A composed of a water nozzle 21, an air nozzle 22, and an oil nozzle 23 at the start of the inspection, as shown in FIG. At the other end (the chuck 6A side, or the chuck 6B side if the arrangement of the nozzles is changed), and water and air are respectively ejected from the water nozzle 21 and the air nozzle 22 as shown in FIG. The surface of the bar W is washed and dried by moving to the one end side (the chuck 6B side) while moving, and the camera 2A is moved to one end to capture the surface of the bar W so as to follow the surface.
[0042]
At this time, the bar W is to be rotated at a predetermined speed corresponding to the moving speed of the camera 2A, so that the surface of the bar W can be imaged over the entire circumference and the entire length in one step. Become. At this time, the oil nozzle 23 is moved from the other end to the one end of the bar W so as to follow the camera 2A while spraying oil.
[0043]
Thereby, it is possible to carry out cleaning, drying, inspection, and oiling of the bar W in one step.
[0044]
As described above, by applying a line sensor having a high image capturing speed as the camera 2A, the inspection can be completed with a small number of steps.
[0045]
As shown in FIG. 5, a line sensor is applied as the camera 2A, and an air nozzle 22A and an oil nozzle 23A are provided on the opposite side of the water nozzle 21 so as to be symmetrical with the air nozzle 22 and the oil nozzle 23. In this case, the inspection can be performed in both directions from the other end to the one end and from the one end to the other end of the bar W.
[0046]
At this time, as shown in FIG. 5B, in the inspection from the other end to the one end of the bar W, the air nozzle 22 and the oil nozzle 23 on the rear side in the traveling direction of the camera 2A indicated by the arrow C are dried and oiled. And the air nozzle 22A and the oil nozzle 23A on the front side are simply moved to one end. This relationship is reversed in the inspection from one end to the other end of the bar W.
[0047]
【The invention's effect】
As described in detail above, according to the present invention, the inspection accuracy of the flaw inspection of the round bar is improved, and the coating is re-formed at the end of the inspection. Therefore, an excellent effect of improving quality and productivity can be obtained.
[Brief description of the drawings]
FIG. 1 is a block diagram showing a schematic configuration of a flaw inspection device according to an embodiment of the present invention.
FIGS. 2A and 2B are schematic diagrams showing an inspection execution sequence by the flaw inspection apparatus, wherein FIG. 2A shows the arrangement of cameras and nozzles at the start of an outward process, and FIG. The operation mode of each unit will be described.
3A and 3B are schematic diagrams showing a sequence of inspection execution by the flaw inspection apparatus, wherein FIG. 3A shows the arrangement of cameras and nozzles at the start of a return process, and FIG. The operation mode of each unit will be described.
FIGS. 4A and 4B are schematic diagrams showing another sequence of inspection execution by the flaw inspection apparatus, wherein FIG. 4A shows the arrangement of cameras and nozzles at the start of inspection, and FIG. The operation mode of is shown.
5A and 5B are schematic diagrams showing still another sequence of the inspection execution by the flaw inspection apparatus, wherein FIG. 5A shows the arrangement of cameras and nozzles at the start of the inspection, and FIG. The operation mode of each unit will be described.
[Explanation of symbols]
A flaw inspection device W round bar 1 flaw inspection device main body 2 optical sensor (area camera, line sensor)
3 Nozzle mechanism 4 Transfer mechanism 4a Camera transfer mechanism 4b Nozzle mechanism transfer mechanism 5 Tracking controller (transfer mechanism controller)
11 control unit 12 flaw detection processing unit 13 flaw site database 21 water nozzle 22 air nozzle 23 oil nozzle

Claims (4)

A flaw inspection device for inspecting flaws of a round bar on which a coating such as an oil film is horizontally arranged,
A nozzle mechanism having at least a coating removing unit for removing the coating, and a coating forming unit for re-forming the coating on the round bar material from which the coating has been removed by the coating removing unit;
Imaging means for imaging the round bar material surface from which the coating has been removed by the coating removal unit,
A transfer mechanism for transferring the imaging means and the nozzle mechanism in the axial direction of the round bar,
A flaw inspection apparatus comprising: a transfer mechanism control unit that controls the transfer mechanism. 2. The flaw inspection device according to claim 1, wherein the nozzle mechanism has a drying unit for drying the surface of the round bar from which the coating has been removed by the coating removing unit. 2. The flaw inspection apparatus according to claim 1, further comprising a rotating mechanism for rotating the round bar, wherein the rotating mechanism rotates the round bar in synchronization with imaging by an imaging unit. 2. A flaw according to claim 1, wherein the foreign matter attached to the surface of the round bar is removed by ejecting air from a nozzle mechanism and moving the round bar from the other end to one end thereof. Inspection equipment.

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