JP4929133B2 - Inspection support system - Google Patents

Description

  The present invention relates to an inspection support system, and more particularly to an inspection support system including an image processing controller that outputs a determination signal based on a camera image obtained by imaging an inspection object.

  The image processing controller that performs image processing on a camera image obtained by photographing the inspection object and outputs a determination signal indicating the determination result based on the shape, position, and camera image of the inspection object as a processing result includes a series of processes. A method that can change the procedure is known (for example, Patent Document 1). Usually, a control program for causing such an image processing controller to execute a series of processing procedures is created using an editor (software) that operates on an information processing terminal such as a PC (personal computer). The user can perform a desired inspection on the inspection object by transferring the created control program to the image processing controller.

  Generally, when a control program is repeatedly executed, the time required for image processing for extracting measurement results from camera images differs from the time required for output processing for outputting measurement results or camera images to a memory card or the like via an output interface. ing. For this reason, when measurement is repeated, there is a difference between the timing at which the measurement result or camera image obtained by the image processing is written to the output buffer as the inspection result and the timing at which the inspection result is read from the output buffer for output processing. It becomes. That is, when the time required for image processing is shorter than that for output processing, the writing cycle of the inspection result exceeds the reading cycle, and the free capacity in the output buffer is insufficient.

  Usually, in the case of inspecting an inspection object conveyed on the production line, priority is given to image processing in order not to affect the operation of the production line. In other words, when the newly obtained inspection result is written to the output buffer, if the free space in the output buffer is insufficient, the execution of the control program may be continued without writing the newly obtained inspection result. It is done. In such an image processing priority mode, the inspection result obtained while the free space is insufficient is lost. On the other hand, in the case where the inspection results obtained by a series of measurements are collected without omission, or the camera images are collected without omission when the judgment result of the quality of the inspection object becomes the default value, priority is given to the output processing. It is possible to make it. That is, when the free space in the output buffer is insufficient, it is conceivable that the execution of the control program is interrupted until the inspection result can be written to the output buffer by reading the inspection result.

However, in the conventional image processing controller, whether to prioritize image processing or output processing is fixed by the device that is the output destination of the inspection result and cannot be changed. For example, whether to give priority to image processing when outputting test results to a removable recording medium such as a memory card and when outputting to an external device such as a PC via a communication interface, or The priority is predetermined and cannot be changed. For this reason, in the case where the inspection result is output using a device that has priority for output processing as an output destination, there is a problem in that image processing is stopped when insufficient free space occurs.
JP-A-9-288568

  As described above, in the conventional image processing controller, whether to give priority to image processing or output processing is fixed by the device to which the inspection result is output and cannot be changed. When the inspection result is output using a device with priority for processing as an output destination, there is a problem in that image processing is stopped when a shortage of free space occurs.

  The present invention has been made in view of the above circumstances, and can select whether to prioritize image processing or output processing when outputting the inspection result obtained when the control program is executed. The purpose is to provide a support system. In particular, an object of the present invention is to provide an inspection support system capable of selecting whether to give priority to image processing or output processing in the case of outputting a camera image and the case of outputting a measurement result as an inspection result. To do.

  The inspection support system according to the first aspect of the present invention includes a camera that shoots an inspection object and generates a camera image, acquires the camera image from the camera, extracts a measurement result from the camera image, An inspection support system comprising an image processing controller for determining pass / fail of the inspection object and outputting a determination signal, and a program creation device for creating a control program for the image processing controller, wherein the program creation device comprises: As a processing unit that indicates processing executed by the image processing controller, an imaging unit that acquires a camera image from the camera based on an imaging trigger signal, and two or more that extract measurement results from the camera image acquired by the imaging unit Measurement unit, an image that outputs the camera image used to extract the measurement results A flow chart generated by arranging the output unit and the processing unit storage means for holding the result output unit for outputting the measurement result, and the processing unit on the execution flow starting at the start symbol and ending at the end symbol. A flowchart display means for displaying the image processing controller, a program generation means for generating a control program for the image processing controller based on the flowchart, and a transfer means for transferring the control program to the image processing controller. The program execution means for repeatedly executing the control program and the camera image acquired by the imaging unit when the control program is executed are written in the output buffer as the inspection result when the image output unit is executed. A test result writing means for writing the measurement result extracted by the measurement unit into the output buffer as a test result when the result output unit is executed, and the camera image in the output buffer is read and output via the output interface. A camera image output means; and a measurement result output means for reading out the measurement result in the output buffer and outputting the result via an output interface, and the inspection result writing means stores the newly obtained inspection result in the output buffer. When writing, when the free space in the output buffer is insufficient, the image processing priority writing means for continuing execution of the control program without writing the newly obtained inspection result, the camera image output means, and the above The measurement result output means reads the inspection result to the output buffer. Output processing priority writing means for interrupting the execution of the control program until the inspection result can be written, and for each of the camera image output means and the measurement result output means, the image processing priority writing means and the output Any one of the processing priority writing means is configured to be selectable.

  In this inspection support system, when the newly obtained inspection result is written to the output buffer, if the free space in the output buffer is insufficient, the control program is continuously executed without writing the newly obtained inspection result. Image processing priority to be output and output processing priority to interrupt execution of the control program until the inspection result can be written to the output buffer by reading the inspection result. It is possible to select for each case of outputting. Therefore, the user can select whether to prioritize image processing or output processing according to the control program.

