JP2005265543A - Testing and recording device for die, and testing and recording method for die - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a testing and recording device for dies and a testing and recording method for dies which can surely distinguish and view minute irregularity on a test object such as dust and blemish on a non-plane molding face of a die from a specific reflection area. <P>SOLUTION: The testing and recording device for dies comprises a light source irradiating light on the non-plane molding face of tested die, an imager for imaging the non-plane molding face from a specific one direction, an image processing means for converting brightness value of a high brightness continuous pixel data group in which pixel data with higher brightness value in the image data imaged by the imager than a specific value is continuing over a specific number, to a corrected value lower than the specific value and produces corrected image data, and an indication means for indicating the image based on the corrected image data. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a mold inspection recording apparatus and a mold inspection recording method for inspecting a minute unevenness inspection target such as dust and scratches on a curved molding surface of a mold, and recording and displaying an inspection result.

  If the molding surface of the mold used in injection molding etc. is dusty or scratched, there is a risk that the finished molded product may become defective. There is a need to. Therefore, conventionally, the molding surface of the mold is irradiated with light, the inspector visually confirms dust and scratches, and the inspection result is recorded on a recording sheet. However, such manual work has a problem that the work efficiency is low and the inspector directly sees the light from the light source, which places a heavy burden on the inspector's eyes. For this reason, various apparatuses for automatically inspecting dust and scratches on the molding surface of the mold have been devised (for example, Patent Document 1 and Patent Document 2).

  In Patent Document 1, an inspection device for inspecting dust or scratches on a molding surface of a mold is attached to an injection molding device. This inspection apparatus is provided with a fixed light source for irradiating light on the molding surface of the mold and a camera for photographing the molding surface. The camera retracts to a position that does not face the molding surface of the mold during the molding operation, and moves to a position that faces the molding surface of the mold after the molding operation to photograph the molding surface. Then, the photographed image is processed by an image processing apparatus connected to the camera to determine the presence or absence of dust or scratches.

In Patent Document 2, a mold removed from a molding apparatus is placed on a mold inspection apparatus, the molding surface is irradiated with light from a fixed light source, the molding surface is photographed with a camera, and the photographed image is image processing apparatus. Processing is performed by the (arithmetic processing unit), and the result (presence or absence of scratches) is displayed on the monitor.
Japanese Patent No. 3322618 JP 2001-183123 A

  Since minute irregularities such as dust and scratches have a property of strongly reflecting light, when the molding surface is photographed with a camera, the minute irregularities appear brighter than other portions. Therefore, the apparatus of patent document 1 and patent document 2 can distinguish micro unevenness | corrugation from another part.

  However, when the molding surface of the mold is concave or convex, a part of the molding surface (specific reflection area) reflects as strongly as or more than the minute irregularities, so this specific reflection area is continuous with the minute irregularities. If they are overlapped or overlapped, the devices of Patent Literature 1 and Patent Literature 2 cannot distinguish the minute irregularities from the specific reflection area.

  An object of the present invention is to provide an inspection record for a mold that can reliably inspect minute unevenness inspection objects such as dust and scratches on a non-planar molding surface of a mold from a specific reflection area on the non-planar molding surface. An object of the present invention is to provide an apparatus and a mold inspection recording method.

  According to the first aspect, the mold inspection recording apparatus of the present invention is a light source for irradiating light to the non-planar molding surface of the test mold, and images the non-planar molding surface from a specific direction. A luminance value of a high-luminance continuous pixel data group in which a predetermined number or more of pixel data having a luminance value higher than a predetermined value in image data captured by the imaging device is lower than the predetermined value. It is characterized by comprising image processing means for generating corrected image data by converting to a corrected value, and display means for displaying an image based on the corrected image data.

  The light source is movable relative to the test mold, irradiates light on the non-planar molding surface from a plurality of different relative irradiation positions, and the imaging element moves the light source to the different relative irradiation positions. In some cases, the non-planar molding surface is imaged from one specific direction, and the image processing means has a luminance value of the high-luminance continuous pixel data group in all the different-direction image data captured by the image sensor. The pixel data having the highest luminance among the pixel data at the corresponding positions of the plurality of corrected different-direction image data are compared with each other at the pixel level. And combining the selected highest luminance pixel data groups to generate one combination image data, and the display means may display an image based on the combination image data. By acquiring a plurality of pieces of image data while changing the relative irradiation position of the light source in this way, it becomes possible to reliably display a fine unevenness inspection target such as dust or scratches on the non-planar molding surface on the display means.

  In the conversion of the brightness value, for example, the image processing means recognizes the high brightness continuous pixel data group in the image data or all the different-direction image data, and the brightness value of the recognized high brightness continuous pixel data group. Is converted into the correction value to generate the corrected image data or the corrected different-direction image data.

  When the non-planar molding surface is rotationally symmetric, the image processing means recognizes the high-luminance continuous pixel data group in one different-direction image data and recognizes the recognized high-luminance continuous pixels. Based on the positions of the data groups and the relative irradiation positions at the time of capturing all the different-direction image data, the positions of the high-luminance continuous pixel data groups in the other different-direction image data are calculated, and all the high-luminances are calculated. The luminance value can also be converted by converting the luminance value of the continuous pixel data group into the correction value to generate the corrected different direction image data.

  If the correction value is set to 0, it is possible to clearly distinguish the object for inspecting minute unevenness on the non-planar molding surface from the specific reflection area.

