JP2014107177A - Fitting state inspection method, and fitting state inspection device of connector - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fitting state inspection method and a fitting state inspection device of a connector which can efficiently and accurately inspect a fitting state of a connector connecting a cable.SOLUTION: A fitting state inspection method of a connector 42 includes: an imaging step in which light is irradiated to a claw part 43a and a locking piece 44a in a state in which an insertion body 43 and a fitting body 44 are connected, and the insertion body 43 and the fitting body 44 are imaged with cameras 21a, 21b (equivalent to imaging devices); an image processing step in which a contrast image pattern showing contrast of reflection light is created from the image captured in the imaging step; and a determination step in which an inclination state of the locking piece 44a is detected on the basis of the contrast image pattern created in the image processing step to determine whether or not the connector 42 is normally fitted on the basis of the inclination state.

Description

  The present invention relates to a fitting state inspection method and a fitting state inspection device for inspecting a fitting state of a connector.

In an assembly work process of a vehicle engine or the like, a plurality of wires are connected by a connector. If the connector is not fully mated, not only will it cause assembly failures, but it will also lead to product quality degradation.
For this reason, whether or not the connector has been properly fitted is determined by checking whether there is a “click” sound during the connector fitting operation, visually confirming the “claw engagement”, etc. It is carried out at joint points.

By the way, although it differs from the method of confirming the fitting state of a connector, for example, in Patent Document 1, a hose is inserted into a vehicle tube and an assembled state when these connecting portions are fixed with clips is inspected. A method is disclosed.
In this inspection method, the connection portion between the tube and the hose is imaged with a camera, the density level is scanned with respect to the piping image M of the captured image, and the position coordinates of the spool portion and the tip end of the hose that are the enlarged diameter portion of the tube , And the dimension L1 from the spool portion to the tip of the hose is measured.
Further, the density level is scanned with respect to the piping image M, and the position coordinates of the tip of the hose clip are detected. And the dimension L2 from the front-end | tip of a hose to the front-end | tip of a hose clip is measured. Thereafter, if the dimensions L1 and L2 are within a preset allowable range, the appearance inspection is accepted.

JP 2001-82928 A

  However, the above-mentioned sound confirmation, visual confirmation method for confirming the fitting state of the connector is performed in a narrow work space under the environment of the inspection line where various work sounds are generated. It is difficult to perform reliably for all connectors. For this reason, it is difficult to ensure sufficient reliability of the fitting confirmation, and it takes time for the visual confirmation work, which hinders improvement in work efficiency.

  Further, in the inspection method described in Patent Document 1, since the distance between the connection portion of the tube and the hose and the camera is different for each photographing, that is, for each vehicle to be inspected, the dimensions are determined according to the distance between the connection portion and the camera. L1 and L2 must be corrected. Since the determination is performed based on the corrected value, there is a problem that the reliability of the determination result is low.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a connector fitting state inspection method and a fitting state inspection device that can efficiently and accurately inspect the fitting state of connectors that connect cables.

The connector fitting state inspection method according to the present invention that solves the above-described problems includes an insert having a claw projecting outward, and the claw that passes over the claw when the insert is inserted. A fitting state inspection method for a connector comprising a fitting body having a locking piece that engages with and prevents the insertion body from coming off.
An imaging step of irradiating light to the claw portion and the locking piece in a state where the insertion body and the fitting body are connected, and imaging the insertion body and the fitting body with an imaging device;
An image processing step of creating a grayscale image pattern indicating the density of reflected light from the captured image captured in the imaging step;
A determination step of detecting an inclined state of the locking piece based on the grayscale image pattern created in the image processing step and determining whether the connector is normally fitted based on the inclined state. And.

According to the connector fitting state inspection method, the inclination state of the locking piece is detected on the basis of the gray image pattern indicating the density of the reflected light of the light irradiated to the connected insertion body and the fitting body. In addition, since it is determined whether or not the fitting state between the insertion body and the fitting body is normal based on the detected result, it is not necessary to perform correction or the like based on the distance between the connector and the imaging device that has been conventionally performed. . For this reason, the fitting state of the connector can be inspected with high accuracy.
In addition, the imaging process, the image processing process, and the determination process can be performed in a short time using a computer such as a PC. For this reason, the sound confirmation work at the time of fitting and the visual confirmation work of the fitting state which have been performed by humans can be omitted. Thereby, the work efficiency of inspection can be improved.

The imaging step includes
Radial direction imaging processing for irradiating light at a right angle to the surface of the fitting body having the locking piece and imaging the insertion body and the fitting body with an imaging device from the light irradiation direction;
An axial imaging process is performed in which light is applied in parallel to the surface of the fitting body having the locking piece, and the insertion body and the fitting body are imaged by an imaging device from the irradiation direction of the light. It is good as well.

Conventionally, even when the inserted body and the mated body are imaged, the amount of light is insufficient, or the shadow of other parts such as a wire harness is captured, and the inserted body and the mated body are clearly imaged. However, in the present invention, since the imaging is performed from the axial direction and the radial direction, the insertion body and the fitting body can be reliably imaged from at least one direction.
In addition, when the locking piece is normally engaged with the claw, that is, when the connector is in an abnormal state, the reflected light reflected by the locking piece is input to the imaging device, so that the gray image pattern Is represented in white. On the other hand, when the locking piece is not normally engaged with the claw part, that is, when the connector is in an abnormal state, the reflected light reflected from the locking piece is not input to the imaging device. Represented in black. Thereby, the fitting state of a connector can be easily confirmed by the difference in light and shade.

