JP2015203613A - Coil inspection method and coil inspection apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil inspection method capable of calculating the linearity of a coil as an inspection object without giving any influence on cycle time while improving efficiency in coil inspection.SOLUTION: The coil inspection method includes: an image acquisition step S02 to acquire an image of a coil as an inspection object which is taken by using an imaging camera and an illumination; a binarizing processing step S03 to perform binarizing processing on the image; an edge extraction step S06 to extract edge of the coil as the inspection object; an integration graph creation step S08 to create an integration graph by integrating the extracted edge in a winding direction of the coil as the inspection object; and a linearity calculation step S09 to calculate the linearity of the coil as the inspection object based on the height of the integration graph.

Description

  The present invention relates to a winding inspection method and a winding inspection apparatus for inspecting a winding state in a stator of a rotating electrical machine.

  In the winding process of the stator of a small motor, it is necessary that the winding coils are wound at equal intervals on each layer. Visual inspection and pressure resistance inspection are performed to check for winding defects and abnormalities. However, the visual inspection has problems such as “there is a difference in ability in inspection time” and “there is an individual difference in inspection results”.

In order to solve this, a winding inspection device is provided immediately after the winding process to provide an outer shape inspection device separately from the winding device, and determines the size of the winding outer shape of the winding coil wound around the stator core, thereby determining the quality. Is disclosed (for example, Patent Document 1).
In addition, a determination method is disclosed in which an intensity distribution of a spatial frequency component is generated from a captured image of a coil to be inspected, and the degree of collection of the intensity distribution is determined to determine whether the coil to be inspected is good or bad (for example, Patent Document 2) ).

Japanese Patent Laid-Open No. 4-84406 (page 4, lower left, FIG. 8) JP-A-2005-241582 (paragraphs [0010], [0011], [0020], FIG. 3)

  In the disclosed invention of Patent Document 1, it is difficult to add to an existing production line, and the cycle time increases. Moreover, in the disclosed invention of Patent Document 2, there is a problem that the linearity of the winding cannot be calculated.

  The present invention has been made in order to solve the above-described problem, and can calculate the linearity of the winding coil to be inspected without affecting the cycle time, thereby improving the efficiency of the winding inspection. An object is to provide a wire inspection method and a winding inspection apparatus.

  The winding inspection method according to the present invention includes an image acquisition step of acquiring an image of a winding coil to be inspected imaged using an imaging camera and illumination, and binarization for performing binarization processing on the captured image Processing step, an edge extraction step for extracting the edge of the winding coil to be inspected by performing a differentiation process on the binarized processing data, and an integration graph by integrating the extracted edge in the winding direction of the winding coil to be inspected An integration graph creation step to be created, and a linearity calculation step to calculate the linearity of the winding coil to be inspected from the height of the integration graph are provided.

  The winding inspection apparatus according to the present invention includes an imaging camera, illumination, and an image processing apparatus, and the image processing apparatus acquires an image of a winding coil to be inspected that is imaged using the imaging camera and illumination. An acquisition unit, a binarization processing unit that performs binarization processing on the captured image, an edge extraction unit that performs differentiation processing on the binarization processing data and extracts the edge of the winding coil to be inspected, and extraction An integration graph creation unit that creates an integration graph by integrating edges in the winding direction of the winding coil to be inspected, and a linearity calculation unit that calculates the linearity of the winding coil to be inspected from the height of the integration graph Is.

  Since the winding inspection method according to the present invention includes the above-described steps, the linearity of the winding coil to be inspected can be calculated without affecting the cycle time. It is possible to prevent outflow of defects into the product and improve productivity.

  Since the winding inspection apparatus according to the present invention is configured as described above, the linearity of the winding coil to be inspected can be calculated without affecting the cycle time, so that the efficiency of the winding inspection is improved. Therefore, it is possible to prevent defective outflow to the subsequent process and improve productivity.