  According to the second aspect, the mold inspection recording apparatus of the present invention is movable relative to the test mold, and emits light from a plurality of different relative irradiation positions to the non-planar molding surface of the mold. An illuminating light source, an image sensor that images the non-planar molding surface from a specific direction when the light source is at the different relative irradiation position, and a predetermined reflectance or more on the non-planar molding surface The light shielding means for preventing the light reflected by the specific reflection area from going to the image sensor and all the different direction image data captured by the image sensor are compared at the pixel level, and the plurality of different direction image data are compared. Image processing means for selecting pixel data having the highest luminance from pixel data at corresponding positions of the image data, and combining the selected highest luminance pixel data groups to generate one combination image data; and the combination image Is characterized in that characterized in that it comprises display means for displaying an image based on over data, the.

  In any aspect, it is practical to include a recording unit capable of recording the image data, the different-direction image data, and the combination image data.

  According to the first aspect, the mold inspection and recording method of the present invention includes an irradiation step of irradiating light to the non-planar molding surface of the test mold, and imaging the non-planar molding surface from a specific direction. In the imaging step, the luminance value of the high-luminance continuous pixel data group in which the pixel data whose luminance value is higher than the predetermined value in the imaged image data is continuous for a predetermined number or more is converted into a correction value lower than the predetermined value. A luminance value converting step for generating corrected image data, and a display step for displaying an image based on the corrected image data.

  The irradiation step is a step in which a light source is relatively moved with respect to the test mold, and light is irradiated onto the non-planar molding surface from a plurality of different relative irradiation positions, and the imaging step is performed by the light source When there is a different relative irradiation position, the non-planar molding surface is imaged, and the luminance value conversion step is performed by calculating the luminance value of the high-luminance continuous pixel data group in all captured different-direction image data. A step of generating corrected different-direction image data by converting to the correction value, and comparing all the corrected different-direction image data at a pixel level, and pixels at corresponding positions of the plurality of corrected different-direction image data The pixel data having the highest luminance is selected from the data, and the combined highest luminance pixel data group is combined to generate one combination image data. Have up, the display step may be a step of displaying an image based on the combination image data. If a plurality of pieces of image data are acquired while changing the relative irradiation position of the light source in this way, it is possible to reliably display a target for inspecting minute irregularities such as dust and scratches on the non-planar molding surface.

  In the luminance value conversion step, for example, the high luminance continuous pixel data group in the image data or all the different-direction image data is recognized, and the recognized luminance value of the high luminance continuous pixel data group is set as the correction value. This can be implemented as a step of converting and generating the corrected image data or the corrected different direction image data.

  Further, when the non-planar molding surface is rotationally symmetric, the luminance value conversion step recognizes the high-luminance continuous pixel data group in one different-direction image data and recognizes the recognized high-luminance continuous Based on the position of the pixel data group and the relative irradiation position at the time of capturing all the different-direction image data, the position of the high-luminance continuous pixel data group in the other different-direction image data is calculated, It is also possible to implement the step of converting the luminance value of the luminance continuous pixel data group into the correction value to generate the corrected different direction image data.

  If the correction value in the luminance value conversion step is set to 0, the minute unevenness inspection target of the non-planar shaped surface can be clearly identified from the specific reflection area.

  According to the second aspect, the mold inspection and recording method of the present invention is such that the light source is moved relative to the test mold, and light is emitted from a plurality of different relative irradiation positions onto the non-planar molding surface of the mold. An imaging step for imaging the non-planar molding surface from a specific direction when the light source is at the different relative irradiation positions, and a predetermined reflectance or more on the non-planar molding surface, respectively. A light blocking step for preventing light reflected by the specific reflection area from traveling toward the image sensor, comparing all the different direction image data captured by the image sensor at a pixel level, and An image processing step of selecting pixel data having the highest luminance from pixel data at corresponding positions and generating one combination image data by combining the selected highest luminance pixel data groups; Display step of displaying an image based on micro the combination image data, is characterized by having a.

  In any aspect, it is practical to have a recording step for recording the image data, the different-direction image data, and the combined image data.

  According to the present invention, a minute unevenness inspection target such as dust and scratches on a non-planar molding surface of a mold can be reliably recognized separately from a specific reflection area on the non-planar molding surface.

Hereinafter, a first embodiment of the present invention will be described with reference to FIGS.
The mold inspection recording apparatus 100 of the present embodiment inspects a concave lens molding surface (non-planar molding surface) 11 having a circular shape in plan view, which is mirror-finished, of a lens molding die (test die) 10. And the state of the concave lens molding surface 11 is displayed, and includes an imaging device 20, a personal computer 30, a keyboard 40, and a display 50. First, each component 20, 30, 40, 50 of the mold inspection recording apparatus 100 will be described.

The imaging device 20 has the following structure.
A mold support base 22 having a circular shape in plan view is fixed to the center of the upper surface of the base 21 having a substantially circular shape in plan view placed on the floor, and the mold support bases 22 are arranged in the circumferential direction. And three openable / closable gripping claws (not shown). On the mold support base 22, the mold 10 on which the concave and convex lens forming surface 11 has a micro unevenness inspection target S (see FIGS. 1 and 4, actually there are a plurality but only one is shown) such as dust and scratches. When each gripping claw is closed in a state where the mold is placed, each gripping claw is strongly pressed against the peripheral surface of the mold 10 to make the mold 10 immovable with respect to the base 21. A circumferential annular recess 21a is formed on the upper surface of the base 21, and an annular rotating portion 23 is rotatably fitted in the annular recess 21a. The base 21 incorporates a stepping motor M1 as a drive source for the annular rotating part 23 and a power transmission mechanism DM1 for transmitting the power of the stepping motor M1 to the annular rotating part 23. A rotation mechanism is configured by the mechanism DM1. When the stepping motor M1 rotates, this power is transmitted to the annular rotating part 23 via the power transmission mechanism DM1, and the annular rotating part 23 rotates in the direction of arrow A in FIGS. As shown in FIGS. 1 and 3, a linear mark B is attached to the outer peripheral edge of the upper surface of the base 21.

