JP2007005062A - Manufacturing method of spark plug - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a spark plug capable of stabilizing the form of an earth electrode after provisionally bending for each work in a provisional bending process for provisionally bending the earth electrode to a housing. <P>SOLUTION: The torsion of the earth electrode 13 is defined as the state of a chip bonding face 13c when the end face side 10a of the housing 10 is looked from the other end side of the earth electrode, tilting from a state vertically crossing a straight line connecting the center of the sectional face of the earth electrode 13 in a direction vertical to a center electrode axial line Z1 and the center electrode axial line Z1 and bonded to the end side 10a of the housing 10. In a second vertical direction Y, the larger the torsion of the earth electrode 13 becomes, the farther a searcher 81 is positioned from the earth electrode 13 for each work and the provisional bending of the earth electrode 13 is conducted by pressing the earth electrode 13 to the searcher 81 from the opposite side of a center electrode 12 by a bend punch 90. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a spark plug to be assembled in an internal combustion engine mounted on an automobile or the like.

  In the conventional spark plug, a columnar center electrode is insulated and held inside the housing, one end of the ground electrode is joined to one end surface of the housing, the middle part of the ground electrode is bent, and the other end of the ground electrode is the center electrode. It is arrange | positioned facing the front end surface. A ground electrode side tip is bonded to the ground electrode at a location facing the center electrode, and an intermediate portion of the ground electrode is bent so that the ground electrode side tip faces the center electrode. A spark gap is formed between the central electrode. Hereinafter, the surface of the ground electrode where the ground electrode side chip is bonded is referred to as a chip bonding surface.

Such a ground electrode is processed so that the spark gap is slightly larger than the standard in a temporary bending process performed after one end of the ground electrode is joined to the housing. Specifically, in the temporary bending step, first, a searcher that serves as a guide for temporary bending of the ground electrode is fixed at a predetermined position. Thereafter, the temporary bending punch is pressed from the anti-chip bonding surface side of the ground electrode toward the center electrode side, whereby the ground electrode is bent at the intermediate portion, the ground electrode is pressed against the searcher, and the searcher is removed. Thus, the ground electrode is processed into a substantially L shape by provisional bending (see, for example, Patent Document 1).
JP 2000-164320 A

  However, in the conventional technique, the ground electrode is temporarily bent in the temporary bending process regardless of the twist of the ground electrode. Here, the torsion of the ground electrode means that when one end of the ground electrode is joined to one end surface of the housing and the one end surface side of the housing is viewed from the other end of the ground electrode, it is perpendicular to the long axis of the housing. This indicates a state where the chip joint surface does not intersect perpendicularly to a straight line connecting the center of the cross section of the ground electrode and the long axis of the housing in any direction.

  That is, even if there is a work (spark plug) in which the ground electrode is twisted, the searcher is arranged and fixed at the same position with respect to any work. Therefore, the work with the larger twist of the ground electrode is less likely to bend the ground electrode. As a result, the springback amount (bending return amount) of the temporarily bent ground electrode differs between the case where the twist of the ground electrode is large and the case where the twist is small, and the shape of the temporarily bent ground electrode is different for each workpiece. It becomes unstable.

  In view of the above, the present invention provides a spark plug manufacturing method capable of stabilizing the shape of a ground electrode after temporary bending for each workpiece in a temporary bending step of temporarily bending the ground electrode joined to a housing. The purpose is to do.

  In order to achieve the above object, according to the present invention, in the provisional bending step, the searcher (81) increases in the twist of the ground electrode (13) for each workpiece in the direction (Y) orthogonal to the center electrode axis (Z1). , 82) are arranged away from the ground electrode.

  As described above, when the ground electrode is largely twisted, the searcher is arranged away from the ground electrode according to the amount of twist. Thereby, the ground electrode can be easily bent, and even if the ground electrode is greatly twisted, the springback amount of the ground electrode during temporary bending can be reduced. Therefore, the amount of spring back can be made substantially the same regardless of the twist of the ground electrode, and the shape of the ground electrode after provisional bending for each workpiece can be made almost the same shape. As described above, the shape after provisional bending can be stabilized in each workpiece.

  The present invention obtains each reflection line width of the first reflection line (310) and the second reflection line (320) shown in the photographed image in the provisional bending process for the ground electrode bonded to the housing, Based on the difference between the reflection line widths, a temporary bending correction value corresponding to the torsional magnitude of the ground electrode is obtained. Then, the searcher (81, 82) is placed away from the ground electrode so as to face the front end surface of the center electrode based on the temporary bending correction value, and the ground electrode is temporarily bent.

  In this way, the ground electrode is photographed, and the twist of the ground electrode is obtained from the photographed image, and a provisional bending correction value corresponding to the magnitude of the twist of the ground electrode is obtained. Then, the searcher is arranged away from the ground electrode according to the provisional bending correction value, and the ground electrode is temporarily bent by pressing the ground electrode against the searcher. Thereby, even if the ground electrode is largely twisted and joined to the housing, the difference in the springback amount of the ground electrode for each workpiece can be reduced. That is, regardless of the amount of twist of the ground electrode, the amount of springback can be made substantially constant for each workpiece, and the shape after temporary bending can be stabilized in each workpiece.