1 is a configuration diagram of a winding inspection device according to a winding inspection method of Embodiment 1 of the present invention. FIG. It is explanatory drawing of the winding process which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is explanatory drawing of the winding process which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is a perspective view of the stator core after the winding which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is a side view of the stator core after the winding which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is a top view of the stator core after winding which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is a flowchart which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is an enlarged view of the stator core which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is explanatory drawing (integral graph) which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is explanatory drawing (distribution graph) which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is an enlarged view of the stator core which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is explanatory drawing (integral graph) which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is explanatory drawing (distribution graph) which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is a perspective view of the connection stator core which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is a perspective view at the time of the winding of the connection stator core which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is a perspective view after the assembly of the connection stator core which concerns on the winding test | inspection method of Embodiment 1 of this invention. It is explanatory drawing (winding spill defect) which concerns on the winding test | inspection method of Embodiment 2 of this invention. It is explanatory drawing (insulation member integral graph) which concerns on the winding test | inspection method of Embodiment 2 of this invention. It is explanatory drawing (winding coil integral graph) which concerns on the winding test | inspection method of Embodiment 2 of this invention. It is a block diagram which concerns on the coil | winding test | inspection apparatus of Embodiment 3 of this invention.

Embodiment 1 FIG.
In the first embodiment, as basic steps, an image acquisition step of acquiring a captured image of a winding coil to be inspected, a binarization processing step of performing binarization processing on the captured image, a differential processing, and an inspection target Edge extraction process to extract the edge of the winding coil, integration graph creation process to create an integration graph by integrating the extracted edge in the winding direction of the winding coil to be inspected, and the winding coil to be inspected from the height of the integration graph The present invention relates to a winding inspection method including a linearity calculating step for calculating the linearity of the winding. Furthermore, the winding inspection method according to the first embodiment quantifies the alignment of the winding coil by creating a defect position identifying step for identifying a winding defect position of the winding coil from the integral graph and a distribution graph from the integral graph. An alignment quantification step.

  Hereinafter, regarding the function and operation of the winding inspection method according to the first embodiment of the present invention, FIG. 1 is a configuration diagram of the winding inspection device, FIG. 2 and FIG. 3 are explanatory diagrams of a winding process, and after winding 4 to 6 which are perspective views of the stator core, FIG. 7 which is a flowchart of the inspection method, FIG. 8 which is an enlarged view of the stator core, FIGS. 9 and 10 which are explanatory views, and FIG. 11 which is an enlarged view of the stator core 12 and 13 which are explanatory diagrams, and FIGS. 14 to 16 which are perspective views of a connecting stator core.

  FIG. 1 shows the configuration of a winding inspection apparatus used in the winding inspection method according to the first embodiment of the present invention. In FIG. 1, a winding inspection device 1 applied to the present invention includes an imaging camera (hereinafter referred to as a camera) 2, an illumination 3, and an image processing device 4, and a winding coil 6 of a stator core 5 to be inspected. Perform the inspection. Note that the imaging camera is an image processing camera, and uses a high-quality and high-definition camera. The illumination 3 uses bar-type illumination.

  In the first embodiment, it is assumed that the camera 2 uses a color camera and the illumination 3 uses white illumination. A winding inspection method performed by processing a captured image of the stator core 5 to be inspected using a color camera and white illumination will be described below.

Next, a winding process for winding the winding coil 6 around the stator core member 10 will be described with reference to FIGS.
As shown in FIG. 2, the insulating member 11 is inserted into the stator core member 10. The insulating member 11 includes a first insulating member 11a and a second insulating member 11b.
The first insulating member 11a is inserted into the winding portion of the stator core member 10 from one end in the axial direction (from the top in FIG. 2) to insulate one side. The second insulating member 11b is inserted into the winding portion of the stator core member 10 in the axial direction from the other end (from the lower part in FIG. 2) to insulate one side.
FIG. 3 shows a state in which the insulating member 11 is inserted into the stator core member 10. On the other hand, the winding coil 6 is wound, and FIG. 4 shows the stator core 5 after the winding is completed.
In addition, the stator core after the completion of winding is distinguished from the stator core member 10 as the stator core 5.

  The winding alignment state of the stator core 5 around which the winding coil 6 is wound is imaged by the camera 2 and the illumination 3, and the quality of the winding coil 6 to be inspected is determined by the image processing device 4.

