JP2023100150A - Led illumination device, inspection unit and inspection method - Google Patents

Abstract

To provide an LED illumination device for an inspection device, and others, capable of achieving a longer lifetime of an LED illumination, and more securely preventing a reduction in inspection accuracy by the inspection device.SOLUTION: An LED illumination device 110 includes LED illuminations 111a, 111b that irradiate an imaging object by a camera 120 with light, and an LED control unit 112 that controls the LED illuminations 111a, 111b. The LED control unit 112 switches intermittent lighting control for intermittently the LED illuminations 111a, 111b or continuous lighting control for continuously lighting the LED illuminations 111a, 111b, according to an operation speed of a mechanical device. Accordingly, compared to a configuration of only continuous lighting, a lighting time of the LED illuminations 111a, 111b can be reduced, and even when the mechanical device has a high operation speed, a good image causing no inspection damage can be obtained by the continuous lighting control.SELECTED DRAWING: Figure 5

Description

TECHNICAL FIELD The present invention relates to an LED lighting device for an inspection device having an imaging means for repeatedly capturing images according to the operation of a mechanical device, an inspection unit provided with the LED lighting device, and an inspection method using LED lighting. .

2. Description of the Related Art Conventionally, an inspection apparatus is known that has an imaging means for imaging an inspection object irradiated with light from a predetermined irradiation means, and an image processing means for performing inspection processing based on the image obtained by the imaging means. The inspection apparatus is applied to various mechanical devices such as production equipment, and is used for inspection of workpieces and products processed and produced by the mechanical devices.

Also, the imaging means of the inspection apparatus may be configured to repeatedly perform imaging in accordance with the operation of the mechanical device to which it is applied. For example, in an inspection device that has a rotatable core and is applied to a winding device that winds various sheets by rotating the core to obtain a wound element, the imaging means is the phase ( In other words, there is a configuration in which various sheets are imaged every time the rotation angle of the winding core reaches a constant value (for example, see Patent Document 1, etc.).

Furthermore, for the purpose of extending the life of the irradiation means (illumination lamp), there has been proposed a lamp illumination device that intermittently lights the irradiation means in accordance with the imaging timing (see, for example, Patent Document 2, etc.). In this lamp illumination device, lighting of the irradiation means (illumination lamp) is started prior to the imaging timing (opening of the camera shutter). This is because, as shown in FIG. 18, it takes some rise time tx until the luminance of the light emitted from the irradiation means is sufficiently increased.

As the irradiation means, LED lighting is widely used in order to save power.

JP 2018-170103 A JP-A-7-333174

By the way, it is conceivable to apply irradiation means that is intermittently lit in accordance with the imaging timing to an inspection apparatus that repeatedly performs imaging as described above, and adopt LED lighting as the irradiation means. In this case, as shown in FIG. 19, in consideration of the rise time tx, the brightness of the light emitted from the LED illumination when the imaging timing comes (that is, when the phase of the mechanical device reaches the angle θ2) is sufficiently high, it is necessary to start lighting the LED illumination when the phase of the mechanical device reaches an angle θ1 smaller than the angle θ2.

In the above configuration, when the operating speed of the mechanical device is not so high, the time from the start of lighting of the LED illumination to the start of imaging (the time from the angle θ1 to the angle θ2) Δt is more than the rise time tx. is long enough. Therefore, imaging is performed in a state in which sufficiently high-intensity light is emitted from the LED illumination, and inspection processing based on the captured image is not hindered at all.

However, when the operating speed of the machine increases, the time Δt becomes shorter than the rise time tx. Therefore, imaging is performed in a state where the brightness of the light is low, and there is a possibility that the accuracy of the inspection based on the captured image may deteriorate.

On the other hand, even when the operating speed of the mechanical device is high, in order to perform imaging in an environment where high-intensity light is irradiated, It is conceivable to continuously light the LED lighting. However, this defeats the purpose of extending the life of the LED lighting. In addition, with continuous lighting, there is a risk that the temperature of the junction of the LED lighting will rise and the wavelength of the light emitted from the LED lighting will shift. When the wavelength shift occurs, the obtained image also changes, which may lead to deterioration in inspection accuracy.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an inspection device capable of extending the life of LED lighting and more reliably preventing deterioration in inspection accuracy of an inspection device. An object of the present invention is to provide an LED lighting device or the like for an apparatus.

Each means suitable for solving the above object will be described below by itemizing. It should be noted that actions and effects peculiar to the corresponding means will be added as necessary.

Means 1. an imaging means for repeatedly performing imaging in accordance with the operation of the mechanical device;
An LED lighting device for an inspection device, comprising an image processing means for performing inspection processing based on the image obtained by the imaging means,
an LED lighting that emits light toward an object to be imaged by the imaging means;
LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means performs intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing of the imaging means, or lighting the LED lighting regardless of the imaging timing, according to the operating speed of the mechanical device. 1. An LED lighting device characterized in that it is configured to switch continuous lighting control for continuous lighting.

The LED control means performs intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing of the imaging means when the operating speed of the mechanical device is lower than a predetermined reference speed. Continuous lighting control may be performed to continuously light the LED illumination regardless of the imaging timing when the operating speed of the mechanical device is higher than the reference speed.

According to the above means 1, for example, when the operating speed of the mechanical device is relatively low, the LED lighting can be lit intermittently, and when the operating speed of the mechanical device is relatively high, the LED lighting can be lit continuously. becomes. Therefore, the lighting time (energization time) of the LED lighting can be reduced compared to a configuration in which only continuous lighting is performed, and the life of the LED lighting can be extended. In addition, the shift of the wavelength of the light emitted from the LED illumination is less likely to occur, and deterioration in inspection accuracy can be suppressed.

On the other hand, when the operating speed of the mechanical device is high and the imaging interval is short, continuous lighting control enables imaging with sufficiently high-intensity light emitted from the LED illumination. Therefore, it is possible to obtain a good image that does not interfere with the inspection, and it is possible to more reliably prevent deterioration of the inspection accuracy.

It should be noted that the determination regarding switching between intermittent lighting control and continuous lighting control may be performed by the LED control means as in means 2 described below, or may be performed by a device other than the LED control means (for example, a mechanical device, etc.). You may allow

Means 2. Determination means for determining switching between the intermittent lighting control and the continuous lighting control,
The LED lighting device according to means 1, wherein the determination means is provided in the LED control means.

According to the means 2, the determination means for determining switching between the intermittent lighting control and the continuous lighting control is provided in the LED control means. Therefore, compared with the case where the determination means is provided on the mechanical device side, there is no need to excessively change the settings and configuration of the mechanical device side. Thereby, the effect of the means 1 can be obtained more easily.

Means 3. An input means capable of inputting a lighting time for each LED illumination at least when the intermittent lighting control is performed to the LED control means,
The LED lighting device according to means 1 or 2, wherein the LED control means controls the LED lighting based on the input lighting time.

It should be noted that the term "lighting time" more precisely refers to the time during which current is supplied to the LED illumination.

According to the means 3, the input means can input the lighting time per LED illumination when performing the intermittent lighting control to the LED control means. This makes it possible to easily perform appropriate settings according to inspection conditions, use environments, and the like.

Means 4. Determination means for determining switching between the intermittent lighting control and the continuous lighting control,
The determining means determines switching between the intermittent lighting control and the continuous lighting control according to the magnitude of the light emission duration of the LED lighting when the intermittent lighting control is performed with respect to the lighting cycle of the LED lighting. The LED lighting device according to any one of means 1 to 3, characterized by:

The term "lighting period" refers to the time from the start of current supply to the LED lighting (lighting start) to the start of the next current supply. Also, "light emission duration" refers to the time during which the LED illumination is emitting light. LED lighting continues to emit light for a predetermined fall time even after the supply of current is stopped. The light emission duration can be said to be the total time of the lighting time (current supply time) and the fall time.

According to the means 4, intermittent lighting control can be performed when the light emission duration is shorter than the lighting cycle of the LED illumination, and continuous lighting control can be performed when the light emission duration is longer than the lighting cycle. Therefore, during intermittent lighting control (when the light emission duration is shorter than the lighting cycle of the LED lighting), the time from when the current supply to the LED lighting is stopped to when the next supply is started can be set to be longer than the fall time. can. As a result, it is possible to reduce the processing load associated with current supply, and to improve the operational stability. In addition, it is possible to use a device whose response speed for current switching is not so high, and it is possible to reduce costs.