  The present invention relates to the coordinates of the first edge (E1) that is the boundary between the first background and the first reflection line, the coordinates of the second edge (E2) that is the boundary between the first reflection line and the imaging surface, and imaging. Obtaining the coordinates of the third edge (E3), which is the boundary between the surface and the second reflection line, and the coordinates of the fourth edge (E4), which is the boundary between the second reflection line and the second background, respectively; The reflection line width A of the first reflection line is obtained using the coordinates at the first edge and the second edge, the reflection line width B of the second reflection line is obtained using the coordinates at the third edge and the fourth edge, The provisional bending correction value is obtained based on the difference between the reflection line width A and the reflection line width B.

  As described above, in order to obtain the reflection line widths A and B of the first and second reflection lines shown in the image, the coordinates of the boundaries (edges) between the background and the imaging surface and the first and second reflection lines are determined. get. Then, the reflection line widths A and B of the first and second reflection lines are obtained by obtaining the difference between the coordinates of each edge. By such a method, the reflection line width A of the first reflection line corresponding to the surface opposite to the chip bonding surface and the reflection line width B of the second reflection line corresponding to the chip bonding surface can be easily obtained. The provisional bending correction value can be obtained by obtaining the difference between the reflection line widths A and B.

  It can be said that the larger the difference between the reflection line widths A and B, the larger the ground electrode is twisted and joined to the housing, and the larger the temporary bending correction value.

  According to the present invention, in the step of temporarily bending the ground electrode, when the temporary bending correction value exceeds the threshold value, the searcher is disposed away from the ground electrode by a distance corresponding to the temporary bending correction value, and the temporary bending correction value is When the threshold value is not exceeded, the searcher is arranged at a normal position.

  In this way, a threshold value is provided for the temporary bending correction value, and the searcher is arranged according to whether or not the temporary bending correction value exceeds this threshold value. At this time, if the provisional bending correction value exceeds the threshold value, the searcher is disposed away from the ground electrode by a distance corresponding to the provisional bending correction value. As a result, the ground electrode can be bent easily, and the amount of springback that occurs when the ground electrode is temporarily bent in a twisted state can be made to be approximately the same as when the ground electrode is not twisted. it can.

  The present invention is characterized in that, in the step of obtaining a temporary bending correction value, a plurality of windows (W1 to W4) are provided in an image, and the coordinates of the first to fourth edges are respectively acquired in these windows.

  As described above, a window (designated region) is provided in the image, and the coordinates of the edge are respectively acquired in the window. Thereby, since it is only necessary to search for an edge only in the window in the image, the acquisition efficiency of the coordinates of each edge can be improved.

  In addition, the code | symbol in the bracket | parenthesis of each said means shows the correspondence with the specific means as described in embodiment mentioned later.

(First embodiment)
Hereinafter, a first embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is a front view showing a spark plug manufactured by the manufacturing method of the present invention in a half section. As shown in FIG. 1, the spark plug 1 has a substantially cylindrical housing 10 made of a conductive steel material. The housing 10 has a substantially cylindrical insulator made of a ceramic having a high insulation property. 11 is inserted and fixed. A substantially cylindrical center electrode 12 made of a conductive metal material is inserted and fixed in the shaft hole 11 a of the insulator 11. One end surface 10a of the housing 10 is joined to one end side of a plate-like ground electrode 13 made of a Ni-based alloy, and the other end side of the ground electrode 13 is made of a circle made of, for example, an Ir (iridium) alloy having excellent spark wear resistance. A columnar noble metal tip 14 is joined.

  The ground electrode 13 is a straight plate member as indicated by a broken line before the temporary bending, and extends in the direction of the axis Z1 of the center electrode 12. Further, the ground electrode 13 is processed into a substantially L shape by provisional bending, and further bent to process the spark gap G into a predetermined dimension as shown by the solid line in FIG. In other words, the ground electrode 13 has a leg portion 13a extending substantially parallel to the center electrode axis Z1 and a facing portion 13b extending in a direction substantially orthogonal to the center electrode axis Z1, and the noble metal tip 14 is the center electrode 12. A predetermined spark gap G is formed between the noble metal tip 14 and the center electrode 12 in the direction of the center electrode axis Z1.

  In the present embodiment, the surface of the ground electrode 13 before temporary bending where the noble metal tip 14 is bonded is referred to as a chip bonding surface 13c, and the surface of the ground electrode 13 before temporary bending where the noble metal tip 14 is not bonded (that is, The surface opposite to the chip bonding surface 13c) is referred to as an anti-chip bonding surface 13d. The above is the configuration near the center electrode 12 of the spark plug 1 manufactured by the manufacturing method of the present invention.

  In the present embodiment, in order to manufacture the spark plug 1, a preparatory processing device is used to stabilize the shape of the temporary bending of the ground electrode 13 for each work (spark plug 1). This preparatory processing apparatus detects the twist of the ground electrode 13 joined to the one end face 10a of the housing 10 for each work, and obtains a temporary bending correction value corresponding to the amount of the twist for each work. This temporary bending correction value is used when the ground electrode 13 is temporarily bent.

  Here, the twist of the ground electrode 13 is a direction perpendicular to the center electrode axis Z1 when the one end face 10a side of the housing 10 is viewed from the other end side of the ground electrode 13 in the spark plug 1 shown in FIG. The chip joint surface 13c does not intersect perpendicularly to the straight line connecting the center of the cross section of the ground electrode 13 and the center electrode axis Z1.

  Hereinafter, a preparatory processing apparatus is demonstrated with reference to FIG. 2 and FIG. FIG. 2 is a schematic front view of a preparatory processing apparatus used in a preparatory stage before temporary bending of the ground electrode 13. FIG. 3 is a plan view of the preparatory processing apparatus shown in FIG.

  As shown in FIG. 2, the preparation processing apparatus includes first and second illuminations 21 and 22, a slit plate 30, a camera 40, an image processing device 50, and a control device 60. ing.