The determination step includes
A diameter for comparing whether the inclination state of the locking piece matches the radial normal inclination condition of the locking piece set in advance as normal based on the image captured in the radial imaging process. Direction comparison processing,
An axis for comparing whether or not the inclination state of the locking piece matches the axial normal inclination condition of the locking piece set in advance as normal based on the image captured in the axial imaging process And a direction comparison process,
The comparison state of at least one of the comparison results of the radial direction comparison process and the axial direction comparison process may be determined to be normal in the connector.

In this way, whether or not the fitting state of the insertion body and the fitting body matches the normal condition of connector fitting based on the captured image is compared for each direction, and the comparison result in at least one direction Since it is determined that the fitting state between the insertion body and the fitting body is normal when the two match, the fitting state of the connector can be accurately confirmed.
And since it determines with the fitting state of an insertion body and a fitting body being normal based on the captured image of at least any one direction of an axial direction or radial direction, the insertion body and fitting body are imaged clearly. It is possible to prevent the inspection line from stopping due to the absence. Thereby, when an inspection line stops, a worker can go to an inspection location and work such as work can be saved. Therefore, the work efficiency of inspection can be improved.

The radial direction comparison process
The white portion corresponding to the locking piece of the gray image pattern created in the image processing step is a white portion corresponding to the locking piece of the pass image pattern set in advance as a normal gray image pattern; It is also possible to execute image confirmation processing for confirming whether or not they match.

  Thus, since it is confirmed whether the white part corresponding to a locking piece corresponds with a pass image pattern, the comparison result by radial direction can be derived | led-out accurately.

The radial direction comparison process
Insert base end detection processing for detecting a coordinate position of the base end of the insert in the captured image;
A fitting body tip detection process for detecting a coordinate position in the captured image of the tip of the fitting body;
A calculation process for calculating a distance from the proximal end of the insertion body to the distal end of the fitting body from position coordinates respectively detected by the insertion body proximal end detection process and the fitting body distal end detection process;
A distance confirmation process for confirming whether or not the distance calculated by the calculation process is within a prescribed range defined in advance;
When the result of the image check process matches and the check result of the distance check process is within the specified range, the fitting state of the insert and the fitting matches the radial normal condition. It may be a thing.

  In this way, when the white portion corresponding to the locking piece matches the acceptable image pattern and the distance from the base end of the insert to the tip of the fitting is within the specified range, the insert and fitting Since the fitting state matches with the normal condition in the radial direction, the comparison result in the radial direction can be accurately derived.

The axial direction comparison process
A measurement process for measuring the area of the black portion where the shade of the engaging portion between the locking piece and the claw portion in the gray image pattern created in the image processing step is;
An area confirmation process for confirming whether or not the area of the black portion measured by the measurement process is less than a predetermined value,
When the confirmation result by the area confirmation process is less than the specified value, the fitting state between the insertion body and the fitting body may match the normal axial condition.

  Thus, when the area of the black region in the gray image pattern of the engagement portion between the claw portion of the insert and the locking piece of the fit is within the specified range, the fit between the insert and the fit Therefore, the comparison result in the axial direction can be accurately derived.

The imaging device is mounted on a robot provided on the side of an inspection line of an assembly target constructed by connecting the insertion body and the fitting body,
The robot moves the imaging device to a predetermined position where the insertion body and the fitting body can be imaged based on connection position information between the insertion body and the fitting body that is set in advance. Then, the insertion body and the fitting body may be imaged.

  In this way, by instructing the robot with the imaging positions of the different inserts and fittings depending on the model of the object, it is possible to flexibly cope with the connector fitting state inspection even in a multi-model mixed line.

A connector fitting state inspection device according to the present invention that solves the above-described problems includes an insert having a claw protruding outwardly, and the claw that moves over the claw when the insert is inserted. A fitting state inspection device for a connector comprising a fitting body having a locking piece that engages with and prevents the insertion body from coming off,
An imaging device that irradiates light to the claw portion and the locking piece in a state where the insertion body and the fitting body are connected, and images the insertion body and the fitting body,
Image processing means for creating a grayscale image pattern indicating the density of reflected light from a captured image captured by the imaging device;
A determination unit that detects an inclined state of the locking piece based on the grayscale image pattern created by the image processing unit and determines whether or not the connector is normally fitted based on the inclined state. And.

According to the connector fitting state inspecting apparatus of the present invention, the inclination state of the locking piece is detected based on the gray image pattern showing the density of the reflected light of the light irradiated to the inserted body and the fitting body in the connected state. In addition, in order to determine whether or not the fitting state of the insertion body and the fitting body is normal based on the detected result, it is necessary to perform correction or the like based on the distance between the connector and the imaging device that has been conventionally performed There is no. For this reason, the fitting state of the connector can be inspected with high accuracy.
In addition, the imaging process, the image processing process, and the determination process can be performed in a short time using a computer such as a PC. For this reason, the sound confirmation work at the time of fitting and the visual confirmation work of the fitting state which have been performed by humans can be omitted. Thereby, the work efficiency of inspection can be improved.

  ADVANTAGE OF THE INVENTION According to this invention, the fitting state inspection method and fitting state inspection apparatus of the connector which can test | inspect the fitting state of the connector which connects a cable efficiently and correctly can be provided.

It is a perspective view which shows the connector fitting state test | inspection apparatus and engine test line which concern on embodiment of this invention. It is a top view which shows the connector fitting state test | inspection apparatus and engine test line which concern on embodiment of this invention. It is a perspective view explaining the insertion body and fitting body which comprise the connector which concerns on embodiment of this invention. It is a block diagram of a connector fitting state inspection device concerning an embodiment of the present invention. It is explanatory drawing of the pass pattern of the connector fitting state of radial direction, (a) is a top view, (b) shows AA sectional drawing of (a), (c) shows a pass pattern. It is explanatory drawing of the failure pattern of the connector fitting state of radial direction, (a) is sectional drawing, (b) shows a failure pattern. It is explanatory drawing of the pass pattern of the connector fitting state of an axial direction, (a) is sectional drawing, (b) shows a pass pattern. It is explanatory drawing of the failure pattern of the connector fitting state of an axial direction, (a) is sectional drawing, (b) shows a failure pattern. It is a flowchart explaining the fitting state inspection method of the connector which concerns on this invention. It is a flowchart explaining the comparison method of the grayscale image pattern and radial image pattern of a radial direction which concern on this invention. It is a flowchart explaining the comparison method of the grayscale image pattern of an axial direction which concerns on this invention, and a pass image pattern.