A substantially arc-shaped arm portion 24 extends from the annular rotating portion 23. An inner side surface of the arm portion 24 is open, and an arcuate guide groove 24a centering on the concave lens molding surface 11 of the mold 10 fixed to the mold support base 22 is formed on one side surface. Yes. In this arm part 24, the light source 25 is supported in the state which the inner side edge part protrudes inside the arm part 24, and when the engaging pin 25a provided in the light source 25 engages with the guide groove 24a, The light source 25 is movable along the guide groove 24a. When the light source 25 moves along the guide groove 24a, the inclination angle θ (see FIG. 1) formed by the straight line connecting the mold 10 and the emission end face 25b and the plane including the annular rotating portion 23 is 20 ° to 75 °. Although it varies depending on the range, the emission end face 25 b of the light source 25 always faces the concave lens molding surface 11 side of the mold 10. The base 21 and the arm part 24 have a built-in stepping motor M2 as a driving source for the annular rotating part 23 and a power transmission mechanism DM2 for transmitting the power of the stepping motor M2 to the light source 25. The tilt angle variable mechanism AM is configured by M2, the power transmission mechanism DM2, the guide groove 24a, and the engagement pin 25a.
When the annular rotating portion 23 rotates, the arm portion 24 rotates in the A direction, and the rotation angle α that is a circumferential position of the arm portion 24 (light source 25) with respect to the mold support base 22 in a plan view changes. As shown in FIG. 3, the rotation angle α is an angle that the arm portion 24 (light source 25) makes in a clockwise direction with respect to a straight line connecting the mold support base 22 and the mark B.
Since the light source 25 can be taken out from the arm portion 24, a new light source 25 can be attached to the arm portion 24 when the light source 25 fails, and other light sources having different intensities (brightness) can be attached to the arm portion 24. Is possible.

  From the side of the base 21, a large arm portion 26 extends upward from the arm portion 24, and a box-like case 27 is provided at the tip of the arm portion 26. A photographic lens 28 is provided on the lower surface of the case 27 and is located immediately above the mold support base 22. The photographic lens 28 is located on the imaging surface of the case 27. A CCD (imaging device) 29 on which the transmitted image is formed is provided. The CCD 29 is a monochrome type having 256 gradations (8 bits).

As is well known, the personal computer 30 includes a CPU (Central Processing Unit) 31 and a recording device (recording means) 32 such as a hard disk, and a control program for controlling the operation of the imaging device 20 is installed, and further a keyboard. 40 and a display (display means) 50 are connected. Further, the personal computer 30 is electrically connected to the CCD 29 and the stepping motors M1 and M2 of the imaging device 20 through a cable 33A shown in FIG. 1, and is electrically connected to the light source 25 through a cable 33B. The recording device 32 of the personal computer 30 records image data captured by the CCD 29 (different direction image data), various information related to the image data input by the keyboard 40, and the like. The CPU 31 sends predetermined signals to the light source 25, the stepping motors M1 and M2, and the CCD 29 to control the operation of the light source 25, the annular rotating unit 23 and the CCD 29, and the image data recorded by the recording device 32. It functions as an image processing means for image processing by this method.
The display 50 displays an image based on the image data completed by the image processing of the CPU 31 and various information recorded by the recording device 32.

Next, an inspection procedure for the mold 10 using the mold inspection recording apparatus 100 will be described together with specific functions of the mold inspection recording apparatus 100.
First, the mold 10 is placed on the mold support base 22 and fixed with the gripping claws, the arm portion 24 is rotated to set the rotation angle α to 0 °, and the engagement pin 25a is moved to the outermost position of the guide groove 24a. By moving to the lower end, the inclination angle θ of the light source 25 is set to the minimum angle of 25 °.
Next, the inspector operates the keyboard 40 to send a signal based on the control program from the personal computer 30 to the light source 25, the stepping motors M1, M2, and the CCD 29 to operate the light source 25, the stepping motors M1, M2, and the CCD 29.

