JP3500711B2 - Appearance inspection device - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an appearance inspection device which allows a user program created by a user to specify an inspection item in an appearance inspection device for determining the quality of the appearance of a product or the like in a production process by image processing. It relates to the device.

[0002]

2. Description of the Related Art In recent years, in a production process, an external appearance of an object to be inspected such as a work conveyed on a line is imaged by an image input device such as a TV camera, and the image obtained by the image input device is subjected to image processing. As a result, an appearance inspection device is used that determines whether the appearance of the object to be inspected is good or bad. In this type of appearance inspection device, it is necessary to set measurement conditions and determination conditions before the inspection in order to obtain required information (dimension / shape and quality) from the image. The conditions to be set before the inspection include inspection start conditions for instructing the timing of imaging the inspection object with the image input device, the position or range of the inspection area such as a line or window set with the inspection object as a reference, and the input image. Procedure of correcting the position of the inspection area in the image according to the position of the inspection object in the image, the area of the inspection object from the information obtained in the inspection area, the position of the center of gravity, the direction of the main axis, dimensions, shape, etc. There is a procedure (generally represented by a mathematical expression) for determining various characteristic amounts of, and a criterion of quality of the characteristic amount. Since these measurement conditions and determination conditions differ for each type of measured object, they are managed as product type data for each measured object.

On the other hand, since the appearance inspection apparatus has a limited function provided in advance as a system, an appearance in which a user program can be described so that the user can expand or change the function as needed. Inspection devices have been proposed. In particular, in the product data, the inspection area for the inspected object, the feature amount to be extracted from the inspected area, and the inspection content, which is the criterion for determining the feature amount, differ from inspected item to inspected item. Often needed.

[0004]

By the way, in the above-mentioned appearance inspection apparatus, if an inspection item is to be defined by a user program, the user will not only describe the appearance inspection apparatus in detail in the characteristics of the apparatus itself in addition to the program description method. There is a problem in that the user program cannot be easily set without sufficient knowledge even though the user program is structured so that it can be written. In particular, with the recent improvement in the function of the appearance inspection device, it has become difficult to know the details of the device, and the development of a user program has become more difficult.

Further, the appearance inspection apparatus is provided with a plurality of types of inspection item data in advance as a system so that a desired inspection item can be selected from a plurality of types of inspection items.
Necessary inspection items can be selected by operating switches provided on the appearance inspection device. The inspection item data selected in this way is written to the inspection item memory (generally a partial area of the memory is allocated) managed by the system program and used for inspection. Since the program is written in a program memory (generally a partial area of the memory is allocated) provided separately from the inspection item memory, the inspection item data created by the user program cannot be used by the system program. That is, there is a problem that the inspection item data created by the user program cannot be handled in the same way as the inspection item data prepared in the appearance inspection device, and can be used only by the user program. As a result, even if it is considered that the inspection item can be executed by actually delivering the inspection item data to the system program, it is necessary to describe the process of executing the inspection item data in the user program. It is a heavy burden for users who want to create programs.

Further, when the visual inspection device is used as a visual sensor of a working device such as a processing device, an inspection device, and an assembly device, if there are a plurality of working devices that perform the same operation, the visual inspection with the same inspection item data is set. Requires multiple devices. In this case, after setting the inspection item data for one visual inspection device and adjusting the device, the inspection item data is copied to each visual inspection device. It is necessary to manually adjust the inspection item data according to the error in the relative position between the image input device used for the target device and the inspected object, and the adjustment work is time-consuming and the results may vary. there were.

The present invention has been made in view of the above problems. A first object of the present invention is that, when describing inspection item data as a user program, a system program can be diverted as an execution process of inspection item data. about,
The user program can be reused, and the inspection item data can be handled without providing the system program and the user program, facilitating the creation of the user program. The second purpose is to perform all inspections. By allowing the user program to read and write the item data, by describing the adjustment method for device variations as the user program,
An object of the present invention is to provide a visual inspection device that enables automatic adjustment of inspection item data.