  The first and second illuminations 21 and 22 illuminate a work (spark plug 1) fixedly held by a holder (not shown) with the spark gap G portion facing upward. As such 1st, 2nd illuminations 21 and 22, white LED (light emitting diode) is employ | adopted, for example. Each of the illuminations 21 and 22 is provided with a diffusion plate on each light irradiation surface, and the LED light is scattered by the diffusion plate, so that a wide range is illuminated.

  Such 1st, 2nd illuminations 21 and 22 are arrange | positioned at V shape, as FIG. 3 shows. Specifically, the light irradiation surfaces of the respective illuminations 21 and 22 are opposed to each other, and among the illuminations 21 and 22, the first illumination 21 illuminates at least the anti-chip bonding surface 13d of the ground electrode 13 in the workpiece, The second illumination 22 illuminates at least the chip joint surface 13c of the ground electrode 13 on the workpiece. And the angle formed when each extension line of each light irradiation surface cross | intersects in FIG. 3 is 60 degrees-90 degrees, for example.

  Each of the illuminations 21 and 22 is installed in a range where the distance between the farthest place from the work and the center electrode 12 of the work is, for example, 140 to 160 mm on each light irradiation surface.

  The slit plate 30 is for preventing light emitted from the respective illuminations 21 and 22 from entering the camera 40. Such a slit plate 30 is disposed between the work fixed to a holder (not shown) and the camera 40. In the slit plate 30, for example, a φ31 hole 31 is provided at a position facing the camera 40. The slit plate 30 is painted, for example, in black so as not to reflect light on the surface.

  The camera 40 photographs the ground electrode 13 of the workpiece through the hole 31 of the slit plate 30, and a CCD camera, for example, is employed. Such a camera 40 is provided with a close-up ring (for example, 50 mm), and a lens (for example, a lens length of 43 mm) is fixed to the close-up ring. In this embodiment, the camera 40 having a resolution of, for example, 512 × 480 pixels, a visual field (V × H) of, for example, about 6.0 mm × about 6.5 mm, and a resolution of, for example, about 0.0126 mm / pix is used. It is done. The camera 40 corresponds to the photographing means of the present invention.

  In this camera 40, an intermediate portion of the ground electrode 13 of the workpiece, that is, a portion that will be temporarily bent is photographed. Then, an image signal of an image taken by the camera 40 is output to the image processing device 50. The camera 40 is movable in the vertical direction, and is arranged at an optimal position for taking an image.

  As shown in FIG. 3, the illuminations 21 and 22, the workpiece, the slit plate 30, and the camera 40 are arranged in the order of the camera 40, the slit plate 30, the workpiece, and the first and second illuminations 21 and 22. In addition, the center of the hole 31 of the slit plate 30, the center of the cross section perpendicular to the center electrode axis Z 1 in the ground electrode 13, and the intersection of each extension line of each light irradiation surface of each illumination 21, 22 are the major axis of the camera 40. Arranged above each.

  In the present embodiment, the shooting direction of the camera 40 orthogonal to the center electrode axis Z1 is the first orthogonal direction X, and the direction orthogonal to both the center electrode axis Z1 and the first orthogonal direction X is the second orthogonal direction Y. (See FIG. 3).

  The image processing device 50 obtains a correction amount (that is, a temporary bending correction value) for the position of the searcher when the ground electrode 13 of the workpiece is temporarily bent based on the image signal of the image input from the camera 40. . Therefore, the image processing apparatus 50 can recognize the positions of the center electrode 12 and the ground electrode 13 displayed in the image by coordinates.

  Such an image processing apparatus 50 includes a ROM, a RAM, a CPU, a temporary bending correction value calculation program for calculating a correction at the time of temporary bending of the workpiece ground electrode 13, and various arithmetic expressions and data. An I / O port (both not shown) is provided. The provisional bending correction value obtained by the image processing device 50 is output to the control device 60. The image processing device 50 corresponds to the image processing means of the present invention.

  The control device 60 has a function of moving the position of the searcher used when the workpiece ground electrode 13 is temporarily bent based on the data of the temporary bending correction value input from the image processing device 50. Similar to the image processing device 50, the control device 60 has a ROM, a RAM, a CPU, and an I / O port (all illustrated) in which various arithmetic expressions and data, a program for operating the driving device, and the like are stored. Not)).

  In the present embodiment, since the provisional bending correction value is a coordinate value, the coordinates used in the image processing device 50 and the control device 60 are common.

  Hereinafter, a temporary bending apparatus for temporarily bending the workpiece ground electrode 13 will be described with reference to FIGS. 4 and 5. FIG. 4 is a schematic plan view of a temporary bending apparatus for temporarily bending the ground electrode 13 of the workpiece. This temporary bending apparatus is for processing a workpiece based on this temporary bending correction value when the preliminary bending correction value is obtained by the above-mentioned preliminary processing apparatus. The preliminary bending apparatus shown in FIGS. A workpiece is held while being held by a holder (not shown).

  As shown in FIG. 4, the temporary bending apparatus is disposed so as to face the two searchers 81, 82 arranged facing the center electrode 12 and the ground electrode 13, and the anti-chip bonding surface 13 d of the ground electrode 13. And a columnar temporary bending punch 90 to be configured.

  The two searchers 81 and 82 are mounted on the searcher block 100 so as to be relatively movable in the first orthogonal direction X, and the temporary bending punch 90 is mounted on the common block 101 so as to be relatively movable in the second orthogonal direction Y. Has been. The searcher block 100 is mounted on the common block 101 so as to be relatively movable in the second orthogonal direction Y.

