JP2009149416A - Incorrect collating inspection device equipped with maintenance informing means to bookbinding device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To specify a reason of the position deviation of a signature in an initial stage in which the signature starts deviation, and to carry out maintenance information of a bookbiding machine in early stage so as not to stop the bookbinding machine due to a simple position deviation of the signature, in an incorrect collating inspection device inspecting the presence/absence of incorrect collating by comparing image information shooting a printed article with image information of a proper printed article stored in a memory, where in the bookbiding machine is stopped to check the signature when incorrect collating occurs, and the bookbinding is stopped to cause the deterioration of productivity even in irregular gethering due to the simple position deviation of the signature. <P>SOLUTION: In an incorrect collating inspection means inspecting the presence/absence of incorrect collating by comparing the image information shooting the printed article with image information of the proper printed article stored in a memory, the incorrect collating inspection device analyzes the tendency of the position deviation of the signature 11 from the image information used for inspecting the incorrect collating, specifies the reason of the position deviation from the analyzed result, and carries out the maintenance information on the basis of the specified reason. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  This is a technique related to maintenance notification of a bookbinding apparatus performed based on random inspection data.

Conventionally, in the bookbinding process in which the signatures are stacked one after the other and then bound and cut, the stacking order of the signatures is out of order, the same signatures overlap, or the stacking is upside down. If you do this, you will get messed up.

Conventionally, as an inspection means for preventing such a typographical error, a typographical inspection that inspects whether or not there is a typographical error by comparing image information obtained by imaging a printed matter immediately before collation with image information of a regular printed matter stored in a memory. Although the means (refer to Patent Document 1) has been adopted, in the inspection means, even if the signature is misaligned or the signature is shifted from the predetermined position, an error is detected. Since the judgment was made, the production efficiency was lowered.
In addition, as a method for checking the misalignment with the measure against misalignment, it has been conventionally performed to perform an accurate signature inspection using a bar code regardless of the misalignment of the signature (see Patent Document 2).
JP-A-7-257065 JP-A-2005-47288

  As shown in Patent Document 1, when a typographical inspection device that detects the presence or absence of typographical characters in comparison with image information obtained by imaging a printed matter and image information of regular printed matter stored in a memory, Corresponding process to stop the machine and check the signature, and to continue the production and flow the error book to the end of the bookbinding line, and the error book discharging device is excluded from the bookbinding line according to the discharge timing set for each piece Processing has been performed conventionally.

  However, in the former case, the occurrence of an error due to the misalignment of the signature may occur accidentally, and often the cause of the disorder cannot be found even if the machine is stopped and the signature is confirmed. In that case, production will continue, and it will not be possible to judge that the position of the signature is misplaced until after a considerable number of error judgments have occurred, leading to a reduction in production efficiency. It was.

In the latter case, the error book ejecting device is excluded from the bookbinding line according to the ejection timing set for each frame, but it does not display the location or cause of the errored piece. It was not possible to identify the piece where the misalignment of the ditch occurred.
Therefore, a great deal of effort had to be taken to investigate the cause of the error and take countermeasures.

  In addition, in a typographical inspection apparatus using a bar code, since the bar code must be printed, the cost and labor thereof are great.

  In view of this, the present invention avoids a decrease in production efficiency due to an error determination due to a mere misalignment of the signature, so that the signature misalignment is detected from the displacement of the misalignment at the initial stage when the signature starts misalignment. The cause of the problem is identified, and the bookbinding machine maintenance based on the cause is notified.

The present invention is based on the elucidation that the mechanical cause of the positional deviation of the signature and the phenomenon have the following relationships (a) to (c).
That is,
(A). The rotational displacement of the signature is due to the collapse of the suction balance between the plurality of suction nozzles provided to suck the signature downward.
(I). The displacement of the signature in the direction perpendicular to the conveyance direction depends on the gripping force of the gripper that pulls out the signature.
(C). The displacement of the signature in the conveyance direction is due to the displacement of the signature setting position.

