JP4772452B2 - Inter-process visualization system and computer program - Google Patents

Description

The present invention relates to engineering Hodoma visualization systems and computer programs, for example, using the production condition analysis in the image of the preferred technique in the production line.

  For example, a steel sheet production line is composed of a plurality of manufacturing processes such that a steel piece cast by a continuous casting machine is processed into a thick steel sheet and a thin steel sheet through a plurality of stages of rolling processes. In such a production system where (1) the material is rolled for each process and the length is changed, (2) the speed is different for each process, or (3) the production time in each process is different. Uses a monitoring device such as a wrinkle inspection device to detect appearance defects such as wrinkles and dirt in the entire steel sheet in each process for quality control.

  The quality control performed in such a production system is, for example, a graph for storing appearance defect data in appearance inspection in each process for each process, analyzing the tendency of the appearance defect, and feeding back to the operation. An inspection system that performs data output such as display has been proposed (see, for example, Patent Documents 1 and 2).

JP 2000-200388 A JP 2005-181347 A

  However, in the inspection system described in Patent Document 1, it is possible to know how many defects have occurred in each process, but there is a problem that it is not possible to know what kind of appearance defect is concretely. Moreover, in the inspection system described in Patent Document 2, it is possible to detect what kind of appearance defect is caused by pattern matching. However, the steel sheet is rolled by a process and the length is changed or manufactured. There was a problem that the speed was not considered. Moreover, since the image data of the steel plate photographed at each process is used as it is, there is a problem that the correspondence becomes insufficient depending on the process.

  In view of the above-mentioned problems, the present invention enables the correspondence of defective appearance parts between image data in each process when a single material is processed through a plurality of processes while being deformed and processed. The purpose is to do.

The inter-process visualization system of the present invention is arranged in each of a plurality of manufacturing steps constituting a manufacturing line for continuously deforming and processing a steel plate, and images imaged steel plates flowing in each of the plurality of manufacturing steps to generate image data. a plurality of inspection devices, and at least one or more databases storing data including an imaging time with the steel of lots that are Oite processed into each of the plurality of manufacturing steps, and a visualization aid device, via the network a visualization system between the connected process, said plurality of production processes each of the inspection apparatus captures the steel plate by the camera, while generating the image data, and the imaging time by detecting the movement status of said steel plate association and detects the passing speed and the length of the steel sheet, wherein the visualization support device placed to each of the plurality of production steps which are inputted from the database Based on the data including the image capturing time of about steel sheet processed lot and the length of the velocity and the steel plate manufacturing line, or a plurality of image data obtained from said plurality of production processes each of the inspection apparatus, et al, the same Calculation means for associating image data of a common steel plate part which is a corresponding position of a steel plate of a lot, and calculation results of the calculation means from each of a plurality of image data acquired by the inspection devices of each of the plurality of manufacturing steps Based on the pegging, the extraction means for extracting the image data of the common steel plate portion from the image data for the steel plates of the same lot, and the image data of the common steel plate portion extracted by the extraction means are displayed. And display means for displaying side by side on the apparatus.

The computer program of the present invention is characterized by causing a computer to realize the functions of each means of the visualization support apparatus in the inter-process visualization system described above.

  According to the present invention, based on data about a plurality of manufacturing processes, image data of a common steel sheet part is extracted from a plurality of image data, and a common steel sheet is extracted by associating appearance defects in each process. Since the image data of the part is displayed side by side on the display device, image data such as defective appearance in a production line where a steel sheet flows while a single material is deformed and processed at high speed in multiple processes, such as in the steel industry. Can be managed for each common steel plate part, and in which process the appearance defect has occurred can be reliably identified.

(First embodiment)
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a diagram showing an outline of an inspection system using a camera. In the present embodiment, an example of an inspection system in three steps of the first step A to the third step C will be described.
In the first step A, the raw material is processed, and in the second step B, the material manufactured in the first step A is used as a material. Further, the third step C is processed using the material manufactured in the second step B as a material.