In describing the processing procedure of the winding inspection method, the coordinate system necessary for image processing will be described first.
The insertion direction of the insulating member 11 (the winding direction of the winding coil 6 on the long side) is the X axis direction, and the radial direction of the stator core 5 (the direction perpendicular to the winding of the winding coil 6 on the long side) is the Y axis. The direction of winding of the winding coil 6 on the short side is defined as the Z-axis direction.

The linearity and alignment of the winding coil used to determine the quality of the winding coil are defined as follows.
The degree of parallelism to the winding direction of the winding coil 6 of the stator core 5 to be inspected is called linearity in the winding coil alone. The entire winding coil 6 of the stator core 5 after the winding of the winding coil 6 is completed is called alignment.

The outline of the winding inspection will be described, and then the winding inspection processing procedure will be described based on the flowchart of FIG.
First, the outline of the winding inspection will be described with respect to the calculation of the linearity of the winding coil, which is the basis of the present invention, and the quantification of the alignment of the entire winding coil.
The captured image is acquired by the image processing device 4. The acquired captured image is binarized. Noise is removed by a filtering process on the binarized image after the binarization process. The edge information of the winding coil 6 is extracted from the captured image after the noise removal.

Since the captured image includes the edge information of the insulating member 11, the edge information of the insulating member 11 is removed and only the edge information related to the winding coil 6 is extracted.
Based on the edge information of the winding coil 6, an integration graph is created by integrating in the X direction, which is the winding direction of the winding coil 6. The linearity of the winding coil 6 is calculated at the height of the graph corresponding to each winding coil 6 in the integration graph.
Furthermore, the alignment of the whole winding coil 6 of the stator core 5 is quantified by acquiring the distribution at each height (each linearity) from the integral graph.

  Next, a perspective view, a side view, and a top view of FIGS. 4 to 6, and an enlarged view and an explanatory view of FIGS. 8 to 10, and a flowchart of FIG. The processing procedure of the winding inspection method will be described based on the above.

  In the imaging step of Step 1 (S01), the camera 2 captures an image of the side surface portion of the winding coil 6 of the stator core 5 around which the winding coil 6 shown in FIGS.

  In the image acquisition step of Step 2 (S02), the captured image captured by the camera 2 is acquired by the image processing device 4.

In the binarization process step of Step 3 (S03), the binarization process is applied to the acquired captured image with the threshold values of the RGB values.
Specifically, if a threshold value is provided for the B value, the winding coil 6 cannot be detected. Therefore, the threshold value for the R value is increased without setting the threshold value for the B value, and the binary value is determined based on the threshold value for only the R value and the G value. Process. However, when the binarization process is performed on the captured image using only the threshold values of the R value and the G value, the data of the white insulating member 11 is also detected at the same time.
In order to obtain edge information of only the winding coil 6 in a later step, in order to obtain binarization processing data of only the insulating member 11 in this step, the binarization processing is performed by setting threshold values for all the RBG values. Then, binarization processing data of only the insulating member 11 is acquired.

  In the filtering process of step 4 (S04), when noise needs to be removed, the filtering process is performed on the data after the binarization process.

  In the winding coil data extraction step of step 5 (S05), binarization processing data for only the winding coil 6 is obtained. Specifically, by removing the binarization processing data of the insulating member 11 from the binarization processing data of both the winding coil 6 and the insulating member 11 acquired in step 4, the binary of only the winding coil 6 is obtained. To obtain data.

  In the edge extraction process of step 6 (S06), differentiation processing is performed on the binarization processing data of only the winding coil 6 obtained in step 5 (S05), and the differential value is 1 or more from the data after differentiation processing. The edge of the winding coil 6 is extracted by performing the process of extracting the region.

In the dividing step of Step 7 (S07), the edge of the winding coil 6 is divided at equal intervals in the direction of the winding coil 6, that is, in the X direction, as necessary.
Although it is possible to simply inspect the entire axial direction without dividing in the direction of the winding coil 6, if the division is not divided or the number of divisions is small, defective parts are averaged including the good parts as a whole. , Winding inspection accuracy decreases.
As the number of divisions increases, a winding defect can be detected more accurately, so that it is possible to make a quality determination with high accuracy.