  In the inspection support system according to the second aspect of the present invention, in addition to the above configuration, the output interface is an interface for outputting the inspection result read from the output buffer to an external device that is detachably connected. Composed.

  In addition to the above-described configuration, the inspection support system according to a third aspect of the present invention provides the determination result of the quality of the inspection object determined by the measurement unit based on the measurement result when the image processing controller executes the control program. When the result output unit is executed, when the test result writing means writes to the output buffer, the camera output the camera image by including a determination result output means for reading the determination result in the output buffer and outputting it via an output interface. For each of the means, the measurement result output means, and the determination result output means, either the image processing priority writing means or the output processing priority writing means can be selected. According to such a configuration, it is possible to select either image processing priority or output processing priority for each of a case where a camera image is output, a case where a measurement result is output, and a case where a determination result is output. it can.

  The inspection support system according to the fourth aspect of the present invention is configured such that, in addition to the above configuration, the determination result output means outputs a determination result via an output terminal for outputting an electrical signal.

  The inspection support system according to the fifth aspect of the present invention is the inspection support system according to the present invention, wherein, in addition to the above-described configuration, the program creation apparatus uses the image processing priority writing unit and A write method determining unit is provided that selects any one of the output processing priority write units and determines a method for writing the test result to the output buffer. According to such a configuration, since the image processing controller is operated by the control program in which the method for writing the inspection result is determined as the parameter of the image processing unit or the result output unit in the program creation device, the image processing is executed during the execution of the control program. It is possible to automatically switch whether to give priority to output or to give priority to output processing.

  An inspection support system according to a sixth aspect of the present invention captures an inspection object and generates a camera image, acquires the camera image from the camera, extracts a measurement result from the camera image, An inspection support system comprising an image processing controller for determining pass / fail of the inspection object and outputting a determination signal, and a program creation device for creating a control program for the image processing controller, wherein the program creation device comprises: As a processing unit that indicates processing executed by the image processing controller, an imaging unit that acquires a camera image from the camera based on an imaging trigger signal, and two or more that extract measurement results from the camera image acquired by the imaging unit Measurement unit, an image that outputs the camera image used to extract the measurement results A flow chart generated by arranging the output unit and the processing unit storage means for holding the result output unit for outputting the measurement result, and the processing unit on the execution flow starting at the start symbol and ending at the end symbol. A flowchart display means for displaying the image processing controller, a program generation means for generating a control program for the image processing controller based on the flowchart, and a transfer means for transferring the control program to the image processing controller. The program execution means for repeatedly executing the control program and the camera image acquired by the imaging unit when the control program is executed are written in the output buffer as the inspection result when the image output unit is executed. In addition, a test result writing means for writing a determination result of pass / fail of the test object determined based on the measurement result extracted by the measurement unit into the output buffer as a test result when the result output unit is executed; The inspection result writing means, comprising: camera image output means for reading out the camera image and outputting it through an output interface; and determination result output means for reading out the determination result in the output buffer and outputting it through the output interface. However, when the newly obtained inspection result is written to the output buffer, if the free space in the output buffer is insufficient, the image obtained by continuing the execution of the control program without writing the newly obtained inspection result. Processing priority writing means, the camera image output means and the determination result output means It consists of output processing priority writing means for interrupting the execution of the control program until the inspection result can be written to the output buffer by reading the inspection result, and for each of the camera image output means and the determination result output means, Any one of the image processing priority writing means and the output processing priority writing means can be selected.

  According to the inspection support system of the present invention, when the newly obtained inspection result is written to the output buffer, when the free space in the output buffer is insufficient, the control program is not written without writing the newly obtained inspection result. When outputting a camera image, either image processing priority that continues execution of the image processing or output processing priority that interrupts execution of the control program until the inspection result can be written to the output buffer by reading the inspection result And the case of outputting the measurement result can be selected. Therefore, the user can select whether to prioritize image processing or output processing according to the control program.

<Inspection support system>
FIG. 1 is a perspective view showing a configuration example of an inspection support system according to an embodiment of the present invention. The inspection support system includes an image processing apparatus 1 arranged on a conveyance line of an inspection object, and a PC (personal computer) 2 that generates a control program for the image processing apparatus 1.

  The image processing device 1 is a sensor device that includes an image processing controller 11, a camera 12, a display 13a, and an operation unit 13b, and outputs a determination signal based on a camera image obtained from an inspection object. This determination signal is input to a PLC (Programmable Logic Controller) not shown, and the image processing apparatus 1 is used as an FA (Factory Automation) sensor.

  The camera 12 is an imaging device that shoots a subject, generates image data, and outputs it as a camera image, and is detachably connected to the image processing controller 11. The camera 12 is disposed on a conveyance line through which the inspection object is conveyed, and photographing is performed using the inspection object as a subject.

  The display 13a is an output device for displaying a camera image obtained by photographing an inspection object and an image processing result based on the camera image. The display 13 a is display-controlled by the image processing controller 11 and is usually disposed in the vicinity of the image processing controller 11. That is, the display 13a is a display device for allowing the user to check the operation state of the image processing controller 11 when the image processing controller 11 is in operation. The operation unit 13b is an input device for moving a focus position on the display 13a and selecting a menu item.