  As shown in FIG. 1, when the raw steel plate 2 (a) passes through the first step A, the entire material of the steel plate 2 (a) is captured by the first step A camera 7 and a plurality of images. Data is generated. The plurality of pieces of image data are stored in the first process A image recorder 8. The raw material steel plate 2 (a) is processed in the first step A to become a steel plate 2 (b).

  And when this steel plate 2 (b) passes the next 2nd process B, the whole steel plate 2 (b) is imaged with the camera 11 for 2nd process B, and several image data are produced | generated. . These plural pieces of image data are stored in the second process B image recorder 12. The raw steel plate 2 (b) in the second step B is processed in the second step B to become a steel plate 2 (c).

  Similarly, when the raw steel plate 2 (c) in the third step C passes the next third step C, the entire material of the steel plate 2 (c) is imaged by the third step C camera 13. Thus, a plurality of image data is generated. The plurality of pieces of image data are stored in the third process C image recorder 14. In this way, a camera is installed for each process, and it is possible to inspect for each process whether or not appearance defects such as wrinkles and dirt have occurred. The product steel plate 2 (d) is manufactured by processing in the third step C.

FIG. 2 is a diagram illustrating a state in which the steel plates 2 (a) to 2 (d) are imaged by the camera. In FIG. 2, an example of imaging using the first process A camera 7 will be described.
The first process A camera 7 in the first process A inspection apparatus 4 is, for example, a CCD camera. As shown in FIG. 2, the light emitted from the illumination 3 and reflected by the steel plate 2 is reflected. The steel plate 2 placed on the road and illuminated by the illumination 3 is imaged, and the image is captured by the first process A image recorder 8 and displayed on the monitor 9 in real time.

FIG. 3 is a diagram illustrating an example of an inspection system according to the present embodiment.
The first process A image recorder 8, the second process B image recorder 12, and the third process C image recorder 14 are connected to a network 20. In the present embodiment, a first process A database 15, a second process B database 16, a third process C database 17, and an inter-process database 18 are connected to a network 20. Further, a visualization support device 19 capable of displaying each image data imaged and generated in the first process A to the third process C is connected to the network 20.

  The first process A database 15 stores detailed data of materials and products processed in the first process A. Specifically, information such as production line data, line speed in the first step A, and material length is stored. The second process B database 16 and the third process C database 17 store the detailed data of the materials and products processed in the second process B and the third process C, respectively. Yes.

  The inter-process database 18 stores information relating to materials and products processed in each process (first process A to third process C). Details will be described later with reference to FIG.

  The visualization support device 19 can display the image data captured by the first process A camera 7, the second process B camera 11, and the third process C camera 13 side by side. Details of the display procedure will be described later with reference to the flowchart of FIG.

FIG. 4 is a block diagram illustrating an example of functional configurations of the first process A inspection device 4 and the visualization support device 19 of the present embodiment.
In the first process A inspection apparatus 4, the movement state detection unit 31 detects the movement state of the steel plate 2 (a) moving in the production line direction (Y direction in FIG. 2), and generates a movement state detection signal. It has a function. Further, the current time measured by the time measuring unit 32 is associated with the movement status.

  The imaging control unit 33 controls the imaging unit 34 to monitor the passing speed and length of the steel plate 2 (a) flowing in the production line based on the movement state detection, and further, the illumination 3 and the imaging unit It has a function of controlling all 34 operations. The imaging unit 34 has a function of capturing the entire material of the steel plate 2 (a) to generate an image signal and detecting the passing speed and length of the steel plate 2 (a).

  The image processing unit 35 takes in the image signal generated by the imaging unit 34, performs predetermined image processing, for example, generates an image processing signal for display on the monitor 9, and converts the image signal into image data. And stored in the storage unit 37. The first process A inspection device 4 is connected to the network 20 via the network I / F 38. The second process B inspection apparatus 21 and the third process C inspection apparatus 22 are configured in the same manner as the first process A inspection apparatus 4, and thus the description thereof is omitted.