  Hereinafter, as an example, the processing procedure of the winding inspection method will be described with respect to the divided portion at the center in the X direction of the non-defective stator core 5 of FIG. 4 shown in FIG.

In the integral graph creation step of Step 8 (S08), the winding coil 6 is formed in each division range of the division performed in Step 7, specifically, in the division portion at the center in the X direction of the stator core 5, as shown in FIG. Create an integral graph that is integrated in the winding direction of.
In FIG. 9, the horizontal axis indicates the pixel position in the winding Y direction, and the vertical axis indicates the existence probability.

  In the linearity calculation step of Step 9 (S09), the linearity of the winding coil 6 is calculated from the integral graph of FIG. Linearity is so good that the value in the arrangement position of each winding coil is near 1.0 (100%).

  In the defect position specifying step of step 10 (S10), when there is a winding coil with poor linearity, the arrangement position in the Y direction of the winding coil with poor linearity is specified from the integral graph. That is, the arrangement position of each winding coil 6 in the Y direction can be detected from the integral graph, and the position of the winding coil is specified in association with the position of the linearity defect.

In the alignment quantification step of Step 11 (S11), a probability distribution is acquired for each height (linearity) from the integral graph of FIG. 9, and the distribution graph of FIG. 10 is created.
In FIG. 10, the horizontal axis represents frequency, and the vertical axis represents existence probability (corresponding to the vertical axis in FIG. 9). Specifically, the horizontal axis of FIG. 10 represents the number of points on the line when a horizontal line is drawn on the horizontal axis at 0.1 in FIG.
Further, in step 11 (S11), from the distribution graph of FIG. 10, the number of points (190 points in FIG. 10) in the region exceeding the criterion (0.7 in FIG. 10) is calculated, and the entire winding coil 6 is aligned. Quantify sex.

  In the pass / fail judgment process of step 12 (S12), the result of linearity calculation of step 9 and the result of alignment quantification of step 11 are used to compare with the set inspection standard, thereby winding the winding coil of the stator core 5 6 and the whole winding coil 6 are judged.

  Next, in order to clarify the winding inspection method of the present invention, a case where the winding inspection method of the present invention is applied to the stator core 5 in which a winding defect exists is based on FIGS. 11 to 13. I will explain.

FIG. 11 is a view corresponding to FIG. 8 for the non-defective product, and is a winding misalignment state diagram in which a winding failure exists in the split portion at the center of the stator core 5.
FIG. 12 is a diagram corresponding to FIG. 9 which is a non-defective product, and is an integration graph when there is a winding coil winding defect. It is the graph which performed the binarization process and the edge extraction process with respect to the captured image, and integrated in the winding coil winding direction.
FIG. 13 is a diagram corresponding to FIG. 10 for a non-defective product, and is a probability distribution when there is a winding defect with respect to the integral graph of FIG. 13 is a distribution graph created by acquiring a probability distribution for each height (linearity) with respect to the integral graph of FIG.

Comparing FIG. 9 and FIG. 12, it can be seen that in the integral graph where the winding defect exists, the peak height corresponding to each winding coil is low and the linearity is poor.
In FIG. 12, a position with a low existence probability (peak) is a winding failure, and can be associated with a winding position (pixel position) in the Y direction (a direction perpendicular to the winding direction).

  Comparing FIG. 10 and FIG. 13, it can be seen that the distribution graph of the whole winding coil of the stator core in which the winding defect exists has a small distribution of the reference value (0.7) or more and the alignment is poor. Specifically, in the distribution graph of the winding coil of the non-defective stator core, the reference value or more is 190 points, whereas in the distribution graph of the winding coil of the defective stator core, 69 points are clearly lower.

  In the above description, the camera 2 and the illumination 3 are used one by one, and one side surface of the winding coil 6 of the stator core 5 is inspected to determine the linearity of the winding coil alone and the overall alignment. However, if there is a sufficient installation space in the automatic winding machine, the camera 2 and the illumination 3 can be installed on both sides and inspected. By performing pass / fail determination from both sides, it is possible to perform pass / fail determination with higher accuracy.

