JP4073670B2 - Image inspection system - Google Patents

Description

[0001]
[Field of the Invention]
The present invention is required for required materials such as a roll forming line for producing a shaped steel with a predetermined cross-section by adding roll forming to a strip steel sheet fed from an uncoiler, and a tube mill line for producing a pipe by roll forming and welding. This is related to an inspection system for inspecting whether or not the molding operation is properly performed in a continuous molding line in which product production is performed by adding molding, and in particular, the material being molded or the material after molding is imaged. The present invention relates to an image inspection system that performs inspection by comparing the captured image data with stored image data stored in advance and analyzing the difference numerically.
[0002]
[Technical background]
In the roll forming line, the strip steel sheet fed from the uncoiler is formed into a predetermined shape by a roll forming machine and then cut. The roll forming machine often requires fine adjustment of the forming roll, and in particular, it is said that correction due to a difference in material or the like requires skill. Further, even by adjustment by a skilled person, many defective products are generated until the shape to be molded is stabilized.
[0003]
In recent years, the number of lines that include a hole drilling process is increasing in the previous process of roll forming. However, such lines are prone to problems such as variations in molding dimensions due to roll forming and waviness. In addition, since the inspection is performed after the product is completed, a large number of defective products are generated until the line adjustment is completed.
[0004]
In order to solve this type of problem, the applicant of the present invention has taken an image of a molded product, and compared with the reference image data stored in advance to analyze the imaged data to determine whether the molding is good or bad. An application was filed (Japanese Patent Application No. 2000-254879). However, in this invention,
If the captured image data deviates more than expected from the reference image data, it may be difficult or impossible for the user to use the molding line. In some cases, it was necessary for the engineer on the molding line provider side who performed the design installation to go to the molding line to deal with it.
[0005]
[Technical solutions]
In view of the above-described points, the present invention provides an image inspection system for enabling quick and appropriate handling even when imaging data is deviated more than expected from reference image data. It is aimed.
[0006]
[Means for solving]
That is, the image inspection system according to the present invention inspects a forming operation of a continuous forming line for manufacturing a product by adding a required forming to a required material, such as a roll forming line or a tube mill line for forming a strip-shaped metal material into a predetermined shape. And an image inspection system for performing necessary correction control for the molding operation based on the inspection result, which is installed on the user side of the continuous molding line. From the user side, such as the first image inspection apparatus for inspecting whether or not the molding operation to be performed is appropriate based on imaging data of the shape of the material during or after molding, and the provider side of the continuous molding line A second image that is installed at a remote location and inspects whether or not the molding operation performed on the continuous molding line is appropriate based on imaging data of the shape of the material during or after molding The first image inspection apparatus includes an imaging unit that images the material during or after molding, imaging data obtained based on imaging by the imaging unit, and pre-stored reference image data And a first image analysis unit for comparing and analyzing, and based on the analysis result, a correction control necessary for the molding operation in the continuous molding line can be performed. The inspection apparatus includes a second image analysis unit that compares and analyzes imaging data obtained based on imaging by the imaging unit and reference image data stored in advance, and the first and second image inspection apparatuses are connected to a telephone line, It is possible to connect via a communication line such as Ethernet (registered trademark), the image data is analyzed by the second image inspection device, and the above-described continuous molding line is processed based on the analysis result. It performs takes necessary correction control to the molding operation, characterized in that to allow.
[0007]
The first image inspection apparatus includes correction data for performing correction control on the molding line in advance based on the analysis result in the first image analysis unit, selects correction data according to the analysis result, and based on the correction data The correction control can be performed.
[0008]
The first image inspection apparatus can have input means for the operator to correct and add correction data provided in the apparatus in advance.
In addition, the second image inspection apparatus may have a correction unit for correcting and adding correction data provided in advance in the first image inspection apparatus.
[0009]
The correction means of the second image inspection apparatus is an input for the operator to correct or add correction data provided in advance in the first image inspection apparatus according to the analysis result in the second image analysis unit. Means can be included.
[0010]
The second image inspection apparatus includes correction data for performing correction control on the molding line in advance based on the analysis result in the second image analysis unit, selects correction data according to the analysis result, and based on the correction data The correction control can be performed.
[0011]
When the material supplied to the molding line is a long material, the first and second image analysis units analyze cross-sectional shapes at different positions in the length direction of the long material that has undergone molding. Further, it is possible to inspect warpage and twist in the length direction of the long material.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment when the image inspection system according to the present invention is applied to a roll forming line will be described.
[0013]
A roll forming line 1 shown in FIG. 1 forms an uncoiler 11 that feeds a steel plate 10 from a strip-shaped steel plate 11 wound in a cylindrical shape (to the right in FIG. 1), and the steel plate 10 from the uncoiler 11 into a predetermined cross-sectional shape. And a traveling cutting machine 13 that cuts the steel plate 10 formed into a predetermined shape by the roll forming machine 12 into a predetermined length.
The roll forming machine 12 has a plurality of forming roll portions 14 arranged in the direction of steel plate transfer, and the steel plate 10 is formed into a predetermined shape by passing the plurality of forming roll portions 14. Is done.
The traveling cutting machine 13 cuts the steel sheet into a predetermined length while traveling at the same speed as the steel sheet 10 formed into a predetermined shape.
The present invention provides an image inspection system that captures an image of a steel sheet formed in such a roll forming line 1 and determines whether or not the forming operation in the line is properly performed based on the image data. However, in the example shown in FIG. 1, the camera 15 that captures the steel sheet is set to the position where the steel sheet 10 has passed the forming machine 12, that is, the steel sheet is imaged when the forming operation is completed. . The position of this camera can be set to a required position in accordance with the inspection purpose, and FIG. 1 shows only one camera, but it is preferable to set a plurality of images and take images from various angles. .
As shown in FIG. 2, the image inspection system according to the present invention includes a first image inspection device 30 installed on the user side of the molding line 1 and the molding line provider side located remotely from the user side. The image inspection apparatuses 30 and 40 are connected to each other through an existing communication line such as a telephone line or Ethernet (registered trademark).