  The image processing controller 11 is a main unit of the image processing apparatus 1 that captures and processes a camera image from the camera 12 and outputs a determination signal indicating a determination result made based on the camera image as a processing result. The camera image acquisition operation is performed based on, for example, an imaging trigger signal that is a control signal input from an external device such as a PLC and that defines a timing for capturing a camera image.

  Up to four cameras 12 are connected to the image processing controller 11, and image processing is performed based on camera images acquired from these cameras 12. The determination signal output from the image processing controller 11 is generated as a signal indicating a determination result such as product quality.

  Further, the display 13a and the operation unit 13b are connected to the image processing controller 11, and the operation unit 13b can be operated as an input device and the display 13a can be operated as an output device without being connected to the PC 2.

  The PC 2 is a program creation device that creates a control program for the image processing controller 11, and a control program is generated by an editor (software) operating on the PC 2. When creating a control program for the image processing controller 11, a simulation can be performed on the PC 2 to confirm the operation.

  In the PC 2, layout information that defines the display mode on the display 13 a by the image processing controller 11 is created. This layout information is also created on the editing screen in the PC 2 by the editor, and inspection setting data including a control program and layout information is generated.

  The PC 2 and the image processing controller 11 of the image processing apparatus 1 are connected via a communication network such as Ethernet (registered trademark). A plurality of image processing controllers 11 are detachably connected to the PC 2. By transferring the inspection setting data created on the PC 2 to the image processing controller 11, the inspection setting data in the image processing controller 11 can be rewritten. In addition, inspection setting data in the image processing controller 11 can be taken in and edited on the PC 2. The PC 2 is normally connected to the image processing controller 11 during maintenance of the image processing apparatus 1.

  In this inspection support system, the camera image acquired from the camera 12 during the operation of the image processing controller 11 and the measurement result extracted from the camera image are accumulated as history information and displayed on the display 13a or the PC 2 as necessary. Can do.

<System configuration>
FIG. 2 is a block diagram showing an example of the system configuration of the inspection support system of FIG. The inspection support system 100 includes a single PC 2 and a plurality of image processing apparatuses 1 connected to the PC 2 via the communication network 3. The control program created on the PC 2 is stored in the memory 21 as inspection setting data 22.

  The examination setting data 22 created on the PC 2 is transferred to the image processing controller 11 via the communication network 3. At this time, by specifying the transfer destination and transferring the inspection setting data 22, the inspection setting data 15 in the memory 14 is updated for the desired image processing controller 11, or new inspection setting data is stored in the memory 14. Can be added.

  In the image processing controller 11, a plurality of examination setting data 15 is held in a memory 14 such as a flash memory. Each inspection setting data 15 is composed of a control program having different processing procedures and inspection contents, and the inspection setting data 15 to be executed can be changed based on a user operation.

  In the PC 2, an operation for acquiring and editing the examination setting data 15 from the image processing controller 11 connected by the communication network 3 is performed.

<Editor screen>
FIG. 3 is a diagram showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. The editor screen 40 is an editing screen for newly creating inspection setting data on the PC 2 or editing inspection setting data acquired from the image processing controller 11, and is displayed on the PC 2.

  The editor screen 40 includes a plurality of window screens whose display positions and display ranges can be changed. Specifically, it consists of a system view window 41, a parts list window 42, a unit property window 43, a vision view window 44, and a result view window 45.

  The system view window 41 is a window screen for displaying a list of system configuration and examination setting data to be edited, and includes a controller list screen 41a and a workspace list screen 41b.

  The controller list screen 41 a is a screen for displaying a list of the image processing controllers 11 connected to the PC 2. The controller list screen 41 a displays icons indicating the image processing controller 11 and inspection setting data 15 held in the image processing controller 11. An icon is displayed.

  The icons indicating the image processing controller 11 and the inspection setting data 15 are displayed in a tree format. That is, it is possible to identify which image processing controller 11 holds the inspection setting data 15 with the image processing controller 11 as the upper layer and the inspection setting data 15 held in the image processing controller 11 as the lower layer. It is displayed as follows.

  The workspace list screen 41b is a screen for displaying a list of inspection setting data to be edited. An icon indicating a work area on the memory 21 provided for each image processing controller 11 or an icon indicating inspection setting data. It is displayed. A work area on the memory 21 provided for each image processing controller 11 is associated with the corresponding image processing controller 11 and displayed as a work space. That is, inspection setting data is held for each image processing controller 11 on the PC 2, and editing is performed in a work space for each image processing controller 11.

  Such icons indicating work areas and icons indicating inspection setting data are displayed in a tree format. That is, the workspace corresponding to the image processing controller 11 is set as the upper hierarchy, and the examination setting data in this workspace is set as the lower hierarchy, so that the workspace in which the examination setting data exists can be identified. .

  When an update button (icon) arranged in the heading column of the controller list screen 41a is operated, new inspection setting data is acquired from the image processing controller 11, and the inspection setting data and system configuration held on the PC 2 are changed. Updated to the latest. If the registration button is operated, the examination setting data created on the PC 2 is transferred to the image processing controller 11.

  When the update button (icon) arranged in the heading column of the workspace list screen 41b is operated, the examination setting data to be edited is updated with the examination setting data acquired from the image processing controller 11. When the add button is operated, a new work area is provided, and an icon indicating inspection setting data is added.