  In the above description, the stator core 5 divided as the stator core is an inspection object. However, the present invention is not limited to this, and the present invention is applied to a connected stator core 15 (described as a connected stator core as appropriate) as shown in FIG. The winding inspection method can be applied.

In the connection stator core 15, the space factor of the winding coil 6 is improved by winding the winding coil 6 in a state where the connection stator core 15 is unfolded during winding as shown in FIG. After the winding is completed, it is bent by the next stator core and sequentially wound. However, after the winding coil 6 is wound by the automatic winding machine, the connecting portion is welded and fixed in a circular shape in the automatic winding machine as shown in FIG. A visual inspection by a person cannot be performed.
Therefore, in the stator core manufacturing line, the winding coils of each stator core immediately after the completion of the winding are processed in sequence in a processing time that does not affect the cycle time, and the winding inspection is performed by sequentially processing the winding coils. However, it is possible to check whether the winding coil is linear or aligned.

  Moreover, in the conventional automatic winding machine, even if the connection stator core 15 has a defect in the middle of the winding, the winding is performed up to the final stator core. However, by applying the winding inspection method of the present invention and sequentially inspecting the winding coils of each stator core, it becomes possible to take out a defective stator core after the occurrence of a failure, so that waste of coil wires can be reduced. it can.

As described above, in the description of the first embodiment, a color camera is used as the imaging camera 2 and white illumination is used as the illumination 3. As the imaging camera 2, a monochrome camera may be used instead of a color camera.
In general, when a monochrome camera is used as an imaging camera, the RGB values are changed by using red illumination or blue illumination for illumination. However, the monochrome camera and color illumination can also be applied to the winding inspection of the present invention.

Further, although the bar-type illumination has been described as the illumination shape, one type or a plurality of types of ring-type illumination, dome-type illumination, and coaxial illumination may be used.
In the first embodiment, the bar-type illumination is used because the inspection object range is a rectangular shape, but the shape is not limited to this as long as the winding coil to be inspected can be illuminated uniformly.

In the first embodiment, the winding inspection method including the linearity calculation process, the defect position identification process, and the alignment quantification process has been described. However, depending on the purpose of the winding inspection and the required inspection accuracy, it is possible to simplify the inspection method by using an inspection method including only a basic linearity calculation process.
By adding a defect position specifying step and an alignment quantification step according to the purpose of the winding inspection, the inspection accuracy can be improved and the inspection efficiency can be improved.

  As described above, in the winding inspection method according to the first embodiment, as a basic process, an image acquisition process for acquiring a captured image of a winding coil to be inspected, and a binary for performing binarization processing on the captured image An integration process step, an edge extraction step of performing differential processing to extract the edge of the winding coil to be inspected, and an integration graph creation step of creating an integral graph by integrating the extracted edge in the winding direction of the winding coil to be inspected And a linearity calculating step of calculating the linearity of the winding coil to be inspected from the height of the integral graph. Accordingly, since the linearity of the winding coil to be inspected can be calculated, the efficiency of the winding inspection can be improved, the outflow of defects to the subsequent process can be prevented, and the productivity can be improved. For this reason, there is an effect of energy saving and yield improvement.

  Furthermore, the winding inspection method according to the first embodiment quantifies the alignment of the winding coil by creating a defect position identifying step for identifying a winding defect position of the winding coil from the integral graph and a distribution graph from the integral graph. An alignment quantification step. For this reason, it is possible to further improve inspection accuracy and save labor in the inspection process.

Embodiment 2. FIG.
The winding inspection method according to the second embodiment relates to a winding inspection method for detecting winding spillage, which is one of the causes of short circuit failure.
Specifically, in the winding inspection method of the second embodiment, in addition to each processing step of the winding inspection method of the first embodiment, an insulating member edge extraction step for extracting the edge of the insulating member and the inspection target winding A spillage detecting step for detecting spillage of the coil is provided.