[0008]

According to a first aspect of the present invention, there is provided an appearance inspection apparatus for performing an appearance inspection of an inspection object by performing image processing on an image obtained by picking up an image of the inspection object with an image input device. A rewritable inspection item memory for storing inspection item data indicating the inspection area and inspection content in the image, and inspection item data provided separately from the user program.
The execution processing unit that executes the inspection by using, and the inspection item data included in the user program created by the user is extracted.
A test item extracting unit for storing the test item memory Te, and a scheduler to be passed to the execution processing unit test items selected data with each inspection item data stored in the inspection item memory selects a predetermined procedure, The scheduler is characterized by being started by a user program.

According to a second aspect of the present invention, the inspection item memory stores the inspection item data set separately from the user program and the inspection item data included in the user program in a mixed manner. To do. According to a third aspect of the present invention, in an appearance inspection apparatus that performs an appearance inspection of an inspection object by performing image processing on an image obtained by capturing the inspection object with an image input device, Using the inspection item memory, which is a volatile memory that stores the inspection item data shown, and the inspection item data
The execution processing unit that executes the inspection, the storage memory that is the non-volatile memory that stores the inspection item data registered in the inspection item memory, and the user program created by the user .
A test item extracting unit for storing inspection item data to the inspection item memory extracted and the contained, the execution processing inspection item data selected with the respective inspection item data stored in the inspection item memory selects a predetermined procedure And a scheduler which is handed over to the department, and the scheduler is activated by a user program.

According to a fourth aspect of the present invention, there is provided an appearance inspection device that performs an appearance inspection of an inspection object by performing image processing on an image obtained by capturing the inspection object with an image input device.
An inspection item memory that is a volatile memory that stores inspection item data indicating an inspection area and inspection content in an image, and an inspection
Extraction and execution processing unit for executing a test by using the item data, the storage memory is a nonvolatile memory that stores the inspection item data, the test <br/>査項th data included in the user program the user has created The inspection item extraction unit that stores the data in the memory for storage and the data copying unit that copies the inspection item data from the memory for storage in the inspection item memory, and each inspection item data stored in the memory for the inspection item is selected in a predetermined procedure. the inspection item data selected while a scheduler to be passed to the execution unit, the scheduler characterized in that it is activated by the user program.

According to a fifth aspect of the invention, the inspection item data stored in the storage memory is permitted to be modified by the user program.

[0012]

According to the invention of claim 1, the inspection item data included in the user program created by the user is stored in the inspection item memory, and each inspection item data stored in the inspection item memory is selected by the scheduler in a predetermined procedure. In addition, the inspection item data selected by the scheduler is passed to the existing execution processing unit that executes the inspection using the inspection item data, and the scheduler is started by the user program, so the inspection item data is sent to the user program. At the time of description, the existing process included in the visual inspection apparatus as a system can be used for the process of executing the inspection corresponding to the inspection item data. Compared with the case described in, the time required to create a user program is significantly Is Gensa. Also, the existing execution processing unit is created by the manufacturer in consideration of the characteristics of the appearance inspection device, and the inspection is performed only by passing the inspection item data to the existing execution processing unit. Therefore, it is not necessary for the user to consider the characteristics of the details of the appearance inspection device, and even a user who does not have sufficient knowledge about the appearance inspection device can relatively easily create a user program. .

According to the second aspect of the present invention, since the user program and the existing inspection item data are mixed in the inspection item memory, the same inspection item data as the inspection item data held by the visual inspection apparatus is stored in the user program. When used, it can be used by simply transferring the existing inspection item data to the inspection item memory, the amount of description of inspection items in the user program is reduced, and the creation of the user program becomes easier.

According to the third aspect of the present invention, a volatile memory is used as the inspection item memory, and a storage memory including a non-volatile memory for storing the inspection item data registered in the inspection item memory is added. Allows the inspection item data to be saved in the storage memory even when the power is cut off, and the next time the power is turned on, the inspection item data can be copied from the storage memory to the inspection item memory to perform the inspection. There is no need to reset inspection item data again.