  The parts list window 42 is a window screen for displaying processing units that can be selected when creating inspection setting data as a unit list. The processing unit is a symbol indicating a process whose parameters can be changed, and is processed by an image processing unit indicating image processing, an imaging unit indicating imaging processing, a control unit indicating flow control processing, an output unit indicating output processing, and the like. It is provided as a unit. By arranging such processing units on a flowchart in a flow view window, which will be described later, a control program composed of a desired flow sequence is created.

  A plurality of processing units are displayed in the parts list window 42. In this example, the processing units are divided into eight categories depending on the type of processing, and icons indicating each category are displayed. Specifically, it is divided into categories of “image input”, “measurement”, “control”, “calculation”, “timing”, “display”, “output”, and “command output”.

  “Image input” is a category to which a processing unit related to imaging belongs, and an imaging unit that captures a camera image belongs to it. The imaging unit is a processing unit that acquires a camera image for image processing based on an imaging trigger signal. As the imaging trigger signal, an input signal input from an external device such as a PLC via an imaging trigger input terminal and an internal trigger signal generated in the image processing controller 11 can be used. Such an imaging unit is associated with parameters for specifying shutter speed, camera sensitivity, flash delay time, flash on time, imaging target camera, flash terminal, and trigger terminal as properties.

  “Measurement” is a category to which a processing unit related to measurement belongs, and a measurement unit that extracts a measurement result from a camera image acquired by an imaging unit and determines the quality of an inspection object based on the measurement result belongs. . Such measurement units include image processing units such as a pattern search unit, an edge position detection unit, a blob detection unit, and a color inspection unit.

  The pattern search is a process for detecting a position that matches a previously registered pattern image by scanning the search area on the camera image. Edge position detection is a process of obtaining an average density in a direction perpendicular to the detection direction for a measurement region on a camera image and detecting the edge position from the density change in the detection direction.

  The blob detection is a process of binarizing the camera image, extracting a block of pixels having the same density as a blob, and detecting the number, area, and barycentric position of the blob existing in the measurement region. The color inspection is a process of measuring the color in the inspection area, and a numerical value corresponding to the color is extracted as a measurement result.

  In such image processing related to measurement, the shape and size of the inspection object, the position in the camera image, and the like are detected, and the measured values are output as image processing results. Further, the measurement value is compared with a parameter designated in advance by the user, and the quality of the inspection object, for example, the presence or absence of a defect or abnormality is determined based on the comparison result, and the determination result is output as an image processing result. The When such an image processing result is displayed, a symbol that graphically indicates an image region to be measured, a detected position of the inspection object, and the like can be displayed on the camera image.

  “Control” is a category to which processing units related to control belong, and control units such as a repeat unit, a bypass unit, and an end symbol belong to it. The repeat unit is a processing unit composed of a repeat start unit indicating the start point when repeating the execution flow and a repeat end unit indicating the end point, and the execution flow between the start unit and the end unit is repeated until a predetermined condition is satisfied. The processing to be performed is shown.

  The bypass unit is a processing unit that includes a branch unit that branches an execution flow into two or more branch flows and a merging unit that joins the branch flows branched by the branch unit, and branches the execution flow under a predetermined condition. Indicates processing. The end symbol is a display object for ending one flow sequence.

  “Calculation” is a category to which a processing unit related to calculation belongs, and includes an image processing unit such as a numerical calculation unit and a position correction unit. “Timing” is a category to which processing units related to flow transition timing control belong, and to which control units such as a timer waiting unit and an event waiting unit belong. The timer waiting unit is a waiting unit indicating a process for stopping the flow transition for a predetermined time. The event waiting unit is a waiting unit indicating a process of stopping the flow transition until the terminal input or the variable value is in a predetermined state.

  “Display” is a category to which a processing unit relating to display belongs, and to which an image processing unit such as a graphic display unit belongs. A graphic display unit refers to another processing unit and indicates processing for graphically displaying a processing result of the processing unit.

  “Output” is a category to which a processing unit related to output belongs, and output units such as an image output unit, a result output unit, and a terminal output unit belong to this category. The image output unit is an output unit for outputting the camera image used for the extraction of the measurement result in the measurement unit. The reference destination unit, the camera image, the data format for outputting the image data, and the image data A parameter for specifying the output destination is associated as a property.

  The result output unit is an output unit for outputting the measurement result in the measurement unit and the determination result of the inspection object in the measurement unit. When outputting the reference destination unit, the numerical data indicating the measurement result, and the numerical data Parameters for specifying the data format (text format or binary format) and the output destination of the numerical data are associated as properties.

  The terminal output unit is an output unit for outputting the pass / fail judgment result of the inspection object in the measurement unit. The reference destination unit, the judgment result and the parameter for designating the output destination terminal of the judgment result are associated as properties. It has been. In addition to the determination result in the measurement unit, data indicating the measurement value can be assigned to this terminal output unit.

  “Command output” is a category to which processing units related to command output belong, and output units of command issue units, display pattern switching units, and dialog display units belong to this category. The command issuing unit indicates processing for issuing commands such as image registration, inspection setting switching, and reset.

  The unit property window 43 is a window screen for displaying the properties of the processing unit selected on the controller list screen 41a, the work space list screen 41b or the flow view window.

  The vision view window 44 is a window screen for displaying a camera image associated with the processing unit selected on the controller list screen 41a, the work space list screen 41b, or the flow view window.

  The result view window 45 is a window screen for displaying the parameters of the processing unit selected on the controller list screen 41a, the work space list screen 41b or the flow view window, and the simulation result.