The first image inspection device 30 compares the imaging data processed by the image processing unit 17 with the image processing unit 17 that intermittently acquires and processes the imaging data captured by the camera 15 and the reference image data, and compares the difference. An image analysis unit 18 that performs numerical analysis, a storage unit that stores reference image data, correction data for instructing correction necessary for forming on the roll forming line in accordance with an analysis result by the image analysis unit 18 (FIG. (Not shown). The image processing unit 17 performs a process of extracting data related to the contour shape of the formed steel sheet from data captured by the camera. 3 and 4 show an example in which the contour shape data and the reference image data are displayed as images on the monitor screen of the image analysis unit when a steel plate is formed into channel steel.
In FIG. 2, the second image inspection device 40 shows only its appearance, but as with the first image inspection device 30, an image processing unit that processes imaging data, a storage unit, and an image analysis Department.
[0014]
FIG. 5 shows a flowchart of the inspection work by the image inspection system.
The normal inspection work is performed based on the first image inspection apparatus 30 on the molding line user side.
First, the camera 15 continuously images the formed steel plate.
The image processing unit 17 intermittently acquires imaging data and sets it as contour shape data representing the contour of the formed steel plate (step 61), and the contour shape data is compared with the reference image data (step 62). If the difference (deviation) from the reference image data is within the allowable range (FIG. 3), the process returns to step 61, the same operation is repeated, and the molding operation is continued without any correction on the roll forming line.
[0015]
When the difference between the contour shape data and the reference image data exceeds the allowable range (FIG. 4), a numerical analysis is performed to determine which portion is deformed beyond the allowable range (step 64). Based on this, optimum data is selected from the correction data stored in advance in the storage unit (step 65), and the selected correction data is transmitted to the cutting machine control unit, molding machine control unit, or feeder control unit. (Step 66).
Each control unit receives the correction data (step 70) and starts the required correction (step 71). A large number of correction data can be prepared for each pattern of a change in molding shape (for example, a dimension shift in the width direction, a change in molding angle, etc.).
[0016]
If the correction data stored in advance is not appropriate or is insufficient, the operator on the molding line user side can correct or add correction data via an input means (not shown). It can be done.
[0017]
However, when the formed steel sheet has undergone a deformation that is more unexpected than the standard shape, it may be difficult or impossible for the operator on the forming line user side to respond. In such an image inspection system according to the present invention, in such a case, imaging data on the molding line is received by the image inspection device on the molding line provider side, and an operator on the molding line provider side performs image analysis. Thus, it is possible to perform necessary correction control for the molding operation in the molding line.
[0018]
That is, in such a case, the image inspection device 40 on the molding line provider side and the image inspection device 30 on the molding line user side are connected (step 50), and the imaging data from the camera is sent to the molding line provider. The same image inspection work as that performed in the first image inspection apparatus 30 is performed (steps 61'-66 '), and necessary correction data is supplied to the first image inspection apparatus 30. Based on this, correction data necessary for correction work in the image inspection apparatus is corrected and added, and correction control necessary for the molding operation on the molding line is performed. In this case, at the stage where it was possible to analyze which part is deformed and how much (step 64 '), the analysis result is transmitted to the operator on the molding line user side, and correction by the first image inspection apparatus is performed by the operator. Data can be corrected and added. Further, if it is known that the cause of the abnormal deformation is, for example, due to wear of the forming roll, it can be transmitted to the operator of the first image inspection apparatus, and the forming roll can be replaced.
[0019]
As described above, in the image inspection system according to the present invention, the necessary correction in the line is performed while continuously performing the forming operation in the forming line. In addition to performing inspections, warpage and twisting in the length direction of the steel sheet can be inspected and corrected. That is, if it describes in the example shown in FIG. 4, the groove | channel bottom edge outline b'-c 'in a'-b'-c'-d' which shows the outline shape of the cross section of the shape | molded grooved steel plate will be shown. , Lifted from the reference bc, it can be seen that the warp in the length direction has occurred, and b'-c 'is inclined in the left-right direction, it can be seen that the twist has occurred However, in the present invention, the amount of movement can be measured by moving the contour shape a′-b′-c′-d ′ so as to coincide with the reference image abcd. By performing on other cross sections of the grooved steel sheet, the degree of warpage and twisting of the steel sheet can be analyzed based on the distance between the cross sections and the measured movement amount.
[0020]
【The invention's effect】
The image inspection system according to the present invention is as described above, and the image analysis apparatus installed on the molding line provider side (roll forming line provider side) can perform image analysis on the shape of the molded product. If the molded shape is beyond expectation and it is difficult or impossible for the molding line user to respond, the molding line provider will respond (that is, perform image analysis). Based on this, it is possible to give an instruction on the molding line user side, such as a correction method for the molding line, and perform the necessary correction.
[0021]
Further, in such a case, the image inspection device on the molding line provider side instructs the image inspection device on the molding line user side to correct the molding line molding operation from the image inspection device on the molding line provider side. It is also possible to add or modify correction data.
[0022]
Furthermore, the operator on the molding line provider side can remotely control the molding line from the image inspection apparatus. That is, the operator can perform necessary correction work in the molding line in real time while looking at the monitor screen of the image inspection apparatus on the equipment provider side.
[0023]
Furthermore, when the material to be molded is a long material, it is possible to inspect warpage or twist generated in the material during molding. This warp and twist inspection can be performed without the need for a dedicated camera.
[Brief description of the drawings]
FIG. 1 is a side view of a roll forming line in which an image inspection system according to the present invention is used.
FIG. 2 is a block diagram of an image inspection system according to the present invention.
FIG. 3 is a diagram showing imaging data and reference image data represented as images on a monitor screen of an image processing unit in the image inspection system.
4 is a diagram showing imaging data and reference image data represented as images as in FIG. 3;
FIG. 5 is a flowchart of image processing performed in the image inspection system and control based thereon.
1: Roll forming line 15: Imaging means (camera)
17: Image processing unit 18: Image analysis unit 20: Cutting machine control unit 21: Molding machine control unit 22: Feeder control unit 30: First image inspection device 40: Second image inspection device