  Hereinafter, the present invention will be described in detail with reference to embodiments shown in the drawings. However, the dimensions, materials, shapes, relative arrangements, and the like of the component parts described in this embodiment are not intended to limit the scope of the present invention to that unless otherwise specified. In the following embodiment, a case where an ignition coil connector is used will be described. However, the present invention is not limited to the ignition coil, and can be applied to other connectors.

FIG. 1 is a perspective view showing a connector fitting state inspection device and an engine inspection line according to an embodiment of the present invention.
As shown in FIG. 1, the final stage of the production line 12 of the engine 11 (corresponding to an assembly object) is called a dress-up line 13 in which a wiring harness, various pipes, etc. are assembled to the engine 11. Inside, an inspection line 14 for inspecting the fitting state of the connector is provided, and a connector fitting state inspection device 20 is installed in the inspection line 14.

The inspection line 14 includes a conveyor 16 having a plurality of rollers and a plurality of pallets 17 (only one is shown in the figure) that is transported on a predetermined track on the conveyor 16, and each pallet 17 has a different model. It is a multi-model mixed line in which the engines 11 are placed in a state where each engine 11 is positioned.
In the inspection line 14, each pallet 17 and the engine 11 are temporarily stopped for inspection of the fitting state of the connector 42 in the middle of a constant flow.

  The connector fitting state inspection device 20 illuminates two cameras (corresponding to imaging devices) 21a and 21b that capture the fitting state of the connectors, and these cameras 21a and 21b, respectively, to illuminate a connector as an imaging target. An illuminating lamp 22, arm-type robots 23a and 23b arranged on both sides of the inspection line 14 to support the cameras 21a and 21b and the illuminating lamp 22, respectively, and the pallet 17 between the robots 23a and 23b. A pallet sensor 25 that detects various positions and acquires various information of the engine 11 placed on the pallet 17, and an inspection process that controls the robots 23a and 23b and performs an inspection process based on images captured by the cameras 21a and 21b. Device 26.

  The cameras 21a and 21b are provided on the robots 23a and 23b, respectively. The cameras 21a and 21b respectively image the connector from the radial direction and the axial direction (the radial direction and the axial direction will be described later).

  In addition, a safety fence 35 is provided to surround the inspection line 14, the cameras 21a and 21b, the illumination lamp 22, and the robots 23a and 23b. The safety fence 35 also serves as a disturbance light prevention fence that prevents external light from entering the cameras 21a and 21b and the imaging target.

FIG. 2 is a plan view showing the connector fitting state inspection device 20 and the inspection line 14 of the engine 11 according to the embodiment of the present invention.
As shown in FIG. 2, the robots 23a and 23b are arranged on both sides of the inspection line 14, and the cameras 21a and 21b attached to the tips of the robots 23a and 23b are independent while the pallets 17 and the engine 11 are temporarily stopped. Then, it moves to a different predetermined position in the vicinity of the engine 11 (a position determined for each model of the engine 11), and the connector is imaged by the cameras 21a and 21b.

FIG. 3 is a perspective view illustrating an insertion body and a fitting body constituting the connector according to the embodiment of the present invention.
As shown in FIG. 3, the connector 42 of the ignition coil 41 includes an insertion body 43 having a claw portion 43 a protruding outward, and a fitting body 44 having a locking piece 44 a engageable with the claw portion 43 a. It is equipped with.
When the insertion body 43 is inserted from the insertion port 44e of the fitting body 44, after the locking piece 44a of the fitting body 44 gets over the claw portion 43a, the claw portion 43a is engaged in the hole 44d of the locking piece 44a. This prevents the insert 43 from slipping out. The locking piece 44a is movable outward so as to be able to get over the claw portion 43a, and is formed of a synthetic resin.
In this specification, as shown in FIG. 3, the direction in which the fitting body 44 is inserted into or removed from the insertion body 43 is referred to as the axial direction. A direction perpendicular to the axial direction is referred to as a radial direction.
In the present embodiment, the connector 42 for the ignition coil 41 is used. However, the present invention is not limited to this. The connector 42 includes an insertion body 43 having a claw portion 43a and a fitting body 44 having a locking piece 44a. I just need it.

  A conductor pin 43b and a terminal block 44b are provided inside the insertion body 43 and the fitting body 44, respectively. By inserting the insertion body 43 into the fitting body 44, the pin 43b and the terminal block 44b are connected. It is possible to conduct by contacting.

FIG. 4 is a block diagram of the connector fitting state inspection apparatus 20 according to the embodiment of the present invention.
As shown in FIG. 4, the connector fitting state inspection device 20 includes cameras 21a and 21b, a pallet sensor 25, an inspection processing device 26, an illumination lamp 22, and robots 23a and 23b.

The inspection processing device 26 includes an inspection command unit 51 and a processing / control unit 52.
When the pallet sensor 25 detects that the pallet has arrived at the inspection line 14 and has stopped temporarily, the pallet sensor 25 outputs a pallet position signal PPS indicating that the pallet has arrived to the inspection command unit 51.