According to a fourth aspect of the present invention, like the configuration of the third aspect, the inspection item data is stored in a storage memory composed of a non-volatile memory, and the inspection item data is stored in the storage memory. Since it is copied to the inspection item memory after it is stored, even if the power is cut off while setting the inspection item data, the already set inspection item data will remain in the storage memory, making the inspection item data safer. Can be saved.

According to the invention of claim 5, the inspection item data stored in the storage memory is permitted to be corrected by the user program. Therefore, even the inspection item data once set can be corrected as necessary. When the difference between the inspection item data before correction and the inspection item data after correction is small, new inspection item data can be created using the inspection item data stored in the storage memory. This makes it easier to create inspection item data.

[0017]

【Example】

(Embodiment 1) First, the overall structure of the appearance inspection apparatus used in this embodiment will be outlined. As shown in FIG. 2, the appearance inspection apparatus 1 converts an image of an object to be inspected captured by a CCD camera 2 as an image input device into a digital image by an A / D converter 3 and stores the digital image in an image memory 4. A /
The image obtained by the D converter 3 and the image memory 4 is processed by the image processing unit 5 including a microcomputer, and the characteristic amount necessary for the inspection of the inspection object is obtained. The arithmetic processing unit 6 determines whether the object to be inspected is good or bad based on the characteristic amount obtained by the image processing unit 5, and reads or writes the image memory 4. Here, in the image processing unit 5, the grayscale image is binarized, the binarized image is written in the image memory 4, and the feature amount is obtained for this binarized image. The images stored in the image memory 4 are
It is also output to a monitor 8 such as a CRT through the D / A converter 7. Further, the arithmetic processing unit 6 is provided with an input / output unit 9 for exchanging data with an external device such as a computer device and transmitting the result obtained by the appearance inspection device 1 and the external device. As the input / output unit 9, RS232
A general-purpose interface such as C or RS422 and an interface for connecting a keyboard are provided. Further, the arithmetic processing unit 6 includes a nonvolatile memory 12 including an EEPROM or a SRAM backed up by a power source.
And DRAM or SR without power backup
A volatile memory 11 made of AM is provided. The non-volatile memory 12 stores user programs read and written through the input / output unit 9, and the volatile memory 11
Stores inspection item data and the like.

Next, the operation of the image processing unit 5 will be described. As shown in FIG. 1, test査項th data DTu described in the user program Pu is written in the area At the scheduler 13 to be described later a region As the system program for managing one of the volatile memory 11 is referenced. That is, the area At provided in the volatile memory 11 is used as the inspection item memory. Here, the inspection item data DTu is extracted from the user program Pu and the area At is extracted.
The work of writing to is executed by the inspection item extraction unit realized by the system program that describes the function of the image processing unit 5. The scheduler 13 is also realized by a system program, and has a function of determining the execution order of the inspection item data so as to utilize the characteristics of the appearance inspection device 1 as a device and executing the inspection item data DTu described in the system program. It has a function of delivering the inspection item data DTu to the execution processing unit.

In the scheduler 13, for example, as shown in FIG. 3, first, the number of inspection item data that can be processed at a time by the image processing unit 5 is confirmed (S1), and then the inspection item data DTu in the area At is targeted for inspection items. Is a white pixel (2
It is determined whether or not there is a pixel on the bright side of the threshold value of the binarized image) (S2). If there is the inspection item data DTu targeting the white pixels, the inspection item data DTu of the number equal to or less than the number confirmed in step S1 for the inspection item data DTu targeting the white pixels are fetched (S3), and the execution processing unit of the system program is executed. The inspection item data DTu is delivered (S4), and the inspection item data D for the object to be inspected
The required feature amount set by Tu is obtained (S5). If there is unprocessed inspection item data DTu for the white pixels (S6), the process returns to step S3 to fetch the next inspection item data DTu.

When the inspection item for the white pixels is completed, it is determined whether or not there are black pixels (pixels on the dark side with respect to the threshold value among the pixels of the binarized image) (S7). .
Thereafter, as in the case of the white pixels, the inspection item data DTu, which is equal to or less than the number that can be processed at the same time, is fetched (S8) and delivered to the execution processing unit of the system program (S9) to obtain the characteristic amount of the inspection object (S10). . When all the inspection item data DTu for the black pixels are processed (S1
1), the processing of the scheduler 13 ends.