  Based on the relationship, the displacement of the inspected image obtained by imaging the inspected signature from the specified position in the inspection area where the inspected image should be displayed when there is no misalignment of the signature. Based on the factors (A) to (C), the mechanical maintenance of the bookbinding apparatus is notified according to the classification.

According to the present invention, since the tendency of the misalignment of the signature is analyzed from the image information used for the check of the collation and the cause of the misalignment of the signature can be determined based on the analysis result, the burden of investigating the cause is reduced.
Further, since the mechanical cause that causes the misalignment of the signature is notified in a timely manner, it is possible to reduce the frequency of error occurrence based on the simple misalignment of the signature.

Based on FIG. 1, FIG. 2, FIG. 3, the disorder checking apparatus and its operation will be described.
In FIG. 1, reference numeral 10 is a collating machine, reference numeral 11 is a signature, reference numeral 12-1 is a signature table, reference numeral 12-2 is a signature storage unit, reference numeral 13 is a rotary shaft, and reference numeral 14 is a rotary shaft. Drum installed, reference numeral 15 is a gripper for pulling out a signature, reference numeral 16 is a suction nozzle, reference numeral 17 is a starter for generating a timing signal, reference numeral 18 is a drive unit, reference numeral 19 is a conveying line, reference numeral 20 is a piece irregularity inspection device, reference numeral Reference numeral 21 denotes a CCD camera for imaging a signature, and reference numeral 22 denotes a frame control unit.

The collating machine 10 includes a rotating shaft 13 extending in the horizontal direction, a driving unit 18 that rotationally drives the rotating shaft 13, and a plurality of signature storage units 12-2 disposed on the signature table 12-1. Correspondingly, it is composed of a drum 14 and a conveying line 19 respectively arranged on the rotary shaft 13, and when the rotary shaft 13 is driven to rotate, the signature arranged in the signature storage section 12-2. 11 is pulled out one by one by the gripper 15 of the drum 14 and falls to the transport line 19.
The dropped signatures 11 are sequentially stacked as they are conveyed, and all the plurality of signatures are stacked in page order at the end of the collating machine 10.

  The piece random check inspector 20 is composed of a CCD camera 21 and a piece control unit 22. When the piece control unit 22 detects the timing signal from the starter 17 via the network, the piece control unit 22 controls the CCD camera 21 and extracts it. The captured signature 11 is imaged. Next, the captured inspected image is captured, the reference pattern image stored in the storage unit 22A is called, and the degree of coincidence (correlation) between the reference pattern image and the acquired inspected image is calculated and determined. The operation information including information related to the determination result and the inspected image information are stored in the storage unit 22A, and are output to the main randomness inspection device 30 via the network.

FIG. 2 is a schematic configuration diagram of a random inspection apparatus in the collating process.
The irregularity inspection device includes a piece irregularity inspection device 20 and a main randomness inspection device 30. The piece irregularity inspection device 20 is arranged corresponding to each drum 14, and each piece irregularity inspection device 20 includes a network, an I / O It is connected to the main random number controller 30 via the O terminal 30E.
The piece random check inspector 20 includes a CCD camera 21 and a piece control unit 22. The piece control unit 22 matches the storage means 22A, the display means 22B, the counter 22C, and the reference pattern image with the image to be inspected. (Correlation) determination means, CCD camera control means, operation information creation means, data input / output means, and piece control means 22D responsible for control of each means.

  On the other hand, the main irregularity inspector 30 controls the storage means 30A, the display means 30B, the input operation means 30C, and the respective means that store the inspected image data and operation information data transmitted from the piece irregularity inspector 20. The display unit 30D and the display unit 22B of the piece checker 20 have the same display function.