Means 5. an inspection apparatus having imaging means for repeatedly imaging in accordance with the operation of a mechanical device, and image processing means for performing inspection processing based on the image obtained by the imaging means;
An inspection unit comprising an LED lighting device having LED lighting that irradiates light toward an object to be imaged by the imaging means,
The LED lighting device has LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means performs intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing of the imaging means, or lighting the LED lighting regardless of the imaging timing, according to the operating speed of the mechanical device. An inspection unit characterized in that it is configured to be able to switch between continuous lighting control for continuously lighting.

According to the above means 5, the same effect as that of the above means 1 can be achieved.

Means 6. Determination means for determining switching between the intermittent lighting control and the continuous lighting control,
6. The inspection unit according to claim 5, wherein said determination means is provided in said LED control means.

According to the above means 6, the same effects as those of the above means 2 can be obtained.

Means 7. an imaging step of repeatedly performing imaging according to the operation of the mechanical device;
an image processing step of performing inspection processing based on the image obtained by the imaging step;
and an irradiation step of irradiating an object to be imaged in the imaging step with a predetermined LED illumination,
In the irradiation step, an intermittent lighting step of intermittently lighting the LED illumination in accordance with the imaging timing in the imaging step according to the operating speed of the mechanical device, or continuously lighting the LED illumination regardless of the imaging timing. An inspection method, characterized in that a continuous lighting process for lighting the lamp is alternately performed.

According to the above means 7, the same effect as that of the above means 1 can be obtained.

1 is a schematic perspective view showing the configuration of a battery element; FIG. It is a schematic plan view showing the configuration of a battery element. It is a schematic block diagram of a winding device. 4 is a schematic configuration diagram of a winding portion; FIG. 4 is a block diagram showing the electrical configuration of the winding unit; FIG. It is a flow chart of a winding process. It is a flow chart of an imaging process. It is a flow chart of an inspection process. 4 is a flowchart of a control mode determination process; It is a flow chart of an irradiation process. 1 is a schematic diagram of an image obtained by a camera; FIG. FIG. 4 is a schematic configuration diagram of the winding portion when winding is started; 4 is a schematic configuration diagram of a winding portion when the separator sheet is cut; FIG. It is a graph for explaining a lighting cycle, rise time, and the like. It is a graph for showing the relationship between the rotation speed of the winding core and the control mode of the LED lighting. FIG. 5 is a diagram showing an example of timing and changes in the phase of the winding core, the brightness of the LED lighting, the current supply to the LED lighting, and the like. FIG. 10 is a diagram showing an example of timing and changes in brightness of LED lighting, current supply to LED lighting, and the like in another embodiment. It is a graph for demonstrating the rise time in an irradiation means. FIG. 5 is a diagram showing an example of timing and changes in the phase of a mechanical device, the brightness of LED lighting, etc., when a technique of intermittently lighting an irradiation means in accordance with imaging timing is applied to an inspection apparatus.

An embodiment will be described below with reference to the drawings. First, the configuration of a lithium ion battery element as a wound element obtained by a winding device will be described.

As shown in FIGS. 1 and 2, a lithium ion battery element 1 (hereinafter simply referred to as "battery element 1") is composed of a positive electrode sheet 4 and a negative electrode sheet 5 which are superimposed with two separator sheets 2 and 3 interposed therebetween. It is manufactured by being wound in a rolled state. In the following description, the separator sheets 2, 3 and the electrode sheets 4, 5 may be collectively referred to as "various sheets 2 to 5".

The separator sheets 2 and 3 are each strip-shaped with the same width, and are made of an insulating material such as polypropylene (PP) in order to prevent the different electrode sheets 4 and 5 from coming into contact with each other and causing a short circuit. It is composed of The separator sheets 2, 3 are transparent or translucent. Therefore, it is possible to visually recognize the positive electrode sheet 4 and the negative electrode sheet 5 through the separator sheets 2 and 3 .

The electrode sheets 4 and 5 are made of thin metal sheets, and active materials are applied to both the front and back surfaces of the sheets. An aluminum foil sheet, for example, is used for the positive electrode sheet 4, and a positive electrode active material (for example, lithium manganate particles, etc.) is applied to both sides of the sheet. A copper foil sheet, for example, is used as the negative electrode sheet 5, and a negative electrode active material (for example, activated carbon, etc.) is applied to both sides of the sheet. The materials of the separator sheets 2 and 3 and the electrode sheets 4 and 5 are not particularly limited and may be changed as appropriate.

The electrode sheets 4 and 5 are continuously coated electrode sheets, and predetermined portions in the sheet width direction are active material coated portions 4a and 5a (portions marked with dotted patterns in FIG. 2), and the remaining portions are active material non-coated portions 4b and 5b. Ions can be exchanged between the positive electrode sheet 4 and the negative electrode sheet 5 via the active material coating portions 4a and 5a. More specifically, ions move from the positive electrode sheet 4 side to the negative electrode sheet 5 side during charging, and ions move from the negative electrode sheet 5 side to the positive electrode sheet 4 side during discharging.

Also, the negative electrode sheet 5 is narrower than the separator sheets 2 and 3 , and the positive electrode sheet 4 is narrower than the negative electrode sheet 5 . In the battery element 1 , the positive electrode sheet 4 is covered with the negative electrode sheet 5 . As a result, problems associated with the positive electrode sheet 4 not being covered with the negative electrode sheet 5 (for example, needle-like deposits being formed on the positive electrode sheet 4 and the separator sheets 2 and 3 being damaged, etc.) is suppressed, and the quality of the battery element 1 is improved.

Furthermore, a plurality of positive electrode leads (not shown) extend from one widthwise edge of the positive electrode sheet 4 , and a plurality of negative electrode leads (not illustrated) extend from the other widthwise edge of the negative electrode sheet 5 .

When obtaining a lithium ion battery, the battery element 1 is arranged in a cylindrical battery container (case) (not shown) made of metal, and the positive electrode lead and the negative electrode lead are put together. Then, the combined positive lead is connected to a positive terminal component (not shown), and the negative lead that is also combined is connected to a negative terminal component (not shown), and both terminal components are opened at both ends of the battery container. A lithium ion battery can be obtained by being provided so as to block the space.

Next, a winding system 200 (Fig. 5) will be explained. In this embodiment, the winding device 10 constitutes a "mechanical device". First, the winding device 10 will be described.

As shown in FIG. 3, the winding device 10 includes a winding section 11 for winding various sheets 2 to 5, and a positive electrode sheet supply mechanism 31 for supplying the positive electrode sheet 4 to the winding section 11. , a negative electrode sheet supply mechanism 41 for supplying the negative electrode sheet 5 to the winding section 11, separator supply mechanisms 51 and 61 for supplying the separator sheets 2 and 3 to the winding section 11, respectively, and a control device. 81. Various devices in the winding device 10 , such as the winding unit 11 and the supply mechanisms 31 , 41 , 51 , 61 , are controlled in operation by the control device 81 .

The positive electrode sheet supply mechanism 31 includes a positive electrode sheet material 32 formed by winding the positive electrode sheet 4 into a roll. The original positive electrode sheet 32 is supported by a support shaft 33 rotatable by driving means (not shown). As the support shaft 33 rotates, the positive electrode sheet 4 is pulled out from the original positive electrode sheet 32 .

The positive electrode sheet supply mechanism 31 also includes a sheet insertion mechanism 71 , a sheet cutting cutter 72 , a tension application mechanism 73 and a buffer mechanism 75 .

The sheet inserting mechanism 71 supplies the positive electrode sheet 4 to the winding part 11 , and along the transport path of the positive electrode sheet 4 , there is an approach position approaching the winding part 11 It is configured to be movable between the separated positions. The sheet inserting mechanism 71 includes a pair of chucks 71a and 71b capable of gripping the positive electrode sheet 4. As shown in FIG. The chucks 71a and 71b can be opened and closed by driving means (not shown). When supplying the positive electrode sheet 4 to the winding portion 11, the positive electrode sheet 4 is gripped by the chucks 71a and 71b, and then the sheet inserting mechanism 71 approaches the winding portion 11 side. there is

The sheet cutting cutter 72 is for cutting the positive electrode sheet 4, and has a pair of blades 72a and 72b located on both sides of the positive electrode sheet 4, respectively. The sheet cutting cutter 72 is movable between a sheet cutting position where the pair of blades 72a and 72b sandwich the positive electrode sheet 4 and a retreat position where the positive electrode sheet 4 is retreated outside the transport path. It is configured.

The cutting of the positive electrode sheet 4 is performed while the positive electrode sheet 4 is gripped by the chucks 71a and 71b. When the sheet inserting mechanism 71 moves closer to the winding portion 11 to supply the positive electrode sheet 4 to the winding portion 11, the pair of blade portions 72a and 72b convey the positive electrode sheet 4, respectively. By separating from the path, movement of the sheet insertion mechanism 71 is not hindered.