  Next, in the visualization support apparatus 19, the storage unit 41 stores information sent from the first process A inspection apparatus 4 and information read from the inter-process database 18. The visualization support apparatus 19 is connected to the network 20 via the network I / F 45 and can obtain various information from devices connected to the network 20.

  The image extraction unit 42, based on the result calculated by the calculation unit 44, the first process A inspection apparatus 4, the second process B inspection apparatus 21 and the third process stored in the storage unit 41. Image data at a specific position is extracted from the image data captured by the process C inspection apparatus 22. Details will be described later with reference to the flowchart of FIG. Then, each extracted image data is displayed on the display unit 43.

  The calculation unit 44 associates the image data acquired in the first process A to the third process C. This is because the imaging time of each image data is different, the line speed and the length of the steel plate 2 are different, and the position of the steel plate 2 is calculated in order to have the correspondence of the positions. Yes. A specific method will be described later with reference to the flowchart of FIG.

FIG. 5 is a diagram illustrating the relationship between the imaging times stored in the database according to the present embodiment.
FIG. 5A shows the time and the length of the material imaged by the first process A camera 7. In this embodiment, the imaging starts just at 10 o'clock, and 10:01:40. Imaging is finished in seconds. In the first step A, the length of the steel plate 2 is 100 m, and it takes 100 seconds to image the length of 100 m.

  Further, FIG. 5B shows the time and the length of the material imaged by the second process B camera 11, and in this embodiment, the imaging starts at 12 o'clock and starts at 12 o'clock. Imaging is completed at 50 minutes. In the second step B, the length of the steel plate 2 is 200 m, and it takes 50 seconds to image the length of 200 m.

  Further, FIG. 5C shows the time and the length of the material imaged by the third process C camera 13, and in this embodiment, the imaging starts just at 15:00, and the time 15:00 Imaging is completed at 20 minutes. In the third step C, the length of the steel plate 2 is 400 m, and it takes 200 seconds to image the length of 400 m.

  As can be seen from the above, in the first step A, the second step B, and the third step C, the line velocities are different, so it is difficult to observe the image data side by side. In the present embodiment, the visualization support apparatus 19 obtains the information stored in the first process A database 15, the second process B database 16, and the third process C database 17, and adjusts the time. Thus, the image data captured in each of the processes A to C is converted to a relative time and displayed on the display unit 43.

  FIG. 6 is a diagram illustrating an example of information stored in the inter-process database 18 according to the present embodiment. The other steel plates are processed continuously in each process, and the inter-process database 18 is provided so that the data of the steel plates 2 in the same lot can be extracted. Specifically, a table as shown in FIG. 6, a lot number of the steel plate 2, and the like are stored.

  6 (a) and 6 (b) are tables showing the relationship between the preceding and following processes. According to FIG. 6 (a), the second process B is performed before the third process C, and the second process. Before B, the first step A is indicated. Further, FIG. 6B shows that after the first step A, the second step B is performed, and after the second step B, the third step C is performed. That is, as a manufacturing process, the steel plate 2 is processed in the order of the first process A, the second process B, and the third process C.

  FIGS. 6C to 6E are tables showing the relationship between the imaging time differences. FIG. 6C shows the imaging time difference with reference to the time of the first step A. FIG. FIG. 6D shows the difference in imaging time based on the time of the second step B, and FIG. 6E shows the difference in imaging time based on the time of the third step C.

FIG. 7 is a flowchart illustrating an example of a procedure in which the first process A inspection apparatus 4 images the steel plate 2 in the present embodiment.
In the first step S <b> 1, the imaging control unit 33 causes the lamp in the illumination 3 to emit light and operates the CCD camera that is the imaging unit 34.

  Next, in step S <b> 2, the imaging control unit 33 starts recording by the first process A image recorder 8 by emitting light from the illumination 3 and using the imaging unit 34.

  Next, in step S3, the movement status detection unit 31 determines whether the head of the steel plate 2 (a) flowing on the production line has been detected. If the head of the steel plate 2 (a) is not detected as a result of this determination, the process waits until it is detected.