The display contents displayed when the display means 22B specifies the position deviation of the signature will be described with reference to FIG.
The XY coordinate axes are set with the center of the inspection image specified position □ where the inspection image is to be displayed when the position of the signature 11 is not blurred in the imaging screen captured by the CCD camera 21 of the random inspection device 20 as the origin. Based on the mechanical cause, the region sandwiched between the standard region as the misalignment range of the accidental signature 11 that does not depend on the mechanical cause of the collator 10 and the inspection region to be scanned for the image to be inspected. The initial position shift area of the signature 11 is set as a limit area. Then, the correlation coefficient γ (m, n) is equal to or greater than a predetermined value, that is, based on the XY coordinate position of the image to be inspected and the rotation angle displacement thereof, the center point of the image to be inspected is an arrowhead, The coordinate is displayed as an arrow having an inclination corresponding to the rotational angular displacement with the X axis as 0 degree.

The irregularity inspection will be described with reference to FIG.
Different signatures 11 are arranged in the signature storage section (12-2) arranged in plural on the signature table (12-1), and the suction nozzle 16 is synchronized with the rotation of the drum 14 with respect to the signature 11. The first signature 11 is sucked, and the signature 11 is bent downward and bent. The gripper 15 clamps the separated and bent signature 11 and rotates together with the drum 4, the gripper 15 releases the clamp on the conveying line 19 and drops the signature 11, and the dropped signature 11 is conveyed by a conveyance line. Since this operation is performed for each signature storage unit 12-2, the signatures are sequentially stacked as they are conveyed.
While the signature 11 is sandwiched between the gripper 15 and rotating together with the drum 4, the random signature inspection device 20 arranged for each signature is fed from the CCD camera 21 according to the timing signal from the starter 17. Whether or not the inspection image is taken in, and the correlation coefficient between the image to be inspected and the reference pattern image in the image is obtained, and whether or not the signature 11 is dropped in the wrong direction such as a signature drop, upside down or sideways If a check is detected as an error determination by the inspection, the bookbinding machine is stopped and a visual check or the like is performed.

FIG. 5 is an external view of the random inspection device 20 from which the CCD camera 21 is removed.
In FIG. 5, reference numeral 22-1 indicates a power switch for turning on / off the power of the disorder checker 20, reference numeral 22-2 indicates a stop switch for stopping output of the disorderly detection signal, and reference numeral 22-3 indicates a reference pattern image. A storage switch for instructing storage, reference numeral 22-4 is a mode switch set according to the state of the inspected image, such as whether the inspected image is text or shade, and reference numeral 22-5 is a history of the inspected image Is a history switch for displaying a reference numeral 22-6 is a direction switch for moving a selection range to search for a candidate for a reference pattern image, 22-7 is a decision switch for fixing various states, and 22-8 is fixed. A release switch for canceling various states, 22-9 is a speaker.

The display means 22B displays an image of the inspection area and display related items, and the specific display contents are as follows.
In the image of the inspection area, the standard area shown in FIG. 3, the limit area, and the arrow display as the pass determination result are displayed with the coordinate position and the inclination corresponding to the rotation angle displacement.

Items displayed as display-related items are “display selection”, “display count”, “scale”, and “color designation”, and specific display contents of the items are as follows.
In "Display selection", select and display what unit, for example, every lot or every predetermined time, or whether to display every lot and every predetermined time, and in "Display count", for example, In the case of every predetermined time, select and display how many times the result has been in the past, and in “Scale”, select and display the unit of the display scale, for example, dot unit or millimeter unit In “color designation”, for example, when selecting each lot, and simultaneously displaying the first and third times every two hours, or the current inspection result at the same time, color-coded display for each number of display times In addition, the standard area data and the limit area data are displayed in different colors.