The tension applying mechanism 73 has a pair of rollers 73a and 73b and a dancer roller 73c swingably provided between the rollers 73a and 73b. The dancer roller 73c is operated by a predetermined constant torque motor (not shown), and is constructed so as to always apply constant tension to the positive electrode sheet 4. As shown in FIG. By applying tension to the positive electrode sheet 4, the positive electrode sheet 4 is prevented from being loosened.

The buffer mechanism 75 temporarily stores the positive electrode sheet 4 delivered from the original positive electrode sheet 32 . The buffer mechanism 75 has a pair of driven rollers 75a and 75b and an elevating roller 75c that is vertically displaceable between the two rollers 75a and 75b. The vertical position of the lifting roller 75 c is displaced based on the storage amount of the positive electrode sheet 4 .

The negative electrode sheet supply mechanism 41 has, on its most upstream side, a raw negative electrode sheet 42 formed by winding the negative electrode sheet 5 into a roll. The negative electrode sheet material 42 is supported by a support shaft 43 rotatable by driving means (not shown). As the support shaft 43 rotates, the negative electrode sheet 5 is pulled out from the original negative electrode sheet 42 .

Further, the negative electrode sheet supply mechanism 41 includes a sheet insertion mechanism 71 , a sheet cutting cutter 72 , a tension application mechanism 73 and a buffer mechanism 75 like the positive electrode sheet supply mechanism 31 . These are the same as those provided in the positive electrode sheet supply mechanism 31 except that they function for the negative electrode sheet 5 . Therefore, detailed description of these will be omitted.

On the other hand, the separator supply mechanisms 51 and 61 are provided with separator raw sheets 52 and 62 formed by winding the separator sheets 2 and 3 into rolls, respectively. The separator raw sheets 52, 62 are supported in a freely rotatable state, from which the separator sheets 2, 3 are appropriately pulled out.

Furthermore, the separator supply mechanisms 51 and 61 are provided with a tension imparting mechanism 73 like the electrode sheet supply mechanisms 31 and 41 . The tension imparting mechanism 73 is the same as that provided in the positive electrode sheet supply mechanism 31 except that it functions for the separator sheets 2 and 3 . Therefore, detailed description thereof will be omitted.

Also, a pair of nip rollers 78a and 78b are provided in the middle of the conveying path of the various sheets 2-5. The nip rollers 78a and 78b are for stacking the various sheets 2 to 5 so that the various sheets 2 to 5 are conveyed along the same conveying path. Various sheets 2 to 5 are supplied to the winding section 11 while being overlapped by nip rollers 78a and 78b.

In addition, the amount of rotation of the nip rollers 78a and 78b (in this embodiment, the amount of rotation of the nip roller 78b) can be grasped by a nip roller encoder (not shown). Information about the amount of rotation of the nip roller 78b is input to the control device 81 from the nip roller encoder. The amount of rotation of the nip roller 78b corresponds to the feeding amount of various sheets 2-5.

Next, the configuration of the winding portion 11 will be described. As shown in FIG. 4, the winding section 11 includes a turret 12 consisting of two disk-shaped tables facing each other and rotatably provided by a drive mechanism (not shown), and a turret 12 with an interval of 180° in the rotation direction of the turret 12 . Two winding cores 13 and 14, chuck portions 15a and 15b, a separator cutter 16, a pressing roller 17 for suppressing the various sheets 2 to 5 after winding from coming apart, and a predetermined fixing and a tape sticking mechanism 18 for sticking an application tape.

The winding cores 13 and 14 are for winding various sheets 2 to 5 on their outer peripheral sides, respectively, and are configured to be rotatable about their central axes by a drive mechanism (not shown). The rotation angle and amount of rotation of the winding cores 13 and 14 are detected by a winding core encoder 82 (see FIG. 5). is input to

In addition, the cores 13 and 14 are provided so as to be retractable with respect to one of the tables constituting the turret 12 along the axial direction of the turret 12 (the depth direction of the paper surface of FIG. 4, etc.). When the winding cores 13 and 14 protrude from one of the tables, the tips of the winding cores 13 and 14 are inserted into receiving holes formed in the other table, and are rotatable by both tables. It is supported.

In addition, the winding cores 13 and 14 are configured such that the outlines thereof are non-circular in the cross section perpendicular to the rotating shaft. In this embodiment, the winding cores 13 and 14 have an elliptical shape in a cross section orthogonal to their own rotating shafts. However, the shape of the winding cores 13 and 14 is not limited to this. .

Further, the winding core 13 (14) has a pair of core pieces 13a, 13b (14a, 14b) extending along its own axial direction (the depth direction of the paper surface of FIG. 4). A gap 13c (14c) is formed between the core pieces 13a, 13b (14a, 14b).

Further, the winding cores 13 and 14 are configured to turn and move between the winding position P1 and the removing position P2 by rotating the turret 12 .

The winding position P1 is a position where various sheets 2 to 5 are wound around the winding cores 13 and 14. FIG. Various sheets 2 to 5 are supplied from the supply mechanisms 31, 41, 51, 61 to the winding position P1.

The removal position P2 is a position for removing the various sheets 2 to 5 after winding, that is, the battery element 1. FIG. A removal device (not shown) or the like for removing the battery element 1 from the winding cores 13 and 14 is provided around the removal position P2.

The chuck portions 15a and 15b are for sandwiching the separator sheets 2 and 3 between the winding position P1 and the removing position P2. The chuck portions 15a and 15b are configured to be rotatably movable about a rotation shaft parallel to the rotation shafts of the turret 12 and the winding cores 13 and 14 by driving means (not shown). The chuck portions 15a and 15b are movable between the clamping position and the retracted position. When the chuck portions 15a and 15b move to the nipping positions, the chuck portions 15a and 15b can nip the separator sheets 2 and 3 arranged from the nip rollers 78a and 78b to the removal position P2 (see FIGS. 12 and 13). ). On the other hand, when the chuck portions 15a and 15b are moved to their retracted positions, they are arranged at positions that do not hinder the movement of the cores 13 and 14 and the separator sheets 2 and 3 (see FIG. 3).

The separator cutter 16 is arranged between the winding position P1 and the removing position P2, and provided closer to the removing position P2 than the chuck portions 15a and 15b. The separator cutter 16 can reciprocate vertically between predetermined upper and lower positions, and cuts the separator sheets 2 and 3 by moving from the upper position to the lower position.

The pressing roller 17 is arranged in the vicinity of the removal position P2, and has a close position to approach the turret 12 and press the various sheets 2 to 5, and a retracted position to separate from the turret 12 and not hinder the movement of the cores 13 and 14. is configured to be movable between

The tape applying mechanism 18 is arranged near the removal position P2, and applies the fixing tape to the end portions of the separator sheets 2 and 3 when the winding is finished. By attaching the fixing tape, the winding of the battery element 1 is stopped.

Next, the control device 81 will be explained. The control device 81 includes a CPU as a calculation means, a ROM for storing various programs, a RAM for temporarily storing various data such as calculation data and input/output data, and a hard disk for long-term storage of calculation data and the like. .

The control device 81 operates as follows when the various sheets 2 to 5 are wound. That is, the control device 81 starts the rotation of the winding cores 13 and 14 to start the winding process of the various sheets 2 to 5, and the rotation angle of the winding cores 13 and 14 winding the various sheets 2 to 5. becomes a preset fixed imaging execution angle θ2, an imaging signal is output to the camera 120 (see FIG. 5) of the inspection unit 100 .

Further, the control device 81 outputs a predetermined pulse signal to the LED control section 112, which will be described later, each time the rotation angles of the winding cores 13 and 14 reach a predetermined angle.

Further, the control device 81 controls driving of a servo motor for moving the camera 120 when various sheets 2 to 5 are wound. That is, when the winding of the various sheets 2 to 5 is started, the control device 81 controls the drive of the servomotor so that the camera 120 moves at a speed corresponding to the rotation speed of the winding cores 13 and 14. do.

In addition, the control device 81 outputs a movement stop signal and a position reset signal to the servomotor when the positive electrode sheet 4 is wound around the winding cores 13 and 14 by a predetermined amount, thereby causing the camera 120 to rotate. is stopped and moved to an initial position to be described later. However, when the various sheets 2 to 5 that are being wound are determined to be defective, the control device 81 outputs a movement stop signal and a position reset signal before the positive electrode sheet 4 is wound by a predetermined amount. do.

Then, when a predetermined amount of the various sheets 2 to 5 are wound without causing defects in the various sheets 2 to 5, the control device 81 gradually reduces the rotation speed of the winding cores 13 and 14 to finally wind the sheets 2 to 5. The rotation of the cores 13, 14 is stopped.