  Moreover, when the head of the steel plate 2 (a) is detected as a result of the determination in step S3, the process proceeds to step S4, and the imaging unit 34 determines the passing speed and length of the steel plate 2 (a) flowing in the production line. Monitor.

  Next, in step S5, the movement state detection unit 31 determines whether or not the trailing end of the steel plate 2 (a) being imaged by the imaging unit 34 has been detected. If the result of this determination is that the tail of the steel plate 2 (a) has not been detected, the process returns to step S4, and the passage speed and length of the steel plate 2 (a) are continuously monitored.

  On the other hand, if the tail of the steel plate 2 (a) is detected as a result of the determination in step S5, the process proceeds to step S6, and information on the imaging time, length, and passing speed regarding the steel plate 2 (a) is obtained in the first step A. Output to database.

  Next, in step S <b> 7, the imaging control unit 33 determines whether or not to end the recording by the first process A image recorder 8. As a result of this determination, if the recording is to be ended, the recording is ended and the imaging process is ended. On the other hand, if the result of determination in step S8 is that recording is not terminated, processing returns to step S3 and processing is repeated for the next steel plate.

FIG. 8 is a diagram illustrating an example of a procedure for displaying an image by the visualization support apparatus 19 in the present embodiment.
As shown in FIG. 8, in step S11, data for performing a linking process is obtained. Specifically, the image data of the captured steel sheet 2 is obtained from the first process A inspection apparatus 4, the second process B inspection apparatus 21 and the third process C inspection apparatus 22, respectively. From the process A database 15, the second process B database 16, and the third process C database 17, data such as the time and length at which the steel plate 2 was imaged in each process is obtained. Furthermore, the data which shows the relationship between the processes of a product as shown in FIG.

  Next, in step S12, the time of the acquired image data is adjusted. As described above, since the line speed and the length of the steel plate 2 are different depending on the process, processing for relativizing time is performed in this embodiment.

  Next, in step S13, the image data is linked. Specifically, the calculation is performed by the following calculation.

When the steel plate 2 (or lot name) processed in the process X is PX, the length of the PX is XL, and the line speed (passing speed) of the PX is XV, the elongation rate between the process X and the process Y is considered. The corrected time correction rate CXY is
CXY = XL / YL * YV / XV,
It becomes. In the example shown in FIG. 5, AL = 100 (m), AV = 1 (m / s), BL = 200 (m), BV = 4 (m / s), CL = 400 (m), CV = 2 ( m / s)
CAB = 100/200 * 4/1 = 2
CBA = 200/100 * 1/4 = 0.5,
CAC = 100/400 * 2/1 = 0.5,
CCA = 400/100 * 1/2 = 2
CBC = 200/400 * 2/4 = 0.25,
CCB = 400/200 * 4/2 = 4,
It becomes.

Further, when the image at the time of n_x seconds in the process X is IX [n_x] and the image at the position corresponding to IX [n_x] in the process Y is IY [n_y], how to obtain n_y for n_x is as follows. become.
n_y = n_x / CXY.
If it demonstrates in the example shown in FIG. 5, the image of the center position of the steel plate 2 will be IA [50] in the 1st process A, and IB [50 / CAB] = IB [25 in the 2nd process B. ]. In the third step C, IC [50 / CAC] = IC [100].

However, if time is managed in seconds, n_x / CXY may not be an integer. in this case,
n_y = ceil (n_x / CXY), (ceil (x): smallest integer greater than x)
It becomes. A specific example will be described with reference to the table shown in FIG.

  FIG. 9 is a diagram illustrating an example of an image reference table (0 ≦ n_A ≦ 50) in the present embodiment. For example, in the case of n_A = 5, n_A / CAB = 5/2 = 2.5, and therefore n_B = ceil (2.5) = 3.