  The searcher block 100 is driven in the second orthogonal direction Y by a searcher Y-axis drive device 83 fixed to the common block 101.

  The first searcher 81 is driven in the first orthogonal direction X by the first searcher X-axis drive device 84 fixed to the searcher block 100, and the second searcher 82 is driven to the second searcher X-axis fixed to the searcher block 100. The device 85 is driven in the first orthogonal direction X. The temporary bending punch 90 is driven in the second orthogonal direction Y by a temporary bending punch driving device 91 fixed to the common block 101.

  When the temporary bending is performed, the tip portions 81a and 82a on the ground electrode 13 side of the two searchers 81 and 82 are brought into contact with the chip bonding surface 13c, and grounded from the anti-chip bonding surface 13d side by the temporary bending punch 90. By pressing the electrode 13, the ground electrode 13 is pressed against the surfaces 81b and 82b of the searchers 81 and 82 opposite to the center electrode (hereinafter referred to as surfaces opposite to the center electrode).

  In addition, the two searchers 81 and 82 are provided with relief portions 81c and 82c for avoiding interference with the insulator 11 and the center electrode 12 when performing temporary bending, and with the noble metal tip 14 when performing temporary bending. Notches 81d and 82d are formed to avoid interference.

  FIG. 5 is a view of the temporary bending apparatus for temporarily bending the ground electrode 13 shown in FIG. 4 as viewed from the first orthogonal direction X. As shown in FIG. 5, the common block 101 is divided into two, and one block is inclined so that the temporary bending punch 90 moves in an oblique direction with respect to the center electrode axis Z1. .

  Specifically, as shown in FIG. 5, the common block 101 includes a first common block 103 and a second common block 104 that are driven by the block Z-axis drive device 102 in the direction of the center electrode axis Z <b> 1. It is comprised by what was couple | bonded so that relative rotation was possible.

  Further, the angle of the second common block 104 with respect to the first common block 103 is adjusted by a block rotation driving device 106 fixed to the first common block 103. A searcher Y-axis drive device 83 and a temporary bending punch drive device 91 are fixed to the second common block 104.

  Further, the second common block 104 is inclined with respect to the center electrode axis Z1. Therefore, the temporary bending punch 90 moves in an oblique direction with respect to the center electrode axis Z1. More specifically, the temporary bending punch 90 moves in the direction of the center electrode axis Z1 and closer to the tip surface 12a of the center electrode 12 with the movement in the direction Y orthogonal to the center electrode axis Z1. .

  Each of the drive devices 83, 84, 85, 91, 102, 106 of the temporary bending apparatus is provided with a servo motor or a hydraulic / pneumatic cylinder, and operates according to a command from the control device 60. It has become.

  The above is an apparatus used for a temporary bending process, and its structure, when manufacturing the spark plug 1 which concerns on this embodiment.

  Next, in the method for manufacturing the spark plug 1 shown in FIG. 1, a step of temporarily bending the ground electrode 13 using the above-described apparatus will be described.

  First, a method of detecting a twist of the ground electrode 13 joined to the housing 10 and obtaining a provisional bending correction value for provisional bending according to the twist of the ground electrode 13 will be described with reference to FIGS. To explain. FIGS. 6A and 6B show the contents of detecting the twist of the ground electrode 13 after the ground electrode 13 is joined to the housing 10 and determining the provisional bending correction value at the time of provisional bending according to the twist. It is the flowchart which showed. FIG. 6B is a flowchart subsequent to FIG.

  The flowchart shown in FIGS. 6A and 6B is executed according to the temporary bending correction value calculation program stored in the image processing apparatus 50, and the ground electrode 13 is joined to the housing 10 in FIGS. As shown in FIG. 3, the operation is started in a state of being fixedly held by a holder (not shown) of the preparatory processing apparatus.

  In step 200, initialization is performed. That is, data such as previously obtained coordinates and provisional bending correction values are cleared.

  In step 201, an image is input. Specifically, as shown in FIGS. 2 and 3, the anti-chip bonding surface 13d of the ground electrode 13 of the workpiece is illuminated by the first illumination 21, and the chip bonding surface of the ground electrode 13 is illuminated by the second illumination 22. 13c is illuminated. When the workpiece is illuminated by the respective illuminations 21 and 22 as described above, the ground electrode 13 of the workpiece is photographed by the camera 40. Then, image data of an image photographed by the camera 40 is input to the image processing device 50.

  FIG. 7 shows an image of the ground electrode 13 taken by the camera 40 of the preparatory processing apparatus. In the present embodiment, dark portions in the image are expressed by point hatching. As shown in FIG. 7, among the two reflection lines 310 and 320 extending in the vertical direction in the drawing, the first reflection line 310 is due to the light of the first illumination 21 reflected by the anti-chip bonding surface 13 d. The second reflection line 320 is due to the light of the second illumination 22 reflected by the chip bonding surface 13c. The photographing surface 330 sandwiched between the white lines 310 and 320 is perpendicular to the chip joint surface 13c (or the anti-chip joint surface 13d) and perpendicular to the one end surface 10a of the housing 10 and faces the camera 40. It was taken.

  In the image shown in FIG. 7, the dark area on the left side of the first reflection line 310 (that is, the side facing the anti-chip bonding surface 13d) is the dark area on the right side of the first background 341 and the second white line (that is, the side opposite to the anti-chip bonding surface 13d). The center electrode 12 side of the chip bonding surface 13c) shows the second background 342.