Next, the inspection unit 100 will be explained. The inspection unit 100 includes an LED illumination device 110 and an inspection device 150, as shown in FIG.

The LED illumination device 110 includes LED lights 111 a and 111 b , an LED control section 112 that controls the LED lights 111 a and 111 b, and an input section 113 for inputting various information to the LED control section 112 . In this embodiment, the LED control unit 112 constitutes "LED control means", and the input unit 113 constitutes "input means".

The LED lights 111a and 111b and the camera 120 are arranged corresponding to the winding position P1 (see FIG. 4).

The LED lights 111a and 111b have LEDs (light emitting diodes) and lighting circuits for lighting the LEDs. The LED lights 111a and 111b emit predetermined light (for example, , visible light such as red light, and infrared light). In order to more clearly image the various sheets 2 to 5 with the camera 120, it is preferable to irradiate the separator sheets 2 and 3 with red light or infrared light, which has the property of being transmitted.

In the present embodiment, the LED lights 111a and 111b start lighting when the LED control unit 112 starts supplying current. However, it takes some time (rise time tx) from the start of current supply until the brightness of the LED lights 111a and 111b becomes sufficiently high (see FIG. 14).

Also, the LED lights 111a and 111b are turned off when the current supply from the LED control unit 112 is stopped. However, it takes some time (falling time ty) from the time the current supply is stopped until the light emission of the LED lights 111a and 111b is completely extinguished.

The LED control unit 112 is configured by a computer having a CPU, RAM, storage medium, and the like. The LED control unit 112 switches between lighting and extinguishing of the LED lights 111a and 111b by switching between supply and stop of current supply.

In addition, in the present embodiment, the LED control unit 112 is provided with the lighting time t1 per lighting time of the LED lights 111a and 111b when the intermittent lighting control described later is performed, and the imaging time by the camera 120 (the imaging time of the imaging element 122 described later). Exposure time t2 and lighting start time t3 are stored (see FIGS. 14 and 16 for times t1 to t3). The lighting start time t3 is a time indicating the current supply timing to the LED lights 111a and 111b based on the imaging start timing by the camera 120. FIG.

Furthermore, the LED control unit 112 stores information about the current values supplied to the LED lights 111a and 111b, and the rise time tx and the fall time ty of the LED lights 111a and 111b (see FIGS. 14 and 16). . By increasing or decreasing the supply current value, the brightness of the LED lights 111a and 111b can be increased or decreased.

Also, the LED control unit 112 switches between intermittent lighting control and continuous lighting control according to the operating speed of the winding device 10 . The intermittent lighting control is control for intermittently lighting the LED lights 111a and 111b in accordance with the imaging timing of the camera 120. FIG. Continuous lighting control is control for continuously lighting the LED lights 111 a and 111 b regardless of the imaging timing by the camera 120 .

In this embodiment, the LED control unit 112 performs intermittent lighting control when the operating speed of the winding cores 13 and 14 in the winding device 10 is lower than a predetermined reference speed. When intermittent lighting control is performed, the LED control unit 112 performs the following operation each time the winding cores 13 and 14 rotate once.

That is, the LED control unit 112 uses the pulse signal sent from the control device 81, the lighting start time t3 (see FIG. 16), etc., so that the rotation angle (phase) of the winding cores 13 and 14 becomes the imaging execution angle θ2. The previous current supply start timing is calculated.

Then, when the calculated supply start timing comes, the LED control unit 112 starts supplying current to the LED lights 111a and 111b. When the rotation angle of the winding cores 13 and 14 reaches the imaging execution angle θ2 due to the start of the current supply, the LED lights 111a and 111b emit light with sufficiently high luminance.

After that, the LED control unit 112 stops supplying the electrodes to the LED lights 111a and 111b at the timing when the lighting time t1 has passed since the supply of current was started.

When the LED control unit 112 operates as described above, the LED lights 111a and 111b are alternately turned on and off when the intermittent lighting control is performed. Note that "lights out" refers to a state in which power is not being supplied to the LED lights 111a and 111b.

Furthermore, the LED control unit 112 performs continuous lighting control when the operating speed of the winding cores 13 and 14 is higher than the reference speed. When performing continuous lighting control, the LED control unit 112 continuously supplies current to the LED lights 111a and 111b. Therefore, when continuous lighting control is performed, the LED lights 111a and 111b continue to light.

Note that the LED control unit 112 calculates the current supply start timing even when performing continuous lighting control. However, when continuous lighting control is performed, the calculated current supply start timing is not used for power supply to the LED lights 111a and 111b, but is used for determination by the determination unit 112a described below. .

Furthermore, the LED control unit 112 has a determination unit 112a that determines switching between intermittent lighting control and continuous lighting control. The determination unit 112a performs determination using the lighting period T (see FIG. 16) corresponding to the operating speed of the winding device 10 (cores 13 and 14) and the reference period corresponding to the reference speed. The lighting cycle T refers to the time interval between current supply start timings. On the other hand, the reference period is a threshold for determination that is set based on the lighting time t1 and the like. In this embodiment, the reference cycle is set to a time equal to the lighting time t1.

More specifically, the determination unit 112a calculates the lighting cycle T of the LED lights 111a and 111b based on the calculated current supply start timing each time the winding cores 13 and 14 make one rotation. In addition, when the calculated lighting period T is greater than the reference period, that is, when the operating speed of the winding cores 13 and 14 is lower than the reference speed, the determination unit 112a performs intermittent lighting control. It is determined to be performed, and the continuous lighting flag is turned off. The continuous lighting flag is information for determining which of intermittent lighting control and continuous lighting control is to be executed. If the continuous lighting flag is off, intermittent lighting control is performed, and if the continuous lighting flag is on, continuous lighting control is performed.

On the other hand, when the calculated lighting period T is shorter than the reference period, that is, when the operating speed of the winding cores 13 and 14 is higher than the reference speed, the determination unit 112a performs continuous lighting control. is determined, and the continuous lighting flag is turned on. In this embodiment, the determination unit 112a performs continuous lighting control even when the rotation period T is equal to the reference period, that is, when the operating speed of the winding cores 13 and 14 is equal to the reference speed. is determined, and the continuous lighting flag is turned on.

By configuring the LED control unit 112 as described above, as shown in FIGS. At the initial stage of winding sheets 2 to 5, the continuous lighting flag is turned off, and intermittent lighting control is performed. Therefore, current is intermittently supplied to the LED lights 111a and 111b, and the LED lights 111a and 111b alternately turn on and off.

Then, when the operation speed of the cores 13 and 14 increases and reaches the middle stage of winding the various sheets 2 to 5, and the lighting cycle T becomes smaller than the reference cycle, the continuous lighting flag is switched from off to on, Intermittent lighting control is switched to continuous lighting control. With the switching to the continuous lighting control, current is continuously supplied from the LED control unit 112 to the LED lightings 111a and 111b, and the LED lightings 111a and 111b are continuously lit.

After that, the various sheets 2 to 5 are further wound up, and when the winding of the various sheets 2 to 5 is reached, the operation speed (rotational speed) of the cores 13 and 14 gradually decreases, so that the lighting continues. The flag is switched from on to off, switching from continuous lighting control to intermittent lighting control. As a result, the current supply to the LED lights 111a and 111b is intermittently performed again, and the LED lights 111a and 111b are alternately turned on and off. The LED lights 111a and 111b are turned off when the winding of the various sheets 2 to 5 is almost completed.

The input section 113 is used to input various information to the LED control section 112 . The input unit 113 can input the lighting time t1, the imaging time t2, the lighting start time t3, the rise time tx, the fall time ty, and the like to the LED control unit 112, respectively. However, the imaging time t2 that can be input is automatically limited to a time obtained by subtracting the rise time tx and the fall time ty from the lighting time t1. Also, the lighting start time t3 that can be input is automatically limited to a time equal to or longer than the rise time tx. In order to more reliably extend the life of the LED lights 111a and 111b, it may be configured such that only the lighting time t1, which is equal to or less than the preset upper limit time, can be input.

Returning to FIG. 5 , the inspection device 150 has a camera 120 and an image processing device 130 . In this embodiment, the camera 120 constitutes the "imaging means", and the image processing device 130 constitutes the "image processing means".

The camera 120 has sensitivity in the wavelength range of the light emitted from the LED lights 111a and 111b, and captures images of at least the various sheets 2 to 5 (inspection targets) illuminated by the LED lights 111a and 111b. is.

In this embodiment, two sets of the LED lights 111a and 111b and the camera 120 are provided. It is provided corresponding to the other edge in the width direction of the sheets 2-5.