When the pallet position signal PPS is input, the inspection command unit 51 creates a lighting signal TSS for lighting the lighting lamp 22 and outputs the lighting signal TSS to the lighting lamp 22. The illumination lamp 22 to which the lighting signal TSS is input lights up.
In addition, when the pallet position signal PPS is input, the inspection command unit 51 creates a control signal SS for instructing various processes and control (details will be described later), and outputs the control signal SS to the processing / control unit 52.

  The processing / control unit 52 forms an image pattern R1, R2, R3, A1 indicating the density of reflected light based on the captured images GSa, GSb of the connector 42 captured by the cameras 21a, 21b. The storage unit 55 storing the pass image patterns PP and PQ indicating the density of the connector 42 in a normal state for each engine model, and the grayscale image pattern R1 output from the image processing unit 54 are output from the storage unit 55. And an image confirmation unit 56 for confirming whether or not the image matches the accepted image pattern PP.

As shown in FIGS. 5A, 5B, and 6A, the camera 21a images the entire connector 42 irradiated with the light from the illumination lamp 22 from the radial direction. The illuminating lamp 22 emits light at a right angle to the surface of the fitting body 44 having the locking piece 44a.
Moreover, the camera 21b images the whole connector 42 irradiated with the light of the illumination lamp 22 from an axial direction, as shown to Fig.7 (a) and Fig.8 (a). The illumination lamp 22 irradiates light parallel to the surface of the fitting body 44 having the locking piece 44a.
The captured images GSa and GSb captured by the cameras 21a and 21b are output from the cameras 21a and 21b to the image processing unit 54, respectively.

The image processing unit 54 extracts the engagement portion (I portion in FIG. 5A) between the locking piece 44a and the claw portion 43a in the captured image GSa, and creates a grayscale image pattern R1 indicating the density of the reflected light. To do. The created grayscale image pattern R1 is output to the image confirmation unit 56.
In addition, the image processing unit 54 extracts the base end 43c portion (the II portion in FIG. 5A) of the insertion body 43 in the captured image GSa, and creates a grayscale image pattern R2 indicating the density of the reflected light.
Furthermore, the image processing unit 54 extracts the tip 44c portion (III portion in FIG. 5A) connected to the insertion body 43 of the fitting body 44 in the captured image GSa, and a grayscale image pattern indicating the density of reflected light. Create R3. The created grayscale image patterns R2 and R3 are output to the coordinate detection unit 60.

  Further, the image processing unit 54 extracts an engagement portion (IV portion in FIG. 7A) between the locking piece 44a and the claw portion 43a in the captured image GSb, and a grayscale image pattern A1 indicating the density of reflected light. Create The created grayscale image pattern A1 is output to the area measuring unit 64.

<About radial inspection>
The image confirmation unit 56 confirms whether the input grayscale image pattern R1 matches the acceptable image pattern PP output from the storage unit 55.
FIG. 5C shows a pass image pattern PP, and FIG. 6B shows an example of a fail image pattern. The pass image pattern PP shows a state (FIGS. 5A and 5B) in which the locking piece 44a of the fitting body 44 is normally engaged with the claw portion 43a of the insertion body 43, and the reject image. The pattern shows a state (FIG. 6A) in which the engagement between the locking piece 44a of the fitting body 44 and the claw portion 43a of the insertion body 43 is not normal.

  As shown in FIG. 5C, the acceptable image pattern PP is represented by two types of shades (lightness) of white and black depending on the presence or absence of reflected light. Specifically, the locking piece 44a is white due to the reflected light from the locking piece 44a, and the claw portion 43a is black because the reflected light from the claw portion 43a does not enter the camera 21a.

  On the other hand, as shown in FIGS. 6A and 6B, for example, when the locking piece 44a is placed on the claw portion 43a, that is, the engagement between the locking piece 44a and the claw portion 43a. If the alignment is not normal, the reflected light not only from the claw portion 43a but also from the many locking pieces 44a does not enter the camera 21a, so that it is generally displayed in black.

  The image confirmation unit 56 confirms whether the grayscale image pattern R1 matches the acceptable image pattern PP. Then, a coincidence signal AS is created when they coincide, and a disagreement signal DS is created when they do not coincide (for example, when the grayscale image pattern R1 is shown in FIG. 6B). The coincidence signal AS or the disagreement signal DS is output to the radial direction comparison unit 63 described later.

  As shown in FIG. 4, the processing / control unit 52 includes a coordinate detection unit 60, a distance calculation unit 61, a distance confirmation unit 62, and a radial direction comparison unit 63.

The coordinate detection unit 60 detects the X coordinate of the position of the base end 43c of the insert 43 and the position of the tip 44c of the fitting 44 from the input grayscale image patterns R2 and R3.
The coordinate detector 60 detects the X coordinate of the position of the base end 43c of the insert 43 based on the difference in density between the insert 43 portion and the ignition coil 41 portion.
Further, the X coordinate of the position of the tip 44c of the fitting body 44 is detected based on the difference in density between the insertion body 43 portion and the fitting body 44 portion.
The detected X-coordinate values of the position of the proximal end 43c of the insertion body 43 and the position of the distal end 44c of the fitting body 44 are output to the distance calculation unit 61, respectively.

  The distance calculation unit 61 determines the distance from the base end 43c position of the insertion body 43 to the front end 44c position of the fitting body 44 based on the input X-coordinate values of the base end 43c position of the insertion body 43 and the tip end 44c position of the fitting body 44. The distance D is calculated. The calculated distance D is output to the distance confirmation unit 62.