  On this editor screen 40, if a flow view button 41c arranged at the bottom of the system view window 41 is operated, a flow view window can be displayed instead of the system view window 41 described above. The flow view window is a window screen that displays a processing procedure to be executed by the image processing controller 11 as a flowchart, and displays examination setting data selected on the work space list screen 41b.

  Further, by operating the extraction list button 45 a arranged at the lower part of the result view window 45, the extraction list window can be displayed instead of the result view window 45. The extraction list window is a window screen for extracting the parameters and processing results selected on the result view window 45 and displaying a list of extraction results for each processing unit.

<Flow view window>
FIG. 4 is a diagram showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. The flow view window 46 is a window screen that displays a flowchart 47 showing a processing procedure in order to newly create a control program for examination setting data or to edit the control program acquired from the image processing controller 11.

  In the flow view window 46, a flow chart 47 configured by arranging a plurality of processing units 48 is displayed. The flowchart 47 shows processing units that are executed in time series on the execution flow that starts at the start symbol “S” and ends at the end symbol “E”. The user can configure a desired control program by arranging the processing unit 48 on such an execution flow.

  That is, a series of image processing to be performed by the image processing controller 11 is blocked as a processing unit, and the user simply arranges the processing unit on the execution flow in the flow view window 46, and the processing unit is immediately before the processing unit. It is possible to create a flow sequence for performing predetermined processing based on the processing result of the processing unit.

  By operating a system view button 46 a arranged at the bottom of the flow view window 46, the system view window 41 can be displayed instead of the flow view window 46.

  The processing unit selected on the flow view window 46 is displayed in focus, and its properties are displayed in the unit property window 43. An edit button 43a is arranged in the unit property window 43. When the edit button 43a is operated, a property edit screen for editing the properties of the processing unit is displayed. The property editing screen is an editing screen for designating processing unit parameters based on user operations or changing parameters that have already been designated.

<Flowchart>
FIG. 5 is a diagram showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. In the flowchart 47, a plurality of processing units are arranged on the execution flow starting with the start symbol 61a and ending with the end symbol 61b.

  When the flowchart 47 is created and edited on the flow view window 46, the part list window 42 is used for work. For example, when a processing unit is inserted into the flowchart 47, it is inserted by selecting a desired processing unit on the parts list window 42 and designating a position on the execution flow with a mouse pointer or the like.

  In this example, the flowchart 47 includes a branch unit 62a, an imaging unit, a color inspection unit, a numerical operation unit, a merge unit 62b, a blob detection unit, a repeat start unit 65a, an edge position detection unit, a pattern search unit, a repeat end unit 65b, and The graphic display units are arranged on the execution flow in this order.

  The branch unit 62a and the merge unit 62b are control units that constitute a bypass unit. When the bypass unit is inserted into the execution flow, the branch unit 62a and the merge unit 62b are always inserted as a pair. In the branch unit 62a, processing for selectively selecting a branch flow after branching is performed based on the measurement result or determination result of the immediately preceding processing unit. The condition for selecting which branch flow after branching is specified by the user as a parameter of the branch unit 62a.

  In this example, the execution flow from the start symbol 61a is branched into two branch flows 63 by the branch unit 62a, and the branch flows branched by the branch unit 62a are merged in the merge unit 62b. At this time, one branch flow 63 reaches the merging unit 62b via the imaging unit, the color inspection unit, and the numerical operation unit, whereas the other branch flow 63 reaches the merging unit 62b via the imaging unit. It is a bypass route (bypass).

  The repeat start unit 65a and the repeat end unit 65b are control units that constitute the repeat unit. When the repeat unit is inserted into the execution flow, the repeat start unit 65a and the repeat end unit 65b are inserted as a pair. .

  In this example, the edge position detection unit and the pattern search unit are arranged between the repetition start unit 65a and the repetition end unit 65b, and the processing of the edge position detection unit and the pattern search unit is repeated at the time of execution.

  In the branch unit 62a and the repeat start unit 65a in the flowchart 47, a folding icon 64a is arranged. The folding icon 64a is an icon for displaying the flowchart 47 by omitting the execution flow between the control units, and is displayed adjacent to the processing unit.

  The processing unit selected on the flowchart 47 is displayed in focus, and the property of the processing unit can be displayed in the unit property window 43, or the property of the processing unit can be changed as an editing target.

<Output unit property editing screen>
6 to 8 are diagrams showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. 2, and a property editing screen for editing the properties of the output unit is shown. FIG. 6 shows a property editing screen 70 of the image output unit. The property editing screen 70 is an input screen for setting on the PC 2 a writing method when the image processing controller 11 writes the inspection result to the output buffer, and is displayed on the editor screen 40.

  In the property editing screen 70, an output device setting column 72, an image variable input column 73, a storage format selection column 74, and a priority selection column 75 are provided as output data settings 71. Yes. The output destination device selection column 72 is an input column for designating an output destination device of image data when a camera image is output as an inspection result. External devices that can be selected as an output destination device include a memory card connected via an output interface such as a card slot and a terminal device such as a PC connected via a communication interface.

  The image variable input field 73 is an input field for designating a variable assigned to a camera image, and image data to be output can be designated via such a variable. The storage format selection column 74 is an input column for designating a data format when outputting image data. When the output destination device of the image data is a memory card, a bitmap is used as the storage format of the image data. A format, JPEG (Joint Photographic Experts Group) format, etc. can be selected.