  The lighting signal to the light source 25, the rotation signal to the stepping motors M1 and M2, and the imaging signal to the CCD 29 are all transmitted intermittently at regular intervals, and the lighting signal and the imaging signal are transmitted simultaneously. More specifically, at the moment when the rotation signal is sent to the stepping motor M1, that is, at the relative irradiation position at the rotation angle α = 0 °, the lighting signal and the imaging signal are sent to the light source 25 and the CCD 29, and the first imaging is performed. . When the stepping motor M1 rotates, the driving force causes the annular rotating portion 23 to rotate by 5 ° in the direction of arrow A in FIG. 3, and the rotation angle α of the light source 25 increases from 0 ° by 5 °. Each time the rotation angle α of the light source 25 changes from 0 ° to every 5 °, the light source 25 has a predetermined relative irradiation position (for example, PA (α = 5 °), PB (α = 45 °) in FIG. 3). , Each time the light source 25 reaches each relative irradiation position, a lighting signal and an imaging signal are sent to the light source 25 and the CCD 29, and the light source 25 irradiates the concave lens molding surface 11. Then, the CCD 29 images the concave lens molding surface 11. Further, each time the annular rotating portion 23 makes a round, a rotation signal is sent from the personal computer 30 to the stepping motor M2, and the inclination angle θ of the light source 25 increases by 5 ° by the driving force of the stepping motor M2, and the circle of the light source 25 increases. The diameter of the circumferential circulation path R (see FIG. 3) is reduced. Each time the light source 25 reaches each relative irradiation position (not shown) set at intervals of 5 ° on this reduced circular circumference path (not shown), a lighting signal and an imaging signal are sent to the light source 25 and the CCD 29. And the CCD 29 images the concave lens molding surface 11. When the annular rotating portion 23 makes 11 turns, the engaging pin 25a reaches the uppermost end of the guide groove 24, and the inclination angle θ of the light source 25 reaches the maximum angle of 75 °, and when the annular rotating portion 23 makes 12 turns, the personal computer 30 The transmission of the rotation signal from the motor to the stepping motor M1 is finished, and the annular rotating unit 23 stops.

All the image data picked up by the CCD 29 is recorded in the recording device 32, and further information (relative irradiation position information) regarding the rotation angle α and the inclination angle θ of the light source 25 at the time of image pickup of each image data is stored in the recording device 32. It is recorded while being associated with the corresponding image data. Further, when the inspector inputs the intensity information of the light source 25 using the keyboard 40, the intensity information is recorded in the recording device 32.
When the annular rotating unit 23 finishes the 12 rounds and stops, all the image data recorded in the recording device 32 is sent to the CPU 31, and the CPU 31 performs the following image processing.

FIG. 5 is a conceptual diagram for explaining image processing by the CPU 31.
Image data (different direction image data) A shown in FIG. 5 is image data picked up by the CCD 29 when the light source 25 is at the relative irradiation position PA (α = 5 °) shown in FIGS. 3 and 4. The image data (different direction image data) B and C are image data picked up by the CCD 29 when the light source 25 is at the relative irradiation position PB (α = 45 °) and PC (α = 90 °), respectively. Since the CCD 29 includes tens of thousands to millions of pixels, each image data A, B, C... Is actually composed of tens of thousands to millions of pixel data. , Only a part of each of the image data A, B, C... Is taken out, and a total of 64 pieces of pixel data A11, A12, B11, B12, C11, C12, 8 in the X direction and Y direction in FIG. ... Only (the number on the right of the alphabet indicates the position in the Y direction, and the number on the right side indicates the position in the X direction. The same applies to the drawings showing other pixel data. is there). A group of pixel data corresponding to each of the image data A, B, C... (Pixel data at positions where the X-direction position and the Y-direction position match. For example, A11, B11, and C11) are all the same in the CCD 29. The image is taken by a pixel.

  The CPU 31 converts the luminance values of all pixel data having a luminance value of 70 or less in each of the image data A, B, C. These pixel data groups having a luminance value of 70 or less appear black when an image based on this data is displayed on the display 50. When such processing is performed, the luminance values of the pixel data other than the pixel data (see FIG. 5) indicated by the oblique lines in the respective image data A, B, C. Pixel data indicated by oblique lines is obtained by imaging the specific reflection areas RAa, RAb, RAc... Or the minute unevenness inspection target S on the concave lens molding surface 11.

  As shown in FIG. 3, when the light source 25 irradiates the concave lens molding surface 11 with light from the relative irradiation position PA, the opposite side to the relative irradiation position PA across the center of the concave lens molding surface 11 is brighter than its surroundings. A specific reflection area RAa that reflects (reflects at a reflectance equal to or higher than a predetermined value) is generated. Further, when the concave lens molding surface 11 is irradiated with light from the relative irradiation positions PB and PC, the light beam 25 is reflected brighter than the surroundings on the opposite side of the light source 25 across the center of the concave lens molding surface 11 (a predetermined value or more). A specific reflection area RAb and a specific reflection area RAc (which reflect with brightness) are generated. These specific reflection areas RAa, RAb, and RAc are high-luminance continuous pixel data groups HDa, HDb, and HDc in which pixel data having a luminance value greater than 70 are continuously generated in each image data A, B, and C (hatched lines in FIG. 5). In FIG. 5, it is displayed as four consecutive pixel data for convenience).

In addition, since the minute unevenness inspection object S on the concave lens molding surface 11 reflects light more strongly than the other smooth portions (except for the specific reflection areas RAa, RAb, RAc...) The luminance value of the pixel data obtained by imaging is larger than 70. Therefore, the pixel data obtained by imaging the specific reflection areas RAa, RAb, RAc... And the pixel data obtained by imaging the minute unevenness inspection object S cannot be identified only by the luminance value.
Therefore, the CPU 31 searches the image data A, B, and C for a region where 3000 or more pixel data having a luminance value of 70 or more are continuous, and if there is such a region, this is used as a high-brightness continuous pixel data group HDa, Recognize HDb and HDc, convert the luminance values of the recognized high-luminance continuous pixel data groups HDa, HDb, and HDc to uniform 0 (correction values), and modify the corrected image data (correction differences) of the image data A, B, and C. Direction image data) A ′, B ′, C ′ (see FIG. 6) are generated. The pixel data in which the luminance value in each of the corrected image data A ′, B ′, C ′... Is not set to 0 is the pixel data obtained by imaging the minute unevenness inspection target S.
Further, the CPU 31 compares the corrected image data A ′, B ′, C ′,... For each pixel data at the corresponding position, and the pixel data having the highest luminance (the highest luminance pixel in the pixel data group compared). Data group) A11, B12, B13, C14, C21, C22, C23, C31, A44. Further, all the selected pixel data A11, B12, B13, C14, C21, C22, C23, C31, A44... Are combined without changing their positions, and each corrected image data A ′, B ′, C ′ is combined. One combination image data CD1 (see FIG. 7) having the same resolution is generated. Further, the minute unevenness inspection object S appears at a position 44 (shaded portion in FIG. 5) of each image data. At this position 44, the pixel data A44 of the image data A has the highest luminance, and the image data B, C Since the brightness of the pixel data B44 and C44 is lower than this, the pixel data at the 44 position of the combination image data CD1 is A44 having the highest brightness.
The combined image data CD1 is recorded in the recording device 32, and an image based on the combined image data CD1 is displayed on the display 50.