In the distance confirmation unit 62, the input distance D is a prescribed range of the distance from the position of the base end 43 c of the insertion body 43 to the position of the front end 44 c of the fitting body 44 in the normally fitted connector 42 output from the storage unit 55. Check if it is inside.
When the distance D is within the specified range, it is considered that the insertion body 43 and the fitting body 44 are normally fitted.
On the other hand, when the distance D is shorter than the lower limit value of the specified range, the inserted body 43 and the fitting body 44 are in an abnormally close state, and either one is damaged or the wrong connector 42 is used. There is a risk that. Further, when the distance D is longer than the upper limit value of the specified range, the insert 43 may not be sufficiently inserted into the fitting body 44. For this reason, when distance D is outside a regulation range, it is in a poor fitting state.

When the distance D is within the specified range, an in-range signal IP indicating that the distance D is within the specified range is generated. When the distance D is out of the range, an out-of-range signal OP is generated. The in-range signal IP or the out-of-range signal OP is output to the radial direction comparison unit 63.
The prescribed range of the distance from the base end 43c position of the insertion body 43 to the front end 44c position of the fitting body 44 in the connector 42 in the normal fitting state is set in advance and stored in the storage unit 55. .

The radial direction comparison unit 63 determines whether the connector 42 is fitted in the radial direction based on the coincidence signal AS or the disagreement signal DS from the image confirmation unit 56 and the in-range signal IP or the out-of-range signal OP from the distance confirmation unit 62. Compare whether the normal conditions are met.
Specifically, when the signal from the image confirmation unit 56 is the coincidence signal AS and the signal from the distance confirmation unit 62 is the in-range signal IP, the fitting state of the connector 42 matches the normal condition. .
On the other hand, when the input signal includes at least one of the mismatch signal DS and the out-of-range signal OP, the fitting state of the connector 42 does not match the normal condition.
Then, if the fitting state of the connector 42 matches the normal condition, a match signal RAS is created, and if it does not match, a non-match signal RUS is created. The match signal RAS and the non-match signal RUS are output to the determination unit 57 described later.

<About axial inspection>
As illustrated in FIG. 4, the processing / control unit 52 includes an area measurement unit 64, an area confirmation unit 65, and an axial direction comparison unit 66.

The area measuring unit 64 measures the area S of the black region in which the gray value in the gray image pattern A1 from the image processing unit 54 is a predetermined threshold value or less. A black region whose gray value is a predetermined value or less will be described below.
FIG. 7B is a diagram showing an acceptable image pattern, and FIG. 8B is a diagram showing an example of an unacceptable image pattern. The acceptable image pattern PQ shows a state (FIG. 7A) in which the locking piece 44 a of the fitting body 44 is normally engaged with the claw portion 43 a of the insertion body 43, and the unacceptable image pattern is the fitting body 44. This shows a state (FIG. 8A) in which the engagement between the locking piece 44 a and the claw portion 43 a of the insert 43 is not normal.

  As shown in FIG. 7B, the acceptable image pattern PQ is obtained by imaging the claw portion 43a in the IV frame in FIG. 7A, the upper end surface of the fitting body 44, and a part of the periphery of the fitting body 44. The upper end surfaces of the claw portion 43a and the fitting body 44 are white due to the reflected light, and a portion around the fitting body 44 is not reflected and thus is displayed in light black. Since the periphery of the fitting body 44 is bright by illumination such as a fluorescent lamp installed in the factory, it becomes light black. In such a case, as shown in FIG. 7A, the locking piece 44a is hidden behind the upper surface of the fitting body 44 and is not imaged.

On the other hand, as shown in FIG. 8B, for example, when the tip 44c portion of the locking piece 44a is positioned on the upper surface of the claw portion 43a, the tip 44c portion of the locking piece 44a is above the fitting body 44. Since it protrudes outward from the end face (see FIG. 8A), the irradiated light is reflected by the locking piece 44a in a direction different from that of the camera 21b and is displayed in a dark black color at a position adjacent to the fitting body 44. Is done.
Therefore, when the locking piece 44a of the fitting body 44 is normally engaged with the claw portion 43a of the insertion body 43, a dark black region hardly occurs.
In the present embodiment, the gray value at the boundary between light black and dark black is set as the predetermined threshold. In addition, since the shade value of the boundary between light black and dark black differs depending on each site, it is measured in advance.
And the area S of the dark black area | region below a predetermined threshold value is measured. The measured area S is output to the area confirmation unit 65.

The area confirmation unit 65 confirms whether the input area S is less than a preset specified value.
When the area S is less than the specified value, the locking piece 44a does not protrude outward from the fitting body 44, and the locking piece 44a is normally engaged with the claw portion 43a.
On the other hand, when the area S is equal to or larger than the specified value, the locking piece 44a protrudes outward from the fitting body 44, and the locking piece 44a may not be normally engaged with the claw portion 43a. .

  When the area S is less than the specified value, a signal less than the specified value VU indicating that the area S is less than the specified value is generated. When the area S is equal to or greater than the specified value, the signal VO outside the specified value is generated. The generated less than specified value signal VU or outside the specified value signal VO is output to the axial direction comparison unit 66.

The axial direction comparison unit 66 confirms whether or not the fitting state of the connector 42 matches the normal condition in the axial direction based on the input signal.
Specifically, when the input signal is a signal VU that is less than the specified value, it is assumed that the fitting state of the connector 42 matches the normal condition. On the other hand, when the input signal is the out-of-specified value signal VO, it is assumed that the fitting state of the connector 42 does not match the normal condition.
If the fitting state of the connector 42 matches the normal condition, a match signal AAS is generated, and if it does not match, a non-match signal AUS is generated. The match signal AAS and the non-match signal AUS are output to the determination unit 57 described later.

  As shown in FIG. 4, the processing / control unit 52 includes a determination unit 57 and a display unit 58.