  Hereinafter, the function and operation of the winding inspection method of the second embodiment will be described with reference to the drawings of the first embodiment on the basis of FIGS. 17 to 19 which are explanatory diagrams related to the inspection method.

If the winding coil 6 of the stator core 5 is normally wound at regular intervals and linearly, the winding coil 6 spills from the insulating member and comes into contact with the stator core member 10 as shown in FIG. 4 of the first embodiment. There is no. However, when the winding coil 6 is disturbed, the winding coil 6 may spill from the insulating member 11 as shown in FIG. A spilled winding coil is indicated by 6A.
Thus, when inspecting whether the winding coil 6 is housed in the predetermined insulating member 11, the winding inspection method described in the first embodiment can be applied.

The difference from the first embodiment is that, in the first embodiment, after the binarization processing data for only the winding coil 6 is extracted in Step 5 (S05), the insulating member data is not used.
However, in the second embodiment, the insulating member data is also used to extract the edge of the insulating member and detect the spilled winding coil 6A.

In step 3 of the flowchart of FIG. 7, in order to obtain binarization processing data only for the insulating member 11, threshold values are provided for all RBG values and binarization processing is performed to obtain binarization processing data for only the insulating member 11. did.
In the above binarization processing data, the edge of the winding coil 6 may remain thin. In order to remove the edge of the winding coil 6, a minimum filter and a maximum filter are used.
For example, if a 3 × 3 minimum filter is used and then a 3 × 3 max filter is used, detections smaller than 3 pixels are removed and detections larger than 3 pixels remain at their original size.

  Thereafter, by performing the processing from step 6 to step 8 in the flowchart of FIG. 7, an integral graph in which only the edge of the insulating member 11 is extracted as shown in FIG. 18 can be obtained, and the edge coordinates of the extreme ends on both sides can be obtained. (Insulating member edge extraction step).

For example, a case where a defective winding coil 6A as shown in FIG. 17 is generated will be described as an example. In FIG. 18, the extreme end edge coordinates on both sides of the insulating member 11 can be obtained as the left side 29 and the right side 160. Similarly, in FIG. 19, the extreme end edge coordinates on both sides of the winding coil 6 can be obtained as the left side 10 and the right side 142.
Comparing the respective results, the coordinates of the winding coil 6 are smaller than the coordinates of the insulating member 11 at the leftmost end, and it can be detected that the winding is spilled. Further, at the rightmost end, the coordinates of the winding coil 6 are smaller than the coordinates of the insulating member 11, and it can be confirmed that the winding is normally performed (rolling-out detection step).

As described above, the winding inspection method according to the second embodiment includes the insulating member edge extraction step for extracting the edge of the insulating member and the inspection target winding in addition to the processing steps of the winding inspection method according to the first embodiment. A spillage detecting step for detecting spillage of the wire coil is provided.
For this reason, according to the invention of the second embodiment, in addition to the effects of the first embodiment, it is possible to further detect a winding spill defect, thereby further improving the accuracy of the winding inspection. In addition, since it is not necessary to prepare a separate detection device in order to detect the winding of the winding coil to be inspected, the winding inspection apparatus can be simplified.

Embodiment 3 FIG.
The third embodiment relates to a winding inspection apparatus that applies the winding inspection method described in the first embodiment to inspect the winding coil of the stator core.

Hereinafter, the configuration and operation of the winding inspection device 1 according to the third embodiment of the present invention will be described based on FIG. 20, which is a configuration diagram according to the winding inspection device, with reference to the diagram of the first embodiment as appropriate. To do.
FIG. 20 shows in detail the internal configuration of the image processing apparatus of FIG. 1 according to the first embodiment. In FIG. 20, the same or corresponding parts as in FIG.

20, a winding inspection apparatus 1 applied to the present invention includes an imaging camera 2, an illumination 3, and an image processing apparatus 4, and inspects the winding coil 6 of the stator core 5 to be inspected.
Since the basics of the winding inspection method, such as the coordinate system, are the same as those in the first embodiment, the configuration and functions of the image processing apparatus 4 will be mainly described below.