When an image based on the combination image data CD1 is displayed on the display 50, only the minute unevenness inspection object S appears white and the other parts appear black. Therefore, the minute unevenness inspection object S and other parts are clearly distinguished on the display 50. it can.
In addition, since the pixel data obtained by imaging the minute unevenness inspection object S in the combination image data CD1 is captured in a state where the minute unevenness inspection object S is most strongly reflected, the minute unevenness inspection object S is clearly displayed on the display 50. Is done.
Further, the CPU 31 selects each pixel data constituting the combination image data CD1 based on whether the luminance value is 0 or not, and pixel data having a luminance value other than 0 is pixel data obtained by imaging the minute unevenness inspection target S. recognize. Then, information on the rotation angle α and the tilt angle θ (relative irradiation position information) at the time of imaging of these pixel data is recorded in the recording device 32 in association with these pixel data. Further, the CPU 31 displays information on the rotation angle α and the inclination angle θ (relative irradiation position information) on the display 50 in association with the corresponding minute unevenness inspection object S. Further, intensity information of the light source 25 is displayed on the display 50.

As described above, according to the present embodiment, by setting the luminance values of the high-luminance continuous pixel data groups HDa, HDb, and HDc of the image data A, B, C. Is displayed on the display 50, the specific reflection area is reflected in black, so that the inspector does not confuse the minute uneven inspection object S that appears white on the display 50 with the specific reflection area.
Furthermore, although the minute unevenness inspection object S reflects strongly or weakly depending on the irradiation angle of light, all the minute unevenness inspection objects S in the combination image data CD1 are captured with the highest luminance value. (Because it was imaged in the most strongly reflected state), all the minute unevenness inspection objects S can be clearly displayed on the display 50, and the inspector can surely grasp the minute unevenness inspection objects S.

  Further, since the display 50 displays the intensity information of the light source 25 used and the information (relative irradiation position information) of the rotation angle α and the inclination angle θ associated with each minute unevenness inspection object S, the inspector It is possible to easily grasp under what conditions each minute unevenness inspection object S is imaged. Further, since these pieces of information are recorded in the recording device 32 in association with the combination image data CD1, if the concave lens molding surface 11 is illuminated under the same conditions as this information after the main inspection, minute irregularities on the concave lens molding surface 11 are recorded. The inspection object S can be clearly displayed again on the display 50.

  Further, for example, the mold 10 is inspected in various processes (for example, a pre-cleaning process, a post-cleaning process, etc.), information on the inspected processes is input by the keyboard 40 and recorded in the recording device 32, and the display 50 If it is displayed or printed out, it can be easily grasped how the concave lens molding surface 11 of the mold 10 has changed over time.

Next, a second embodiment of the present invention will be described with reference mainly to FIGS. The same members as those in the first embodiment are designated by the same reference numerals, and detailed description thereof is omitted.
In the present embodiment, the image processing method of each image data A, B, C... Captured by the CCD 29 is different from that in the first embodiment. Hereinafter, the inspection procedure and the image processing method by the CPU 31 will be described in detail.
In the present embodiment, first, with the rotation angle α and the inclination angle θ both set to 0 °, the mold 10 is placed on the mold support base 22 and the gripping claws are opened (the mold 10 is placed on the mold support base 22. The light is continuously irradiated from the light source 25 to the concave lens molding surface 11. Further, the image pickup signal is continuously transmitted from the personal computer 30 to the CCD 29, the concave lens molding surface 11 is continuously imaged by the CCD 29, and the concave lens molding surface 11 is continuously (always) displayed on the display 50. Then, the inspector manually turns the mold 10 on the mold support base 22 while visually observing the display 50, and stops the rotation of the mold 10 at a position where the specific reflection area and the minute unevenness inspection target S do not overlap. Then, the gripping claws are closed to fix the mold 10 to the mold support base 22. Each time the mold 10 is rotated, the relative position of the specific reflection area and the minute unevenness inspection object S changes. Therefore, when the inspector looks at the display 50, the specific reflection area and the minute unevenness inspection object S do not overlap. Can recognize the state.