The determination unit 57 determines whether or not the fitting state of the connector 42 is normal based on the match signals RAS and AAS or the non-match signals RUS and AUS from the radial direction comparison unit 63 and the axial direction comparison unit 66.
The determination unit 57 determines that the fitting state of the connector 42 is normal when at least one of the signals from the radial direction comparison unit 63 and the axial direction comparison unit 66 is a match signal RAS or AAS. To do.
On the other hand, the fitting state of the connector 42 is determined to be abnormal only when the signals from the radial direction comparing unit 63 and the axial direction comparing unit 66 are both non-match signals RUS and AUS.

  The determination unit 57 generates a pass signal PS when it is determined that the fitting state of the connector 42 is normal, and generates a fail signal RS when it is determined that the connector 42 is abnormal. The created pass signal PS or fail signal RS is output to the display unit 58.

  The display unit 58 receives the input pass signal PS or fail signal RS and displays “pass” or “fail”.

  Further, the processing / control unit 52 receives the control signal SS from the inspection command unit 51 when the pallet is temporarily stopped based on the pallet position signal PPS from the pallet sensor 25, and sends a drive signal ES to the robots 23a and 23b. A robot control unit 59 for controlling is provided.

  The connector 42 fitting state inspection method using the connector fitting state inspection device 20 having the above-described configuration will be described below in accordance with the inspection procedure.

<Connecting state inspection flow of connector 42>
FIG. 9 is a flowchart illustrating a fitting state inspection method for the connector 42 according to the present invention.
As shown in FIG. 9, first, the inspection information of the engine model that has flowed through the inspection line 14 is acquired (step S1).

Next, it is determined whether or not the engine 11 placed on the pallet 17 has stopped at a predetermined position on the inspection line 14 (step S2).
If it is determined that the engine 11 has not stopped at the predetermined position on the inspection line 14 (step S2: NO), step S2 is executed again.
On the other hand, if it is determined that the engine 11 has stopped at a predetermined position on the inspection line 14 (step S2: YES), the cameras 21a and 21b are subsequently moved to the predetermined position of the engine model by the robots 23a and 23b. The camera position is fixed (step S3).
Thereafter, the cameras 21a and 21b are zoomed to a predetermined magnification of the engine model. A camera without a zoom function may be used.

Next, the camera 42a images the connector 42 from the radial direction (step S4).
Subsequently, the camera 42b images the connector 42 from the axial direction (step S5).
The captured images GSa and GSb captured by the cameras 21a and 21b are output to the image processing unit 54, respectively.

Next, the density image pattern R1 in the radial direction is compared with the acceptable image pattern PP (step S6).
FIG. 10 is a flowchart for explaining a method of comparing the radial gray image pattern R1 and the acceptable image pattern PP according to the present invention.
As shown in FIG. 10, the image processing unit 54 creates grayscale image patterns R1, R2, and R3 (step S11).
The image processing unit 54 extracts an engagement portion (I portion in FIG. 5A) between the locking piece 44a and the claw portion 43a in the captured image GSa captured in step S4, and obtains a grayscale image pattern R1. create. The created grayscale image pattern R1 is output to the image confirmation unit 56.
Further, the image processing unit 54 extracts the base end 43c portion (the II portion in FIG. 5A) of the insert 43 in the captured image GSa, and creates a grayscale image pattern R2.
Furthermore, the image processing unit 54 extracts the tip 44c portion (III portion in FIG. 5A) connected to the insertion body 43 of the fitting body 44 in the captured image GSa, and creates a grayscale image pattern R3. The created grayscale image patterns R2 and R3 are output to the coordinate detection unit 60.

Subsequently, the image confirmation unit 56 confirms whether the grayscale image pattern R1 matches the acceptable image pattern PP (step S12).
Then, if they match, a match signal AS is created, and if they do not match (for example, in the case of FIG. 6B), a mismatch signal DS is created. The coincidence signal AS or the disagreement signal DS is output to the radial direction comparison unit 63.

Next, the coordinates of the position of the base end 43c of the insert 43 are detected (step S13).
The coordinate detection unit 60 detects the X coordinate of the position of the base end 43c of the insert 43 from the grayscale image pattern R2. The detected X coordinate value of the position of the proximal end 43 c of the insert 43 is output to the distance calculation unit 61.

Further, the X coordinate of the tip 44c of the fitting body 44 is detected (step S14).
The coordinate detection unit 60 detects the X coordinate of the position of the tip 44c of the fitting body 44 from the grayscale image pattern R3. The detected X coordinate value of the position of the tip 44c of the fitting body 44 is output to the distance calculation unit 61.

Subsequently, a distance D from the proximal end 43c of the insertion body 43 to the distal end 44c of the fitting body 44 is calculated (step S15).
The distance calculation unit 61 calculates a distance D from the base end 43c of the insert 43 to the tip 44c of the fit body 44 based on the X coordinate values of the base end 43c position of the insert 43 and the tip 44c position of the fit body 44. To do. The calculated distance D is output to the distance confirmation unit 62.

Next, it is confirmed whether the distance D is within a specified range (step S16).
The distance confirmation unit 62 confirms whether the distance D is within a prescribed range that is prescribed in advance. When the distance D is within the specified range, an in-range signal IP indicating that the distance D is within the specified range is generated. When the distance D is out of the range, an out-of-range signal OP is generated. The in-range signal IP or the out-of-range signal OP is output to the radial direction comparison unit 63.

Next, it is compared whether the fitting state of the connector 42 matches the radial direction normal condition (step S17).
When the signal from the image confirmation unit 56 is the coincidence signal AS and the signal from the distance confirmation unit 62 is the in-range signal IP, the radial direction comparison unit 63 matches the fitting condition of the connector 42 with the normal condition. And
On the other hand, when the input signal includes at least one of the mismatch signal DS and the out-of-range signal OP, the fitting state of the connector 42 does not match the normal condition.
Then, if the fitting state of the connector 42 matches the normal condition, a match signal RAS is created, and if it does not match, a non-match signal RUS is created. The match signal RAS or the non-match signal RUS is output to the determination unit 57.