  In the present embodiment, the lower left of the image shown in FIG. 7 is the origin (0, 0) of the image, and the direction perpendicular to the first reflection line 310 (or the second reflection line 320 or the imaging surface 330) is set. A direction parallel to the x axis and the first reflection line 310 (or the second reflection line 320 or the imaging surface 330) (that is, a direction perpendicular to the x axis) is defined as the y axis.

  In step 202, the first window W1 is set. Specifically, as shown in FIG. 7, a predetermined range is set in the y-axis direction, and a range including at least the first reflection line 310, the imaging surface 330, and the second reflection line 320 in the x-axis direction. A first window W1 formed by setting is stretched in the image. In the first window W1, the range set in the x-axis direction includes a part of the first background 341, the first reflection line 310, the imaging surface 330, the second reflection line 320, and a part of the second background 342. It is included. Such a first window W1 is a detection range for detecting each surface of the ground electrode 13 in the subsequent steps.

  The first window W1 is stored in advance in the image processing device 50 as coordinates (that is, four coordinates) constituting the first window W1, and after image data of an image is input to the image processing device 50 in this step, The first window W1 is formed by setting the coordinates constituting the first window W1 therein. The windows formed below are the same.

  In step 203, a command for detecting the first edge E1 is issued. Specifically, in the first window W1, the boundary between the first background 341 and the ground electrode 13, that is, the boundary between the first background 341 and the anti-chip bonding surface 13d (first reflection line 310) of the ground electrode 13 is present. It is detected. That is, in the first window W1, a boundary where a dark part (first background 341) in the figure changes to a bright part (first reflection line 310) is detected, and the coordinates (x1, y1) of the boundary are detected. The

  Thus, by providing the first window W1 in the image and acquiring the coordinates of the first edge E1 in the first window W1, the first edge E1 only in the first window W1 in the image. Therefore, the acquisition efficiency of the coordinates of the first edge E1 can be improved.

  In this step, when the boundary between the dark part and the bright part in the figure is not detected and the coordinates are not detected, it is determined that the coordinates are not detected and the process proceeds to the next step. The same applies to each step of detecting the boundary shown below.

  In step 204, it is determined whether or not the first edge E1 is detected. That is, in this step, the presence / absence of the coordinates of the first edge E1 is determined. When it is determined in step 203 that the coordinates of the first edge E1 are not detected, the process proceeds to step 205 shown in FIG. On the other hand, if it is determined in step 203 that the coordinates of the first edge E1 have been detected, the process proceeds to step 206.

  In step 205, error processing is performed. That is, the reason why the coordinates of the first edge E1 are not detected in the step 204 is that the ground electrode 13 of the work is not normally photographed in the step 201 or the ground electrode 13 is not normally joined in the work. Cases can be considered. Therefore, in this step, a process of obtaining a temporary bending correction value and a process of canceling the temporary bending process based on the temporary bending correction value are performed on such a workpiece. By this error processing, the workpiece fixed and held in the preparatory processing apparatus shown in FIGS. 2 and 3 is removed from the preparatory processing apparatus. And this flowchart is complete | finished, another workpiece | work is attached to a preparation processing apparatus, and the flow shown by FIGS. 6-1 and 6-2 is performed again.

  In step 206, the second window W2 is set. That is, as shown in the drawing of FIG. 7, the same range is set in the same location as the first window W1 in the y-axis direction, and a range including at least the first reflection line 310 is set in the x-axis direction. Thus, the second window W2 formed is stretched in the image. In the second window W2, the range set in the x-axis direction includes a part of the first background 341, the first reflection line 310, and a part of the imaging surface 330.

  In step 207, a detection command for the second edge E2 is issued. In this step, as in step 203, the boundary between the first reflection line 310 and the imaging surface 330, that is, the anti-chip bonding surface 13d and the anti-chip bonding surface 13d is perpendicular to and opposed to the camera 40 in the second window W2. A boundary with the surface is detected. Specifically, in the second window W2, a boundary where a bright part (first reflection line 310) in the drawing changes to a dark part (imaging plane 330) is detected, and the coordinates (x2, y1) of the boundary are detected. Detected.

  In step 208, it is determined whether or not the second edge E2 has been detected. In this step, the same processing as in step 204 is performed. If it is determined in step 207 that the coordinates of the second edge E2 have not been detected, the process proceeds to step 205 shown in FIG. 6-2, and error processing is performed as described above. On the other hand, if it is determined in step 207 that the coordinates of the second edge E2 have been detected, the process proceeds to step 209 shown in FIG.

  In step 209 shown in FIG. 6B, the third window W3 is set. FIG. 8 shows an image of the ground electrode 13 taken by the camera 40 of the preparatory processing apparatus, and shows the same image as that shown in FIG. In FIG. 8, the first and second windows W1 and W2 are omitted. As shown in FIG. 8, the same range is set in the same place as the first and second windows W1 and W2 in the y-axis direction, and at least the imaging surface 330, the second reflection line 320, and the second reflection line in the x-axis direction. A third window W3 formed by setting a range including the two backgrounds 342 is stretched in the image.

  In step 210, a third edge detection command is issued. In this step, as in the above steps 203 and 207, in the third window W3, the boundary between the imaging surface 330 and the second reflection line 320, that is, the surface perpendicular to the anti-chip bonding surface 13d and facing the camera 40, and the chip. A boundary with the joint surface 13c is detected. That is, in the third window W3, a boundary where a dark part (imaging plane 330) in the drawing changes to a bright part (second reflection line 320) is detected, and the coordinates (x3, y1) of the boundary are detected. .