In the above procedure, step S5 and step S
In 10, the execution processing unit in the system program executes the inspection item data DTu to obtain the characteristic amount, so that the user does not need to know the detailed characteristics of the appearance inspection apparatus 1 and simply outputs the inspection item data DTu to the user program Pu.
It should be described as. In addition, the portion which executes the execution processing of the inspection item data DTu is the user program P.
Since it is not necessary to describe it as u, the user program P
The description of u becomes easy, and the size of the user program Pu can be reduced compared to the conventional case if the same processing is performed.

The activation of the scheduler 13 may be performed by the user program Pu, and the inspection item data DTu described in the user program Pu by the activation of the scheduler 13 from the user program Pu.
Is executed by the execution processing unit of the system program. (Second Embodiment) In the first embodiment, only the inspection item data DTu is written from the user program Pu into the area At managed by the scheduler 13, but in the present embodiment,
As shown in FIG. 4, the inspection item data DTs set by the system program is written in the area At together with the inspection item data DTu. That is, in the inspection procedure described by the user program Pu, the inspection item data D already prepared in the system program
In some cases, Ts may be diverted. Therefore, inspection item data DT prepared in plural types in the system program
Of s, desired inspection item data DTs is selected and stored in the region At, and the inspection item data DTu defined by the user program Pu is also stored in the region At. Area At of the required inspection item DTs from the system program
The work of storing in the input / output unit 9 provided in the visual inspection apparatus 1
It can be done by a command from.

The inspection item data DTs and DTu are in the area At
Then, the scheduler 13 is activated from the user program Pu and the inspection item data DTs and DTu are executed by the system program as in the first embodiment. Other configurations are similar to those of the first embodiment. (Example 3) In Example 2, the inspection item data DTs, D
Although Tu was stored only in the area At set in the volatile memory 11, in this case, the inspection item data DTs and DTu will be lost when the power is turned off. Therefore, in this embodiment, as shown in FIG. 5, the inspection item data DTs and DTu stored in the area At are stored in the nonvolatile memory 1.
It is designed to be stored in 2.

That is, the inspection item data DT is set in the area At.
After storing s and DTu, a corresponding appropriate empty area of the non-volatile memory 12 (this area becomes a storage memory)
The inspection item data DTs and DTu are copied to the.
When the power is turned on, the inspection item data DTs and DTu are copied from the non-volatile memory 12 to the area At, and the inspection can be executed. Here, the copying of the inspection item data DTs, DTu between the volatile memory 11 and the non-volatile memory 12 is processed by the data copying unit described in the system program. Other configurations and operations are similar to those of the second embodiment.

(Embodiment 4) In this embodiment, as shown in FIG. 6, the inspection item data DTu defined by the user program Pu is first stored in an appropriate empty area of the non-volatile memory 11 (this area becomes a storage memory). ), And the inspection item data DTs selected from the system program are also stored in the non-volatile memory 12. In this way, after the inspection item data DTs and DTu are arranged in the non-volatile memory 12, the inspection item data DTs and DTu are copied to the area At managed by the scheduler 13 in the volatile memory 11. This copying is processed by the data copying unit realized by the system program.

In the procedure of this embodiment, the inspection item data DT
Since s and DTu are temporarily stored in the non-volatile memory 12, the inspection item data DTs and DTu can be held even when the power is turned off, as in the third embodiment. Other configurations and operations are similar to those of the second embodiment. (Fifth Embodiment) This embodiment is an example in which the inspection item data DTs and DTu already stored in the non-volatile memory 12 can be used by the newly described user program Pu, and is shown in FIG. User program P
In u, the inspection item data DTs and DTu read from the non-volatile memory 12 are corrected and can be stored again in the non-volatile memory 12. When such processing is performed, the user program Pu is stored in the non-volatile memory 12 as in the third or fourth embodiment.
Inspection item data D actually used by the user program Pu
There is no significant difference between Ts and DTu and the inspection item data DTs and DTu already stored in the non-volatile memory 12, and the inspection item data DTs and DTu stored in the non-volatile memory 12 can be simply modified. If it can be used in a certain degree, the inspection item data D in the user program Pu
The definition of Ts and DTu becomes easy.