Next, as shown in FIG. 9, the grayscale image pattern A1 in the axial direction is compared with the acceptable image pattern PQ (step S7).
FIG. 11 is a flowchart illustrating a method for comparing the axial gray image pattern A1 and the accepted image pattern PQ according to the present invention.
As shown in FIG. 11, the image processing unit 54 creates a grayscale image pattern A1 (step S21).
The image processing unit 54 extracts the engagement portion (IV portion in FIG. 7A) between the locking piece 44a and the claw portion 43a in the captured image GSb captured in step S5, and displays the grayscale image pattern A1. create. The created grayscale image pattern A1 is output to the area measuring unit 64.

Next, the area S of the black region below the predetermined threshold is measured (step S22).
The area measuring unit 64 measures an area S of a dark black region whose density value is equal to or less than a predetermined threshold value defined from the density image pattern A1. The measured area S is output to the area confirmation unit 65.

Next, it is confirmed whether the area S of the black region is less than a predetermined value (step S23).
The area confirmation unit 65 confirms whether the measured area S of the black region is less than a predetermined value. When the area S is less than the specified value, a signal less than the specified value VU indicating that the area S is less than the specified value is generated. When the area S is equal to or greater than the specified value, the signal VO outside the specified value is generated. The generated less than specified value signal VU or outside the specified value signal VO is output to the axial direction comparison unit 66.

Next, it is compared whether the fitting state of the connector 42 matches the normal condition in the axial direction (step S24).
The axial direction comparison unit 66 compares the fitting state of the connector 42 with the normal condition in the axial direction based on the signal from the area confirmation unit 65.
When the signal from the area confirmation unit 65 is the signal VU less than the specified value, the matching signal AAS is created assuming that the fitting state of the connector 42 matches the normal condition. On the other hand, in the case of the out-of-specified value signal VO, the non-matching signal AUS is generated assuming that the fitting state of the connector 42 does not match the normal condition. The match signal AAS or the non-match signal AUS is output to the determination unit 57.

Next, as shown in FIG. 9, it is determined whether or not the connection state of the connector 42 is normal (step S8).
In the determination unit 57, when at least one of the signals input from the radial direction comparison unit 63 and the axial direction comparison unit 66 is a match signal RAS or AAS, the fitting state of the connector 42 is normal. Is determined.
When it determines with a fitting state being normal (step S8: YES), the pass signal PS is produced. The created pass signal PS is output to the display unit 58, and “pass” is displayed in step S9.
On the other hand, when both the signals input from the radial direction comparing unit 63 and the axial direction comparing unit 66 are non-match signals RUS and AUS, it is determined that the fitting state of the connector 42 is abnormal.
When it determines with a fitting state being abnormal (step S8: NO), the failure signal RS is produced. The created fail signal RS is output to the display unit 58, and “fail” is displayed in step S10.

According to the connector fitting state inspection device 20 and the inspection method according to the present invention described above, the inserted body 43 and the fitting body 44 in the fitted state are imaged from the radial direction and the axial direction, respectively, and the captured images are displayed. On the basis of whether or not the fitting state of the insertion body 43 and the fitting body 44 matches the normal condition of the connector fitting for each direction, and if the comparison result in at least one direction matches, the insertion body 43 and the fitting body 44 are determined to be in a normal fitting state, so that the fitting state of the connector 42 can be accurately confirmed.
Further, unlike the prior art, it is not necessary to perform correction according to the distance from the connector 42 to the cameras 21a and 21b on the captured image. For this reason, the fitting state of the connector 42 can be confirmed with high accuracy.

  Conventionally, even when the inserted insert 43 and the insert 44 in the fitted state are imaged, the amount of light is insufficient or the shadow of other parts such as a wire harness is detected. In some cases, the merged 44 was not clearly imaged. However, in the present invention, since the imaging is performed from the axial direction and the radial direction, the insertion body 43 and the fitting body 44 can be reliably imaged from at least one direction. And since it determines with the fitting state of the insertion body 43 and the fitting body 44 being normal by the picked-up image by any one direction of an axial direction or radial direction, the insertion body 43 and the fitting body 44 are imaged clearly. This prevents the inspection line from stopping. Thereby, when an inspection line stops, a worker can go to an inspection location and work such as work can be saved. Therefore, the work efficiency of inspection can be improved.

  In addition, the gray image pattern of the engagement portion between the claw portion 43a of the insertion body 43 and the locking piece 44a of the fitting body 44 matches the acceptable image pattern, and the distal end 44c of the fitting body 44 extends from the base end 43c of the insertion body 43. When the distance up to is within the specified range, the fitting state of the insertion body 43 and the fitting body 44 matches the normal condition in the radial direction, so that the comparison result in the radial direction can be accurately derived.

  And when the area of the black area in the gray image pattern of the engaging part of the nail | claw part 43a of the insertion body 43 and the locking piece 44a of the fitting body 44 is in a regulation range, the insertion body 43, the fitting body 44, Therefore, the comparison result in the axial direction can be accurately derived.

  Furthermore, by instructing the robots 23a and 23b with different imaging positions of the insertion body 43 and the fitting body 44 depending on the model of the object, it is possible to flexibly cope with the inspection of the connector 42 fitting state even in a multi-model mixed line. be able to.

  Moreover, the insertion body 43 and the fitting body 44 at different locations can be simultaneously imaged by the plurality of robots 23a and 23b. Thereby, inspection time can be shortened and productivity can be improved.