  Next, in step S14, the images in the first process A to the third process C that have been converted to relative times are displayed, and the process is terminated. For example, when it is desired to display the position of the steel plate 2 when n seconds have elapsed in the first step A, the positions of the corresponding steel plates 2 in the second step B and the third step C are simultaneously displayed. Like that.

FIG. 10 is a flowchart showing an example of the linking process procedure in step S13 of FIG.
In step S21 of FIG. 10, in order to link the image data of the first process A and the image data of the second process B, the time correction factor CAB described above is obtained from the data of the line speed and the length of the steel plate 2. calculate.

  Next, in step S22, the position of the steel plate 2 displayed on the display unit 43 is calculated for how many seconds from the start of imaging in the first process A, and the value of n_A is designated.

  Next, in step S23, in order to obtain n_B, it is determined whether or not the value of n_A / CAB is an integer. If the result of this determination is an integer, the process proceeds to step S24, and the value of n_A / CAB is determined as n_B. On the other hand, if the result of determination in step S23 is not an integer, the process proceeds to step S25, and the value of ceil (n_A / CAB) is determined as n_B.

  Next, in step S26, in order to link the image data of the first process A and the image data of the third process C, the time correction factor CAC described above is obtained from the data of the line speed and the length of the steel plate 2. calculate.

  Next, in step S27, in order to obtain n_C, it is determined whether or not the value of n_A / CAC is an integer. If the result of this determination is an integer, the process proceeds to step S28, and the value of n_A / CAC is determined as n_C. On the other hand, if the result of determination in step S27 is not an integer, the process proceeds to step S29, and the value of ceil (n_A / CAC) is determined as n_C.

  Next, in step S30, an image at a position corresponding to IA [n_A], IB [n_B], and IC [n_C] is extracted from the image data of each process for display on the display unit 43.

  As described above, in the present embodiment, for example, based on data on a plurality of manufacturing processes such as the first process A to the third process C, image data of a common steel plate part is extracted from a plurality of image data. And, since the image data of the common steel plate part extracted by matching the appearance defect in each process is displayed side by side on the display unit 43, the appearance changed by being deformed and processed in a plurality of processes A defect can be specified as the same appearance defect. As a result, in a production line where a steel sheet flows while a single material is deformed and processed at multiple speeds in multiple processes, such as in the steel industry, image data such as defects is managed for each common steel sheet part, and in which process the appearance Whether or not a defect has occurred can be reliably identified.

  Moreover, in this embodiment, the example which pinpoints the position in the 2nd process B and the 3rd process C was demonstrated on the basis of the position of the steel plate 2 (a) at the time of n second progress in the 1st process A. However, the position in another process may be specified based on the second process B or the third process C.

(Other embodiments according to the present invention)
In order to operate various devices to realize the functions of the above-described embodiments, program codes of software for realizing the functions of the above-described embodiments are provided to an apparatus or a computer in the system connected to the various devices. What is implemented by operating the various devices according to a program supplied and stored in a computer (CPU or MPU) of the system or apparatus is also included in the scope of the present invention.

  In this case, the program code of the software itself realizes the functions of the above-described embodiments, and the program code itself and means for supplying the program code to the computer, for example, the program code are stored. The recorded medium constitutes the present invention. As a recording medium for storing the program code, for example, a flexible disk, a hard disk, an optical disk, a magneto-optical disk, a CD-ROM, a magnetic tape, a nonvolatile memory card, a ROM, or the like can be used.

  Further, by executing the program code supplied by the computer, not only the functions of the above-described embodiments are realized, but also the OS (operating system) or other application software in which the program code is running on the computer, etc. It goes without saying that the program code is also included in the embodiment of the present invention even when the functions of the above-described embodiment are realized in cooperation with the embodiment.

  Further, after the supplied program code is stored in the memory provided in the function expansion board of the computer or the function expansion unit connected to the computer, the CPU provided in the function expansion board or function expansion unit based on the instruction of the program code Needless to say, the present invention includes a case where the functions of the above-described embodiment are realized by performing part or all of the actual processing.