  The priority selection field 75 is an input field for designating a writing method when a camera image is written in the output buffer as an inspection result, and either image processing priority or output processing priority can be selected. When the image processing priority is selected, when the free space in the output buffer in the image processing controller 11 is insufficient, the image processing is continued by continuing the execution of the control program without writing the newly obtained inspection result. Takes precedence.

  On the other hand, if output processing priority is selected, when the free space in the output buffer is insufficient, the execution of the control program is suspended until the inspection result can be written to the output buffer by reading the inspection result. The

  FIG. 7 shows a property editing screen 80 of the result output unit. The property editing screen 80 is an input screen for setting on the PC 2 a writing method when the image processing controller 11 writes the inspection result in the output buffer, and is displayed on the editor screen 40.

  In the property editing screen 80, an output destination device selection column 82, a measurement result data display column 83, and a priority selection column 84 are provided as output data settings 81. The output destination device selection column 82 is an input column for designating an output destination device of numerical data when outputting a measurement result in the measurement unit as an inspection result.

  The measurement result data display field 83 is a display field for displaying a list of numerical data indicating the measurement results, and a preview value (simulation result) and the like are displayed together with identification information of the numerical data. The priority selection field 84 is an input field for designating a writing method when the measurement result is written in the output buffer as the inspection result, and either image processing priority or output processing priority can be selected.

  FIG. 8 shows a property editing screen 90 of the terminal output unit. The property editing screen 90 is an input screen for setting on the PC 2 a writing method and the like when the image processing controller 11 writes the inspection result in the output buffer, and is displayed on the editor screen 40.

  The property editing screen 90 includes an output count input field 92, a data setting display field 93, and a priority selection field 94 as detailed settings 91. The number-of-outputs input column 92 is an input column for designating the number of times of output when the determination result of the inspection object in the measurement unit is output as the inspection result.

  The data setting display field 93 is a display field for displaying a list of output destination terminals that output data indicating determination results and measurement values. The data preview value (simulation result) is displayed together with the terminal name and output variable name of the output terminal. ) Etc. are displayed. The priority selection field 94 is an input field for designating a writing method when writing the determination result or measurement value in the output buffer as the inspection result, and it is possible to select either image processing priority or output processing priority. it can.

<Functional structure of editor>
FIG. 9 is a block diagram illustrating a configuration example of the PC 2 in the inspection support system 100 of FIG. 2, and illustrates an example of a functional configuration of an editor that creates a control program for the image processing controller 11. The PC 2 includes a memory 21, a processing unit storage unit 23, a flowchart display unit 24, a program generation unit 25, a transfer unit 26, an operation input unit 27, a unit property editing unit 28, and a writing method determination unit 29.

  In the processing unit storage unit 23, processing units such as an imaging unit, a measurement unit, and an output unit are held as processing units that indicate processing whose parameters can be changed. The flowchart display unit 24 performs an operation of displaying the flowchart 47 generated by arranging the processing unit on the execution flow starting at the start symbol and ending at the end symbol on the flow view window 46 of the editor screen 40. Yes.

  The program generation unit 25 performs an operation of generating a control program for the image processing controller 11 by converting a flowchart 47 created on the flow view window 46 by the user into an execution format.

  In the memory 21, a control program generated by the program generation unit 25 is held as inspection setting data 22. The transfer unit 26 performs an operation of transferring the inspection setting data 22 in the memory 21 to the image processing controller 11.

  The operation input unit 27 performs an operation of outputting a predetermined input signal based on operation of an operation key on the keyboard or operation of a pointing device such as a mouse. The unit property editing unit 28 performs an operation for editing the property of the processing unit selected on the flowchart 47. Specifically, the property editing screen is displayed for the processing unit selected by the user, and the operation for changing the parameter of the processing unit that is specified based on the user operation is performed.

  The writing method determination unit 29 selects either image processing priority or output processing priority as the parameter of the output unit selected on the flowchart 47, and the writing method when the image processing controller 11 writes the inspection result in the output buffer. The action to determine is performed. This writing method is determined for each output unit selected in the flowchart 47, and either image processing priority or output processing priority can be selected for each output unit.

<Image processing controller>
FIG. 10 is a block diagram illustrating a configuration example of the image processing controller 11 in the inspection support system 100 of FIG. 2, and illustrates an example of a functional configuration in the image processing controller 11. The image processing controller 11 includes a memory 14, a communication unit 51, a program execution unit 52, an inspection result writing unit 53, an output buffer 56, a camera image output unit 57, a measurement result output unit 58, and a terminal output unit 59. The memory 14 is a storage unit for a control program that holds the examination setting data 15 transferred from the PC 2 via the communication unit 51.

  The program execution unit 52 is an image processing unit that reads out and executes a control program held as inspection setting data 15 in the memory 14 and performs a series of image processing. In the program execution unit 52, the control program is repeatedly executed.

  The cycle (measurement cycle) when the control program is repeatedly executed is defined by a flowchart 47 corresponding to the control program. That is, the measurement cycle is determined by using the flow sequence from the start symbol (unit) to the end symbol on the flowchart 47 as image processing for one cycle. Therefore, when one imaging unit is arranged on the flowchart 47, each time one camera image is acquired as a measurement target, one measurement is performed based on the camera image, and measurement is performed from the camera image. The result will be extracted.