  The image processing apparatus 4 includes a functional unit necessary for performing the winding inspection method described in the first embodiment. Specifically, the image processing apparatus 4 includes an image capturing unit 21, a binarization processing unit 22, an edge extraction unit 23, an integral graph creation unit 24, a linearity calculation unit 25, a defect position specifying unit 26, an alignment quantification. A control unit 29 that controls the camera 2 and the illumination 3 to control the entire winding inspection. The control unit 29 also performs signal processing with a display device (CRT), a keyboard, a mouse, and the like (not shown).

  The inspector uses the display device and the keyboard to set the necessary inspection conditions such as the determination standard for the winding inspection and the illuminance of the illumination 3, and starts the winding inspection.

  The side surface portion of the winding coil 6 of the stator core 5 is imaged by the camera 2, and this captured image is acquired by the image capturing unit 21.

Next, in the binarization processing unit 22, binarization processing is performed on the acquired captured image with each RGB value threshold value. When noise removal is necessary, the binarization processing unit 22 performs a filtering process on the data after the binarization process.
The binarization processing unit 22 also performs processing for obtaining binarization processing data for only the winding coil 6. Specifically, the binarization processing data of only the winding coil 6 is obtained by removing the binarization processing data of the insulating member 11 from the binarization processing data of both the winding coil 6 and the insulating member 11. .

  Next, the edge extraction unit 23 performs a differentiation process on the binarized data of only the winding coil 6, extracts a region having a differential value of 1 or more from the data after the differentiation process, and extracts the winding coil 6. Extract edges.

Next, the integration graph creation unit 24 creates an integration graph by integrating the edge information acquired by the edge extraction unit 23 in the winding direction of the winding coil 6.
An integral graph is created after the edges of the winding coil 6 are divided at equal intervals in the direction of the winding coil 6 into the number of divisions set in advance under the inspection conditions.

  Next, the linearity calculation unit 25 calculates the linearity of the winding coil 6 from the integration graph created by the integration graph creation unit 24.

  Next, when there is a winding coil with poor linearity, the defective position specifying unit 26 specifies the arrangement position in the Y direction of the winding coil with poor linearity from the integral graph.

  Next, the alignment quantification unit 27 acquires a probability distribution for each height (linearity) of the integral graph and creates a distribution graph. Furthermore, the score of the area | region exceeding the criterion set beforehand by the test condition is calculated from this distribution graph, and the alignment property of the whole winding coil 6 is quantified.

  Next, in the pass / fail judgment unit 28, the linearity of the winding coil 6 calculated by the linearity calculation unit 25 and the alignment data of the entire winding coil 6 quantified by the alignment quantification unit 27 are set in advance. The quality of the winding coil 6 of the stator core 5 is determined in comparison with the inspection standard.

  The control unit 29 displays the result of the winding inspection, that is, the determination result of the pass / fail determination unit 28 on the display device and presents it to the inspector. When there is a winding coil with poor linearity, the control unit 29 also displays the arrangement position in the Y direction of the winding coil specified by the defect position specifying unit 26 on the display device.

In the winding inspection apparatus 1 according to the third embodiment, the image processing apparatus 4 has been described as a configuration including the linearity calculation unit 25, the defect position specifying unit 26, and the alignment quantification unit 27. However, depending on the purpose of the winding inspection and the required inspection accuracy, the winding inspection apparatus can be simplified by using an image processing apparatus including only the basic linearity calculation unit 25.
By providing the defect position specifying unit 26 and the alignment quantifying unit 27 according to the purpose of the winding inspection, it is possible to improve the inspection accuracy and increase the efficiency of the inspection.

  In the winding inspection apparatus 1 of the third embodiment, the image processing apparatus is configured to include each functional unit corresponding to each processing step of the winding inspection method. However, the image processing apparatus can be constituted by a CPU, a memory, a disk, an input / output device, and a peripheral device, and each processing step of the winding inspection method can be processed by software.