It is a figure showing the outline of the inspection system using a camera. It is a figure which shows the state by which the steel plate is imaged with the camera. It is a figure which shows an example of the visualization system between processes in this embodiment. It is a block diagram which shows an example of a function structure of the inspection apparatus and visualization assistance apparatus of a 1st process of this embodiment. It is a figure which shows the relationship of the imaging time stored in the database of this embodiment. It is a figure which shows an example of the information stored in the database between processes of this embodiment. It is a flowchart which shows an example of the procedure in which the inspection apparatus of a 1st process images a steel plate in this embodiment. It is a figure which shows an example of the procedure which displays an image with the visualization assistance apparatus in this embodiment. It is a figure which shows an example of the image reference | standard table (0 <= n_A <= 50) in this embodiment. It is a flowchart which shows an example of the linking process procedure in step S13 of FIG.

Explanation of symbols

2 Steel plate 3 Illumination 4 Inspection device for first process A 7 Camera for first process A 8 Image recorder for first process A 9 Monitor 11 Camera for second process B 12 Image recorder for second process B 13 Third process C camera 14 Third process C image recorder 15 First process A database 16 Second process B database 17 Third process C database 18 Interprocess database 19 Visualization support apparatus 20 Network 21 Second Process B Inspection Device 22 Third Process C Inspection Device 31 Movement Status Detection Unit 32 Timekeeping Unit 33 Imaging Control Unit 34 Imaging Unit 35 Image Processing Unit 36 Display Unit 37 Storage Unit 38 Network I / F
41 Storage Unit 42 Image Extraction Unit 43 Display Unit 44 Calculation Unit 45 Network I / F

Claims (4)

A plurality of inspection devices each of which is arranged in a plurality of manufacturing steps constituting a manufacturing line for continuously deforming and processing a steel plate, images a steel plate flowing in each of the plurality of manufacturing steps, and generates image data; at least one or more databases storing data including an imaging time with the steel of lots that are Oite processed each production step, and visualization support device, the connected-process visualization systems via a network There,
The inspection apparatus for each of the plurality of manufacturing steps captures a steel plate with a camera, generates the image data, detects a movement state of the steel plate, associates it with an imaging time, and passes the steel plate through speed and length. Detect
The visualization support device includes:
Based on the data including the length of the velocity and the steel sheet of the imaging time and production line with steel Oite processed lot to the plurality of manufacturing steps which are inputted from the database, the plurality of manufacturing steps each inspection device a calculating means for tying the image data of the steel plate portion in common from among the plurality of image data, a corresponding position of the steel plate of the same lot that is acquired from,
From each of the plurality of image data acquired by the inspection apparatus of each of the plurality of manufacturing processes, based on the association that is the calculation result of the calculation means, the common steel plate part from the image data for the steel plate of the same lot Extraction means for extracting the image data of
Display means for displaying the image data of the common steel plate parts extracted by the extraction means side by side on a display device ;
Inter-process visualization system characterized by The production line includes a rolling process,
It said computing means, for steel plate of the same lot, the manufacturing process length of the processed steel sheet with each Sato, with a production line speed of the manufacturing process, respectively, each of the imaging time of the steel plate for each of the manufacturing process The relative time of the corresponding steel sheet part in each manufacturing process is obtained by calculating the time correction factor CXY considering the elongation rate between the manufacturing processes , and the position of the corresponding steel sheet part in each manufacturing process is calculated. The inter-process visualization system according to claim 1 . The relative time is a time based on the time when the tip of the steel sheet passes through each of the manufacturing steps,
The length of the steel sheet processed in the manufacturing process X is XL, the line speed (passing speed) is XV, and the time correction factor CXY in consideration of the elongation rate between the manufacturing process X and the manufacturing process Y,
CXY = XL / YL × YV / XV
The inter-process visualization system according to claim 2, wherein the calculation is performed by: The computer program which makes a computer implement | achieve the function of each means of the visualization assistance apparatus in the visualization system between processes in any one of Claims 1-3 .

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