After the continuous image signal transmission from the personal computer 30 to the CCD 29 is interrupted and the light source 25 is turned off, the control program is transferred from the personal computer 30 to the light source 25, the stepping motors M1, M2 and the CCD 29 in the same manner as in the first embodiment. Is sent to operate the light source 25, the stepping motors M1 and M2, and the CCD 29. All the image data A, B, C... Imaged at each relative irradiation position are recorded in the recording device 32, and the CPU 31 performs the following image processing.
The CPU 31 uniformly sets the luminance value of the high-luminance continuous pixel data group obtained by imaging the specific reflection area of the first image data (image data in which the specific reflection area and the minute unevenness inspection target S do not overlap) to 0 (correction value). Convert. Further, the CPU 31 is based on the position of the light source 25 when the first image data is imaged (both the rotation angle α and the inclination angle θ are 0 °) and the position of the light source 25 when other image data is imaged. The range of the high-luminance continuous pixel data group in the other image data is calculated from the range of the high-luminance continuous pixel data group in the first image data, and the luminance value of the high-luminance continuous pixel data group in the other image data Is uniformly converted to 0, and corrected image data (not shown) corresponding to each image data is generated. As shown in FIG. 8, in the image data A, for example, pixel data A14, A15, A24, and A25 (portions surrounded by thick lines) are the high luminance continuous pixel data group HDa, and the luminance value of this portion is 0. . Further, the high-brightness continuous pixel data groups HDb and HDc appear at different positions from the image data A in the image data B and C (B11, B12, B21, B22, and C14, C15, C24, and C25, both bold lines). However, the brightness values of these high-brightness continuous pixel data groups HDb and HDc are also converted to zero.

Then, the CPU 31 generates a combination image data CD2 (see FIG. 9) by combining all the corrected image data in the same manner as in the first embodiment. The combined image data CD2 is recorded on the recording device 32, and an image based on the combined image data CD2 is displayed on the display 50.
Further, as in the first embodiment, the CPU 31 recognizes pixel data obtained by imaging the minute unevenness inspection object S in the combination image data CD2, and information (relative to the rotation angle α and the inclination angle θ of these pixel data). (Irradiation position information) is recorded in the recording device 32 in association with these pixel data, and displayed on the display 50 in association with the corresponding minute unevenness inspection object S. Further, intensity information of the light source 25 is displayed on the display 50.

  According to this embodiment, since the image processing is performed after distinguishing the minute unevenness inspection target S from the specific reflection area, the minute unevenness inspection target S is high in each of the image data A, B, C. There is no continuous or overlapping with the luminance continuous pixel data group. Therefore, all the minute unevenness inspection objects S can be reliably displayed on the display 50.

Finally, a third embodiment of the present invention will be described with reference mainly to FIGS. The same members as those in the first embodiment are designated by the same reference numerals, and detailed description thereof is omitted.
In the present embodiment, the specific reflection areas RAa, RAb, RAc,... Are reflected on the display 50 by preventing the light reflected by the specific reflection areas RAa, RAb, RAc,. The minute unevenness inspection object S is prevented from being continuous or overlapping.

As shown in FIG. 10, the mold inspection recording apparatus 200 of the present embodiment has substantially the same configuration as that of the first embodiment, but one end of a substantially annular support fitting 60 is attached to the distal end portion of the arm portion 24. It is pivotally attached, and a rectangular light-shielding plate (light-shielding means) 61 is pivotally attached to the other end of the support metal 60 so that the support metal 60 and the light-shielding plate 61 can be held in an arbitrary direction. In the present embodiment, by adjusting the orientation of the support bracket 60 and the light shielding plate 61, as shown in FIG. 11, when viewed from the CCD 29 side, the rotation angle α and the inclination angle θ of the arm portion 24 (light source 25). Regardless, the light shielding plate 61 always covers about half of the concave lens molding surface 11 opposite to the light source 25. As described above, the specific reflection areas RAa, RAb, RAc... Appear in the portion covered by the light shielding plate 61, and therefore, the high-luminance continuous pixel data group does not appear in the image data captured by the CCD 29.
These image data A, B, C... Are shown in FIG. Without the light shielding plate 61, the pixel data A41, A42, A51, A52 (shaded portions) are a group of continuous high-intensity pixel data. However, since the entire portion surrounded by the thick line is the pixel data in which the light shielding plate 61 is copied, Does not show a high brightness continuous pixel data group. Since the pixel data obtained by imaging the light shielding plate 61 has a small luminance value (close to 0), it can be clearly distinguished from the pixel data A44 obtained by imaging the minute unevenness inspection object S. The same applies to the image data B and C, and the pixel data groups (B11, B12, B21, B22 and C14, C15, C24, C25) in which the specific reflection areas RAb and RAc appear without the light shielding plate 61 are surrounded by thick lines. Since it is covered with a portion (pixel data obtained by imaging the light shielding plate 61), it does not become a high luminance continuous pixel data group.

  Each of the image data A, B, C,... Is combined by the CPU 31 to generate one combination image data CD3 (see FIG. 13). Since the high-luminance continuous pixel data group does not appear in the combination image data CD3, the pixel data obtained by imaging the minute unevenness inspection object S does not continue or overlap with the high-luminance continuous pixel data group. Therefore, if an image based on the combination image data CD3 is displayed on the display 50, the inspector can surely visually recognize the minute unevenness inspection object S without being confused with the specific reflection area.

  Further, also in this embodiment, all the image data A, B, C... Are recorded in the recording device 32, and the CPU 31 images the minute unevenness inspection target S in the combination image data CD as in the first embodiment. The pixel data is recognized, information on the rotation angle α and inclination angle θ (relative irradiation position information) of these pixel data is recorded in the recording device 32 in association with these pixel data, and the corresponding minute unevenness inspection is performed. The information is displayed on the display 50 in association with the object S. Further, intensity information of the light source 25 is displayed on the display 50.