  In step 211, it is determined whether or not the third edge E3 is detected. In this step, the same processing as in steps 204 and 208 is performed. If it is determined in this step that the coordinate of the third edge E3 has not been detected, the process proceeds to step 205, where error processing is performed as described above. On the other hand, if it is determined in this step that the coordinates of the third edge E3 are detected, the process proceeds to step 212.

  In step 212, the fourth window W4 is set. In this step, the same range is set in the same location as the first to third windows W1 to W3 in the y-axis direction, and at least the imaging surface 330, the second reflection line 320, and the second background 342 are in the x-axis direction. A fourth window W4 formed by setting the included range is stretched in the image (see FIG. 8).

  As shown in FIG. 8, the fourth window W4 set in this step is set to have a narrower range than the third window W3 in the x-axis direction of the image.

  In step 213, a detection command for the fourth edge E4 is issued. In this step, as in the above steps 203, 207, and 210, the boundary between the second reflection line 320 and the second background 342, that is, the boundary between the chip joint surface 13c and the second background 342 is set in the fourth window W4. Detected. That is, in the fourth window W4, a boundary where a bright part (second reflection line 320) in the drawing changes to a dark part (second background 342) is detected, and the coordinates (x4, y1) of the boundary are detected. The

  In step 214, it is determined whether or not the fourth edge E4 has been detected. In this step, processing similar to that in steps 204, 208, and 211 is performed. If it is determined in this step that the coordinates of the fourth edge E4 have not been detected, the process proceeds to step 205, where error processing is performed as described above. On the other hand, if it is determined in this step that the coordinates of the fourth edge E4 are detected, the process proceeds to step 215.

  In step 215, the thickness of the first reflection line 310 (that is, the reflection line width A) is calculated. Specifically, this will be described with reference to FIG. FIG. 9 is a diagram showing the edges E1 to E4 detected in the above steps shown in FIGS. 6-1 and 6-2 respectively drawn in the image shown in FIG. .

  As described above, since the coordinates of the edges E1 and E2 are detected, the thickness of the first reflection line 310 in the x-axis direction can be obtained. The thickness of the first reflection line 310 can be obtained by obtaining the difference between the x-coordinates of the first and second edges E1 and E2. That is, the thickness of the first reflection line 310 is x2-x1. In the present embodiment, this x2-x1 is defined as A.

  In step 216, the thickness (reflection line width B) of the second reflection line 320 is calculated. Similar to the above step, the thickness of the second reflection line 320 is obtained by calculating the difference between the x-coordinates of the third and fourth edges E3 and E4. That is, the thickness of the second reflection line 320 is x4-x3. In the present embodiment, this x4-x3 is defined as B.

  In step 217, a temporary bending correction value is calculated. This provisional bending correction value is a value for moving each searcher 81, 82 from the normal position to the opposite side to the ground electrode 13 in the second orthogonal direction Y when the ground electrode 13 is provisionally bent by the provisional bending apparatus. It corresponds to (coordinate value). That is, the searchers 81 and 82 are arranged away from the ground electrode 13 according to the provisional bending correction value.

  In the present embodiment, the provisional bending correction value is calculated by an arithmetic expression | A−B | / 2. Here, | A−B |, which is a numerator, indicates the difference in the absolute value of the thickness of each of the reflection lines 310 and 320, and the larger this value is, the greater the twist of the ground electrode 13 is. . The provisional bending correction value is obtained by setting | A−B | / 2.

  It should be noted that the denominator “2” in the arithmetic expression for obtaining the provisional bending correction value is obtained experimentally. Further, by obtaining the temporary bending correction value as an absolute value, a common result can be obtained whether the twisting of the ground electrode 13 shown in FIG. 3 is clockwise or counterclockwise. In other words, in this embodiment, the greater the amount of twist of the ground electrode 13, the farther the searchers 81 and 82 are from the ground electrode 13, so the direction of twist is not a problem.

  The temporary bending correction value obtained in this step is output from the image processing device 50 to the control device 60. Thus, the process for obtaining the temporary bending correction value shown in FIGS. 6-1 and 6-2 is completed.

  Next, the temporary bending process performed based on the temporary bending correction value obtained by the image processing apparatus 50 will be described. When the provisional bending correction value is obtained by the image processing apparatus 50, the workpiece is attached to the provisional bending apparatus as shown in FIGS.

  Thereafter, it is determined whether or not the temporary bending correction value input to the control device 60 exceeds a threshold value. If the temporary bending correction value does not exceed the threshold value, it is determined that the ground electrode 13 is hardly twisted. Thus, the searchers 81 and 82 are fixed at regular locations, and the ground electrode 13 is temporarily bent.

  This threshold value is set in advance to a value that can be said that the ground electrode 13 is twisted according to the value of the provisional bending correction value. Therefore, when the provisional bending correction value exceeds this threshold, it can be said that the ground electrode 13 is twisted and joined to the housing 10.

  When the temporary bending correction value input to the control device 60 does not exceed the threshold value, each drive is performed in accordance with a command from the control device 60 in a state where the workpiece is fixedly held as shown in FIGS. The devices 83-85, 102, 106 are activated and the searchers 81, 82 are moved to a predetermined location. After this state, the provisional bending punch driving device 91 is activated, and the provisional bending punch 90 is pressed against the anti-chip bonding surface 13 d of the ground electrode 13. Further, when the temporary bending punch 90 is pressed, the intermediate portion of the ground electrode 13 is bent, and the chip joint surface 13 c of the ground electrode 13 is pressed against the surfaces 81 b and 82 b on the side opposite to the center electrode of the searchers 81 and 82. Thus, the ground electrode 13 is temporarily bent.