The calculation of the correlation coefficient will be described with reference to FIG.
For example, as shown in FIG. 6, assuming that the inspection area B is vertical and horizontal b pixels and the reference pattern image A is vertical and horizontal a pixels, the correlation coefficient γ with the inspection pattern image B in the XY coordinates (m, n) of the inspection area B (M, n) is given as follows when image data A (i, j) of the reference pattern image A and image data B (m + i, n + j) of the pattern image B to be inspected.
The correlation coefficient γ (m, n) is the sum of A (i, j) × B (m + i, n−j) where i and j are 0 to (a−1). Multiplying the square root of the sum of squares i, j from 0 to (a-1) by the square of B (m + i, n + j) and the square root of the sum of i, j from 0 to (a-1). It is calculated based on the correlation calculation formula.
The correlation coefficient γ (m, n) is translated from the upper left corner of the inspection area B by one pixel in the X and Y directions as indicated by arrows in the reference pattern image A, and the correlation coefficient γ (m , N).
At this time, in order to cope with the rotational displacement of the pattern image B to be inspected, a predetermined number of images obtained by rotating the reference pattern A in advance by a predetermined rotation angle, for example, by 1 degree are stored as reference images.
Therefore, the correlation coefficient γ (m, n) of the pattern image B to be inspected is the maximum correlation coefficient γ (m, n) of the plurality of reference pattern images A. The correlation coefficient γ (m, n) And
Therefore, the rotation angle is the rotation angle of the reference pattern image A adopted as the maximum correlation coefficient γ (m, n).

The displacement of the signature and its mechanical cause will be explained with reference to Fig. 1 (a). When the suction force of the suction nozzle 16 is not balanced, the position of the gripper 15 is changed because the bending amount of the signature to be sucked is different.
Therefore, it is displaced in the direction orthogonal to the transport direction, that is, in the Y-axis direction.
(I). When the gripping force of the gripper is weak, if the one side is thick and heavy due to binding to the signature 11 as shown in the left signature storage section 12-2 in FIG. Since the applied left and right frictional forces are different, the gripper 15 cannot pull out the signature 11 uniformly, and the signature 11 is rotationally displaced.
(C). When setting the signature, when the stacked signatures are randomly protruding, or when placed at a position different from the original position, as shown in FIG. 1, α, the conveyance direction of the signature, That is, it is displaced in the X-axis direction.

Next, based on FIGS. 3 and 5, a description will be given of a process for identifying a mechanical cause that causes a misalignment of a signature.
When the limit area data number reaches the set number, the limit area data is called from the storage means 22A, and vector analysis is performed to determine the direction.
That is, the positional deviation of the signature 11 based on the mechanical cause shows a tendency that is different from the positional deviation of the signature that occurs accidentally even in the initial stage of the positional deviation. If it is in the X-axis direction, maintenance notification that there is a problem in signature setting is performed, and if the identification is in the Y-axis direction, maintenance notification that the suction force of the suction nozzle is unbalanced is performed.
In the case of the direction between the X and Y axes, both mechanical causes related to the X axis and the Y axis are assumed, so the setting of the signature and the suction force of the suction nozzle perform an unbalanced maintenance notification.
As the specifying process, a statistical process may be used instead of the vector analysis.

Also, the rotational angular displacement of the signature 11 is the same as the XY-axis coordinate position deviation. For example, +3 degrees to +5 degrees (−3 degrees to −5 degrees) is set as the limiting area. When the number of area data reaches the set number, the maintenance notification of insufficient gripping force of the gripper 15 is given regardless of the XY coordinate position.
Therefore, according to the example displayed on the display unit in FIG. 5, since the arrowheads are distributed in the Y-axis direction and the arrow tips are parallel to the Y-axis, it is determined that no rotational angular displacement has occurred, and the suction nozzle Maintenance notification that the suction force is unbalanced is performed.