  As described above, the winding inspection apparatus according to the third embodiment includes the imaging camera, the illumination, and the image processing apparatus. The image processing apparatus includes the imaging coil and the inspection target winding coil that is captured using the illumination. An image acquisition unit that acquires a captured image, a binarization processing unit that performs binarization processing on the captured image, an edge extraction unit that performs differentiation processing and extracts an edge of the winding coil to be inspected, and an extraction edge An integration graph creation unit that creates an integration graph by integrating in the winding direction of the winding coil to be inspected, and a linearity calculation unit that calculates the linearity of the winding coil to be inspected from the height of the integration graph is there. Accordingly, since the linearity of the winding coil to be inspected can be calculated, the efficiency of the winding inspection can be improved, the outflow of defects to the subsequent process can be prevented, and the productivity can be improved.

  Furthermore, the winding inspection apparatus of the third embodiment creates a distribution graph from the integration graph by identifying a defective position specifying unit for specifying the winding defective position of the inspection target winding coil from the integral graph, and aligns the inspection target winding coil. Alignment quantification unit for quantifying performance. For this reason, it is possible to further improve inspection accuracy and save labor in the inspection process.

  Note that the present invention can be freely combined with each other within the scope of the invention, and the embodiments can be modified or omitted as appropriate.

1 winding inspection device, 2 imaging camera, 3 lighting, 4 image processing device,
5 stator core, 6 winding coil, 10 stator core member, 11 insulating member,
11a 1st insulating member, 11b 2nd insulating member, 15 connection stator core,
21 image capture unit, 22 binarization processing unit, 23 edge extraction unit,
24 integral graph creation unit, 25 linearity calculation unit, 26 defect position specifying unit,
27 Alignment quantification part, 28 Pass / fail judgment part, 29 Control part.

Claims (10)

An image acquisition step of acquiring a picked-up image of a winding coil to be inspected imaged using an image pickup camera and illumination, a binarization processing step of performing binarization processing on the picked-up image, and binarization processing data An edge extraction step of performing differentiation on the edge of the winding coil to be inspected and extracting an edge of the inspection target winding coil; A winding inspection method comprising: a linearity calculating step of calculating the linearity of the winding coil to be inspected from the height of the integral graph. The winding inspection method according to claim 1, further comprising an alignment quantification step of creating a distribution graph from the integral graph and quantifying alignment of the winding coil to be inspected. The winding inspection method according to claim 1, further comprising a defect position specifying step of specifying a winding defect position of the inspection target winding coil from the integral graph. Further, binarization processing, edge extraction and integration graph are created for the captured image, and an insulating member edge extraction step for extracting the edge of the insulating member of the winding coil to be inspected, and the inspection that can be determined from the integration graph 4. The spillage detection step of comparing the left and right end positions of the target winding coil with the edge position of the insulating member and detecting a spillage of the inspection target winding coil. 5. Winding inspection method described in 1. The winding inspection method according to any one of claims 1 to 4, wherein the imaging camera is a color camera, and the illumination is white illumination. The winding inspection method according to any one of claims 1 to 4, wherein the imaging camera is a monochrome camera, and the illumination is color illumination. The winding according to any one of claims 1 to 6, wherein the illumination is one of bar illumination, ring illumination, dome illumination, and coaxial illumination, or a plurality of illuminations. Inspection method. It consists of an imaging camera, illumination, and an image processing device.
The image processing apparatus includes an image acquisition unit that acquires an image of a winding coil to be inspected that has been imaged using an imaging camera and illumination, and a binarization processing unit that performs binarization processing on the captured image. An edge extraction unit that performs differential processing on the binarization processing data and extracts the edge of the winding coil to be inspected, and an integration graph is created by integrating the extracted edge in the winding direction of the winding coil to be inspected And a linearity calculating unit that calculates the linearity of the winding coil to be inspected from the height of the integral graph. The winding inspection apparatus according to claim 8, further comprising an alignment quantification unit that creates a distribution graph from the integral graph and quantifies alignment of the winding coil to be inspected. Furthermore, the said image processing apparatus is a winding test | inspection apparatus of Claim 8 or Claim 9 provided with the defect position specific | specification part which pinpoints the winding defect position of the said test | inspection winding coil from the said integral graph.

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