  On the other hand, when the provisional bending correction value input to the control device 60 exceeds the threshold value, it is determined that the ground electrode 13 is twisted, and the searchers 81 and 82 are moved from the regular locations to temporarily provision the ground electrode 13. Bending is performed. In such a case, each searcher 81, 82 is moved from the normal position to the side opposite to the ground electrode 13 by the value of the provisional bending correction value. That is, as the provisional bending correction value is larger, the searchers 81 and 82 are further away from the ground electrode 13. This is shown in FIG. FIG. 10 is a diagram showing how the searcher 81 is moved by the provisional bending correction value.

  As shown in FIG. 10, the searcher 81 (not shown in FIG. 10, but the searcher 82 is also the same) is moved away from the ground electrode 13 by the provisional bending correction value in the second orthogonal direction Y from the normal place. Moved in the direction. Thereafter, as described above, the temporary bending punch 90 is pressed against the ground electrode 13 and temporarily bent.

  At this time, the ground electrode 13 is joined to the housing 10 in a twisted state. However, since the searchers 81 and 82 are moved away from the ground electrode 13, each side surface (that is, the chip joint surface 13 c) in the intermediate portion of the ground electrode 13. And a large bending stress is not applied to a surface perpendicular to the one end surface 10a of the housing 10. Thereby, the amount of spring back in the ground electrode 13 is reduced, and the shape of the ground electrode 13 temporarily bent in each workpiece can be stabilized.

  As described above, in this embodiment, the searchers 81 and 82 are arranged away from the ground electrode 13 according to the amount of twist of the ground electrode 13. Thereby, even if the ground electrode 13 is joined to the housing 10 in a twisted state, the ground electrode 13 can be easily bent. Therefore, the difference in the amount of spring back caused by the different temporary bending conditions can be reduced for each workpiece. In this way, the amount of springback can be made substantially the same for each workpiece regardless of the twist of the ground electrode 13, and the shape of the ground electrode 13 after temporary bending for each workpiece can be made almost the same. it can. As described above, the shape after provisional bending can be stabilized in each workpiece.

  Further, a threshold value is provided for the temporary bending correction value for correcting the arrangement position of the searchers 81 and 82, and the searcher is arranged depending on whether or not the temporary bending correction value exceeds this threshold value. . That is, when the provisional bending correction value exceeds the threshold value, the searchers 81 and 82 are arranged away from the ground electrode 13 by a distance corresponding to the provisional bending correction value (corresponding to coordinates in this embodiment). Thereby, the ground electrode 13 that has become difficult to bend due to being twisted and joined to the housing 10 can be easily bent.

(Other embodiments)
Each device shown in the above embodiment shows an example, and the configuration and the like are not limited to this.

  In the said embodiment, although each illumination 21 and 22 is arrange | positioned in V shape in FIG. 3, another arrangement | positioning form may be sufficient.

  In the above embodiment, the flowcharts shown in FIGS. 6A and 6B are examples, and the flow for obtaining the provisional bending correction value is not limited to this.

  The calculation formula for the provisional bending correction value in the above embodiment shows an example, and the present invention is not limited to this. That is, the provisional bending correction value may be obtained based on another arithmetic expression.

  In the above embodiment, the provisional bending correction value is obtained by the image processing device 50, but the image processing device 50 acquires only the thickness information of each reflection line 310, 320 and outputs the information to the control device 60. However, the provisional bending correction value may be obtained by the control device 60.

  The steps shown in each figure correspond to means for executing various processes.

It is a front view which shows the spark plug manufactured by the manufacturing method of this invention in a half section. It is a typical front view of the preparatory processing apparatus used in the preparatory stage before performing temporary bending of a ground electrode. It is a top view of the preparatory processing apparatus shown by FIG. It is a typical top view of the temporary bending apparatus for temporarily bending the ground electrode of a workpiece | work. FIG. 5 is a view of a provisional bending apparatus that performs provisional bending of the ground electrode shown in FIG. 4 as viewed from a first orthogonal direction X. It is the flowchart which showed the content which calculates | requires the temporary bending correction value in the case of temporary bending. It is a flowchart following FIG. It is the figure which showed the image of the ground electrode image | photographed with the camera of the preparatory processing apparatus shown by FIG. 2 and FIG. It is the figure which showed the same image as the image shown by FIG. It is the figure which showed what each detected edge E1-E4 was each drawn in the image shown by FIG. It is the figure where a mode that the searcher was moved by the temporary bending correction value was shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Housing, 10a ... One end surface, 12 ... Center electrode, 12a ... Front end surface,
13 ... Ground electrode, 13c ... Chip joint surface, 13d ... Anti-chip joint surface,
14 ... Precious metal tip, 21, 22 ... First and second lighting, 40 ... Camera,
50 ... Image processing device, 60 ... Control device, 81, 82 ... Searcher, 90 ... Bending punch,
310, 320 ... first and second reflection lines, 330 ... photographing surface,
341, 342 ... 1st, 2nd background, E1-E4 ... 1st-4th edge,
X: first orthogonal direction, Y: second orthogonal direction, Z1: axis of the center electrode.