Next, the operation processing of the present invention will be described based on the flowchart of FIG.
Step S1: Initial setting is performed.
Step S110: A part of the signature is selected as the reference pattern, and the image information of the rectangular pattern is stored as the reference pattern image information.
Step S120: A correlation coefficient is set as a criterion for determining whether or not to make an error determination as a clutter.
Step S130: A standard area is set that is not caused by deterioration or malfunction of the mechanical elements of the bookbinding apparatus, although the misalignment of the signature occurs accidentally.
Step S140: A limit region is set in which the cause of the misalignment of the signature is considered to be the deterioration or malfunction of the mechanical elements of the bookbinding apparatus.
Step S150: The number of image data to be inspected required for specifying the cause of the misalignment of the signature, that is, the limit area data number that is data in the limit area is set.
Step S2: Capture the inspection image Step S3: Obtain the correlation coefficient between the captured image information of the inspection image and the reference pattern image information.
Step S4: It is determined whether or not the correlation coefficient obtained in Step S3 is greater than or equal to the correlation coefficient set in Step S120. If the determination result is NO or less than the correlation coefficient set, an error in Step S10 The process is performed, and the process returns to step S2. On the other hand, if the determination is YES, the process proceeds to step S5.
Step S5: Depending on whether the XY coordinate position and the rotation angle of the image to be inspected belong to the standard area or the limit area, the coordinate position and the rotation angle are stored in the storage means as standard area data and limit area data. Remember.
Step S6: The unit amount is expanded with the XY coordinate position as the arrowhead for each image to be inspected, an arrow having an inclination corresponding to the rotation angle is displayed on the display means, and the process proceeds to Step S7 and Step S11.
Step S7: It is determined whether or not the rotational angular displacement representing the arrow inclination in step S6 is within the limit region. If the determination result is NO determination in the standard region, the process returns to step S2, and YES determination is in the limit region. Advances to step S8.
Step S8: It is determined whether or not the limit area data number is equal to or greater than the set number. If NO is determined not to exceed the set number, the process returns to Step S2, and if YES is determined to be greater than the set number, the process proceeds to Step S9. Notify the gripper adjustment to pull out.
Step S11: It is determined whether or not the XY coordinate position representing the arrowhead in step S6 is within the limit region. If the determination result is NO determination in the standard region, the process returns to step S2, and if YES is determined in the limit region. Proceed to step S12.
Step S12: It is determined whether or not the limit area data number is equal to or greater than the set number. If NO is determined not to exceed the set number, the process returns to step S2, and if YES is determined to be greater than the set number, the process proceeds to step S13.
Step S13: An XY coordinate direction specifying process using the limit data of the set number is performed.
Step S14: Notifying the setting position adjustment of the signature and the adjustment of the suction balance of the suction nozzle in the X-axis direction or the Y-axis direction based on the result of the specific process in step S13.

According to the above embodiment, the following effects can be obtained.
As the inspection data used to determine the misalignment of the signature 11, the maintenance notification is performed using only the inspected image of the inspected image and the limit area data in the limit area where the mechanical cause is suspected. , Maintenance of mechanical malfunction can be performed early.
Therefore, errors due to mechanical causes do not continue, and the frequency of machine stoppage is reduced, so that the efficiency is increased.

As a modification,
(A). Only the imaging means may be provided in the piece random inspection device 20 provided for each collating piece, and all the control may be performed by the main random detector 30 connected to each random piece detector 20 through a network.
(I). The XY coordinate position and rotation angle displacement display of the image to be inspected displayed on the display means may be displayed in different colors depending on whether they are in the standard area or in the limit area.
(C). As shown in FIG. 8, instead of the arrow display, a circular display is performed at the XY coordinate position of the image to be inspected, the circle is divided into two, one is assigned to the coordinate position, and the other is assigned to the rotational displacement. Whether it belongs to the limit area or the limit area may be displayed by color classification.
(D). The maintenance item to be notified is one of the adjustment of the suction balance of the suction nozzle, the adjustment of the gripper for pulling out the signature, the setting position of the signature, or any combination thereof. You may select suitably according to characteristics, such as an inspection screen.
(E). Whether or not maintenance notification is made regarding the XY coordinate position and rotation angle displacement of the inspection image belonging to the limit area may be determined based on statistical processing, for example, statistical values such as mode values and standard deviations.