Furthermore, in each said embodiment, it is possible to implement this metal mold | die test | inspection recording apparatus 100, 200 in the modified aspects as follows.
For example, the CPU 31 can be provided with a function as determination means for determining whether or not the mold 10 can be used. Specifically, what the CPU 31 recognizes as the pixel data obtained by imaging the minute unevenness inspection object S by the function of recognizing the minute unevenness inspection object S is predetermined in each combination image data CD1, CD2, CD3. When the number of continuous projections is several or more, it is determined that there is a minute unevenness inspection target S larger than the reference dimension on the concave lens molding surface 11, the fact is displayed on the display 50, and the determination result is recorded in the recording device 32. When the minute unevenness inspection target S is not a dust but a flaw, an inspector who has seen the determination result can easily determine that the mold 10 is unusable. On the other hand, if there is no minute uneven inspection object S larger than the reference dimension, the fact is displayed on the display 50 and recorded on the recording device 32.

  Further, the CPU 31 selects each of the image data A, B, C... Recorded in the recording device 32 according to whether or not there is data regarding the minute unevenness inspection target S based on the reference luminance, and the minute unevenness inspection. Image data A, B, C... Without data relating to the target S may be automatically deleted from the recording device 32. In this way, the load on the personal computer 30 can be reduced.

Furthermore, the image processing method for preventing the specific reflection area on the concave lens molding surface 11 from appearing on the display 50 described in the first embodiment is also applicable to the case where the CCD 29 acquires only one image data. Applicable. That is, the luminance value of the high-luminance continuous pixel data group of one image data captured by the CCD 29 is converted to 0 (correction value) to generate corrected image data, and the corrected image data and the related information are recorded in the recording device 32. And the image based on the corrected image data can be displayed on the display 50 in association with the related information.
Further, the mold inspection recording apparatuses 100 and 200 can be applied to inspection inspection of a mold for molding an object other than a lens, and further have a convex shape, a concave portion and a convex portion, etc. It can also be used for inspection recording of non-planar molding surfaces other than the concave shape (rotationally symmetric non-planar molding surfaces in the second embodiment).

Furthermore, even if the CCD 29 is replaced with a color CCD, the minute unevenness inspection object S can be clearly displayed on the display 50.
Further, by changing the input value from the keyboard 40 to the personal computer 30 and changing the signals from the personal computer 30 to the stepping motors M1, M2, CCD 29, and the light source 25, for example, the interval between the rotation angle α and the inclination angle θ of the light source 25. The angle may be changed to an angle other than 5 °.
Further, the stepping motor M2 and the power transmission mechanism DM2 may be omitted, and the inclination angle θ of the light source 25 may be changed manually.
Furthermore, the shape of the guide groove 24a may be changed to change the range of the inclination angle θ.
In addition, it goes without saying that numerical values (predetermined luminance value, number of continuous pixel data) for defining a high-luminance continuous pixel data group can be changed as necessary.

1 is a perspective view of an imaging apparatus according to a first embodiment of the present invention. It is a conceptual diagram of the whole structure of a metal mold | die inspection recording device. It is a perspective view of the metal mold | die with which light is irradiated from various angles. It is a schematic diagram which shows a mode that a light source goes around the periphery of a metal mold | die. It is a conceptual diagram for demonstrating the image processing which CPU performs. It is a schematic diagram of corrected image data. It is a schematic diagram of combined image data. It is a schematic diagram of the image data of the 2nd Embodiment of this invention. It is a schematic diagram of combined image data. It is a perspective view of the imaging device of the 3rd Embodiment of this invention. (A) It is a top view when the concave lens shaping | molding surface is seen from CCD when light is irradiated from relative irradiation position PA. (B) It is a top view when the concave lens shaping | molding surface is seen from CCD when light is irradiated from the relative irradiation position PB. (C) It is a top view when the concave lens shaping | molding surface is seen from CCD when light is irradiated from relative irradiation position PC. It is a schematic diagram of image data. It is a schematic diagram of combined image data.

Explanation of symbols

100 200 Mold inspection recording apparatus 10 Mold (test mold)
11 Concave lens molding surface (non-planar molding surface)
DESCRIPTION OF SYMBOLS 20 Image pick-up device 21 Base 22 Mold support stand 23 Annular rotation part 24 Arm part 24a Guide groove 25 Light source 25a Engagement pin 25b Output end face 26 Arm part 27 Case 28 Shooting lens 29 CCD (imaging element)
30 PC 31 CPU (image processing means)
32 Recording device (recording means)
33A 33B Cable 40 Keyboard 50 Display (display means)
60 Support metal fitting 61 Light shielding plate (light shielding means)
A B C image data (different direction image data)
CD1 CD2 CD3 Combination image data DM1 DM2 Power transmission mechanism M1 M2 Stepping motor PA PB PC Relative irradiation position of light source RAa RAb RAc Specific reflection area α Rotation angle θ Inclination angle

Claims (14)