  When a plurality of examination setting data 15 is held in the memory 14, image processing is performed based on examination setting data selected and designated as an execution target by the user.

  The inspection result writing unit 53 includes an image processing priority writing unit 54 and an output processing priority writing unit 55. The inspection result writing unit 53 performs an operation of sequentially writing the inspection results obtained by the program execution unit 52 to the output buffer 56 when the control program is executed. Yes. Specifically, when the control program is executed, a camera image acquired from the camera 12 by the imaging unit is written in the output buffer 56 as an inspection result when the image output unit is executed. In addition, the measurement result extracted from the camera image by the measurement unit is written in the output buffer 56 as an inspection result when the result output unit is executed. Further, the quality determination result of the inspection object determined by the measurement unit based on the measurement result is written in the output buffer 56 as the inspection result when the result output unit and the terminal output unit are executed. The inspection result is written into the output buffer 56 at the timing of executing the output unit.

  The image processing priority writing unit 54 does not write the newly obtained inspection result when the newly obtained inspection result is written in the output buffer 56 and the free space in the output buffer 56 is insufficient. The program continues to run.

  The output processing priority writing unit 55 outputs the camera image output unit 57, the measurement result output unit 58, or the terminal output when there is not enough free space in the output buffer 56 when writing the newly obtained inspection result to the output buffer 56. The operation of causing the program execution unit 52 to interrupt the execution of the control program is performed until one of the units 59 reads the test result to write the test result to the output buffer 56.

  In the image processing priority mode, the image processing can be continued even when the free capacity of the output buffer 56 is insufficient, but the inspection result obtained while the free capacity is insufficient is lost. Become. On the other hand, in the output processing priority mode, image processing is interrupted when the free space is insufficient, but the inspection results obtained by a series of measurements can be collected without omission. Moreover, in the branch unit, when the output unit is arranged on the branch flow selected when the determination result of the inspection object is a predetermined value, for example, NG, the determination result is NG. The camera images can be collected without omission.

  The output buffer 56 is a test result storage unit that holds the test result from the test result writing unit 53, and includes, for example, a volatile buffer memory.

  The camera image output unit 57 performs an output process of reading the camera image in the output buffer 56 and outputting it via an output interface. The measurement result output unit 58 performs an output process of reading the measurement result in the output buffer 56 and outputting it via the output interface. As an output interface used by these output units 57 and 58, a card slot for detachably storing a memory card and a communication interface to which a terminal device such as a PC or a PLC is detachably connected are provided.

  The memory card is a non-volatile recording medium and includes, for example, a flash memory. As the output destination device of the inspection result data 56a, either a memory card or a communication interface can be selected. When the communication interface is selected, the inspection result data 56a is sent to the terminal device via a communication network such as Ethernet. Is output.

  The terminal output unit 59 performs an output process of reading data indicating a determination result or a measurement value in the output buffer 56 and outputting the data via an output interface. As an output interface used by the terminal output unit 59, for example, an output terminal for outputting an electrical signal is provided, and data indicating a determination result or a measured value is transmitted to a terminal device such as a PC or a PLC via the output terminal. Is output.

  Here, the description has been made assuming that three output units 57 to 59 are provided for one output buffer 56, but the output buffer 56 may be provided for different combinations of data types to be output and output destination devices. For example, an output buffer for holding camera images and an output buffer for holding measurement results and determination results are provided. Furthermore, an output unit for outputting the data in the output buffer to the memory card and an output unit for outputting to a terminal device such as a PC or PLC via a communication interface are provided, and combined with each output buffer. A configuration to be used is conceivable.

  In the inspection result writing unit 53, either the image processing priority writing unit 54 or the output processing priority writing unit 55 can be selected for each of the camera image output unit 57, the measurement result output unit 58, and the terminal output unit 59. .

  In this embodiment, since it is specified in advance whether to select the image processing priority writing unit 54 or the output processing priority writing unit 55 as the parameter of the output unit, priority is given to the image processing by executing the control program. It is possible to automatically select whether to give priority to output processing. In addition, it is possible to specify in advance whether image processing priority or output processing priority is selected for each output unit of the image output unit, the result output unit, and the terminal output unit. Can be written by a desired writing method depending on whether or not is output as an inspection result.

It is the perspective view which showed one structural example of the test | inspection assistance system by embodiment of this invention. It is the block diagram which showed an example of the system configuration | structure of the test | inspection assistance system of FIG. FIG. 4 is a diagram illustrating an example of the operation of the PC 2 in the inspection support system 100 of FIG. 2, and shows an editor screen 40 for creating inspection setting data 22. FIG. 4 is a diagram showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. 2, and shows an editor screen 40 on which a flow view window 46 is displayed. FIG. 4 is a diagram showing an example of the operation of the PC 2 in the examination support system 100 of FIG. 2, and shows an example of a flowchart 47 in the flow view window 46. FIG. 4 is a diagram showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. 2, and shows an image output unit property editing screen 70. FIG. 6 is a diagram showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. 2, and shows a result output unit property editing screen 80. FIG. 9 is a diagram showing an example of the operation of the PC 2 in the inspection support system 100 of FIG. 2, and shows a terminal output unit property editing screen 90. FIG. 3 is a block diagram showing a configuration example of a PC 2 in the inspection support system 100 of FIG. 2, showing an example of a functional configuration of an editor. FIG. 3 is a block diagram illustrating a configuration example of an image processing controller 11 in the inspection support system 100 of FIG. 2.