The collation process and the schematic block diagram of the disorder | damage | failure check apparatus arrange | positioned there. Schematic configuration diagram of random inspection equipment Imaging screen by imaging means of random inspection device Side view of the collating piece in FIG. Appearance of the random inspection system with the imaging means removed Explanatory diagram for obtaining correlation coefficient The flowchart figure which shows the operation | movement process of this invention (A). Main flow diagram (B). Initial setting subroutine in step S1 The figure which shows the circular display example of XY coordinate position, a limit area | region, or a standard area | region of a to-be-inspected image. Overall view (B). Enlarged view of circular display

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Collating machine 11 Signature 12-1 Folding stand 12-2 Collating accommodation part 13 Rotating shaft 14 Drum 15 Gripper 16 Suction nozzle 17 Starter 18 Drive part
19 Conveyance Line 20 Topology Check Machine 21 CCD Camera 22 Top Control Unit 22-1 Power Switch 22-2 Stop Switch 22-3 Storage Switch 22-4 Mode Switch 22-5 History Switch 22-6 Direction Switch
22-7 determination switch 22-8 release switch 22A storage means 22B display means 22C counter 22D piece control means 23 I / O terminal 30 main disorder checker 30A storage means 30B display means 30C input operation means 30D main control means 30E I / O Terminal

Claims (7)

An image pickup means, a display means, a storage means, a notification means, an image analysis means, a correlation coefficient calculation / judgment means, a randomness control means for controlling each means, etc., and an image to be inspected and a reference imaged by the image pickup means In the random order inspection device that performs the pass / fail determination of the signature by the correlation coefficient with the pattern image,
The irregularity control means uses the specified position where the inspected image captured by the imaging means should be displayed on the display means as the XY coordinate origin with the signature conveyance direction as the X axis to the correlation coefficient calculation / determination means. The XY coordinate position of the image to be inspected that has been determined to pass is obtained, and whether the coordinate position belongs to a standard area or a limit area that is recognized as a cause of mechanical malfunction is discriminated and stored as standard area data and limit area data. And the coordinate position is displayed on the display means, and when the limit area data reaches the set number, the limit area data of the set number is specified by the XY coordinate axis direction specifying process of the image analysis means. An irregularity inspection device that notifies bookbinding machine maintenance items such as adjusting the setting position of each signature and adjusting the suction balance of the suction nozzle based on the direction displacement and the Y-axis direction displacement. An image pickup means, a display means, a storage means, a notification means, an image analysis means, a correlation coefficient calculation / judgment means, a randomness control means for controlling each means, etc., and an image to be inspected and a reference imaged by the image pickup means In the random order inspection device that performs the pass / fail determination of the signature by the correlation coefficient with the pattern image,
The irregularity control means uses the specified position where the inspected image captured by the imaging means should be displayed on the display means as the XY coordinate origin with the signature conveyance direction as the X axis to the correlation coefficient calculation / determination means. The XY coordinate position of the image to be inspected and the rotation angle displacement of the image to be inspected are determined, and each of the coordinate position and the rotation angle displacement belongs to the standard area, or is a limit area that is recognized to be caused by a mechanical malfunction. Is stored in the storage means as standard area data and limit area data, and the coordinate position and rotation angle displacement are displayed on the display means. When the limit area data at the XY coordinate position reaches a set number, the image is displayed. Based on the X-axis direction displacement or the Y-axis direction displacement specified by the XY coordinate axis direction specifying process of the analysis means, the setting position of the signature or the suction balance of the suction nozzle is adjusted. And notifying Maintence matters, and if the limit region data of the rotational angular displacement reaches a set number, to inform the binding machine maintenance items such as adjustment of the gripper to withdraw the signature, erratic pagination inspection apparatus.   The display unit according to claim 1 or 2, wherein the display means displays the standard area data and the limit area data in different colors.   4. The XY coordinate axis direction specifying process according to claim 1 is a random inspection apparatus using vector analysis.   The XY coordinate axis direction specifying process according to claim 1 is a random inspection apparatus using statistical processing.   6. The random number inspection device according to claim 1, wherein the random order control means is a distributed processing type or a centralized processing type.   The coordinate position and rotation angle displacement display according to claim 2 is an irregularity inspection apparatus in which the XY coordinates of the image to be inspected are arrowheads and the rotation angle displacement is an arrow display having a rotation angle with respect to the X axis of the XY coordinates.

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