Furthermore, in the imaging range of the camera 120, the positive electrode sheet 4 was positioned at the outermost periphery, the separator sheet 3 was positioned thereunder, the negative electrode sheet 5 was positioned thereunder, and the separator sheet 2 was positioned thereunder. state. Therefore, at least the positive electrode sheet 4 , the separator sheet 3 , the negative electrode sheet 5 visible through the separator sheet 3 , and the separator sheet 2 are imaged at once by the camera 120 .

The camera 120 has a lens 121 , an image sensor 122 , an image memory 123 and a camera control section 124 .

The lens 121 collects the light reflected from the various sheets 2 to 5 among the light emitted from the LED illuminations 111a and 111b, and forms an image on the imaging element 122. FIG. The lens 121 may be a general lens or a telecentric lens.

The imaging element 122 converts light passing through the lens 121 into an electric signal, and is configured by, for example, a CMOS image sensor or a CCD image sensor.

The image memory 123 stores the image input from the imaging device 122 . In this embodiment, one image is obtained while the winding cores 13 and 14 make one rotation when the various sheets 2 to 5 are wound, and this one image is stored in the image memory 123 . Also, the obtained image is sent to the image processing device 130 .

The image obtained by the camera 120 includes the positive electrode sheet 4, the separator sheet 3, the negative electrode sheet 5 captured through the separator sheet 3, and the separator sheet 2 (see FIG. 11). However, since the edges 2E and 3E (edges in the width direction) of the separator sheets 2 and 3 usually overlap each other, the separator sheet 2 may not be identified in the image. In this embodiment, the camera 120 is configured to have a relatively shallow depth of field, and the resulting image has a relatively high resolution, that is, a relatively high measurement resolution. .

The camera control unit 124 performs various controls related to the camera 120 . For example, the camera control section 124 outputs a trigger signal to the imaging device 122 . Each time the trigger signal is output, the image sensor 122 is exposed and images (image data) of various sheets 2 to 5 are output from the image sensor 122 to the image memory 123 . The output of the trigger signal is performed each time the imaging signal is input from the control device 81 . Accordingly, the camera 120 repeatedly performs imaging according to the movement of the winding cores 13 and 14 . Note that the camera control section 124 may be capable of adjusting the exposure time of the image sensor 122 using the imaging time t2 stored in the LED control section 112 .

In addition, the camera 120 is attached to a ball screw (not shown) extending parallel to the optical axis OP (see FIG. 4) of the lens 121, and the ball screw is rotated by being driven by a servomotor (not shown). As a result, the camera 120 is driven by the servomotor to move along the optical axis OP direction of the lens 121 relative to the winding cores 13 and 14 positioned at the winding position P1.

Further, the camera 120 is arranged at a preset initial position at least immediately before the various sheets 2 to 5 start to be wound around the winding cores 13 and 14 . The camera 120 arranged at the initial position is in a state in which the outer peripheral surfaces of the winding cores 13 and 14 are in focus.

By controlling the servomotor by the control device 81, while the various sheets 2 to 5 are being wound around the winding cores 13 and 14, the various sheets 2 to 5 positioned at the outermost periphery are brought into focus. , the camera 120 moves according to the thicknesses of the various sheets 2 to 5 wound around the cores 13 and 14. As shown in FIG.

When a predetermined movement stop signal is input from the control device 81, the servomotor stops the movement of the camera 120. FIG. Further, when a predetermined position reset signal is input from the control device 81, the servo motor resets the position of the camera 120 to the initial position.

The image processing device 130 performs an inspection process regarding misalignment of various sheets 2 to 5 based on the image obtained by the camera 120 . Inspection results are sent to the control device 81 . Incidentally, the inspection process will be described later.

Next, the winding process of the various sheets 2 to 5 by the winding device 10 will be described. Prior to the winding process, the separator sheets 2 and 3 are previously arranged in the gap 13c (14c) in one winding core 13 (14), and the separator sheets 2 and 3 are attached to the chuck portions 15a and 15b. (see FIG. 12).

In the winding process, as shown in FIG. 6, first, in step S11, one winding core 13 (14) is rotated by a predetermined number so that the separator sheets 2 and 3 are wound around the one winding core 13 (14). is taken up by a predetermined amount. After that, the chuck portions 15a and 15b are moved to their retracted positions.

Next, in step S12, the sheet inserting mechanism 71 of the negative electrode sheet supply mechanism 41 supplies the negative electrode sheet 5 to one winding core 13 (14) side. Specifically, the sheet insertion mechanism 71 that grips the negative electrode sheet 5 approaches the winding portion 11 side, and the negative electrode sheet 5 is inserted between the separator sheets 2 and 3, whereby the negative electrode sheet 5 is supplied. be done. After the insertion, the grip of the negative electrode sheet 5 by the sheet inserting mechanism 71 is released, and the sheet inserting mechanism 71 returns to its original position.

In the subsequent step S13, after the supply of the negative electrode sheet 5, one winding core 13 (14) is rotated by a predetermined number (for example, 1). A positive electrode sheet 4 is supplied to the core 13 (14) side. Specifically, the sheet insertion mechanism 71 that grips the positive electrode sheet 4 approaches the winding portion 11 side, and the positive electrode sheet 4 is inserted between the separator sheets 2 and 3, whereby the positive electrode sheet 4 is supplied. be done. After the insertion, the grip of the positive electrode sheet 4 by the sheet inserting mechanism 71 is released, and the sheet inserting mechanism 71 returns to its original position.

Next, in step S14, an imaging process is performed. The imaging step is a step of repeatedly imaging the various sheets 2 to 5 with the camera 120 while the various sheets 2 to 5 are wound by the winding cores 13 and 14 .

In the imaging process, as shown in FIG. 7, first, in step S31, one of the winding cores 13 (14) starts to rotate, whereby various sheets 2 to 5 are wound. As the various sheets 2 to 5 start to be wound, the camera 120 moves away from the cores 13 and 14 at a speed corresponding to the rotational speed of the cores 13 and 14 .

In the subsequent step S32, it is determined whether or not the feed amount of the positive electrode sheet 4 has reached a predetermined amount. That is, it is determined whether or not the end condition of the imaging process is satisfied. As the feeding amount of the positive electrode sheet 4, the feeding amount of the various sheets 2 to 5 from the start of winding, which is acquired by the nip roller encoder, is used. Also, this predetermined amount corresponds to the length of the positive electrode sheet 4 constituting one battery element. When the positive electrode sheet 4 is fed to the winding cores 13 and 14 by the predetermined amount, the end portion of the positive electrode sheet 4 for one element is arranged corresponding to the sheet cutting cutter 72 .

If the determination in step S32 is affirmative, it is time to end the imaging process, so the process proceeds to step S38.

On the other hand, if the determination in step 32 is negative, in step S33, based on the latest inspection result obtained by the inspection process by the image processing device 130, the rolled sheets 2 to 5, that is, the rolled sheets It is determined whether or not there is a defect in the battery element 1 on the way.

If there is no defect in the battery element 1 that is being wound (step S33: No), the process proceeds to step S36. On the other hand, if there is a defect in the battery element 1 during winding (step S33: Yes), the winding of the various sheets 2 to 5 is stopped halfway in step S34, and the battery element in the middle of winding is stopped in step S35. 1 is determined to be defective, and the process proceeds to step S40.

In step S36, based on the information about the rotation angle of the one winding core 13 (14) output from the winding core encoder 82, it is determined whether the rotation angle of the one winding core 13 (14) is the imaging execution angle θ2. is determined. In other words, it is determined whether or not it is time for the camera 120 to capture an image.

If a negative determination is made in step S36, it is not time to perform imaging by the camera 120, so the process returns to step S32. On the other hand, if the determination in step S36 is affirmative, the process proceeds to step S37 so that the camera 120 can perform imaging, and an imaging signal is output from the control device 81 to the camera 120 . As a result, a trigger signal is output from the camera control unit 124, and the various sheets 2 to 5 being wound are imaged by the camera 120. FIG. An image obtained by imaging is output from the camera 120 to the image processing device 130 . After step S37, the process returns to step S32.

As the winding of the various sheets 2 to 5 progresses and the total thickness of the various sheets 2 to 5 wound around one of the winding cores 13 (14) increases, the camera 120 moves in the direction of the optical axis OP. , gradually moving in the direction away from one core 13 (14). As a result, each time the rotation angle of one of the winding cores 13 (14) reaches the imaging execution angle θ2, the distance from the outermost wound portion of the various sheets 2 to 5 to the camera 120 becomes substantially constant. Various types of sheets 2 to 5 are positioned within the in-focus range of 120 . Therefore, a focused image is acquired.