Explanation of symbols

1 Image processing device 2 PC
3 communication network 11 image processing controller 12 camera 13a display 13b operation unit 14, 21 memory 15, 22 inspection setting data 23 processing unit storage unit 24 flowchart display unit 25 program generation unit 26 transfer unit 27 operation input unit 28 unit property editing unit 29 Write method determination unit 40 Editor screen 46 Flow view window 47 Flowchart 48 Processing unit 51 Communication unit 52 Program execution unit 53 Inspection result writing unit 54 Image processing priority writing unit 55 Output processing priority writing unit 56 Output buffer 56a Inspection result data 57 Camera image Output unit 58 Measurement result output unit 59 Terminal output unit 100 Inspection support system

Claims (6)

A camera that shoots an inspection object and generates a camera image; obtains the camera image from the camera; extracts a measurement result from the camera image; and determines pass / fail of the inspection object based on the measurement result In an inspection support system comprising an image processing controller that outputs a determination signal and a program creation device that creates a control program for the image processing controller,
The program creation device is a processing unit indicating processing executed by the image processing controller, an imaging unit that acquires a camera image from the camera based on an imaging trigger signal, and a measurement result from the camera image acquired by the imaging unit. Two or more measurement units for extracting the measurement results, an image output unit for outputting the camera image used for the extraction of the measurement results, and a processing unit storage means for holding the result output unit for outputting the measurement results;
Flowchart display means for displaying a flowchart generated by placing the processing unit on an execution flow starting at a start symbol and ending at an end symbol;
Program generating means for generating a control program for the image processing controller based on the flowchart,
Transfer means for transferring the control program to the image processing controller,
The image processing controller includes program execution means for repeatedly executing the control program;
When the control program is executed, the camera image acquired by the imaging unit is written into the output buffer as an inspection result when the image output unit is executed, and the measurement result extracted by the measurement unit is written when the result output unit is executed. A test result writing means for writing to the output buffer as a test result;
Camera image output means for reading out the camera image in the output buffer and outputting it via an output interface;
A measurement result output means for reading the measurement result in the output buffer and outputting it via an output interface;
When the test result writing means writes the newly obtained test result to the output buffer and the free space in the output buffer is insufficient, the test result writing means does not write the newly obtained test result, Image processing priority writing means for continuing execution;
The camera image output means and the measurement result output means comprise output processing priority write means for interrupting the execution of the control program until the test results can be written to the output buffer by reading the test results.
One of the image processing priority writing means and the output processing priority writing means can be selected for each of the camera image output means and the measurement result output means.   The inspection support system according to claim 1, wherein the output interface is an interface for outputting the inspection result read from the output buffer to an external device that is detachably connected. In the image processing controller, when the control program is executed, the inspection result writing means stores in the output buffer the inspection result writing result determined by the measurement unit based on the measurement result when the result output unit is executed. A determination result output means for reading out the determination result in the output buffer and outputting the result via an output interface when written;
2. The image processing priority writing unit and the output processing priority writing unit can be selected for each of the camera image output unit, the measurement result output unit, and the determination result output unit, respectively. The inspection support system described in 1.   4. The inspection support system according to claim 3, wherein the determination result output means outputs a determination result via an output terminal for outputting an electric signal.   The program creation device selects either the image processing priority writing unit or the output processing priority writing unit as the parameter of the image output unit and the result output unit selected on the flowchart, and the output buffer. The inspection support system according to claim 1, further comprising a writing method determination unit that determines a writing method of a test result with respect to the test result. A camera that shoots an inspection object and generates a camera image; obtains the camera image from the camera; extracts a measurement result from the camera image; and determines pass / fail of the inspection object based on the measurement result In an inspection support system comprising an image processing controller that outputs a determination signal and a program creation device that creates a control program for the image processing controller,
The program creation device is a processing unit indicating processing executed by the image processing controller, an imaging unit that acquires a camera image from the camera based on an imaging trigger signal, and a measurement result from the camera image acquired by the imaging unit. Two or more measurement units for extracting the measurement results, an image output unit for outputting the camera image used for the extraction of the measurement results, and a processing unit storage means for holding the result output unit for outputting the measurement results;
Flowchart display means for displaying a flowchart generated by placing the processing unit on an execution flow starting at a start symbol and ending at an end symbol;
Program generating means for generating a control program for the image processing controller based on the flowchart,
Transfer means for transferring the control program to the image processing controller,
The image processing controller includes program execution means for repeatedly executing the control program;
When the control program is executed, the camera image acquired by the imaging unit is written in the output buffer as the inspection result when the image output unit is executed, and the inspection object is determined based on the measurement result extracted by the measurement unit. A test result writing means for writing a result of pass / fail judgment to the output buffer as a test result when executing the result output unit;
Camera image output means for reading out the camera image in the output buffer and outputting it via an output interface;
A determination result output means for reading the determination result in the output buffer and outputting the determination result via an output interface;
When the test result writing means writes the newly obtained test result to the output buffer and the free space in the output buffer is insufficient, the test result writing means does not write the newly obtained test result, Image processing priority writing means for continuing execution;
The camera image output means and the determination result output means comprise output processing priority writing means for interrupting the execution of the control program until the inspection result can be written to the output buffer by reading the inspection result.
One of the image processing priority writing means and the output processing priority writing means can be selected for each of the camera image output means and the determination result output means.