A light source for irradiating the non-planar molding surface of the test mold with light;
An imaging device for imaging the non-planar molding surface from a specific direction;
In the image data picked up by the image sensor, the luminance value of the high-luminance continuous pixel data group in which a predetermined number or more of pixel data having a luminance value higher than a predetermined value is converted into a correction value that is lower than the predetermined value. Image processing means for generating corrected image data,
A mold inspection recording apparatus comprising: a display unit configured to display an image based on the corrected image data. In the mold inspection recording apparatus according to claim 1,
The light source is movable relative to the test mold, and irradiates the non-planar molding surface with light from a plurality of different relative irradiation positions.
Each of the imaging elements, when the light source is at the different relative irradiation position, respectively, images the non-planar molding surface from a specific direction;
The image processing means converts all the corrected different-direction image data generated by converting the luminance value of the high-luminance continuous pixel data group in all the different-direction image data captured by the imaging element into the correction value. Compared at the pixel level, the pixel data having the highest luminance is selected from the pixel data at the corresponding positions of the plurality of modified different-direction image data, and the combination of the selected highest luminance pixel data groups is combined image data. Produces
A mold inspection recording apparatus in which the display means displays an image based on the combined image data. The mold inspection recording apparatus according to claim 1 or 2,
The image processing means recognizes the high luminance continuous pixel data group in the image data or all the different-direction image data, and converts the recognized luminance value of the high luminance continuous pixel data group into the correction value. A mold inspection recording apparatus for generating the corrected image data or the corrected different-direction image data. In the mold inspection recording apparatus according to claim 2,
The non-planar molding surface is rotationally symmetric,
The image processing means recognizes the high-luminance continuous pixel data group in one different-direction image data, and recognizes the position of the recognized high-luminance continuous pixel data group and the relative irradiation at the time of capturing all the different-direction image data. Based on the position, the position of the high-brightness continuous pixel data group in the other different-direction image data is calculated, and the brightness values of all the high-brightness continuous pixel data groups are converted into the correction values. A mold inspection recording apparatus for generating different-direction image data. The mold inspection recording apparatus according to any one of claims 1 to 4,
A mold inspection recording apparatus in which the correction value is set to zero. A light source that is movable relative to the test mold and irradiates the non-planar molding surface of the mold from a plurality of different relative irradiation positions;
When the light source is at the different relative irradiation position, an imaging device that images the non-planar molding surface from a specific direction;
A light shielding means for preventing light reflected by a specific reflection area having a predetermined reflectance or more on the non-planar molding surface from being directed to the image sensor;
Compare all the different direction image data imaged by the image sensor at the pixel level, and select and select the pixel data with the highest luminance from the pixel data at the corresponding position of the plurality of different direction image data Image processing means for generating one combination image data by combining the highest luminance pixel data groups,
And a display unit for displaying an image based on the combined image data. In the mold inspection recording apparatus according to any one of claims 1 to 6,
A mold inspection recording apparatus comprising recording means capable of recording at least one of the image data, the different-direction image data, and the combined image data. An irradiation step of irradiating light to the non-planar molding surface of the test mold;
An imaging step of imaging the non-planar molding surface from a specific direction;
Modified image data obtained by converting the luminance value of a high-luminance continuous pixel data group in which pixel data having a luminance value higher than a predetermined value in a captured image data continues for a predetermined number or more to a correction value lower than the predetermined value A luminance value converting step for generating the image, and a display step for displaying an image based on the corrected image data,
A mold inspection recording method characterized by comprising: The mold inspection recording method according to claim 8,
The irradiation step is a step of irradiating light on the non-planar molding surface from a plurality of different relative irradiation positions by moving the light source relative to the test mold,
The imaging step is a step of imaging the non-planar molding surface, respectively, when the light source is at the different relative irradiation positions;
The luminance value conversion step is a step of generating the corrected different direction image data by converting the luminance value of the high luminance continuous pixel data group in all the captured different direction image data into the correction value,
Further, all the corrected different-direction image data are compared at the pixel level, and the pixel data having the highest luminance is selected from the pixel data at the corresponding positions of the plurality of corrected different-direction image data, and the selected highest luminance is selected. A combination step of generating one combination image data by combining pixel data groups;
A mold inspection recording method, wherein the display step is a step of displaying an image based on the combined image data. The mold inspection recording method according to claim 8 or 9,
The luminance value converting step recognizes the high luminance continuous pixel data group in the image data or all the different-direction image data, and converts the recognized luminance value of the high luminance continuous pixel data group into the correction value. A mold inspection recording method, which is a step of generating the corrected image data or the corrected different direction image data. The mold inspection recording method according to claim 9,
The non-planar molding surface is rotationally symmetric,
The luminance value conversion step recognizes the high-luminance continuous pixel data group in one different-direction image data, recognizes the position of the recognized high-luminance continuous pixel data group and the relative at the time of capturing all the different-direction image data. Based on the irradiation position, the position of the high-luminance continuous pixel data group in the other different-direction image data is calculated, the luminance values of all the high-luminance continuous pixel data groups are converted into the correction values, and A mold inspection recording method, which is a step of generating corrected different-direction image data. In the inspection recording method of the metal mold according to any one of claims 8 to 11,
A mold inspection recording method in which the correction value in the luminance value conversion step is set to zero. An irradiation step of moving the light source relative to the test mold and irradiating the non-planar molding surface of the mold with light from a plurality of different relative irradiation positions;
An imaging step of imaging the non-planar molding surface from a specific direction when the light source is at the different relative irradiation positions;
A light shielding step for preventing light reflected by the specific reflection area having a predetermined reflectance or higher on the non-planar molding surface from being directed to the image sensor;
Compare all the different direction image data imaged by the image sensor at the pixel level, and select and select the pixel data with the highest luminance from the pixel data at the corresponding position of the plurality of different direction image data An image processing step for generating one combination image data by combining the highest luminance pixel data groups, and a display step for displaying an image based on the combination image data;
A mold inspection recording method characterized by comprising: The mold inspection recording method according to any one of claims 8 to 13, further comprising:
A mold inspection recording method comprising a recording step of recording at least one of the image data, the different-direction image data, and the combined image data.

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