When the inspection is carried out smoothly and the feeding amount of the positive electrode sheet 4 reaches a predetermined amount (step S32: YES), the process proceeds to step S38, and the rotation of one of the winding cores 13 and 14 is stopped. Next, in step S39, the battery element 1 in the middle of winding is finally determined as a non-defective product, and the process proceeds to step S40.

When the battery element 1 in the middle of winding is determined to be a non-defective product or a defective product, the camera 120 is stopped by outputting a movement stop signal from the control device 81 to the servomotor in step S40. Then, in step S41, a position reset signal is output to the servomotor to return the camera 120 to the initial position, and the imaging process ends.

Returning to FIG. 6, after the imaging process of step S14 is performed, the positive electrode sheet 4 is gripped by the sheet inserting mechanism 71 and then cut by the sheet cutting cutter 72 in step S15. be. In the inspection process, if the battery element 1 in the middle of winding is determined to be a non-defective product, the terminal portion of the positive electrode sheet 4 for one element is cut. On the other hand, if the battery element 1 in the middle of the winding is determined to be defective in the inspection process, the positive electrode sheet 4 is cut at a position before the end portion.

In the subsequent step S16, it is determined whether or not a good determination was made in the inspection process. If the determination is good, the rotation of one winding core 13 (14) is restarted, and the process proceeds to step S17.

On the other hand, if a negative determination is made in step S16, the process proceeds to step S18 without restarting the rotation of one winding core 13 (14). That is, when the battery element 1 in the middle of winding is determined to be defective, the supply of the negative electrode sheet 5 is stopped.

In step S17, it is repeatedly determined whether or not the feed amount of the negative electrode sheet 5 from the start of supply has reached a predetermined amount until the condition is satisfied. This predetermined amount corresponds to the length of the negative electrode sheet 5 constituting one battery element. The feed amount of the negative electrode sheet 5 is derived based on the feed amounts of the various sheets 2 to 5 obtained by the nip roller encoder. If the determination in step S17 is affirmative, that is, if the terminal end of the currently wound negative electrode sheet 5 for one element has reached the sheet cutting cutter 72, one winding core 13 (14) rotates. is temporarily stopped, and the process proceeds to step S18.

In step S<b>18 , the negative electrode sheet 5 is gripped by the sheet inserting mechanism 71 and then cut by the sheet cutting cutter 72 .

Next, in step S19, by restarting the rotation of one winding core 13 (14), the end portions (unwound portions) of the electrode sheets 4 and 5 are wound up.

In step S20 following step S19, the turret 12 is rotated counterclockwise without cutting the separator sheets 2 and 3. As shown in FIG. As a result, one of the cores 13 (14) at the winding position P1 draws out the separator sheets 2 and 3 from the separator supply mechanisms 51 and 61 and moves to the removal position P2. On the other hand, the other winding core 14 (13) at the removal position P2 moves toward the winding position P1 while being submerged in one of the tables of the turret 12 .

Subsequently, in step S21, one winding core 13 (14) around which the various sheets 2 to 5 are wound is rotated in accordance with the rotation of the turret 12. FIG.

Then, in the next step S22, the winding process is completed by performing winding end processing.

In the winding end process, first, when the amount of rotation of one of the winding cores 13 (14) from the cutting of the negative electrode sheet 5, which is detected by the winding core encoder 82, reaches a predetermined amount, one of the winding cores is rotated. The rotation of 13 (14) is stopped. The rotation of the turret 12 is stopped before and after the rotation of one core 13 (14) is stopped, or at the same time when the rotation is stopped.

When one core 13 (14) and the turret 12 stop rotating, the one core 13 (14) at the winding position P1 is positioned at the removal position P2, and the other core 13 (14) at the removal position P2 is positioned at the removal position P2. The winding core 14 (13) is positioned at the winding position P1.

In this state, the pressing roller 17 is moved closer to one of the winding cores 13 (14), whereby the various sheets 2 to 5 are pressed by the pressing roller 17. FIG. Further, the separator sheets 2 and 3 are held between the positions P1 and P2 by moving the chuck portions 15a and 15b from the retracted positions to the clamping positions. After that, the separator sheets 2 and 3 are cut by the separator cutter 16 approaching the separator sheets 2 and 3 (see FIG. 13).

Further, the other core 14 (13) protrudes from one table of the turret 12, so that the separator sheets 2 and 3 are arranged in the gap 14c (13c) of the other core 14 (13). In the next winding step, the other core 14 (13) is rotated by a predetermined amount, so that the separator sheets 2 and 3 are wound by a predetermined amount on the outer circumference of the core 14 (13). Then, the electrode sheets 4 and 5 are supplied to the other winding core 14 (13) around which the separator sheets 2 and 3 are wound.

After the separator sheets 2 and 3 are cut, one winding core 13 (14) is rotated while the various sheets 2 to 5 are pressed by the pressing roller 17. FIG. As a result, the end portions of the various sheets 2 to 5 are completely wound up without unraveling. After that, the end portions of the separator sheets 2 and 3 are stopped by the fixing tape by the tape attaching mechanism 18, and the winding end processing is completed. The wound battery element 1 is removed from one winding core 13 (14) by the removing device. Then, the battery element 1 determined as non-defective is sent to a regular line. On the other hand, the battery element 1 determined as a defective product is sent to a predetermined defective product discharging mechanism.

Next, an inspection process by the image processing device 130, which is performed in parallel with the imaging process, will be described. In this embodiment, the inspection process corresponds to the "image processing process".

In the inspection process, as shown in FIG. 8, first, in step S61, whether or not a new image has been input from the camera 120 is repeatedly determined. Then, when the image is input, the process proceeds to step S62.

In step S62, the input image is subjected to binarization processing based on a predetermined threshold value, and the edge portion 3E (width direction edge) of the separator sheet 3 is processed based on the binarized image obtained by this processing. part), the edge portion 2E of the separator sheet 2, the edge portion 4E of the positive electrode sheet 4, and the edge portion 5E of the negative electrode sheet 5 are extracted (see FIG. 11). If the edge portions 2E and 3E overlap and the edge portion 2E cannot be extracted, the edge portion 3E is treated as the edge portion 2E.

In the following step S63, based on the input image, the boundary portion 4T between the active material coated portion 4a and the active material uncoated portion 4b on the positive electrode sheet 4, the active material coated portion 5a and the active material coated portion 5a on the negative electrode sheet 5, and Boundary portion 5T of active material uncoated portion 5b is extracted (see FIG. 11).

Next, in step S64, various distances are calculated based on the edge portions 2E, 3E, 4E and 5E and the boundary portions 4T and 5T extracted in steps S62 and S63. That is, the positional deviation amounts of the various sheets 2 to 5 wound around one of the winding cores 13 (14) are calculated.

Specifically, with the edge portion 3E as a reference, the distance L1 to the boundary portion 4T in the sheet width direction, the distance L2 to the edge portion 4E in the sheet width direction, and the distance L3 to the boundary portion 5T in the sheet width direction. , the distance L4 to the edge portion 5E in the sheet width direction and the distance (not shown) to the edge portion 2E in the sheet width direction (see FIG. 11).

After that, in step S65, it is determined whether or not each distance is within a preset allowable range based on each distance calculated in step S64.

Here, if it is determined that any one of the distances is not within the allowable range, that is, if there is a winding displacement in the various sheets 2 to 5 or a displacement in the application position of the active material-coated portions 4a and 5a. If so, it is determined in step S66 that the battery element 1 in the middle of winding is defective, and the process returns to step S61.

On the other hand, if it is determined in step S65 that all the distances are within the allowable range, it is determined in step S67 that there is no defect in the battery element 1 during winding, and the process returns to step S61.

Incidentally, the pass/fail determination method in the inspection process may be changed as appropriate. For example, quality determination may be made based on the absolute positions of the various sheets 2 to 5 instead of the relative positions. In this case, for example, marks provided on the winding cores 13 and 14 may be used to obtain the absolute positions of the various sheets 2-5. Also, inspection items performed in the inspection process may be changed as appropriate.

Next, the control mode determination process by the determination unit 112a, which is performed in parallel with the imaging process, will be described. The control mode determining step is a step for determining which of intermittent lighting control and continuous lighting control is to be performed.

In the control mode determining process, as shown in FIG. 9, first, in step S81, it is determined whether or not it is time to calculate the lighting cycle T. Whether or not it is the calculation timing is determined based on a pulse signal sent from the control device 81, for example.

If the determination in step S81 is affirmative, the lighting period T is calculated in step S82. Next, in step S83, it is determined whether or not the calculated lighting period T is longer than the reference period. If the lighting period T is longer than the reference period (step S83: Yes), the continuous lighting flag is turned off in step S84, and the process returns to step S81.