For example, when the inspection item data DTs and DTu are set in a plurality of appearance inspection devices that perform the same work, the inspection item data DTs and DTu adjusted by one appearance inspection device 1 are used for other appearance inspection devices. When copied to the inspection device 1,
In the other appearance inspection device 1, the inspection object and the image input device (CC
Adjustment work such as correction of the position included in the inspection item data DTs, DTu for the difference in relative position with the D camera 2) is required. If such an adjustment work is manually performed, it may be time-consuming and the contents of the adjustment may vary. Therefore, in the user program Pu, a process for automatically adjusting the inspection item data DTs and DTu as shown in FIG. Is added. That is, the positional deviation caused by the mechanical error of the device is measured (S1), and the mechanical error is calculated (S2). Positional correction is performed on the inspection item data DTs and DTu with respect to the error thus obtained (S3). Also, the inspection item data DTs and DTu for obtaining the optimum threshold value necessary for obtaining the binarized image.
Is executed (S4), the threshold is corrected and the threshold is stored in the non-volatile memory 12 (S5). Next, step S
The inspection item data DTs and DTu whose position has been corrected in step 3 are executed (S6), and the inspection item data DT for the object to be inspected
The position deviations of s and DTu are corrected, and the corrected inspection item data DTs and DTu are registered in the nonvolatile memory 12 (S7). Here, the judgment criterion is also corrected if necessary.

By using the user program Pu as described above, it is possible to set the inspection item data DTs and DTu for a plurality of appearance inspection devices 1 according to the machine difference of the appearance inspection devices 1. Since it is set automatically, there is no hassle.

[0029]

According to the invention of claim 1, the inspection item data included in the user program created by the user is stored in the inspection item memory, and each inspection item data stored in the inspection item memory is subjected to a predetermined procedure by the scheduler. In addition, the inspection item data selected by the scheduler is passed to the existing execution processing unit that executes the inspection using the inspection item data, and the scheduler is started by the user program. When describing the data, the existing process that the visual inspection device has as a system can be used as the process for executing the inspection corresponding to the inspection item data. Compared to writing in a user program, the time required to create the user program is It has the advantage of being reduced to the width.
Also, the existing execution processing unit is created by the manufacturer in consideration of the characteristics of the appearance inspection device, and the inspection is performed only by passing the inspection item data to the existing execution processing unit. Therefore, the user does not need to consider the characteristics of the details of the appearance inspection device, and even a user who does not have sufficient knowledge about the appearance inspection device can create a user program relatively easily. There is.

According to the second aspect of the present invention, since the user program and the existing inspection item data are mixed in the inspection item memory, the same inspection item data as the inspection item data possessed by the appearance inspection apparatus can be stored in the user program. When used, it can be used by simply transferring the existing inspection item data to the inspection item memory, which reduces the description amount of the inspection item in the user program and makes it easier to create the user program. is there.

According to the third aspect of the invention, a volatile memory is used as the inspection item memory, and a storage memory including a non-volatile memory for storing the inspection item data registered in the inspection item memory is added. Allows the inspection item data to be saved in the storage memory even when the power is cut off, and the next time the power is turned on, the inspection item data can be copied from the storage memory to the inspection item memory to perform the inspection. There is an advantage that the trouble of resetting the inspection item data again does not occur.

According to a fourth aspect of the invention, like the third aspect of the invention, the inspection item data is stored in a storage memory composed of a non-volatile memory, and the inspection item data is stored in the storage memory. Since it is copied to the inspection item memory after it is stored, even if the power is cut off while setting the inspection item data, the already set inspection item data will remain in the storage memory, making the inspection item data safer. It has the advantage that it can be saved.