Claims (5)

A columnar center electrode (12) is insulated and held inside the housing (10), one end of the ground electrode (13) is joined to one end face (10a) of the housing, and a columnar noble metal tip is connected to the other end of the ground electrode. (14) is joined, and the ground electrode is a linear plate member extending in the direction of the axis (Z1) of the center electrode before provisional bending, and the other end side of the ground electrode is in relation to the center electrode axis A spark plug manufacturing method in which the noble metal tip is provisionally bent to an angle substantially perpendicular to the tip end surface (12a) of the center electrode,
The searcher (81, 82) is arranged to face the tip surface of the center electrode, and the ground electrode is pressed against the searcher from the side opposite to the center electrode by using a temporary bending punch (90). A provisional bending process for provisionally bending the ground electrode;
In the ground electrode, a surface to which the noble metal chip is bonded is defined as a chip bonding surface (13c), and when the one end surface side of the housing is viewed from the other end side of the ground electrode, The ground electrode is in a state where the chip joint surface is tilted from a state where it intersects perpendicularly with respect to a straight line connecting the center of the cross section of the ground electrode and the center electrode axis in a perpendicular direction. Is defined as the twist of
In the temporary bending step, in the direction (Y) orthogonal to the central electrode axis, the searcher is disposed farther from the ground electrode as the twist of the ground electrode is larger for each workpiece. Plug manufacturing method. A columnar center electrode (12) is insulated and held inside the housing (10), one end of a ground electrode (13) is joined to one end face (10a) of the housing, and a columnar noble metal tip is connected to the other end of the ground electrode. (14) is joined, and the ground electrode is a straight plate member extending in the direction of the axis (Z1) of the center electrode before the temporary bending, and the other end of the ground electrode is the center in the temporary bending step. A spark plug manufacturing method in which the noble metal tip is temporarily bent to an angle substantially perpendicular to an electrode axis, and the noble metal tip is disposed to face the tip surface (12a) of the center electrode,
In the ground electrode, a surface to which the noble metal chip is bonded is defined as a chip bonding surface (13c), and when the one end surface side of the housing is viewed from the other end side of the ground electrode, The ground electrode is in a state where the chip joint surface is tilted from a state where it intersects perpendicularly with respect to a straight line connecting the center of the cross section of the ground electrode and the center electrode axis in a perpendicular direction. Is defined as the twist of
A first illumination (21) for illuminating a surface (13d) opposite to the chip joint surface of the ground electrode, a second illumination (22) for illuminating the chip joint surface of the ground electrode, and the ground Photographing means (40) for photographing a portion of the electrode where the ground electrode is temporarily bent, and a provisional bending correction value corresponding to the twist of the ground electrode based on an image photographed by the photographing means. Have the required preparatory processing equipment,
The temporary bending step includes
Illuminating the ground electrode with the first illumination and the second illumination, and photographing the surface of the ground electrode perpendicular to the chip joint surface and perpendicular to the one end surface of the housing with the photographing means;
The reflection line width of the first reflection line (310) shown in the image photographed by the photographing means and reflected by the surface opposite to the chip joint surface, and the first illumination light, The reflection line widths of the second reflection lines (320) resulting from the reflection of the light of the second illumination at the chip joint surface are respectively obtained, and the provisional bending according to the twist of the ground electrode based on the difference between the reflection line widths. Obtaining a correction value;
In the direction (Y) perpendicular to the center electrode axis, the searchers (81, 82) are arranged for each workpiece on the basis of the provisional bending correction value and facing the tip surface of the center electrode away from the ground electrode. A step of temporarily bending the ground electrode by pressing the ground electrode against the searcher from a side opposite to the center electrode using a temporary bending punch (90). Manufacturing method of spark plug. In the image, there is a surface between the first reflection line and the second reflection line that is perpendicular to the chip joint surface of the ground electrode and perpendicular to one end surface of the housing and faces the imaging unit. Shown as the imaging plane (330),
In the image, an area photographed on the opposite side to the photographing surface in the first reflection line is defined as a first background (341), and an area photographed on the opposite side to the photographing surface in the second reflection line. When the second background (342) and the direction perpendicular to the first reflection line is defined as the x-axis,
In the step of obtaining the temporary bending correction value,
A boundary between the first background and the first reflection line as a first edge (E1), and obtaining coordinates of the first edge in the x-axis direction;
Obtaining a second edge (E2) as a boundary between the first reflection line and the imaging surface, and obtaining coordinates of the second edge in the x-axis direction;
A boundary between the imaging surface and the second reflection line is defined as a third edge (E3), and the coordinates of the third edge in the x-axis direction are obtained;
A boundary between the second reflection line and the second background is a fourth edge (E4), and the coordinates of the fourth edge in the x-axis direction are obtained;
Using each coordinate in the x-axis direction at the first edge and the second edge to determine a reflection line width A of the first reflection line;
Using each coordinate in the x-axis direction at the third edge and the fourth edge to determine a reflection line width B of the second reflection line;
The method for producing a spark plug according to claim 2, further comprising a step of obtaining the provisional bending correction value based on a difference between the reflection line width A and the reflection line width B. In the step of temporarily bending the ground electrode, a threshold value for the temporary bending correction value is provided, and when the temporary bending correction value exceeds the threshold value, the ground electrode is orthogonal to the central electrode axis. In the direction, the searcher is disposed away from the ground electrode by a distance corresponding to the temporary bending correction value, and when the temporary bending correction value does not exceed the threshold value, the searcher is disposed at a normal position. The method for manufacturing a spark plug according to claim 2 or 3, wherein: The step of obtaining the provisional bending correction value includes providing a plurality of windows (W1 to W4) in the image, and acquiring the coordinates of the first to fourth edges in each of the windows. Or the manufacturing method of the spark plug of 4.

Images