On the other hand, if the determination in step S83 is negative, that is, if the calculated lighting period T is shorter than the reference period, the continuous lighting flag is turned on in step S85, and the process returns to step S81. Also when the lighting period T is equal to the reference signal, the continuous lighting flag is turned on in step S85, and the process returns to step S81.

Next, the irradiation process by the LED lighting device 110, which is performed in parallel with the imaging process, will be described. In the irradiation step, as shown in FIG. 10, first, in step S101, it is determined whether or not the continuous lighting flag is ON. That is, it is determined which of the intermittent lighting control and the continuous lighting control is to be executed.

If a negative determination is made in step S101, that is, if intermittent lighting control is to be performed, it is determined in step S102 whether or not it is time to turn off the LED lights 111a and 111b. This is determined based on whether or not the lighting time t1 has elapsed from the current supply start timing.

When an affirmative determination is made in step S102, the process moves to step S103, stops the supply of current to the LED lights 111a and 111b, and moves to step S104. The LED lights 111a and 111b are extinguished by stopping the current supply. On the other hand, when a negative determination is made in step S102, step S103 is skipped and the process proceeds to step S104. If a negative determination is made in step S102, the state in which current is supplied to the LED lights 111a and 111b or the state in which the current supply to the LED lights 111a and 111b is stopped is continued.

In step S104, it is determined whether or not it is time to turn on the LED lights 111a and 111b. This is determined based on the current supply start timing calculated by the LED control unit 112 .

When an affirmative determination is made in step S104, the process proceeds to step S105, starts (resumes) the supply of current to the LED lights 111a and 111b, and returns to step S101. On the other hand, if a negative determination is made in step S104, step S105 is skipped and the process returns to step S101. If a negative determination is made in step S104, the state in which current is supplied to the LED lights 111a and 111b or the state in which the current supply to the LED lights 111a and 111b is stopped is continued. In this embodiment, steps S102 to S105 correspond to the "intermittent lighting process".

If the determination in step S101 is affirmative, that is, if continuous lighting control is to be performed, the process proceeds to step S106 to start or continue supplying current to the LED lights 111a and 111b, and then returns to step S101. In this embodiment, the process of step S106 corresponds to a "continuous lighting process."

As described in detail above, according to the present embodiment, when the operating speed of the winding device 10 is relatively low, the LED lights 111a and 111b are lit intermittently, and the operating speed of the winding device 10 is relatively low. When it is high, continuous lighting of the LED lights 111a and 111b is performed. Therefore, the lighting time (energization time) of the LED lights 111a and 111b can be reduced as compared with a configuration in which only continuous lighting is performed, and the life of the LED lights 111a and 111b can be extended. In addition, the shift of the wavelength of the light emitted from the LED lights 111a and 111b is less likely to occur, and deterioration in inspection accuracy can be suppressed.

On the other hand, when the operation speed of the winding device 10 is high and the imaging interval is short, continuous lighting control enables imaging with sufficiently high-intensity light emitted from the LED lights 111a and 111b. Therefore, it is possible to obtain a good image that does not interfere with the inspection, and it is possible to more reliably prevent deterioration of the inspection accuracy.

Further, the determination unit 112a for determining switching between intermittent lighting control and continuous lighting control is provided in the LED control unit 112 . Therefore, compared to the case where the determination section is provided on the winding device 10 side (for example, the control device 81), there is no need to excessively change the setting or configuration of the winding device 10 side. As a result, it is possible to more easily obtain the effects such as the longer life of the LED lights 111a and 111b described above.

In addition, the input unit 113 can input the lighting time t<b>1 and the like to the LED control unit 112 . This makes it possible to easily perform appropriate settings according to inspection conditions, use environments, and the like.

In addition, it is not limited to the description content of the said embodiment, For example, you may implement as follows. Of course, other applications and modifications not exemplified below are naturally possible.

(a) In the above-described embodiment, the determination unit 112a is configured to perform determination related to switching between intermittent lighting control and continuous lighting control based on the lighting cycle T. On the other hand, the determination unit 112a makes the determination based on a value other than the lighting period T, which varies according to the operating speed of the winding device 10 [for example, a light-off time (see FIG. 14), etc.]. may

(b) In the above embodiment, the determination unit 112a provided in the LED control unit 112 is configured to perform determination regarding switching between continuous lighting control and intermittent lighting control. On the other hand, the winding device 10 side (for example, the control device 81) may be configured to make the determination. In this case, the determination result is sent from the control device 81 to the LED control section 112, and the LED control section 112 controls the LED lights 111a and 111b based on the sent determination result.

Further, in the above embodiment, a pulse signal is sent from the control device 81 to the LED control unit 112, and the LED control unit 112 uses this pulse signal to control the lighting or extinguishing of the LED lights 111a and 111b. is configured to On the other hand, an encoder signal indicating the phase of the cores 13 and 14 is input from the core encoder 82 to the LED control section 112, and the LED control section 112 detects the phases of the cores 13 and 14 ascertained from the encoder signals. may be configured to control the LED illuminations 111a and 111b using the phase of .

(c) In the above embodiment, the winding device 10 is used as a "mechanical device", but the mechanical device is not limited to the winding device. The "mechanical device" may be, for example, a PTP packaging machine for manufacturing PTP sheets.

The PTP packaging machine includes transport means for transporting the container film (for example, a film feeding roll), means for forming a pocket portion in the transported container film, means for filling the pocket portion with contents (tablets, etc.), and It has a means for attaching a cover film to the container film so as to cover the pocket after filling, a means for obtaining a PTP sheet by cutting the PTP film in which the cover film is attached to the container film, and the like.

Further, the PTP packaging machine is provided with imaging means for repeatedly imaging in accordance with the operation (conveyance of the container film) of the PTP packaging machine (especially the transportation means), and an image for performing inspection processing based on the image obtained by the imaging means. An inspection device may be provided having a processing means. The image pickup means picks up an image of an object to be inspected, such as the pocket portion and contents.

The LED illumination device according to the present invention can be applied to such an inspection device as follows. That is, the LED illumination is set so as to irradiate light toward the object to be imaged (inspection object) that is intermittently transported. The object to be imaged repeatedly starts and stops moving. More specifically, the object to be imaged repeats the movement of gradually accelerating from a stopped state, reaching a predetermined maximum speed, then gradually decelerating, and finally stopping again.

The LED control means switches between intermittent lighting control and continuous lighting control according to the operating speed of the PTP packaging machine. For example, when the operating speed of the PTP packaging machine (conveyance speed of the object to be imaged) is lower than a predetermined reference speed, the LED lighting is intermittently turned on in accordance with the imaging timing of the imaging means, and the operating speed of the PTP packaging machine is reduced. is higher than the reference speed, the LED illumination is lit continuously.

By applying the LED lighting device according to the present invention to the inspection device provided in the PTP packaging machine as described above, it is possible to extend the life of the LED lighting and improve the inspection accuracy as in the above embodiment. can be more reliably prevented from decreasing.

(d) In the above embodiment, when the intermittent lighting control is performed, the current supply to the LED lights 111a and 111b is started at the timing before the lighting start time t3 from the start of imaging by the camera 120. It is Therefore, the rotation angles of the winding cores 13 and 14 at the start of current supply can vary. On the other hand, when the intermittent lighting control is performed, the current supply to the LED lights 111a and 111b may be started at the timing when the rotation angles of the winding cores 13 and 14 become constant rotation angles. . That is, the rotation angle of the winding cores 13 and 14 may be always constant when starting to supply current. In the case of such a configuration, by comparing the time required for the rotation angle of the winding cores 13 and 14 to reach the imaging execution angle θ2 from the above constant angle with the rise time tx, continuous lighting can be performed. A determination may be made regarding switching of control or intermittent lighting control.

(e) In the above embodiment, the determination unit 112a is configured to determine switching between intermittent lighting control and continuous lighting control based on the reference cycle (lighting time t1) and the lighting cycle T. On the other hand, the determination unit 112a may perform the above determination based on the magnitude of the light emission duration ta (see FIG. 17) with respect to the lighting cycle T. The light emission continuation time ta refers to the time during which the LED lights 111a and 111b continue to emit light when the intermittent lighting control is performed. The light emission duration ta includes the fall time ty, and can be said to be the total time of the lighting time t1 and the fall time ty.

When the determination unit 112a is configured as described above, intermittent lighting control is performed when the light emission duration ta is shorter than the lighting cycle T, and continuous lighting control is performed when the light emission duration ta is longer than the lighting cycle T. can be done. Therefore, as shown in FIG. 17, during the intermittent lighting control, the time from the stop of the current supply to the LED lights 111a and 111b to the next start of the current supply can be made longer than the fall time ty. As a result, it is possible to reduce the processing load associated with current supply, and to improve the operational stability. In addition, it is possible to use a device whose response speed for current switching is not so high, and it is possible to reduce costs.