According to the fifth aspect of the present invention, the inspection item data stored in the storage memory is permitted to be corrected by the user program. Therefore, even the inspection item data once set can be corrected as necessary. When the difference between the inspection item data before correction and the inspection item data after correction is small, new inspection item data can be created using the inspection item data stored in the storage memory. Therefore, there is an effect that the inspection item data can be created more easily.

[Brief description of drawings]

FIG. 1 is a conceptual explanatory diagram of a first embodiment.

FIG. 2 is a block diagram of an appearance inspection device used in the first embodiment.

FIG. 3 is an operation explanatory diagram of a scheduler used in the first embodiment.

FIG. 4 is a conceptual explanatory diagram of a second embodiment.

FIG. 5 is a conceptual explanatory view of the third embodiment.

FIG. 6 is a conceptual explanatory diagram of the fourth embodiment.

FIG. 7 is a conceptual explanatory diagram of the fifth embodiment.

FIG. 8 is an operation explanatory diagram showing an example of a user program used in the fifth embodiment.

[Explanation of symbols]

1 Visual inspection device 11 Volatile memory 12 Non-volatile memory 13 scheduler At area DTp inspection item data DTu inspection item data Pu user program

─────────────────────────────────────────────────── ─── Continuation of the front page (56) Reference JP-A-6-186003 (JP, A) JP-A-3-59476 (JP, A) JP-A-5-340983 (JP, A) JP-A-6- 75014 (JP, A) JP-A-6-75939 (JP, A) JP-A-62-76756 (JP, A) JP-A-63-1245 (JP, A) JP-A-64-13477 (JP, A) JP-A-3-100409 (JP, A) JP-A-5-113879 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) G01B 11/24 G01N 21/88 G06T 1/00

Claims (5)

(57) [Claims] 1. A visual inspection apparatus for visual inspection of an object to be inspected by performing image processing on an image obtained by picking up an image of the object to be inspected by an image input device. Perform the inspection using the rewritable inspection item memory that stores the item data and the inspection item data.
Execution processing unit for executing, inspection item extraction unit for extracting inspection item data contained in the user program created by the user and storing it in the inspection item memory, and each inspection item data stored in the inspection item memory in a predetermined manner. and a scheduler to deliver the inspection item data selected with select in step to said execution processing unit, the appearance inspection apparatus scheduler is characterized in that it is activated by the user program. 2. The inspection item memory stores inspection item data preset in addition to the user program and inspection item data included in the user program in a mixed manner. Appearance inspection device. 3. An appearance inspection apparatus for performing an appearance inspection of an inspection object by performing image processing on an image obtained by picking up an image of the inspection object by an image input device, and an inspection indicating an inspection area and inspection content in the image. Using the inspection item memory, which is a volatile memory that stores item data, and the inspection item data
An execution unit for executing inspection, and storage memory is a nonvolatile memory that stores the inspection item data registered to the inspection item memory, including the user program that you have created
A test item extracting unit for Murrell storing inspection item data to the inspection item memory extract and the said run processing inspection item data selected with the respective inspection item data stored in the inspection item memory selects a predetermined procedure A visual inspection apparatus, comprising: a scheduler for handing over to a unit, the scheduler being activated by a user program. 4. An appearance inspection apparatus for performing an appearance inspection of an inspection object by performing image processing on an image obtained by picking up an image of the inspection object by an image input device, and an inspection indicating an inspection area and inspection content in the image. Using the inspection item memory, which is a volatile memory that stores item data, and the inspection item data
Execution processing unit that executes inspection, storage memory that is a non-volatile memory that stores inspection item data, and inspection item data included in user programs created by the user
The inspection item extraction unit that stores the data in the memory for storage and the data copying unit that copies the inspection item data from the memory for storage in the inspection item memory, and each inspection item data stored in the memory for the inspection item is selected in a predetermined procedure. and a scheduler for the inspection item data selected delivered to the execution processing unit as well as, appearance inspection apparatus scheduler is characterized in that it is activated by the user program. 5. The appearance inspection apparatus according to claim 3, wherein the inspection item data stored in the storage memory is permitted to be modified by a user program.