Claims (5)

Inspect the forming operation of a continuous forming line that manufactures products by adding the required forming to the required material, such as a roll forming line and tube mill line that form the strip metal material into a predetermined shape, and based on the inspection result, the forming operation In the image inspection system for enabling the necessary correction control to be performed,
Wherein is installed in the first place a user side of the continuous molding line, whether the molding operation proper or performed in the continuous molding line, inspected based on the sensing data of the shape of the material during and after molding or shaping a first image inspection device, wherein are installed from the second location a was in the first place is a provider side of the continuous molding line in a remote place, the molding operation or proper to be performed in the continuous molding line A second image inspection device that inspects whether or not based on imaging data of the shape of the material during or after molding,
The first image inspection apparatus, compares the imaging means for imaging the material during or after molding the molding, the imaging data obtained on the basis of imaging by the imaging means, and a first reference image data stored in advance and a first image analysis unit for analyzing a row Umono the necessary correction control to the forming operation in the continuous molding line based on the analysis result,
The second image inspection apparatus includes an imaging data obtained on the basis of imaging by the imaging means, the second image analysis unit for comparative analysis and the second reference image data stored in advance,
Said first and second image inspection device, connected through a communication line including a telephone line, the analysis processing of the image data by the second image inspection apparatus were made in the first image inspection device Is performed in the same manner as described above, and based on the analysis result, necessary correction control to the molding operation in the continuous molding line is performed,
The first image inspection apparatus has an input means for an operator for correcting and adding correction data provided in advance in the apparatus,
The image inspection system, wherein the second image inspection apparatus includes correction means for correcting and adding correction data provided in advance in the first image inspection apparatus . The image inspection system of claim 1, wherein the first image inspection apparatus, based on the analysis result in the first image analysis unit, the correction data previously provided with for correcting control to the molding line, vision inspection system, wherein the selected correction data according to the analysis result, and performs the correction control based thereon. The image inspection system of claim 1, wherein the second of said correction means of the image inspection device, provided in advance in the second image analysis in the analysis result of the first image inspection apparatus in accordance with the portion An image inspection system having an input means for an operator for correcting and adding correction data. The image inspection system according to any one of claims 1 to 3, wherein the second image inspection apparatus, based on the analysis result in the second image analysis unit, for performing correction control to the molding line correction data previously provided with, by selecting the correction data corresponding to the analysis result, an image inspection system, characterized in that it performs the correction control based thereon. The image inspection system according to any one of claims 1 to 4, wherein a material elongate material fed to the molding line, the first and second image analysis unit has received the molding the vision inspection system, characterized in that by analyzing the cross-sectional shape at different positions in the length direction of the elongated material, is intended to inspect the warpage or twisting in the longitudinal direction of the elongated material.

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