(f) The reference used when determining switching between intermittent lighting control and continuous lighting control (corresponding to the reference cycle in the above embodiment) may be a numerical value of 1, or a certain range. It may be a numerical range having. In the latter case, for example, determination may be made based on whether or not a value that varies according to the operating speed of the mechanical device (for example, lighting cycle T) is included in this numerical range.

(g) In the above embodiment, the lighting time t1, the lighting start time t3, and the like are configured not to change when the imaging process is performed. It may be configured such that the time t3 and the like are automatically changed.

(h) In the above embodiment, the camera 120 is configured to move when the various sheets 2 to 5 are wound, but the configuration may be such that the camera 120 does not move.

DESCRIPTION OF SYMBOLS 10... Winding apparatus (mechanical apparatus) 100... Inspection unit 110... LED lighting apparatus 111a, 111b... LED illumination 112... LED control part (LED control means) 112a... Judgment part (judgment means) 113... Input unit (input means) 120 Camera (imaging means) 130 Image processing device (image processing means) 150 Inspection device.

Means 1. an imaging means for repeatedly performing imaging in accordance with the operation of the mechanical device;
An LED lighting device for an inspection device, comprising an image processing means for performing inspection processing based on the image obtained by the imaging means,
an LED lighting that emits light toward an object to be imaged by the imaging means;
LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means is
Intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing by the imaging means, or continuous lighting for continuously lighting the LED lighting regardless of the imaging timing according to the operating speed of the mechanical device It is configured to be able to switch lighting control,
when the operating speed of the mechanical device is relatively low, performing the intermittent lighting control;
The LED lighting device , wherein the continuous lighting control is performed when the operating speed of the mechanical device is relatively high .

Means 5. an inspection apparatus having imaging means for repeatedly imaging in accordance with the operation of a mechanical device, and image processing means for performing inspection processing based on the image obtained by the imaging means;
An inspection unit comprising an LED lighting device having LED lighting that irradiates light toward an object to be imaged by the imaging means,
The LED lighting device has LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means is
Intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing by the imaging means, or continuous lighting for continuously lighting the LED lighting regardless of the imaging timing according to the operating speed of the mechanical device It is configured to be able to switch lighting control,
when the operating speed of the mechanical device is relatively low, performing the intermittent lighting control;
The inspection unit , wherein the continuous lighting control is performed when the operating speed of the mechanical device is relatively high .

Means 7. an imaging step of repeatedly performing imaging according to the operation of the mechanical device;
an image processing step of performing inspection processing based on the image obtained by the imaging step;
and an irradiation step of irradiating an object to be imaged in the imaging step with a predetermined LED illumination,
In the irradiation step,
An intermittent lighting step of intermittently lighting the LED lighting in accordance with the imaging timing in the imaging step according to the operating speed of the mechanical device, or a continuous lighting of the LED lighting regardless of the imaging timing. The lighting process is switched and performed,
When the operating speed of the mechanical device is relatively low, the intermittent lighting step is performed,
The inspection method , wherein the continuous lighting step is performed when the operating speed of the mechanical device is relatively high .

Means 1. an imaging means for repeatedly performing imaging in accordance with the operation of the mechanical device;
An LED lighting device for an inspection device, comprising an image processing means for performing inspection processing based on the image obtained by the imaging means,
an LED lighting that emits light toward an object to be imaged by the imaging means;
LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means is
Intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing by the imaging means according to the operating speed of the mechanical device , and continuous lighting for continuously lighting the LED lighting regardless of the imaging timing It is configured to be able to switch between control and
when the operating speed of the mechanical device is lower than a predetermined reference speed , performing the intermittent lighting control;
The LED lighting device, wherein the continuous lighting control is performed when the operating speed of the mechanical device is higher than a predetermined reference speed .

Means 2. Determination means for determining switching between the intermittent lighting control and the continuous lighting control ,
The LED lighting device according to means 1, wherein the determination means is provided in the LED control means.

Means 4. Determination means for determining switching between the intermittent lighting control and the continuous lighting control ,
The determination means performs the intermittent lighting control according to the magnitude of the light emission duration of the LED lighting when the intermittent lighting control is performed with respect to the lighting cycle of the LED lighting determined according to the operating speed of the mechanical device . 4. The LED lighting device according to any one of means 1 to 3, characterized in that switching to the continuous lighting control is determined.

Means 5. an inspection apparatus having imaging means for repeatedly imaging in accordance with the operation of a mechanical device, and image processing means for performing inspection processing based on the image obtained by the imaging means;
An inspection unit comprising an LED lighting device having LED lighting that irradiates light toward an object to be imaged by the imaging means,
The LED lighting device has LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means is
Intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing by the imaging means according to the operating speed of the mechanical device , and continuous lighting for continuously lighting the LED lighting regardless of the imaging timing It is configured to be able to switch between control and
when the operating speed of the mechanical device is lower than a predetermined reference speed , performing the intermittent lighting control;
The inspection unit, wherein the continuous lighting control is performed when the operating speed of the mechanical device is higher than a predetermined reference speed .

Means 6. Determination means for determining switching between the intermittent lighting control and the continuous lighting control ,
The inspection unit according to means 5, wherein the determination means is provided in the LED control means.

Means 7. an imaging step of repeatedly performing imaging according to the operation of the mechanical device;
an image processing step of performing inspection processing based on the image obtained by the imaging step;
and an irradiation step of irradiating an object to be imaged in the imaging step with a predetermined LED illumination,
In the irradiation step,
an intermittent lighting step of intermittently lighting the LED illumination in accordance with the imaging timing in the imaging step according to the operating speed of the mechanical device ; and a continuous lighting step of continuously lighting the LED illumination regardless of the imaging timing. The process and are performed by switching,
When the operating speed of the mechanical device is lower than a predetermined reference speed , the intermittent lighting step is performed,
The inspection method, wherein the continuous lighting step is performed when the operating speed of the mechanical device is higher than a predetermined reference speed .

Claims (7)

an imaging means for repeatedly performing imaging in accordance with the operation of the mechanical device;
An LED lighting device for an inspection device, comprising an image processing means for performing inspection processing based on the image obtained by the imaging means,
an LED lighting that emits light toward an object to be imaged by the imaging means;
LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means performs intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing of the imaging means, or lighting the LED lighting regardless of the imaging timing, according to the operating speed of the mechanical device. 1. An LED lighting device characterized in that it is configured to switch continuous lighting control for continuous lighting. Determination means for determining switching between the intermittent lighting control and the continuous lighting control,
2. The LED lighting device according to claim 1, wherein the determination means is provided in the LED control means. An input means capable of inputting a lighting time for each LED illumination at least when the intermittent lighting control is performed to the LED control means,
3. The LED lighting device according to claim 1, wherein the LED control means controls the LED lighting based on the input lighting time. Determination means for determining switching between the intermittent lighting control and the continuous lighting control,
The determining means determines switching between the intermittent lighting control and the continuous lighting control according to the magnitude of the light emission duration of the LED lighting when the intermittent lighting control is performed with respect to the lighting cycle of the LED lighting. The LED lighting device according to any one of claims 1 to 3, characterized by: an inspection apparatus having imaging means for repeatedly imaging in accordance with the operation of a mechanical device, and image processing means for performing inspection processing based on the image obtained by the imaging means;
An inspection unit comprising an LED lighting device having LED lighting that irradiates light toward an object to be imaged by the imaging means,
The LED lighting device has LED control means for controlling lighting and extinguishing of the LED lighting,
The LED control means performs intermittent lighting control for intermittently lighting the LED lighting in accordance with the imaging timing of the imaging means, or lighting the LED lighting regardless of the imaging timing, according to the operating speed of the mechanical device. An inspection unit characterized in that it is configured to be able to switch between continuous lighting control for continuously lighting. Determination means for determining switching between the intermittent lighting control and the continuous lighting control,
6. The inspection unit according to claim 5, wherein said determination means is provided in said LED control means. an imaging step of repeatedly performing imaging according to the operation of the mechanical device;
an image processing step of performing inspection processing based on the image obtained by the imaging step;
and an irradiation step of irradiating an object to be imaged in the imaging step with a predetermined LED illumination,
In the irradiation step, an intermittent lighting step of intermittently lighting the LED illumination in accordance with the imaging timing in the imaging step according to the operating speed of the mechanical device, or continuously lighting the LED illumination regardless of the imaging timing. An inspection method, characterized in that a continuous lighting process for lighting the lamp is alternately performed.

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