In the present embodiment, the connector 42 is imaged from the radial direction (step S4, see FIG. 9) and then the connector 42 is imaged from the axial direction (step S5). However, the present invention is not limited to this. After imaging from the axial direction, imaging from the radial direction may be performed, or imaging from the radial direction and imaging from the axial direction may be performed in parallel.
In the present embodiment, the radial gray image pattern and the pass image pattern are compared (step S6), and then the axial gray image pattern and the pass image pattern are compared (step S7). However, the present invention is not limited to this, and after the comparison in the axial direction is performed, the comparison in the radial direction may be performed, or the comparison in the radial direction and the comparison in the axial direction may be performed in parallel.

  The present invention can be applied to an apparatus including a connector including an insertion body having a claw portion and a fitting body having a locking piece.

11 Engine (equivalent to the object to be assembled)
DESCRIPTION OF SYMBOLS 12 Production line 13 Dress-up line 14 Inspection line 16 Conveyor 17 Pallet 20 Connector fitting state inspection apparatus 21a, 21b Camera (equivalent to an imaging device)
22 Illuminating lamps 23a, 23b Robot 25 Pallet sensor 26 Inspection processing device 35 Safety fence 41 Ignition coil 42 Connector 43 Insertion body 43a Claw part 43b Pin 43c Base end 44 Fitting body 44a Locking piece 44b Terminal block 44c Tip 44d Hole 44e Insertion Mouth 51 Inspection command section 52 Processing / control section 54 Image processing section 55 Storage section 56 Image confirmation section 57 Determination section 58 Display section 59 Robot control section 60 Coordinate detection section 61 Distance calculation section 62 Distance confirmation section 63 Radial direction comparison section 64 Area Measurement unit 65 Area confirmation unit 66 Axial direction comparison unit

Claims (8)

An insert having a claw part protruding outward, and a fitting having a locking piece for preventing the insertion body from slipping out over the claw part and engaging the claw part when the insert is inserted A connector fitting state inspection method comprising
An imaging step of irradiating light to the claw portion and the locking piece in a state where the insertion body and the fitting body are connected, and imaging the insertion body and the fitting body with an imaging device;
An image processing step of creating a grayscale image pattern indicating the density of reflected light from the captured image captured in the imaging step;
A determination step of detecting an inclined state of the locking piece based on the grayscale image pattern created in the image processing step and determining whether the connector is normally fitted based on the inclined state. And a connector fitting state inspection method. The imaging step includes
Radial direction imaging processing for irradiating light at a right angle to the surface of the fitting body having the locking piece and imaging the insertion body and the fitting body with an imaging device from the light irradiation direction;
An axial imaging process is performed in which light is applied in parallel to the surface of the fitting body having the locking piece, and the insertion body and the fitting body are imaged by an imaging device from the irradiation direction of the light. The connector fitting state inspection method according to claim 1. The determination step includes
A diameter for comparing whether the inclination state of the locking piece matches the radial normal inclination condition of the locking piece set in advance as normal based on the image captured in the radial imaging process. Direction comparison processing,
An axis for comparing whether or not the inclination state of the locking piece matches the axial normal inclination condition of the locking piece set in advance as normal based on the image captured in the axial imaging process And a direction comparison process,
The connector is determined to be normal when a comparison result in at least one of the comparison results of the radial direction comparison process and the axial direction comparison process matches. Item 3. The connector fitting state inspection method according to Item 2. The radial direction comparison process
The white portion corresponding to the locking piece of the gray image pattern created in the image processing step is a white portion corresponding to the locking piece of the pass image pattern set in advance as a normal gray image pattern; 4. The connector fitting state inspection method according to claim 3, wherein an image checking process for checking whether or not they match is executed. The radial direction comparison process
Insert base end detection processing for detecting a coordinate position of the base end of the insert in the captured image;
A fitting body tip detection process for detecting a coordinate position in the captured image of the tip of the fitting body;
A calculation process for calculating a distance from the proximal end of the insertion body to the distal end of the fitting body from position coordinates respectively detected by the insertion body proximal end detection process and the fitting body distal end detection process;
A distance confirmation process for confirming whether or not the distance calculated by the calculation process is within a prescribed range defined in advance;
When the result of the image check process matches and the check result of the distance check process is within the specified range, the fitting state of the insert and the fitting matches the radial normal condition. The connector fitting state inspection method according to claim 4, wherein the connector is fitted. The axial direction comparison process
A measurement process for measuring the area of the black portion where the shade of the engaging portion between the locking piece and the claw portion in the gray image pattern created in the image processing step is;
An area confirmation process for confirming whether or not the area of the black portion measured by the measurement process is less than a predetermined value,
4. The fitting state between the insertion body and the fitting body matches the normal condition in the axial direction when a confirmation result by the area confirmation processing is less than the specified value. The connector fitting state inspection method according to 1. The imaging device is mounted on a robot provided on the side of an inspection line of an assembly target constructed by connecting the insertion body and the fitting body,
The robot moves the imaging device to a predetermined position where the insertion body and the fitting body can be imaged based on connection position information between the insertion body and the fitting body that is set in advance. The connector insertion state inspection method according to claim 1, wherein the insertion body and the fitting body are imaged. An insert having a claw part protruding outward, and a fitting having a locking piece for preventing the insertion body from slipping out over the claw part and engaging the claw part when the insert is inserted A connector fitting state inspection device composed of a unity,
An imaging device that irradiates light to the claw portion and the locking piece in a state where the insertion body and the fitting body are connected, and images the insertion body and the fitting body,
Image processing means for creating a grayscale image pattern indicating the density of reflected light from a captured image captured by the imaging device;
A determination unit that detects an inclined state of the locking piece based on the grayscale image pattern created by the image processing unit and determines whether or not the connector is normally fitted based on the inclined state. And a connector fitting state inspection device.

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